RPCL Nit Technical Specification
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Dani Kirky YlaganRPCL Nit Technical Specification
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Dani Kirky YlaganTECHNICAL SPECIFICATION
COAL HANDLING PLANT and MILL REJECT
HANDLING SYSTEM
(PART-A)
FOR
2x800MW YERMARAS THERMAL POWER STATION PROJECT
OF
RAICHUR POWER CORPORATION LIMITED
PREPARED BY:
Evonik Energy Services India Pvt. Ltd.
(A wholly owned subsidiary of Evonik Energy Services GmbH, Germany)
A-29 & 30, Sector-16
Noida 201301, India
MARCH 2011
2X800 MW YERMARAS TPS PROJECT
PART A
COAL HANDLING PLANT SPECIFICATIONS
(COAL HANDLING PLANT & MILL REJECT
HANDLING SYSTEM)
R3
10-03-2011
Final Issue
S.K.A
J.K.K
K.B
R2
10-02-2011
Revised Issue
S.K.A
J.K.K.
K.B.
R1
08-12-2010
Revised Issue
S.K.A
J.K.K.
K.B.
R0
03-08-2010
Draft Issue
S.K.A
J.K.K.
K.B.
Rev
Date
Description
Prepared By
Checked
Approved By
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TABLE OF CONTENTS
SECTIONS
1.0
PAGE
SYSTEM DESCRIPTION ................................................................... 6
1.1
MECHANICAL ................................................................................. 7
1.1.1 General........................................................................................ 7
1.1.2 Coal Unloading System ................................................................ 8
1.1.3 Coal Crushing System .................................................................. 8
1.1.4 Coal Bunkering System .............................................................. 10
1.1.5 Coal Stacking and reclaiming System ......................................... 10
1.1.6 Coal blending system ................................................................ 12
1.1.7 Manual unloading system .......................................................... 12
1.1.8 Coal area Drainage system......................................................... 13
2.0
1.2
ELECTRICAL.................................................................................. 13
1.3
CONTROL AND INSTRUMENTATION ............................................. 14
SCOPE OF WORK ......................................................................... 15
2.1
MECHANICAL ............................................................................... 16
2.2
ELECTRICAL.................................................................................. 23
2.3
CONTROL AND INSTRUMENTATION ............................................. 30
2.4
CIVIL ............................................................................................ 32
3.0
TERMINAL POINTS AND EXCLUSIONS ........................................... 37
4.0
TECHNICAL REQUIREMENTS OF COAL HANDLING PLANT.............. 40
4.1
4.2
MECHANICAL ............................................................................... 41
4.1.1 Rated and design capacity ......................................................... 41
4.1.2 Standards/Codes ....................................................................... 42
4.1.3 Specification of Equipment ........................................................ 43
ELECTRICAL.................................................................................. 86
4.2.1 Power Transformer .................................................................... 86
4.2.2 LT Distribution Type Transformer ............................................ 100
4.2.3 HT Switchgear ......................................................................... 105
4.2.4 LT Switchgear .......................................................................... 135
4.2.5 HT & LT Power and Control Cables ........................................... 149
4.2.6 Instrumentation cables ............................................................ 162
4.2.7 DC System ............................................................................... 165
4.2.8 HT Motor ................................................................................. 175
4.2.9 LT Motor.................................................................................. 180
4.2.10 HT< Bus Duct ....................................................................... 186
4.2.11 Neutral Grounding ................................................................... 194
4.2.12 Illumination system ................................................................. 196
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4.2.13 Installation / Erection .............................................................. 216
4.2.14 Earthing................................................................................... 242
4.2.15 Control Panels & Cabinets and Miscellaneous Electrical Equipment
250
4.3
CONTROL AND INSTRUMENTATION ........................................... 253
4.3.1 General Requirements.............................................................. 254
4.3.2 Design Criteria ........................................................................ 255
4.3.3 Control and Instrumentation Items .......................................... 257
4.3.4 Programmable Logic Controller (PLC) ....................................... 260
4.3.5 Field Instruments ..................................................................... 269
4.3.6 Drive Control Philosophy ......................................................... 274
4.3.7 Instrumentation Cables, Wiring & Terminals ............................. 276
4.3.8 Instrumentation Interconnection Philosophy ............................ 276
4.3.9 Junction Box (JB) ...................................................................... 276
4.3.10 Installation / Erection .............................................................. 277
4.4
CIVIL .......................................................................................... 279
4.4.1 General.................................................................................... 279
4.4.2 Specific Requirements for various components of Coal Handling
Plant ........................................................................................ 285
4.4.3 Field Quality Plan ..................................................................... 306
3.1.1 IS Codes & References ............................................................. 307
4.4.4 Deliverables ............................................................................. 308
5.0
OPERATION & CONTROL PHILOSOPHY ........................................309
6.0
SPARES LIST...............................................................................316
7.0
8.0
6.1
MECHANICAL ............................................................................. 317
6.2
ELECTRICAL................................................................................ 321
6.3
CONTROL AND INSTRUMENTATION ........................................... 326
DRAWINGS AND DOCUMENTS TO BE FURNISHED BY BIDDER .......329
7.1
DATA TO BE FURNISHED WITH THE BID ...................................... 330
7.2
DATA TO BE FURNISHED AFTER AWARD OF CONTRACT ............. 331
PERFORMANCE & AVAILIABILITY .................................................339
8.1
8.2
ILLUMINATION LEVELS ................................................................ 342
8.3
EARTHING RESISTANCE .............................................................. 342
8.4
DUST CONTROL SYSTEM ............................................................ 342
8.5
9.0
SYSTEM PERFORMANCE REQUIREMENTS ..................................... 340
ENDURANCE TEST ...................................................................... 342
LAYOUT & MAINTAINANCE REQUIREMENT ..................................343
10.0 VENDOR LIST .............................................................................345
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11.0 DATA SHEETS ............................................................................347
DATA SHEETS-A: SPECIFIC DATA SHEET................................................ 348
Mechanical .......................................................................................... 348
Electrical ............................................................................................. 371
Control and Instrumentation ............................................................... 394
DATA SHEET-B: DATA TO BE FILLED BY THE BIDDER ............................. 408
Mechanical .......................................................................................... 408
Electrical ............................................................................................. 424
Control and Instrumentation ............................................................... 493
12.0 LIST OF DRAWINGS ENCLOSED ...................................................501
LIST OF DRAWINGS ENCLOSED .............................................................. 502
13.0 ANNEXURES ...............................................................................503
ANNEXURE-1: MECHANICAL-COAL ANALYSIS REPORT .......................... 504
ANNEXURE-2: SUMMERY OF SCOPE ...................................................... 506
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1.0 SYSTEM DESCRIPTION
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SYSTEM DESCRIPTION
1.1
MECHANICAL
1.1.1
General
1.1.1.1
The propose 2 X 800 MW TPS is receiving coal from mines which has
calorific value ranging from 4000 5100 Kcal/Kg. It is also proposed
to use imported Indonesian coal with calorific value of 6000 Kcal/Kg
and high volatile and moisture content. The Indian coal and the
imported coal shall be blended with maximum 70:30 % ratio. Thus the
coal handling plant is required to operate with different type and
combination of coal depending upon the availability of both Indian
and imported coal. The boiler has been designed with worst Indian
coal with calorific value of 4100 Kcal/Kg.
1.1.1.2
The daily coal consumption of 2 X 800 MW Yermaras TPP works out to
16500 - 19000 MT of coal based on the type of coal being used in the
plant like blended coal or the indigenous coal.
1.1.1.3
Coal in size of (-) 300mm for the proposed 2 X 800 MW power plant is
envisaged to brought to Site by Railway in all types of Box-N type
wagons as per latest RDSO G-33 norms. All transporting facilities
including wagons and locomotives to transport the coal from the mine
to the plant will be provided by Railways.
1.1.1.4
In order to handle the large quantity of coal required for the plant at
90% PLF five to six rakes are required to be handled daily. In order to
handle unloading of six (6) nos. rake per day and avoid demurrage for
holding the wagons it is proposed to install Five (5) nos. wagon
tipplers with three available for actual operation and other one under
maintenance and the other as the standby. The availability of three
wagon tippler at any time would facilitate unloading of three rakes
simultaneously with in the allotted time of unloading of wagons. The
arrangement of wagon tippler is designed in cluster of three and two
wagon tipplers so that the normally one stream of conveyor from two
wagon tippler would be operated at full capacity.
1.1.1.5
Coal handling plant has been designed for operation of 14 hours.
However CHP shall be capable to operate for 24 hours. Two streams of
conveyors considered from Conveyor BCN-1A/B/C/D/E to bunker bay
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except stack yard conveyors. Out of two stream conveyors one stream
will be working and other stream will be standby. However coal
handling plant shall be designed for simultaneous and continuous
operation of all the conveyors. Single stream conveyor will be provided
for each stacker-cum Reclaimer,
The capacities of conveyors from Wagon tippler to bunker including
yard conveyor are, Designed 2200 TPH and Rated 2000 TPH.
Except manually unloaded coal conveyor BCN-23A/B, which has a
capacity of Designed- 600 TPH and Rated- 500 TPH.
Coal Stock yard shall be designed for about 30 days storage of coal
requirement of both units. Maximum consumption of coal will be
considered 800 Ton/hr for both the units. (Minimum capacity shall be
6.0 lacks tons.)
The scope of work shall be as per coal flow diagram drawing No.
E072-03-CHP-M-03-01 and Coal handling plot plan drawing No.
E072-03-CHP-O-03-02.
1.1.2
Coal Unloading System
1.1.2.1
Below each wagon tippler, hopper shall be provided. Each hopper at
the bottom will be provided with rack and pinion gate for isolation of
hoppers. Below the each wagon tippler hoppers apron feeder and
dribble feeder shall be provided. Apron feeder and dribble feeder will
feed coal to conveyor BCN-1A from Wagon tippler-1, BCN-1B from
Wagon tippler-3, BCN-1C from Wagon tippler-5, BCN-1D from Wagon
tippler-2, BCN-1E from Wagon tippler-4.
In wagon tippler hoppers, grizzlies shall be provided at ground level.
Wagon tippler shed floor level will be equal to rail top level.
1.1.3
Coal Crushing System
1.1.3.1
Path -1- Coal of (-) 150 mm is received (Raw/washed coal):
The
raw/washed coal from wagon tippler WT-1, WT-3 and WT-5 will be
fed to conveyor BCN-1A, BCN-1B and 1C respectively and further shall
be transferred either to conveyor BCN-2A or BCN-2B at junction tower
JT-15. Coal from Conveyor BCN-2A/B shall be transferred to either
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conveyor BCN-4A/B through secondary crusher house. The conveyor
BCN-2A will feed two Nos. of secondary crushers and the conveyor
BCN 2B will feed two Nos. of secondary crushers each of Designed
capacity - 1250TPH, Rated capacity - 1000 TPH, out of four crushers
two crushers will be working and other two will be stand-by. However
it shall be possible to operate all the four crushers simultaneously so
that coal from two crushers of stream-A can be fed to bunkers and
coal from Stream-B can be stacked.
1.1.3.2
Path-2- Coal of (-)25 mm is received (Washed coal or imported coal):
The washed/imported coal from wagon tippler WT-1, WT-3 and WT-5
will be fed to conveyor BCN-1A, BCN-1B and 1C respectively and
further shall be transferred to conveyor BCN-3, at junction tower JT-
15, in turn the same will be fed to conveyor BCN-5A/B at junction
tower JT-14 without crushing.
1.1.3.3
Path-3- Coal of (-)300 mm is received (Raw coal): The raw coal from
wagon tippler WT-2 and WT-4 will be fed to conveyor BCN-1D and 1E
respectively and further shall be transferred either to conveyor BCN2C or 2D at junction tower JT-19, which in turn feed to conveyors
BCN-4C/D at primary crusher house, PCH. In primary crusher house
there are four Nos. of primary crushers of rotary breaker type which
shall reduce the size of coal from (-) 300 mm to (-) 150 mm. Output
of primary crushers shall be feed to conveyor BCN-4C/D for further
transportation of coal to secondary crusher house SCH-1.The capacity
of each rotary breaker are of Designed capacity - 1250TPH, Rated
capacity - 1000 TPH, out of four primary crushers, two crushers will
be working and other two will be stand-by. However it shall be
possible to operate all the four crushers simultaneously.
1.1.3.4
In secondary crusher house there are four Nos. of secondary crushers
of ring granulator type which shall reduce the size of coal from (-) 150
mm to (-) 20 mm. Vibrating screens shall be provided above crushers
to screen out the coal of size (-) 20 mm. Coal above 20 mm size from
Screens will feed to secondary Crushers Output of secondary crushers
shall
be
feed
to
conveyor
BCN-5A/B
or
10A/B
for
further
transportation of coal. However it shall be possible to operate all the
four crushers simultaneously so that coal from two crushers of
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stream-A can be fed to bunkers and coal from Stream-B can be
stacked.
1.1.4
Coal Bunkering System
1.1.4.1
Path-1: The crushed coal from secondary crusher at SCH-2 shall be
fed to Junction towers JT-14, JT-6, JT-5, JT-4, JT-3, JT-2 and JT-1
through conveyors BCN
4A/B, 5A/B, 16A/B, 17A/B, 18A/b, 19A/B,
20A/B, 21A/B and 22A/B respectively for direct bunkering.
1.1.4.2
Path-2: The imported/washed coal from conveyor either BCN-1A,
BCN- 1B or BCN-1C will be fed to conveyors BCN -3, at Junction tower
JT-15 (bypassing primary and secondary crushers). The bypassed coal
through conveyors BCN -3, 5A/B, 16A/B, 17A/B, 18A/b, 19A/B,
20A/B, 21A/B and 22A/B respectively for direct bunkering.
1.1.4.3
Path-3:The crushed coal from primary crusher (PCH) and secondary
crusher at SCH-1 shall be fed to Junction towers JT-14, JT-6, JT-5,
JT-4, JT-3, JT-2 and JT-1 through conveyors BCN
5A/B, 16A/B,
17A/B, 18A/B, 19A/B, 20A/B, 21A/B and 22A/B respectively for direct
bunkering.
1.1.5
Coal Stacking and reclaiming System
1.1.5.1
For stacking and reclaiming of coal Three (03) nos. stacker cum
reclaimer will be provided each of stacking capacity 2200 TPH
(Designed)/2000 TPH (Rated) and reclaiming capacity 2200 TPH
(Designed) /2000 TPH (Rated). In stack area six numbers (2 for
imported coal and 4 for Indian coal) coal pile shall be provided to
store crushed coal in stock pile area. Stockpile shall be capable to
store 30 days coal requirement of the plant. The height of each stock
pile shall be 8.75 meters. Boom length of each stacker cum reclaimer
shall be 36 meters. Minimum capacity of coal stackyard shall be 6.0
lakh MT
1.1.5.2
Path-1: The coal from Secondary crusher house SCH-2 shall be feed to
either conveyor BCN- 10A/B. coal from conveyor BCN-10A/B shall be
transferred to Junction towers JT-11, JT-12 and JT-13 through
conveyors BCN-6, BCN-7 and BCN-8 for stacking of coal in six nos of
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stack piles for stacking Indian/imported coal pile through stacker cum
reclaimer SCR-1, SCR-2 and SCR-3 respectively.
1.1.5.3
The reclaimed coal through yard conveyors BCN-6, BCN-7 and BCN-8
will feed coal to conveyor BCN 11A/B at junction towers JT-8, JT-9 and
JT-10. The reclaimed and blended coal received on to conveyor BCN-
11A/B will be fed to conveyor BCN-15A/B at junction tower JT-7 and
onward transfer to junction towers JT-6, JT-5, JT-4, JT-3, JT-2 and
JT-1 through conveyors BCN
11A/B, 15A/B, 16A/B, 17A/B, 18A/B,
19A/B, 20A/B, 21A/B and 22A/B respectively for bunkering.
1.1.5.4
Path-2: The imported/washed coal from conveyor either BCN-1A,
BCN- 1B or BCN-1C will feed bypass conveyors BCN -3(bypassing
primary and secondary crushers), which in turn feed conveyor BCN-
10A/B at Junction towers JT-11, JT-12 and JT-13 through conveyor
BCN-6, BCN-7 and BCN-8 for stacking of coal in six nos of stack piles
for stacking Indian/imported coal pile through stacker cum reclaimer
SCR-1, SCR-2 and SCR-3 respectively.
1.1.5.5
The reclaimed coal through yard conveyors BCN-6, BCN-7 and BCN-8
will feed coal to conveyor BCN 11A/B at junction towers JT-8, JT-9 and
JT-10. The reclaimed and blended coal received on to conveyor BCN11A/B will be fed to conveyor BCN-15A/B at junction tower JT-7 and
onward transfer to junction towers JT-6, JT-5, JT-4, JT-3, JT-2 and
JT-1 through conveyors BCN
11A/B, 15A/B, 16A/B, 17A/B, 18A/b,
19A/B, 20A/B, 21A/B and 22A/B respectively for bunkering.
1.1.5.6
Path-3 - The coal from Secondary crusher house SCH-1 shall feed to
either conveyor BCN-5A/B. coal from conveyor BCN-9A/B shall be
transferred to Junction towers JT-16, JT-17and JT-18, through
conveyors BCN-6, BCN-7 and BCN-8 for stacking of coal in six nos. of
stack piles for stacking Indian/imported coal pile through stacker cum
reclaimer SCR-1, SCR-2 and SCR-3 respectively.
1.1.5.7
The reclaimed coal through yard conveyors BCN-6, BCN-7 and BCN-8
will feed coal to conveyor BCN 11A/B at junction towers JT-8, JT-9 and
JT-10. The reclaimed and blended coal received on to conveyor BCN11A/B will be fed to conveyor BCN-15A/B at junction tower JT-7 and
onward transfer to junction towers JT-6, JT-5, JT-4, JT-3, JT-2 and
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JT-1 through conveyors BCN
11A/B, 15A/B, 16A/B, 17A/B, 18A/b,
19A/B, 20A/B, 21A/B and 22A/B respectively for bunkering.
1.1.6
Coal blending system
1.1.6.1
The stacker cum reclaimer shall be used for blending of coal for
feeding to the boiler bunker during normal operation when rakes are
not available. Any of the stacker cum reclaimer (SCR) shall be able to
reclaim the indigenous coal from the dedicated indigenous coal stock
pile for the purpose of blended coal, the indigenous coal and the
imported coal can be blended in any ratio from 90:10 up to 70:30.
1.1.6.2
The indigenous coal shall be reclaimed through one SCR and other
SCR would reclaim the imported coal. On the common conveyor
mixture of the two coals shall be blended through three transfer tower
(JT-8, JT-9and JT-10) to provide reasonably good mixture for feeding
to raw coal bunker.
1.1.6.3
In case any of the SCR is out of service the blending can be achieved
through one SCR reclaiming indigenous coal while the imported coal
shall be reclaimed through manual reclaiming hoppers.
1.1.6.4
Blending can also be done on crusher by unloading one rake each for
both Indian and imported coal simultaneously. Feed rate of coal will be
adjusted by adjusting the feed rate of the feeder below wagon tippler
hopper during direct bunkering of coal. During bunkering of coal from
stock pile feed rate for blending of coal will be controlled from
reclaiming by adjusting the reclaiming capacity of the stacker
reclaimer.
1.1.7 Manual unloading system
A manual unloading hopper shall be provided for unloading of coal from sick
wagon. Double stream conveyor BCN-23A/B (1W+1S) of 600 TPH (Designed)
/500 TPH (Rated) capacity shall be provided for transportation of coal from
manual unloading hopper to primary crusher. Rack and pinion gates shall be
provided below manual unloading hopper for isolation of hoppers.
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1.1.8
Coal area Drainage system
Around the coal stock yard, ground drains shall be constructed to take all the
effluents/leach water from coal stockyard. This water along with water from
other coal handling areas shall be led to decantation tanks (02 nos.) where all
the coarse particles will settle down. The decanted water with finer particles will
be collected in coal pile run off pond (2 nos.). Clear water from runoff pond will
be collected in a RCC collection tank where it will be pumped to CMB/ETP.
Two (02) Nos. pumps (1W+1S) shall be provided. Capacity of each decantation
pond shall be 25000 M3. Capacity of collection tank shall be 35000 M3 and
capacity of each pump shall be 300 M3/hr.
Suitable drains shall be provided in entire coal handling plant area. These drains
shall be connected to decantation tank.
1.2
ELECTRICAL
The Electrical system is designed to operate both streams of CHP simultaneously
& continuously. The Electrical system is also capable to feed the power when all
wagon tipplers, all primary and secondary crushers and all stacker Reclaimers
are under operation.
One 11 kV switchgear is envisaged for the CHP operation. Power is fed from 11
kV station switchgear (under BHEL scope), to this switchgear.
From the 11 kV switchgear, the power is fed to all CHP loads through 11 / 3.6
kV transformer, 11 /0.433 kV transformers and to the motors having capacity of
more than or equal to 1500 kW.
The number of the transformers, switchgears and their ratings is to be decided
by the contractor based on the geographical location of the loads and will be
finalized during detailed engineering. For the stacker reclaimers, the required
number of feeders derived from 3.3 kV switchgear located in CHP Switchgear
room. The 3.3 kV power supply is further distributed in SR through LT
transformer for its auxiliary loads. Power Supply to Mill reject system shall be
sourced from the nearby LT MCC of either Coal Handling or Ash Handling
systems.
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For the motors up to 160 kW, the power is fed through 415 V switchgear, >160
kW and less than 1500 kW motors, the power is fed through 3.3 kV switchgear.
All local push button stations for HT drives are provided with only Emergency
stop PB, all LT drives are provided with Start / Stop PB to enable Starting /
Stopping of all equipment locally for maintenance purposes.
A separate DC system is envisaged for the CHP area for breakers, DC lighting,
etc., Separate lighting transformers are provided for illumination purposes. A
decorative type 3 x 36 W CFL fitting is envisaged for the CHP control rooms and
switchgears. The illumination level and type of fittings are described in the
specification.
AC drive (VFD) and DC drive (like for Apron feeders) is provided as per the
system requirement.
The peripheral earthing for the CHP is made to reduce the earth resistance less
than 0.5 ohm. The required treated pit and test pit is as per IS 3043. For
electronic equipment earthing is to be done as per IEEE 1100 and separate earth
pit is to be provided.
1.3
CONTROL AND INSTRUMENTATION
I&C system will consist of all local instruments Viz. Pressure Gauge, Temperature
Gauge, limit switch, Pull cord switch, Belt Sway switch, Electronic Zero speed /
Under speed switch, Bunker level switch/ indicator, other field sensors, Local
panel & push button station, CHP control room equipment, as required erection
hardware & interconnecting cables required for the control & monitoring of the
entire Coal handling Plant along with control of Wagon Tippler & StackerReclaimer as turnkey basis. A PLC based control system shall be provided for
operation, control, interlocking, tripping of the entire coal handling plant and all
associated equipment whenever required under specified abnormal conditions.
All 3.3 KV drives shall be provided with fluid coupling temperature/ bearing
Temperatures measurement & shall be measured with Duplex RTD. Redundant
Temperature Measurement sensor shall be provided for all bearing temperature
measurement. Stator winding temperature measurement element shall be
duplex type and all temperature measuring points shall be connected to PLC.
Winding temperature high alarm will be generated in the PLC system. 3.3 KV
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drives shall also be provided with vibration monitoring devices and shall be
connected with PLC.
2.0 SCOPE OF WORK
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SCOPE OF WORK
The scope of supply and work for Coal Handling System under the specification
covers the design, engineering, manufacture, supply, assembly and testing at
manufacturers works, inspection, packing, forwarding, delivery FOR site and
handling with storage at site (i.e. taking delivery of materials from carriers,
transportation
to
site),
fabrication
(as
needed),
construction,
erection,
commissioning, trial run, PG testing including painting protection of all items as
specified hereinafter but without excluding any other necessary components,
which are not mentioned herein but are required for the completeness and;
efficient, easy and reliable operation of the system.
The supplier will provide the equipment including all necessary features,
components, accessories, electrical and C&I accessories and appurtenances for
efficient and reliable erection operation and maintenance whether mentioned in
this specification or not. The equipment will consist of the following main
components (however, not limited to the items listed).
All necessary tools and tackles required for the maintenance of the proposed
system shall also be supplied along with mandatory spares.
2.1
MECHANICAL
The scope of coal handling plant shall be deemed to include all such items
which although are not specifically mentioned in this section but are needed to
make the system complete in all respect for safe reliable, efficient and trouble
free operation but not limited to followings:
2.1.1
Five (05) Nos. wagon tipplers along with integral weighing system.
Wagon tippler shall be consisting of rails, tippling platform, cradle
arms, cradle arm bearing, Side stop with pads, top stop with pads,
driving motors, Girth gear and pinion drive, balance weight,
limit
switches for top and bottom stops, shafts, bearings, supporting
steel, walkways, platforms and all other associated equipment to
make a complete unit.
2.1.2
Five (05) Nos. Side arm chargers with power supply system, support,
Rack and Pinion, Hydraulic arrangement, electricals, buffer stop etc;
one no. for each wagon tippler.
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2X800 MW YERMARAS TPS PROJECT
2.1.3
One (01) No. RCC Hopper for each wagon tippler.
2.1.4
One (01) No. rack and pinion gate for each wagon tippler hopper.
2.1.5
Five nos. (05) Wagon tippler gratings of mesh size 300mm X 300mm
for wagon tippler hoppers; One no. for each hopper.
2.1.6
One (01) No. Apron feeder for each wagon tippler hopper with drive
and accessories.
2.1.7
One (01) No. Dribble feeder for each wagon tippler hopper with drive
and accessories.
2.1.8
Rail above the tippler Hopper.
2.1.9
Belt conveyors:
Each conveyor will be complete with drive equipment including motor,
Gear Box, Fast speed coupling, Slow speed coupling, Carrying idlers,
self aligning carrying idlers, Return idlers, self aligning return idlers
impact idlers, head pulley, snub pulley, tail pulley, pull cord, belt sway
and zero speed switches, chute jam switches, deck plate for complete
length of conveyors, gravity take-up system, internal and external
scrappers stringers with short support, all over ground conveyors will
be provided with conveyor galleries.
2.1.10
All Chute works for transfer of Coal with SS liner of SS 409M on
wearing surface with all sides welded and provided with countersunk
bolt of hexagonal head (Allen key removable). The size of the liner
shall be maximum 500X500 mm.
2.1.11
Junction towers from Wagon tippler to bunker bay.
2.1.12
Flap gates with SS liner of 409M complete with electrically operated
actuators as shown in flow scheme.
2.1.13
Four (04) Nos. Rotary breaker (Primary crushers) with drive equipment
including motor.
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2.1.14
Four (04) Nos. Ring granulator (Secondary crushers) with drive
equipment including motors in Secondary Crusher house -1.
2.1.15
Four (04) Nos. Ring granulator (Secondary crushers) with drive
equipment including motors in Secondary Crusher house -2.
2.1.16
Four (04) Nos. Vibrating screens with drives and supporting structure;
one no. for each secondary crusher in Secondary crusher House -1.
2.1.17
Four (04) Nos. Vibrating screens with drives and supporting structure;
2.1.18
One (01) No. elevator in secondary crusher house-1.
2.1.19
One (01) No. elevator in secondary crusher house -2.
2.1.20
One (01) No. Elevator near third JT of Unit #1 (Bunker bay).
2.1.21
Three (03) Nos. Emergency reclaim hoppers.
2.1.22
One (01) No. Rack and pinion gates for each Emergency reclaim
one no. for each secondary crusher in Secondary crusher House -2.
hoppers
2.1.23
One (01) No. Vibrating feeder below each emergency reclaim hoppers
2.1.24
Three (03) Nos. Bucket wheel type traveling Stacker-cum-Reclaimer
with drive and supporting structures
complete with all electrical, controls and structural including boom
conveyer, intermediate conveyer, bucket wheels, rails with rail fixing
arrangement to operate in conjunction with yard conveyor.
2.1.25
Eight (08) Nos. Mobile trippers complete with all electrical, rails and
rail fixing arrangement to operate in conjunction with bunker feeding
conveyors.
2.1.26
Four(04) Nos. fixed trippers on Conveyor BCN-17A/B and 18A/B; One
(01) No. for each conveyor.
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2.1.27
Eight (08) Nos. fixed tripper on Conveyor 9A/B and 10A/B; Two (02)
Nos. for each conveyor
2.1.28
Eight(08) Nos. Metal detectors, one at each conveyor BCN-2A, 2B, 2C,
2D, 4C, 4D,16A and 16Bcomplete with all accessories.
2.1.29
Eight (08) Nos. In-line magnetic separators, one at each conveyor
BCN- 2A, 2B, 2C, 2D, 4C, 4D,16A and 16Bcomplete with all
accessories and supporting structures.
2.1.30
Nine (09) Nos. Electronic continuous belt weigher, one at each
Conveyor BCN-2A, 2B, 4C, 4D, 6, 7, 8 (near junction tower JT-8, JT-9
and JT-10), 16A and 16B complete with all accessories.
2.1.31
Three (03) Nos. Electronic continuous belt weigher, one at Yard
conveyor BCN-6, BCN -7 and BCN-8 of each stacker reclaimer near
junction tower JT-11, JT-12 and JT-13 respectively.
2.1.32
Six (06) Nos. Coal sampling units, one at each conveyor BCN-2A, 2B,
4C, 4D, 16A and 16B
2.1.33
One (01) No. Manual unloading hopper for unloading sick wagons
2.1.34
One (01) No. rack and pinion gates below manual unloading hopper
2.1.35
One (01) No. vibrating feeders below manual unloading hopper
2.1.36
Dust suppression (DS) system and service water system
(1). Dust Suppression system (Dry fog type) completed with piping,
valves, pumps, nozzles water tanks, supporting structures, other
accessories as required for Wagon tippler area and all coal transfer
points except Bunker bay and Crusher House. DS system shall consists
of water pumps (1W + 1S), compressor (1W + 1S), enclosed hood, etc.
(2). There shall be two service water pumps (1W + 1S) which supply
water to (a) local water storage tank of DS system of stock yard,
transfer house, etc., (b) service water tap point for plant sealing, toilet,
etc., each system DS shall be provided with (1W + 1S) pumps.
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(3). Service water piping shall be provided all along the tunnels and
galleries with tap off points at 30 m interval to enable cleaning of
walkways / deck plates using flexible hose.
(4). Service water piping with tap off points (with isolating valve and
quick connecting coupling) shall be provided for each floor of junction
towers, transfer house and crusher house. Two (2) points per floor in
junction tower and transfer house and four (4) points per floor in
crusher house. Flexible hose of 20 m long each shall be provided with
storage box.
(5). Each tap off point shall contain isolating valve with quick
connecting coupling to enable fixing of hoses.
(6). Each water spray header in DS system shall be provided with a
solenoid valve to stop the water spray when the concerned plant and
equipment of Coal handling system do not operate. Necessary load
monitor shall be provided for all conveyors to detect presence of
material on them.
(7). Each DS system shall be operated from the local control panel and
shall be interlocked with respective conveyor / equipment.
2.1.37
General requirements of Dust extraction (DE) system
(1). Dust extraction system in all Junction towers (at all coal transfer
point) and crusher house.
(2).Except for the requirements stipulated in the specification, all
other design and construction features of DE system shall be generally
in conformity with the recommendation of American Conference of
Governmental Industrial Hygienists. The duct sizing and fan selection
shall be based on balancing without blast gate criterion.
(3). The bag filter material shall be fire proof, non woven type with
antistatic property.
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(4). The air to cloth ratio of the bag filter shall not exceed 2
m3/min/sqm. The bag filter cleaning system shall be reverse pulse jet
air system. Necessary instrument air supply shall be provided.
(5). Thickness of suction hood, dust collecting hopper and ducts shall
be minimum 5 mm. Thickness of casing of centrifugal fan shall be
minimum 5 mm.
(6). Dust extraction system shall be provided for at all coal transfer
points and also in the crusher house. The DE system shall have
cyclone separator and / or bag filter. The outlet dust emission shall be
max 50 mg/Nm3.
(7). Bunker ventilation system will be provided for the bunkers to
minimize the dust nuisance on the tripper floor and also to prevent
fire hazards inside the bunkers due to volatile gases liberated by coal.
The DE system shall have cyclone separator and bag filter. The outlet
dust emission shall be max 50 mg/Nm3. The bunker ventilation shall
be designed for handling minimum of 60,000 m3/hof volume of dusty
air.
(8). These shall be operated from the local control panels with
monitoring in CHS and interlocked with operation of conveyor
equipment.
(9). DE system shall be designed for two stream operation.
The tunnel ventilation system shall be designed based on a minimum
of 12 air changes per hour. Adequate capacity of supply air fan and
exhaust fan shall be provided.
2.1.38
Dust extraction system for coal bunkers of each units (Bunker
ventilation system). The bunker ventilation system should be designed
for handling minimum of 60,000 m3/hr of volume of dusty air.
The outlet dust emission of DE system shall be maximum 50 mg/Nm3
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2X800 MW YERMARAS TPS PROJECT
2.1.39
Dust suppression system (Plain water type) completed with piping,
valves, pumps, nozzles water tanks, supporting structures, other
accessories as required for all stock pile areas
2.1.40
One (01) No. Dust sweeping hopper covered with removable
chequered plate for conveyor galleries at each trestle location
2.1.41
Two (02) Nos. Dust sweeping hopper covered with removable
chequered plate at each floor of each junction tower and each crusher
house.
2.1.42
Mechanical Ventilation equipment for underground structures, MCC
room, bunker floor. Pressure ventilation shall be provided for all
switchgear rooms.
2.1.43
Two Nos. (1 W+1 S) Sump pumps with piping and valves at each pent
house, Emergency Reclaim hopper, Manual unloading hopper and
wagon tippler hopper areas and connected tunnels. The sump pump
shall be suitable to handle coal slurry and impeller shall be of non
clogging type.
2.1.44
Hydraulic press type belt-vulcanizing machine complete with all
accessories and consumables for a period of minimum three years
operation.
2.1.45
Five (05) Nos Bulldozer along with Dozer shed with repair bay for
reclaiming coal from stock piles.
2.1.46
Four (04) Nos. locomotives along with all accessories and loco shed
with repair bay.
2.1.47
Coal pile runoff pond near stock pile area.
2.1.48
Air conditioning of main CHP control room wagon tippler control and
operator cabin of SCR complete with all accessories
2.1.49
Material handling facilities including associated electrical and support
structures shall be provided for handling all the equipment during
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maintenance/repair/replacement at all working floors of all TPs,
Crusher house, Bunker bay, loco shed, underground building and
wherever required. Electric hoist with traveling trolley will be provided
when capacity is 2.0T or more. Capacity less than 2.0 T, manually
operated chain pulley block with traveling trolley will be provided. All
hoists will be able to lift material from ground to place of use.
One (01) No. each 40 ton capacity EOT crane shall be provided in each
wagon tippler shed.
One (01)No. electric hoist each of capacity 15 ton shall be provided in
primary crusher house, secondary crusher house-1 and secondary
crusher house-2.
2.1.50
Painting of all equipment and technological structures.
2.1.51
All equipment open to outdoor application shall be provided with
suitable weather and corrosion proof enclosure.
2.1.52
Plummer block shall be of Cast steel with Aluminum labyrinth seal.
2.2 ELECTRICAL
The scope of Contractor shall include Engineering design, manufacture,
inspection, supply including transportation to site, transit insurance, storage at
site, transportation from place of storage to erection site, erection, testing and
commissioning and handing over in fully operable condition satisfactory to
Owner of all electrical equipment required for the coal Handling System for
2X800 MW Yeramaras Thermal Power Project, besides obtaining all statutory
clearances such as clearance from chief Electrical inspector to Government
including furnishing of all Drawings, data etc. to the satisfaction of the statutory
authorities shall be in the scope of the Bidder. The entire cost including all
necessary fees, incurred for obtaining such approval / clearances, shall be borne
by the contractor.
The bidder shall design the Electrical system suitable to operate both streams of
CHP simultaneously & continuously. Electrical system should also be designed in
such a way that the transformers, switch gears, bus duct, etc., are adequately
rated considering simultaneous operation of all wagon tipplers, primary &
secondary crushers, coal conveyers etc. continuously.
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Power & Service Transformers 2 nos. 11/3.6 kV Power Transformer for all HT
loads of CHP and required No. of 11/0.433 kV transformers for feeding all the
auxiliary loads of Wagon tipplers and crusher area LT loads and 2 nos. 11/0.433
kV transformers for feeding all the auxiliary loads of Bunker area and required
number of transformers as per system requirement for SR area. The
transformers shall be complete with all fittings and accessories. The quantity
shall depend on the geographical location of loads and shall be chosen such that
the transformers are 100% redundantand shall be rated to take care of the entire
load on the respective switchgear considering the outage of the other
transformer. The fire wall is to be provided as per CBIP / Indian Electricity rules.
Neutral earthing equipment The adequate value of neutral grounding resistor
is to be selected to restrict the phase to earth fault current for 3.3 kV system to
300 A. The resistor is to with stand the fault current for a period of 10 seconds.
HT Switchgear (11 & 3.3 kV): Fully draw out type 11 kV& 3.3 kV Switchgears
with two incomers (2x100%) & a bus coupler scheme complete with Vacuum
Circuit breakers, busbars, Instrument
transformers,
relays,
meters,
transducers, line PT, Bus PT, terminal blocks & accessories for feeding all the
loads of the Coal Handling System package shall be included in the scope of
work. All HT feeders shall have vacuum circuit breaker.
The bidder has to submit the electrical system arrangement in entire CHP area
including SR to the Owner / Consultant for his approval. Any change made by the
Owner / Consultant is final.
LT Switchgear (415 V): Fully draw out type 415 V switchgear with 2x100%
incomers & bus coupler scheme complete with Air Circuit breaker, bus bar,
Instrumentation transformers, line PT, relays, meters, terminal blocks &
accessories as required for the Coal Handling System. The SR LT MCC is based
on the system requirement however it generally as per LT switchgear specs
mentioned elsewhere in the specs. For apron feeder of WT and long travel of
stacker reclaimer, the bidder can offer VFD/Variable Speed drives. In case of
apron feeder the drive panels may be located in Wagon tippler control room,
which can be discussed & finalized during detailed Engineering.
It shall be the responsibility of the CHP vendor to finalize and propose
the quantity and locations of the LV Switchgear required to feed the
auxiliary systems connected with the Coal Handling System. In general a
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dedicated LV switchgear shall be considered for each area / yard (covered
as
part
of
the CHP) that are having a significant number of electrical
consumers to warrant a separate switchgear. The quantity and location of the
switchgear proposed by the Vendor will be subjected to review and approval by
the Owner / Consultant.
Segregated / Non-Segregated Bus Duct one lot of Segregated Phase Bus Duct
between 11 kV / 3.6 kV transformer secondary to 3.3 kV switchgear, Non
segregated phase Bus Duct between 415 V Service Transformer to service
switchgear with required bends, supporting structures with related civil work.
Control Panel / JB/ PB - Control panels for auxiliaries like Hoist electrics, trolley
lines and power supply arrangement, Electrics for ventilation, air-conditioning,
JB's as required for all systems pertaining to CHP, Local start/stop PB for all
motors and forward / reverse / off PB for all valve/Flap Gate/Sector Gate
actuators (as applicable), as well as PBs and JBs required to meet requirements
shall be provided. All outdoor JBs shall be of FRP / die cast aluminum make with
canopy, IP-65 degree of protection. Local push button stations will be with IP-65
with canopy for outdoor use and IP-54 for indoor applications.
Cable & Cable Carrier System shall consist of but not limited to the following:
a)
One lot of MV/LV Power, control, Instrumentation, trailing cable and any
other special cables required for proper operation, monitoring and
control
of
the
CHP system. Sizing of the cable is to be designed as
mentioned in the specification.
b)
Cable raceway system consisting of cable racks, cable trays, Cable rack
/ tray supporting structures, support members / channels for cable
trays, cable tray covers, cable trenches, Duct Banks, conduits, pipe
sleeves, hume pipes, associated foundation and civil works, cable tray
accessories, etc., as required.
c)
Cable laying and cable termination including all necessary accessories
like cable termination kits, cable jointing kits, glands, lugs, tools for
termination, ferrules, identification tags etc.,
d)
Necessary fire protection systems like fire barriers, fire breaks, fire
stops, and fire proof sealing for wall/floor openings(after laying of all
cables) and fire protective coating systems etc., as necessary.
All the above items and any other item required for completing the Cable carrier
system shall be provided for the entire Coal Handling System.
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220V DC System: complete with Batteries, Chargers, Battery racks, Battery
MCBs, Distribution Board, associated flexible and power cables as required for
supplying all the DC loads and DC lighting system of the Coal Handling
System package.
As a minimum requirement, 1x100% 220 V batteries of suitable capacity with
2x100% float cum boost chargers and DC distribution board shall be provided
for catering to the requirements of Coal Handling System. The sizing of the
battery and charger is to be designed as per the specification.
Primary and Secondary Earthing and Lightning protection system: For the entire
Coal Handling System area, buildings, etc., complete with buried peripheral
earthing and earth electrodes or earth pits for the entire area shall be provided
in
this
package. This
shall
include
earthing
conductors
buried
in soil,
earthing conductors embedded in concrete inside the buildings, equipment
earth conductors, treated earth pits, earth rods, all above ground earth
conductors to which all the electrical equipment & metallic structures are
connected to have earth continuity for safety reasons. The primary earthing shall
be interconnected with the main grid at minimum four points. The system is to
be designed in such a way that the earth resistance is less than 0.5 ohm when it
is isolated from the main earth grid.
Lightning protection complete with vertical air termination rods, horizontal roof
conductors, down comers, test links and pipe electrodes shall be provided for all
structures for which the safety norms dictate requirement as per relevant
standards.
Coal handling system earth mat shall be connected to the owners main
earth gird at minimum four places.
Illumination:
Indoor, outdoor, road and yard lighting, power and welding receptacle system
for entire Coal handling system Package areas shall be provided as part of this
contract. This shall include, but not be limited to, lighting transformers, normal
Lighting DBs, AC / DC lighting panels, towers, poles, lighting fixtures, lamps,
Power sockets, welding receptacles etc for the entire coal handling system
covering all the buildings, outdoor areas, yard lighting, in its scope as per the
requirement. Lighting circuits will be protected by MCB/ELCB as required. At
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MLDB, two (2) nos. adequate capacity of uncabled feeders are to be given to
GCW bidder for his further usage.
The major areas to be illuminated under the scope of this package are
o
Conveyor and underground tunnel conveyor
CHP all control rooms
HT /LT switchgear
Crusher area
Transfer tower/Junction Towers
Transformer area
Roads under CHP.
The required uncabled lighting feeder will be given to General civil
works bidder for his usage and the same will be discussed during
detailed Engg.
Coal yard
Stacker reclaimer
Wagon tippler
Marshalling yard
Loco shed
Dozer shed
The areas listed are however indicative only for the purpose of guidance to the
bidder and is subjected to change during detail engineering after finalization of
plant layouts.
The minimum lux level shall be as per highest value mentioned in the IS 3646 /
as mentioned in the specs whichever higher is to be maintained.
The necessary software shall be used to determine the number of fittings
required in a particular area and desired lux level.
Equipment painting and its thickness is to as per relevant standard.
Special
tools
and
tackles
as
required
for
installation,
maintenance of electrical equipment shall be supplied.
operation
and
Essential and Start-up spares for all equipment shall be included in the
scope. Bidder shall furnish a comprehensive list of the same.
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Control room alarms/indications/SER points:
Remote Control, monitoring, alarm and indication for the electrical system such
as switchgears, transformers, DC system etc shall be from PLC / DCS system
provided in the CHP control room. All Control, Digital & Analog signals as
required shall be included and shall be subject to approval by owner
during
detail design
taken care by bidder.
stage.
All necessary communication protocol shall be
Control, monitoring, measurement and annunciation of complete electrical
system shall be possible from CHP main control room PLC / DCS through HMIs.
Control of all 11 kV, 3.3 kV and 415V breakers i.e. incomer, Bus coupler,
outgoing breakers of all switchboards shall be possible from PLC / DCS and the
same shall be linked with plant DCS located in the main control room. Remote
position, service position, breaker healthy i.e. trip circuit healthy, spring
charged, reset position of trip relay, other permissives interlocks, etc., shall be
considered as input to PLC / DCS system.
The current and voltage measurements for each bus and line shall be available
on PLC / DCS. The operation, indications and fault alarms for the motors of the
auxiliaries shall be displayed.
Any other electrical equipment which are not specifically listed above but
are required to make the CHP complete in all respects as per specification shall
be included in the scope of work.
The scope shall also include preparation and submission of all required
drawings for Owners approval not limited to:
i)
Main One Line Diagram for CHP clearly highlighting the scope of work
considered by the vendor.
ii)
Detailed Single Line Diagram for 11 kV, 3.3 kV and 415 V, DC and UPS
iii)
Protection and metering One Line Diagram clearly indicating the
iv)
system.
detailed protection and instrumentation provided by the vendor.
Layout drawings - Electrical equipment layout drawings including
General Arrangement
layouts
for
equipment, Cable tray and trench
drawings,
Earthing &
Doc. No.: E072-03-CHP-O-02
all
layout
CHP
areas / buildings /
drawings,
lighting
layout
Lightning Protection layout drawings including
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earthing
details
etc.,
as
required
by Owner with all supporting
calculations and documentation.
v)
Scheme drawings for all Switchgear / MCC /Motor modules/Control
vi)
Block Logic Diagrams for 11, 3.3 kV & 415 V systems.
vii)
Vendor drawings for all equipments covered in the scope.
Panels.
viii)
Relay Setting calculations, relay co-ordination studies, largest motor
starting study and recommended relay settings.
ix)
Foundation drawings with supporting calculations.
x)
The scope shall include submission of all required design calculations for
the following:
(a) Transformer sizing calculations for arriving at the MVA rating,
Selection of transformer impedances and tap ranges vis--vis Voltage
drops, Voltage dips and fault levels etc.
(b) MV & LV Switch board sizing
o
Bus Ducts Calculation for Span and Supporting Arrangement, and
busbar and enclosure sizing. Heat loss and temperature rise
calculations for conductor and enclosure
CT & VT Sizing calculations
Cable Sizing All Power Cables.
Voltage Dip Calculations.
220 V DC Battery & Battery Charger Sizing
Earthing Conductor and below and above ground earthing sizing.
Lightning Protection System Design
Lighting System Design and lux level calculations using well
known software like Calculux or Dialux.
o
o
Short Circuit Calculation for the entire coal handling system.
Relay Setting and Relay Co-ordination graphs for the Coal
Handling System plant
The contractor shall include all the required schedules including the following in
the scope:
Drawing control schedule
Cable Schedules For all Power, Control and Instrumentation Cables.
Interconnection cable Schedule for all cables supplied and installed by
contractor.
Relay setting schedules
Procurement schedule etc
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Data Sheets for all equipments included in the scope shall be submitted for
review & approval by Owner.
MQP & Field Quality Plan (FQP) are to be submitted for Owners approval.
2.3 CONTROL AND INSTRUMENTATION
2.3.1
The operation and control of entire coal handling plant including
Wagon unloading, conveyer, tippler, stacker-reclaimer etc. shall be
performed from its own dedicated PLC located in CHP & respective
control room in a completely integrated manner. This shall include
following as minimum:
a)
Redundant processor, redundant communication controller,
redundant power supply modules, redundant bus at all level,
I/O cards, operator work station and engineering work station
with dedicated keyboard and 24 TFT monitor, printers and
time synchronisation facility with plant GPS master clock ( time
format shall be as per GPS master clock requirement).
b)
Three nos. 24 TFT operator work station, one no. 24 TFT
operator work station cum engineering work station, Two nos.
industrial grade 52 thin bezel LCD display unit, one no. A4 size
(B/W), one no. A3 colour medium speed laser and one no. high
speed (180 columns) dot matrix printer shall be provided in
CHP control room. For more details regarding number of HMI,
Printers, LCD display units and others bidder shall refer CHP
PLC configuration diagram E072-03-CHP-1-03-08-R1.
c)
Solid
d)
Emergency Trip push button for HT drives & for all Electrical
e)
state
annunciation
system/PLC
hardwired annunciation windows.
based
system
with
power breakers mounted on auxiliary console/ panel.
Bidder shall provide necessary modular control desk and
standard make furniture for installation of operator station /
engineering station in the control room shall be subject to
approval by Owner.
f)
Bidirectional Redundant TCP/IP fast Ethernet connectivity/
redundant serial MODBUS RTU interface with plant DCS for
monitoring
including
cable,
both
side
required
hardware/software are under bidder scope. Bidder shall also
co-ordinate with Main Plant DCS supplier for achieving suitable
interface between Coal Handling Plant PLC and Main Plant DCS.
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g)
Few hardwired signals exchange between CHP PLC and Main
Plant DCS provision has to be made.
h)
2.3.2
Local control panels for Belt weigher, ILMS, Dust suppression,
Dust extraction, ventilation system, etc. shall be provided.
One no. 24 TFT operator work station and one no. 24 TFT operator
work station cum engineering work station and one no. A4 size (B/W
printer shall be provided for each stacker cum reclaimer control room.
Bidirectional communication shall be provided between stacker cum
reclaimer PLC and CHP control System. For more details regarding
number of HMI, Printers, LCD display units and others bidder shall
refer CHP PLC configuration diagram E072-03-CHP-1-03-08-R1.
2.3.3
One no. 24 TFT operator work station and one no. 24 TFT operator
work station cum engineering work station and one no. A3 colour
medium speed laser and one no. high speed (180 columns) dot matrix
printer shall be provided for each wagon tippler control room.
Bidirectional communication shall be provided between wagon tippler
PLC and CHP control System. For more details regarding number of
HMI, Printers, LCD display units and others bidder shall refer CHP PLC
configuration diagram E072-03-CHP-1-03-08-R1.
2.3.4
All junction boxes, local push button stations, all Interconnected
cabling between sensors to JB/ Panel, Panel to I/O card, card to PLC
system operator station, Instrumentation/ special cables/ RTD cables/
pre-fabricated cable/ earthing cable, cable glands, Lugs, ferrules,
cable trays, conduits, instrument racks, impulse/ air supply pipes/
tubes, erection hardware, instrument isolation valves, instrument
fittings (double compression type) and other accessories are within
battery limits.
2.3.5
All field instruments/ sensors/ switches/ belt protection switches,
final control elements with actuators as per finalised P&IDs, schemes,
operation and control philosophy and logics approved during detailed
engineering stage within the coal handling plant package.
2.3.6
Vibration monitoring system for HT drives as recommended by
package vendor and same shall be located in the CHP control room
and interfaces with CHP PLC. The vibration monitoring system shall
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include
the
Vibration
Probes
(Proximity/
Thrust/
Velocity/
Accelerometer), Special Cables, Sensors/ Signal Conditioners, PreAmplifiers (if required), minimum IP-55 Junction Boxes, Signal
Conditioners, Pre-Amplifiers, Vibration Monitors, etc.
2.3.7
Coal Bunker Level measurement instrument shall be provided by BTG
supplier, all necessary required cable (laying and termination) up to
CHP control room, instrument installation hardware, installation of
instrument, etc. of coal bunker level instrument are under CHP
Package supplier scope.
2.3.8
PLC I/O cards and relays for control and monitoring of all instruments,
drive and equipment are to be housed in air-conditioner environment
(room/enclosure).
2.3.9
Licensed software required for complete PLC operation as well as for
interface of CHP PLC with plant DCS.
2.3.10
Redundant UPS power supply requirements & conversions to required
voltage levels and further distribution of entire coal handling plant
shall be in the scope of bidder.
2.3.11
Any other item not covered herein but essential for successful
installation and commissioning of the coal handling plant and integrity
of the system shall be included by the Bidder.
2.3.12
2.4
All necessary Vendor/Drawing/documents shall be subject to approval
from Owner.
CIVIL
The works to be performed under this specification include execution of
complete civil, architectural and structural works for foundations for equipment,
buildings, facilities, substructures, superstructures including structural steel
fabrication and erection and infrastructure works for the entire coal handling
system. The works shall generally comprise (but not limited to) carrying out
detail engineering, design computations, preparation of detail construction
drawings & design reports and getting the same approved by owner/ consultant
including
all
necessary
survey,
tests,
studies,
investigations
including
geotechnical investigation work as may be required for design, construction or
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erection up to the specified terminal points mentioned elsewhere, including
supply of all materials, consumables, tools & plants and labour etc as per
approved drawings and these specification for the following:
Site clearance, leveling and grading to achieve FGL as per requirement: for
complete coal handling plant area.
Coal Crushing and screening system Includes crushers and screens.
Main CHP control room and MCC Room
Wagon tippler control room and MCC Room
Wagon Tippler shed and allied works
Wagon Tippler (WT) & side arm charger- 5 nos.
Conveyor tunnels from tipplers
Conveyor tunnels from Manual Reclaim hoppers
Transfer Towers (TT) Nos. as per mechanical specification.
Transfer House (TH) Nos. as per mechanical specification.
Stacker Reclaimer foundations
Coal stack yard
Manual Reclaim Hopper (MRH)
Bulldozer Shed.
Pent House Nos. as per mechanical specification.
Dust suppression system as per mechanical specifications
Dust extraction system as per mechanical specifications
Works related to transformers and other electrical facilities for CHP area (As
per Electrical specification & scope)
Foundations and Support columns (as and where required ) for Belt
Conveyors/Gallaries etc.
All main roads in CHP area and approach roads connecting all facilities in the
Coal Handling package to the nearest main roads of BTG area, including
drains, culverts and bridges, diversion / training of existing nalas wherever
required.
Civil works required for illumination of the facilities in the Coal Handling
package and connecting approach roads.
Any other structure / building necessary for completion of coal handling
plant.
Water Tanks and pump houses for Dust Suppression System
Tunnel Ventilation System
Emergency Reclaim Hopper/Mill reject Handling system; Quantity as per
Mechanical Specification
No of stacks/stacker reclaimer as per Mechanical specification
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Garland Drains, Decantation tanks, Coal pile run off pond, Coal sampling
room and Office Complex for O & M staff for CHP
About 15 nos. of toilet blocks along with adequate size of soak pit / septic
tanks and water tanks and connections are to be provided in the coal
handling area. The location and size of the toilets blocks to be decided
during detail engineering.
The work to be performed under this specification shall include all incidental
items not mentioned or specified but reasonably implied or necessary for the
completion and proper functioning of the plant, all in strict accordance with the
specifications including revisions and amendments thereto as may be required
during the execution of work.
This specification covers the methodology to be followed for design and
construction of all civil, structural and architectural works for the complete Coal
handling system. Description of various items of work and nature of work
involved under this specification are given hereinafter. The items, though not
specifically mentioned, but are needed to make the system complete shall be
treated as though included and the same shall also be furnished and erected /
constructed unless otherwise specifically mentioned as excluded.
The bidder should also note the following details, pertaining to the scope of
civil works under this specification:
i)
The civil works to be performed shall cover providing all labour,
materials, construction equipment, tools and plant, scaffolding, supplies,
transportation, all incidental items necessary for successful completion
of the work. The work shall involve earthwork in excavation including
controlled blasting and very deep underground excavation, extensive de-
watering, shoring and strutting, sheet piling, back filling around
completed structures and plinth protection, area paving, disposal of
surplus excavated materials, concreting including reinforcement and
form work, brick work, fabrication and erection of structural /
miscellaneous steel works, inserts, architectural items & finishes such as
plastering, painting, flooring, doors, windows & ventilators, glass and
glazing, rolling shutters etc., permanently colour coated profiled steel
sheeting, anchor bolts, R. C.C. trenches with covers, laying and testing of
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water pipes, sanitation, water supply, drainage, damp proofing, water
proofing and other ancillary items.
ii)
The work shall be carried out both below and above ground level and
shall include basements, equipment foundations including vibration
isolation systems, grounding, slabs, beams, columns, footings, rafts,
walls, steel frames, brick walls, stairs, trenches, pits, access roads,
culverts, conveyer galleries, trestles, penthouses, wagon tippler hoppers,
emergency reclaim hoppers, underground tunnels, crusher house,
transfer
towers, buildings for switchgear and control room, finishes,
complete architectural aspects, drainage, sanitation, water supply (from
terminal points to various buildings,
conveyor galleries) and all other
civil, structural and architectural works associated with
Coal Handling Plant.
iii)
the complete
All buildings shall be complete with all electrical, civil, structural,
architectural works, cable trenches, fire safety walls, foundation, earth
mat, fencing, earthing for transformers. All cables, duct banks, trenches,
cable trestles shall be complete with associated civil/ structural work and
necessary civil foundations. Buildings to be provided shall include the
following:
a)
b)
c)
Underground/partially
underground
transfer
points
(RCC
construction)
Overground transfer points and Crusher House (steel construction)
Electrical & control buildings (RCC construction) listed below:
Main switchgear and central control room building near
crusher house
Wagon tippler/ emergency reclaim hopper switchgear and
control building near wagon tippler complex
Office complex for O&M staff and storage rooms near main
control room.
iv)
Scope shall also include supply and laying earthing mat all around the
periphery of buildings, structures, and outdoor equipment, as per the
approved drawings.
v)
The analysis, design and detailed drawing for the structures like wagon
tipplers tunnels etc. coming below the railway track shall be got
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approved from the
concerned railway authority before taking up
construction.
vi)
Arranging construction water from underground sources, storage in
underground/ over ground tanks and taking the water to construction
site through pipelines by pumping or by road tankers etc., including all
necessary accessories, tools & tackles etc.
vii)
Access roads to all buildings/facilities of CHP including construction and
maintenance
of
temporary
access
roads
for
building/facilities for construction/erection activities.
approach
to
the
The scope shall also include setting up by the Contractor of a complete testing
laboratory in the field to carry out all relevant tests required for the Civil and
structural works as detailed elsewhere in the specification.
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3.0 TERMINAL POINTS AND EXCLUSIONS
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TERMINAL POINTS AND EXCLUSIONS
3.1
Terminal Points
3.1.1 Mechanical
Tripper conveyor along with its rail at Bunker floors.
Potable and service water at one point 5 meter away from Secondary crusher
house -1.
CMB/ETP for coal yard drainage piping.
3.1.2 Electrical
Two nos uncabled breaker terminals of 11 kV Station switch board (under
BHEL scope).
Four points of Main earth grid for below ground earthing.
Two uncabled feeders at MLDB for GCW bidders scope
3.1.3 Control & Instrumentation
Few hardware signals of CHP for linking with Main Plant DCS:
All Cables (including laying and termination) up to Main Plant DCS Marshalling
Cabinet.
SOE - Points for CHP:
All Cables (including laying and termination) up to Main PlantDCS Marshalling
Cabinet.
Interfacing Cable for CHP PLC with Main Plant DCS:
All required software/hardware, cable (including laying and termination) up to
Main Plant DCS system.
3.1.4 Civil
Roads:
All approach roads interconnecting all facilities under CHP package and their
connections to the Main plant roads at suitable locations. (As per enclosed
drawing).
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Sewerage line:
Upto existing connection chamber/ manhole nearest to the toilets. However, if
no chamber / manhole exists, the bidder shall provide the same with proper
connections.
Drains:
All garland drains/ local drains for effective drainage of rain water at all facilities
and roads under CHP package and their connections to the Main storm water
drainage network at suitable locations.
3.2
Exclusions
3.2.1 Mechanical
Service water pipe line beyond the terminal point
Potable water pipe line beyond the terminal point
Bunker house including bunker floor
Marshalling yard on either side of the wagon tippler rail
3.2.2 Control & Instrumentation
Coal bunker level instrument:
BTG supplier scope.
3.2.3 Civil
Roads:
Main plant roads except approach roads interconnecting all facilities under CHP
package and their connections to the Main plant roads at suitable locations.
Sewerage line:
Beyond connection chamber/ manhole near the toilet.
Drains:
Storm water drains beyond CHP battery limit.
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4.0 TECHNICAL REQUIREMENTS OF COAL
HANDLING PLANT
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TECHNICAL REQUIREMENTS
4.1
MECHANICAL
4.1.1 Rated and design capacity
Conveyor system
Design and Rated Capacity
of each
conveyor
The capacities of conveyors from
Wagon tippler to bunker including
yard conveyors are, Designed
2200 TPH and Rated 2000 TPH.
Except manually unloaded coal
conveyor BCN-23A/B, which has a
capacity of Designed-600 TPH
and Rated- 500 TPH.
Primary Crusher
Rated capacity of each Crusher
1000 TPH
Designed capacity of each crusher
1250 TPH
Input coal size
(-) 300 mm
size of crusher output
(-) 150mm
Vibrating Screens
Rated capacity of each screen
1000 TPH
Designed capacity of each screen
1250 TPH
Size of coal screened
(-) 20mm
Secondary Crushers (Ring granulators)
Rated capacity {considering 100% feed 1000 TPH
coal above 20 mm size}
Designed
capacity
{considering
100% 1250 TPH
feed coal above 20 mm size}
Input coal size
(-) 150 mm
Guaranteed size of crusher output
98% down to (-) 20 mm
Traveling Trippers (Mobile)
Capacity (Rated/Design)
2000/2200 TPH
Stacker cum Reclaimer
Rated/Guaranteed
capacity
of
yard 2000/2200 TPH
conveyor
Design Capacity (considering specified %
bucket fill)
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(i) Stacking
2200
TPH(Designed)/2000
(ii) Peak Reclaiming (for bucket sizing)
2200
TPH(Designed)/2000
TPH(Rated)
TPH(Rated)
Height of stock pile to be formed
8.75 Meters
Boom length (Minimum)
36 meters
Lump size to be handled
(-) 20 mm
All other equipment under the scope of work of the contract shall be suitable to
the system capacities parameters as specified above.
4.1.2 Standards/Codes
The design, manufacture, inspection and testing of all equipment/system shall
comply with all the currently applicable statutes, regulations and safety codes in
the locality where the equipment is to be installed. All equipment/system shall
conform to the latest edition of the following standards and codes. Other
internationally acceptable standards/codes, which ensure equal or higher
performance than those specified, shall also be accepted. Nothing in this
specification shall be construed to relieve the contractor of the required
statutory responsibility.
In case of any conflict in the standard and this
specification, the decision of the RPCL shall be final and binding.
All construction, installation, workmanship, design & equipment shall conform
to following or equivalent standards or codes, in so far as they apply:
IS: 7155:
Codes of Practice for Conveyor Safety.
IS: 1891 (Part-I) :
General Purpose Belting
IS: 8598:
Idlers and Idler Sets for Belt Conveyors
IS: 4009 (Part-II) :
Conical Head Grease Nipples
IS: 8531:
Pulleys for Belt Conveyors.
IS: 2062:
Structural Steel (Standard Quality)
IS: 4682:
Codes of Practice for Lining of Vessels and Equipment
for Chemical Processes.
IS: 11592:
Code of practice for selection and design of Belt
Conveyors.
CAN / CASA - M422
Canadian standard association.
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Conveyor Equipment Manufacturers Association (CEMA) All other national /
international codes and standards.
4.1.3 Specification of Equipment
4.1.3.1
Wagon Tippler
Wagon tippler shall be as per RDSO latest G-33 (Revision-1) norms. The wagon
tippler provided shall be hydraulically operated type.
The wagon clamping
arrangement shall necessarily be hydraulic type. The wagon tippler shall be
suitable for continuous duty, designed to unload all standard broad gauge
wagons of Indian Railways. It shall be capable of taking at a time one all Box N
type open Wagons for weighing and unloading at a rate not less than as
specified
in
data
sheet. The wagon tippler shall be equipped with inline
Electronic weighing.
The tippler shall consist of tippling platform, cradle arms, cradle arm
bearing, Side stop with pads, top stop with pads, driving motors, gear and
pinion drive, balance weight,
limit
switches for top and bottom stops,
shafts,
steel,
walkways,
bearings, supporting
associated equipment to make a complete unit.
platforms
and
all
other
During each cycle of operation, the tippler shall be capable of holding, complete
unloading
and
replacing
the
standard
railway
wagon
to
its
original
position. The wagon tippler shall be designed for outdoor installation and
shall be of heavy
and
suitable
duty
construction
rigidly
reinforced
throughout
for continuous duty.
The operation of the wagon tippler shall be through hydraulic motor without
gear
box
&
coupling
&
directly
coupled
to
driven
shaft
and
completely automatic such that one operator can control all the operations
from a single control panel. However, one more labourer shall be required to
uncouple loaded wagon from the rake during operation of wagon tippler.
The location of the control room shall be such that the operator can have a
clear view of the tippler operation as well as the railway facilities. The
tippler design shall be co-ordinated with that of the unloading hopper
and it shall be arranged to provide convenient access to any part of the
tippler
and
the hopper from any point above or below ground, as may
be required during operation and/or in-operative periods.
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The design of civil and structural work for the wagon tippler complex shall be as
per relevant IS codes. The design of equipment as well as civil and structural
work of
tippler shall conform to the requirements of latest Indian Railways
Research, Designs and Standards Organization (RDSO) G-33 regulation of
local railways authorities and all other statutory norms with regard to the
nature of loading,
be
the
impact
factor
and
allowable
stresses
etc.
It
shall
sole responsibility of the Bidder to ensure that each & every
component of the wagon tippler is adequate in rigidity, strength of heavy
duty construction and of first class quality to guarantee against failure or
major repair, assuming proper maintenance and usage. The tippler table shall
be designed to allow passage of the standard main Indian Railways diesel
locomotive
of
over
the table. The wagon tippler shall be capable of adjustments
clamps automatically i.e. without physically changing attachments to cater
different type of wagons.
The tippler shall be driven by suitable separate hydraulic systems for
operation of tippler drive hydraulic motors and hydraulic clamp cylinders.
The individual
hydraulic power packs to be located away from tippler
shall be provided inside a room at the ground floor of WT control room.
The wagon tippler drive shall comprise of independent hydraulic motors
each mounted directly on the shaft of drive pinion meshing with cast steel racks
bolted to the periphery of the one end section of wagon tippler. All hydraulic
motors shall be provided with disc brakes to hold the tippler at any position
during rotation.
All working parts requiring lubrication shall be of sealed construction so
that dust,
with
dirt
and
other
wearing surface.
proper
tippling
angle
The
foreign
tippler
at
the
do
not
come
shall
be
designed
in
contact
to
have
to discharge all the contents of the wagon from it. The
top stop structure shall be designed
wagon
matter
maximum
to
hold
the
partially
uploaded
tipping position for specified length of time,
without any damage or distortion. Limit switches shall be provided to cut off
power supply at the end of travel. Back up limit switches shall also be provided.
Provisions shall be made for alignment of tippler
platform
by
inching
operation in case it does not align properly with outside rail.
All rack and pinions, unless otherwise specified in the Data Sheet shall
be of steel. Gear teeth shall be of 200
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involute stub form, and shall be
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machine
cut from
solid
lubrication of the gear drives.
housed
in
fabricated
blank.
All
Provision shall be made for adequate
gears
shall
be
totally
enclosed
and
steel housing. This shall be fitted with bolted type
machined inspection covers. Dip sticks or indicators shall be provided for
indicating the oil level. Bidder shall give guarantee for the noise less and
distortion-less operation of the gears when handling the specified full load.
A reliable braking arrangement shall be provided to hold the tippler table at the
maximum tipping position for a specified length of time or at any intermediate
position on failure of power supply. The brake shall be located such as to
ensure
positive
braking
action,
actuated
by
remote
operation.
The
torque capacity shall be equal to the normal operating torque of the
driving motor. A weather proof cover shall be provided for each complete
brake
mechanism. The
brake
shall
be
heavy
released, spring set, friction shoe type and shall
supply is cut off. All
duty
type,
electrically
apply when the power
auxiliary equipment for the brake shall be supplied by
Bidder. The brake shall be fail safe type and it shall perform satisfactorily even
in the event of power failure.
Rack & Pinion arrangement shall have ample strength to drive cradle with full
wagon. The material of construction shall be of a high grade steel to
suite the specific operating condition. Factor of safety to be considered as
per code to withstand the operation. Colour signal shall be provided at the
inhaul side of tippler table for the guidance of loco operator.
All shafting shall be proportioned for stiffness as well as strength. Shafts
76 mm (3) in diameter and more shall be fabricated from steel forgings
or hot rolled steel rounds with a minimum carbon content of 0.3%. Shafts
smaller than 76mm may be made from cold finished steel, or hot rolled
steel. Shafts turned to provide changes of section shall have a minimum 6
mm fillet radius wherever such changes occur.
All shaft couplings shall be gear type flexible and an approved product
of a reputed
develop
manufacturer
of
equipment
of
this
nature
and
shall
full strength of the shafting which it connects and shall be
pressed and keyed to the shafting. Rigid plate guards shall be
provided for
all couplings.
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All antifriction bearings shall be of approved make, shall have a minimum
life expectancy of 30,000 working hours and may be ball / roller type.
Bearing housing shall be split and designed to exclude dirt and prevent
leakage of oil or grease.
Bidder shall furnish necessary electricals, control desk, safety interlocks for
controlling the operation of the wagon tippler from control desk.
It should be possible to control the operation of the wagon tippler by a
single push button. Operation of this switch shall rotate loaded wagon, hold it
at the maximum tipping position for the specified length of time and lower the
empty wagon
tilting
to
the
original
position.
Separate
push
buttons
for
and repositioning of tippler table shall also be provided by the Bidder.
Suitable interlocks shall include but not being limited to the following:
Signal light:
It shall not be possible to operate the tippler when the Wagon
placing is taking place.
Suitable interlocks shall be provided so that tippler operates only if the
wagon is centrally located on the tippler table.
Limit Switches shall be provided to stop the travel of the tippler table at
the predetermined extreme positions. In addition, back-up over-travel limit
switches shall be provided for the tippler discharge position.
Besides above, any other limit switches required for the safe operation of
wagon tippler shall be provided.
Ballast, necessary for proper balancing of the tippler, shall be provided so
as to have minimum power requirement. Any concrete work required for it
shall be provided by the Bidder.
The complete design of the wagon tippler and accessories shall meet the
approval of RDSO and obtaining the necessary approval from RDSO / Zonal
railways statutory authority for wagon tippler and its layout is included in
the scope of Bidder, under this specification.
However necessary application
only as an Owner shall be given by the Owner to the bidder as and
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when required, for obtaining above approval. All the statutory fees/charges
for obtaining such approval shall be borne by bidder.
4.1.3.2
Side Arm Charger
The side arm charger shall be used for wagon positioning at the wagon
tippler for unloading of materials, It shall be used for pushing / pulling a rake of
60 wagons of 110MT gross weight each and locating wagons one by one on
tippler platform. The tractive effort shall not be less than 30 Tons.
The train shall be brought by locomotive either heading or pushing and
stopped with the leading wagon within range of the side arm charger. The
charger shall be driven to the leading wagon, its arm shall be lowered and it
shall be coupled to the first wagon of the train. The train shall be hauled forward
by the charger until the front of the second wagon is about 2 meters
away from the tippler. The charger shall stop and the first wagon shall be
uncoupled from the train. The charger shall then propel the leading wagon to
the tippler, automatically uncouple and shall run clear of the tippler. Its
arm shall be raised and it shall travel back to the train and the tippler shall
rotate. On reaching near the standing train, the charger arm shall be lowered
and shall be coupled to the train ready for repeating the cycles. In the next cycle
the train shall be drawn up by the wagon length and the previously tippled
wagon on the tippler table shall be pushed on the outhaul side. The charger
shall be used under manual control to eject the last wagon from the tippler, if
the next wagon is not already in position.
The supply includes side arm charger with power supply system, support, Rack
and Pinion, electricals, buffer stop etc
The side arm charger shall be mounted alongside the main rail track and shall
run on its rail track parallel to the main track. It shall have a suitable stroke from
point just over one wagon length ahead of tippler to a point just beyond the
tippler on the outgoing side. The rail envisaged for SAC shall be standard rail
section.
It shall be fitted with an arm pivoted at right angles to the track capable of being
raised and lowered and carrying at its outer end an automatic coupler to couple
the train.
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The charger frame shall consist of a single fabrication from rolled sections and
plate on which every other item shall be directly mounted to form a robust
compact unit.
The charger shall run on four steel wheels mounted on spherical roller
bearings.
To resist the moment reaction of the pushing force, two pairs of steel side guide
rollers shall be fitted. They shall be fitted on spherical roller bearings and shall
have a simple lockable adjustment for true running and to take up wear. The
side guide rollers shall run on the sides of the heads of the charger
running track.
The arm shall be of welded construction. Raising and lowering of the arm shall
be by means of a hydraulic power cylinders mounted on the charger frame. A
spring-loaded coupler shall enable automatic coupling of the arm to the wagon
coupler and an actuator release mechanism with a hydraulic cylinder shall be
provided for decoupling.
The charger shall have adequate power for pulling a train load of 60 loaded all
type of Box-N wagons on a straight and level track. It shall be hydraulically
driven by means of a pinion and land mounted rack.
The drive pinion shall be mounted on the output shaft of the hydraulic drive
motor without any gear box & coupling.
The side arm charger shall have a hydraulic power pack mounted on board,
which shall provide power to independent hydraulic motors without any gear
box & coupling directly coupled to driven shaft for charger transverse and arm
hoist.
The power pack shall be complete with variable displacement pumps,
proportional control valves with electronic cards, filters, piping, tank and
accessories.
The charger shall be electrically interlocked with tippler for proper sequential
operation with respect to operational and safety requirements.
Easy access, adequate maintenance spaces, working platforms, inspections
covers shall be provided for all the equipment located in the side Arm
Charger for safe and quick maintenance. All edges and openings shall be
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provided with toe guard. Chequered plates on floor shall be provided to prevent
slipping.
Centralized system of lubrication shall be provided for the equipment. However,
all parts of the equipment needing manual lubrication shall be easily
accessible. All oil pipes and grease nipples shall be well covered to prevent
materials from falling on them.
The side arm charger shall be suitable to move 60 loaded Box N wagons on a
straight and level track and shall be suitable to position all types of
wagons at the centre of wagon tippler designed considering available track
layout.
The equipment shall be of robust construction, suitable for operation in
dusty, humid and outdoor operation. The SAC rails and main rails shall be
supported on RCC foundation.
The SAC shall be operated automatically and controlled from common WT
control room and will be housed in common control desk of tippler &
marshalling system.
4.1.3.3
Apron Feeder
The apron feeder shall be suitable for continuous duty and shall be robust in
construction. It shall be capable of absorbing the shock load due to impact of
falling large coal lumps of up to 300 mm size and other heavy metallic
components / pieces without damaging the feeder.
The driving and driven ends with sprocket shafts shall be supported in heavyduty anti-friction bearing with minimum triple labyrinth sealing for dust
protection and shall have provision for external lubrication. The Sprocket shaft
shall be constructed of alloy Steel.
The design shall be sturdy and shall
withstand fatigue and provide torsional stability.
The steel chain shall be constructed out of wear resistant deep hardening alloy
steel, in heavy sections. The steel sections shall be held together by alloy steel
bar pins with wheels on either side which will move on rails. All sections shall be
so designed that it can operate under the worst conditions of operation with wet
coal, muddy coal etc. without jamming. All parts shall move smoothly.
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The entire assembly of the feeder parts, the bearings, driving and driven
sprockets etc shall be housed on heavy duty structural frame with arrangement
for mounting the same on RCC foundation.
The feeder shall be provided with reliable tensioning arrangement to take care
of elongation in the feeder.
The Apron feeder shall be driven through variable speed electric drive without
any gear box & coupling & directly coupled to driven shaft. The feed shall be
regulated by variable speed electric drive.
All drive components shall be provided with safety guards.
The Apron feeder construction shall be of an approved and proven design and
shall ensure operation of feeder in an aligned motion.
Apron feeder parts shall be either lubricated for life or shall be provided with
centralized lubrication arrangement.
The pan construction shall be such that it shall prevent leakage of coal dust
during loading / conveying and discharging pan shall be fabricated with side
plate of adequate height and style suitable for installation below wagon tippler.
Also stationary skirt plate shall be provided to guide coal below wagon tippler
hopper without clogging or jamming. Pans/ aprons should be reinforced to take
impact of maximum 300 mm lump of coal falling for a height to suit the system
& thickness of pan shall be 20 mm (min.). Pan material should be LA-55/ boron
steel material.Hardness of material shall be 45 to 50 RC.
The feed of coal over the downstream conveyor from both the apron feeders
should not cause overloading of the downstream conveyor over the entire range
of speed of operation of the apron feeder. To achieve this, belt weigher signal
may be suitably used to trip the apron feeder in the event of any overloading of
the conveyor belt.
Zero speed switches shall be provided on apron feeder.
4.1.3.4
Belt Conveyor System
All Belt Conveyors shall be supplied and erected along with necessary
supporting structures, platforms, on ground or overhead galleries, trestle
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ups, pulleys, drive motors with suitable reduction units and couplings, belting,
transfer chutes, flap gates, hydraulic couplings and other necessary accessories
as per scope specified elsewhere.
Design Requirement
Belt conveyor system shall be designed as per latest edition of 'Belt Conveyors
for
Bulk
Materials",
published
by
CEMA
or
equivalent
latest
National/International Standards. Design of belt conveyor system shall be based
on coal parameters as specified.
Conveyors shall be provided with electro hydraulic thrustor brakes or flywheels
to adjust the coasting time of conveyors such that there will not be any build up
of material in the chutes.
In case of traveling trippers, the requirement of minimum radius can be relaxed
only where space constraints do not permit the same. Where minimum radius
over concave curves is less than 250 m, in those cases suitable belt hold down
guide pulley shall be provided over the concave curve of belt.
In no case, the diameter of the idler roll shall be less than 152.4 mm for both
carrying side and return side.
Pulleys of all conveyers shall be rated for 120% of actual requirement of driven
equipment at specified design capacity. The nominal diameter and face width of
the pulleys shall be as per IS: 8531. For selection of pulley shaft diameter a
margin of minimum 20% shall be considered on maximum tension. In
determination of pulley diameter no account shall be taken of pulley lagging.
Pulleys of same diameter shall be completely interchangeable in totality and
component wise. To have interchangeability of same diameter pulleys procured
under separate contracts for a station, the bearing center distance of pulleys
shall be adjusted.
Idlers
Carrying idlers shall be provided with three equal rolls with troughing angle of
35 deg. and 2 deg. forward tilt
The rolls used in idlers shall be supported from fabricated steel brackets. Fixing
arrangement of rollers with brackets shall be drop-in type. For adjusting the
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alignment of the idlers, slotted holes shall be provided in idler supporting base
plates. Direction of belt travel shall be clearly marked on the brackets of carrying
idlers.
Idler rollers shall be waterproof, dust proof and weather proof against a high
velocity water jet. All idlers shall be provided with at least double labyrinth dust
seal.
Impact idlers used at the loading and transfer point shall be so designed as to
avoid direct loading impact, belt damage and excessive punishment to the
carrier.
The self-aligning idlers shall be direct acting type, complete with actuating
rollers fitted with the ball bearings and mounted inclined towards the belt. The
idler frame shall be suitably cradled about a vertical pivot, supported in bearing
over a fixed plate. Adequate sealing arrangement shall be provided to prevent
contamination of the lubricant by dirt and moisture.
Transition type toughing idlers shall be used adjacent to all pulleys to permit
proper support of the loaded belt near the pulleys without excessive stretch of
the belt edges. The transition idlers shall be provided with preferably adjustable
concentrator (end) rolls and long center rolls to suit the toughed belt contour
between the last regular toughing idler and the adjacent pulleys.
All the conveyors shall be provided with one self-cleaning type rubber disc
return idler located near the head pulley for cleaning the return belt.
Proper arrangement shall be provided in the brackets of all types of idlers for
preventing the rollers from coming out of the brackets during normal /
abnormal conditions. The base frame for all carrying shall be of C-channel and
side bracket shall be of pressed C- type. The pulleys below the magnetic
separator shall be non magnetic material (Aluminum / SS)
External Belt Cleaner
Counter Weight scraper type cleaner with modular segmented and replaceable
polyurethane scrapers blades complete with main cleaner, pre-cleaner along
with accessories and necessary fines chutes shall be furnished for all belt
conveyors, tripper head pulley and belt feeders at discharge pulleys. The
modular units shall be easily replaceable. The scraper assembly shall be easily
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maintainable from outside without any interference with the chute arrangement
and assembly.
Internal Belt Cleaner
V-plough type belt cleaner made of mild steel flats and hard rubber strips with
automatic wear adjustment and necessary accessories shall be furnished for
cleaning internal surface of the conveyor belt.
Belt Take-up Arrangement
The automatic take-ups should be located at a place where these will work best
in relation to the drive to keep the belt tension at a minimum.
Height of take-up guide structure shall be sufficient to allow the take-up weight
movement up and down for all operating conditions of conveyor.
Automatic take-up of gravity type shall be provided with necessary take-up
arrangements complete with bend pulleys, take-up pulley, with its supporting /
sliding assembly, wire ropes for suspending the separate take - up weight
sliding assembly close to the ground, counter weights and other accessories.
Suitable guards marked up scale attached to the frame to monitor belt stretch
and access/maintenance platforms with handrails all around etc. shall be
provided. Adequate access from conveyor gallery/transfer house/ground etc.,
as the case may be shall be provided to inspect, repair and maintain the gravity
take-up arrangement. Suitable arrangements shall be provided for clearing
accumulated coal from various platforms to ground level.
Two meter safety fencing along with suitable gate and locking arrangement shall
be provided around gravity take-up at the base level / ground level.
Suitable guides shall be provided both for take up pulley and take up weight.
Suitable buffer arrangement shall be provided to arrest the fall of take-up pulley
in order to avoid damage of the pulley assembly in case of belt snapping.
Similar buffer arrangement shall be provided for take-up weight also in case of
take-up weight travel zone terminating above a building floor. Suitable sand
pits shall be provided at ground below the take-up weights.
For double stream conveyors, a partition of 3mm steel plate shall be provided
between the two take-up pulleys along entire travel zone of take-up pulleys.
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Intermediate platforms shall be provided in the take up zone for maintenance of
take-up pulleys/counter weight.
Hold Back Devices
Suitable hold back devices for preventing running back of the conveyor belt in
case of conveyor being stopped in loaded conditions due to power failure or
during normal operational delays shall be provided to give positive protection. It
shall be released instantly when power resumes or the delay is removed. The
holdback devices shall be integral with gear Box.
Pulleys
Pulleys shall be mounted on machined & ground surfaces. Suitable guards shall
be provided for all tail pulleys and bend pulleys for safety of operating
personnel.
The Plummer blocks for pulleys shall be of horizontally split type construction
with minimum (4) nos. bolts holding the two split halves and with min (4) nos.
foundation bolts. Conical head shape nipples conforming to IS: 4009, suitable
drain plug and eyebolt shall be provided. Side covers of Plummer blocks shall be
heavy-duty metallic sheets. No plastic components shall be used.
The snub pulleys on each conveyor shall be located to provide a belt wrap on the
drive pulleys.
The rubber lagging of pulleys and method of lagging and testing the same shall
conform to IS: 4682.
Pull chord Switch & Belt Sway Switches
Pull chord type (manually reset type) emergency stop switches shall be located
on both sides of belt conveyors along the walkways for the entire length of
conveyors for emergency stopping of conveyor with a spacing of 30m. Local pull
chord actuation shall be provided by means of mechanical flap. Local indication
for pull as well as remote chord actuation shall be provided. Their enclosure
shall be of cast aluminum having degree of protection of IP-65.Remote Pull Cord
Trip Indicators/Locators shall be provided in the CHP Control room to inform the
operator about the exact location of the actuated switch.
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Belt sway switches of self-resetting type shall be provided at 50m periodic
intervals to limit belt sway to permissible extent. Local belt sway actuation
indication shall be provided.
These shall have a separate terminal box with a separate hinged cover totally
sealed from the main box containing actuating mechanism/ limit switch etc.
Each switch shall have two NO and two NC contacts one for alarm and one for
trip, which shall be wired up to terminal block. The terminal block shall have
facilities for cable looping.
Zero Speed Switch
Each conveyor drive shall be provided with zero speed switches to stop the
system in case of belt speed falling below the tolerable limit. Adequate
mechanical protection by means of non-metallic shields shall be provided on
top of the switch to prevent any damage due to falling coal / metallic pieces etc.
In built initial start up delay and nuisance tripping delay through timers shall be
provided. Each switch shall have two NO and two NC contacts wired out to the
terminal blocks.
Under belt switch
These switches shall be installed under the belt for detecting the presence of
material on the belt whose contacts shall in turn be used for operating solenoid
valves of dust suppression system elaborated elsewhere. The minimum degree
of protection of switch shall be IP-62. The switch shall be capable of detecting
three events simultaneously. Those are (i) Belt loaded (ii) Belt running at more
than preset speed (iii) Preset initial start delay.
Skirt Boards
Skirt board shall ensure centralised loading of conveyor belt to avoid coal
spillage. In the belts before Crusher House where coal of appreciable lump size
(300 mm) is being conveyed, the gap between the bottom of the skirt board and
the belt shall be made to increase uniformly in the direction of belt travel. The
skirt plates shall be fitted with modular segmented and replaceable rubber
skirting pads having facility of adjusting the pressure on the belt conveyor and
shall have provision of on-line removal for the purpose of easy maintenance.
Conveyor Galleries
All over ground and overhead conveyors shall be located in suitably enclosed
Galleries made of Structural steel. Galleries of adequate width and depth (2700
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mm clear head room) shall be provided complete with conveyor bottom deck
plates, seal plates, walkways of chequered plates hand rails on both sides of
each conveyor belt (except where equipment like trippers etc. traverse over
conveyor), conveyor supports etc.
Construction of walkway shall be done with chequered plate with antiskid
arrangement. Chequered plate steps shall be provided where conveyor slope
exceeds 10 degrees. It should be totally sealed so that no water falls down while
washing.
The conveyors shall be provided with continuous steel decking plate of
minimum 3 mm thickness.
Provision shall be kept with platforms and ladders for crossing over conveyors at
approximately every 100m intervals of route length and minimum one per
conveyor.
Steel trestle to support the conveyor bridge shall rest upon concrete foundation
with suitable approach/access platforms. Hand railing shall be provided to
approach the conveyor gallery through monkey ladder. Suitable wire mesh doors
on steel frame construction lockable from outside only shall be provided at
these locations. All monkey ladders shall have cage for safety of personnel using
them. The monkey ladder shall be placed on every trestle where height of
conveyor gallery is 10 m or more. There shall be hand railings, suitable seating
& holding arrangement for manual pickers and disposal chutes to ground level
etc.
The bottom portion of galleries of conveyors which crosses the buildings, roads,
railway tracks, main plant area shall be provided with chequered plate of
minimum 3 mm thickness. The bottom portion of gallery at road and rail
crossing shall be minimum 8.0 meter from the top of the rail/road. For natural
ventilation of galleries of above ground conveyors a gap of 300 mm shall be
provided through out the length of gallery between roof and side cladding at the
top and 150 mm at the bottom.
Chequered plate shall be provided for walkways of galleries.
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4.1.3.5
Transfer Chutes
Transfer chutes shall be adequately sized (The size of transfer chute shall be
20% more than the design size to avoid the chokage of wet coal) and sloped to
ensure smooth flow of coal without any accumulation anywhere. The actual
valley angle and chute design shall be finalised after carrying out coal flow
ability studies at worst conditions. In any case the minimum valley angle of
chutes shall not be less than 60 degrees from horizontal.
Direct impact of material on conveyor belt shall be avoided by providing an
inclined surface at 60 degrees valley angle at the feeding point to guide the
material in the direction of belt travel. Further, chute construction below flap
gate shaft shall be such that there will not be any accumulation of coal dust
between chute and flap gate in that zone.
Chutes shall be made of structural steel plate conforming to IS 2062 unless
otherwise stated in the Data Sheet and shall be welded construction. Mating
flanges shall be bolted. Felt gaskets shall be provided at all flanged connections.
The minimum thickness of steel plate shall be as indicated in the Data Sheet.
Liners shall be applied as called for in Data Sheet. For chutes liners shall be
applied over all sides unless otherwise stated. Material and thickness of liner
plates shall be as indicated in Data Sheet. Liners shall be fastened with chutes by
countersunk hexagonal head nut. The maximum size of liner shall be 500mm X
500mm.
A long chute guiding flow from considerable height shall be provided with
impact plates wherever change in direction of flow takes place. Hinged
inspection doors (generously sized) of leak proof construction shall be provided
for access/ maintenance purpose, at approachable heights, of the chutes. All
chutes should have one inspection door at every floor and for the ones in
between the floors, suitable access ladder and platform etc. shall be provided.
Maximum distance between two inspection doors in a chute shall be 2 meters. In
addition to mounting bolts, swiveling eccentric handle(s) to tighten the door
further against rubber shall also be provided.
Bolted flange joints shall be of dust tight construction and necessary sealing
material shall be provided in all the flange connections for adequate sealing
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4.1.3.6
Flap gates
2-position flap gates complete with electrically operated actuators in transfer
chutes shall be provided at various locations as specified. The gates shall be of
robust construction and suitable for trouble free operation.
Lever arm shall be provided between actuator and flap gate shaft for obtaining
required thrust. The linkage mechanism proposed shall be indicated in the Bid.
All the actuators in the plant should be selected on the basis of heaviest
loadings. Lever arm shall be provided between actuator and flap gate shaft for
obtaining required thrust. The actuator shall be capable of being operated for at
least 15 switching per hour at rated load and thrust and shall be suitable for 10
Nos. consecutive switching at rated load and thrust. The equipment shall be
shop tested to prove this requirement
Provision for alternative manual operation shall also be made using detachable
hand wheel in flap gates for their easy operation and maintenance. Limit switch
for safety of person operating the hand wheel shall be provided. Manual effort
required to operate flap gates shall not exceed 25 Kg and shall be convenient
for a single operator. Minimum diameter of hand wheel shall be 500 mm.
Suitable travel and thrust dependent limit switches shall be furnished. These
shall be placed internal to the drive unit and shall be completely dust-proof. The
limit switches shall be capable of adjustments to vary the total length of travel of
the gates. The travel dependent switch shall control the travel and prevent any
over travel of gates on either direction. The thrust dependent limit switch shall
trip off the actuator motor in case of excessive thrust due to jamming of the
gates during its travel in either direction.
Both faces of flap gate main plate, liner plate of suitable material and thickness
shall be provided as per enclosed data sheet.
For standardization purposes, only one standard type of actuator for flap gates
shall be provided as per enclosed Data Sheet.
Approach/maintenance platforms complete with the chequered plate floor, hand
rails, ladders etc. shall be provided for all flap gates.
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4.1.3.7
Rack and Pinion Gates
Rack and pinion gates shall be complete with all accessories as specified herein
after and shall conform to the requirement specified unless modified in data
sheet A.
Design and Construction requirement
Each RPG shall be operated by means of double rack and pinion. The RPG shall
be provided by motorized operation facility. The limit switches shall be provided
for close and open position. Gates can be operated manually also. One side of
driving shaft carrying two pinions shall be provided with wheel and endless
chain hanging over it for manual operation. The wheel diameter shall be
sufficiently large so that one person can easily operate the gate with minimum
applied effort.
The frame of RPG shall be fabricated from the structural steel, IS: 2062 and shall
be connected to flange of hopper.
The gate assembly shall be compact and adequately sized to meet duty
requirement. The slide gate plate shall be fabricated from 12mm thick IS: 2062
plat and run on suitable rollers mounted on both side of frames. Wheel shall be
mounted and keyed to shaft for safe operation. Hold back device shall be
provided with the pinion shaft to ensure non-reversal of the gate movement
during opening and closing.
Gate shall be provided with seals on all four sides. Pressure lubricated tight ball
bearings shall be provided for shaft and rollers. The gate plate shall be provided
with suitable liner fixed on gate plate.
Pinion shaft shall be of EN 8 material. Wheels, Pinions and racks shall be made
of CI, IS: 210 grade 260.Chain shall conform to IS: 2429.
4.1.3.8
Primary Crusher
Rotary breaker shall be used as primary crushers to reduce the coal size from (-)
300 mm to (-) 150 mm. Crusher shall be supplied complete with accessories
and sub systems.
Crushers shall be provided with vibration isolation system.
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Design and general arrangement of crusher shall permit easy maintenance,
maximum accessibility for inspection and effective dust sealing.
Crushers shall be designed in such a way that Maximum crushing efficiency shall
be obtained. The crusher shall be capable of delivering the normal rated output
even when handling damp sticky coal having maximum moisture content.
The drive chain equipment for each crusher shall consist of drive motor, fluid
coupling. The crushers with its drive chain equipment shall be mounted on a
base plate with necessary accessories, e.g., anchor bolts, coupling guards etc.
The entire inside surface of crusher coming in contact with coal shall be
provided with abrasion resistant steel liners.
The Plummer block shall be fixed with minimum four numbers of high tensile
steel bolt studs of adequate size complete with adequate locking device and
locating arrangement. Also, the jacking screw shall be provided for easy lifting
of top part of the plumber block.
Additional support shall be provided to plummet block across the longitudinal
axis of crusher rotor to take care of misalignment against certain jerk, regular
vibration etc., with simple readjustment facilities. Further, Plummer blocks shall
be provided with provisions for installing vibration monitoring equipment.
Necessary locking arrangements shall be provided for suspension bars at both
the ends of rotor assembly to arrest any relative movement of the same.
Two
suspension bars shall be provided in each row to facilitate replacement of
broken hammers without requiring withdrawal of other hammers.
The general arrangement of crusher and the drive equipment shall permit at
least 50% extraction of suspension bars towards the drive end also, besides full
extraction towards non-drive end.
For safety, necessary tramp iron pocket of sturdy design with adequate cover
shall be provided inside the crusher. The bottom of tramp iron pockets shall be
of screen type.
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4.1.3.9
Secondary Crushers
Crusher shall be provided for sizing the input coal to (-) 150 mm size and (-) 20
mm size output coal. Crusher shall be supplied complete with accessories and
sub systems.
Crushers shall be provided with vibration isolation system.
Design and general arrangement of crusher shall permit easy maintenance,
maximum accessibility for inspection and effective dust sealing.
Maximum crushing efficiency shall be obtained. The crusher shall be capable of
delivering the normal rated output even when handling damp sticky coal having
maximum moisture content.
The gap between cage bars/cage screen and the hammers shall be adjustable to
compensate for the normal wear and tear and the mechanism shall be made
simpler for easy operation and maintenance having separate cage, actuating
shaft and suitable hinge connection.
The drive chain equipment for each crusher shall consist of drive motor, fluid
coupling. The crushers with its drive chain equipment shall be mounted on a
base plate with necessary accessories, e.g., anchor bolts, coupling guards etc.
The entire inside surface of crusher coming in contact with coal shall be
provided with abrasion resistant steel liners.
The Plummer block shall be fixed with minimum four numbers of high tensile
steel bolt studs of adequate size complete with adequate locking device and
locating arrangement. Also, the jacking screw shall be provided for easy lifting
of top part of the plumber block.
Additional support shall be provided to plummet block across the longitudinal
axis of crusher rotor to take care of misalignment against certain jerk, regular
vibration etc., with simple readjustment facilities. Further, Plummer blocks shall
be provided with provisions for installing vibration monitoring equipment.
Necessary locking arrangements shall be provided for suspension bars at both
the ends of rotor assembly to arrest any relative movement of the same.
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suspension bars shall be provided in each row to facilitate replacement of
broken hammers without requiring withdrawal of other hammers.
The general arrangement of crusher and the drive equipment shall permit at
least 50% extraction of suspension bars towards the drive end also, besides full
extraction towards non-drive end.
For safety, necessary tramp iron pocket of sturdy design with adequate cover
shall be provided inside the crusher. The bottom of tramp iron pockets shall be
of screen type.
4.1.3.10 Vibrating Screen
Vibrating screen shall be provided before each crusher so as to ensure uniform
feeding above 20 mm size of coal to the crusher.
Design Requirement
IS: 3823 - Dimensions for vibrating conveyors and feeders with rectangular or
trapezoidal trough.
The vibrating screen shall be capable to segregate (-)20 mm size of coal along
with coal dust, any muck & muddy coal, which is likely to be encountered during
rainy season. The equipment shall be designed in such a manner that choking
does not occur during operation, particularly during rainy season when the coal
gets sticky. The segregated material shall be directly fed onto the corresponding
belt conveyors/feeders through separate hoppers/chutes provided under each
vibrating screen. The width of vibrating screen shall match to feed the material
uniformly over the entire length of crusher rotor without any deflector in the
feeding chute.
Construction Requirement
The deck of vibrating screen shall have robust construction.
The vibrating screens shall be mounted on the floor with the help of helical
springs made of alloy steel. No rubber/synthetic material for the support shall
be acceptable.
Suitable sealing arrangement shall be provided between the vibrating structure
and chute work to avoid dust nuisance in the surrounding area. Proper
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arrangement to avoid dust ingress into lubricant shall be provided. Necessary
arrangements shall be provided for maintaining the complete vibrator assembly.
4.1.3.11 Electro-Mechanical Vibrating Feeder
Vibrating feeder shall be of electro-mechanical type. The vibrating unit of the
feeder shall be of unbalanced motor type. The vibrating feeders and their
mounting arrangement shall be properly designed to suit the existing lay out. It
shall be ensured that no vibration is transmitted to the supporting/surrounding
structures from springs / Rubber cushions. The trough of the feeders shall be of
tray type construction and shall be made out of minimum 8 mm thick MS plate
(IS 2062-1992). Liner (Sail Hard) shall be provided inside the trough bottom
along its length and sidewall for entire cross section. The trough liner shall be
provided with adequate side guard to avoid spillage. Liners shall be fitted with
counter sunk head bolt. The trough shall be covered with dust tight hoods with
provision of cut out and flange for dust extraction. The equipment will be
provided with enclosed dust proof vibrators (un-balanced masses). The
unbalanced mass unit (minimum Four (4) for each motor) shall have provision
for change near location as required at field. The feeders shall be of base
mounted type.
Each vibrating feeder shall be supplied complete with supporting structures,
feed chutes, manually operated feed control gates, hood cover, electric plates
and fixing nuts and bolts, suspension rods, turnbuckles etc. Anchor bolts for
base mounting connection for base mounted feeders, if any, to the floor are also
included under the scope of supply of the bidder.
The successful bidder shall insure that minimum amount of assembly will be
required for erection and commissioning of equipment at site. Site welding etc.
shall be avoided as far as possible.
The feeders shall be of robust construction and of balanced design.
Existing Switchgear and Control System shall control vibro-feeders for flow
control.
Duty Condition
The feeder is to be installed under surge hopper in crusher house and shall be
required to operate all the three shifts per working day and 330 days per year.
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The surrounding may be quite dusty and wet. The feeder shall be able to give
satisfactory performance under the worst working condition.
Constructional Features
General
The feeder shall be of adequate strength to withstand heavy-duty operation. It
shall be sturdy and robust in construction and at the same time can give
uninterrupted operation. It shall have inherent design characteristic viz. rugged
construction low power consumption, low maintenance and variable rate control.
Trough
The trough and trough frame shall be rugged enough for duty condition and
shall be designed for easy assembly and dish-assembly. The trough shall be
provided with replacement abrasion resistant liner plate. The size of the feeder
shall be selected to suit the duty condition. Trough shall be constructed from
Mild steel fabricated from plates and sections. Wear resistant liners shall have to
be used for heavy-duty application purpose.
Stroke Length
The equipment shall have long stroke and low frequency to give the required
Rated output of 1000 TPH. The frequency controller suitable for manual, remote,
automatic adjustment shall have to be used from 0 100% of the capacity
utilization.
Drive Unit
The feeder shall have low HP to weight ratio so as to permit the use of small
motor to drive the eccentric weights at the optimum frequency for a specific
application. The feeder should have each starting, smooth stopping features and
shall operate at extremely low noise level.
Lubrication
Grease nipples are to be provided at all bearing points for manual greasing. The
arrangement for centralize greasing system should also be provided.
Compliance to standards
The design and construction of the feeder shall conform form to the relevant ISS
or equivalent international standard. The material of the different component of
the feeder shall have to be selected to suit heavy-duty application purpose.
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4.1.3.12 Stacker cum Reclaimer
Traveling stacker cum reclaimer operating in conjunction with yard conveyor
shall be capable of both stacking and reclaiming complete with adequate length
of rail track, cantilever boom conveyor, intermediate conveyor, boom hoist,
reclaimer bucket wheel, control panel, operators cabin, electrical power
distribution system, motorized cable reeling drum, adequate length of trailing
cables etc.
Codes and Standards
Mobile Continuous Bulk Handling Equipment- ISO 5049/1.
Federation Europeanne De La Appliance Manutention Section-I-Rules for Design
of Hoisting Appliance-FEM.
Design Requirement
Stacker/Reclaimer shall be capable of operating at high wind velocities
encountered in the working region. It shall also be able to withstand maximum
wind velocity as indicated in "Criteria for Wind Resistant Design of Structures &
Equipment" when not operating. A suitable anemometer shall be provided which
shall indicate the wind velocity in the control cabin.
Electro-hydraulic thruster operated rail clamp shall be provided for holding the
stacker-cum-reclaimer. Suitable arrangement shall be provided for keeping the
stacker-reclaimer in fixed stable position when the weather is stormy.
Stacker-cum-reclaimer shall operate on rail track running for adequate length to
cover the entire coal stockyard. Suitable number of rail scrappers shall be
provided.
The machine shall be mounted on traverse carriage provided with driven and
non-drive wheels of cast or forged steel and double flange design. The track
wheels shall be combined in pairs in the track wheel bogies.
The reclaimer shall be traversed by manual control at any desired speed within
its speed range. During stacking/reclaiming operation, the equipment travel
shall be limited to its travel zone and shall automatically stop at the extreme
ends of its travel zone.
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The rail mounting for under-carriage shall be four legged system with
hydraulic/mechanical equalising arrangement to make it three point suspension
system for the best stability during operation. The traverse carriage and the
under-carriage shall be interconnected in a manner, which will permit uniform
distribution of overloads even if the rails are not level.
The bucket wheel boom shall be provided in Centre of machine and suspended
on supporting mast.
The drive mechanism of the boom conveyor shall consist of protective devices
against overloads. The slew speed shall be variable. Boom conveyor shall be
provided with self-training arrangement of latest design to avoid belt sway in
the boom conveyor. Walkway with hand railing shall be provided on both sides
of boom conveyor.
The hydraulic system of luffing of bucket wheel boom shall be such that in case
of failure of hydraulic system due to leakage or any other reason the boom
could be held in position.
Bucket wheel drive system with hydraulic coupling shall be provided. The
buckets shall be readily removable. Bucket wheel drive would be revisable type
to facilitate withdrawal of wheel in event of under cutting. Material shall be
reclaimed by buckets and discharge into boom conveyor.
One tripper and one intermediate conveyor shall be furnished for stacker-cumreclaimer unit for working in conjunction with the yard conveyor. The tripper &
intermediate conveyor shall be complete with supporting structure, walkways,
platforms, railing, belt scrapper, head pulleys, bend pulleys, hold-down pulley,
chute and support of welded constructions with wheel bogies.
Group-wise lubrication system shall be provided combining different zones of
lubrication points under different groups depending upon location and number
of lubrication points.
Each group lubrication unit shall be independently
functional through separate pump (motorised), grease container, valves,
metering devices, pipes and other accessories etc.
The stacker-reclaimer shall receive power through trailing cables. Separate
motorised cable reeling drums for power and control cable shall be provided
with arrangements for winding and rewinding of the cables. The trailing cables
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shall run in a cable tray in-between the track rails. Cushion shall be provided in
the cable reeling drums for about 15 m extra cabling length.
Further, limit switches shall be provided to prevent traverse movement, slew and
hoisting etc. beyond the respective safe extremities. Interlocking shall also be
provided for S/R rail clamps and travel motors.
Hydraulic control shall be provided for:
Hoisting/luffing
Operator cabin level adjustment
Equalising arrangement for travel carriage
Axial piston pumps for pressurising hydraulic control fluid.
Construction Requirement
Suitable RCC platform to be provided at one end of travel of the stacker-cumreclaimer to rest the head end of the boom during maintenance or out of
operation. Walkways with hand railings shall be provided on both sides of boom
conveyor.
The air conditioned operators cabin shall be suitable for operation in monsoon
and tropical conditions. The cabin shall be provided with toughened glasses with
wipers and the arrangement shall be such that glasses can be cleaned from
outside without any scaffolding. The cabin shall be kept in horizontal position
through hydraulic cylinders irrespective of the angle of inclination of the boom
conveyor. Lights and fan for operators cabin shall be provided.
4.1.3.13 Coal Sampling Units
Coal Sampling Unit shall be complete with necessary samplers, crushers, flap
valves, chutes, hoppers, belt feeders and sample collectors etc. to give samples
from any of the two streams running at guaranteed capacity.Local control panel
shall be provided with PLC control.
Codes and Standards
ASTM-D-2234 Standard methods for collection of a gross coal sample.
ASTM-D-2013 Standard method of preparing Coal Samples for Analysis.
Design Requirement
The coal sampling units suitable to give Samples conforming to ASTM-D-2234
/ ISO 13909 shall be selected for taking samples from any of the two streams
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running at guaranteed capacity. The different Equipment selected for coal
sampling unit shall be such that there shall be no loss of fines and moisture
from the samples. There should be no re-circulation of fines in the crushers of
sampler.
Primary samplers (separate for each conveyor) shall be rugged, able to withstand
severe shock loads and operate trouble free.
Belt feeders shall be provided for entire sampling path up to sample collector.
The feeders shall meter the flow accurately, produce a non-plugging condition
and resist sticky and wet coal. For rejects path also, belt feeders shall be
preferred.
Lot size shall be equivalent coal quantity handled in 8 hours operation
assuming average conveyor loading at 75% of rated conveyor capacity. However,
sampling system shall also be suitable for taking one gross sample for each lot
of coal in one full rake load.
Minimum 4 nos. sample collecting bins of stainless steel shall be provided. The
bins shall be provided with air tight connection and automatic indexing
arrangement.
Construction Requirement
The traversing mechanism and all parts including electrical shall have dust tight
protection. Belt feeders shall be positively self cleaning. No chain/belt drives
shall be accepted. The primary / secondary samplers shall be self-contained
type.
The crushers base should be built of reinforced concrete and be sufficiently
large in mass.
No control gates to regulate the flow of material shall be incorporated in the
chute work.
Bias connections shall be provided at suitable locations. The materials rejected
from samplers shall be returned to main conveyor stream
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4.1.3.14 Traveling Trippers & Bunker Sealing Arrangement
Mobile Trippers on bunker conveyors along with belt sealing arrangement over
the bunkers to prevent dust emission into tripper bay shall be furnished and
erected
complete
with
rails,
including
necessary
supporting
structures,
approach/ maintenance platforms with ladders and hand railings, trailing cables,
all electrical including machine mounted local control panel & control panel on
one end of Bunker.
Design Requirement
It shall also consist of belt scrapper with adjustable rubber strip, rubber lagged
head and bend pulleys complete with shaft bearings, chutes, stops & limit
switches, brakes etc. The tripper shall have provision for dropping coal both
sides of conveyor into the bunker and also back to the conveyor for the purpose
of skipping intermediate bunkers.
The rating of tripper travel motor shall be adequate to move the tripper
smoothly either in same or opposite direction to belt direction under fully
loaded conditions. Coefficient of adhesion shall be considered as maximum
0.15.
Minimum two drive axles shall be provided for tripper travel. Arrangement shall
be provided at the starting point of the tripper to avoid folding of belt.
In case of tripper running at a speed more than its rated speed due to chute
jamming or other reason, conveyor shall trip and annunciation shall appear.
The supporting structures for the rails with necessary end stops shall also be
supplied under this specification. Suitable belt hold down guide pulley shall be
provided over the concave curve of belt over tripper.
The Bidder shall include in his proposal necessary electrical for traveling trippers
such as motorised cable reeling drum with trailing cables, cable trays for resting
the trailing cables and end limit switches for protection against over travel of the
tripper. The cable reeling drum and trailing cable of each tripper shall be
suitable for the entire length of the bunker bay. Mechanical track stops shall
also be provided. The cables shall have copper conductors, proper insulating
material and braided armouring in accordance with IS: 691.
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The traveling trippers shall be provided on either side with fail-safe A.C.
thrustor operated brake of totally enclosed type, which shall engage as soon as
tripper travel motor stops. A.C. thrustor operated rail clamps with hand
operation facility from either side of the tripper shall also be provided.
The bunker sealing arrangement shall keep the bunkers sealed and prevent dust
emission into tripper room. Separate openings shall be provided on the bunker
floor of each bunker to measure level of coal in the bunker. Hinged door/flaps
shall be provided on these openings.
Suitable grating to be provided in between bunkers in the tripper travel zone.
Opening size will be decided during the detail engineering stage.
Construction Requirement
Suitable dust cover shall be provided over tripper head pulley. Serrated rubber
seal shall be provided at open side to prevent dust nuisance. Suitable dust tight
access doors shall be provided. Counter-weighted type belt cleaner shall be
provided below the tripper head pulley for cleaning the carrying side of the belt.
The tripper shall run on rails (90 lbs/yard) with double-flanged wheels. Rails for
tripper travel shall be mounted on supporting structure of respective conveyors.
Suitable system for monitoring position of tripper shall be provided. In addition,
travel end limit switches and end stops shall also be provided.
Suitable access platform of chequered plate with ladders, hand railing and
walkways on both sides shall be provided for access/maintenance of equipment
on tripper.
Also crossover platform shall be provided with tripper so that
operator can cross the belt through the same. Needed guide rollers, bearings,
brackets, safety guards etc. shall be provided by the Bidder.
Suitable rail cleaners shall be provided on leading and trailing edge of tripper for
either track. 3mm deck plate continuous shall be provided below carrying idlers
on the tripper conveyors.
Provision shall be kept for automatic tripping of bunker bay conveyor in event of
traveling tripper getting dragged (i.e. travel speed in excess of rated speed).
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4.1.3.15 Thrustor Brakes and Clamps
Rail Clamp and brakes shall be actuated by compression springs. The spring
shall apply the clamping/braking force directly on the Rail clamp/shoe
mechanism without using lever arm linkages. Necessary electro hydraulic
thrustor (AC) brakes shall be totally enclosed and fail-safe.
The electro hydraulic thrustor shall be fitted with the brake. Limit switches shall
be provided for brake applied/released positions. The lining shall be fixed to the
shoe by counter sunk screws.
Rail clamp shall be designed for holding the machine stationary. Electro
Hydraulic thrustor shall be fitted directly above spring without any intermediate
linkage mechanism. Rail clamp shall operate satisfactorily under this condition
without the need for any adjustments.
4.1.3.16 In-line Magnetic Separators
Inline Magnetic Separators shall be provided for continuous and automatic
extraction and discharge of tramp iron pieces from coal being discharged from
conveyors as specified. The sets shall be complete in all respects with drives,
magnets, inline belts, hoppers, chutes, tramp-iron boxes and all electrical
ancillaries like control panels etc. The magnetic separator shall be able to
separate M 20 bolts and nuts and 50KG MS Plates/ MS round bar of L/D ratio of
less than 5.
Design Requirement
The minimum strength of the magnet shall be 1000 gauss (force index of
magnet shall be 100000) at the specified mounting height. Designer shall select
magnet width to suit above.
Characteristic curve of magnet with the value of flux density varying between 50
mm from magnet surface to face of conveyor belt shall be provided. The
magnetic separator shall be located such that it picks-up tramp iron from coal
trajectory after it has been discharged from head pulley.
Suitable zero speed switch shall be provided.
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The belt shall be designed to withstand high temperature at the bottom of the
magnet and any serious damage due to the impact of the sharp edges of the
tramp iron. The belt shall be provided with rubber cleats spaced suitably.
Construction Requirement
Suitable structural member from the top shall support the magnetic separator
units by taking support from the operating floor beams with turnbuckle
arrangement to facilitate the necessary adjustments during operation.
ON/OFF control push buttons with indicating lamps shall be provided at the
local station.
Suitable arrangements shall be provided in the magnet for keeping the coil of
the magnet dry from atmospheric condensation when the magnetic separator is
not in use.
4.1.3.17 Belt Scales
Belt weighs scale for measurement of coal flow rate and quantity shall be
provided at specified locations. System shall be complete with flow rate
indicator, totaliser, control panel etc.
Codes and Standards
NEMA
NEC
For electronic circuit enclosures.
IS: 11547
Electronic weighing in motion system.
Design & Construction Requirements
The weigh scale shall be automatic and electronic type. It should be designed for
continuous automatic weighing, metering and printing of coal flow.
It shall have unitised construction for ease of installation and shall be fully
floating type (without pivot points).
It shall be provided with self-diagnostic features for trouble shooting of the
entire belt scale system.
Fully automatic zero and span calibration facility and minimum three years
battery back-up power failure protection shall be provided.
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The electronic systems shall include all signal conditioning, power amplifiers
and printed circuits etc. The printed circuits shall be encapsulated against dust
and moisture.
It shall be suitable for outdoor installation in a dusty area. The electronic circuit
enclosure, sensors housing shall be dust and water tight and explosion proof.
The electronic printed circuits shall be encapsulated with epoxy or other suitable
material for protection against dust and moisture.
The contractor shall furnish one (1) necessary test load chain sets required for
calibration and periodic testing of the equipment.
4.1.3.18 Metal Detectors
Metal detectors shall have high reliability with enough sensitivity to detect
tramps below the burden of coal. It shall also detect other metals, like brass,
copper, stainless steel, manganese steel, bars, scraps cast iron etc. The capacity
of metal detectors shall be to detect minimum 25mm aluminum sphere.
Metal detectors shall be completely solid state using latest state of art
technology. It shall be suitable for 70C ambient and RH of 100%. The search
sensor shall be protected from rain and direct sunlight by means of a nonmetallic covering other than wood. Control unit shall have adjustable controls
for sensitivity, ON/OFF push buttons, reset table operation counter, audio-visual
alarms local remote selector switch and all other necessary controls for trouble
free operation of metal detector. It shall be suitable for mounting on wall,
column, structure etc. with IP-65 Degree of protection. It shall be constructed
from FRP with thickness not less than 2mm.
The coils of metal detectors shall be protected against being struck by an
oversized material/coal. In order to counteract interferences from external
sources such as motors, lightning and radio-transmitters, and to nullify the
effect of climate charges/aging, dual receiver coils are to be used.
Location of tramp metal pieces shall be indicated by liquid color spray. Suitable
arrangements shall be provided to allow passing of metal belt fasteners without
giving alarm and at the same time detecting tramps.
LED display of COAST COUNT to indicate the number of tramp iron pieces
detected since last reset shall be provided so that the operator is alerted for the
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pieces of tramps, if any, between tramp marker and coil before restoring
conveyor. TOTAL COUNT, which is not reset table, shall also be provided on the
same LED display on demand.
4.1.3.19 Drive Chain Equipment
Suitable Drive Chain Equipment like electric motors, gearboxes (where
applicable) & fluid couplings (where applicable) and other accessories shall be
provided as and where applicable for all the belt conveyor systems, crushers,
mobile trippers, various pumps of dust suppression system, fans for ventilation
system, monorail electrical hoists and other equipment specified in this
specifications. Various requirements as spelt out in the Technical Specifications
for individual equipment shall be taken into consideration while designing the
associated drive chain equipment.
Gear Boxes
IS: 3688
Dimensions for shaft ends
IS: 3681
General plan for spur and helical gears
IS: 7403
Selection of standard worm and helical gear boxes
The gearboxes shall be designed for 24 hours continuous duty. Gearboxes with
cooling coils are not acceptable.
The gears used shall be helical or worm reduction units or spiral bevel speed
reduction units conforming to suitable Standards. Above 40 kW drive rating, all
gearboxes shall be helical or bevel helical type only.
Gear Boxes shall be of sealed type and mounted on machined or ground
surfaces.
Service factor will be taken 1.25 for conveyor drive gearboxes and for gear
boxes in other application service factor will be taken 1.2
Flexible Couplings
The design of the coupling shall be such that it can take shock and
misalignment without sacrificing its efficiency.
Flexible couplings shall be
provided on low speed side of gearbox for all conveyors. Flexible couplings shall
be geared type.
Fluid Couplings
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Fluid couplings shall be provided in all the drive chains for belt conveyor
systems and coal crushers if the actual power requirement at motor output shaft
is more than 30 KW. The fluid coupling for LT motors shall be of traction type
(except for yard conveyor). Cooling water coils for traction type fluid coupling
shall not be accepted.
Scoop tube type fluid coupling shall be provided for
conveyors with HT motors and coal crushers.
Suitable electrically operated
actuators shall be provided for scoop tube operation from local as well as
remote.
For motor rating up to 30KW Resilant type flexible coupling.
For LT motor of above 30KW Traction type fluid coupling.
For HT motor Actuator operated scoop type fluid coupling.
4.1.3.20 Belt Vulcanizing Machine
Belt Vulcanizing Equipment shall be suitable for hot vulcanizing of belt splice
and shall be of easy-to-handle type. Heating element should be preferably of
flexible type.
Equipment should be suitable for vulcanizing of entire splice width in single
setting. It should be capable of applying uniform pressure over the splice by
pneumatic or hydraulic means.
4.1.3.21 Dust Extraction System
Dust Extraction System shall be provided in Bunker for Bunker ventilation and
allJTS and crusher house. Dust Extraction System shall be with dry type off
cyclone separator and/or bag filters.
4.1.3.22 Dust Suppression system
For all transfer points D.S. Systems (Dry Fog Type) shall be provided and the
same shallbe capable of being controllable manually as well as automatically.
The fixed nozzles spraying Water on to coal at the discharge of various
conveyors shall be energized only when the respective conveyors are moving
with coal. Suitable inter locking between conveyor drive and solenoid valve in
water pipe- line shall be provided.
The water flow through the swiveling nozzles at stockpile is to be controlled
manually by provision of suitable globe valve and gate valve combination. The
throw and spread of the swiveling nozzles will be so selected that two or three
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nozzles will be able to cover the operating range of Stacker/Reclaimer on an
average day
Necessary instrumentation and local control board/panels incorporating push
buttons for start and stop, control switches contactors etc for solenoid valves,
indication lamps etc. shall be provided wherever required.
4.1.3.23 LOCOMOTIVE
Locomotive shall have two 2-axle bogies with all 4 axles independently
motored. The locomotive shall have two diesel engines of 350 h.p. Gross driving
two nos. traction generators. The generators output is fed to the traction. Power
from the Traction Generators will be transmitted to bogie wheels by means of
four traction motors through a single reduction spur gear unit having a gear
ratio of 17 / 94.
The design incorporates the features and equipment well proven in traction
service and conforms to the extent possible to Indian Railways Standards.
The Loco shall be designed for fairly heavy rainfall and dusty atmosphere.
The leading dimensions and data of the CAR shall be as under:
Wheel Arrangement
BO-BO
Rail Gauge
1676 mm (Broad Gauge)
Loco O.G.A. Drawing
37180001108
Weight Per Axle (Max.)
22.5t 3%
Fuel Tank Capacity
3000 Liters. (approx)
Lube Oil Tank Capacity
68 Liters.
Wheel Diameter (New)
1000 mm
Bogie Wheel Base
2200 mm
Bogie Pivot Centers
6000 mm
Length Over Buffer Plate
11500 mm
Maximum Width (Over Cab)
3040 mm
Maximum Height
4030 mm
Height of Buffer over rail level
1065 mm
Clearance above rail level with New
Wheel
Clearance above rail level with full
worn Wheel
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102mm (Below Motor Gear Case)
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Traction Motor Gear Ratio
17/94
90 + 0% Tonnes
Maximum Gross weight
- 3% Tonnes
Negotiability on Curve
45 Meters
Two
Diesel Engine
nos.
Cummins
India
Make
NTA855L
Two nos. MIS BHEL make, Type
Traction Generator
TG4302AZ
Traction Motors
Four nos. BHEL make Type TM4605AZ
Locomotive Performance Curve
LME/1242
Maximum speed
30Kph
Continuous Tractive Effort on wheel &
continuous Loco Speed
Maximum starting Tractive Effort on
Wheel Tread
15200 Kgs. @ 7.4 Kph
24300 Kg @27% adhesion
The loco shall be able to operate satisfactorily under the following conditions:
Ambient Temperature
0- 55 deg. C
Altitude
Up to 1000 mtrs AMSL
Humidity
40 % to 100 % RH
Mechanical Parts
Main Frame
The main frame shall be all-welded steel construction using rolled sections and
plates. It shall be designed to withstand a squeeze load of 400 tonnes. The
frame ends shall be suitable for fitting standard transition type center buffer
couplers, draft gear and side buffers.
The design of the main frame shall permit lifting the complete locomotive from
suitably located jacking pads and lifting pins.
The design of the main frame shall include a heavy deck plate extending over
the entire length of the frame. All equipment shall be mounted on the deck plate
through brackets and pads suitably positioned for both the Power Pack.
Provisions shall be made in the design of the main frame for placement of
ballast weights as required to increase I adjust locomotive axle load.
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Cast steel centre pivots shall be welded to the main frame.
Bogies
The bogie frames shall be of all-welded steel construction using plates and
rolled sections.
Load shall be transferred from the bogie frame to the axles through helical
springs and spring beams hinged at the axle box bottoms. Provision shall be
made for liners between spring pads and bogie frame brackets to take up wheel
wear and to adjust locomotive trim.
Cast steel bogie centre pivot rings shall be welded onto the bogie frames. These
shall be provided with mild steel liners at the bottom on which the pivots of the
main frame shall rest. Metallic sideliners shall also be provided. Oil lubrication
shall be provided between the pivot of mainframe and pivot seat of bogie.
Multi wear mono block rolled steel wheel shall be fitted on fully machined forged
axles having outboard bearing journals.
Sealed grease lubricated A P taper roller bearings, with adapters shall be used
on the axle bearing journals. The adapters shall be of cast steel with welded
manganese steel wear liners.
Sand boxes and pneumatic sand traps shall be provided as a part of our
standard design at each end of the two bogies to deliver sand to the respective
wheels.
The wheel hub shall be provided with the arrangement for easy extraction of
wheel from axle by oil injection devices.
Brakes
The locomotive shall be provided with air brakes for the locomotive. All wheels
shall be provided with clasp brakes, with 2 opposed brake blocks acting on each
wheel tread. The brake blocks shall be of the composite type having cast steel
brake shoe holders carrying renewable cast iron brake shoe inserts.
Effective brake force on each wheel shall be in the range of 70-80% of the wheel
load. Adjustment of the brake power to suit wheel load shall be achieved by
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corresponding adjustment of the brake cylinder air pressure. The brake rigging
linkage shall be common for all axles.
A hand brake shall be provided, which shall act on two wheels of anyone axle,
through the same set of brake blocks and rigging as for main brakes. The hand
brake shall also be actuated from the driver's cab.
Buffing and Drawgear
Each end of the locomotive shall be fitted with a standard transition type centre
buffer coupler, draw gear and side buffers (using rubber pads).
Superstructure
The superstructure shall essentially comprise of driver's cabin and separate
hood for radiator, diesel engine & generator for ease of handling during
maintenance.
The entire superstructure shall be fabricated from rolled sections and clad with
rolled sheet. The arrangement for attaching the superstructure to the main
frame shall permit easy removal when required.
A hood shall be provided over the each power pack. The superstructure of the
hood shall be of fabricated steel construction, thoroughly braced and secured to
the main frame.
The layout of the full width cab shall be such as to enable free movement by the
driver from one side to the other.
Cab roof and sidewalls shall be provided with internal paneling of steel sheet
with glass wool insulation.
Entry to the cab shall be through two diagonally opposite doors leading from the
walkways.
Provision shall be made for large sliding glass windows on the cab side panels
and fixed glass windows on end panels. All glass panels shall be of safety glass
mounted in rubber bidding.
Two upholstered seats shall be provided in the cab.
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Two numbers dry powder type; 2.5 kg capacity fire extinguisher shall be
provided.
Fuel Tank
A fuel tank fabricated from heavy gauge steel plate shall be located below the
main frame and between the bogies. The tank has capacity of approximately
3000 litters. The tank shall be provided with a standard filling connection; a
glass level indicator; a vent and cleaning out lets.
Equipment
The Power pack shall consists of CIL, Pune make diesel engine NT A855l as
prime mover for Traction Generator TG 4302AZ. The output of traction
generator is fed to axle hung nose suspended traction motors TM 4605AZ
(BHEL) through single reduction gear ratio of 17/94.
Diesel Engine
The locomotive shall be powered by Kirloskar Cummins Diesel Engine. Details of
diesel engine are as given below:
Make
M/s. CIL, Pune
Type
NTA855l
Cylinder arrangement
In Line
Bore & Stroke
140 X 152
Gross Output at Std. Cond. As per
335hp at 2100 rpm
BS 5514
Engine governing
Multiple unit throttle control (MUTC)
Governor
The engine shall be required to run in climatic conditions as given below:
The rating of engine shall conform to latest BS 5514.
Traction Generator
The generator is a compact machine having six poles with single bearing
construction. It is a self I separately excited machine having a series field
winding for cranking of the engine. The frame is circular rolled steel fabrication
with laminated poles and field coils. The armature is built on solid shaft with a
steel fan. The commutator has arch bound construction. Anti-friction bearing
mounted in the frame supports one end of the generator armature, and the rear
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main bearing of the engine supports the other end. The magnet frame is bolted
to the engine flywheel housing.
The machine receives its cooling air through the car body filters.
This alternator confirms to the following parameter:
Application rating
345V, 650A, 2100 rpm
Weight complete
900KGs
Ventilation
Self cooled
Feature
-Light weight (900 kg)
-18 nos. corrosion-resistant brush holders
- Anti friction sealed armature bearing
-Self I Separately excited machine.
Traction Motors
The traction motor shall confirm to the following parameters:
No. of Poles
Connections
Lap wound: series
Application rating
170 Volts; 650 Amps.
Maximum Current
1000 Amps.
Weight Complete with Gear case
1935 Kgs.
Ventilation
Forced Cooled
Charging Generator Alternator
One 27 volts charging alternator along with voltage regulator shall be provided
on the engine. This shall be used for battery charging and auxiliary circuits load.
Battery
One set of 24 volts, 180 hr, lead acid type batteries shall be provided.
Compressor
One compressor per power pack, of adequate capacity driven from non-driven
end of traction Generator shall be provided.
The compressed air circuit shall be designed for the following:
-
Provision of adjustment in brake cylinder operating pressure to achieve
desired braking force.
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Operation of 2 pneuphonic horns.
Operation of wheel sanding gear.
Operation of brakes from both sides of the cab.
Operation of electro pneumatic contactor and reverser.
Operation of four windscreen wipers.
For ease of maintenance, valves, filters and other fittings in the air circuit shall,
as far as possible be grouped together.
Blower
One blower per power pack shall be provided. Each of these blowers is rated for
4000 cfm. Each blower provides cooling to the two traction motors of one bogie
through duct.
Lighting
The locomotive shall be provided with headlight at each end.
Aspect lights shall be provided with headlight at each end.
The cab shall be provided with lights on the ceiling for general illumination. The
load ammeter & air pressure gauges shall be illuminated.
Conveniently positioned lights shall be provided in the hoods.
Fan
One ceiling fan shall be provided in the driver's cab.
Horn
Two dual- tone pneuphonic horns shall be provided with air-operated wipers.
Controls and Instruments
Driver's Controls
The necessary controls and gauges for the operation of the locomotive by the
driver shall be provided at two control stations on both sides of the cab. These
controls and gauges are completely duplicated and consist of the following:
-
Throttle Handle
Reverse Handle
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Driver's Brake Valve Handle
Sanding Gear Switch
Horn Switch
Load Ammeter
Brake Cylinder And Main Air Reservoir Pressure Gauge
Wiper Switch
Battery switch
In addition to the above, the following shall be located conveniently in the
driver's cab:
-
Engine Control Switch
Engine Start and Stop Switch
Switches for cab Lights
Battery charge I discharge indication
Protection and Alarms
Safety devices provided on the locomotive shall provide protection against the
following faults:
-
High engine water temperature
Low Lube oil pressure
Engine over speed
Ground fault
Wheel slip
The following gauges I meters shall be conveniently located in the cab:
-
load Ammeter
Brake Cylinder And Main Air Reservoir Pressure Gauge
Battery ammeter
Lube oil pressure gauge
Water temperature gauge
4.1.3.24 Monorail Electric hoists with Traveling trolley
Codes and Standards
The Equipment to be supplied under this specification shall conform to the
following
codes and standards unless otherwise specified hereafter:
IS: 807:1976
Code of Practice for design, manufacture, erection and
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testing (structural portion) of cranes and hoists.
IS: 2266
Specification for steel wire ropes for general engineering
purposes
IS: 3815
Steel hooks for standard shank design
IS: 325
Three phase induction motors
IS: 3938
Electric wire rope hoists
IS: 694 (Pt 1)
Copper conductor PVC insulated cables up to 1000V
IS: 3043
Code of practice for earthing
Design requirements and constructions features
The Hoists shall be of robust design. The hoist and cross travel motions will be
electrically operated.
The hoists shall conform to class II as per IS: 3938
Hoists shall be of modular construction complete with drive motors, rope drum,
gearboxes, electrical control panel, traveling trolley and brakes.
The drum shall preferably be of mild steel/cast steel and stress relieved in case
of fabricated drum. The drum shall have machined grooves and working
surfaces shall accurately receive the wire rope in single layer when hook is in
highest position.
The wire rope shall be 6 x 36 or 6 x 37 construction with fibber/steel core for.
The rope sheaves shall be of cast steel.
Hooks shall be of heavy-duty, forged type supported on thrust bearing and free
swiveling type.
Gears shall be helical/spur type cut from alloy steel duly heat-treated. All gears
shall preferably be totally enclosed.
In case of fabricated gear boxes, stress
relieving shall be done.
All bearings shall be anti-friction ball/roller type and of SKF/FAG or equivalent
Indian make.
Material of the wheel shall be forged/cast steel/high grade cast iron.
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Wheels shall be provided with anti-friction bearings.
All crane motors shall be totally enclosed fan cooled squirrel cage induction type
with class-F insulation limited to temperature rise of Class-B and suitable for
heavy duty reversible crane service with duty rating as per data sheet A. The
starting torque of motor shall not be less than 2.75 times the rated torque and
pull out torque shall not be less than 250% of the rated full load torque.
Hoist motion shall be provided with two brakes.
One of the brakes shall be
electro hydraulic thyristors and other electromagnetic type. The design shall be
such that braking action in the off position and release with current are
provided.
Trolley travel shall be provided with electro-magnetic brake.
The brake shall be effective in both directions. All brakes shall apply
automatically when power supply fails or when the main contactor is in off
position or emergency push button is operated.
Each hoist will be operated Pendent push button station. The pendent push
button station shall be robust and heavy-duty type. It shall be suspended by
wire rope to prevent pull on cables.
For trolley travel, flexible trailing cable system mounted on retracting
supporting system shall be preferred. The conductors shall consist of insulated
conductor cables with permanent Termination on hoist machinery.
Suitable limit switches shall also be provided to limit the travel of bottom block
at either end of its travel when lowering and hoisting. Similarly limit switches
shall be provided to limit the travel of trolley at either end of its travel.
Hoists will move on Monorail beam supported on structures.
Training
Further to
relevant clauses regarding
training specified elsewhere, the
manufacturer / supplier has to b provide the technical training to Onwers
technocal team ( 10 members including both Operational and maintenance
personnel) in the following areas
Operation and maintenance training
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4.2
Any other specialized training as required for system operation and
maintenance
ELECTRICAL
4.2.1
Power Transformer
4.2.1.1
Design criteria
The power transformer of 11 kV/3.6 kV, three phase, two winding, 50 Hz,
ONAN/ONAF cooled transformer with OCTC 5% in steps of 2.5% on HV side.
The minimum quantity will be as per the Electrical single line diagram.
The 11/3.6 kV power transformers shall be oil immersed type rated for 100%
load and shall be three phase, two winding, ONAN /ONAF cooled with off circuit
taps of 5% in steps of 2.5% on HV side.
The impedance of 11/3.6 kV transformers shall be so chosen such that the fault
level does not exceed short circuit capability of 40 kA for 3 sec on 3.3 kV
Switchgear including the motor contributions. The voltage drop should not be
more than 10% at the bus during starting of the highest motor when transformer
is fully loaded.
The transformers shall be capable of continuous operation at rated output under
the following condition:
a.
Voltage variation
10%
b.
Frequency variation
5%
c.
Combined voltage and
:
10%
frequency variation
absolute sum)
The transformers shall be so designed that it is capable of operation at 125%
rated voltage for a period of one minute and 140% rated voltage for a period of
five seconds due to sudden load throw off.
Transformers shall be able to operate without injurious heating, at rated MVA at
any voltage within +/-10% rated voltage of that particular tap continuously.
Transformers shall be capable of delivering the rated current, at a voltage equals
to 115% of rated voltage without exceeding rated temperature rise.
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Transformers shall operate below the knee point of the saturation curve at 110%
voltage to preclude Ferro-resonance and non linear oscillations.
Starting from Hot condition, transformers shall be capable of remaining in
operation for following conditions without injurious heating after failure of
forced cooling:
a. At full load for not less than 10 minutes after outage of all cooling
b. At 80% load continuously after outage of forced cooling.
Transformers and accessories shall be designed for fault levels indicated in 11
kV, 3.3 kV Switchgear specifications. Dynamic ability and thermal to withstand
the short circuit force shall be demonstrated by tests/ calculations.
The transformer shall be free from annoying hum or vibration. The design shall
be such as not to cause any undesirable interference with radio or
communication circuits.
The noise level shall be limited to the value specified by NEMA Standard
Publication No. TR-1-1993 when measured in accordance with conditions
outlines in ANSI/IEEE C57.12.90-1999/IS13964/CBIP publication.
4.2.1.2
Sizing
It will be the responsibility of the contractor to adequately size the transformers
to cater for all the auxiliaries of the main equipment, mechanical systems and
loads due to lighting, A/C & ventilation system, battery charger, cranes, plug
points and all other loads and based on the ambient temperature. The basis
given below is the minimum requirement. In case during the operation of plant it
is found that the rating selected is not adequate due to incorrect load
assumptions or due to any other reason, it will be Contractors responsibility to
replace the transformer and associated switchgear and breakers.
MVA rating of the transformer shall be based on the actual load figures and
redundancy.
Each transformer shall be rated to cater to the entire load on the respective
switchgear taking into consideration the outage of the other transformer.
The rating that shall be established shall take into account load variations
during the design engineering stage. Due consideration for reduction in
capacity due to transformer regulation shall be given. Spare Capacity of at
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least 10% shall be available in each transformer at the time of handing over
the plant.
4.2.1.3
Specific Requirements
Tanks
The tank shall be fabricated from good commercial grade low carbon steel of
adequate thickness and shall be of welded construction.
The tank wall shall be reinforced by stiffener to ensure rigidity so that it can
withstand
without
any
deformation
(a)
mechanical
shock
during
transportation, (b) oil filling by vacuum, c) Short circuit forces and (d)
continuous internal pressure of 35 kN/m2 over normal hydrostatic pressure
of oil, e) Continuous vacuum of Mercury as specified in CBIP.
All removable covers shall be provided with weatherproof, hot oil resistant,
resilient gaskets. The design shall be such as to prevent any ingress of water
into or oil from the tank.
The tank shall be provided with one set of bi-directional flanged wheels for
rolling the transformer parallel to either center line over 1676 mm rail gauge.
In case more than two rails are required to be provided the rail gauge of
1676 mm shall be maintained between two adjacent rails
Jacking pads, lifting lugs and pulling eyes shall be provided to facilitate
movement of the transformer. All heavy removal parts shall be provided with
eye bolt for ease of handling.
Manholes/ Inspection cover with handles of sufficient size shall be provided
for access to leads, windings, bottom terminals of bushings and taps.
One drain valve, which can be operated safely even when transformer is on
fire, located away from main transformer, shall be provided.
Suitable guide shall be provided in the tank for positioning the core and coil
assembly.
Adequate space shall be provided at the bottom of the tank for collection of
sediments.
Core & Coils
The core shall be built up with high grade, non-aging, low loss, high
permeability, grain oriented, cold-rolled silicon steel laminations especially
suitable for core material.
The laminations shall be free of burrs and sharp projections. Each sheet shall
have an insulating coating resistant to the action of oil,
Insulation structure for the Core to bolt and core to core clamp plates shall
be adequate such as to withstand a voltage of 2 kV for one minute.
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Frame work and clamping arrangements shall be securely earthed.
The coils shall be manufactured from electrolytic copper conductor of 99.9%
purity and fully insulated for rated voltage.
Winding shall not contain sharp bends which might damage the insulation or
produce high dielectric stresses. No strip conductor wound on edge shall
have width exceeding six times the thickness.
Insulating material shall be of proven design. Material used in the insulation
and assembly of the windings shall be insoluable non-catalytic and
chemically inactive in the hot transformer oil and shall not soften under the
operating conditions. Coils shall be so insulated that impulse and power
frequency voltage stresses are minimum.
Coil assembly shall be suitably supported between adjacent sections by
insulating spacers and barriers. Bracing and other insulation used in
assembly of the winding shall be arranged to ensure a free circulation of the
oil and to reduce the hot spot of the winding.
All leads from the windings to the terminal board and bushings shall be
rigidly supported to prevent injury from vibration or short circuit stresses.
Guide tube shall be used where practicable.
The core and coil assembly shall be securely fixed in position so that no
shifting or deformation occurs during movement of transformer or under
short circuit stresses.
Off Circuit Tap Changer (OCTC)
Off circuit taps as specified shall be provided on the high voltage winding.
The transformer shall be capable of operation at its rated kVA on any tap
provided the voltage does not vary by more than 10% of the rated voltage
corresponding to the tap.
The winding including the tapping arrangement shall be designed to
maintain electromagnetic balance between HV and LV windings at all voltage
ratios.
The off circuit tap changing will be by a three phase gang operated switch.
Arrangement shall be such that contacts are correctly engaged.
A warning plate indicating that switch shall be operated only when the
transformer is de-energized shall be provided. Arrangement shall be such
that switch can be operated at standing height from ground level. The
operating handle can be padlocked at any tap position. The design shall be
such that lock cannot be inserted unless the contacts are correctly engaged.
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The mechanism shall be provided with a tap position indicator. All contacts
shall be silver plated and held in position under strong contact pressure to
ensure low contact drop and avoid pitting.
Insulating Oil
The transformer shall be filled with mineral insulating oil suitably inhibited to
prevent sludging.
The transformer oil is to be supplied shall be low viscosity type, pure
hydrocarbon mineral oil, without any additive, clean and free from moisture
or other foreign matter and shall conform generally to the provisions of IEC
60296
and
the
specific
requirements
specified
in
the
schedule
of
characteristics indicated below.
S.No.
Test
Characteristics
Appearance
Density @ 200 C Kg/cm3
Methods
IEC: 296
Specification
Clear,
free
from
sediment & suspended
matter
Density @
3
29.50C
Kg/cm3
Kinematic Viscosity,
ISO: 3675
---
---
0.820 - 0.895
mm2/s
@400C
11.0 Max
@270C
@
ISO: 3014
-300C
16.0 Max
1800Max
Flash point (PMCC)
ISO: 2719
140 Min.
Pour Point 0C
ISO: 3016
- 30 Max
Interfacial Tension, N/m @ 250C
ISO: 6295
0.04
Neutralisation Value, mg KOH/gm
IEC: 296
0.03 Max
Corrosive Sulphur
ISO: 5662
Non corrosive
0C
Electric Strength (Breakdown Voltage)
KV rms
30KV rms Min.
a. As received (New unfiltered oil)
IEC: 156
b. After filtration
10
60KV rms Min.
(After filteration)
Resistivity
@270C
IEC: 247
@900C
11
(Before filteration)
2500 x 1012
150 x 1012
Dielectric dissipation factor
[Tan delta] 900C
[Tan delta]
IEC: 247
270C
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0.002 Max
0.0005
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S.No.
Test
Characteristics
Methods
12
Antioxidant additives
IEC: 666
Not Detectable
13
Water content, ppm
IEC: 733
40 Max.
14
Oxidation stability
@
1000C
(164 hours)
a. Neutralisation value, mg KOH/gm
b. Sludge content % by mass
c. Tan Delta @
0.15 Max
IEC: 74
900C
0.03 Max
0.1 Max
15
S.K. value % V/V
---
4 Max
16
Aromatic Content
FTIR
4-8
IEC: 247
25 x 1012 Min
IEC: 247
2 x 1012 Min
c. Dielectric Dissipation factor @ 900C
IEC: 247
0.1 Max
d. Total Acidity mg KOH/gm
17
Accelerated Ageing Test (Open beaker
Method)
a. Sp.Resistance (Resistivity) ohm cm
@ 270C
b. Sp.Resistance (Resistivity) ohm cm
@ 900C
18
Specification
IEC: 296
0.05 Max
e. Total Sludge weight %
---
0.05 Max
Ring Analysis Ca, Cp, Cn
FTIR
---
First filling of oil along with 10% excess shall be furnished for each
transformer. Oil shall be supplied in non-returnable containers suitable for
outdoor storage.
Oil preservation shall be by means of flexible oil resistant air bag sealed
conservator tank with silica gel breather to avoid direct connection between
atmosphere and transformer oil. It shall be complete with level gauges,
pipes, drain valve, air release valve & plugs, Air cell breather valve, pressure
gauge (on top of conservator) etc. The level gauges shall be so placed that
same can be readable standing from ground. Necessary device shall be kept
to provide annunciation in the event of rupturing of Air cell. Magnetic oil
level gauge shall be provided with low level contacts for signaling shall be
provided.
Bushings
Bushings shall be provided with terminal connectors of approved type and
size.
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All Porcelain used in the bushings shall be homogenous, nonporous,
uniformly glazed to brown color and free from blisters, burrs and other
defects.
All bushings shall have non ferrous flanges and hardware.
Bushings shall conform to IS 2099 (for Electrical) and IS 3347 Part-IV (for
metal parts).
Bushing location shall provide adequate phase and ground clearances.
Terminal Arrangement
The physical position of the terminals and the markings shall be as per
relevant IS/IEC unless otherwise required to suit the layout.
In general, the arrangement shall be such as to permit removal of
transformer without dismantling the bus duct/cable connection.
The 11kV side shall be connected through self supported detachable type
cable end box. Gland plate shall be provided at the bottom to facilitate cable
entry.
Cooling System
Transformer cooling shall be ONAN/ONAF. In addition cooling equipment shall
conform to the requirement stipulated below:
a) The transformer shall be provided with 2 x 60% capacity cooler banks
mounted on transformer. Each cooling unit shall be complete with its radiator
banks, fans and other accessories.
b) Each cooler bank shall have its own cooling fans, shut off valves at the top
and bottom (80mm size), lifting lugs, air release plug at the top, a drain and
sampling valve at bottom.
c) Cooler fans of both cooler banks shall operate continuously. Each cooler
bank shall be provided with standby fan. Selector switch shall be provided for
selection of fans to be in service or in standby. Cooling calculation for
number of fans to be provided shall be submitted or purchasers approval.
Provision shall be kept to start the coolers by WTI contacts of HV & LV
winding.
d) Suitable manual control facility for cooler fans shall be provided. Control
shall be suitable for manual and automatic operation of fans.
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e) Cooling fan shall be suitable for operation on 415 + 10% V, three phase, 50
Hz +/-5% power supply. & shall conform to IS:325. Each cooling fan shall be
provided with starter with thermal overload & short circuit protection. The
motor winding insulation shall be conventional class F type. Motor shall have
enclosure with degree of protection equivalent to IP 55 as per IS: 4691. The
temperature rise of the motor shall be limited to 70 deg. C above ambient of
50 deg by winding resistance method.
Cooling fans shall not be overhung from radiator fins. They shall be mounted
on suitable structural members using vibration mounts. They shall be
provided with a galvanized mesh guards. Terminal covers and greasing cups
of fan motors shall be accessible without removing the guard. The fans shall
be removable without dismantling supporting framework.
f) Duplicate feeders shall be provided for cooler control cabinet. The contractor
shall supply all necessary equipment for automatic changeover from 415 V, 3
phase, 3 wire from notmal to standby incoming supply in the event of failure
of normal supply and vice versa. Changeover scheme shall included on delay
timer to prvent immediate changeover.
Marshalling Box
A sheet steel, weatherproof, IPW55, marshalling box shall be provided for the
transformer. The box shall contain all auxiliary devices except those which
must be located directly on the transformer.
All terminal blocks for cable connection shall be located in this box.
The marshalling box shall be provided with cubicle lamp with door switch,
space heater with thermostat and removable cable gland plate.
Requirement of 230 V AC single phase / 110 V AC supply shall be arranged
by the contractor.
All equipments and devices shall be suitably labeled.
Contractor shall provide following potential free contacts / analog outputs
(two sets each) in the Marshalling box to facilitate wiring to remote panel /
DCS / PLC.
Potential free contacts
a)
Cooler power supply auto changeover
b)
Cooling fan / fan failure for each radiator bank
c)
Control supply fail
d)
Status indications for Fan ON, Auto / manual selection etc.,
e)
Mechanical protection such as
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Bucholz alarm and trip
MOG oil level low
LV winding temp high and High High
HV winding temp high and High High
Oil temperature High and High High
Abnormal tap position
f)
PRV operated
Analog outputs
LV winding temperature
HV winding temperature
Oil temperature
Wiring
All control, alarm and indication devices provided with the transformer shall
be wired up to the terminal blocks.
Wiring shall be done with flexible, 1100 V grade PVC wires in conduit or PVC
armoured cable. Minimum wire size shall be 2.5 mm2 copper. Not more
than two wires shall be connected to a terminal. 10% spare terminals shall be
provided.
Multi-way terminal block complete with mounting channel, binding screws
and washers for wire connections and marking strip for circuit identification
shall be provided for terminating the panel wiring. Terminals shall be stud
type, suitable for terminating 2 nos. 2.5 mm2 stranded copper conductor
and provided with acrylic insulating cover. Terminals for C.T. secondary leads
shall have provision for shorting and grounding.
All devices and terminal blocks shall be identified by symbols corresponding
to those used in applicable schematic or wiring diagram. Each wire shall be
identified, at both ends, with interlocking type permanent markers bearing
wire numbers as per Contractor's Wiring Diagrams. AC / DC wiring shall have
separate colour-coding.
Wire termination shall be made with crimping type connectors with insulating
sleeves. Wires shall not be spliced between terminals.
Grounding
The grounding pads, located on the opposite sides of the tank, shall be
provided for connection to ground mat.
Grounding pad shall have clean buffed surface with two tapped holes, M10
G.I. bolts and spring washers for connection to 75x10 mm G.I. flat.
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Two numbers Ground terminals shall be also provided on marshalling box to
ensure its effective earthing.
Two nos neutral earthing via neutral grounding resistor of required rating to
restrict the fault current to full load current / 300 A.
For continuity of earth connection, all gasketed joints shall be provided with
braided copper wire jumpers
4.2.1.4
Auxiliary Equipments
Current transformer
Two core, turret mounted, Neutral current transformer and Two core. Turret
mounted phase bushing current transformer with multi ratio taps (On one
phase of HV & LV winding) shall be provided.
The arrangement shall be such that the C.T. can be removed from the
transformer without removing the tank cover.
CT secondary leads including tappings shall be brought to a weather proof
outlet box near the bushing. Conduit wiring from the outlet box up to the
transformer marshalling box shall be carried out by the contractor.
Bushing current transformer name plate shall be mounted on the equipment
tank adjacent to the terminal box.
Gas & Oil actuated relay (Buchholz Relay)
A double float type Buchholz relay of proven design complete with all
accessories such as test cock, gas collecting device and valves required for
sampling shall be provided. The device shall be provided with two electrically
independent contacts, one for alarm on gas accumulation and other for
tripping on sudden rise in gas pressure.
Pressure relief device
Tank shall be provided with two numbers of pressure relief device which shall
operate at a pressure below the test pressure for the tank and radiators. The
device shall be rain proof after blowing and shall be provided with a device
visible from ground to indicate operation. This device shall be equipped with
remote monitoring / alarm contacts.
Valves
Valves shall be of full way type with flanged ends and shall be opened by
turning counter clockwise when facing the hand wheel. There shall be no oil
leakage when the valves are in closed position. The flanges shall have
machined faces.
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Every valve shall be provided with an indicator to show the open and close
positions and shall be provided with pad locking facility. All flanged valves
shall be provided with oil tight blanking for protection.
Painting
All steel surfaces shall be thoroughly cleaned by sand blasting or chemical
agents as required, to produce a smooth surface free of scales, grease and
rust.
The internal surfaces in contact with insulating oil shall be painted with heat
resistant insulating varnish which shall not react with and be soluble in the
insulating liquid used.
The external surfaces, after cleaning, shall be given a coat of high quality red
oxide or yellow chromate primer followed by filler coats.
The transformer shall be finished with two coats of synthetic enamel paint
conforming to shade 632 of IS 5.
Interior surface of mechanism chambers and marshaling kiosks shall receive
three coats of paint after proper cleaning. The Final coat shall be of a light
coloured anti condensation paint.
Paints shall be carefully selected to withstand heat and environmental
conditions.
All supporting structures and hardware shall be hot dip galvanized.
Transportation
Transformer tank shall be dispatched filled with oil. A positive pressure of 2
to 2.5 Psi at temperature of 36C approximate shall be kept. Sufficient space
is left above the oil to take care of the expansion of the oil. The space is
filled with inert gas under atmospheric pressure.
Impact Recorder
Impact
recorder/indicator
shall
be
provided
to
monitor
the
impact
experienced by the transformer during transport. After delivered the
transformer to site and handing over of the test result of impact recorder for
Owners analysis, it can be taken back by the contractor.
Fittings and Accessories
Transformer shall be equipped with fittings and accessories as listed below :
Oil conservator with filler cap, drain valve, plain oil level gauge, air release
valve & plugs, air cell breather valve, pressure gauge (on top of conservator)
and MOG.
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Oil preservation system complete with accessories.
4 Nos of Air release plugs.
Two numbers of Pressure release device with trip contacts.
150 mm dial magnetic oil level gauge with low level alarm contacts
150 mm dial oil temperature indicator with maximum reading pointer and
electrically separate contacts for trip and alarm and embedded temperature
detectors (PT-100). Separate RTDs with CCU units with two numbers of
analog outputs shall be provided for remote indications.
150 mm dial LV winding temperature indicator with maximum reading
pointer and electrically separate sets of contacts for trip, alarm and cooler
control and embedded temperature detectors (PT-100). Separate RTDs with
CCU with two numbers of analog outputs shall be provided for remote
indications PLC / DCS.
150 mm dial HV winding temperature indicator with maximum reading
pointer and electrically separate sets of contacts for trip, alarm and cooler
control and embedded temperature detectors (PT-100) .Separate RTDs with
CCU Units with two numbers of analog outputs shall be provided for remote
indications/ PLC / DCS.
Remote winding temperature indicators for HV & LV for mounting on remote
panel.
Seven Numbers Thermometer pockets (two nos each for OTI, HV WTI, LV WTI
and one no spare).
Filter valve with threaded adopter (top and bottom).
Drain valve with threaded adopter.
Sampling valves at Top, Bottom and Middle.
Jacking pads at least four in number at suitable height for lifting the
complete transformer filled with oil, pulling eyes on each face of transformer
and lifting lugs.
Cover lifting lugs/ eyes.
Bi-directional flanged wheels and skids.
Clamping device with bolts & nuts.
Manhole / Inspection cover of sufficient size for access to interior of the
tank.
Two-grounding pads.
Neutral earthing bar of copper of specified section installed from the neutral
bushing to ground level suitably supported along its run on porcelain
insulators together with clamping arrangements at neutral bushing.
Ladder with safety device for access to the top of transformer tank.
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Weather proof marshalling box for housing control equipment and terminal
connections.
H.V. and L.V. bushing terminal connectors.
Rating and terminal marking plates, oil filling instruction plate, valve
schedule and caution plate.
4.2.1.5
Standards
All equipments provided under the specification shall in general, conform to the
latest issue of the following standards:
International &
Indian
Standards
Title
No.
IS: 2026
Insulating for alternating voltages switchgear
IEC: 296, BS:148
IS: 2099
Bushing for alternating voltages above 1000 V
IS: 325
Three phase induction motors
Current transformers
IS: 375
Marking & arrangement for switchgear bus
IS: 3637
Gas operated relays
Code of practice for selection installation&
IS: 4691
Degree of protection provided by enclosure for
IS: 2147
Degree of protection provided by enclosure for
IS : 5
Colours for ready mix paints
IS: 6272
Industrial cooling fans
IS: 320
Code of practice for climatic proofing of
IS: 3347
Specification for dimensions of porcelain
IS: 6600
IEC: 137, BS: 223
IEC: 185
IEC: 34
bars, main connections & auxiliary wiring.
IS: 10028
IS: 1866
standards
IEC: 76
Fittings & accessories for power transformers
IS: 2705
recognized
Power transformers
IS: 3639
IS: 335
internationally
maintenance of transformers
rotating electrical machinery
low voltage switchgear & control
IEC: 144
Code of practice for maintenance & Supervision
of mineral insulating oil in equipment
Guide for Loading of oil immersed
transformers
IEC: 354
Electrical equipment
bushing
High voltage test technique
Insulation co-ordination
NEMA standard publication for Power
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IEC: 60
IEC: 71
NEMA-TR-1
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International &
Indian
Standards
internationally
Title
No.
recognized
standards
transformers
IS: 10597
Code of practice for selection, Installation
operation & maintenance of pumps for
industrial applications
IS: 9434
Guide for sampling & analysis of free &
dissolved gas & oil from oil filled electrical
IEC: 567
equipment
IS: 12676
Dimensions for OIP insulated condenser
IEEE: 32
IEEE standard requirement terminology& test
bushings
procedure for neutral grounding device
The electrical installation shall meet the requirements of Indian Electricity Rules
1956 & IS: 10028 Code of practice for selection, installation & maintenance of
transformers as named up to date.
4.2.1.6
Tests
The following tests are to be carried out in both the transformers
Routine Tests as per IS 2026
Dielectric test.
Measurement of winding capacitance and tan delta.
Oil leakage test for transformers and radiators.
Functional tests on Marshalling box, Air cell, conservator, pressure relief
device.
2 kV AC HV test between core and end frame.
The following tests shall be conducted on one transformer.
a. Heat Run Test with dissolved gas analysis before and after.
b. Vacuum Withstand and deflection measurement on tank.
c. Pressure test on tank with deflection measurement
d. Measurement of losses and efficiency
e. Measurement of Noise level. Noise level shall be restricted to NEMA TR-1
f. Measurement of Harmonic in No load current at 90%, 100% & 110%
voltage.
g. Measurement of Zero sequence impedance.
h. Measurement of power taken by the fans
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Valid type test certificates for impulse test shall be submitted. The type test
report shall not be more than 5 years old. If valid type test certificate is not
available then type test shall be carried out on each type of transformers without
any extra cost. For short circuit the valid test certificate of similar transformer is
to be produced.
All auxiliary equipments shall be tested as per relevant standards. Test
certificates shall be furnished for brought out items. High voltage withstand test
(2000 V to earth) shall be performed on auxiliary equipments and wiring after
complete assembly.
4.2.2
LT Distribution Type Transformer
4.2.2.1
General criteria
The number and rating of service transformers shall be decided based on the
Electrical single line diagram for auxiliary power distribution drawing without
sacrificing the unit and common load concept. The transformers shall generally
comply with specific requirements as follows:
The service transformers shall be rated for 100% load and shall be three-phase,
two winding, ONAN cooled with off-circuit taps of +/- 5% in steps of 2.5% on HV
side. The transformers shall be suitable for outdoor applications having Dyn11
Vector group. The star point shall be solidly earthed.
The impedance of the transformers shall be chosen such that the fault level does
not exceed the short circuit capability (50 kA /1 sec) on 415 V switchgear
including the motor contributions and also voltage dip while starting any
auxiliary does not exceed the limit acceptable for the equipment concerned but
not exceeding 10%.
In case of single core cable termination, gland plate shall be of aluminium.
Transformer shall operate without injurious heating, at rated MVA at any voltage
within 110% of rated voltage of that particular tap.
Transformers shall be capable of delivering the rated current, at a voltage equals
to 115% of rated voltage without exceeding rated temperature rise.
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Transformer shall operate below the knee of the saturation curve at 110%
voltage to preclude ferro resonance and non-linear oscillations.
Transformers and accessories shall be designed for fault levels indicated in 415
V switchgear specifications. Dynamic ability and thermal ability to withstand the
short circuit force shall be demonstrated by tests / calculations.
Noise level shall be as per NEMA TR-1.
The transformers shall be designed with particular attention to suppress
harmonic voltage, especially third and fifth, so as to eliminate wave form
distortion.
Each transformer shall be rated to take care of the entire load on the respective
switchgear considering the outage of the other transformer. An appropriate
diversity factor with a minimum of 0.9 for continuously running loads and 0.4
for intermittent loads like cranes, plug points, sump pumps, elevator etc., shall
be considered.
The rating established shall takeinto account, load variations during the design
engineering stage. Due consideration for reduction in capacity due to
transformer regulation shall be given. Spare capacity of at least 10% shall be
available in each transformer at the time of handing over the plant.
4.2.2.2
Specific Requirements
The transformer shall generally comply with all following specific requirements
a)
b)
The tank cover shall be conventional one with bolted joint at the top
The transformers shall be provided with detachable built on radiators of
adequate number.
c)
d)
Off-circuit tap changers with lockable operating handle and mechanical tap
position indicator shall be provided.
Pressure relief device / explosion diaphragm as applicable shall be
provided.
e)
Conservator need not be sealed expansion type.
g)
The transformer shall be suitable for cable connection for HV /bus duct
f)
The wheels shall be flat roller type
connection for LV side.
h)
For bus ducts suitable flanged bushing connection shall be provided. The
winding terminations shall be brought out on outdoor type of bushings.
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i)
If cables are used the neutral of the LV side of the transformer shall be
brought out in a separate cable box or if the same cable box is used for
neutral also, then metallic partition between phases and neutral shall be
provided.
j)
Transformer mounted protective devices (OTI, WTI, MOG, CCU, Neutral CTs,
etc) shall be provided and wiring from all devices mounted on
transformer such as OTI, WTI, MOG, Neutral CTs etc. shall be brought to
one terminal box with cables for connection to plant protection, indication
and controls. Remote winding and oil temp indicators is under the scope of
k)
the bidder The cables should not touch transformer body to avoid heating.
The HV winding of all transformers shall be brought out through suitably
rated bushing mounted on non magnetic material in separate air insulated
cable box with disconnecting chambers. The cable box shall also be
provided with facility for supporting from ground.
l)
Necessary lifting lugs, jacking pads, and pulling eyes shall be provided
lifting and skidding of transformers without removing oil.
m)
Each radiator bank shall be provided independently mounted with inlet and
out let valves to enable replacement of radiator when transformer is in
service.
n)
Transformer shall be capable of being used with any make of transformer
oil complying with IS 335.
o)
The rating and nameplate shall contain all details as per IS 2026. In
addition, following details shall also be included.
i)
Connection diagram showing internal connections.
iii)
Insulation level of windings
iv)
Transportation weight.
vi)
Core and winding weight.
vii)
Table showing tapping voltage, tapping current, Taping power for
ii)
v)
viii)
Temperature rise
Untanking weight.
each winding.
Values of short circuit impedance on extreme tapping and on
principle tapping and an indication of the winding to which
ix)
p)
impedance is related.
Serial number of transformer
Transformers shall be provided with oil conservator of sufficient volume to
maintain the oil seal from the minimum ambient temperature of 5 deg up
to an oil temperature of 105 deg,with oil level varying within minimum and
maximum oil levels. The conservator shall be provided with filing plug,
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drain valve, bolted cover at one end for cleaning, valves for shutting off oil
to transformer, breather and Buchholz relay.
4.2.2.3
Materials of Construction and Design
Core
Core shall be constructed with high-grade cold rolled non-ageing grain oriented
silicon steel. Each lamination shall have insulated coating. The insulated
structure for core to bolts and core to clamp plates shall withstand 2.0 kV for
one minute. The core clamping structure shall be designed to minimize eddy
current losses. The core shall be provided with lugs for lifting of core with coils.
The core and coil assembly shall be rigidly fixed to avoid their shifting during
transport or short circuit. Frame work and clamping arrangement shall be
securely earthed.
Winding
Winding shall be made up of tinned or enameled electrolytic copper more than
99.9% purity unless and otherwise specified. Conductor shall be transposed at
sufficient intervals in order to minimize the eddy current. Permanent current
carrying connection in the winding shall be brazed or welded. Clamping bolts for
current carrying parts in the oil shall be made up of oil resistant material. The
coils shall be properly supported and shall be subjected to seasoning process so
that further shrinkage should not occur during service.
The complete core and coil assembly shall be dried in vacuum at not more than
0.5 mm of mercury absolute pressure and shall be immediately impregnated
with oil after the drying process.
Tank
The tank shall be made from good commercial grade low carbon steel and shall
be of welded constructions with suitable lugs and bosses for lifting and shifting.
Tank together with accessories shall be designed to withstand full vacuum of
760 mm of HG and Internal gas pressure of 0.35 kg/cm2 with oil at working
level. Top cover shall be bolted type to remove the core and winding at site. Man
holes with bolted covers shall be provided in the top / side of transformer for
access to lower end of bushings, tap changers and to permit replacement of
auxiliaries without removal of top covers.
Adequate space shall be provided at bottom for collection of sediments. At the
bottom, wheels shall be provided for skidding with pulling eyes. The entire
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gasket shall be of cork neoprene or better type and all gasketted joints shall be
so arranged that gaskets shall not be exposed to whether. Valves of forged
carbon steel up to 50mm and of gunmetal or of cast iron bodies with gun metal
fittings above 50mm shall be provided. Valves for drain, filtration, oil sampling,
vacuum pulling and radiator isolation shall be provided with adequate size.
Bushings
All the bushing shall be of porcelain type. Bushing rated for 400 A and above
shall have non-ferrous flange and hardware. Busing shall confirm to IS 3347 and
insulation level as per IS 2099.
4.2.2.4
Tests
Valid type test certificate shall be submitted. If valid type test certificate is not
available then type test shall be carried out on each type of transformer without
any price implication to Owner.
Routine tests as per IS 2026 on all transformers. In addition to all routine test as
per IS 2026, the following tests shall be conducted on one transformer of each
type and size.
a. Heat Run Test with dissolved gas analysis before and after.
b. Vacuum Withstand and deflection measurement on tank.
c. Pressure test on tank with deflection measurement
d. Measurement of losses and efficiency
e. Measurement of Noise level. Noise level shall be restricted to NEMA TR-1
f. Measurement of Harmonic in No load current at 90%, 100% & 110% voltage.
g. Measurement of Zero sequence impedance.
For short circuit the valid test certificate of similar transformer is to be
produced.
All auxiliary equipments shall be tested as per relevant standards. Test
certificates shall be furnished for brought out items. High voltage withstand test
(2000V to earth) shall be performed on auxiliary equipments and wiring after
complete assembly.
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4.2.3
HT Switchgear
4.2.3.1
Design criteria
Coal handling system shall be fed from station switchgear.
The 3.3 kV switchgear shall be used to supply power to HT motors, transformers
and other loads in the plants. Duty involves direct on line starting of large
induction motors. The motor starting current shall be 6 times the full-load
current with IS tolerance, with a maximum of 3 starts per hour.
The switchgear shall be located in a clean but hot, humid and tropical
atmosphere. For continuous operation at specified ratings, temperature rise of
the various switchgear components shall be limited to the permissible values
stipulated in the relevant standards and/or this specification.
The Switchgear and components shall be capable of withstanding the
mechanical forces and thermal stresses of the short circuit current without any
damage or deterioration of material. Circuit breaker shall not produce any
harmful over-voltage during switching off of induction motors, unloaded lines
and unloaded transformers. If required, surge protective device shall be
provided in the scope of supply to limit the over-voltage
4.2.3.2
Short circuit current rating selection criteria
a) The fault level for the switchgear, circuit breakers, isolators, earth switch
shall be arrived at, on the following basis
i) Short circuit current contribution from upstream side of the
transformer plus short circuit contribution by the motors running on
the bus; this is supported with software short circuit study.
b) A margin of 5% over the S.C. current thus calculated shall be applied and
rounded off to the next higher standard ratings and this value shall be
adopted for the breakers and switchgears. The momentary current ratings
shall be 2.55 time this value.
c) Short time current withstands duration for switchgear & all components shall
be considered as three second.
d) Asymmetrical S.C current breaking capacity of the breaker shall consider the
higher time constant for decay of current in the vicinity of power generating
stations and the breaker offered shall be suitable for the same.
e) Calculations for arriving at the time constant at this plant shall be furnished
to justify breaker selection in accordance with IEC for breakers.
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4.2.3.3
Continuous Current Ratings
a) The continuous current rating of the 3.3 kV switchgear buses and their
incomer breaker shall be rated as LV winding current of respective
transformer with 20% margin rounded off to the next higher standard rating.
b) The continuous current rating of the feeders shall be based on the name
plate current rating of the connected equipment with 20% margin.
c) The continuous current rating of 3.3 kV buses with bus coupler arrangement
shall be the maximum load on the bus due to running auxiliaries plus 20%
margin, rounded off to the next higher standard rating.
4.2.3.4
Detailed Requirements
4.2.3.5
Construction- Switchgear Panel
The switchgear shall be indoor, metal clad, floor mounted, draw out type and
suitable for located in a clean but hot, humid and tropical atmosphere. Degree
of protection shall be IP42. Additional stiffeners shall be provided to increase
rigidity wherever cutouts are made.
Enclosure shall be constructed with rolled steel sections and cold rolled steel
sheets of at least 2.0 mm thickness, Gland plates shall be 2.5 mm thick made
out of hot rolled or cold rolled steel sheets and for non-magnetic material it
shall be 3.0 mm.
Each circuit shall have a separate vertical panel with distinct compartments for
circuit breaker/contactor truck, cable termination, main bus bars and auxiliary
control devices. The adjacent panels shall be completely separated by steel
sheets except in busbar compartments where insulated barriers shall be
provided to segregate adjacent panels. However, manufacturer's standard
switchgear designs without inter panel barriers in busbar compartment may also
be considered.
The circuit breakers / contactors and bus VTs shall be mounted on withdraw
able trucks which shall roll out horizontally from service position to isolated
position. For complete withdrawal from the panel, the truck shall rollout on the
floor or shall roll out on telescopic rails. In case the later arrangement is offered,
suitable trolley shall be provided by the Bidder for withdrawal and insertion of
the truck from and into the panel. The number of trolleys to be provided shall be
two nos. per switchboard.
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The trucks shall have distinct SERVICE, TEST and ISOLATED positions. It shall be
possible to open the breaker/contactor compartment door in isolated position
only, so that the switchgear retains its specified degree of protection.
The switchgear assembly shall be dust, moisture, rodent and vermin proof, with
the truck in any position SERVICE, TEST, ISOLATED, and all doors and covers
closed. All doors, removable covers and glass windows shall have gaskets all
round with synthetic rubber or neoprene gaskets.
The VT/ relay compartments shall have degree of protection not less than IP: 52
in accordance with IS: 13947. However, remaining compartments can have a
degree of protection of IP: 42. All louvers if provided shall have very fine brass
or GI mesh screen. IPH-2 degree of protection as per IS: 3427 to all live parts
shall (whether isolated or removed from panel) even when the breaker /
contactor compartment door is opened. Tight fitting gourmet/gaskets are to be
provided at all openings in relay compartment.
The switchgear construction shall be such that breaker operation and internal
explosions do not endanger the operating personnel, and the front of the panels
shall be specially designed to withstand these. Pressure relief device shall be
provided in each high voltage compartment of a panel, so that in case of a fault
in a compartment, the gases produced are safely vented out, thereby minimizing
the possibility of its spreading to other compartments and panels. The pressure
relief device shall not however reduce the degree of protection of panels under
normal working conditions.
The switchgear shall be cooled by natural airflow and forced cooling shall not be
accepted.
Total height of the switchgear panels shall not exceed 2600 mm. The height of
switches, pushbuttons and other hand-operated devices shall not exceed 1800
mm and shall not be less than 700 mm.
Necessary guide channels shall be provided in the breaker compartments for
proper alignment of plug and socket contacts when truck is being moved to
SERVICE position. A crank or lever arrangement shall preferably be provided for
smooth and positive movement of truck between Service, Test and Isolated
positions.
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Safety shutters complying with IEC - 298 shall be provided to cover up the fixed
high voltage contacts on bus bar and cable sides when the truck is moved to
ISOLATED position. The shutters shall move automatically, through a linkage
with the movement of the truck. Preferably it shall however, be possible to open
the shutters of busbar side and cable side individually against spring pressure
for testing purpose after defeating the interlock with truck movement
deliberately. It shall also be possible to padlock shutters individually. In case,
insulating shutters are provided, these shall meet the requirements of Clause
3.102.1 Note -2 of IEC - 298 and necessary tests as per IEC -298 Clauses
5.103.1 shall be carried out. A clearly visible warning label "Isolate elsewhere
before earthing" shall be provided on the shutters of incoming and tie
connections that could be energized from other end.
Switchgear construction shall have a bushing or other sealing arrangement
between the circuit breaker / Contactor compartment and the bus bar / cable
compartments, so that there is no air communication around the isolating
contacts in the shutter area with the truck in service position.
The breaker / contactor and the auxiliary compartments provided on the front
side shall have strong hinged doors.Bus bar and cabling compartments provided
on the rear side shall have bolted covers with self retaining bolts. Breaker /
Contactor compartment doors shall have locking facility. Suitable interlock shall
be provided, which will ensure that breaker is OFF before opening the back
doors.
In the Service position, the truck shall be so secured that short circuit forces do
not displace it. Bus bars, jumpers and other components of the switchgear shall
also be properly supported to withstand all possible short circuit forces
corresponding to the short circuit rating specified.
Suitable base frames made out of steel channels shall be supplied along with
necessary anchor bolts and other hardware, for mounting of the switchgear
panels. These shall be dispatched in advance so that they may be installed and
leveled when the flooring is being cast.Welding of base frame to the insert plates
as per approved installation drawings shall be in Bidder's scope.
Dummy panel shall be provided in the switchgear line up, if required, for easy
termination access of power and control cables. Dummy panel / bus trunking
panel shall be of full cubicle with closed roof and rear door similar to enclosures
for active cubicles.
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4.2.3.6
Bus bars and Insulators
All bus bar and jumper connections shall be of high conductivity Copper with
specified
current
ratings
with
below
mentioned
maximum
temperature
limitations. They shall be adequately supported on insulators to withstand
electrical and mechanical stresses due to specified short circuit currents.
For bolted joints (Plain or tinned)
90oC
For bolted joints (Silver plated)
105oC
It shall be possible to extend the bus bars at either end of the switchboard for
addition of panels in future. Both ends of bus bars must be suitably drilled for
this purpose.
Bus bar cross-section shall be uniform throughout the length of switchgear.
Continuous current rating of bus connections / dropper shall be same as that of
continuous current rating of associated breaker. Bus bars and other high voltage
connection shall be sufficiently corona free at maximum working voltage.
Contact surfaces at all joints shall be silver plated and no oxide grease applied
to ensure an efficient and trouble free connection. All bolted joints shall have
necessary plain and spring washers. All connection hardware shall have high
corrosion
resistance.
connections.
Suitable
bimetallic
connectors
shall
be
used
for
Bus bar insulators shall be of arc and track resistant high strength, nonhygroscopic, non-combustible type and shall be suitable to withstand stresses
due to over-voltages, and short circuit current. Bus bar shall be supported on
the insulators such that the conductor expansion and contraction are allowed
without straining the insulators. In case of organic insulator partial discharge
shall be limited to 100 pico coulomb at rated voltage x 1.1 / v3. Use of
insulators and barriers of in-flammable material such as Hylam shall not be
accepted.
Successful Bidder shall furnish calculation establishing adequacy of busbar sizes
for the specified continuous and short time current ratings.
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Bus bars shall be color coded for easy identification and so located that the
sequence R-Y-B shall be from left to right, top to bottom or front to rear, when
viewed from front of the switch-gear assembly.
The temperature rise at the switchgear terminals intended for external cable
termination shall not exceed 40 deg. C. Further the switchgear parts handled by
the operator shall not exceed a rise of 5 deg. C.
4.2.3.7
Vacuum Circuit Breakers
The VCBs offered shall be of gang-operated type. The whole equipment shall
conform to the relevant IS/IEC specifications of the latest publications whether
specifically mentioned or not with regard to construction, safety protection,
clearance etc.
The VCBs along with accessories shall be mounted in a withdraw able truck. The
VCBs are meant for direct on-line charging of transformers and starting of
motors and for incomers/tie feeders.
The contact arms for connecting the Vacuum Circuit Breakers conducting part
to the main bus bars and to the cable side shall be of copper with silver plating.
High quality metal oxide surge arresters shall be provided with VCBs for
transformer & motor feeders.
The wiring for the VCBs shall be of plug and socket arrangement. The length of
the plug cord shall be such that the plug can be inserted into the socket only
when the breaker is in service and Test positions but it shall be necessary to
withdraw the plug from the socket before the breaker truck can be withdrawn
from the cubicle.
The VCBs shall be physically and electrically interchangeable.
All similar and
removable parts shall be interchangeable with each other.
The VCBs shall be of fully drawout type having test, service and isolated
positions with mechanical indication for test and service positions. The breaker
shall be provided with mechanical indication for ON & OFF,closing Spring
charged & released status and operation counter. The status indications and the
operation counter reading shall be visible from outside through the inspection
window provided in the breaker chamber door.
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The operating mechanism shall be stored energy type. The status of the closing
spring shall be such that the spring shall be automatically re-charged after the
closing operation of the breaker. The closing spring shall be charged through
220 V DC spring charging motors. Provision shall also be available for manual
charging. Each VCB shall be provided with necessary handle for the same.
Spring charging motor of suitable rating shall be provided with necessary limit
switches and protection. The spring charging motors supplied for all the
breakers shall be of the same make and rating. The charging time for the motors
shall not be greater than 15 secs at rated voltage. Motor shall be rated for 220 V
DC and shall operate satisfactorily at all voltage between 85-110% of the rated
voltage. Power supply to the spring charging motor shall be cut off when the
closing spring is charged manually.
The operating mechanism shall be trip free. Anti-pumping relay has to be
provided.
The VCB shall be provided with suitable mechanical close and trip
devices.
Working parts of the mechanism shall be of corrosion resistant
material. Bearing pin bolts nuts and other parts shall be adequately pinned and
locked to prevent loosening or changing with repeated operation of the breaker.
The VCBs shall be provided with close release and shunt trip coils. The control
supply for the VCBs shall be through 220 V DC. The close release coil shall
operate satisfactorily at all values of voltage between 85-110% while the shunt
trip coils shall operate between 70-110% of rated voltage.
Provision shall be made available in the VCB for checking the wear of the main
contacts.
Each VCB shall be provided with auxiliary contacts / limit switches as indicated
below.
Sufficient number of auxiliary contacts operated by the breaker mechanism for
interlocking / indication / feedback purpose shall be provided.
Auxiliary
contacts of the breaker directly operated by the breaker operating mechanism
shall be capable of carrying a current of 10 Amps continuously at 220 V DC.
Provision shall be made available in the switchgear for locking the VCBs
mechanically in the test and service positions.
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All auxiliary contacts of the VCB including the spare contacts are to be wired and
brought up to the multi pin control plug.
Positive earthing of the circuit breaker frame shall be maintained with the earth
bus in the breaker compartment in test and service positions. The circuit breaker
frame shall be earthed before the main breaker contacts / control circuit
contacts are plugged in the associated stationary contacts.
The following interlocks are to be provided.
a)
The truck cannot be moved from test to service or vice versa when the
breaker is ON
b)
The circuit breaker cannot be switched on when the truck is in any
c)
The control wiring plug cannot be disconnected from the socket when the
position between test and service position.
breaker is in service position.
d)
Provision shall be made to trip the breaker if tried to draw out when the
breaker is in closed condition.
Supporting insulators for the poles shall be of epoxy cast resin type and shall be
able to withstand stresses due to maximum short circuit current.
The bus bars fixed in the breaker shall be of electrolytic copper of suitable cross
section to withstand a short circuit current of 40 kA/3 sec.
Inter pole insulation shall be provided between adjacent poles. The entire joints
/ connections end shall be silver plated.
ensured.
Adequate contact pressure shall be
Control wiring for the breaker shall be with single core, flexible, 1100 V grade
insulated wire with multi strand copper conductor of 1.5 mm2 cross section.
4.2.3.8
Control and Interlocks
The circuit breaker will normally be controlled from remote control panels
through interposing relays. The control switch located on the switchgear would
normally be used only for testing of circuit breaker in isolated position, and for
tripping it in an emergency.
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Facilities shall be provided for mechanical tripping of the breaker/ contactor and
for manual charging of the stored energy mechanism for a complete duty cycle,
in an emergency. These facilities shall be accessible only after opening the
compartment door.
Each panel shall have sufficient no. of limit switches, for the Service position and
TESTposition. Each of these limit switches shall have at least four (4) contacts
that shall close in the respective positions.
Auxiliary Contacts of breaker may be mounted in the fixed portion or in the
withdraw able truck as per the standard practice of the manufacturer, and shall
be directly operated by the breaker / contactor operating mechanism.
Auxiliary contacts mounted in the fixed portion shall not be operable by the
operating mechanism, once the truck is withdrawn from the service position, but
remain in the position corresponding to breaker open position. Auxiliary
contacts mounted on the truck portion, and dedicated for Owner's use shall be
wired out in series with a contact denoting breaker service position. With truck
withdrawn, the auxiliary contacts shall be operable by hand for testing.
For Owner's use six (6) normally open (NO) and six (6) normally closed (NC)
auxiliary contacts shall be provided for all feeders.
Contact multiplication, if necessary to meet the above contact requirement, shall
be done through suitable latch relay of reputed make.
Movement of truck between SERVICE, TEST and ISOLATED positions shall be
mechanically prevented when the breaker is closed.
Closing of the breaker shall be possible only when truck is either in TEST or in
SERVICE position and shall not be possible when truck is in between. Further,
closing shall be possible only when the auxiliary circuits to breaker truck have
been connected up, and closing spring is fully charged.
Mechanical (Castell key) or a full proof electrical interlock shall be provided
between the isolator and associated circuit breaker such that the former cannot
be operated unless the latter is opened.
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It shall be possible to easily insert breaker of one typical rating into any one of
the panel meant for same rating but at the same time shall be prevented from
inserting it into panels meant for a different type or rating.
Indicating lamps shall be provided in the panel front as brought out in the
specification elsewhere. It shall be possible to easily make out whether the truck
in SERVICE, TEST OR ISOLATED POSITION even when the compartment door is
closed.
4.2.3.9
Current Transformers
All current transformers (CT) shall be cast resin type. All secondary connections
shall be brought out to terminal blocks where wye or delta connection shall be
made.
Core balance CTs (CBCT) shall be provided on all feeders. These CBCTs shall be
mounted inside the switchgear panel. The window size of CBCT's shall be based
on the overall diameter of the cables, to be finalized during detailed
engineering.
Accuracy class of the Current Transformers and its metering shall be as per CEA
regulation on installation and metering 2006 and its amendment in 2010 or the
following whichever gives higher accuracy is to be selected for metering and
protection:-
Class PS for differential relaying (or as required depending on the type of relay
selected).
Class 5P20 for other relaying.
Class 0.5 and ISF <=10 for metering.
Class 0.2 or better and ISF <=2 for performance / precision metering.
Current transformer secondary shall be rated for 1 A.
Feeders requiring remote metering and/or current monitoring shall be provided
with current transducers with calibration for full-scale reading.
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The burden and the parameters of the CTs shall be commensurate with the
connected loads including lead burdens, changes during engg stage and 20%
spare.
In case of smaller rated CTs (say 200 A and less), at the expected fault level, the
CT saturation may result in the non operation of the instantaneous short circuit
protection. In such cases, separate protection CT with higher ratio, selected to
avoid saturation at high fault currents shall be provided if required or else
calculations to prove non-requirement shall be furnished for Owners approval.
Calculations for sizing and selection of various CT parameters shall be
submitted for owners approval.
4.2.3.10 Voltage Transformers
All Voltage Transformer (VT) shall be cast-resin, draw out type. Accuracy class
of the Voltage Transformers and its metering shall be as per CEA regulation on
installation and metering 2006 and its amendment in 2010 or the following
whichever gives higher accuracy is to be selected for metering and protection:-
3.3 kV Bus and line VTs shall be 3 nos. single phase VTs with an accuracy class
of 0.5 / 3P with 75 VA burden for secondary winding -1 and class 3P with 25 VA
burden for secondary winding-2. For tie feeders it shall be 1 no. 1 phase VT of
Class 0.2 / 3P with 10 VA burden. Bus PTshall be mounted in a separate vertical
panel.
The voltage transformers shall have suitable HRC current limiting fuses on
primary. Primary fuses shall be mounted on the withdrawable portion.
Replacement of the primary fuses shall be possible with VT truck in ISOLATED
position without requiring the trolley.
Low voltage winding of voltage transformer shall have MCB, installed in all
ungrounded secondary leads. MCBs shall be suitably located to permit easy
replacement while the switchgear is energized.
The voltage transformer and fuses can be completely disconnected and visibly
grounded in fully draw-out position.
General Requirements for both CT & VT
All CT & VT shall withstand the power frequency and impulse test voltage
specified for the switchgear assembly. The current transformer shall further
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have the dynamic and short time ratings at least equal to those specified for the
associated switchgear and shall safely withstand the thermal and mechanical
stress produced by maximum fault currents specified when mounted inside the
switchgear for circuit breaker modules. However, current transformer mounted
in fuse backed contactor module shall have the dynamic and short time rating
compatible with the let through current of the fuses.
The parameters of CT & VT specified in this specification are tentative and shall
be finalized by the Owner in due course duly considering the actual burden of
various relays and other devices finally selected and 20% spare. In case the
Bidder finds that the specified ratings are not adequate for the relays and other
devices offered by him, he shall offer CT & VT of adequate ratings and shall
bring out this fact clearly in his bid.
All CT & VT shall have clear indelible polarity markings. All secondary terminals
shall be wired to separate terminals on an accessible terminal block.
4.2.3.11 Relays
Relays shall be of draw out design with built-in testing facilities and flush
mounted at the front of panel. Small auxiliary relays may be in non-draw out
execution and mounted within the cubicle.
Relays shall be rated for operation on 110 V secondary voltage and 1 or 5 A
secondary current. Number and rating of relay contacts shall suit the job
requirements.
Unless mentioned otherwise in the specification, protective relays shall be
multifunction type numerical relays.
All relays shall be able to communicate
through communication protocol.
Multifunction numerical relays shall be selected to provide an integrated
protection, continuous measurement and monitoring functions. Features such as
self-diagnosis and external testing, disturbance recording, sequence of event
recording, time stampings, shall be available with the relay. Relevant data shall
be possible to be stored in non-volatile memory backed up by battery. The relay
shall have multiple setting groups, optically isolated input / output, front LCD
display and menus, fixed function and programmable LEDs, keypad and
password
protection.
All
functions
including
protection,
automation,
communication, LEDs, input / output shall be programmable and can be
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modified, if required, using the front panel user interface. Communication port
for local and remote (with suitable protocol) communication shall be located in
the front and rear part of the relay. A laptop loaded with support software
(complete
version)
shall
be
supplied
for
local
off
line
programming,
measurements, extracting and viewing of events, disturbance etc. The relay shall
be housed in dust tight enclosure, suitable for IP 52 degree of protection.
Separate numerical relay shall be provided for differential protection of motors
above 1000 kW and E/F protection of motor shall be achieved through CBCT.
The Contractor shall furnish, install & co-ordinate all relays to suit the
requirements of protection, interlock schemes and bus transfer schemes.
Detailed relay setting calculations for all the switchgears shall be furnished for
owners review and approval.
All relays shall withstand a minimum test voltage of 2 kV AC rms for one minute.
4.2.3.12 Instruments and Meters
Indicating instruments and integrating meters shall be flush mounted on panel
front and shall be digital multifunction type except for motor feeders. For motor
feeders the instruments shall be of at least 96 mm x 96 mm size with 90 deg.
scales, and shall have an accuracy class of 0.5Sor better unless otherwise
specified. The covers and cases of instruments and meters shall provide a dust
and vermin proof construction.
Analog meters shall have white dials with black numerals and lettering. Black
knife edged pointer with parallax free details will be preferred.
Ammeters on motor feeders shall have a compressed scale at the upper current
region to cover the motor starting current without gradation from one to six
times the rated CT secondary current. These shall be suitable to withstand the
above current of motors which can last up to 30 seconds (under stalled
condition) without any damage or loss of accuracy.
Ammeter current coils shall withstand the rated CT secondary current
continuously and ten times the rated CT secondary for 0.5 second, without any
loss of accuracy. The voltmeters shall withstand 120% of rated voltage
continuously and twice the rated voltage for 0.5 second.
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Instruments and meters shall be compensated for temperature errors and
factory calibrated to directly read the primary circuit quantities. Means shall be
provided for zero adjustment without dismantling the instruments.
Suitable self powered transducers as per IS: 12784 Part - I for feeding signals to
panel mounted electrical meters (ammeters, voltmeters, VAR meters and Watt
meters etc.) shall be provided and mounted by the bidder as shown in different
modules.
4.2.3.13 Transducer
All transducers shall be tested as per IEC - 298 (for impulse test etc) and SWC as
per ANSI C 3790a. 1989
Transducers shall be provided for conversion of AC electrical quantities such as
voltage, current and power. Transducers shall be of low burden type having 4
20 mA DC linear galvanically isolated output compatible with secondary
indicating instrument. Transducer shall be dual channel type. Accuracy Class
shall be 0.5.
4.2.3.14 Control and Selector Switches
Control and selector switches shall be of heavy duty, rotary type with
escutcheon plates clearly marked to show the positions. The switches shall
be of sturdy construction suitable for mounting on panel front. Switches with
shrouding of live parts and sealing of contacts against dust ingress shall be
preferred.
On-Off control switches shall have three positions and shall be spring return
to 'Neutral' from close and trip positions. They shall have two contacts
closing in close position and two contacts closing in trip positions, and shall
have Pistol Grip handles. Last motion feature shall be provided wherever
required.
Selector switch shall have two stay put positions as per the module
requirements. They shall have two contacts for each of the positions and
shall have black Spade handle
Ammeter and Voltmeter selector switches shall have four stay put positions
with adequate number of contacts for three phase system. These shall have
OVAL handles. Ammeter selector switches shall have make before break type
contacts to prevent open circuiting of CT secondary.
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Contacts of the switches shall be spring assisted and shall be of suitable
material to give a long trouble free service. The contact rating shall be at
least the following.
o
Make and carry continuously................. 10A
Breaking current at 220 V DC (Inductive)..............1A
Breaking current at 240 V AC/ 110V AC 5A at 0.3 pf lag.
Emergency Push button
Push button shall be heavy duty, shrouded, push to actuate type with colored
button and inscription plate. Each push button shall have 2 NO + 2 NC contacts,
rated 10 A and 0.5 A at their respective operating AC and DC voltage.
4.2.3.15 Fuse & MCB
Fuses shall be HRC, link type, with minimum interrupting capacity equal to
the listed short circuit current. Fuses shall be furnished complete with fuse
bases and fittings. Visible indication shall be provided on blowing of the
fuse.
MCBs, if used, shall be three/four pole, trip free, with manual close / open
mechanism. Automatic tripping provision for over load and short circuit shall
also be provided. MCBs shall be rated for full fault level of the system. MCB
shall be provided with required number of auxiliary contacts as per circuit
requirement.
4.2.3.16 Indicating Lamps
i)
Indicating lamps shall be of the panel mounting reputed make, clustered LED
type only. The lamps shall have escutcheon plates marked with its function,
wherever necessary.
ii) Lamps shall have translucent lamp-covers of the following colours,
RED
Breaker Closed
GREEN
Breaker Open and Spring Charged
AMBER
Trip circuit healthy
Breaker/Contactor in TEST
Breaker/Contactor in SERVICE
Breaker/Contactor in LOCAL
Breaker/Contactor in REMOTE
DC ON
iii) LED lamps and lamp covers shall be easily replaceable from the front of the
cubicles, the method of mounting indicating lamps fittings on panels shall
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prevent their rotation under the action of lamp removal or replacement,
reliance upon the tightness of a ring-nut for the purpose is not sufficient
iv) All indicating lamps shall be suitable for continuous operation at 90 to 100%
of their rated Voltage.
4.2.3.17 Secondary Wiring
a) The switchgear shall be fully wired at the factory to ensure proper
functioning of control, protection, transfer and interlocking schemes.
b) Fuse, links and MCB shall be provided to permit individual circuit isolation
from bus wires without disturbing other circuits. All spare contacts of relays,
switches and other devices shall be wired up to terminal blocks.
c) Wiring shall be done with flexible, 1100 V grade, PVC insulated wires with
stranded copper conductors of 1.5 mm2 for control and 2.5 mm2 for current
and voltage circuits.
d) Each wire shall be identified, at both ends, with interlocking type permanent
markers bearing wire numbers as per Contractor's Wiring Diagrams. AC / DC
wiring shall have separate color-coding.
e) Wire termination shall be made with crimping type connectors with insulating
sleeves. Wires shall not be spliced between terminals.
f) All spare contacts of relays, timers, auxiliary switches shall be wired up to
the terminal block.
4.2.3.18 Terminal Blocks
a) Terminal blocks shall be 1100 Volts grade, 10 Amps rated, one piece
moulded complete with insulating barriers. Clip on type terminals, washers,
nuts and identification strips. Marking on terminal strips shall correspond to
the terminal numbering in wiring diagrams. It shall be similar to Klippon type
RSFI (ELMEX type CSLT-I) with insulating material of Melamine conforming to
ESI standard 12.1 or equivalent. WAGO terminal of cage clamp with lugs shall
also be acceptable.
b) Terminal blocks for CT and VT secondary leads shall be provided with links
to facilitate testing, isolation star/delta formation and earthing. Terminal
blocks for CT secondary shall have the short circuiting facility. It shall be
similar to ELMEX CATD type.
c) Separate terminal blocks shall be used for AC/DC wiring termination
d) At least 20% spare terminals shall be provided on each panel and these spare
terminals shall be uniformly distributed on all terminal blocks. Space for
adding another 10% spare terminals shall also be available in each panel.
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e) There shall be minimum clearances of 250 mm between the terminal blocks
and the cable gland plate and 150 mm between two rows of terminal blocks.
f) All panel wiring for external connections shall terminate on separate terminal
blocks which shall be suitable for connecting two (2) stranded copper
conductors of 2.5 sq. mm on each side.
g) Terminal blocks used for interface with DCS/PLC via termination cabinet shall
be suitably sized to facilitate proper termination of interconnecting cables
4.2.3.19 Power Cable Termination
a) Cable termination compartment shall receive stranded Aluminium / Copper
conductor, XLPE insulated, shielded, armoured / unarmoured, PVC jacketed,
single core / three core unearthed / earthed grade power cable(s).
b) Clearance as per Indian / International standard shall be kept between the
cable lug bottom ends and gland plates for stress cone formation for XLPE
cables. Inter phase clearance in the cable termination compartment shall be
adequate to meet electrical and mechanical requirement besides facilitating
easy connections and disconnections of cables. Dimensional drawing of cable
connection compartment showing the location of lug, glands, CTs, gland
plates etc. and the electrical clearances available shall be submitted for
Owner's approval during detail engineering.
c) Cable termination compartment shall be completed with power terminals,
power lugs and associated hardware (to suit the cable size) and removable
undrilled gland plates. For all single core cables gland plates shall be of
nonmagnetic material.
4.2.3.20 Bus Duct Connection
a) Bus duct connections shall be along with transition panel, if required. Unless
mentioned otherwise bus duct connections shall generally be from the top.
b) All connecting bus work shall have the same continuous rating as associated
switchgear bus and shall be fully braced for the listed short circuit current.
c) All provisions such as matching flange and other accessories shall be
furnished for connection to bus duct.
4.2.3.21 Ground Bus
a) A ground bus, rated to carry maximum fault current, shall extend for the full
length of the switchgear.
b) The ground bus shall be provided with two-bolt drilling with G.I. bolts and
nuts at each end to receive 75 x 10 mm G.I. flat.
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c) Each stationary unit shall be connected directly to the ground bus. The frame
of each circuit breaker and draw out VT unit shall be grounded through
heavy multiple contacts at all times except when the primary disconnecting
devices are separated by a safe distance.
d) Wherever, the schematic diagrams indicate a definite ground at the
switchgear, a single wire for each circuit thus grounded shall be run
independently to the ground bus and connected thereto.
e) CT and VT secondary neutrals shall be earthed through removable links so
that earth of one circuit may be removed without disturbing other.
4.2.3.22 Earthing and Earthing Devices
a) A 50 x 6 mm2 Copper earthing bus shall be provided at the bottom and shall
extend throughout the length of each switchboard. It shall be bolted/ welded
to the framework of each panel and each breaker / contactor earthing
contact bar.
b) The earth bus shall have sufficient cross section to carry the momentary
short circuit and short time fault currents to earth as indicated under
switchgear parameters without exceeding the allowable temperature rise.
c) Suitable arrangement shall be provided at each end of the earth bus for
bolting to earthing conductors. All joint splices to the earth bus shall be
made through atleast two bolts and taps by proper lug and bolt connection.
d) All non-current carrying metal work of the switchboard shall be effectively
bonded to the earth bus. Electrical continuity of the whole switchgear
enclosure framework and the truck shall be maintained even after painting.
e) The truck and breaker / contactor frame shall get earthed while the truck is
being inserted in the panel and positive earthing of the truck and breaker /
contactor frame shall be maintained in all positions i.e. SERVICE, TEST and
ISOLATED as well as throughout the intermediate travel. The truck shall also
get and remain earthed when the control plug is connected irrespective of its
position.
f) All metallic cases of relays, instruments and other panel mounted equipment
shall be connected to earth by independent stranded copper wires of size not
less than 2.5 sq. mm. Insulation colour code of earthing wires shall be green.
g) Earthing wires shall be connected to terminals with suitable clamp
connectors and soldering shall not be acceptable. Looping of earth
connections that would result in loss of earth connection to other devices,
when a device is removed is not acceptable. However, looping of earth
connections between equipment to provide alternative paths of earth bus is
acceptable.
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h) VT and CT secondary neutral point earthing shall be at one place only on the
terminal block. Such earthing shall be made through links so that earthing of
one secondary circuit may be removed without disturbing the earthing of
other circuits.
i)
The Contractor for maintenance work shall provide separate earthing trucks
for each switchboard. These trucks shall be suitable for earthing the
switchgear busbars as well as outgoing / incoming cables or bus ducts. The
trucks shall have a voltage transformer and an interlock to prevent earthing
of any live connection. The earthing trucks shall in addition have a visual and
audible annunciation to warn the operator against earthing of live
connections.
Interlocks shall be provided to prevent:
Closing of the earthing switch if the associated circuit breaker truck is in
Service position.
Insertion of the breaker truck to Service position if earthing switch is in
closed position.
Closing of the earth switch on a live connection. Three (3) nos. voltage
capacitive dividers shall be provided on each phase of the section intended
for earthing and three (3) nos. "RED" neon lamps connected to these on the
panel front for visual indication.
Energizing an earthed Section: Complete details of arrangement offered shall
be included in the bid, describing the safety features and interlocks.
The earthing device (truck/ switch) shall have the short circuit withstand
capability equal to that of associated switchgear panel. 4 NO + 4 NC of
auxiliary contacts of the earthing device shall be provided for interlocking
purpose.
All hinged doors shall be earthed through flexible earthing braid.
4.2.3.23 Name Plates and Labels
a) Each switch board shall have a name plate for its identification. All enclosure
mounted equipment shall be provided with individual engraved name plates
for clear equipment identification. All panels shall be identified on front as
well as backside by large engraved name plates giving the distinct feeder
description along with panel numbers. Back side name plates shall be fixed
in panel frame and not on the rear removable cover.
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b) Name plate shall be of non-rusting metal or 3-ply lamicoid (3 mm thick) with
white engraved letterings, on black background. Inscriptions and lettering
shall be subjected to Owner's approval.
c) Suitable stenciled paint mark shall be provided for identification of all
equipment, located inside the enclosure, as well as for door mounted
equipment, from the back side in addition to plastic sticker labels, if
provided. These labels shall be located directly by the side of the respective
equipment, shall be clearly visible and shall not be hidden by equipment
wiring. Labels shall have device number as mentioned in wiring drawings.
Type of labels and fixing of labels shall be such that they are not likely to
peel off/fall off during prolonged use.
d) Nameplate size shall be minimum 20 x 75 mm for instrument/device and 40
x 150 mm for panels. Caution notice on suitable metal plate shall be affixed
at the back of each vertical panel
4.2.3.24 Space Heater
a) Each switchgear panel shall be equipped with thermostatically controlled
space
heater(s),
suitably
located
in
breaker
contactor
and
cable
compartments to prevent condensation within the enclosure. The space
heater shall be connected to 240 V single-phase AC auxiliary supply
available in the switchgear, through switches and fuses provided separately
for each panel.
b) For motor space heater supply, one breaker / contactor normally closed (NC)
auxiliary contact of each motor feeder shall be wired out in series of switch
fuse upto terminals block in the respective panels of switch boards. The
motor space heater supply shall be taken from Panel space heater supply
given to switch board.
c) A 240V single phase 50 Hz AC plug point shall be provided in the interior of
each cubicle with ON-OFF switch for connection of hand lamp. Cubicle
heater, motor heater, plug/socket circuits shall have individual switch fuse
units
4.2.3.25 Control Supply and Space Heater Supply
a) The following power supplies shall be provided to each switchgear:
1. AC supply
2. DC supply
: 230 V double feeder
: 220 V double feeder
b) Isolating switch fuse units shall be provided at each switchgear for the
incoming supplies, 4-pole, single throw for A.C. and 2-pole, double throw
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for D.C. Moulded case circuit breaker (MCCB) shall also be accepted as an
alternative for AC circuit only.
c) Bus-wires of adequate capacity shall be provided to distribute the incoming
supplies to different cubicles. Isolating switch fuse units / MCCB shall be
provided at each cubicle for A.C/D.C. supplies.
4.2.3.26 Tropical Protection
a) All equipment, accessories and wiring shall have fungus protection, involving
special treatment of insulation and metal against fungus, insects & corrosion.
b) Screens of corrosion resistant material shall be furnished on all ventilating
louvers to prevent the entrance of insects.
4.2.3.27 Painting
a) All sheet steel work shall be pretreated, in tanks, in accordance with IS:
6005.
b) Alkaline cleaning shall do degreasing. Rust and scales shall be removed by
pickling with acid. After pickling, the parts shall be washed in running water.
Then these shall be rinsed in slightly alkaline hot water and dried.
c) The phosphate coating shall be "Class-C as specified in IS: 6005. The
phosphated surfaces shall be rinsed and passivated prior to application of
stoved lead oxide primer coating. After primer application, Electrostatic
Powder Painting shall be used.
d) Finishing paint shade for complete panels excluding end covers shall be light
grey shade of 631 of IS 5 for extreme end covers of all boards, unless
required otherwise by the Owner. The paint thickness shall not be less than
100 microns.
e) Finished parts shall be coated by peelable compound by spraying method to
protect the finished surfaces from scratches, grease, dirt and oil spots during
testing, transportation, handling and erection.
4.2.3.28 Changeover scheme
For Switchgears with bus coupler arrangement, Interlocks shall be provided
among the two incomers and bus coupler such that under normal operation only
two breakers can be closed at any given time. However for planned live
changeover between two sources, synchronising facility shall be provided locally
on the switchgear. The synchronizing operation is either from local (HT
switchgear / remote (control room).
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For this purpose, synchronising facility complete with synchro check relay and
other required accessories are to be provided as per the requirement.
During planned outage, the breaker to be brought in shall be closed after
checking synchronism of the incomer and running bus and the breaker to be
taken out shall be tripped automatically through a trip selector switch. In the
event of selected breaker failing to trip, the incoming breaker shall be tripped
after a time delay.
During normal running conditions, should any of the incomer trip due to
tripping of corresponding station switchgear breaker, the bus coupler breaker
shall be automatically closed after ensuring bus no voltage. This changeover
will, however, be inhibited in the event of incomers tripping on fault.
4.2.3.29 Module Description
Depending on functional requirement each switchgear panel has been
categorized under specific modules, defined hereafter. Each module shall be
complete with all necessary hardware as required functionally and as per
approved control schematic drawings.
Circuit Breaker Module
All circuit breaker modules shall have the following accessories:
a) Two core current transformers on each phase for metering and protection.
b) One separate CT for differential protection where ever required.
c) Relays as per relevant clauses / single line diagrams
d) Ammeter for all three phases
e) ON-OFF control switch
f) Switchgear / Normal(Local/Remote) selector switch for DDC/PLC controlled
motor feeders & other feeders.
g) Indicating LED lamps with series resistors.
h) Anti pumping relay.
i)
Trip circuit supervision relay.
j)
Spring charging motor, with its protection and control
k) Auxiliary contacts.
l)
Terminal blocks
m) Interposing relays
n) Hand reset lockout relay
PT module type G1/G2
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Item Description
Module G1
Module G2
1 phase VT*
Fuses (VT Primary)
Fuse (VT Secondary)
27 (VAGM-22) (microprocessor /
----
27 N (VAG21) (microprocessor / Numerical
Voltmeter **
Voltmeter Selector Switch
220 V DC Timer (0.1-1 Sec)
-----
220 V DC self Reset Aux. Relay
As required
As required
Indication Lamps(with resistors)
Numerical relays)
relays)
*3.3 kV System the VT ratio is 3.3 / 3 kV /110/ 3 V, for 11 kV 11/3 kV
/110/ 3 V
**3.3 kV System the range of voltmeter is 0-3.6 kV, for 11 kV range of
voltmeter 0-12 kV
4.2.3.30 Surge Arrestor
The surge arrestors shall be provided for all feeders and shall be metal oxide,
gap less type generally in accordance with IEC 99-1 and suitable for indoor duty.
These shall be mounted within the switchgear cubicle between line and earth,
preferably in the cable compartment. Surge arrestor selected shall be suitable
for non-effectively earthed system and rating shall be in such a way that the
value of steep fronted switching over voltage generated at the switchgear
terminals shall be limited to the requirements of switchgear. Bidder shall furnish
temporary over voltage capability curve along with the bid.
4.2.3.31 Control room Alarms / Indications / SER points
Following indications / alarms are the minimum to be provided in the CRT in
control room. In addition to the same additional indications / alarms considered
necessary during detailed engg stage shall also be provided. Out of these some
will be selected for the sequential event recording. For each feeder grouped
alarm for any abnormal condition of that feeder shall be provided on the control
panels. The control / interlock schemes for various types of feeders shall be
commensurate with their application.
a) Common for each breaker panel
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i.
Status indication
Breaker ON
Breaker OFF
Breaker in remoteor Local
Breaker in service
Breaker in test
Circuit side earthed
Bus side earthed
4.2.3.32 Protections
Minimum protections to be provided for different type of circuits are listed
below
Incomer
1. IDMTL over current (51) for phase fault
2. IDMTL over current (51N) for earth fault
3. IDMTL over current (51SN) for stand by earth fault (for incomer from
transformer only).
4. Restricted E/F (64) (for incomer from transformer only)
5. Under voltage with time delay (27)
6. VT fuse failure
7. Circuit breaker failure
8. Local Breaker Back Up
Tie feeder
a) IDMTL over current (51) for phase fault
b) IDMTL over current (51N) for earth fault
c) Under voltage with time delay (27)
d) VT fuse failure
e) Circuit breaker failure
f) Synchronizing check relay, if applicable, complete with guard relay and hard
wires.
Motor feeder
Comprehensive motor protection relay consist of following minimum protection
a) Inst. short circuit
b) Thermal overload (49)
c) Phase fault (50)
d) Unbalance(-Ve seq.) (46)
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e) Locked rotor (50 LR)
f) Definite time O/C (50G) for earth fault (through CBCT)
g) Circuit breaker failure
h) Under Voltage with time delay ( Marshalled from Bus PT U/V timer )
i)
Winding temperature
j)
Bearing temperature
A separate CT / CT core of PS class is to be used for Differential (87) protection
for motor above 1000 kW rating.
Auxiliary transformer
a) Inverse / Definite time over current (50/51) with high set instantaneous units
for phase faults
b) Inst / Definite time O/C (50G) for earth fault (through CBCT)
c) Differential protection (for transformers rated 5 MVA and above)
d) Gas pressure alarm and trip.
e) Winding temperature alarm and trip.
f) Oil temperature alarm and trip.
g) Pressure relief device operated alarm.
h) Conservator oil level low alarm.
i)
Circuit breaker failure.
j)
Zero sequence or earth fault current protection
k) Zero sequence protection on LV side (neutral CT is to be provided in case of
solid grounding)
Line feeder
a) IDMTL over current (51) for phase fault
b) IDMTL over current (51N) for earth fault.
c) Circuit breaker failure.
Bus-coupler
a) IDMTL over current (51) for phase fault.
b) IDMTL over current (51N) for earth fault.
c) Circuit breaker failure.
d) Partial differential scheme shall be provided, wherever applicable.
In case any protection function is not available in a single relay, separate
numerical relays shall be provided to achieve the requirement.
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All protective relays shall be provided with self reset type of contacts.
Apart from protection relays, each breaker shall be provided with separate
discrete auxiliary relays for anti-pumping (94), trip annunciation (30), trip
supervision (74), electrically reset type breaker contact multiplication (52X) relay
and lockout (86) functions. Lockout relay shall be hand reset type. For
multifunction relays however, trip circuit supervision function as an integral
feature of the relay is acceptable.
Individual trip circuit supervision function
shall be provided with respect to each trip coil of circuit breaker.
Numerical under voltage relays (27) with time delay relay including VT fuse
failure relay shall be provided for Bus VTs.
IDMTL relay version shall be decided as per system requirement and the same
shall be finalized during detail engineering.
Zero-sequence CT and associated relay combination shall be such as to ensure a
pick-up sensitivity of 10 A primary ground fault current.
Separate locked rotor protection relay (50 LR) with auxiliary relay (50 LRX) shall
be furnished, if required.
4.2.3.33 Standards
All equipments provided under the specification shall in general, conform to the
latest issue but not limited to the following:
S.N
Code
Description
a)
IS: 722
AC electricity meters.
b)
IS: 996
Single-phase small AC and universal electrical motors.
c)
IS: 1248
Direct Acting indicating analog electrical measuring
instruments and Accessories.
d)
IS: 13947
Degree
of
protection
provided
by
enclosures
for
switchgear and control gear.
e)
IS: 2544
Porcelain post insulators for systems with nominal
f)
IS: 2705
Current transformers
g)
IS: 3156
Voltage Transformers
h)
IS: 3231
Electrical relays for power system protection
voltages greater than 1000 Volts.
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S.N
Code
Description
i)
IS: 3427
Metal enclosed switchgear and control gear
j)
IS: 5082
Specification for wrought aluminium and aluminium
alloy bars, rods, tubes and selections for electrical
purposes.
k)
IS: 6005
Code of practice for phosphating of iron and steel.
l)
IS: 8686
Specification for static protective relays.
m)
IS: 9046
AC contactors for voltages above 1000 volts and upto
and including 11000 Volts.
n)
IS: 9224
Low voltage fuses
o)
IS: 9385
HV fuses
p)
IS: 9431
Specification for indoor post insulators of organic
material for system with nominal voltages greater than
1000 volts upto and including 300 KV
q)
IS: 9921
A.C. disconnectors (isolators) and earthing switches for
r)
IS: 11353
Guide for uniform system of marking and identification
voltages above 1000 V
of conductors and apparatus terminals.
s)
t)
IS: 13118
Specification for high voltage AC circuit breakers.
IEC99 part- Metal oxide surge arrestor without gap for AC system
4
u)
IEC-56
High voltage alternating current circuit breakers.
v)
IEC-99-1
Non-linear resistor type gapped arrestor for AC systems
Part-1
w)
IEC-298
High voltage metal enclosed switchgear and control
gear.
x)
CIGRE
WG Recommendation for substitute test for switching over
13.02
voltage test
CHAPTER-3
PART-A&B
Installation shall conform to Indian Electricity Act and Indian Electricity Rules as
amended upto date. The Indian Electricity Act and Indian Electricity Rules can be
obtained from:
Kitab Mahal
State Emporium Building
Baba Kharag Singh Marg
New Delhi - 110 001
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INDIA.
Equipment conforming to any other internationally accepted standards would
also be considered if they ensure performance and constructional features
equivalent or superior to the standards listed above. In such case, the Bidder
shall clearly indicate the standard(s) adopted. The Bidder shall furnish copy in
English of the latest revision of the standards along with the copies of all official
amendments and revisions in force as on date of opening of bid and shall clearly
bring out the salient features for comparison.
4.2.3.34 Tests
Type Tests
All equipment to be supplied shall be of type tested quality. The contractor shall
submit for Owner's approval the reports of all the type tests as listed in this
specification and carried out within last five years from the date of bid opening.
These reports should be for the test conducted on the equipment similar to
those proposed to be supplied under this contract and the test(s) should have
been conducted at an accredited laboratory.
In case the contractor is not able to submit report of the type test(s) conducted
within last five years from the date of bid opening, or in the case of type test
report(s) are not found to be meeting the specification requirements, the
contractor shall conduct all such tests under this contract free of cost to the
Owner and submit the reports for approval.
Type test reports for the following type tests shall be submitted:
1.
Short circuit duty test on circuit breaker, mounted inside the panel offered
2.
Short time withstand test on circuit breaker, mounted inside panel offered
along with CTs, bushing and separators.
together with CTs, bushings and separators.
3.
Power frequency withstand test on breaker mounted in side panel.
4.
Lightning impulse withstand test on breaker mounted in side panel.
5.
Temperature rise test on breaker and panel together. For this test, the test
set up shall include three panels with breakers, the test breaker and panel
being placed in the Center.
6.
The adjacent panels shall also be loaded to their rated current capacity.
Alternatively the test panel may be suitably insulated at the
sides,
will be adjoining to other panels in actual site configuration.
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7.
Test to verify pressure relief devices operation of the panel. This shall be
done on one panel of each voltage class.
8.
9.
Measurement of resistance of main circuit.
Mechanical endurance test on breaker.
10. Mechanical operation test.
11. Verification of the degree of protection.
12. Weather proofing test.
13. Any other testindicated in IEC 694, IEC 298 and IEC 62271.
The following type test reports (as applicable) shall be submitted on surge
arrestor / lightning arrestor of each type:
a) Standard lightning impulse voltage spark over test.
b) Front of Wave Spark over Test
For surge arrestor used along with motor feeder this test shall be carried out.
a) Power frequency spark over and temporary over voltage test.
b) Residual voltage test.
c) Operating duty test
d) Current impulse withstand test (Long duration & high current impulse)
e) Pressure relief test
Short circuit withstand test of earthing device (truck / switch).
Twelve (12) bound copies of the approved test results shall be furnished with
the equipment. These shall include complete reports and results of the routine
tests and type tests (if the latter is carried out) on equipment. If the type tests
are not conducted, the bound copies shall contain copies of the results of type
tests carried out on identical equipment earlier.
Testing to observe compliance to degree of protection, shall be checked for each
switch board enclosure and busbar chambers during routine inspection shall be
as under.
a) IP - 4x: It shall not be possible to insert a one (1) mm. dia steel wire into the
enclosure from any direction, without using force.
b) IP- 5x: It shall not be possible to insert a thin sheet of paper under gaskets
and through enclosure joints.
Routine & Acceptance Tests
a) Dielectric test on the main circuit.
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b) Dielectric test on auxiliary and control circuit.
c) Measurement of the resistance of main circuit.
d) Tightness test.
e) Design and visual checks.
f) Mechanical operation test.
g) Verification of correct wiring.
h) Partial discharge measurement.
i)
Tests after erection at site.
j)
Any other test indicated in IEC 298, IEC 694 nad IEC 62271.
Shop testing of components and bought out items.
Various tests carried out on major components of circuit breaker/ Contactor
during incoming inspection shall be clearly mentioned in the QAP along with
sample size and reference document / acceptance norms.
For various bought out items like CT, VT, Relays, and meters. Surge suppressor,
etc for which identification can be physically verified and test certificate from
manufacturer can be correlated. Contractor should indicate following in the QAP.
1. Review of manufacturer's TC as per relevant standard & Compliance to
requirements of this specification
2. Physical check and functional / operational check to ensure that item is fit
for assembly on the switchboard cubicle.
For
all
other
items
where
identification
has
not
been
envisaged
by
manufacturers, a certificate of conformance to be obtained from manufacturer,
and component identification shall be tagged as per approved drawing /
schematic. Based on contractor's own level of confidence with respective
supplier & nature of criticality of the system either of the following or both shall
be adopted.
1. Random Sample to be tested either in-house or at an independent laboratory
for all tests envisaged in relevant standard.
2. Physical check & functional / operation check to ensure the item is fit for
assembly on the switchboard cubicle.
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4.2.4
LT Switchgear
4.2.4.1
Power sources for LT Switchgear
415 V system shall be 3 phase, 4-wire system with solid neutral earthing. Single
phase feeders shall be provided with control transformers in each bus section.
The switchgear shall derive power from the designated service transformers or
from 415 V switchgear based on geographical location and common loads.
4.2.4.2
Feeder details
Each of the switchgear / MCC shall be provided with two bus sections, two
incomers and a bus coupler each rated for 100% of the loads connected to the
switchgear.
The switch gear / MCC shall be provided with suitable number and type of
outgoing feeders for the respective auxiliary loads of the system/area, power
supply feeders to various panels, lighting, space heating panels, control
cabinets, welding and all other loads encountered in the plant.
In addition, following feeders shall be provided in each bus section of all
switchgear.
(a)
Spare feeders: Minimum of one number feeder of each rating and type in
each switchgear / MCC. 2 nos. 50 kVA (one in each section) lighting
transformer feeder for owners use in switchgear shall be provided.
(The above quantity is the minimum requirement, at the time of handing
over. Any additional quantity required for any increase/change during
detailed engineering stage also shall be duly considered.)
(b)
Bus VT module
(d)
Switchgear test supply module.
(e)
Alarm module for common alarm for out going feeder fault.
(c)
(f)
240V, 1 phase space heating.
DC supply alarm module for incomer, bus coupler fault
4.2.4.3
Power receptacles
3-phase, 4 wire, 63A power receptacle / welding receptacles with switch shall be
provided two nos each in pump house & switchgear rooms.
The receptacle shall be industrial heavy-duty type and shall have suitable
interlock facility for safety. The receptacle shall conform to IS 1293 and the
switch to IS 4064.
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One receptacle in battery rooms for cell charging shall be provided.
4.2.4.4
Short circuit currents
The fault level on the 415V buses shall be calculated based on transformer
contribution and motor contribution and shall be limited to 40 kA. However,
switchgear and all components shall be designed for 50 kA.
A margin of 10% over the S.C current thus calculated shall be applied and
rounded off to next higher standard ratings and this value shall be adopted for
the switchgear. The momentary current rating shall be 2.1 times this value.
The short time current withstands duration for switchgear and all components
shall be considered as one second.
4.2.4.5
Continuous Currents
The continuous current rating of the bus bars, the incomers, bus couplers of the
switchgear, which are fed by the transformers, shall be rated at the LV side full
load current of the corresponding transformers with 20% margin rounded off to
the next higher standard rating.
4.2.4.6
Construction features
All the 415V equipments / devices like bus support insulators, CBs, CTs, PTs etc
mounted inside the switchgear shall be suitable for continuous operation and
satisfactory performance under the following supply conditions.
(a) Variation in supply voltage - +/-10%
(b) Variation in supply frequency - +/-5%
(c) Combined voltage and frequency variations- 10% absolute.
All bus bar, bus-taps shall be insulated with close fitting sleeve of PVC
insulation with high dielectric strength.
The switchgear shall be totally enclosed, metal clad, sheet steel fabricated,
indoor, floor mounted, fully draw out, single / double front, modular type
construction, dust and vermin proof of uniform height of not more than 2450
mm, easily extendable on both sides having switchgear designation indicating
labels on front and rear. For ampere rating up to 1600 A, degree of protection
shall be IP 52 and above 1600 A degree of protection shall be IP 42. Proper
gasketting shall be provided all around the perimeter of the adjacent panels,
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panel and base frame, removable cover and doors. The switchboard shall be
fully compartmentalized conforming to requirements of IS 8623.
The minimum clearance in air between phases and between phases and earth for
the entire run of horizontal and vertical bus bars shall be 25 mm. Wherever it is
not possible to maintain these clearances, insulation shall be provided by
barriers. However, for horizontal and vertical bus bars, the clearances mentioned
above should be maintained even when these are sleeved or insulated. All
connections from bus bars up to fuses shall be fully shrouded to minimize the
risk of phase to phase and phase to earth shorts.
Cable alley shall be minimum 300 mm wide for motor control modules rated up
to 90 kW and 500 mm wide for modules rated above 110 kW and also for circuit
breaker controlled modules. No component shall be mounted in the cable alley.
Operating devices shall be incorporated only in front of the switchgear.
Switchgear shall be divided into distinct vertical section of:(a)
Completely Enclosed bus bar compartment running horizontally.
(b)
Individual feeder modules in multi tier arrangements.
(c)
Enclosed vertical bus bars serving all modules in vertical section.
(d)
A horizontal separate enclosure for all-auxiliary power and control bus as
required.
All modules of identical size & type shall be fully interchangeable without any
modifications. (The ratings of CB / MCCB / LBS for incomer / bus coupler of 415
V switchgear / MCC / ACDB shall be identical)
CRCA Sheet steel of not less than 2 mm thickness shall be used and for base
frame 3 mm is to be provided.
The cable entry shall be from bottom only with separate gland plate for power
and control cable. In case of single core cables, gland plate shall be of non
magnetic material.
4.2.4.7
Bus bars
Three phase, neutral (with atleast 50% rating of main bus bar) and continuous
earth Bus. Bus bar and tapping shall be provided with PVC Sleeve. Bus bars shall
be provided with colour-coded sleeves. Rating of horizontal buses shall be in
line with incomer rating and vertical bus bar for the compartment shall
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commensurate with all outgoing feeders. Temperature rise of bus bars shall not
be more than 40 deg. C above ambient of 50 deg. C. Bus bar and connection
shall be of high conductivity Aluminium / Aluminium alloy of suitable hardness
and purity complying with as per IS 5082. All bus connectors shall be Silver
plated.
4.2.4.8
Air Circuit Breakers (ACBs)
Circuit Breakers shall be three pole, single throw, air break type with stored
energy, trip free mechanism and shunt trip coil.
Circuit breakers shall be draw out type, having SERVICE, TEST & ISOLATED
positions with positive indication for each position.
Circuit breakers of identical rating shall be physically and electrically
interchangeable.
All incomer breakers, bus-section breakers, and motor feeder breakers shall
have motor wound spring charging mechanism. All other outgoing feeders shall
generally have hand-operated spring charging mechanism.
All breakers with motor wound spring charging mechanism shall have facility of
manual spring charging also.
For motor wound mechanism, spring charging shall take place automatically
after each breaker closing operation. One open- close-open operation of the
circuit breaker shall be possible after failure of power supply to the motor.
Mechanical safety interlock shall be provided to prevent the circuit breaker from
being racked in or out of the service position when the breaker is closed.
Automatic safety shutters shall be provided to fully cover the female primary
disconnects when the breaker is withdrawn.
Each breaker shall be provided with an emergency manual trip, mechanical ON-
OFF indicator, an operation counter, mechanism charge/discharge indicator, and
electrical anti-pumping feature.
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In addition to the auxiliary contacts required for normal breaker operation and
indication, each breaker shall be provided with the following for interlocking
purpose :
a) Position/cell switch with minimum 4NO + 4NC contacts.
b) Auxiliary switch, with minimum 6NO +6NC contacts, mounted on the
stationary portion of the breaker panel and operated mechanically by a sliding
level from the breaker in SERVICE position.
Alternatively, electrically reset-latching relay may be used for the purpose. The
exact requirement of contacts of the position/cells switch, limit switch, auxiliary
switch and latching relay shall be decided by the Bidder taking into account the
scheme requirements. Limit/auxiliary switches shall be convertible type, that is,
suitable for changing N.O. contact to N.C. and vice-versa.
Spring charge limit switch shall be provided for breakers with motor wound
spring charging mechanism. These limit switches shall be provided with
minimum 2NO + 2NC contact.
4.2.4.9
Moulded Case Circuit Breakers (MCCBs)
The MCCBs shall be of current limiting type. When MCCBs are used as short
circuit
protection
devices
for
motor
modules
they
shall
provide
type2coordination with associated contactor and thermal overload relay as per
IS:8544 under all operating conditions for all the currents upto the design fault
current. The MCCBs on upstream and downstream shall be co-ordinated. Test
reports to prove the requirements of type-2 Co-ordination shall be furnished.
4.2.4.10 Other Requirements
For switchgear, two number 220 V DC control supply shall be provided with a
manual selection for changing over to either supply. Necessary voltage
monitoring contactors (for remote alarm) and indication lamps shall be
provided.
For CT & VT circuits disconnecting type of terminals shall be provided
Power cable terminal arrangement and size shall be suitable to accommodate
two or more number of cables based on requirements and shall facilitate easy
maintenance.
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Terminal arrangements shall be such that all terminals at switchgear ends, which
are to be connected to remote alarms and indication at DCS / PLC, shall be
separated out and shall be kept isolated from other Terminals. 240 V AC, 110 V
AC, 220 V DC & other voltages shall be segregated to avoid mix up of voltages.
This is specifically required to avoid mixing of switchgear high voltage to C & I
low voltage system.
All CT s/ PT s, transducers and meters on 415 V systems shall be accuracy of
class 1.0 or shall not be inferior to accuracy class mentioned in the latest CEA
regulations, whichever is supporting for higher accuracy for CT and its
associated meters. All meter shall be taut band, 270 deg. Reflection. Meters for
motor feeders shall be with suppressed scale. For MCC verticals, CT pertaining
to a particular module should be mounted in the respective withdraw able
module itself. CT should not be mounted in cable alley.
Switchgear shall be suitable for easy extension on both the sides. It shall be
possible at a later stage to add cubicles on both sides of the switchgear by
extending the bus bars.
Secondary of CTs & VTs shall be made through disconnecting type terminals
with necessary shorting and earthing facilities. All the control wiring shall be
through stud type terminal.
The breaker ratings indicated in the data sheets referred to the nominal rating of
the breaker. However, breakers shall be capable of carrying continuously at least
120% of circuit breaker current at an ambient temperature of 50 deg. and with
breaker mounted inside the panel. If a higher rated breaker is necessary to meet
this, the same shall be used.
If necessary, to avoid beams interfering with cable openings and to facilitate
easy maintenance, Dummy cubicles shall be provided with horizontal bus bars,
power, control and annunciation cable running through the panel.
All the bolted joints in the body of the switchgear shall be earthed through
flexible jumpers.
All indicating and integrating instruments, protection and alarm relays,
operating and indicating devices shall be visible / accessible without opening
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the instrument compartment door. All the hand reset relays shall be mounted on
the panel at a convenient height for operation.
All the internal wiring shall be carried out using 1100 V grade, stranded copper
conductor with PVC insulation and shall be flame, vermin and rodent proof. The
minimum size of the copper conductor used for panel wiring shall be as follows:
(a) All circuit except CT: 2.5 sq mm per lead.
(b) CTs : 4 sq mm or 2 x 2.5 sq mm
The minimum number of strands per conductor shall be 07. Extra flexible wires
shall be used for internal wiring of the Devices mounted on moving parts.
Following colour coding shall be used for internal wiring:(a) Red, Yellow & Blue: For respective phase /PT wires.
(b) Black : For neutral wires.
(c) Green : For Earth wires
(d) Red ferruled wires for trip circuit.
(e) All other with grey coloured wires.
The inter panel wiring shall be brought out to a separate set of terminal blocks
located near the slots meant for inter panel connecting wires.
Control supply of each module shall be taken through dedicated control
transformer of ratio 415 V / 110 V.
At least 20% spare terminal shall be provided on each panel and this spare
terminal shall be uniformly distributed on all rows of terminal blocks. A
clearance of 250 mm shall be maintained between terminal blocks and gland
plate and 150 mm between two rows of terminal blocks.
All LT panels shall be mounted on ISMC 100 channels to prevent ingress of
water.
All hardware required for meeting the functional requirements stated above,
whether specifically listed out in the specification or not, shall be included in the
scope of supply.
Current transducers, power transducers and Voltage transducers shall be
provided for remote metering.
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Separate CTs / cores shall be provided for protection and metering circuits.
The cable terminations inside the cable alley shall be completely shrouded so
that it shall be possible to work on any one of the terminations by switching OFF
the corresponding feeder switch only.
All bezels, handles, screws, bolts, washers, hinges, etc. shall be of the best
quality electro galvanized or passivated to withstand attack from corrosive
atmosphere.
Horizontal busbar chambers shall be at the top of the board for bottom cable
entry. Bus bars shall be completely shrouded to prevent metal pieces falling on
the busbar during maintenance.
In case of copper to aluminium connections, proper treatment shall be given to
minimise the bimetallic effect. That is, all joint surfaces at aluminium to copper
joints shall be silver / tin plated, alternatively Cu-Al washers (bimetallic washers)
can be used.
Motors rated above 90 kW shall be connected to ACB and below shall be with
MCCB.
4.2.4.11 Changeover scheme
All the switchgear with sectionalized buses and circuit breaker controlled will be
normally operated with the bus coupler breakers open. Auto changeover facility
shall be provided for all switchgear such that if there is a prolonged under
voltage on any one of the bus sections, the respective incoming breaker shall
trip and the bus coupler breaker shall close, provided voltage is available on the
other bus section and protection is not operated on other bus. Total change over
time shall not exceed 1.5 seconds. The bus coupler panel shall be provided with
auto-manual-off selector switch and in manual position, an alarm shall be
generated at DCS / PLC.
This auto changeover shall be blocked if the other incoming breaker had tripped
either on a bus fault or manually. Changeover back to the normal source of
supply shall be effected manually. Manual live changeover facility shall be
provided for the switchgear/MCC. When planned outage of one of the normal
incoming supplies is required, the respective incomers shall be tripped
automatically after the bus section breaker is closed manually.
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For this purpose, a selection shall be provided for selecting the incomer to be
tripped. Thus, depending on the selection made, incomer to bus section A or
to bus section B will be tripped once bus section breaker is closed manually,
thus maintaining continuity of supply.
Timers with a time delay on pick up of 0.5. - 5 sec. for annunciation of the
running breaker failing to trip within a pre-set time, (i.e. if the two sources
remain paralleled for more than a pre-set time) shall be provided along with
tripping of last closed breaker if selected breaker does not trip.
When the normal supply is to be brought back into operation, the incomer
breaker shall be closed whereupon the bus coupler shall trip automatically.
4.2.4.12 Incomers, Bus Couplers & breaker control motor and tie feeders
The incomer modules and bus coupler modules of all the switchgear shall be
fully draw out air circuit breakers controlled from local / DCS / PLC located at
control room. The miscellaneous distribution boards rated less than 400 A shall
be provided with MCCBs.
The breaker ratings indicated in the data sheets refersto the nominal rating of
the breaker. However, breakers shall be capable of carrying continuously at least
120% of circuit breaker current at an ambient temperature of 50 deg. and with
breaker mounted inside the panel. If a higher rated breaker is necessary to meet
this, the same shall be used.
The incomer modules shall be interlocked with their upstream breaker such that
they can be closed only when upstream breaker is closed and trip automatically
when upstream breaker is tripped.
All the Tie feeders shall be provided with breakers at both ends with necessary
metering and protection at both ends.
Each circuit breaker cubicle shall be complete with following minimum
accessories:-
(a) One spring return TNC switch.
(b) Large size cluster LEDs for following condition of breaker/contactor:(i) ON(Red)
(ii) OFF (green)
(iii) Auto trip
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(c) Limit switched for test and service position interlocking.
(d) Double pole switch for DC control supply and spring charging motor with
HRC fuses.
(e) Anti pumping relay.
(f) Sufficient terminal blocks.
(g) Auxiliary relays as required for contact multiplication.
(h) Breaker operation counters.
(i) Protective relays along with trip circuit supervision relay and master trip relay.
(j) Meters as indicated elsewhere.
(k) Required CTs/PTs/CBCTs.
(l) Space heaters.
(m) Other associated equipment.
All the circuit breakers shall be of fully draw out execution with Test, Service
& Fully withdrawn positions.
Double tier arrangement shall not be provided for incomers, tie and bus coupler.
In case of motor feeders, double tier arrangement may be provided but two
beakers of same application motor shall not be provided in one vertical.
It shall be possible to bring the circuit breaker to isolated position with the help
of external lever without opening the compartment door.
A stop block shall be provided on the slide rails to prevent the movement of the
circuit breaker out of the compartment when it reaches the isolated position so
that any accidental fall can be avoided.
No control & metering equipments should be mounted on breaker compartment
door (i.e. access to control & metering equipments should be available at all
time without opening Breaker Compartment door).
It shall not be possible to close the Breaker if stored energy mechanism is not
charged.
It shall not be possible to close the Breaker if under-voltage release is not
energized.
It shall not be possible to close the Breaker if closing coil is energized.
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It shall not be possible to close the Breaker if OFF Push Button is locked in off
position.
It shall not be possible to close the Breaker if crank hole is open.
The circuit breaker shall be provided with automatic safety shutters, so that
before the breaker reaches isolated position the main isolating contacts are
completely shrouded. In the draw-out condition, it shall be possible to inspect
the Breaker fixed contacts condition by lifting the shutters.
The
protective
relays
and
instruments
shall
be
mounted
in
separate
compartment. This compartment shall be alongside and immediately next to the
controlled breaker.
Contact erosion indicator shall be provided on Moving contacts of Breaker for
visual indication of contact life.
All the non conducting metal parts of the circuit breaker trolley shall be bonded
together and shall make perfect electrical connection to earth through
substantial sliding contacts, at service and test positions. Such sliding contacts
shall be arranged to make before power plug in and interrupt after power draw
out.
4.2.4.13 Bus and Line PTs
PT shall have a continuous overvoltage factor of 1.2 and short time over voltage
factor of 1.9 for 8 hours.
4.2.4.14 Each PT cubicle shall be complete with following minimum
accessories
(a)
PTs shall be fully draw out type with required no of cores and ratios as
specified elsewhere.
(b)
Voltmeter with selector switch.
(c)
Under voltage and No voltage relays with timers and fuse fail relays.
(d)
Required auxiliary relays.
(e)
LEDs for voltage indication.
(f)
Auxiliary PTs, as required.
(g)
DC and AC control supply and changeover switches with Short Circuit
protection.
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4.2.4.15 Motor Modules
The motor feeders shall be complete with following minimum accessories.
(a)
Contactors and interlocking schemes for space heating arrangements
based on size of motors. Test & services position switches and associated
contactors for interlocking.
(b)
Power contactors and breaker.
(d)
Local indication lamp for ON, OFF & TRIP/Fault indication.
(e)
Relays as required.
(f)
ON & OFF PBs, for testing in Test Position
(c)
CTs as specified elsewhere.
All the motors rated 30 kW and above shall be provided with a CT, ammeter and
a current transducer with remote metering in DCS / PLC.
4.2.4.16 Protections
The minimum protections to be provided for circuit breaker controlled feeders
are listed below :
a)
Incoming Feeders : 3-Inverse time O/C relays (51) for phase faults and 1Inverse time O/C relay (51N) for Earth faults
b)
Motor Feeders (>90 kW) : Microprocessor based Numerical Motor
Protection Relay
Bidder shall quote suitable digital/microprocessor based numerical relay
for motor protection with following minimum facility as indicated below:
- Thermal model based with RTD feedback and negative sequence
current.
- Under voltage, over voltage protection.
- Overload protection.
- Short circuit & SC back-up.
- Locked rotor protection.
- Current unbalance.
- Ground fault.
- Temperature monitoring (stator, bearing etc.).
- Phase reversal.
Apart from above, suitable provision for metering and remote monitoring
such as voltage, current, power factor, watt-hr, event record etc. shall be
provided.
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The relay shall have facility for user interface capability, character display,
keypad, LED indicator and communication port along with licensed
version software.
90 kW and below: - The thermal overload relay in all three phases with
built in protection against single phasing and short circuit protection by
MCCBs.
c)
Lighting transformer: 3-inverse time O/C relays, high set instantaneous
unit (50/51) for phase faults, 1-inverse time O/C relay (51N) for earth
fault
d)
Outgoing Feeders: 2-Inverse time O/C relay (51) for phase fault, 1Inverse time O/C relay (51N) for Earth fault
All inverse time O/C relay shall be 1.3 secs. version / 3 secs. version and the
same will be decided during detailed Engineering.
Apart from protection relays, each electrically operated breaker shall be
provided with anti pumping (94), trip annunciation (30), lockout (86) and trip
circuit supervision (74) relays. Lockout relay shall be hand reset type.
Fuse failure relay shall be provided for the voltage transformer.
4.2.4.17 Control / Alarms / Indication / Ser Points
The control room DCS / PLC shall provide indication & alarms for the 415 V
auxiliary supply as given below. Any additional indications/alarms considered
necessary during detailed engineering also shall be provided. Some of these
shall be selected for sequential event recording. For each breaker and bus,
grouped alarm for any abnormal conditions shall be provided in the control desk
DCS / PLC. For all breaker fed switchgear, status indications shall be available on
Control desk / DCS / PLC in the form of SLD.
(a) Alarms in CRT
Breaker auto tripped / L/O relay operated
Bus under voltage
Sources paralleled beyond pre-set time
Common outgoing feeder fault
Incoming 220 V DC control supply failed
Bus PT fuse failed
Bus PT not in service.
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(b) Status indication in CRT
Motor ON
Motor OFF
Motor Auto trip.
Motor LPB pressed
Feeder fault
Breaker service
Breaker selected for remote
The current, voltage and power measurements for each bus shall be available
both on DCS / PLC as indicated in this section and specified elsewhere in the
specification. The necessary transducers shall be included by the vendor. Also
for
specific
motors
where
the
current
transducers
are
indicated,
the
measurement shall be available at the DCS / PLC.
4.2.4.18 Tests
The switchgear shall be completely assembled, wired, adjusted and tested at the
factory as per the relevant standards.
Routine Tests
The tests shall include but not necessarily limited to the followings:
a) Operation under simulated service condition to ensure accuracy of wiring,
correctness of control scheme & proper functioning of the equipment.
b) All wiring and current carrying parts shall be subjected to appropriate High
Voltage Test.
c) Primary current & voltage shall be applied to all instrument transformers.
d) Routine test shall be carried out on all equipment such as circuit breakers,
instrument transformers, relays, meters, contactors etc as per relevant
standard.
Type Tests
The following type tests shall be performed on a representative sample of the LV
Switchgear assembly, even if type test certificates of these tests are submitted
by the Bidder for Owners approval:
a) Temperature rise Test
b) Short time current test on main circuit and earth circuit.
c) Verification of making and breaking capacity.
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Type test certificates of any equipment shall be furnished if so desired by the
Purchaser. Otherwise, the equipment shall have to be type tested, free of charge,
to prove the design. Type tests performed before five (5) years are not
acceptable.
4.2.4.19 Module selection
Motor feeder
Type
Motor Rating
AU/AR
0 - 5.5 KW
BU/BR
MCCB
Module
Contactor
Cable size
32A
16A
3/c 2.5 Sq.mm Cu
400mm
5.6 - 11KW
63A
32A
3/c - 16 Sq.mm Al
600mm
CU/CR
11.1 - 22 KW
63A
63A
3/c - 35 Sq.mm Al
600mm
DU
22.1 - 50 KW
100A
100A
3/c - 95 Sq.mm Al
900mm
EU
50.1 - 75 KW
200A
160A
3/c - 185 Sq.mm Al
900mm
FU
75.1 -90 KW
400A
300A
2 x 3/c - 185 Sq.mm - Al
1200mm
Rating
size
Outgoing Feeder (MCCB Operated)
Type
MCCB Rating
Cable Size
Module size.
AF
32 A
4/c 16 Sq.mm - Cu
300mm
BF
63 A
4/c 35 Sq.mm - Al
300mm
CF
100 A
3.1/2 95 Sq.mm - Al
600mm
DF
200 A
3.1/2 300 Sq.mm - Al
600mm
EF
400 A
4 x 1/c 630 Sq.mm - Al
900mm
FF
630 A
7 x 1/c 630 Sq.mm - Al
900mm
4.2.5
HT & LT Power and Control Cables
4.2.5.1
HT Power Cables
HT cables shall be 11 kV (UE), 3.3 kV (UE) grade suitable for use in medium
resistance earthed system, with stranded & compacted aluminium conductors,
extruded semi-conducting compound screen, extruded XLPE insulated, dry
cured, extruded semi-conducting compound with a layer of non-magnetic
metallic tape for insulation screen, extruded FRLS PVC (Type ST 2) inner
sheath, round Aluminium / Galvanized steel wire armoured, extruded FRLS PVC
(Type ST 2) outer sheathed, single / multicore conforming to IS 7098 (Part II),
IEC-502 for constructional details and tests.
4.2.5.2
LT Power Cables
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LV Power Cable shall be 1100 V grade, single / multicore, stranded aluminium
conductor, extruded XLPE insulated, dry curedwith, extruded PVC inner sheathed
of type ST-2, galvanized round steel wire armoured and with extruded outer
sheath made of FRLS PVC compound of type ST-2 conforming to relevant
standards. The cables used for DC system shall be of single core type. Minimum
conductor cross section of power cables shall be 4 sq.mm.
4.2.5.3
Control Cables
Control cables shall be 1100V grade, multicore, minimum 2.5 sq.mm cross
section, stranded copper conductor having 7 strands, extruded PVC insulated,
extruded inner PVC sheathed of type ST-1, galvanised steel wire armoured and
extruded outer sheath made of FRLS PVC compound of type ST-1 confirming to
relevant standards. In situations where accuracy of measurement or voltage drop
in control circuit, warrant, higher cross sections as required shall be used. For all
the CT & PT cables, minimum 4 sq.mm cables shall be used.
4.2.5.4
Lighting wires
1100 V grade, single core stranded copper conductor PVC insulated wires
conforming to IS 694-1990 / IEC 60227 part 1 to 5 (1979) / IEEE -719 (1981).
Minimum cross section of copper wire shall be minimum 2.5 mm2 for lighting
circuits and 4 mm2 for receptacle circuits.
4.2.5.5
Trailing power and control cables for mobile equipments
11/3.3 kV (UE) and 1100 V (E) grade power and control flexible trailing annealed
tinned copper conductor, EPR insulated, EPR inner sheathed and CSP outer
sheathed and shall have conductor screen of rubber cable shall conform to IS
requirements and any other applicable standards.
Cable Properties
All single core power cables shall have wire armouring of aluminium, whereas
multicore power cable shall have galvanised steel round wire armouring.
The outer sheath of all cables shall be of extruded layer of suitable synthetic
material compatible with specified ambient and operating temperature of the
cables. The sheath shall be resistant to water, UV radiation, fungus, termite and
rodent attack.
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The inner and outer sheath of FRLS PVC compound shall meet the following
performance requirements:
(a)
The critical oxygen index value shall be minimum 29 when tested at 27+
20C as per ASTM-D-2863-77 and the temperature index shall be
minimum 2500C at oxygen index value of 21 when tested as per NES715.
(b)
The maximum acid gas generation as determined by titration method
shall be less than 20% by weight when tested as per IEC-754-1
(c)
(d)
The smoke generation under fire shall have maximum smoke density
rating of 60% when tested as per ASTM-D-2843-7.
The cables will pass the hydraulic stability and ultraviolet tests as per DIN
53387.
The finished cable shall pass the flammability test as per IEC-332-1 and IEEE383. In addition, it shall also pass flammability test as per Class F3 of Swedish
Standard SS-424-1475.
4.2.5.6
Design Criteria for Cable Sizing
Power cables
Power cable sizes shall be selected on the following basis:
Power cables shall carry the full load current of the circuit continuously under
site conditions considering the various derating factors like ambient air/ground
temperature, grouping, method of laying, short circuit withstand capacity for
applicable fault, maximum voltage drop limits, etc.
Power cables shall withstand the fault current of the circuit for the duration not
less than the maximum time taken by the primary protective system to isolate
the fault. Fault clearing times for 3300 V motor feeders and transformer feeders
having high-set instantaneous protection shall be 0.16 secs, whereas tie
between two 415 V switchgear and any two 3300 V switchgear shall be 0.5 secs,
and for incomers and tie feeders 1.0 sec.
For 3300 V motors controlled by vacuum contactors with back-up HRC fuses,
the minimum cross-section of cables shall be based on the cut-off current of
the fuses and its fusing time.
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For the cables to 415V motors and feeders protected by fuses, the cross section
shall be chosen according to the cut-off current of the fuse and its fusing time
or full load current, whichever is higher.
Voltage dip at motor terminals during starting of motors will be limited to the
following values:
(i)
For all motors 15% of the rated voltage.
Voltage drop in feeder cables shall be limited to 3% during full load running
condition.
For power supply to valve actuator motors, actuators of various isolating and
regulating dampers and exhaust fans, 3 core 2.5 sq. mm stranded copper
conductor cable may be used in view of ease of termination. These cables shall
be in other respects similar to cables described above.
Control Cables
Current transformers leads shall be checked for the lead burden vis--vis the
current transformer VA capacity and 4 sq.mm cables shall be used for
connection of CT to loads. In case 4 mm2 conductor imposes unacceptable high
burden on CTs, higher cross section of conductor shall be used.
Voltage transformer leads shall be checked for voltage drop with 4 sq.mm,
which shall be limited to within 1% for all cases. In case the voltage drop with 4
sq. mm conductors exceed this value, higher conductor sizes shall be used.
In multi core control cables the following minimum reserve cores shall be
provided.
4 to 7 cores One reserve core
10 cores Two reserve cores
14, 19 & 24 cores - Three reserve cores
Copper cables shall be used for all power and control circuits of cranes/hoists as
applicable.
Cable Terminations
All 11 kV termination kits shall be of heat shrinkable type and suitable for XLPE
insulation and the same shall have been tested for short circuit as per relevant
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standards. Double compression type cable glands and copper lugs shall be used
for termination.
All 1100 V termination for XLPE / PVC power cables and control cables shall be
by crimping type tinned copper lugs and double compression type cable glands.
Cable Joints
Cable joints shall be avoided to the extent possible. If joints are unavoidable due
to circuit length, in excess of permissible maximum drum length, they shall be
heat shrinkable type having a short circuit with stand capacity of 40 kA for 0.5
sec. for 11 kV cables and 50 kA for 0.5 sec. for 1100 V grade cables.
4.2.5.7
Cable Carrier System
The cable carrier system shall be designed considering the following:
Facility for easy laying of cables.
Access to maintenance.
Neat and aesthetic appearance.
Safety of equipment & personnel.
Ground water seepage.
Following cable carrier system shall be adopted in various areas as indicated
below.
Coal handling plant
(i)
: Cable trays/Cable trenches/ buried
Direct burial of cables shall be avoided as far as possible. The Contractor shall
prepare detailed cable routing diagram, cable tray layouts, cable schedules,
interconnection schedules for all cables being supplied under this Contract. It is
anticipated that a few cables supplied outside this Contract would be required to
be routed in the cable carrier system being provided by this Contractor. The
details of these cables would be made available to the Contractor to prepare
integrated cable layout/routing drawing considering the cable being installed by
others.
Cable Trench
Cable trenches shall be of different sizes depending on the number of cables
laid in that route.
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Preferred working space between the cable support arms and the wall are as
follows. Contractor shall design the trenches accordingly.
Trench depth
Width of Trays
Working Space
1500 mm (5 tiers)
600 mm
750 mm
1200 mm (4 tiers)
600 mm
750 mm
1000 mm (3 tiers)
600 mm
750 mm
700 mm (2 tiers)
300 mm
350 mm
Buried Cables:
Cables in trenches shall be laid on 8 cm of riddled sand and covered with 8cm of
riddled sand. RCC slabs shall be provided for covering these trenches. On top of
RCC slabs / bricks, the earth shall be back filled, rammed and levelled. Suitable
separation shall be provided when more than one cable is laid in the same
trench. The maximum trench depth shall normally be 1.5 m and thickness of top
cover of 75 mm. If the trench is to cross railways tracks/roads or any load
bearing area the cables shall be taken through suitable GI conduits / pipes /
ducts.
Cable Trays
Cable trays of prefabricated ladder and perforated types and the associated
accessories such as coupler plates, tees, elbows, etc., shall be fabricated from
12 gauge (2.5 mm thick) mild steel sheets. Cable tray covers shall be fabricated
from 16 gauge (1.70 mm thick) MS sheets.
Cable trays, accessories and covers shall be hot dip galvanised. Galvanising
thickness shall be minimum 85 microns and mass of Zinc coating not less than
610 gm/m2.
The spacing of rungs for ladder type of trays shall be not more than 250 mm.
Vertical raceways shall be formed by either structural members or slotted angles
or by running the prefabricated trays vertically.
Conduits & Pipes
The galvanised steel conduits shall be used for sizes up to 63.5 mm. The
conduits shall be manufactured by electric resistance welding process and shall
be hot dip galvanised. The conduits and fittings shall comply with IS: 1653,
3837 & 2667.
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Galvanised steel pipes shall be used for sizes from 80 mm on wards. They shall
be medium duty class-B type as per IS. The pipes shall be manufactured by
electric resistance welding and hot dip galvanised. The pipes and fittings shall
comply with IS.
Flexible steel conduits shall be manufactured with electro galvanising process.
The flexible conduits and their fittings shall comply with IS: 3480, 4649.
The hume pipes/RCC pipes shall comply with IS:458.
Cable/Cable tray supports
Cable tray supports shall be fabricated from standard steel structures of
different sizes. The sizes selected shall be adequate for the weight of
cables/trays encountered.
The steel members shall be cleaned thoroughly for rust and painted as follows:
For indoor - One shop coat of red oxide zinc chromate primer and two site
coats of aluminium alkali paint.
For outdoor & corrosive areas like battery room - Hot dip galvanised.
Cable Carrier Installation practice
Minimum level difference between two tiers of horizontal cable trays in building,
trenches, shall be 300 mm (clear space between top of bottom tray and bottom
of upper tray).In vertical raceways with multi tiers the tiers shall be located at
least with 400 mm intervals.
In trenches & tunnels the width of the cable tray shall be limited to 600 mm.
Separate cable trays/tiers shall be provided for 11 kV, 3.3 kV power, 415 V /
240V power, control cables and instrumentation cables.
Cable trays shall be supported at every 1000 mm interval.
Cable trays shall be welded to the mounting/carrier structures.
All outdoor cable trays shall be erected in vertical plane. Vertical trays (raceways)
and all outdoor cable trays shall be provided with removable 16 gauge
galvanised MS sheet covers.
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Each continuous laid out length of cable tray shall be earthed at minimum two
places by GI flats of minimum size 25 mm x 3 mm, the distance between
earthing points shall not exceed 10 meters.
When cables are taken in vertical raceways /trays and they pass from one floor &
other floor pipe sleeves in concrete shall be provided.
In heat zone areas as far as possible the cables shall be taken away from that
area to avoid heat. If Cabling in heat zones cannot be avoided, the cables shall
be terminated in a junction box of IP 67 protection class away from the heat
zones and small length of cables may be laid from junction box to the respective
equipment to facilitate easier replacement in case of fire. Bunching of cables in
the heat zones and boiler areas shall be avoided and laid in separate groups.
4.2.5.8
Cable Installation
Cables to each circuit shall be laid in one continuous length. Cable jointing and
splicing shall be avoided. Jointing will be allowed only for the cases where the
route length is more than the maximum possible drum length.
Outdoor cable installation
(a) Where cables cross roads and water, oil, gas or sewage pipes, the cables
shall be laid in hume or steel pipes. For road crossings, the pipe for the
cable shall be buried at not less than 600 mm. Hume pipes shall be
preferred to steel pipes from the point of view of corrosion.
(b) The cables shall be tied to tray rungs by means of 3 mm dia. nylon cord at
an interval of 5000 mm and also at bends.
(c) For good sealing arrangement at entry points, suitable pipe sleeves,
adequate in number and of adequate sizes shall be provided in building
walls/slabs
for
passage
of
cables
into
building
from
cable
trays/racks/cable trenches located outside the building.
4.2.5.9
Cables in Trays / on Racks
(a) Different voltage grade cables shall be laid in separate trays. When trays are
arranged in tiers, HV cables shall be laid in top trays and cables of
subsequent voltage grades in lower tiers of trays.
(b) The HV power cables shall be laid in trays/on racks as follows:
i)
In single layer only without exception.
ii) 3 core cables to be laid in touching formation.
iii) Single core cables to be laid in trefoil groups.
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(c) 1100 V grade power cables of 120 mm size and above shall normally be
laid in single layer in trays/on racks.
(d) Smaller 1100 V grade power cables below 120 mm may be run in double
layers, where required, due to space restrictions.
(e) Control and instrumentation cables can be laid up to a maximum of three
(f)
layers in each tray/rack.
Single core power cables for 3 phase AC circuits laid in trays/racks/ trenches
in trefoil groups shall be held in trefoil clamps placed at an interval of 3 m.
The trefoil groups of cables shall be additionally tied by means of 3 mm dia.
nylon cord as follows:
(i) At an interval of 1m when laid in cable trays/racks.
(ii) At an interval of 750 mm when laid in trenches without cable trays.
(g) Control cables and small power cables on racks shall be run in ladder type
cable trays supported on rack carrier arms. The cables shall be tied to tray
rung by means of 3 mm dia. nylon cord at an interval of 5000 mm and also
at bends.
Bending radii for cables
The bending radii for various types of cables shall not be less than those values
specified by the cable manufacturer.
4.2.5.10 Terminations, clamping and miscellaneous details
(a) Cable entry to motors, push button stations and other electrical devices shall
be from the bottom as far as possible or from the sides. Top entry shall be
avoided particularly for outdoor equipment.
(b) Identification tags made from aluminium sheet shall be attached to each end
of each cable by means of GI binding wire. Tags shall be additionally put at
an interval of 30 metres on long runs of cables and in pull boxes.
(c) All cable terminations shall be done with solderless tinned copper crimping
type lug. Cable terminations shall be done with double compression type
brass cable glands. For transformer feeders, HT motors, LT motors of 110
kW and above only RPCL approved make lugs shall be used at both motor
and switchgear ends.
(d) Control cable termination: RPCL approved make of connectors shall be used.
(e) Saddle type clamps to suit number of cables to be clamped at a particular
location shall be used for clamping cables running along walls, ceilings,
structures, etc. at 750mm interval.
(f)
The armour and semi-conducting screen of single core cables shall be
earthed at one end. The continuity of armour and semi conducting screen
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shall not be broken at each joint. The unearthed end of armour and screen
shall be insulated.
4.2.5.11 Testing and commissioning of cables
(a) Cables shall be checked for insulation resistance before and after jointing.
(b) High voltage testing
All cables of 1.1 kV grade 400 mm and above and all HV cables shall be
subjected to DC or AC (preferably DC) high voltage test after terminating but
before commissioning as per Table 4 in IS : 1255.
(c) Type test certificates for each type & size of the cable supplied by the Bidder
shall be submitted. In case Type test certificate for similar type & size is not
available, the same shall be conducted in presence of Purchaser or his
representative if Purchaser so desires, at no extra cost to the purchaser.
4.2.5.12 Earthing
(a) Metallic sheaths, screens and armour of all multi core cables shall be
earthed at both equipment and switchgear end.
(b) Sheath and armour of single core power cables shall be earthed at
switchgear end only. For long lengths of cables multiple earthing may have
to be adopted to safeguard against the presence of standing voltages under
normal as well as fault conditions.
4.2.5.13 Fire proof sealing system (FPS)
Fire proof sealing system shall consist of
(i)
Fire-stops/fire-seals for sealing of cable/cable tray and conduit/pipe
penetrations,
both
horizontal
and
vertical,
through
brick
or
RCC
walls/floors, to prevent the spread of fire from one area, which is separated
from others by fire-resistant barriers.
(ii) `Fire-breaks' provided on long runs of cable racks/trays to prevent the
propagation of fire along the cable rack, within a single fire-area or firezone.
The FPS system shall also include all the necessary accessories and equipment
required for supporting, holding in position, fixing and installation of the firestop/fire-break.
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The FPS system shall comply in all respects with the requirements of the codes
and standards listed below :
IEEE-634
ASTM-E-814 / ASTM-E-119
ANSI-IEEE-383
IEC-331
IEEE 383
IS 3144 / BS 476 / IS 3809 / IS 12458
Fire Stop/Seal
The FPS system adopted for cables or cable trays penetrating through walls and
floor openings, or cables passing through embedded conduits/pipes/ pipesleeves, constitutes a `fire stop/seal', which is meant to prevent spreading of
fire between areas separated by fire-resistant barriers.
Fire Break
The fire proofing system, other than fire-stops, adopted to retard flame
propagation along long runs of horizontal or vertical cable trays in the same fire
zone or area, in an event of a fire, shall constitute a `fire-break' and shall be
provided by applying a suitable fire-resistant coating on cables and cable trays
for the required length, with or without a fire resistant panel, at the point of the
fire break to obtain the fire-rating specified.
Performance Requirements
(i)
Requirement of fire stops
The material, design and construction of the fire stops shall be such as to
provide the fire-rating of 120 minutes for a fire on any side and meet all
requirements listed in this specification and the relevant codes and
standards.
The materials used in the fire stops shall be non-hygroscopic, compatible
with the type of cables.
The fire stops shall be suitable for retrofitting of cables through the
penetration seal without disturbing the sealing of the cables already
existing.
(ii) Requirements of fire breaks
Each firebreak shall have a fire-rating of 30 minutes and shall be capable
of withstanding for the duration specified, a fire on any side of the fire
break.
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Application of fire proof sealing system
(i)
Fire stops
Fire stops shall be provided for cable penetration openings listed below:
The passage of cables/cable trays pipe sleeves/embedded conduits
through walls / floors.
Vertical raceways, which carry cables between successive floors,
through openings provided in the RCC floor slab, shall be sealed by
fire stops at each floor level.
Cable entry through openings in floor slabs below HT/LT switchgear,
MCCs, various control and relay panels and other bottom entry panels,
shall be effectively sealed by fire stops.
(ii)
Location of fire breaks
Firebreaks shall be provided on both cable rack and trenches at all
cable tray intersections and tee-offs.
On linear runs of cable trays between fire stops or fire breaks, fire
breaks shall be provided at intervals of 15 metres on horizontal cable
runs and 5 m on vertical cable runs.
Fire breaks in linear runs of cable trenches between intersections and
tee-offs shall be provided at intervals of 30 metres.
Contractor shall furnish the test certificates for the fire stops and fire breaks
after award of Contract for Purchaser / Purchasers Representative review. If the
certificates are not satisfactory all the tests shall be conducted free of cost. The
offered system i.e. fire stops and fire breaks shall be identical (or better) with
the system which is successfully type tested for the specified rating i.e. the
composition density of the material, thickness of coating in case of fire breaks
and any other properties of the material / system offered shall be identical or
better than the tested system and shall be subject to Purchaser / Purchasers
Representative approval.
Performance Tests: Tests on Fire Stops
(a)
The fire stops shall be subjected to the following type tests:
(i)
(ii)
(b)
Fire Rating Test
Hose Stream Test
Type tests shall be conducted on different fire stop test specimens
described above as per IEEE-634. The sizes of the fire stop test specimens,
shall be similar to the largest of the sizes being used in the plant.
(c)
Preconditioning of fire stop test specimens
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Before conducting the fire rating and hose stream tests, each test specimen
shall be preconditioned for thermal ageing, water immersion and vibration.
(d)
Test on Fire Stops
During the fire rating test, the transmission of heat through the cable
penetration fire stop shall not raise the temperature on its unexposed
surface above the self ignition temperature of the outer cable covering, the
cable penetration fire stop material, or material in contact with the cable
penetration fire stop, with a maximum temperature limit on the unexposed
surface of 200oC.
(e)
Tests on fire breaks
Firebreaks shall undergo the following tests as per ANSI-IEEE-383:
1. Ampacity test
2. Flame test
4.2.5.14 Tests on cables
Shop Tests
The Cables shall be subject to shop tests in accordance relevant IS/IEC standards
to prove the design and general qualities of the Cables as below:
Routine tests on each drum of cables.
Acceptance tests on drums chosen at random for acceptance of the lot.
Type tests on each type of cable, inclusive of measurement of armor
D.Cresistance of power cables.
Additional Tests
Following additional acceptance tests shall also be performed on each type of
cables having outer sheath with improved fire performance (category C1 Type
FR/ Category C2, Type FRLS):
Oxygen index test (for both C1 & C2) the Oxygen index shall not be less than
29.
Temperature Index Test (for both C1 & C2)
The measured value of temperature index shall be 21 at a temperature of
250C
Flame Retardance test on single cable and on bunched cables (for both
C1&C2)
After the test, there should be no visible damages on the testspecimen
within 300 mm from its upper end.
After burning has ceased, the cables should be wiped clean and the
charred or affected portion should not have reached a height exceeding
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2.5 meter above the bottom edge of the burner, measured at the front
and rear of the cable assembly.
Halogen acid gas evolution test (for category C2).
The level of HCL evolved shall not exceed 20 per cent by weight
Smoke density test (for category C2)
The cables shall meet the requirements of light transmission of minimum
40% after the test.)
Test for specific optical density of smoke(for category C2)
Test for rodent & termite repulsion property
The test shall be carried out to note the presence of rodent and termite
repelling chemical in PVC compound. Normal procedure is that a
fewchippingsof the PVC compound are slowly ignited in a porcelain dish
or crucible in amuffle furnace at about 600C. The resulting ignited ash is
boiled with a littleammonium acetate solution (10%). A drop of aqueous
sodium sulphide solutionis placed on a thick filter paper and it is allowed
to soak. The spot is touchedwith a drop of above extract. A black spot
indicates the presence of anti-termite& rodent compound.
4.2.6
Instrumentation cables
4.2.6.1
General Requirement
1.
Bidder shall test,supply, erect, and terminate all instrumentation cables
for control and instrumentation equipment/devices/ system included
under bidder's scope ensuring completeness of the control system.
2.
Any other application where it is felt that instrumentation cables are
required due to system /operating condition requirements, are also be in
3.
bidder scope.
Bidder shall supply all cable erection and laying hardware like cable trays,
supports, flexible conduits, cable glands, lugs, pull boxes etc. on as
4.
required basis for all the systems covered under this specification.
In addition to above, bidder shall supply all the cable including co-axial
cables, OFC cable and required converters for interconnecting main plant
and other subsystems in bidder scope.
Generally the following cable types shall be used.
Overall and pair shielded armored cables for Analog Signals & overall Shielded
armored cables for Digital Signals.
Overall and triad shielded armored triad cables for RTD signals.
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Suitable compensating/Extension cable shall be used for thermocouple
signals.
Signal cables shall be minimum 0.5 Sq.mm. All these cables should be FRLS
type.
4.2.6.2
Detailed requirements
Instrumentation cables shall be 1.1 kV grade with stranded high conductivity
annealed, tinned copper, twisted pair (with min. 20 twists per meter) extruded
PVC insulated with overall and /or individual screening, extruded PVC inner
sheathed, extruded outer sheathed with FRLS PVC compound and galvanized
steel wire armoured. The conductor size shall be minimum 0.5 Sq.mm. Triplex
cable similar to instrumentation cables can be used for RTDs. The cables shall
confirm to relevant latest standards.
Cable Properties
All cable shall have galvanised steel round wire armouring.The outer sheath of
all cables shall be of extruded layer of suitable synthetic material compatible
with specified ambient and operating temperature of the cables. The sheath
shall be resistant to water, UV radiation, fungus, termite and rodent attack.
The outer sheath of FRLS PVC compound shall meet the following performance
requirements:
(a)
The critical oxygen index value shall be minimum 29 when tested at 27+
20C as per ASTM-D-2863-77 and the temperature index shall be
minimum 2500C at oxygen index value of 21 when tested as per NES715.
(b)
(c)
The maximum acid gas generation as determined by titration method
shall be less than 20% by weight when tested as per IEC-754-1
The smoke generation under fire shall have maximum smoke density
rating of 60% when tested as per ASTM-D-2843-7.
(d)
The cables will pass the hydraulic stability and ultraviolet tests as per DIN
53387.
The finished cable shall pass the flammability test as per IEC-332-1 and IEEE-
383. In addition, it shall also pass flammability test as per Class F3 of Swedish
Standard SS-424-1475.
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All the instrumentation cables shall be provided with overall shielding. However
multipair cables carrying analog signals shall be provided with individual pair
shielding in the addition to overall shielding. Shielding shall be of AluminumMylar tape with 100% coverage and with at least 20% overlapping. Separate drain
wires for the individual pair shield (wherever applicable) as well as overall shield
shall be provided.
Cable parameters such as mutual capacitance between conductors, conductor
resistance, insulation resistance, characteristic impedance, cross talk and
attenuation figures at 20 deg. C(3deg. C)
for various types of cables as
applicable shall be as specified in Data sheet A. Identification of the cores &
pairs shall be done with suitable colour coding & band marking as well as by
numbering of cores/pairs as per VDE: 0815.
All prefabricated cables shall have 10% spare cores which will not be connected
to pin connectors.
Voltage grade of the instrumentation cables shall be 1.1 kV grade
Thickness of outer sheath shall not be less than 1.8 mm in any case. The
variation in diameter and the ovality at any cross section shall not be more than
1.0 mm.
All instrumentation cables shall be suitable for continuous operation at 70 deg.
C, except for high temperature resistant Teflon insulated cables, which shall be
suitable for continuous operation at 205 deg. C. The cables shall be suitable for
laying in trays, conduits, ducts.
Panels/Cabinets Internal Wiring
Internal panel/cabinet wiring shall be of multistranded copper conductor with
FRLS PVC insulation without shield and outer sheath.
Wiring to door mounted devices shall be done by 19 strand copper wire
provided with adequate loop lengths of hinge wire so that repeated door
opening shall not cause fatigue breaking of the conductor.
All external connection shall be made with one wire per termination point. Wires
shall not be tapped or spliced between terminal points.
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All floor slots of desk/panels/cabinets used for cable entrance shall be provided
with removable gasketed gland plates and sealing material. Split type grommets
shall be used for prefabricated cables.
All the special tools as may be required for solder less connections shall be
provided by C&I Vendor.
Wire sizes to be utilized for internal wiring:
Current (4-20 mA), low voltage signals (48V)
0.5 Sq.mm.
Ammeter/voltmeter circuit,
1.5 Sq.mm.
2.5 Sq.mm.
control switches etc. for electrical system.
Power supply and internal illumination
Terminal Blocks
All terminal blocks shall be rail mounted/post mounted, cage clamp type/other
standard type with high quality non-flammable insulating material of polyamide
/ melamine suitable for working temperature of 100 deg. C.
The terminal
blocks in field mounted junction boxes, racks, etc., shall be suitable for cage
clamp type / other standard type connections as approved by Owner.
All the terminal blocks shall be provided complete with all required accessories
including assembly rail, locking pin and section, end brackets, partitions, small
partitions, test plug bolts and test plug, transparent covers, support brackets,
distance sleeves, warning label, marking, etc.
The marking on terminal strips shall correspond to the terminal numbering on
wiring diagrams. All terminal blocks shall be numbered for identification and
grouped according to the function. Engraved labels shall be provided on the
terminal blocks.
The terminal blocks shall be arranged with at least 100 mm clearance between
two sets of terminal blocks and between terminal blocks and panel / junction
box walls.
4.2.7
DC System
4.2.7.1
Design criteria
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220V DC system comprising of battery, battery charger and DC switchboard
shall be provided for control, protection, interlock, annunciation of the system.
For feeding the DC supply for the above, the following shall be provided:
The bidder shall provide one (1) 100% rated battery associated with two float cum-boost charger and one DC switchboard.
4.2.7.2
Battery
The battery shall be lead acid type with plante positive plates as per IS 16521991.
The plates shall be designed for maximum durability during all service
conditions including high rate of discharge and rapid fluctuations of load.
For arriving at the battery capacity, the following shall be considered.
The minimum and maximum ambient temperature is to be considered as 5 deg
C & 50 deg C respectively for battery design.
The temperature correction factor as given in IS. For this purpose the lowest
electrolyte temperature shall be considered as 5 deg.C above the minimum
ambient temperature. A min design margin of 15% is to be considered.
4.2.7.3
Specific Requirements
i) Construction
a) Each cell shall be assembled in heat resistant, shock absorbing, robust
transparent SAN container.
b) Electrolyte level shall be marked on the clear glass SAN container or level
indicators as applicable. The markings shall be for upper and lower limits.
c) Sufficient sediment space shall be provided so that the cells will not have to
be cleaned out during normal life.
d) Open type cells shall not be accepted. Anti splash type vent plug shall be
provided for sealed-in type cell.
e) Separator between plates shall permit free flow of electrolyte. Separator shall
be of acid resisting materials. Proper arrangement to keep end plates in
position shall be furnished.
f) The cells shall be supported on porcelain insulator fixed on to the rack with
adequate clearance between adjacent cells.
g) The cell terminals posts shall be provided with connector bolts and nuts,
effectively coated with lead to prevent corrosion.
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h) Lead or lead coated copper connectors shall be used to connect the cells of
battery set.
i)
Positive and negative terminal posts shall be clearly and indelibly marked for
j)
Lead coated bent copper plate, tubular copper lugs, bolts, nuts, washers, etc.
easy identification.
shall be furnished for connection of outgoing copper conductor cables.
k) The battery shall be shipped uncharged with the electrolyte furnished in a
separate non-returnable container. 10% extra electrolyte shall be furnished
to cover spillage in transit or during erection.
ii) Racks
The racks for supporting battery cells shall be constructed of best quality
teakwood, duly painted with at least three (3) coats of black anti sulphuric acid
paint.
Racks shall be free standing type, mounted on porcelain insulators, suitable for
double row single tier arrangement.
Numbering tags / plates for each cell shall be attached on to the racks.
Each battery shall be complete with accessories and devices, including but not
limited to the following :
a) Acid resistant battery racks
b) Porcelain insulators, rubber pads, trays, etc.
c) Set of lead coated intercell, inter-tier and inter bank connectors as required
for the complete installation
d) Electrolyte for first filling + 10% extra
e) Accessories for testing and maintenance
f) One Hydrometer for measuring specific gravity of electrolyte in steps of
0.005
g) One Filler hole thermometer fitted with plug and cap and having specific
gravity correction scale
h) Three Pocket thermometers, Acid resisting funnels
i)
Two Acid resisting jugs of adequate capacity
j)
Two Rubber aprons
k) Four Rubber gloves
l)
Two Cell lifting straps
m) One PVC spill trays under the battery cells
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n) One Bridging clamps
o) One Spanner for cells
p) One Float type level indicator
q) One First aid box
r) Battery cell transporting trolley
4.2.7.4
Battery chargers
The float cum boost charger shall be rated to cater the following:
a) Trickle charging current of the battery
b) Continuous load on the DC system
c) Full load current of the largest DC motor as applicable
d) 25% spare capacity over above loads
e) Boost charging current of the battery
The battery chargers shall be capable of providing the initial charging current as
required for the battery. The charger shall be so designed as to bring the fully
discharged battery at 1.85 V / Cell to fully charged condition in 8 hours.
One float cum boost charger shall be normally ON, supplying the load current
and at the same time float charging the battery.
The characteristics shall be such that if load is high and exceeds the charger
capacity then the excess load shall be supplied by the battery.
The other float-cum-boost charger shall be normally in standby mode and shall
cut into circuit automatically.
a) to take over the functions of charger in case of failure of operating FCBC
The float-cum-boost charger shall also have provision for boost charging the
battery through manual selection.
On failure of Station AC supply both float-cum-boost chargers will go out of
service and battery will take over to supply without any interruption.
4.2.7.5
General
The float-cum-boost charger offered shall be static type comprising of silicon
controlled rectifiers and diodes (complete with resistor / capacitor network for
surge protection) connected in three phase full wave fully controlled bridge
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circuit. It shall be provided with an adequately rated isolation transformer and
filters on input to minimise harmonics on the output to keep ripple factor within
acceptable limits.
The charger shall be natural air cooled and no external fans shall be provided to
dissipate the heat developed within the panel.
The charger shall be provided with automatic voltage regulation, current limiting
circuitry, adjustable between 85-105% of rated current, smoothing filter circuit
and soft-start feature.
Voltage control shall be stepless, smooth and continuous. The current setting of
the load limiting circuitry shall be uniformly adjustable.
The charger shall be self protecting against all A-C and D-C transients and
steady state abnormal currents and voltages.
Charger A-C input and D-C output shall be electrically isolated from each other
and also from panel ground. Isolation shall also be provided between power and
control circuits.
4.2.7.6
Construction
The charger shall comprise a continuous line up of free standing, floor mounted
sheet steel panels, with all access from the front.
The panel shall conform to the degree of protection IP-42. Minimum thickness
of sheet metal used shall be 2 mm CRCA.
Access doors shall be with concealed hinges and neoprene gaskets. Ventilating
louvers shall be covered with fine wire mesh. Door above 600 mm width shall
be double leaf design.
All equipment within the panels shall be arranged in modular units and laid out
with sufficient space for easy maintenance.
MCCB & switches, meters, relays, etc. shall be flush mounted on the front of the
panels. Name plates of approved size and type shall be provided for all circuits
and devices.
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4.2.7.7
Charger equipment
All power diodes and control rectifiers shall be silicon type. Rectifier transformer
shall be dry type, double wound, with copper conductor and class B insulation.
Blocking diodes shall be fully rated and redundant so that failure of a single
diode shall not incapacitate the system in any way.
MCCB shall be air break type, 3 pole / 4 poles as required by scheme,
conforming to IS-13947. Performance category shall be P2.
MCCB shall be equipped with three distinct positions for ON, OFF & TRIP. It
shall be possible to lock the handle in OFF position.
MCCB shall have built in short circuit and overload release.
MCCBs shall be rated for continuous and short circuit current in conformity with
the Battery and Charger equipment rating.
Fuse shall be HRC type and arranged for easy replacement. Semi-conducting
device fuses shall be fast acting.
Indicating lights shall be cluster type LED. Both lamp and lens shall be
replaceable from front.
Meters shall be 96 x 96 mm switchboard type, with 250 deg., antiglare glass,
1% accuracy with zero adjuster on the front.
4.2.7.8
Alarms / Indications / meters
One (1) twenty points alarm facia shall be provided on each charger panel,
complete with proper actuating devices, circuitry and legends.
The arrangement shall be such that on occurrence of a fault the corresponding
window will light up and stays lighted until the fault is cleared and reset button
is pressed.
Each time a window lights up, a master relay will get energized to provide group
alarm signals in PLC located in plant control room.
The alarm points shall be as follows:
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i)
AC supply failure
ii)
DC voltage low
iii)
DC voltage high
iv)
DC system ground
v)
Charger overload
vi)
SCR fuse blown
viii)
DC output fuse blown
ix)
Float bus over / under voltage
x)
Boost bus over voltage
vii)
Filter fuse blown
xi)
Boost over current for each charger
xii)
Failure of thyristor / diodes for each charger
xiii)
Failure of blocking diodes
xiv)
Output MCCB open for each charger
xv)
Battery MCCB open
Following indicating LED lamps shall be provided on FCBC cubicle.
Float cum Boost Charger
i)
Mains AC available
ii)
DC output available
iv)
Charger in boost mode
v)
Charger tripped on fault
iii)
Charger in float mode
The charger shall essentially comprise the following items but not limited to:
a)
b)
AC input voltage and current of each charger (through voltmeter /
ammeter selector switches)
One (1) moving coil DC voltmeter and ammeter for float cum boost
chargers.
Necessary shunts for local and remote metering shall be
provided.
c)
One (1) moving coil centre zero ammeter, with shunt to read discharge /
charge current of the battery, with suitable range.
d)
Battery trickle charging current (through amplifier)
e)
DC bus voltage (through selector switches) to measure between positive
to earth, negative to earth and positive to negative.
In addition to above, any additional indication / alarms considered necessary
during the detailed engineering shall also be provided.
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4.2.7.9
Controls
The following manual controls shall be provided on the front of the panel:
a)
Selection of float, equalizing or boost charge for FCBC panel.
b)
Voltage setters for setting the output of float / equalizing / boost charge.
Setting shall be independent of each other so that setting of one voltage
shall not require resetting the other.
c)
Current limit setter
d)
Alarm window reset button
Lamp / space heaters / receptacles
a)
The charger panels shall be provided with
b)
Internal illumination lamp with door switch
Space heater with thermostat control
Pin 5A receptacle with plug
Lamp, heater and receptacle circuits shall have individual switch fuse
units.
4.2.7.10 Wiring / Cabling
a)
The panels shall be completely wired up. All wiring shall be routed
through wiring troughs. Wires shall be ferruled at both ends for
identification.
b)
Panels shall have removable gland plates at the bottom for cable entry. All
incoming / outgoing cables shall be terminated in suitable terminal
blocks.
c)
Control terminal blocks shall be cage clamp type. 20% spare terminals
shall be provided.
4.2.7.11 Grounding
a)
The charger panels shall have fully rated ground bus with two ground
terminals, one at each end.
b)
Each terminal shall comprise two bolt drilling with M10 GI bolts and nuts
to receive ground connection of 50 x 6 mm GI flat.
4.2.7.12 Painting
a)
The panels shall be chemically cleaned, phosphated and sprayed with two
coats of high quality primer and stoved after each coat.
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b)
The panels shall be finished in light gray shade no.631 as per IS-5 with
two coats of synthetic enamel paint.
4.2.7.13 DC switchboards
For feeding the 220V DC loads, 220V DC switchboard shall be provided.
The switch boards shall be provided with suitable quantity and type of outgoing
feeders for the auxiliaries, control supplies to various panels / systems. For each
load and auxiliary, one separate feeder shall be provided. In addition, the
following feeders shall be provided in switchboard.
a)
Spare feeders 20% of each type and rating with a minimum of two nos.
feeders. This is the minimum quantity at the time of handing over the
system.
The short circuit current rating of the switchboard shall be arrived considering
the contribution from charger and battery with 5% margin, with a minimum of
20 kA for 1 sec.
The continuous current rating of the bus bars, incomers for 220V DC
switchboards shall be the maximum DC load on the bus plus 20% margin
rounded off to the next higher standard rating.
4.2.7.14 Specific requirements
Positive and negative sleeved bus bars in the DC switchgear shall be completely
segregated from each other by sheet steel partitions.
Module details
i) Incomer
The incomer modules shall be suitable for DC application ACB controlled. Each
incomer shall be provided with
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Ammeter & Voltmeter
Earth fault relay with potential free contact for remote annunciation
Ammeter to read earth fault current
Under voltage relay with timer
Indicating lamps for ON, OFF, earth fault, under voltage conditions
One current and one voltage transducer for remote indication
Necessary hardware and circuitry for fault alarm and for lamp test and reset
ii) Outgoing feeders.
These feeders shall have DC switch fuse units of draw out type, ON, OFF &
FAULT indicating lamps, supply supervision relays & lamp test.
The feeders rated 200 Amps and above (as applicable) shall be provided with
a shunt and ammeter.
The offered batteries and chargers shall comply with the technical requirement
enclosed vide DATA SHEET-A.
4.2.7.15 Standards
All equipments provided under the specification shall in general, conform to the
latest issue.
4.2.7.16 Tests and tests reports for Battery, Battery Charger and DC
Distribution Board
a) Acceptance test
The following acceptance tests shall be carriedout at manufacturers works in
presence of Owner or his representatives
Verification of markings
Verification of dimensions
Test for capacity
Test for voltage during discharge
b) Type test
Type test certificates as mentioned below for similar equipment supplied by the
bidder shall be submitted. In case type test certificates for similar equipment is
not available or type test certificate is more than 5 years old, the same shall be
conducted in presence of Owners or his representative if Owner so desires.
Discharge performance test at low temperature
Ampere-hour & Watt-hour efficiency test
Test for retention of charge
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Endurance test
4.2.7.17 Tests for Battery Chargers
The following routine tests shall be conducted at manufacturer's works:
a) Visual checks for dimensions and general arrangement.
b) Wiring checks
c) Functional checks
d) Voltage regulation for rated input supply for loads from 0-100%.
e) Load test to show the charger can deliver the rated duty without the current
limiter device operating.
f) Ripple measurement by oscilloscope at different loads.
g) Demonstration of guaranteed efficiency and power factor.
h) Insulation test (with 500V megger)
i)
High voltage test, excluding electronic controller, at 2kV AC for one minute.
j)
Heat run test shall be conducted at full load for 24 hours at the vendor works
on charger.
4.2.7.18 Tests for DC distribution board
Tests
The BOARD shall be completely assembled, wired, adjusted and tested at the
factory as per the relevant standards.
Routine Tests
The tests shall include but not necessarily limited to the followings:
a) Operation under simulated service condition to ensure accuracy ofwiring,
correctness of control scheme & proper functioning of theequipment.
b) All wiring and current carrying parts shall be subjected to appropriate High
Voltage Test.
c) Routine test shall be carried out on all equipment such as circuit breakers,
relays, meters, contactors, switch-fuses, etc.
Type test reports on identical board issued by an authorised test house shall be
furnished
4.2.8
HT Motor
4.2.8.1
HT Motor Specification
Motors shall be general purpose, constant speed, squirrel cage, three-phase
induction type, shall be rated for continuous duty. The motor characteristics
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shall match the requirements of the driven equipment so that adequate starting,
accelerating, pull up, break down and full load torques are available for the
intended service.
4.2.8.2
ConstructionalFeatures
Motors shall be squirrel cage type. The motor winding shall be of copper.
Motor shall be suitable for voltage variation of 10%, frequency variation of
5% and combined voltage and frequency variation of 10%.
Motor rating for belt conveyors (as applicable) shall have a minimum margin
of 20% and for other motors 10 % over the required kW.
Motor shall run continuously at rated output over the entire range of voltage
and frequency variations.
Motors >160 and up to 1500 kW shall be suitable for 3.3 kV, 3 phase, 50 Hz
power supply.
Motor frame size shall be so chosen such that maximum interchangeability is
achieved over the entire plant.
Motors shall be capable of developing the rated full load torque even if the
supply voltage drops to 70% of rated voltage. If such operation is envisaged
for a period of one-second pull out torque of the motor shall be at least
205% of full load torque.
The motor shall be capable of operating satisfactorily at full load for 5
minutes commencing from hot condition without injurious heating with 80%
rated voltage at motor terminals.
The motor shall be capable of resuming normal operation after a system
disturbance causing temporary loss of supply voltage for periods up to 0.2
sec. (fault clearing time) followed by sudden restoration to 70% rated voltage.
Starting current, starting time, starting voltage etc shall be compatible with
the supply voltage and its parameters, protection system. All motors (except
DC motors) shall be started Direct On Line (DOL).
The motors shall be designed to be energy-efficient and have high power
factor and low starting currents. Motors shall have efficiency and power
factor higher than 0.9 and 0.88 respectively. The starting current with DOL
starting inclusive of all tolerances shall not be higher than 6.0 p.u.
Motors shall be capable of starting and accelerating to full speed at 80% of
the nominal voltage and shall not stall at 70% of nominal voltage for one (1)
minute. With voltage and frequency within permissible variation band, the
motors shall be capable of 3 equally spaced starts in 1 hour with motor
initially at temperature not exceeding rated operating temperature. 2 start in
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succession with motor initially at a temperature not exceeding rated
operating temperature.
The motors shall also be capable of restarting under full load after a
momentary loss of voltage with the possibility of application of a total of
150% nominal voltage during bus transfer.
Motors shall be provided with vibration pads for mounting vibration
detectors.
Motors rated 1000 kW and above shall be provided with differential
protection. These motors shall be provided with star connected stator
windings. The 3 nos. current transformers, one for each phase shall be
mounted in a separate compartment in the neutral side terminal box. The
three phases shall be connected to form the star point after they pass
through the CTs.
The CTs shall be of relay accuracy and the CT
characteristics shall be compatible with the differential relay. The additional
3 nos. CTs of identical characteristics shall be provided in the 11 kV / 6.6 kV
/ 3.3 kV / switchgear panel.
The torque characteristics of all induction motors shall be as required to
accelerate the inertia loads of the motor and driven equipment to full speed
without damage to the motor or the equipment at any voltage from 80
percent to 110 percent of motor nameplate voltage except those to be
individually considered. A voltage drop greater than 10 percent from the
specified motor nameplate rating shall be individually considered for proper
motor starting and operating.
The motor shall be self ventilated type, totally enclosed fan cooled (TEFC). All
insulated winding shall be of copper and. impregnated. All motors shall have
class F insulation, but limited to class B temperature rise as per IS: 325
For 3.3 kV motors, 6 nos. duplex RTDs for winding shall be provided with
terminals brought out in to a separate junction box. These motors shall be
designed to withstand at least 2% unbalance in supply voltage.
Cable boxes of all 3.3 kV motors shall be provided with quick disconnecting
type terminal connectors.
The motor shall start smoothly and rapidly and maintain steady operation.
The motor characteristics such as speed, starting torque, acceleration time
etc. shall be properly coordinated with requirement of driven equipment.
a)
The locked rotor withstand time under hot condition at 110% rated
voltage shall be more than motor starting time at minimum permissible
voltage by at least 2.5 seconds for motors up to 20 seconds starting time
and by 5 seconds for motor with more than 20 seconds starting time.
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b)
All motor enclosures shall conform to the degree of protection IP-55/
IPW-55 unless otherwise specified.For hazardous area approved type of
increased safety enclosure shall be furnished., Motor shall be designed on
50 Deg C ambient temperature and should be suitable for bi directional
c)
rotation .
Cable box and terminal box for 3.3 kV motors shall be phase segregated
type.
d)
e)
All 3.3 kV motors shall have winding temperature detectors and bearing
temperature detectors and indicators.
Motors shall have fungus protection involving special treatment of
insulation and metal against fungus, insects and corrosion.
f)
Motor shall be provided with sealed and optimum lubricated anti friction
bearings, Provision of replacing lubricant without opening the bearing by
use of greasing gun/ drain plug shall be provided.
g)
The Noise level shall not exceed 85 db (A) at a distance of 1.0 M from
motor at no load condition. The maximum double amplitude vibrations
for motors up to 1500 rpm shall be 25 microns and 15 microns up to
3000rpm.
h)
Motor terminal box shall be detachable type, capable of being turned
360 in steps of 180 and located in accordance with Indian Standards
clearing the motor base plate/foundation. It shall be split type with
removable cover with access to connections and shall have the same
degree of protection as motor. It shall have sufficient space inside for
termination connection of XLPE insulated armored aluminum cables. It
shall be capable of withstanding maximum system fault current for
i)
duration of 0.25 sec.
The frame of each motor shall be provided with two separate and distinct
grounding pads complete with tapped hole, GI bolts and washer.
j)
In addition to the minimum information required by IS, the information
about Temperature rise in Deg.C under rated condition and method of
measurement, Degree of protection , Bearing identification no. and
recommended lubricant should be shown on motor rating plate.
k)
l)
Motor shall be provided with space heaters. The space heater shall be
rated 240 V, 1 phase 50 Hz and sized.
All accessory equipment such as space heater, temperature detector shall
be wired to and terminated in terminal boxes, separate from and
independent of motor (power) terminal box. Motors shall have perfectly
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located drain plug. Motors shall be provided with eyebolt or other
adequate lifting provisions.
m)
The motor shall be designed to permit easy access for drilling holes
through motor feet or mounting flange for installation of dowel pins after
assembling the motor and the driven equipment.
n)
Drawings, Documents, Data and Manuals shall be submitted with the bid
and in quantities and procedures as specified in Conditions of Contract
and/or elsewhere in this specification for approval and subsequent
distribution after the Effective Date of Contract.
o)
The type tests must have been conducted not earlier than five years from
the date of bid opening. Type Test certificates shall be furnished for
motors of similar design. Alternatively, type tests shall be conducted
afresh with no cost to owner. The bidder shall furnish two sets of the
following as per IS/IEC along with the offer:
All routine tests including IR of winding before and after HV Tests, IR
of space heater, Resistance Measurement etc.
No load saturation and loss curves up to approximately 115% of rated
voltage.
Surge withstand test on the sample coil after placing it in stator core
at (4U + 5kV) and with at least five impulse of 1.2/50 micro sec. wave,
for HV motors only, where U is the line to line voltage in kV. The
tested sample coil shall not be used for the motors supplied.
Temperature rise test at rated voltage whichever is critical (90% VR or
110% VR).
p)
Momentary over load tests (160% for 15 sec.)
Pull out Torque Measurement.
Load test at 25%, 50%, 75% and 100% of rated kW.
20% over speed test for 2 minutes
Noise level measurement
Degree of protection test for the enclosures.
Terminal box fault level withstand test..
IP 55 first and second numeral test.
Operation of motor at full load at 85% VR for 10 min.
Finally certified reports of all the tests carried out at the works shall be
furnished in requisite no. of copies for approval of the Owner. The
equipment shall be dispatched from works only after receipt of Owner's
written approval of the test reports.
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4.2.8.3
1
Codes and Standards
Induction motors - three phase
IS: 325 and efficiency should be as
per IS12615 EEF 1 or equivalent
standard
Measurement and evaluation of
IS: 12075
vibration rotating electrical
machines
3
Code of practice for climate
BS - CP 1014
Proofing
4
Degrees of protection provided by
IS 4691
enclosures for rotating electrical
machinery
5
Classification of hazardous areas
IS 5572
for electrical installation
6
Terminal marking for rotating
IS 4728
electrical machinery
7.
Designation of methods of cooling
IS6362
for rotating electrical machines
8.
Guide for testing three phases
IS 4029
induction motors
9.
Dimensions of slide rails for electric
IS 2968
10
Designation for types of construction
IS 2253
motors
& mounting arrangements of
rotating electrical machines
11
Classification of maximum surface
IS 8239
temperatures of electrical equipment
for use in explosive atmospheres
12
Flame proof enclosure of electrical
IS 2148
apparatus
4.2.9
LT Motor
4.2.9.1
LT Motor Specification
Motors shall be general purpose, constant speed, squirrel cage three-phase
induction type, shall be rated for continuous duty. The motor characteristics
shall match the requirements of the driven equipment so that adequate starting,
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accelerating, pull up, break down and full load torques are available for the
intended service.
4.2.9.2
Constructional Features:
a) Motors shall be squirrel cage type except for cranes. The motor winding shall
be of copper. Motor shall be suitable for voltage variation of 10%, frequency
variation of 5% and combined voltage and frequency variation of 10%.
b) Motor rating shall have a minimum margin of 10% over the required kW
requirement of driven equipment.
c) Motor shall run continuously at rated output over the entire range of voltage
and frequency variations.
d) Motors shall be suitable for 415 V, 3 phase, 50Hz power supply.
e) Motor frame size shall be so chosen such that maximum interchangeability is
achieved over the entire plant.
f) Motors <160 kW shall be 415V rating. Motors of rating >90 kW shall be ACB
operated.
g) Motors shall be capable of developing the rated full load torque even if the
supply voltage drops to 70% of rated voltage. If such operation is envisaged
for a period of one-second pull out torque of the motor shall be it at least
205% of full load torque.
h) The motor shall be capable of operating satisfactorily at full load for 5
minutes commencing from hot condition without injurious heating with 85%
rated voltage at motor terminals.
i)
The motor shall be capable of resuming normal operation after a system
disturbance causing temporary loss of supply voltage for periods up to 0.2
sec. (fault clearing time) followed by sudden restoration to 70% rated voltage.
j)
Starting current, starting time, starting voltage etc shall be compatible with
the supply voltage and its parameters, protection system.
k) The motors shall be designed to be energy-efficient, eff-1 as per IS-12615
Motors shall be capable of starting and accelerating to full speed at 80% of
the nominal voltage and shall not stall at 70% of nominal voltage for one (1)
minute. With voltage and frequency within permissible variation band, the
motors shall be capable of 3 equally spaced starts in 1 hour with motor
initially at temperature not exceeding rated operating temperature. 2 start in
succession with motor initially at a temperature not exceeding rated
operating temperature
l)
The torque characteristics of all induction motors shall be as required to
accelerate the inertia loads of the motor and driven equipment to full speed
without damage to the motor or the equipment at any voltage from 80
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percent to 110 percent of motor nameplate voltage except those to be
individually considered. A voltage drop greater than 10 percent from the
specified motor nameplate rating shall be individually considered for proper
motor starting and operating.
m) The motor shall be self ventilated type, totally enclosed fan cooled (TEFC). All
insulated winding shall be of copper and. impregnated. 2 RTD duplex type in
each phase of the winding slots with terminals brought out in a junction box
shall be provided. All motors shall have class F insulation, but limited to class
B temperature rise as per IS: 325
n) All motors shall be DOL started.
o) The motor shall be capable of withstanding the stresses imposed if started at
110% rated voltage.
p) The motor shall start smoothly and rapidly and maintain steady operation.
The motor characteristics such as speed, starting torque, acceleration time
etc. shall be properly coordinated with requirement of driven equipment.
q) The outdoor motors are to be provided with Canopy.
The locked rotor withstand time under hot condition at 110% rated voltage shall
be more than motor starting time at minimum permissible voltageby at least 2.5
seconds for motors up to 20 seconds starting time and by 5 seconds for motor
with more than 20 seconds starting time.
All motor enclosures shall conform to the degree of protection IP-55/ IPW-55
unless otherwise specified. For hazardous area approved type of increased
safety enclosure shall be furnished. Motor shall be designed on 50 Deg C
ambient temperature and should be suitable for bi directional rotation.
Cable box for 415 V motors shall be non-phase segregated type. Cable box
shall withstand maximum fault current for duration of 0.25 sec.
Motors shall have fungus protection involving special treatment of insulation
and metal against fungus, insects and corrosion.
Motor shall be provided with sealed and optimum lubricated anti friction
bearings, Provision of replacing lubricant without opening the bearing by use of
greasing gun/ drain plug shall be provided.
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The Noise level shall not exceed 85 db (A) at 1.5 M from motor at no load
condition. The maximum double amplitude vibrations for motors up to 1500
rpm shall be 40 microns and 15 microns up to 3000rpm.
Motor terminal box shall be located in accordance with Indian Standards clearing
the motor base plate/foundation. It shall be split type with removable cover with
access to connections and shall have the same degree of protection as motor. It
shall have sufficient space inside for termination connection of XLPE insulated
armored aluminum cables. It shall be capable of withstanding maximum system
fault current for duration of 0.25 sec.
The frame of each motor shall be provided with two separate and distinct
grounding pads complete with tapped hole, GI bolts and washer.
In addition to the minimum information required by IS, the information about
Temperature rise in Deg.C under rated condition and method of measurement,
Degree of protection, Bearing identification no. and recommended lubricant
should be shown on motor rating plate.
Motor of rating above 30 kW shall be provided with space heaters. The space
heater shall be rated 240 V, 1 phase 50 Hz and sized.
All accessory equipment such as space heater, temperature detector shall be
wired to and terminated in terminal boxes, separate from and independent of
motor (power) terminal box. Motors shall have perfectly located drain plug.
Motors weighing 25 kg or more shall be provided with eyebolt or other adequate
lifting provisions.
Drawings, Documents, Data and Manuals shall be submitted with the bid and in
quantities and procedures as specified in Conditions of Contract and/or
elsewhere in this specification for approval and subsequent distribution after the
Effective Date of Contract.
The type tests must have been conducted not earlier than five years from the
date of bid opening. Type Test certificates shall be furnished for motors of
similar design. Alternatively, type tests shall be conducted afresh with no cost to
owner. The bidder shall furnish two sets of the following tests as per IS/IEC
along with the offer.
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All routine tests including IR of winding before and after HV Tests, IR of
space heater, Resistance Measurement etc.
No load saturation and loss curves up to approximately 115% of rated
voltage.
Temperature rise test at rated voltage whichever is critical (90% VR or
110% VR).
Momentary over load tests (160% for 15 sec.)
Pull out Torque Measurement.
Load test at 25%, 50%, 75% and 100% of rated kW.
20% over speed test for 2 minutes
Noise level measurement
Degree of protection test for the enclosures.
Terminal box fault level withstand test for each type of terminal box of LT
motors only.
IP 55 first and second numeral test.
Operation of LT motor at full load at 85% VR for 10 min. upto 110 KW and
80 % VR for motors above 110 KW.
Finally certified reports of all the tests carried out at the works shall be
furnished in requisite no. of copies for approval of the Owner. The equipment
shall be dispatched from works only after receipt of Owner's written approval of
the test reports.
Motor Operated Valve Actuators
The actuator motors shall be designed for short time duty (S2) in accordance
with IEC 34-1. Degree of protection for actuator motor enclosure shall be IP65 and IP-67 for indoor and outdoor respectively.
The actuator shall be electrically operated electronically controlled type. It
shall be sized to achieve valve/damper closure at the specified differential
pressure.
The actuator motor shall be time rated for at least 15 minutes or twice the
valve stroking time, whichever is higher at an average load of at least 33% of
the maximum valve torque. For regulating service, the actuator shall be
suitably time-rated for the duty cycle involved with necessary number of
starts per hour, but in no case less than 150 starts per hour. It shall be
capable of starting at 85% of rated voltage. Torque switch must trip at
maximum driven equipment torque at 90% rated voltage.
Motor shall have minimum class 'F' insulation with temperature rise restricted
to class 'B'.
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Motor shall be suitable for operation under voltage variation of + 10%,
frequency variation of + 5% and combined voltage & frequency variation of
10% absolute.
Motor shall be suitable for direct on-line (DOL) starting and starter shall be
integral to the motor.
The actuator shall be complete with all accessories viz. torque limit switch,
endof- travel switch, adjustable position limit switch, hand-wheel etc.
Complete actuator shall be tested at factory as per IEC before dispatch.
4.2.9.3
1.
Codes and Standards
Induction motors - three phase
IS: 325 and efficiency
should be as per
IS12615 EEF 1 or
equivalent standard
2.
Measurement and evaluation of
IS: 12075
vibration rotating electrical machines
3.
Code of practice for climate
BS - CP 1014
4.
Degrees of protection provided by
IS 4691
Proofing
enclosures for rotating electrical machinery
5.
Classification of hazardous areas
IS 5572
for electrical installation
6.
Terminal marking for rotating electrical
IS 4728
7.
Designation of methods of cooling for
IS6362
machinery
rotating electrical machines
8.
Guide for testing three phases induction
IS 4029
motors
9.
Dimensions of slide rails for electric
IS 2968
motors
10.
Designation for types of construction &
IS 2253
mounting arrangements of rotating
electrical machines
11.
Classification of maximum surface
IS 8239
temperatures of electrical equipment for use
in explosive atmospheres
12.
Flame proof enclosure of electrical
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apparatus
4.2.10
HT< Bus Duct
4.2.10.1 Design criteria
The 3.6 kV class segregated phase bus ducts will serve as interconnections
between 11/3.6 kV transformers to 3.3 kV switchgears.
The continuous current rating of the bus duct shall be same as the rated current
of respective switchgear bus.
HT bus duct shall be metal enclosed, phase segregated and natural air-cooled
type in construction.
The 1.1 kV class, 415 V non segregated phase bus duct will serve as
interconnections between 11 / 0.433 kV transformers and LT switchgear.
The short time and momentary current ratings of the bus ducts shall be same as
that of associated 3.3 kV / 415 V switchgear.
HT bus duct shall be Aluminum alloy grade 63401 as per IS 5082. The Phases
shall be enclosed in a whether proof, dust tight, non-magnetic material. The
Enclosure shall be rectangular and shall be made of aluminum alloy sheets. The
Bus ducts shall be phase segregated and natural air-cooled type in construction.
LT bus duct shall be Aluminum alloy grade 63401 as per IS 5082. The Phases
shall be enclosed in a whether proof, dust tight, non-magnetic material. The
Enclosure shall be rectangular and shall be made of aluminum alloy sheets. The
Bus ducts shall be non phase segregated and natural air-cooled type in
construction.
The design and construction of the bus ducts shall be such as to limit the
temperature rise within the following values when operating continuously at the
current corresponding to the rated MVA of transformer and 90% rated voltage.
The hot spot temperature of the bus conductor is 90 deg C including joints. The
hot spot temperature of bus enclosure is 70 deg C.
The bus ducts will be installed partially indoor and partially outdoor in a hot,
humid and tropical atmosphere.
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Bus duct, associated equipment and wiring shall be provided with tropical finish
to prevent fungus growth. All ventilation openings shall be screened and drains
shall be filtered to prevent entrance of dust and insects.
Bus duct and auxiliary equipment shall be capable of withstanding the
mechanical forces and thermal stresses of the short-circuit currents without any
damage or deterioration of material. Bus conductor support insulator span shall
be chosen considering minimum factor of safety of 2.5 for cantilever strength
under short circuit condition.
In the bus duct routing the phase changeover is to be avoided. The bus duct
entry to switchgear is from top only.
The portion of bus duct at the transformer end will be subject to vibration
normally prevalent for this type of installation in a power generating station.
Suitable means shall be provided to isolate the transformer vibration from rest
of the bus structure/bus duct.
Equipment mounted outdoors
shall be completely weatherproof (IP-55)
designed to withstand weather conditions, UV radiation and solar heating.
Internal equipment shall be splash proof, dustproof and vermin proof (IP-54). In
addition, the outdoor section shall withstand the wind loading of 150
kg/Sq.mm.
Detailed Requirements
4.2.10.2 Enclosures
The minimum enclosure thickness shall be 3mm. The degree of protection of
the enclosure shall meet the requirement of Appendix-F of IS-8084.
All horizontal runs of the bus ducts shall have a suitably sloped enclosure top to
prevent retention of water.Similarly all gasketed-flanged joints shall be suitably
protected against direct splashing of rainwater in case of outdoor runs. The bus
duct enclosure shall be phase segregated type for HT bus duct and non
segregated type for LT bus ducts.
The circumferential neoprene rubber gaskets shall be provided for dust tight
joints with adjacent enclosure sections. The bus enclosure shall have extended
bellows or equivalent means to allow for temperature changes and vibrations.
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Flexible joints shall be provided in enclosures at all points where the bus duct
terminates at equipment to withstand vibration, expansion/ contraction and at
suitable intervals in any straight run of the bus duct where expansion and
contraction would otherwise result in stresses in the supporting structures.
All outdoor bus-enclosures shall be so designed & constructed as to prevent
accumulation of rain water on top sheet.
Inspection openings/split covers shall be provided to allow easy access for
installation, inspection, replacement or repairs of the insulators, bus connection
and terminations. The inspection openings/split covers, enclosure joints,
termination etc. shall have reliable sealing arrangement with neoprene/rubber
gaskets to prevent dust & water entry. There shall be no joints or fixing bolts on
top of the enclosure through which water can seep.
Epoxy resin cast seal-off bushings complete with wall-frame and support plates
shall be provided where the bus duct penetrates the building wall. The seal is to
prevent free exchange of air between indoor and outdoor portions of the bus
duct.Wall frame assembly and seal off bushings shall be fabricated out of
aluminum angles and sheets.
Silica-gel breather shall be provided on both indoor and outdoor portions of the
bus duct. Filtered drains for drainage of condensate shall be provided at the
lowest points and at such locations where accumulation of condensate can be
expected.
Shipping length of the bus duct shall be not more than three (3) metres in
length. Each shipping section shall have at least two (2) supports both for
conductor in each phase and enclosure. Suitable blanked flanges with cover shall
be provided on the enclosure of the busduct (indoor and outdoor) to allow
connection of hot air duct of hot air blowerto improve insulation level after long
shut down etc.
Phase segregation barrier shall be of aluminium alloy having a minimum
thickness of 3mm. The barrier shall be welded to the enclosure.
4.2.10.3 Bus conductor
The bus conductor shall be of high conductivity aluminum alloy grade 63401,
adequately supported on insulators to withstand dynamic stress due to the
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specified short circuit current, without permanent deformation. Bus conductors
shall be given a coat of matt black paint to facilitate heat dissipation. However
the sizing of the bus conductor shall consider the conductor as bare.
Flexible joints shall be provided between bus duct sections to take care of
expansion and contraction, wherever deemed necessary by the Bidder, for
temperature variations between 0 Deg. C. and that achieved during a short
circuit after full load operation at 50 Deg. C. ambient.
Flexible connection shall also be provided for termination at each transformer
and switchgear end. Clearances provided by removable connections shall be
adequate for independently testing the equipment being connected by these.
Adjacent sections of bus conductors shall be welded or bolted. Welded joints
shall be preferred. Welding procedure shall be subject to Owners/Consultant
approval. Bolted joints shall preferably be silver plated. Non-silver plated joints
shall be thoroughly cleaned and applied with non-oxide grease immediately
prior to making the joints.
All bus joints and connections whether welded or bolted shall be so made that
their resistance does not exceed the resistance of an equivalent length of bus of
same size and the temperature rise on them shall be within the guaranteed
values.The joints along the conductor shall be of highest quality and
temperature rise test shall be conducted including all joints.
4.2.10.4 Insulators
Bus support insulators shall be interchangeable, high creep, high strength, wet
processed, and fine glazed porcelain. Alternatively good quality cast resin
insulators may be offered. Bus support insulators shall be of 7.2 kV/1.1 kV class
and shall be mounted on resilient pad.
Insulator shall be mounted in such a way so as to permit easy removal or
replacement without disassembly of the bus. The insulator mounting plate shall
be designed for cantilever loading to withstand the short circuit force. Support
span shall be taken into consideration.
The conductor shall be fastened on the insulator through fixed and slip joints so
as to allow conductor expansion or contraction without straining the insulator.
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4.2.10.5 Connections & Terminations
All matching flanges, seal-off bushings, gaskets, fittings, hardware and
supports required for termination of the bus duct at the switchgears,
transformers and other equipment shall be furnished.
Flexible connection both for conductor and enclosure shall be furnished
At all equipment termination to provide for misalignment up to 25 mm.
(1") in all directions.
Between the bus duct portions supported from building steel to prevent
transmission of vibration.
The equipment terminal connections shall be easily accessible and shall provide
sufficient air gap for safe isolation of equipment during testing.
Suitable bi-metallic connectors shall be provided wherever the material of bus
conductor and equipment terminals are different.
4.2.10.6 Grounding
A continuous 70x10mm galvanized mild steel earth bar shall be provided along
the entire run of each bus duct. Each section of the bus duct enclosure shall be
bonded to this earth bar at least at both ends of the enclosure. The earth bar
shall be connected to the main earthing system at its two ends by the
contractor.
4.2.10.7 Supporting Structures
All supporting structures required for hanging and/or supporting the complete
bus duct shall be furnished. These include all members, indoor/outdoor posts,
bolts, shims, base plates, beams, hangers, brackets, bracings and hardware.
All buses shall be adequately supported and braced to successfully withstand
normal operation, vibration, thermal expansion, short circuit forces and all
specified design loads.
Support shall be designed to provide tolerance of 12 mm. (1/2") in the
horizontal and vertical directions.
All steel members shall be hot-dip galvanized after fabrication. All hardware
shall be of high strength steel with weather resistant finish.
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Concrete foundation, building steel, concrete, inserts/plates and all other
materials necessary shallbe provided by the Bidder.
4.2.10.8 Wiring
All wiring for space heaters shall be done with insulated stranded copper
conductor cross section not less than 2.5 Sq.mm. Each wire shall be identified at
both ends with wire designation as per contractor's wiring diagram and shall be
brought out to a terminal box outside the bus duct.
Terminal blocks shall be box-clamp type, minimum 10 Sq.mm with marking
strips or approved equal.
At least 20% spare terminals shall be furnished in the terminal block. Not more
than two wires shall be connected to one terminal.
Name Plate
Suitable nameplate shall be furnished with each piece of equipment. Materials
for nameplate shall be Anodized Aluminium, 3 mm thick, using white letters on
black background.
4.2.10.9 Space Heaters
The bus ducts shall be provided with adequate number of thermostatically
controlled space heaters of adequate capacity to maintain the internal
temperature above the dew point to prevent moisture condensation within the
bus duct. Space heaters shall be rated for 240V, single phase, 50Hz AC supply.
The space heaters and thermostats shall be wired up to terminals in suitably
located terminal boxes to be provided by the contractor. The space heater wiring
inside the bus duct enclosure shall be done with high temperature resistant
cables as the ambient temperature existing inside the bus duct enclosure may
vary from 800C to 900C
Controlling the space heaters of each bus duct shall be done from the feeders
earmarked in LT Switch gear panels.Single phase 240 V power supply at the
Switch gear panel for complete run of every bus duct is required. All cabling
between space heaters/thermostats and switch gear panels in the run of bus
duct shall be supplied and erected by the contractor. Cable entry points to the
bus duct shall be sealed properly by providing suitable glands.
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4.2.10.10 Paint and Finish
Except for supporting steel structures, which shall be galvanized, all equipment
shall be finished with an undercoat of high quality primer followed by two coats
of epoxy paints.
The interior surface finish shall be as per manufacturer's standard. The shade of
exterior surface finish shall be light grey shade number 631 for indoor and
battle ship grey shade number 632 outdoor unless otherwise stated.
Pretreatment consisting of degreasing, derusting etc. shall be done on all
fabricated parts before painting or galvanizing.
Paints shall be carefully selected to withstand heat and weather conditions. The
paint shall not scale-off or crinkle or gets removed by abrasion due to normal
handling.
Sufficient quantities of all paints and preservatives required for touching up at
sites shall be furnished.
4.2.10.11 Standards
All equipments provided under the specification shall in general, conform to the
latest issue of the standards but not limited to the following:
S.N
IS code
Description
a)
IS:226
Structural steel (Standard quality)
b)
IS:737
Specification for wrought aluminum and aluminum alloys,
sheet and strip (for engineering purpose).
c)
IS:800
Code of practice for use of structural steel in general
building construction.
d)
IS:1367
Hot dip galvanised coatings on threaded fasteners.
PART-13
e)
IS:2099
Bushing for A.C. voltage above 1000 volts.
f)
IS:13947
Low voltage switchgear & control gear
PART-1
g)
IS:2544
Porcelain post Insulators for system with normal voltage
greater than 1000 volts.
h)
IS:2633
Methods of testing uniformity of coating on zinc coated
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S.N
IS code
Description
articles
i)
IS:4759
Hot dip zinc coating on structural steel and allied
products.
j)
IS:5082
Specification for wrought Aluminum alloys bars, rods,
tubes and sections for electrical purposes.
k)
IS:8084
Interconnecting bus bars for A.C. voltage above 1KV upto
Updated
and including 36KV.
upto:1992
l)
ANSI C37:20
Switchgear Assemblies including Metal enclosed Bus.
Equipment complying with other internationally accepted standards such as IEC,
BS, ANSI, VDE etc. will also be considered if they ensure performance and
constructional features equivalent to or superior to standards listed above. In
such a case, the Bidder shall clearly indicate the standards adopted, furnish a
copy in English of the latest revision of the standards along with copies of all
official amendments and revisions in force as on date of opening of bid and
shall clearly bring out the salient features for comparison.
Installation work shall also conform to Indian Electricity Act and Indian Electricity
Rules as amended up to date.
4.2.10.12 Tests
a) All equipment to be supplied shall be of type tested quality. The contractor
shall submit for Purchaser's approval the reports of all the type tests as listed
in this specification and carried out within last five years from the date of bid
opening. These reports should be for the test conducted on the equipment
similar to those proposed to be supplied under the contract and the test(s)
should have been either conducted at an independent laboratory or should
have been witnessed by a client.
b) In case the contractor is not able to submit report of the type
test(s)
conducted within last five years from the date of bid opening, or in the case
of type test report(s) are not found to be meeting the specification
requirements, the contractor shall conduct all such tests under this contract
free of cost to the Purchaser and submit the reports for approval.
c) All acceptance and routine tests as per the specification and relevant
standards shall be carried out. Charges for these shall be deemed to be
included in the equipment price.
d) Type test reports for the following type tests shall be submitted:
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a. Temperature rise test. millivolt drop shall also be measured across
bolted flexible joint.
b. Impulse voltage withstand test.
c. Short circuit withstand test
d. Water tightness test (As per F-4.1 in Appendix-F of IS: 8084).
e. Air leakage test.
Routine Tests
The routine tests shall include but not limited to the following and all other
components as per relevant Indian Standards & approved QUALITY PLAN. Also
the test certificates shall be furnished for bought out items.
Visual inspection
Dimensional check as per drawing
DP test in 10% of welding joints
Paint adhesion and thickness test
Power frequency voltage withstand test
IR test
Continuity & 2 kV HV test in wiring
4.2.10.13 Data is to be furnished with bid
Typical calculation for arriving the size of the conductor and the insulator
spacing
Performance certificate of the make of bus duct proposed
Type test report (short circuit, impulse withstand, temperature rise test) for
similar bus duct manufactured by the proposed manufacturer.
4.2.11
Neutral Grounding
4.2.11.1 Methods of Earthing
3.3 kV systems shall be medium resistance earthed. The neutral of the
secondary side auxiliary transformer (11 /3.6 kV) shall be connected to a
suitably rated neutral earthing resistor.
Duty rating of the earthing resistor for Power transformer shall be 10 secs to
limit the earth fault current to 300 A.
415 V systems shall be a solidly earthed system. The neutral of the service
transformers shall be independently & directly connected to the earth.
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240V AC systems for lighting and the space heating shall be solidly earthed
system. The neutral of the transformers shall be connected to the earth bus
through a link in the respective board, which is inturn connected to the power
plant earth grid.
240V AC control supply shall be solidly earthed system. The earth side of the
transformer shall be connected solidly through a link to the earth bus in the
respective modules of switchgear/control panels.
110 V AC control supplies shall be a solidly earthed system. The earth side of
the transformers shall be connected solidly through a link to the earth bus in
the respective modules of switchgear / control panels.
220 V DC system shall be unearthed.
Sizing of Neutral Earthing Equipment:
The neutral earthing resistor ohmic value for Power transformer neutral earthing
shall be such that earth fault current is limited to 300 Amps.
4.2.11.2 Specific Requirements
a) Each neutral earthing resistor unit shall be air cooled and self-supporting
type. The enclosure shall have a degree of protection of minimum IP-54 for
indoor and IP-55 for outdoor.
b) The resistor elements shall be made of non-aging stainless steel or
equivalent corrosion resistant material and all element connections shall be
bolted type. All the resistor elements shall be internally connected and end
terminals/taps shall be brought out of tank enclosure in the form of
bushings.
c) The Grid resistor element shall be enclosed in a tank type aluminum
enclosure. The frame shall be adequately protected from rusting and
deterioration due to exposed conditions by anti-rust coating and final
aluminum paint.
d)
The resistors shall be provided with taps at 25%, 50% & 75%.
e) The resistor cubicle shall be mounted on suitably rated insulators. Neutral
Earthing Resistor cubicle shall be suitable for outdoor installation. Enclosure
of the cubicle shall be of 3 mm thick steel with sloping top canopy.
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f)
3.3 kV side of transformer neutral shall be connected to NGR through 3.3
kV XLPE cables with double compression brass cable glands and lugs.
Cable boxes shall be provided for receiving the cables from the
transformers.
g) The resistor cubicle shall be located in transformer yard at a height of
2.5m. If located at ground level, the resistor & transformer area shall be
fenced separately, even though located within the fenced transformer
yard.
4.2.11.3 Tests
1
Measurement of resistance.
IR test by HV megger between terminal and earth.
Checking of earth connection for terminal and for body.
Check for isolator operation and continuity of aux. contacts (if
Check for temp. rise of enclosure and current flow in the resistances.
applicable).
Data to be furnished with the Bid
1. Technical particulars for the neutral earthing resistors as per data sheet
2. Experience list for the make of the resistor offered.
3. Sub vendor list for Neutral earthing equipment shall be submitted for review/
approval
4.2.12
Illumination system
4.2.12.1 Design Criteria
The system should provide lighting and electric service power supply to the
areas covered under the scope work of the bidder. The lighting system shall be
designed based on actual loads, plus 20% margin, for future requirement, on
total load.
The Contractor shall carefully consider these illumination levels before
proceeding with the design work.
Lighting distribution boards shall be provided with Lighting Transformer,
lighting Panel shall be provided with incoming MCCB and a number of outgoing
circuits operated by MCB.
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Number of spare feeder in boards/panels shall be 20% with a minimum of two.
Control Room & Office Lighting shall be done with decorative Compact
Fluorescent Lamp (CFL) fittings. Ventilation Room (if any) shall be done with
fluorescent fittings. Battery Room shall be done with flameproof / anti corrosion
fittings.
Normal AC lighting - This will be provided by A.C. lighting fixtures distributed
throughout the different areas. These lights will be ON as long as the normal
A.C. supply is healthy. The main lighting distribution boards will be fed through
respective 1:1 ratio lighting transformer, which forms a part of the MLDB.
Normal A.C. supply thus made available by the MLDB is 415V-3ph-4 W-50 Hz
effectively grounded. The distribution of lighting circuits should be such that no
two consecutive fixtures are fed from the same circuit.
DC lighting This will be provided by D.C. lighting fixtures located strategically
in critical operating areas. DC lighting will be catered by DC lighting distribution
(DCLDB) boards. These DCLDBs will feed the DC lighting fixtures directly and
through a numbers of DC lighting panels (DCLP) located suitably in respective
areas.
The systems shall be suitable for operation on available power supply (AC/DC)
All fittings of control room / switchgear rooms / office shall also be energy
efficient type and decorative type.
Exit sign with built-in lamp preferably Light Emitting Diode (LED) shall be
provided at all strategic location. The exit lamps shall remain ON all the time.
In an area, the lighting fixtures shall be arranged in different phases/ LPs such
that even in case one lighting panel is faulty complete lighting is not affected. In
case of any location the lighting shall be arranged at least from two phases.
The circuit loading on each circuit shall be restricted to 80% of the MCB rating.
The voltage drop from LDB and any fixture shall not exceed 3%.
Requirements
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All equipment and accessories shall be designed for continuous operation under
site conditions without exceeding permissible temperature rise as stipulated in
relevant standards.
MCCB, miniature circuit breakers (MCB), bus bars shall be fully rated for short
circuit level at the point of application. MCB should be used in place of HRC
fuses
All equipment and accessories shall have proper enclosure to suit the site
conditions. Enclosure degree of protection is subject to Owners approval.
All wiring from lighting panels to fixtures and receptacles shall be carried out by
FRLS PVC wires in G.I. conduits.
Heavy-duty power cables will be used only for connections between:
Lighting distribution board to lighting junction box
Junction boxes of towers
Lighting distribution board to lighting panels
From source of power supply to MLDBs
Method of calculation
Standard Lumen method shall be adopted for interior & exterior lighting in order
to determine the number of lighting fixtures for obtaining the desired average
level of illumination.
The coefficient of utilization shall be considered to take care of Lumen loss due
to
Effect of room dimensions
Absorption of light in luminaries
Absorption of light at various room surfaces i.e. ceiling wall etc
Floor cavity, ceiling cavity
Mounting height
Moreover a maintenance factor shall also be considered to account for the fall of
illumination due to aging, pollution like dust deposit etc. Maintenance factors to
be considered for various areas shall be as follows:
Area
Control Room
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0.65 0.75
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Switchgear/MCC Room
0.60-0.65
General indoor area
0.55 0.60
Ash / Coal dust area
0.50-0.55
Circuit loading of each lighting Panel shall be done in such a way that almost
balanced loading in all the phases i.e R, Y & B is achieved. At least two sub
circuits shall be used for illumination of a particular area. Sub circuit loading of
each lighting panel shall be restricted to 2 kW.
The vendor will submit their total design proposal for area lighting including
lighting of buildings, streets, bays, etc., with detail drawing for the approval of
the owner
4.2.12.2 Detailed Requirements
4.2.12.3 Equipment & Material
Equipment and material shall comply with description, rating, type and size as
required
Equipment and materials furnished shall be complete and operative in all details.
All accessories, control devices, internal wiring, fittings, supports, hangers,
anchor bolts etc. which form part of the equipment or which are necessary for
safe and satisfactory installation and operation of the equipment shall be
furnished.
All parts shall be made accurately to standard gauges so as to facilitate
replacement and repair. All corresponding parts of similar equipment shall be
interchangeable.
4.2.12.4 Lighting Fixtures
Lighting fixtures shall be designed for minimum glare. The surface finish
shall be smooth and scratch resistant.
Reflector shall be of anodizes or aluminium, minimum 20 SWG thick, securely
fixed by fastening device of captive type
Fixture shall be suitable for 19 mm conduit entry and 16 SWG G.I. earth wire
connection.
Fixture shall be furnished complete with lamps and integrally mounted
accessories. These shall include holders, ballast, capacitor, starter, ignitors
(separate type) etc.
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Fixtures shall be fully wired up to respective terminal blocks suitable for
connection of PVC wires, for lighting fixtures 2.5 mm sq. copper per lead and
for the flood light fixture appropriate gauge of copper per lead.
4.2.12.5 Lamps
Energy efficient lamps (higher lumens per watt) should be provided e.g
instead of incandescent lamp CFL should be used wherever appropriate
Sodium vapour lamp shall be colour corrected type with screwed cap
All fluorescent lamps shall be bi-pin rotary type and either cool daylight or
white, preferably 28 W energy efficient
Lamps shall be suitable for use in position and capable of withstanding small
vibrations. Restrictions and special features, if any, shall be clearly indicated
in the bid.
4.2.12.6 Ballast
Electronic ballasts shall be provided for fluorescent & CFL lamps.
Ballast windings shall have maximum operating temperature of 120oC without
rated temperature rise marking.
Ballast for Metal halide / Sodium vapor lamp shall be provided with suitable
tapings to set the voltage within range specified.
Electronic Ballast shall be suitable for 220 V DC and also 240 V AC
Electronic Ballast shall be compact, lightweight, high frequency electronic
standard ballast for fluorescent lamps.
It shall be Flicker-free warm start, ideal for areas with high switching frequency.
Electronic Ballast shall be of such design that minimum 25% reduction in energy
consumption at constant luminous flux compared with conventional gear.
Electronic Ballast shall not be caused to high harmonic distortion. Electronic
Ballast shall provide constant light independent of mains voltage fluctuation.
Ballasts shall be free from hum; Ballasts which produce humming sound shall be
replaced, free of cost, by the Contractor.
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In multi-lamp fixture, each lamp shall be provided with individual ballast.
4.2.12.7 Lighting Distribution Boards / Panels
Lighting boards/panels shall be metal enclosed, cabinet type, fabricated from
CRCA sheet steel minimum 2 mm thick, suitable for either wall / column
mounting on brackets or floor mounting on channel sill.
Indoor boards / panels shall be dust and vermin-proof, IP-54 or better; outdoor
boards / panels shall be weather proof with canopy & double door IP-55 or
better.
Two ground pads with M10 bolts and nuts shall be provided on each board /
panels for connection to 50 x 6/25 x 3 mm G.I. flat.
Each board/panel shall be completed with designation and caution notice plates
fixed on front cover and a circuit directory plate fixed on inside of the front
cover.
The plates shall be of anodized aluminium with inscriptions indelibly etched on
it. Bus bar shall be electrolytic grade, hard drawn aluminium; color coded for
easy identification and designed for a maximum temperature of 85 deg. C.
Minimum size shall be 25 x 6 mm. Incoming and outgoing circuits shall be
terminated in suitable terminal blocks.
4.2.12.8 Board / Panel Equipment
Board shall be designed for the required short circuit level (20-25 kA)
Each board/panel shall have an incoming four pole MCCB and a number of
outgoing four pole MCCB feeders for board and miniature circuit breakers (MCB)
for panels.
Board/Panel access door shall be interlocked with incoming MCCB unit such that
the door can be opened only when switch is in OFF position. Means shall be
provided to defeat this interlock.
MCB shall be suitable for manual closing and opening and also automatic trip on
overload and short circuit.
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Panel busbar shall be electrolytic grade hard drawn aluminium, colour coded for
easy identification of required size.
4.2.12.9 Receptacles
Receptacles shall be heavy duty, complete with individual plug, top socket and
switch.
The conduit box of the receptacle shall be provided with earthing screws with
washer and nuts welded on the surface for grounding with 16 SWG G.I. wire.
Arrangement shall be provided inside the conduit box for grounding of third pin.
Shrouded type plug shall be provided with corresponding matching arrangement
at sockets to prevent accidental contact with finger during plug insertion.
The distribution of receptacles shall be such that the loading on each phase of the
LDB is approximately equal.
4.2.12.10 Fans & Regulators
The fans shall have three well balanced blades, and shall be reasonably free from
noise. Pedestal fans shall also be provided as per Owners requirement.
Fan motor shall be totally enclosed type with copper winding and class E
insulation. Regulator shall have minimum five steps.
Electronic regulator with
smooth control is preferred.
4.2.12.11 Switch & Switch Board
All switch boards/boxes shall be of bent steel construction, fabricated of 14 SWG
M.S. sheet with 6 mm thick bakelite cover.
Switch boards/boxes shall have conduit knock outs on the sides. Adequate
provision shall be made for ventilation of these boxes.
Flush type receptacles where provided shall be so located that only the plug
projects outside.
Switches shall have quick-make and quick-break mechanism operated by a
suitable external handle complete with position indicator.
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4.2.12.12 Lighting Poles
Lighting Poles shall be constructed with galvanized steel sections. Wind pressure
and other service conditions shall be duly considered while designing the pole.
The mounting of fixtures on lighting towers shall be such that fixtures and
associated devices can be easily maintained and replaced, whenever required with
the help of electric winch.
4.2.12.13 Flood Light Tower
Flood light tower shall be a lattice structure with maintenance platform and
approach ladder. All structural members and hardware shall be hot-dip
galvanized.
Structures shall be designed for an additional load of 1500 kg for maintenance
crew.
Deflection under maximum wind pressure shall not exceed 1 in 360.
Structural design shall be as per IS-800 and subject to Owner's approval.
4.2.12.14 Lighting Cables & Wires
Lighting cables shall be heavy duty, 1100 Volt grade, multi-core stranded copper
conductor, FRLS PVC insulated, extruded PVC inner sheath, single round G.I. wire
armoured and over all FRLS PVC sheathed to IS: 1554.
Lighting wires shall be 1100 Volt grade, FRLS PVC insulated, stranded conductor,
inner sheathed, single core cable to IS: 694 colour coded as below:
RED
R phase
BLACK
Neutral
YELLOW
Y phase
RED
+ ve DC
BLUE
B phase
BLACK
- ve DC
Wire size shall be as follows
For point wiring beyond lighting panel stranded Copper:
1C, 6 sq mm
From Junction box to fixture stranded Copper
1C, 4 sq. mm.
4.2.12.15 Conduits and Accessories
Conduits shall be rigid steel, hot dip galvanized, furnished in standard length of 3
meters, threaded at both ends.
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Conduits-upto and including 25 mm shall be of 16 SWG and conduits above 25
mm shall be of 14 SWG. Minimum size of conduits shall be 19 mm.
Each piece of conduit shall be straight, free from blister and other defects and
covered with capped bushings at both ends.
Flexible conduits shall be made with bright, cold rolled annealed and
electro-galvanized mild steel strips and coated with PVC.
4.2.12.16 Junction Box
Junction boxes shall be of 16 SWG sheet steel hot-dip galvanized dust and
damp-proof, generally conforming to IP-55.
Junction boxes shall be complete with gasketed inspection cover, conduit knock
out/threaded hub and terminal blocks.
Junction boxes for outdoor use shall be weatherproof IP-55 and those for
hazardous location shall be flame-proof type.
Junction boxes shall have indelible markings of Circuit nos. on top, Circuit nos.
with ferrules (inside) as per drawing, DANGER sign board in case of 415 V circuit.
4.2.12.17 Terminals
Multi-way terminal blocks of approved type, complete with screws, nuts,
washers and marking strips shall be furnished for connection of incoming /
outgoing wires.
Each terminal shall be suitable for connection up to 2 nos. 10 mm sq. stranded
aluminium conductors without any damage to the conductor or looseness of
connectors.
4.2.12.18 Portable Emergency Lighting Unit
The portable emergency lighting unit shall be complete with 6 volt storage battery
(rechargeable), inverter, automatic charger, twin 6 watts fluorescents tube lamp
and test switch. Contractor shall furnish make, type and catalogue.
4.2.12.19 Nameplate
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Nameplates shall be furnished for identification of devices and circuits. All
switches, controls and indications shall be permanently and legibly marked in
English as to their functions.
4.2.12.20 Painting
All sheet steel enclosures shall be chemically cleaned, rinsed, phosphated, rinsed
and dried. After the treatment, steel surfaces shall be given undercoats of primer
and finished with two coats of sprayed on enamel of lacquer of approved shade.
4.2.12.21 Samples
Owner reserves the right to call for samples, if considered necessary, and the
same shall be submitted by the Contractor free and without any obligation.
4.2.12.22 Consumables and Hardware
The Contractor shall furnish all erection materials, hardware and consumables
required for the complete installation.
The materials shall include but shall not be limited to the following:
Consumables - Welding rods & gas, oil and grease, cleaning fluids, paints,
electrical tape, soldering materials etc.
Hardware - Bolts, nuts, washers, screws, brackets, supports, clamps, hangers,
saddles, cleats, sills, shims etc.
Materials - Junction boxes, terminal blocks, connectors, ferrules, lugs, brass
glands, rigid/flexible conduits, cables, ground wires etc.
Supply - cement, sand, stone etc. required for the execution of the contract shall
be the responsibility of the Contractor.
Testing equipment - The Contractor will provide such checking and testing
equipment as test lamp, buzzer, 500-volt meggar, earth meggar, Lux meter,
multi meters etc. and also other testing equipment as required.
4.2.12.23 Specific Requirement - Installation
General
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Installation work shall be carried out in accordance with good engineering
practices and also manufacturer's instructions/ recommendations where the same
are available.
Equipment shall be installed in a neat workmanlike manner so that it is leveled,
plumbed, squared and properly aligned and oriented.
Lighting fixtures
Continuous rows of fluorescent tubes shall be mounted on a continuous M.S.
angle for each row of lights.
Flood lights shall be mounted on steel pole having facility for maintenance and
easy replacement with the help of electric winch. Fixing holes shall be provided
with slots to turn the fixture about 5 deg. on both sides. Bolts shall be finally
tightened with spring washer.
The Contractor shall supply and install the tower and fixtures. The fixtures shall
be adjustable type for selecting the desired direction.
Terminal connection to the floodlight shall be made through PVC flexible
conduits.
The fixtures after erection shall be marked-up indelibly with corresponding circuit
number for easy identification of lamp circuit.
MLDB, EMLDB DCLDB and Lighting Panel
MLDB, EMLDB DCLDB and Lighting panels shall be erected at the locations after
Lighting layout drawing approval.
Street Lighting Poles - Erection of Street Lighting poles together with all its
accessories including civil foundation work, installing lighting fixture, wiring and
cabling work are included within scope of contractor.
Flood Lighting Tower - Erection of Flood Lighting Towers including civil
foundation work shall be done by Contractor. Contractor shall also mount
assembled fixtures, outdoor & lockable type isolating switch cubicle, install
necessary cabling and wiring and make connections.
Conduit System
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In case of un-armoured cable, all G.I. conduits shall originate from the respective
lighting panel and terminate in lighting fixtures, receptacles, etc. Standard
installation procedure shall be followed for cleaning conduits after installation.
Exposed G.I. conduits shall be run in straight lines parallel to building columns,
beams and walls as far as practicable. Unnecessary bends and crossings shall be
avoided to present a neat appearance.
Conduit supports shall be provided at an interval of 750 mm for horizontal runs
and 1000 mm for vertical runs.
Conduits shall be clamped on to approved type spacer plates or brackets by
saddles or U-bolts. The spacer plates or brackets in turn shall be fixed to the
building steel by welding and to concrete or brickwork by grouting.
Wooden plug inserted in the masonry or concrete for conduit support is not
acceptable.
Embedded conduits shall be securely fixed in position to preclude any movement.
In fixing embedded conduit, if welding or brazing is used, extreme care should be
taken to avoid any injury to the inner surface of the conduit.
Spacing of embedded conduits shall be such as to permit flow of concrete
between them and in no case shall be less than 38 mm.
Where conduits are run on cable trays, they shall be clamped to supporting steel
at an interval of 600 mm.
For directly embedding in soil, the conduits shall be coated with an asphalt base
compound. Concrete pier or anchor shall be provided where necessary to support
the conduit rigid and to hold it in place.
Conduits shall be installed in such a way as to ensure against trouble from
trapped condensation.
Running threads shall be avoided as far as practicable. Where it is unavoidable,
check nuts shall be used.
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Conduits shall be kept, wherever possible, at least 300 mm away from hot pipes,
heating device etc. when it is evident that such proximity may impair the service
life of cables.
Slip joints shall be provided when conduits cross structural expansion joints or
where long run of exposed conduits is installed so that temperature change will
cause no distortion due to expansion or contraction of conduit run.
For long run, junction/pull boxes shall be provided at suitable intervals to
facilitate wiring.
Conduits shall be securely fastened to junction box or cabinets each with a
locknut and insulated bushing inside the box and locknut outside.
Conduit lengths shall be joined by screwed couplers. Couplers shall be clearly cut.
Conduits joints and connections shall be made thoroughly watertight and
rust-proof by application of a thread compound which will not insulate the joints.
White lead is suitable for application on embedded conduit and red lead for
exposed conduit.
Field bends shall have a minimum radius of four (4) times the conduit diameter.
All bends shall be free of kinks, indentations or flattened surfaces. Heat shall not
be applied in making any conduit bend.
The entire metallic conduit system whether embedded or exposed shall be
electrically continuous and thoroughly grounded.
Lighting fixture shall not be suspended directly from junction box in the main
conduit run.
Conduits and fittings shall be properly protected during construction period
against mechanical injury. Conduits ends shall be plugged or capped to prevent
entry of foreign material.
After installation, the conduits shall be thoroughly cleaned by compressed air
before pulling in the wire.
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Wiring
Wiring shall be generally carried out by HR PVC FRLS wires in conduits. All wires
in a conduit shall be drawn simultaneously. No subsequent drawing is
permissible.
Wire shall not be pulled through more than two equivalent 90 bends in a single
conduit run.
Wiring shall be spliced only at junction boxes with approved type connections or
terminal strips. Maximum two (2) wires can be connected to each way of the
terminal block.
For lighting fixtures, connection shall be teed of through suitable round conduit
or junction box so that the connection can be attended without taking down the
fixture.
For vertical run of wires in conduit, wires shall be suitably supported by means of
wooden/hard rubber plugs at each pull/junction box.
A.C. and D.C. circuits shall not be run in the same conduit.
Receptacle sub-circuits shall be kept separate and distinct from lighting and fan
sub-circuits.
Separate neutral wire shall be provided for each circuit. Wiring throughout the
installation shall be such that there is no break in the neutral wire
Cabling
In outdoor areas, main runs shall be by means of armoured cable laid in trenches
or directly buried in ground.
Buried cables shall be laid and covered with sand/riddled earth and protected
from damage by bricks at sides and pre cast concrete slab at top.
When buried cables cross road / railway track, additional protection to be
provided in form of hume / G.I. pipe / RCC box culvert.
4.2.12.24 Grounding
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All lighting boards/panels, junction boxes, receptacles, fixtures, conduit Lighting
Poles, Lighting mast (Tower) etc. shall be grounded in compliance with the
provision of I.E. Rules.
Ground connections shall be made from nearest available ground grid. All
connections to ground grid shall be done by arc welding.
Lighting panels shall be directly connected to ground grid by two (2) nos. G.I. flats
and lighting distribution boards by two (2) nos. G.I. flats of adequate sizes.
A continuous ground conductor of 16 SWG G.I. wire shall be run all along each
conduit run and bonded to it every 600 mm by not less than two turns of the
same size of wire. These conductors shall be connected to each panel ground bus.
All junction boxes, receptacles, fixtures, etc. shall be connected to this 16 SWG
ground conductor.
4.2.12.25 Excavation and Back Filling
The Contractor shall perform all excavation and backfilling as required for buried
cable and ground connections.
Excavation shall be performed up to the required depth. Such sheeting and
shorting shall be done as may be necessary for protection of the work.
The Contractor shall make use of his own arrangements for pumping out any
water that may be accumulated in the excavation.
4.2.12.26 Steel Fabrication
All supports, hangers & brackets shall be fabricated by the Contractor.
Necessary steel shall be supplied by the Contractor.
Steel for fabrication shall be straightened and cleaned of rust and grease. All
fabrication shall be free of sharp edge.
All excavation shall be backfilled to the original level with good consolidation.
4.2.12.27 Foundation & Civil Works, Structural Work
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All structures for equipment, towers, gantries, lighting poles, necessary
foundation, etc. shall be provided by the Contractor.
Any cutting of masonry/concrete work, which is necessary, shall be done by the
Contractor at his own cost and shall be made good to match the original work.
The Contractor shall obtain approval of the Owner before proceeding with any
cutting of masonry/concrete work.
4.2.12.28 Painting
Streetlight poles / flood light towers shall be given two coats of aluminium paints
after installation.
All steel fabrication shall be given two coats of redoxide primer followed by epoxy
finish coating to shade 631 of IS 5.
All equipment shall be given touch-up paint as required after installation.
4.2.12.29 Energy Conservation Measures in Design Stage
All accessories related to illumination system including lamp, ballast, igniter,
reflectors should be inline with latest energy efficient one. The maximum possible
energy conservation measures should be adopted in the illumination system but
not limited to the following
Fluorescent Lamp should be 5 star label according to Bureau of Energy
Efficiency (BEE)
Electronic ballast should be used for the fluorescent and CFL
Energy efficient reflectors
Higher efficacy (lumens per Watt) lamps wherever possible
Timer control for street light
Energy efficient lighting transformer
Panel lamps should be LED
CFL / Energy efficient lamp instead of Incandescent lamp wherever applicable
4.2.12.30 Standards
All equipments provided under the specification shall in general, conform to the
latest issue but not limited to the following:
S.N
a)
IS code
IS:1913
Description
Electric Lighting Fittings General and Safety
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S.N
IS code
Description
Requirements
b)
IS:6665-1972
Code of Practice for Industrial Lighting
IS:3646 (Part-
Calculation of Co-efficient of Utilization
IS:1777
Industrial Lighting Fittings with Metal
III)
c)
Reflectors
d)
IS:5077
Decorative Lighting Outfits
e)
IS:4012
Dust Proof Electric Lighting Fittings
f)
IS:4013
Dust Tight Electric Lighting Fittings
g)
IS:8224
Electric Lighting Fittings for Division
2 Areas as per IS:5572 (P1)
h)
IS:4013
Flame Proof Lighting Fittings
Part I and II
i)
IS:2148
Flame Proof Enclosure
j)
IS:11322
Flood Lights
Pt-V SECT-5
k)
IS:11322
Luminaires for Street Lighting
Pt-V SECT-3
l)
IS:3528
Waterproof Electric Lighting Fittings
m)
IS:3553
Watertight Electric Lighting Fittings
n)
IS:1258
Bayonet Lamp Holders
o)
IS:11276
Edison Screw Lamp Holders
p)
IS:3323
Bi-Pin Lamp Holders for Tubular Fluorescent Lamps
q)
IS:2215
Starters for Fluorescent Lamp
r)
IS:3324
Holders for Starters for Tubular Fluorescent Lamps
s)
IS:1534 (Part
Ballast for Use in Fluorescent Lighting Fittings
1)
t)
IS:7027
Transistorized Ballast for Fluorescent Lamps
u)
IS:6616
Ballast for HP Mercury Vapor Lamp
v)
IS:1569
Capacitors for Use in Fluorescent, HPMV and LP
Sodium Vapor Discharge Lamp Circuits
w)
IS:8017
Vitreous Enamel Reflector for Tungsten Filament
Lamp
x)
IS:2418 (Part
Tubular Fluorescent Lamps
1)
y)
IS:9900
High Pressure Mercury Vapour Lamps
z)
IS:418
Tungsten Filament General Electric Lamps
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S.N
IS code
Description
aa)
IS:7569
Cast Acrylic Sheets for Use in Luminaires
ab)
IS:11322 Pt-III
Screw less Terminal and Electrical Connections for
Lighting Fittings
ac)
IS:9974
High Pressure Sodium Vapor Lamps
ad)
IS:9583
Emergency Lighting Units
ae)
IS:11105
Ignition Proof Enclosures, Dust-Tight for Electrical
Equipment
af)
IS:11322
Luminaires (Part 1 to V)
ag)
IS 5578
Arrangement for Bus bars, Main Connections and
IS 11353
Auxiliary Wiring and Marking
ah)
IS 4237
General Requirements for Switchgear and Control
gear for Voltages not exceeding 1100V
ai)
IS 11118
Code of Practice Installation and Maintenance of
Switchgear
aj)
IS 8623
Factory Built Assemblies of Switchgear and Control
gear for Voltages up to and including 1100 V AC and
1200 V DC
ak)
IS 13947
Degree of Protection of enclosed equipment for Low
Voltage Switchgear and Control gear
al)
IS 13947
Part-3
Switches, Disconnectors, Switch Disconnectors and
Fuse Combination Units for Low Voltage Switchgear
and Control gear
am)
IS 8828
Miniature Air Break Circuit Breakers for AC Circuits
an)
IS 2705
Current Transformers
ao)
IS 3156
Voltage Transformers
ap)
IS 1248
Direct Acting Electrical Indicating Instruments
aq)
IS 722
AC Electricity Meters
ar)
IS 3231
Electrical Relays for Power System Protection
as)
IS 2148
Flameproof Enclosures of Electrical Apparatus
at)
IS 5571
Guide for Selection of Electrical Equipment for
au)
IS 3854
Switches for Domestic and Similar Purposes
Hazardous Areas
av)
IS 1293
Three-Pin Plugs and Socket Outlets
aw)
IS 374
Fans and Regulators, Ceiling Type, Electric
ax)
IS 9537
Rigid Steel Conduits for Electrical Wiring
ay)
IS 3837
Accessories for Rigid Steel Conduits for Electrical
Wiring
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S.N
IS code
Description
az)
IS 3480
Flexible Steel Conduits for Electrical Wiring
ba)
IS 9537
Rigid Non-Metallic Conduits for Electrical Installations
Part-2
bb)
IS 3419
Fittings for Rigid Non-Metallic Conduits
Part-2
bc)
IS 694
PVC Insulated Cables for Working Voltages up to and
including 1100 V
bd)
IS 2713
Tubular Steel Poles
be)
IS 5082
Wrought Aluminium and Aluminium Alloys, Bars,
Rods, Tubes and Sections for Electrical Purposes
bf)
IS 6005
Code of Practice for Phosphating Iron and Steel
bg)
IS 2667
Fittings for Rigid Steel Conduits for Electrical Wiring
bh)
IS 13158
Pre stressed Concrete Circular Spun Poles for
Overhead Power, Traction and Telecommunication
Lines
bi)
IS 2905
Methods of Test for Concrete Poles for Overhead
Power and Telecommunication Lines
Equipment complying with other internationally accepted standards such as IEC,
BS, ANSI, VDE etc. will also be considered if they ensure performance and
constructional features equivalent to or superior to standards listed above. In
such a case, the Bidder shall clearly indicate the standards adopted, furnish a
copy in English of the latest revision of the standards along with copies of all
official amendments and revisions in force as on date of opening of bid and
shall clearly bring out the salient features for comparison.
Installation work shall also conform to Indian Electricity Act and Indian Electricity
Rules as amended up to date.
4.2.12.31 Tests
Routine Tests
During manufacture and on completion, all equipment and accessories shall be
routine tested as per applicable clause of relevant Indian Standards at
manufacturer's works.
Additional Tests on Cable
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To prove the fire resistant characteristics, and rodent and termite repulsion
property, each type of cable shall also be subject to the following additional type
tests at works;
Oxygen index test as per ASTM D 2863. Minimum vale of oxygen index shall be
30.
Flammability test on finished cables as per the requirement of IEEE-383, IEC332-1 and Swedish standard SS 4241475 clause F3.
Smoke generation by outer sheath under fire as per ASTM D 2843. The cables
shall meet the requirements of light transmission of minimum 40% after the test.
The test shall be carried out by extrapolation method beyond temperature at
which the material of sheath may start deformation as per BICC handbook
chapter-6 on cable in fire. The minimum value of temp. index shall be 250 Deg.
C.
Acid gas generation by outer sheath under fire as per IEC-754-1 and the
minimum acid gas generation shall be less than 20% by weight.
Test for rodent & termite repulsion property
The Test shall be carried out to note the presence of rodent and termite
repelling chemical in PVC compound. Normal procedure is that a few chipping of
the PVC compound are slowly ignited in a porcelain dish on crucible in a muffle
furnace at about 600 Deg. C. The resulting ignited ash is boiled with a little
ammonium acetate solution (10%). A drop of aqueous sodium sulphide solution
is placed on a thick filter paper and it is allowed to soak. The spot is touched
with a drop of above extract. A black spot indicates the presence of anti-termite
and rodent compound.
Type Tests
Type test (as indicated in Cable specs) certificates for type tests & as stipulated
in Indian Standard carried out on similar equipment shall be furnished by the
Bidder along with his offer.
All equipment shall be demonstrated to operate in accordance with the
requirements of this specification.
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4.2.13
Installation / Erection
4.2.13.1 Design criteria
Equipment erection
All equipment, conductors, hardware, insulators & clamps etc. will be installed
outdoor in a hot, humid & tropical atmosphere. All erection work shall be carried
out in a neat and efficient way so as not to impair their normal functioning in
any way.
The maximum temperature in any part of the clamps, connectors, conductors etc.
at specified rating shall not exceed the permissible limits as stipulated in the
relevant standards.
All equipment, conductors, clamps, connectors, insulators etc. shall be capable of
withstanding the dynamic & thermal stresses of maximum short circuit current
without any damage or deterioration.
In order to avoid concentration of stresses, all sharp edges of clamps, connectors
etc. shall be rounded off. Bi-metallic connectors shall be used for any connection
between dissimilar materials.
Expansion joints shall be provided in the Aluminium tube bus system, whenever
necessary, to eliminate undue stresses on the equipment terminals and post
insulator stacks.
Erection of cabling work shall be carried out in such a way as to provide a
reliable and assured electric power supply to all equipment. The proper fire
sealing as per relevant standard is under the scope of the bidder. The grounding
system shall comply with Indian Electricity Rules, I.S. specifications & I.S. Code of
Practice.
4.2.13.2 General Requirements
Codes and Standards
All materials and accessories shall be designed, manufactured and tested in
accordance with the latest applicable Indian Standard (IS) except where modified
and/or supplemented by this specification.
The electrical installation shall meet the requirements of Indian Electricity Rules
as amended up to date and relevant IS codes of Practice and Indian Electricity
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Act. In addition, other rules or regulations applicable to the work shall be
followed. In case of any discrepancy, the more restrictive rule shall be binding.
Completeness of Supply
It is not the intent to specify completely herein all detail of the equipment.
Nevertheless, the equipment shall be complete and operative in all aspects and
shall conform to highest standard of engineering, design & workmanship.
Any material or accessory which may not have been specifically mentioned but
which is necessary or usual for satisfactory and trouble-free operation and
maintenance of the equipment shall be furnished without any extra charge.
The Contractor shall supply all brand new equipment, material and accessories
as specified herein with such modification and alteration as agreed upon in
writing after mutual discussion.
Erection Schedule
The entire erection work shall be carried out in a phased manner. A schedule of
the work showing the sequence of erection shall be submitted by the bidder to
the Owner for his approval.
The erection schedule, as approved by the Owner's Engineer shall be strictly
followed by the erection Contractor. If, for any reason beyond the control of the
Contractor, the work is held-up then the Contractor shall bring it to the notice
of the Owner's Engineer without any delay.
4.2.13.3 Detailed Requirements
Equipment & Materials
Equipment and materials furnished shall be complete & operative in all details.
All accessories, fittings, supports, hangers anchor bolts etc. which form part of
the equipment or which are necessary for safe and satisfactory installation and
operation of the equipment shall be furnished.
All parts shall be made accurately to standard gauges so as to facilitate
replacement and repair. All corresponding parts of similar equipment shall be
interchangeable.
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After the treatment of steel surfaces damaged during transit sufficient quantity
of anti-corrosive paint shall be applied and subsequently finished with two coats
of final paint of approved shade.
Cable Trays
Ladder type cable trays shall be pre-fabricated sheet steel, minimum 2.5 mm
thick, with hot dip galvanized (zinc coating not less than 610g/sq. m).
The sizes of the trays shall be as follows:
i.
300 mm wide & 100 mm deep.
ii.
450 mm wide & 100 mm deep.
iii.
600 mm wide & 100 mm deep.
The straight sections shall be supplied in 2.5m standard length.
Cable trays shall be complete with all necessary hot dip galvanized accessories
such as, coupler plates, ground continuity connections, nuts, bolts, washers
hangers, clamps, supports, horizontal/vertical bends, tee, reducers etc.
Conduits & accessories
Conduits shall be of rigid steel, hot dip galvanized, furnished in standard length
of 3 metres, threaded at both ends.
Conduits up to and including 25 mm size shall be of 16 SWG & conduits above
25 mm diameter shall be of 14 SWG. Minimum diameter of conduits shall be 19
mm.
Each piece of conduit shall be straight, free from blister & other defects, internal
surface shall be of smooth finish & covered with capped bushings at both ends.
Flexible conduits shall be made with cold rolled, annealed & electro-galvanized
mild steel strips coated internally with epoxy and externally PVC.
Cable Termination & Jointing Kits
The contractor shall supply cable termination & jointing kits for HT/L.T. power
and control cables along with all accessories of RPCL approved make only.
For the cable termination and straight through joints both HT/L.T. power and
control cables, supply of items of jointing kit such, as, necessary boxes, if any,
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sealing compounds, ferrules, tapes, lugs, glands, shall be of reputable make
approved by RPCL.
Cable Glands
Cable glands shall be nickel plated brass gland, double compression heavy duty
type complete with necessary armour clamp and tapered washer etc. Cable
glands shall match with the sizes of different HT/L.T. power, control &
Instrumentation cables.
Cable lugs
Cable lugs shall be heavy duty tinned copper suitable for termination of different
cross-section of HT/L.T. power, control & Instrumentation cables of AL & CU
conductor. Lugs for power, control & Instrumentation cables shall be crimping
type.
Cable Opening Sealing Compound
Sealing compound shall have adequate fire protection rating and shall be RPCL
approved fire seal type or approved equivalent suitable for sealing both vertical
and horizontal cable penetrations through wall in control Building. The sealing
compound shall form effective fire seals. The sealing compound shall have
special property to allow for thermal expansion of cables both under normal and
short circuit conditions.
Grounding Materials
All materials for grounding work like earth mat, risers, structure and equipment
connections, shield wire etc. shall be supplied by the Contractor.
Specific Requirements - Services
Responsibility of erection
The Contractor shall be fully and finally responsible for proper erection, safe and
satisfactory operation of plant and equipment under his scope of work to the
entire satisfaction of the Owner.
The work shall be executed in accordance with the directions, instructions,
approved drawings and specifications.
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Equipment and material which are wrongly installed shall be removed and reinstalled to comply with the design requirement at the Contractors expense, to
the satisfaction of the Owner without any cost implication to Owner.
Extra Work
The Contractor shall, when requested by the Owner, perform extra work and
furnish extra materials not covered under his scope of work, but necessary to
complete the installation without any price implication.
Methods and Workmanship
All work shall be installed in a first class, neat workmanlike manner by
mechanics/electricians skilled in the trade involved. The erection work shall be
supervised by competent supervisors preferably holding relevant supervisory
license from the Government.
All details on installation shall be electrically and mechanically correct. The
installation shall be carried out in such a manner as to preserve access to other
equipment installed.
Protection of Work
The Contractor shall effectively protect his work, equipment and materials under
his custody from theft, damage or tampering. Finished work where required
shall be suitably covered to keep it clean and free from defacement or injury.
For protection of his work Contractor shall provide fencing and lighting
arrangement, connect up space heaters and provide heating arrangement as
necessary or directed by the Owner. Contractor shall be held responsible for any
loss or damage to equipment and material issued to him until the same is taken
over by the Owner according to Contract.
Contractor shall insure his entire workman against accidental injury/ death. The
Contractor shall also takeout insurance policies which would cover the risk of
losses / damages of his tools & tackle and material/equipment which is in his
custody as also loss/ damages to any personnel.
Safety Measure
All safety rules and codes as applicable to work shall be followed without
exception. All safety appliance and protective devices including belts, hand
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gloves, aprons, helmets, shields, goggles etc. shall be provided by the
Contractor for his personnel.
The Contractor shall provide guards and prominently display caution notices if
access to any equipment/area is considered unsafe and hazardous.
Co-operation
The Contractor shall at all times work in close coordination with the Owners
supervising personnel and afford them every facility to become familiar with
erection and maintenance of the equipment.
The Contractor shall arrange his schedule of work and the method of operation
to minimize inconvenience to other Contractors working on the project. In case
of any difference between Contractors, the decision of the Owners Engineer
shall be final and binding on all parties concerned.
Erection programme and progress
The Contractor shall submit at such times and in such forms as may be
requested by the Engineer, schedule showing the programme and the order in
which the Contractor proposes to carry out the work with dates and estimated
completion time for various parts of the work.
Such schedules shall be approved by the Owner prior to starting the erection.
The Contractor shall adhere to this approved programme for all practical
purposes. If for any reason the work is held up, the Contractor shall bring it to
the attention of the Owner in writing without any delay.
During the progress of work the Contractor shall submit monthly progress
report and such other reports on erection work and organisation as the Owner
may direct.
If in the opinion of the Owner the progress of erection work by the Contractor at
any stage needs expediting so as to ensure completion of work within stipulated
time, the Owner shall have the right to instruct the Contractor to increase
Contractors manpower in appropriate categories and/or the working hours per
day and/or erection tools and tackles and the Contractor shall comply with such
instruction forthwith.
Consumables and Hardware
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The Contractor shall furnish all erection materials, hardware and consumables
required for the complete installation.
The Materials shall include but not limited to the following:
a)
Consumables :Welding rods & gas, oil and grease, cleaning fluids, paints,
electrical tape, soldering materials, cleaning cloths, cotton waste etc.
b)
Hardware:Bolts, nuts, washers, screws, brackets, supports, clamps,
hangers, saddles, cleats, sills, shims ferrules, socket, PVC sleeve, cotton
thread, adhesive / non adhesive PVC tapes, anchor fasteners etc.
Erection Tools & Tackle
The Contractor shall provide all tools, tackle, implements, mobile equipment
such as crane, trailers, scaffoldings, ladders, welding machines, gas cutting,
bending machine, hand cart, chain pulley blocks wire clues, hydraulic jack /
motorized jack, wooden slipper, drill machine, hand / hydraulic compression
tools for cable termination, vacuum cleaners box spanner of various size etc.
which are required for transportation, handling and erection of the plant and
equipment.
Special erection tools, if any & if supplied by the manufacturer along with the
equipment may be used by the Contractor. Such tools shall be returned in good
conditions to the Owner on completion of work. Owners tools and equipment
may be made available on payment of charges if and when available.
Testing Equipment
The major testing equipment that are required to be provided by the Contractor
are listed below:
a)
Power operated Megger of 2.5 kV, 5 kV & 10 kV grade for Insulation
testing.
b)
Hand operated Megger of 500 V & 1 kV grade for Insulation testing and
5000 V motor operated Megger for power circuits, bus bars connections
above 11 kV
c)
Hand driven earth resistance Megger of range 0-1/3/30 ohms.
d)
Tong testers of suitable ranges.
e)
High potential test set suitable for 3.3 kV and 415 V (A.C.)
f)
Contact Resistance measuring set for Micro-ohms.
g)
Torque Wrench of various sizes.
h)
Current Transformer Primary injection set.
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systems.
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i)
Relay testing and checking bench including phase shifter, secondary
injection set, meters etc.
j)
Multimeters, test lamp, field telephone with buzzer set, walkie-talkie,
spirit
level,
continuity
tester,
db-meter,
phase
sequence
tester,
different gauges etc.
k)
Tan delta test kit
Other testing equipment as required shall also be arranged by the Contractor.
Taking Delivery
The Contractor shall make his own arrangement to store all the materials
supplied by him. Materials delivered shall be stored or brought to the erection
site or erected as necessary.
The Contractor shall submit a detailed account of materials after completion of
work and transport back the excess materials to Owners stores.
Opening of Case
All packing cases and packages shall be opened in presence of Owner or his
authorized representatives. Packing cases shall be opened carefully to avoid
damage to timber. Nails and strips shall be collected separately in boxes and not
to be thrown away at random.
All packing materials, timbers, nails and strips shall become property of the
Owner and shall be delivered to the Owner or disposed of as directed by the
Owner.
Checking and Cleaning of Parts
All equipment, accessories and materials shall be carefully inspected and
checked with packing list and identified with the erection drawings. All parts
shall be thoroughly cleaned, all rust removed and surface polished as required.
Cleaned and polished parts shall be coated with anticorrosive paints where
necessary and stored with care, ready for erection.
4.2.13.4 Installation - General
Installation work shall be carried out in accordance with good engineering
practices and also manufacturers instructions/ recommendations where the
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same are available. All necessary jobs required for statutory clearances will
under Bidders scope.
Equipment shall be installed in a neat workmanlike manner so that it is level,
plumb, square and properly aligned and oriented. The contractor shall assemble
all equipment furnished in disassembled condition at site, mount and wire-up
loose equipment, fittings and accessories and complete all connections.
The Contractor shall ensure that instruments and gauges to be used for testing
and inspection have valid calibration and the accuracy can be traced to National
Standards.
The Contractor shall design, fabricate and supply the supporting structures,
base frame, holding down bolts etc, as required, of all equipments. All erection
work shall be carried out in strict compliance with manufacturers instructions
and shall include all necessary adjustments, checks and measurements.
It shall be the Contractors responsibility to obtain valid license and approval
from local statutory authorities including Electrical Inspector/CEA, wherever
applicable, for carrying out any work or for installation carried out which comes
under the purview of such authorities. The entire cost, including all necessary
fees, incurred to obtain such license and approvals, shall be borne by the
contractor.
It is the responsibility of the Contractor to provide watch & ward and security for
the equipment / component parts covered in this contract.
The Contractor shall ensure workmanship of good quality and shall assign
qualified supervisors/Engineers and competent labour who is skilled having
valid licence/authorisation/work permit, careful and experienced in carrying out
similar works. The Purchaser/Engineer shall reserve the right to reject noncompetent person employed by the Contractor, if the workmanship is not found
satisfactory. Wherever required the Contractor shall include loaning of
skilled/unskilled personnel for work by Purchaser/other agencies, on Man-hour
/ Man day rates, for normal & overtime work to meet the project schedule.
All internal wiring of the equipment which has been left incomplete because of
shipping split or which requires minor modifications shall be carried out by the
Contractor. The Contractor shall record results of all erection tests and
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measurements. The Contractor shall submit copies of those test results to the
Owner for his reference and record.
It shall be the responsibility of the Contractor to obtain necessary Licence/
Authorization/permit for work for his personnel from the Licensing Board of the
locality/state where the work is to be carried out. The persons deputed by the
Contractors firm should also hold valid permits issued or recognised by the
Licensing Board of the locality/state where the work is to be carried out.
4.2.13.5 Installation Work Scope
Temporary Lighting arrangement for the work Area
The Contractor shall on his own arrange for the temporary lighting arrangement
for the work area to carry out the installation work in the plant premises.
Construction Power
Construction power for construction activities only will be made available at one
point & suitable number of outlets to cater to all the requirements shall be
derived by the Contractor.
The construction power supply will be 11 kV, 3 Phase, and 50 Hz.The
Construction Power system by its design and nature shall be a temporary system
and not part of the permanent power supply. The Contractor acknowledges that
electricity sourced may be unreliable in quality and availability and its
interruption or non-availability or variations in supply voltage of frequency for
any reason shall not constitute a condition for claim of extra time or costs on
part of the Contractor. Further, Contractor shall be responsible for making
necessary arrangements to ensure that uninterrupted Construction Power supply
(DG sets) is available.
Without limiting the generality of the foregoing, such temporary supplies of
Construction Power shall include without limitation:
a) Power for all construction offices or trailers, temporary warehouses and
storage areas, and other temporary buildings used during the performance
of the Work.
b) Power for temporary equipment put in place until such time as permanent
Plant Power supply systems are installed. Such temporary equipment shall
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include temporary construction lighting on buildings and power to cranes
and hoists.
c) Power utilised by Contractor and sub-contractor on the Site for the purposes
of performance of the Work such activities to include curing, welding,
forming, stress relieving and provision of power for all electrical construction
equipment.
d) Other requirements of construction power as set-forth in the Bid Documents.
Installation of Transformer
The
transformers
and
their
accessories
and
mountings
like
radiators,
conservator, Silica-gel breathers, marshalling box, rollers etc shall be assembled
at site after cleaning by the contractor in proper sequence as per manufacturers
drawings.
Contractor shall place the transformers on the channel at the location indicated
in the layout drawing of outdoor yard. Suitable stoppers shall be provided both
in front as well as rear of transformer to keep it stationary in its position. For the
front wheels such stoppers shall be screwed on the channels.
BDV of the transformer oil shall be tested before energisation of power
transformer. Drying out of transformer shall be carried out to get required
dielectric strength as per relevant Indian Standards.
Oil shall be filled up to the mark shown.
Wherever the power/control cables project above the ground, for termination to
cable box/marshalling box, the same shall be run in GI pipes of suitable cross
section upto the height of 2.0 m from ground and the same shall be supported
properly and pipe ends shall be sealed with bitumen compound.
The contractor shall ensure the following checks on the Transformers:
Physically checking and inspecting, paying particular attention to the
following components to ensure that the same are in sound conditions;
o
Tank sides or cooling tubes
Protruding fittings
Oil sight glass
Bushings
Tightness of Bolts
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Oil leakage
Transportation to erection site
Proper erection on foundation/channels
Assembly of transformer
Checking of oil level filtration / drying of oil
Alignment
Anchoring and tack welding
Mechanical Work
Laying, meggaring, termination, dressing and clamping of cables
Tagging and marking of cables
Testing of cables
Earthing of transformers, earthing strip, earth resistance to comply with IER
(latest revision)
Testing of assembled plant
Testing and calibration of meters, relays, CTs, PTs, etc.
Connection of busbars/cables to primary and secondary of transformers
Series of tests on transformers as per engineers instructions.
IS 1886 and manufacturers recommendations.
Note: All high voltage tests shall comply with IS 2071 Part I and II and all works
in connection with the transformers shall comply with IS 1886 and IER
(latestrevision).
Interconnection of Equipments
The arrangement of connections shall be such that the connected apparatus are
not subjected to any mechanical stress due to expansions, contractions etc., of
the connections.
The connections shall ensure good electrical contact. The connector and joints
shall be rigid to withstand all mechanical and electrical stresses. Suitable
bimetallic clamps shall be used for all the connections between the conductors
of different materials.
All live parts shall have sufficient practical clearances from earthed parts and
ground. The clearances of strung busbar shall be decided considering the effect
of sag.
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The contractor shall be responsible for supplying and installing the various
conductors required for connection of the various equipment. The tenderers
scope shall include all bolts, nuts and washers required for installation. All
connections etc., shall be so made that stress between connecting terminals will
be reduced to the minimum.
The physical layout of the system shall be such that the system extension or
conversion can he carried out with minimum changes and easy methods.
Further, it shall be ensured that all civil works for the foundations are completed
by the agency before taking up erection of structure.
Installation of Switchgear Panels
The base frame of all panels shall be welded to the structures or to the civil
inserts provided on the floor. Fabrication of support/frames, wherever required,
shall be done by the contractor.
The shipping section shall be placed in position before removing the protective
covering to eliminate scratch/damage. The shipping section shall be moved by
using rollers under the shipping skids wherever lifting cranes are not available.
The contractor shall do the assembly at site as per the manufacturers General
Arrangement drawings and installation instructions. While assembling a
complete board comprising several unit type cubicles, the board as a whole shall
be aligned.
The panels shall be properly leveled prior to grouting the holding down bolts or
welding the panels to the inserts. All interconnection of the bus-bars and wiring
between the panels shall be done as per manufacturers instructions and
drawings. Welding work on the panels shall only be carried out after
consultation with the purchaser. Damage to the paint during welding shall be
rectified by the contractor.
After mechanical installation of the board is completed, instruments shall be
installed wherever required and wires shall be connected to the instruments. The
wiring
of
intermediate
terminal
strips
between
disconnected for transport, shall also be connected.
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two
panels,
wherever
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Installation of Grounding / Earthing
Entire system shall be earthed in accordance with the provisions of the
relevant IEC recommendations/ IS code of practice IS 3043-1987 and Indian
Electricity rules.
The principal requirements of the grounding are:
o
o
Low resistance and adequate current carrying capacity.
Uniform and near uniform ground potential on all structural metal
work on all metal enclosures and/ or supports of equipment and
apparatus.
The resistance of earthing network shall be less than 0.5 ohm.
The contractors scope of installation will also include all the civil works
associated with complete earthing network.
All earth connections shall ensure a permanent low resistance contact. Earth
connections required to be removed for the purpose of testing of
equipment/ earthing network shall have bolted connections and joints
fastened. All earthing connections shall be visible for inspection.
Lightning arrestors and transformer neutral shall be connected to two
independent earth electrodes as per IS 3043 (as applicable).
Air termination rods of lightning protection systems shall be connected to
earthing network as per IS 3043 (as applicable).
The grounding connection to the lightning arrestors, air termination points
of lightning protection system shall be as short as possible. Sharp turns in
these conductors shall be avoided.
It has to be ensured that main earth bus in the installation as well as earth
buses in individual sections/areas shall form complete ring and they shall be
interconnected.
Duplicate earthing (two separate and distinct connections with earth) shall be
employed for all equipments.
Wherever burying of earth conductors is specified, they shall be buried as per
approved drawings.
Wherever any earth conductor crosses the road, it shall be taken through GI
pipes.
At all the terminations of earth conductors on equipments, sufficient length
shall be left for any movement of the equipment from its position for
alignment purpose.
Wherever not detailed, the route of the conductor and location of the earth
pit shall be arranged so as to avoid obstruction, crossing etc, according to
convenience at site and shall be got approved by the owners representative
in-charge of the works.
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Installation of Earth Pits
The arrangement of earth electrode/ pit shall be as shown in IS 3043.
Termination arrangement of interconnecting earth strips is included in the
scope of earth pit. Interconnecting earth flats shall be jointed by welding to
the termination arrangement on the electrode. Electrode will be 50 mm dia GI
pipe of 3 m length medium class, in a single piece.
The distance between two pits shall be at a minimum distance of twice the
length of electrodes.
All accessories required for the earth pits such as electrodes, charcoals, salt,
clamps, clips, bolts/ nuts washer, GI pipes, funnel cast iron cover and also
the masonary works of the pits including supply of necessary materials,
bricks, cement and excavation of earth for providing earth pits shall be part
of the scope.
The electrodes shall be well packed with earth, charcoal and salt mix up to
the level of connections.
Joints/Terminations of Earth Strips
All joints of bare galvanised earth strips shall be welded so as to form rigid
earth ring. All such welded joints shall be given necessary coating of cold
galvanized paint as per relevant standards and a coat of suitable bitumen
compound to prevent corrosion.
In case the joints are made by using suitable connectors the entire joint shall
be fully sealed by suitable compound so that no metallic part is exposed.
The contractor shall make his own arrangements for necessary crimping
tools, soldering equipments drilling machines and other tools and tackles
which are necessary for completing the installation.
Installation Bus duct
Bus ducts (Segregated / non-segregated) shall be erected by the Contractor in
accordance with specified code of practice, manufacturers instructions. Indoor
portion of the busduct may be supported from the floor or ceiling beams and
outdoor portion of the busduct shall be supported from ground below on
suitable foundation. Wall frame assembly shall also be installed as per
Contractor's drawings, wherever called for.
Motors
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The installation, commissioning of the motors shall be as per the applicable
code of practice and the Manufacturers instructions.
Battery and Chargers
Each cell of the battery bank shall be inspected for breakage and condition of
cover seals as soon as received at site. Each cell shall be filled with electrolyte in
accordance with the Manufacturers instructions. Battery shall be set up on racks
as soon as possible after receipt, utilizing lifting devices supplied by the
MANUFACTURER. The cells shall not be lifted by the terminals.
Installation - Neutral Grounding Equipment
The Contractor shall install, test and commission the neutral grounding
equipment (NGR etc.) as per MANUFACTURERs instructions/relevant codes and
standards.
Installation - Cabling
General
Cable installation work shall mean supply and erection of cable trays/racks,
supports, hangers, junction boxes, conduits, laying of cables either in ground or
on trays inside trenches, tunnels, overhead trays, in conduits etc. dressing and
clamping, jointing inclusive of supply of necessary jointing kits, lugs, glands,
ferrules, tapes etc. and other accessories, grounding of cable armour. In case of
direct laying in ground, all excavation work, necessary back-filling, supply of
bricks and protective concrete slabs, removal of excess earth shall be part of the
installation work.
Grounding installation work shall mean supply and erection of grounding
materials, jointing/brazing/welding, connection and painting, testing of ground
conductors.
Cable Trays
Pre-fabricated cable trays and accessories shall be assembled & erected at site
as per instructions of Manufacturer.
Cable trays either inside concrete trenches or inside buildings and racks inside
cable shafts shall be aligned and leveled properly. All tray runs shall be installed
parallel to the trench/building walls and floors except otherwise noted in the
drawings.
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Steel inserts will be provided / embedded by contractor in wall/floor/ceiling
surfaces. The Contractor shall have to secure rack/tray supports by welding to
those inserts or other available building steel surfaces. Inserts are to be supplied
by the vendor.
In case of non-availability of embedded steel inserts in certain tray routes, the
Contractor shall have to secure the supports on wall/floor/ceiling surfaces by
suitable anchoring system having adequate load bearing capability & anchor
fastener to be supplied by the vendor.
As far as practicable, cable trays shall be supported from one side only in order
to facilitate installation and maintenance of cables from the other side. The
cable trays shall be supported in general at a span of 1000mm.
Sufficient spacing generally 300 mm but not less than 275 mm shall be provided
between trays and maintained to permit adequate access, for installing and
maintaining the cables.
Cable, Conduit & Accessories
The contractor shall install, terminate and connect all cable and conduits as per
approved layout drawings and approved cable schedules. The approved
drawings shall be strictly followed except where obvious interference occurs. In
such cases, the routing shall be changed as directed and/or approved by the
Owner
The Contractor shall also maintain and submit when requested, a record of cable
insulation value when drawn from store, after laying, before and after
termination/ jointing. Conduit/pipes shall be used only in short lengths in
certain areas where required and/or as directed by the Owner. The Contractor
shall furnish all conduits complete with accessories as required.
Conduits shall be flexible or rigid depending upon nature of application. Except
for inside an enclosure wherever the cable enters or leaves the conduit, the
conduit shall be sealed by suitable sealing compound having fire withstand
capability.
Cables - Storage and Handling
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Cable drums shall be stored on hard and well-drained surface so that they may
not sink. In no case shall the drum be stored on the flat, i.e. with flange
horizontal.
Rolling of drums shall be avoided as far as practicable for short distance; the
drums may be rolled provided they are rolled slowly and in proper direction as
marked on the drum. In absence of any indication, the drums may be rolled in
the same direction as it was rolled during taking up the cable.
For unreeling the cable, the drum shall be mounted on jacks or on cable wheel.
The spindle shall be strong enough to carry the weight without bending. The
drum shall be rolled on the spindle slowly so that the cable should come out
over the drum and not below the drum.
While laying cable, cable roller shall be used at an interval of 2000 mm. The
cables shall be pushed over the roller by a gang of people positioned in between
rollers over a suitable distance. Cable shall not be pulled from the end without
having intermediate pushing arrangement. Bending radius of the cable during
installation shall not be less that what is specified by the manufacturer.
Cable laying
Cable shall be installed in ladder type trays except for some short run in rigid /
flexible conduit for protection or crossings. Cables laid on trays and risers shall
be neatly dressed and clamped at an interval of 1500 mm.
Clamps for multicore cables shall be fabricated out of 25x3 mm aluminium flats.
All power cables shall be clamped individually and control cables shall be
clamped in groups of three or four cables. All single core power cables shall be
laid in trefoil formation and suitably clamped with 25 mm wide 14 SWG
aluminium strips or fibre glass mould pieces of appropriate quality and sizes.
Prior to laying of cables inside both indoor and outdoor trenches, the contractor
shall properly clean inside those trenches. In outdoor areas, buried cables,
wherever called for, shall be laid and covered with sand/riddled earth and
protected from damage by bricks at sides and precast slab at top. Slabs and
bricks shall be supplied by the Contractor.
When buried cables cross road/railway track, additional protection shall be
provided in the form of hume/ galvanised iron pipes. In order to prevent fire
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protection through cable penetrations of wall/floor/ceiling as well as through
cable shaft openings, after laying, dressing & clamping of cables, all the
openings shall be properly sealed by using pieces of mineral wool butted to one
another and spraying with anti-fire propagation liquid such as `Flammastik` or
approved equivalent. Also the cable runs both before and after the fire seals
shall be suitably sprayed with anti-fire propagation liquid at least for 1 m
length.
After completion of installation and prior to connection, insulation resistance
shall be measured for all power cables and control cables.
Cable Tags & Markers
Each cable and conduit run shall be tagged with numbers that appear in the
cable and conduit schedules. Cables and conduits shall be tagged at their
entrance, every 15.0 m and exit from any equipment, junction box.
The tags shall be of aluminium with the number punched on it and securely
attached to the cable by not less than two turns of 16 SWG G.I. wire. The
location of cable joints, if any, shall be clearly indicated with cable marker with
an additional inscription `cable-joint`.
The Contractor shall furnish and install all tags and markers stated above. For
buried cable, the marker shall project 150 mm above ground and shall be
spaced at an interval of 30 meters and at every change of direction.
Cable Termination and Connection
The termination and connection of cables shall be done strictly in accordance
with manufacturers instruction, approved drawings and/or as directed by the
Owner.
The work shall include all clampings, fitting, fixing, soldering, compound filling,
cable jointing, crimping, shorting and grounding as required for the complete
job. All equipment required for all such operations shall be furnished by the
Contractor.
Furnishing of all consumable materials, such as, soldering material, electrical
tape, sealing material as well as cable jointing kits shall be included in the offer.
Cable joint kits for all cables shall be supplied by Contractor under this
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specification. Responsibility for proper termination shall lie on the Contractor.
Guarantee for termination shall also have to be given by Contractor.
The Contractor shall perform all drilling, cutting on the panel blank plate and
any minor modification work required to complete the job. If the cable end box
or terminal enclosure provided on the equipment is found unsuitable and
requires major modification, the same shall be carried out by the Contractor at
the discretion of Owner.
Control cable cores entering switchgear/distribution board etc. shall be neatly
bunched and served with PVC perforated type tape to keep it in position at the
terminal block. The Contractor shall put ferrules on all control cable cores in all
junction boxes and at all terminations. The ferrules shall carry terminal numbers
as per drawings. All ferrules shall be coloured, plastic and interlocked type.
Spare cores shall be similarly ferruled, crimped with lug and taped on the ends.
Spare cores shall be ferruled with individual cable number. Termination and
connection shall be carried out in such a manner as to avoid strain on the
terminals.
All cable entry points shall be properly sealed and made vermin and dust-proof.
Unusual opening, if any, shall be effectively closed. Sealing work shall be carried
out with approved sealing compound having fire withstand capability for at least
three hours.
Cable Joints
Cables shall be installed without joints. However, in exceptional cases, joints
may be allowed by Owner for which prior approval has to be taken.
Grounding Overground & underground Grid for Equipment Connection
The Contractor shall carry out the grounding and lightning protection of all
electrical equipment, steel structures etc. Excavation and backfilling shall be
performed by the Contractor at no extra cost.
The grounding shall be done by flat of suitable sizes and the same shall be
connected to the risers of main ground mat. All ground conductor connections
shall be made by electric arc welding unless otherwise specified. Ground
connections shall be made from nearest available ground grid risers.
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All ground conductors shall be painted black for easy identification. Equipment
ground connections, after being checked and tested by the Owner, shall be
coated with anti-corrosive paint.
Whether specifically shown or not, all conduits, trays, cable armour and cable
end box, electrical equipment, switchboards, panels, cabinets, junction boxes,
switches, fittings, fixtures, structures etc. shall be effectively grounded.
Transformer ground connections and neutral earthing shall be in the scope of
Contractor.
2 nos, earth electrodes to be provided for each transformer body earthing &
neutral earthing. For Neutral earthing of transformer, plate type earthing to be
done. For Electronic parts separate redundant earth pit shall be provided
(Copper Electrode).
Painting
The contractor shall paint steel fabrications at site with two (2) coats of red
oxide primer and two (2) coats of gray (shade no. 631 of IS:5) synthetic enamel
paint.
All damaged parts shall be cleaned and coated with two (2) coats red oxide
primer paint followed by a finishing coat of approved colour. Only touch up
painting shall be done.
All damaged galvanized surfaces shall be coated with cold galvanising paint. All
equipment after erection shall be touch up painted only. All primer and paint
including touch up paints shall be supplied by the Contractor.
Structure Grounding
All steel structures are required to be grounded from ground mat. Laying,
supporting along with foundation connecting at ground mat are within the scope
of this specification.
Installation - Earthing & Lightning Protection System
The installation work shall include unloading at site, storing, laying, fixing,
jointing / termination, testing and commissioning of equipment associated with
the safety earthing system of the plant and lightning protection system for
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buildings and allied structures. All welding / brazing equipment, necessary tools
and testing equipment shall be furnished by the Contractor.
The Contractor shall be responsible if any installation materials are lost or
damaged during installation. All damage and thefts shall be made good by the
Contractor till the installation is handed over to the Purchaser.
The earthing of cable supporting structure, cable carriers, cable trays shall be in
the scope of the Contractor.
The Contractor shall carry out the lightning protection and earthing of all
equipment / panels / structures as indicated in the Project drawings. Whether
specifically
shown
in
drawings
or
not,
building
columns,
handrails,
miscellaneous items such as junction / marshalling boxes, field switches, cable
boxes, etc. shall be earthed.
The Contractor shall install bare / insulated, copper / aluminium / steel
conductors, braids etc. required for the system and individual equipment
earthing. All work such as cutting, bending, supporting, painting/coating,
drilling, brazing /soldering/welding, clamping, bolting and connecting on to
structures, equipment frames, terminals, rails or other devices shall be in the
Contractors scope of work. All incidental hardware and consumables such as
fixing cleats/clamps, anchor fasteners, lugs, bolts, nuts, washers, bitumastic
compound, welding rods, anti corrosive paint as required for the complete work
shall be deemed to be included by the Contractor as part of the installation
work.
If the tap connections (earthing leads) from the floor embedded main earthing
grid to the equipment are more than 500 mm long then the same shall be
embedded in floor by the Contractor where required, together with associated
civil work such as excavation, concreting and surface finish. The concrete cover
over the conductor shall not be less than 50 mm.
The scope of installation of earth conductors in outdoor areas, buried in ground,
shall include excavation of earth upto 600 mm deep and 450 mm wide, laying of
conductor at 600 mm depth brazing / welding / cad welding if required, of main
grid conductor, joints as well as risers of length 500 mm above ground at
required locations and then backfilling. Backfilling material to be placed over
buried conductor shall be free from stones and other harmful mixtures. Backfill
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shall be placed in layers of 150 mm, uniformly spread along the ditch, and
tampered utilising pneumatic tampers or other approved means, If the
excavated soil is found unsuitable for backfilling, the Contractor shall arrange
for suitable soil from outside.
The scope of installation of earth connection leads to equipment and risers on
steel structures/walls shall include laying the conductors, welding/cleating at
specified intervals, welding/brazing to the main earth grids, risers, bolting at
equipment terminals and coating welded/brazed joints by bitumastic paint.
Galvanised conductors shall be touched up with zinc rich paint where holes are
drilled at site for bolting to equipment/structure.
The scope of installation of electrodes shall include installation of these
electrodes (a) directly in earth, (b) in constructed earth pits, and connecting to
main buried earth grid, as per project drawings / relevant standards. The scope
of work shall include excavation, construction of the earth pits including all
materials required for construction of earth pits, placing the rod and fixing test
links on those pipe/rod/plate electrodes in test pits and connecting to main
earth grid conductors.
The scope of installation of lightning conductors on the roofs of buildings shall
include construction of upstands, laying, anchoring, fastening and cleating of
horizontal conductors, grouting of vertical rods wherever necessary, laying,
fastening / cleating / welding of the downcomers on the walls / columns of the
building and connection to the test links to be provided above ground level.
The scope of installation of the test links shall include mounting of the same at
specified height on wall/column by suitable brackets and connections of the test
link to the earth electrode.
Wherever main earthing conductor crosses cable trenches, they shall be buried
below the trench floor.
Earth leads between earthing riser and equipment earthing terminals shall follow
as direct and as short a path as possible.
Neutral connection shall never be used for the equipment earthing.
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Each neutral point of a transformer shall be connected to two separate treated
type earth electrodes.
Crane and track rails shall be bonded with the railboards and connected to the
earthing system. Adjacent railway tracks shall be bonded across fish plates.
Wherever earthing conductor passes through walls, galvanised iron sleeves shall
be provided for the passage of earthing conductor. The pipe ends shall be
sealed using suitable waterproof compound.
All connections in the main earth conductors in earth/concrete and connection
between main earthing conductor and earth leads shall be of welded/brazed
type. Cad welding type connections shall be done only if specifically indicated.
Connection between earth leads and earthing terminal provided on the
equipment shall be bolted type.
All joints shall be made such that contact resistance is negligible.
All bimetallic connections shall be treated with suitable compound to prevent
moisture ingression.
Metallic conduits and pipes shall be connected to the earthing system.
Lightning protection system down conductors shall not be connected to any
earthing conductors above ground level. Also no intermediate earthing
connection shall be made from support structure of lightning arrestor (as
applicable).
Transformer earthing shall be directly connected to the earth electrode.
Electrodes shall as far as practicable, be embedded below permanent moisture
level.
Wherever required, test pits with concrete covers, for periodic testing of earth
resistivity, shall be provided. Installation of rod / pipe / plate electrodes in test
pits shall be suitable for watering. All the necessary materials required for test
pits shall be supplied and installed by Contractor. The installation work shall
also include connection to main earth grid and civil work such as excavation.
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Earth pits shall be treated with salt and charcoal if average resistivity of soil is
more than 20 ohm metre.
The lightning protection air termination rods and/or horizontal air termination
conductors shall be fixed in such a way that they remain in their installed
position even during severe weather conditions.
Air termination system shall be connected to earthing system below ground by
down conductors as shown in various project drawings. The down conductors
shall follow a direct path to earth. There shall not be any sharp bends, turns and
kinks in the down conductors.
All joints in the down conductors shall be of welded/brazed type. All metallic
structures within 2 meters from down conductors shall be bonded to lightning
protection system.
The lightning protection system shall not be in direct contact with underground
metallic service ducts, cables, cable conduits and metal enclosures of electrical
equipment. However all metal projections, railings, vents, tanks etc. above the
roof shall be bonded together to form a part of roof grid.
Excavation and Back Filling
The Contractor shall perform all excavation and backfilling as required for
buried cable and ground connections.
Excavation shall be performed up to the required depth. Such sheeting and
shoring shall be done as may be necessary for protection of the work.
The Contractor shall make use of his own arrangements for pumping out any
water that may be accumulated in the excavation. All excavation shall be
backfilled to the original level with good consolidation.
Cleaning up of Work Site
The Contractor shall, from time to time remove all rubbish resulting from
execution of his work. No materials shall be stored or placed on passage or
drive- ways.
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Upon completion of work, the Contractor shall remove all rubbish, tools,
scaffoldings, temporary structures and surplus materials etc. to leave the
premises clean and fit for use.
Inspection & Testing
On completion of erection works, the Contractor shall request the Owner for
inspection and tests with minimum fourteen (14) days advance notice.
The Engineer shall arrange for joint inspection of the installation for
completeness and correctness of the work. Any defect pointed out during such
inspection shall be promptly rectified by the Contractor.
The installation shall be then tested and commissioned in presence of the Owner
and put on trial run for stipulated Contract period. The Contractor shall arrange
for inspection of his installation work by electrical inspector and shall obtain
necessary approval/certificate for his installation work.
All rectification, repair of adjustment work found necessary during inspection,
testing, commissioning and trial run shall be carried out by the Contractor
without any extra cost.
Commissioning and Trial Run
Following
successful
inspection
and
testing,
the
equipment
shall
be
commissioned and put on trial run along with the main plant in a manner
mutually agreed upon based on the commissioning schedule of main plant.
The Contractor shall assist the purchaser in commissioning and trial run with
men and material as required and/or as directed by the Owner.
Taking over of Installation
On successful testing, commissioning and trial run, the Contractor shall request
Owner in writing for taking over the installation.
The Owner, on receipt of the request, shall arrange to take over the installation
either wholly or in part as the case may be after a final inspection.
Till such taking over, the responsibility of the whole installation against theft or
damage of any kind shall remain with the Contractor.
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Till the equipments taken over by the owner, the equipment will be operated and
maintained by the contractor, however elimination of defects and complete
readiness of equipments for taking over by the owner should be done not
beyond 6 months from the date of commissioning/first trial run of the
equipment
Applicable standards
Description
Code No
(a)
Installation and Maintenance of Transformers
IS:10028
(b)
Installation and Maintenance of Switchgear
IS:10118
(c)
Installation and Maintenance of Induction Motors
(d)
Guide for safety procedures and Practices in Electrical
IS:900
IS:5216
work
(e)
Hot dip galvanising
IS:2629
(f)
Electrical wiring installations for voltages > 650V
(g)
Fire safety of buildings (General) Electrical Installations
IS:732
IS:1646
Guarantee
In the installation if any trouble arises due to the use of defective or faulty
material and/or bad workmanship within a period of 12 months from the date of
taking over, the Contractor shall guarantee to replace or repair the defects to
satisfaction of the Owner free of charge.
4.2.14
Earthing
4.2.14.1 Design Criteria
The main objectives of grounding system are to :
a) Provide safety to personnel from contact of dangerous potential caused
by ground fault.
b) Ensure sufficient grounding current for effective relaying.
c) Stabilize circuit potential with respect to ground.
The grounding system is to be designed to meet the above objectives.
All electrical equipment, non current carrying metal parts, structures, building
steel, lightning protection system shall be connected to main plant ground grid
to have earth continuity for safety.
4.2.14.2 Design Criteria
Fault Current & Duration
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The earthing conductor shall be designed for 50 kA for duration of 3 second.
The minimum below ground conductor dia shall be 40 mm.
Conductor Material
The earthing system conductors and accessories shall be as follows:
(a)
Conductors above ground level and in trenches
Galvanised steel
(b)
Conductors buried in ground or embedded in Mild Steel
concrete
(c)
Electrodes
GS Pipe / Rod
(d)
Lightning protection air termination and down GS Flat
conductors for buildings
The Contractor shall undertake the soil resistivity measurements at site and
select suitable type of conductors.
Size of Conductors
(i) Main Earthing Conductors
The earthing conductor sizes shall be calculated as per the following
formulae.
1
I
= K
------ IS 3043 Cl.12.2.2.1
S
t
I =
S =
Maximum A.C. rms ground fault current amperes.
Cross-section area in sq.mm
t =
Operating times of the protective device to disconnect
K =
Factor depending on the earthing conductor, the
the faulty circuit, in secs.
insulation and other parts, and the initial and final
temperature.
The factor K is determined by the formula
K
Qc
( B 20)
( B f )
ln e
20
( B i )
20 =
-------- IS 3043 Cl.12.2.2.1
Electrical resistivity of conductor material at 20 deg. C
(ohm-mm).
Qc =
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heat
REV. NO.: R3
capacity
of
conductor
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material
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(J/deg.C.cu.m).
B
Reciprocal of temperature co-efficient of resistivity at
0 deg. C for the conductor.
i =
Initial temperature of conductor, (deg.C).
f =
Final temperature of conductor, (deg. C)
The calculated size shall be suitably (depending on the resistivity of soil)
increased as per table below to account for the loss of material (steel) due to
corrosion in soil.
Resistivity of soil Ohm Metric
Reduction in thickness/diameter, mm
>0
<10
8.0
>10
<25
7.0
>25
<50
5.5
>50
<75
4.5
>75
<100
3.0
>100
1.5
(ii) Rod Electrodes
Galvanised steel rod electrodes of suitable diameter and length shall be used as
per the recommendation of IS-3043. For test pits, electrodes shall be heavyduty type (Class C) GI pipe of suitable diameter with perforations. Electrodes
installed in the test pits shall have disconnecting facilities. For treated earth pits,
GI pipe shall be provided as per IS 3043 including charcoal, salt etc. Necessary
number of treated earth pits shall be provided for power transformer and for all
LT transformer Neutral & body earthing.
(iii) Earthing of Electrical equipment on cranes and travelling machines (as
applicable):
Every electrical equipment shall have double earthing.
A ring earthing system shall be provided within the crane / machine to which
electrical equipment shall be connected at least at two places. The earth ring on
the crane/machine shall be connected to the plant earthing system through
gantry rails. Two sets of earth collector brushes shall be provided on each side
of crane/machine to connect its earth ring to the gantry rails.
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Each end of each gantry rail shall be bonded to the plant earthing system. In
addition, intermediate earthing bond shall also be provided on the rails at every
60 m in case of longer tracks. Flexible copper bonds shall be provided across
any gap in the running gantry rails.
For mobile equipment with flexible cables, one separate copper conductor of
adequate size shall be provided for earthing.
(iv) Equipment Earthing Leads
The size of the earthing leads shall be decided based on the type of equipment
and structure to be earthed and shall be provided generally as per IS-3043 and
also with a view to minimize the number of sizes.
(v) Conductors for lightning protection system
The size of conductors for lightning protection system shall be decided based
on mechanical strength.
4.2.14.3 Earthing System Layout
The earthing system design and installation shall generally comply with the
following standards.
(a)
IS-3043
Code of practice for Safety Earthing
(b)
IEEE-80
Guide for safety in Alternating current sub-station
grounding
(c)
Indian Electricity Rules
The Contractor shall submit
the earthing drawing/layouts
to electrical
Inspector/CEA for his approval. All necessary fees for obtaining such approvals
shall be borne by the contractor. Necessary modification wherever required shall
be carried out by the Contractor and got approved by the Inspector at no extra
cost to the Purchaser. After installation the resistance of the ground grid shall be
tested in presence of Purchaser/Consultant as per the IE rules. After the test,
report shall be submitted to Electrical Inspector/CEA for approval. The
submission of Earthing layout, drawings and obtaining Electrical Inspectorates
final clearances & approval shall be within the responsibility of the Contractor. If
the resistance is observed to be not less than 0.5 ohm, the Contractor shall drive
additional earth pits such that resistance is less than 0.5 ohm.
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4.2.14.4 General
Metallic frames of all current carrying equipment, supporting structures
adjacent to current carrying conductors, structures, lightning protection system
conductors and neutral points of various systems shall be connected to a single
earthing system. Two earthing leads shall be used if rated voltage of equipment
is above 250V. If the rated voltage is 250V or below, one earth lead shall be
provided. Metallic structures adjacent to electrical equipment shall be earthed
by one earthing lead.
Earthing conductors in outdoor areas shall be installed at a minimum depth of
600 mm.
All cable trays in the plant buildings as well as inside the trenches shall be
connected to earth grid at an interval of about 10 m.
4.2.14.5 Earthing Conductors Inside Building
Main earthing conductors shall be buried in earth around the building.
Minimum two taps-off from this earthing loop shall be taken inside the building
and connected to the earthing grid embedded in the floor slab with
approximately 50 mm concrete cover.
In case, the building has more than one floor, each floor shall be provided with
earth grid. Floor earthing grids shall be interconnected.
Each RCC / Steel column of the building shall be interconnected to the floor
earthing grid in the ground floor.
Cable trays, steel pipes / conduits, steel columns, etc. shall not be used as earth
continuity conductors.
Instrumentation system and computer system shall be provided with a dedicated
earthing system suitable for the equipment.
Earthing grids of all the buildings, outdoor yards shall be interconnected to
form a single grid for the plant.
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Earthing grid design shall be done in such a manner that the grid resistance is
less than 0.5 ohm.
4.2.14.6 Earthing System Installation
The spacing between two electrodes shall be at least equivalent to twice the
length of the electrode.
Earthing conductor running exposed on column, walls, etc., shall be supported
by suitable cleating, at intervals of 750 mm.
The earthing conductor crossing the road / track shall be laid in hume pipe or
laid at a greater depth to avoid damage.
When earth conductor passes through floors, walls, etc., suitable pipe sleeves
shall be provided and the same shall sealed after installation.
The connection between earthing pads / terminal to the earth grid shall be
made short and direct and shall be free from kinks & splices.
Metallic conduits, and pipes shall not be used as earth continuity conductor.
Flood light poles & towers, their junction boxes shall be connected to the
earthing conductor to be run along with supply cable.
This earth conductor
shall be in turn connected to earth grid at two extreme points.
Flexible earth conductors shall be provided at expansion joints for earthing the
gates, operating handles, etc.
Equipment bolted connection after being checked and tested shall be painted
with anti-corrosive paint / compound.
Connection between the equipment earth lead and the grid conductor shall be
welded.
For rust protection, the welds shall be treated with zinc chromate
primer and coated with zinc rich paint.
The cable screens armour shall be earthed at both ends for multi-core cables.
For single core cables the same shall be done at one end (switchgear end) only.
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All bimetallic connections shall be treated with suitable compound to prevent
moisture ingression.
4.2.14.7 Lightning Protection System
Lightning protection system shall consist of vertical air termination rods,
horizontal roof conductors, down comers, and pipe electrodes.
4.2.14.8 Need for Protection
The need for providing the lightning protection system shall be established by
calculating risk index value for each building structure, etc., as per procedure
given in IS-2309 and any building whose risk index is more than 40 shall be
provided with lightning protection.
4.2.14.9 Lightning Protection System Layout
The lightning systems design and installation shall generally comply with IS:
2309 code of practice for the protection of building and allied structure against
lightning.
Each down conductor shall be connected to a rod electrode, which in turn shall
be connected to the station earthing system through test links.
4.2.14.10 Lightning Protection System Installation
Conductors of lightning protection system shall not be connected with
conductors of safety earthing system above ground level.
The down conductors shall be welded to steel structures at 1000 mm interval or
cleated to wall at 750 mm interval. Wherever welded, the weld locations shall
be treated to provide rust protection.Each down conductor is connected to main
earth grid through a test pit.
Each down conductor shall be provided with a test link at a height of about
1000mm above ground level.
All the metallic structures within a vicinity of 2000 mm shall be connected to
the lightning protection conductors.
The minimum sizes of equipment earthing leads given below are typical and
shall be as per IS 3043
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Sl.no.
Type of Equipment
Size (MM)
Material
No. of
Leads
RISERS
70 X 10
GALVANISED MS FLAT
N.A.
RUNWAY
70 X 10
GALVANISED MS FLAT
N.A.
70 X10
GALVANISED MS FLAT
TWO
CONDUCTOR/ MAIN
EARTH LEAD ALONG
COLUMNS
3
11 kV / 6.6 kV/ 3.3/
415 V SWITCHGEAR /
MCC
SYSTEM NEUTRALS
70 X 10
GALVANISED MS FLAT
TWO
415 V DISTRIBUTION
70 X 10
GALVANISED MS FLAT
ONE FOR
BOARDS
EACH
SECTION
6
FUSE DISTRIBUTION
50 X 8
GALVANISED MS FLAT
TWO
BOARDS
7
HT MOTORS
70 X 10
GALVANISED MS FLAT
TWO
415 V MOTORS :
65 X 10
GALVANISED MS FLAT
TWO
25 X 6
GALVANISED MS FLAT
TWO
ABOVE 55kW
9
415 V MOTORS : 22
TO 55kW
10
415 V MOTORS : 1
25 X 3
GALVANISED MS FLAT
TWO
11
FRACTIONAL HP
8 SWG
G S WIRE
TWO
25 X 6
GALVANISED MS FLAT
TWO
8 SWG
G S WIRE
TWO
70 X 10
GALVANISED MS FLAT
TWO
TO 22kW
MOTORS
12
CONTROL PANEL,
CONTROL DESK,
WELDING
RECEPTACLES
13
PUSH BUTTON
STATION &
JUNCTION BOX
14
CABLE TRAYS,
COLUMNS &
STRUCTURES
15
BUS DUCT
ENCLOSURES
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No. of
Sl.no.
Type of Equipment
Size (MM)
Material
(i)
ISOLATED PHASE BUS
70 X 10
GALVANISED MS FLAT
TWO
70 X 10
GALVANISED MS FLAT
TWO
25 x 6
GALVANISED MS FLAT
TWO
70 X 10
GALVANISED MS FLAT
TWO
70 X 10
GALVANISED MS FLAT
TWO
Leads
DUCT
(ii)
SEGREGATED PHASE/
NON SEGREGATED
PHASE BUS DUCT
16
RAILS & METAL
PARTS, FENCE
17
TRANSFORMER
TANKS/ RADIATORS
TRANSFORMER
NEUTRAL
18
LIGHTING
EQUIPMENT
(i)
LDB/ Lighting panel
50 X 8
GALVANISED MS FLAT
TWO
(ii)
WELDING SOCKETS
50 X 6
GALVANISED MS FLAT
TWO
(iii)
LIGHTING POLES
25 X 3
GALVANISED MS FLAT
TWO
(iv)
FIXTURES & SOCKETS
12 SWG
G S WIRE
TWO
Materials
Above ground
: Galvanised Steel- Galvanizing as per IS 2629-1985
Below ground
: MS.
4.2.15
Control Panels & Cabinets and Miscellaneous Electrical
Equipment
Indoor control panels provided for control of miscellaneous systems in the plant
viz., air conditioning, evaporative air cooling, etc. shall comply with the
requirements outlined under technical requirements below.
All the meters provided on the panel shall be min. 96 sq.mm with an accuracy
class of 0.5. All meters shall be digital type.
For motor circuits, ammeters shall have a suppressed extended scale to indicate
the motor starting current.
The facia annunciation windows if provided on the panel, shall conform to
requirements outlined under instrumentation and control section.
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The required 240V, 1 phase AC supply required for panel illumination and
receptacle and space heaing shall be derived in the control panel itself.
Technical Requirements
S.N.
1
Description
Requirements
Location
Indoor/Outdoor
depending
on
location
2
Type of mounting
Wall/Floor
Cable entry
Top/bottom
depending
on
layout
4
Paint Finish: Outside/Inside
Dark
no.632
admiralty
(epoxy)
Grey
as
shade
per
IS-
5/Glossy white.
5
Supply voltage
Space
heater,
415V, 3 phase, 4 wire
lighting
supply 240V, 1 phase AC
voltage
7
Degree of protection of Enclosure
IP 54 class for Indoor & IP 55
class with canopy for outdoor
Following miscellaneous equipment shall be included in Contractor's scope.
1. Local push button stations.
2. Junction boxes (JBs)
3. Danger boards
4. Rubber mats
5. Welding Sockets
Local Push Button Stations (LPBS)
Local push button station shall be provided for all the drive motors of the plant
(415V motors and HT motors) (start / stop push buttons shall be provided for
unidirectional motors (LT motors), start/stop/reverse push buttons shall be
provided for bi-directional motors (LT motors)& only stop push button for all HT
motors as per scheme requirement.
The degree of protection of LPBs shall be IP65 with canopy for outdoor and IP54
for indoor applications.
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All PBs shall be push to actuate type and the stop PB shall be lockable in off
position as per the scheme requirement.
All push buttons shall be provided with 2 nos. NO and 2 nos. NC contacts for
various interlocking purposes. One contact of stop PB shall be directly wired to
the switchgear module for direct tripping and another contact to control system.
Terminals to be suitable for 2 cores of 2.5 sq mm conductors with 20% spare
terminals.
All LPBs shall be of Poly Carbonate material.
Junction Boxes (JBs)
The JBs used in outdoor areas shall have DOP of IP 65 with canopy and
weatherproof type. Sheet steel thickness of JBs shall be minimum 2.0 mmand
hot dip galvanized.
Junction boxes/marshalling boxes (JBs/MB) shall be provided to enable running
a large core cables from (JB/MB) to control panels, terminal cabinets, etc.
All JBs, shall be of polycarbonate material.
Danger boards shall be provided in line with the statutory requirements.
Rubber mats shall be provided to meet the safety and other statutory
requirements.
Welding Sockets
Industrial type 63A and 100A (welding purpose) sockets shall be provided in
sufficient number to facilitate extension of power supply to various machine
tools, welding sets etc.,
Welding switch socket outlets shall be provided at every 60m distance. Generally
the socket outlets shall be provided in such a manner so that using 30m flexible
cable with welding set, total plant area can be covered. For conveyor area (as
applicable), the welding socket outlets are to be located on either side of the
conveyor.
Testing
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The following testing shall be conducted on all equipments at works.
a.
b.
4.3
IR Test before and after HV Test
HV Test with 2.5 kV meggar.
CONTROL AND INSTRUMENTATION
I&C system will consist of all local instruments Viz. Pressure Gauge, Temperature
Gauge, limit switch, Pull cord switch, Belt Sway switch, Electronic Zero speed /
Under speed switch, Bunker level switch/ indicator, other field sensors, Local
panel & push button station, CHP control room equipment, as required erection
hardware & interconnecting cables required for the control & monitoring of the
entire Coal handling Plant along with control of Wagon Tippler & StackerReclaimer as turnkey basis. A PLC based control system shall be provided for
operation, control, interlocking, tripping of the entire coal handling plant and all
associated equipment whenever required under specified abnormal conditions.
All 3.3 KV drives shall be provided with fluid coupling temperature/ bearing
Temperatures measurement & shall be measured with Duplex RTD. Redundant
Temperature Measurement sensor shall be provided for all bearing temperature
measurement. Stator winding temperature measurement element shall be
duplex type and all temperature measuring points shall be connected to PLC.
Winding temperature high alarm will be generated in the PLC system. 3.3 KV
drives shall also be provided with vibration monitoring devices and shall be
connected with PLC.
PLC System
PLC system shall be redundant with respect to Power Supply, Processor and
Communication bus. Redundant Input card shall be used for measurement of
Critical points related to protection of the equipment. All output commands to
MCC/ SWGR shall be provided through interposing relay and output redundancy
commands for critical drives. The control panel shall be minimum IP 55
protection class.
All alarms shall be generated in the solid state/PLC system and system shall be
connected with 24 TFT for alarm & other display. The control system shall have
hooter with required hardware and driven from PLC output. Test, Accept and
Reset Push Button shall be connected to the PLC system and programmed for
alarm annunciator.
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A modular control desk of approved quality. HMI with 24 TFT monitor editable
programming software with latest configuration hardware and quantities as per
PLC configuration.
Interfacing with Plant DCS
Bidder shall provide interface requirements with plant DCS as per architecture
drawing. CHP PLC shall be linked with plant DCS, wagon tippler, stacker cum
reclamier,
etc.
through
bidirectional
redundant
TCP/IP
fast
Ethernet
connectivity/ Redundant serial MODBUS RTU interface in addition to some
hardware interface signals. Any device/ software required for the same shall be
in bidders scope. Bidder shall co-ordinate with the DCS vendor in achieving the
interface successfully & complete. A typical PLC based control system
configuration block diagram for Coal Handling Plant is provided for reference,
DRG No: E072-03-CHP-I-03-08-1.
4.3.1 General Requirements
i. The control and instrumentation system for Coal handling Plant shall be
designed and constructed to meet all the specification requirements. All
instruments/ equipment offered shall be capable of satisfactory operation for
prolonged period of time and shall perform accurately and safely under the
environmental & operating conditions described in the specification.
ii. All equipment, and accessories furnished under the specification shall be
from the latest proven control and instrumentation product range of
qualified manufacturers whose successful performance has been established
by a considerable record of satisfactory operation in power stations. C&I
devices & systems shall employ latest state-of-the art technology to guard
against any obsolescence. In any case, it shall be required to ensure supply
of spare parts for lifetime of the plant.
iii. Design requirements as specified in the specification shall be followed while
selecting the control and instrumentation items.
iv. Each item included in this specification shall be inspected and tested by the
Bidder in his works for full compliance with specification requirements,
completeness, proper assembly, satisfactory operation, cleanliness and state
of physical condition as applicable.
v. Full details regarding all equipment and systems including complete Bill of
Materials, drawings, data, information, technical literature and other details
required to fully establish the capability and performance of the equipment
and systems offered shall be provided as a part of the contract.
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vi. To ensure smooth and optimal maintenance, easy interchange ability and
efficient spare parts management of various C&I items, it shall be ensured
that each C&I item is of same make, series and from same family of hardware
( as far as practicable).
vii. All plants and equipment which needs regular operation and monitoring shall
be provided with remote operation/ monitoring facilities, at respective
control rooms/centers. Automatic control facilities to be incorporated
wherever applicable.
4.3.2 Design Criteria
Design Codes & Standards
The design, manufacture, inspection, testing, site calibration and installation of
all equipment and systems covered under this specification for the Coal
Handling Plant shall conform to the latest editions of codes and standards. i.e.
ANSI, ASME, IEEE, IEC, NEC, NEMA, ISA, DIN and Indian Standards and their
equivalent standards. Bidder shall state clearly which codes and standards are
followed for measurement hardware.
Following Codes and Standards shall be applicable:
Temperature Measurement
a) Instrument and apparatus for temperature measurement-ASME PTC 19.3
(1974).
b) Temperature Measurement - Thermocouples ANSI - MC 96.1 - 1975.
c) Temperature Measurement by electrical resistance thermometers - IS:2806.
d) Thermometer-element-Platinum resistance - IS:2848 / DIN 43760.
Pressure Measurement
a) Instrument and apparatus for pressure measurement - ASME PTC 19.2
(1964).
b) Bourdon tube pressure and vacuum gauges - IS:3624/1996.
Electronic Measuring Instruments and Control Hardware
a) Safety requirements for electrical and electronic measuring and controlling
instrumentation - ANSI C 39.5 / 1974.
b) Dynamic response testing of process control instrumentation ANSI MC 4.1
(1975) - ISA -S26 (1968).
c) Surge withstand capability (SWC) tests - ANSI C 70.90A (1971) IEC-255.4.
d) Printed circuit boards - IPC TM-650, IEC 326C.
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e) General requirements and tests for printed wiring boards - IS-7405 (PartI)/1973.
Instrument Switches and Contacts
a) Contact Rating
- AC services NEMA ICS Part-2 125, A-600
b) Contact Rating
-DC services NEMA ICS Part-2 125, N-600
Enclosures
a) Types of enclosures - NEMA Standard ICS-6-110.15 through 110.22 (Type 4
to 13).
b) Racks, panels and associated equipment -
EIA : RS-310-B (ANSI C83.9 -
1972).
Apparatus, Enclosures and Installation Practices in Hazardous Area
a) Classification of hazardous area - NEMA Article 500, Volume-6, 1978.
b) Electrical Instruments in hazardous dust locations - ISA-RP 12.11.
c) Intrinsically safe apparatus - NFPA Article 493 Volume-4 1978.
d) Purged and pressurized enclosure for electrical equipment in hazardous
location - NFPA Article 496 Volume-4, 1978.
Annunciator
a) Specifications and guides for the use of general purpose annunciator - ISA PR
18.1.
b) Surge withstand capability tests - ANSI C37.90 a - 1971 and IEEE Standard
472-1974.
Interlocks, Protections
a) Relays and relay system associated with electric power apparatus - IEEE
Standards 3.13.
b) Surge withstands capability tests - ANSI C37.90 a - 1971 and IEEE Standard
472-1974.
c) General requirements and tests for switching devices for control and
auxiliary circuits including contactor relays - IS-6875 (Part-I)/1973.
Instrument Tubing
a) Seamless Carbon Steel Pipe - ASTM-A-106.
b) Material for socket welds fittings - ASTM-A-105.
c) Dimensions of fittings - ANSI-B16.11.
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d) Code for pressure piping, welding, hydrostatic testing ANSI-B 31.1.
e) Nomenclature for instrument tube fittings - ISA-RP 42.1 / 1982.
f) Seamless stainless steel tube ASTM A-312 TP 304.
Cables
a) Thermocouple extension wires / cables - ANSI C96.1.
b) Color coding of single or multi-pair cables - IPCEA S-61-402.
c) Guide for design and installation of cable system in power generating station
(insulation, jacket materials) - IEEE Standard 422.
d) Requirements of vertical tray flame test - IEEE 383.
e) Standard specification for tinned soft or annealed copper wire for electrical
purpose - ASTM B33.
Cable Trays, Conduits
a) Guide for the design and installation of cable system in power generating
station (cable trays, support systems and conduits) IEEE Standard 422, NEMA
VE-1, NEC-1981.
b) Guide for the design and installation of cable system in power generating
station (cable trays, support systems and conduits) IEEE Standard 422, NEMA
VE-1, and NEC-1981. Test Standards NEMA VE-1-1979.
c) Galvanizing of carbon steel cable trays - ASTM A-386.
4.3.3 Control and Instrumentation Items
Bidder shall include complete control & instrumentation system, all field
instrumentation / sensors / final control elements with actuators & all
accessories in his scope of supply. The intent of this specification is to provide
the basic guidelines
for supply of control &
instrumentation
system/
instruments for various systems as described below. However if any instruments
/ equipment which are not covered in this specification but Bidder feels same
are required for completeness of the system, same is to be included by the
Bidder in his scope of supply. Bidder shall prepare and implement all required
control loops, interlock & protection logics to make the entire system complete
for the satisfactory operation & control of the entire system. Bidder shall furnish
all control loops along with write-up, Interlock and protection logic diagrams
along with write-up, operation & control philosophy, Analog / digital monitoring
points, lists etc. for the entire Coal handling Plant.
The operation and control of entire coal handling plant including Wagon
unloading, conveyer, tippler, stacker-reclaimer etc. shall be performed from its
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own dedicated PLC located in CHP & respective control room in a completely
integrated manner. This shall include following as minimum:
i)
Redundant processor, redundant communication controller, redundant
power supply modules, redundant bus at all level, I/O cards, operator
work station and engineering work station with dedicated keyboard and
24 TFT monitor, printers and time synchronisation facility with plant GPS
master clock ( time format shall be as per GPS master clock requirement).
j)
Three nos. 24 TFT operator work station, one no. 24 TFT operator work
station cum engineering work station, Two nos. industrial grade 52 thin
bezel LCD display unit, one no. A4 size (B/W), one no. A3 colour medium
speed laser and one no. high speed (180 columns) dot matrix printer
shall be provided in CHP control room. For more details regarding
number of HMI, Printers, LCD display units and others bidder shall refer
CHP PLC configuration diagram E072-03-CHP-1-03-08-R1.
k)
Solid state annunciation system/PLC based system with hardwire
annunciation windows.
l)
Emergency Trip push button for HT drives & for all Electrical power
breakers mounted on auxiliary console/ panel.
m)
Bidder shall provide necessary modular control desk and standard make
furniture for installation of operator station / engineering station in the
control room, shall be subject to approval by Owner.
n)
Bidirectional Redundant TCP/IP fast Ethernet connectivity/ redundant
serial MODBUS RTU interface with plant DCS for monitoring including
cable, both side required hardware/software are under bidder scope.
Bidder shall also co-ordinate with Main Plant DCS supplier for achieving
o)
suitable interface between Coal Handling Plant PLC and Main Plant DCS.
Few hardwired signals exchange between CHP PLC and Main Plant DCS
provision has to be made.
p)
Local control panels for coal sampler, Belt weigher, ILMS, Dust
suppression, Dust extraction, ventilation system, etc. shall be provided.
One no. 24 TFT operator work station and one no. 24 TFT operator work
station cum engineering work station and one no. A4 size (B/W printer shall be
provided
for
each
stacker
cum
reclaimer
control
room.
Bidirectional
communication shall be provided between stacker cum reclaimer PLC and CHP
control System. For more details regarding number of HMI, Printers, LCD display
units and others bidder shall refer CHP PLC configuration diagram E072-03CHP-1-03-08-R1.
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One no. 24 TFT operator work station and one no. 24 TFT operator work
station cum engineering work station and one no. A3 colour medium speed laser
and one no. high speed (180 columns) dot matrix printer shall be provided for
each wagon tippler control room. Bidirectional communication shall be provided
between wagon tippler PLC and CHP control System. For more details regarding
number of HMI, Printers, LCD display units and others bidder shall refer CHP PLC
configuration diagram E072-03-CHP-1-03-08-R1.
All junction boxes, local push button stations, all Interconnected cabling
between sensors to JB/ Panel, Panel to I/O card, card to PLC system operator
station, Instrumentation/ special cables/ RTD cables/ pre-fabricated cable/
earthing cable, cable glands, Lugs, ferrules, cable trays, conduits, instrument
racks, impulse/ air supply pipes/ tubes, erection hardware, instrument isolation
valves, instrument fittings (double compression type) and other accessories
within battery limits.
All field instruments/ sensors/ switches/ belt protection switches, final control
elements with actuators as per finalised P&IDs, schemes, operation and control
philosophy and logics approved during detailed engineering stage within the
coal handling plant package.
Vibration monitoring system for HT drives as recommended by package vendor
and same shall be located in the CHP control room and interfaces with CHP PLC.
The vibration monitoring system shall include the Vibration Probes (Proximity/
Thrust/ Velocity/ Accelerometer), Special Cables, Sensors/ Signal Conditioners,
Pre-Amplifiers (if required), minimum IP-55 Junction Boxes, Signal Conditioners,
Pre-Amplifiers, Vibration Monitors, etc.
Coal Bunker Level measurement instrument shall be provided by BTG supplier,
all necessary required cable (laying and termination) up to CHP control room,
instrument installation hardware, installation of instrument, etc. of coal bunker
level instrument are under CHP Package supplier scope.
PLC I/O cards and relays for control and monitoring of all instruments, drive and
equipment are to be housed in air-conditioner environment (room/enclosure).
Licensed software required for complete PLC operation as well as for interface of
CHP PLC with plant DCS.
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Redundant UPS power supply requirements & conversions to required voltage
levels and further distribution of entire coal handling plant shall be in the scope
of bidder.
Any other item not covered herein but essential for successful installation and
commissioning of the coal handling plant and integrity of the system shall be
included by the Bidder.
All necessary Vendor/Drawing/documents shall be subject to approval from
Owner.
4.3.4 Programmable Logic Controller (PLC)
4.3.4.1
General Design & Constructional Requirements
Programmable Logic Controller (PLC) shall be microprocessor-based system.
The PLC shall be versatile, expandable, user friendly and latest state of art
technology.
The system shall be envisaged for the purpose of sequential
operation, protection and interlock, data acquisition system, alarm functions,
closed loop control and data archiving for fully automatic operation.
Logic
controller shall be provided with adequate and reliable protection safeguard for
various equipment and to assist the operator for easy safe and efficient starting
and stopping of various drives in the process. The system shall be designed by
selecting high-grade components of proven quality and proper design of system
electronics. The system shall be able to operate satisfactorily with reference to
the specified environmental conditions as indicated in the specification. The
PLCs should have necessary connectivity with DCS to suit operational
requirements.
Data Communication Facility
Different systems of the PLC are interconnected through redundant bus
communication system. The network for communication shall be based on fault
tolerant multi redundant self healing switched Ethernet connection with 100
Mbps or better bus speed between control system and control network. The
communication between this package and DCS shall be redundant. Fibre Optic
cable shall be used for interfacing of remote RTU. Plant internal bus loading and
loading for external communication shall be less than 60%.
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The system shall be modular in construction and expandable 20%in future by
adding additional electronic modules, which shall be easily accessible for
maintenance and repair. The types of modules shall be kept to minimum
possible in order to have interchangeability and spares inventory.
The system shall have extensive self-diagnostic hardware and software features
for easy and fast maintenance of the PLC. Safety barriers shall be provided for
intrinsically safe input / output circuits.
The PLC shall have very high noise immunity in order to ensure safe and reliable
operation when subjected to electrical radio frequency interference and
electromagnetic disturbances expected in a plant.
The system shall be programmed as per the logic requirements required for the
functioning of the systems and equipment. Bidder shall prepare their own logic /
ladder diagrams depending upon the capability of the programmable logic
controller offered by them.
Operation of the PLC shall be completely unaffected by a momentary power loss
of the order of 20 milliseconds.
On-line replacement of any module shall be possible in such a way that the
removal and addition of the module shall be possible without de-energizing the
system or causing any interruption in the system while replacing a faulty module
except for the inputs /outputs which are being handled by that module.
However, in case of triple modular redundant or dual PLC configurations, there
shall not be any process upset while replacement.
a) PLC shall be provided with 10% hard wired spares (up to terminal block), 10%
I/O free channels and expandable 20% free slots for future.
b) The system shall be capable of handling the long-term storage of data for 90
days and retrieval.
c) The system shall be provided with programming and diagnostic facility, while
in operation also.
d) Each processor shall not be loaded not more than 60% including spare I/Os.
4.3.4.2
PLC System configuration
PLC shall consist of following major subsystems.
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Input / Output (I/O) subsystem
I/O subsystem shall be suitable for accepting discrete inputs, BCD inputs and
analog inputs. All digital input/output modules shall have 32/16 channel and
analog input/output modules 16/8 channel. The I/O modules shall be mounted
on the I/O racks. Each I/O shall be electrically isolated from external control
circuit by suitable means. Each I/O shall be provided with galvanic isolation. The
minimum isolation level between I/O and integral electronics shall be 1000 V
DC. Each module shall have LED for each I/O channel to indicate the status of
each input / output. Redundancy in I/O level shall be maintained for critical
services.
PLC inputs shall be provided with potential free dry contacts. All the inputs shall
be double ended i.e., two wires per input and not common return for all inputs.
The contact interrogation voltage for input contacts shall be 24V DC minimum.
Each input channel shall be protected by separate fuse.
Output contacts from the PLC shall be potential free dry contacts. Each output
shall be short-circuit proof and protected by fuse.
Visual indication of fuse blown must be provided for each input and output
channel and should be alarmed.
4.3.4.3
Processor subsystem
The processor sub system shall include CPU, memory, power supply,
communication interface etc.
Dedicated PLC processor shall be envisaged for each Auxiliary plant. The
processor shall have capability to implement all the control functions required.
The processor shall have sufficient memory for storage of the program
instructions as applicable to the logic requirements. CPU shall be of 32/64 bit or
upgraded version of microprocessor. The processor shall not be loaded over
60% of the individual capacity even under the worst data loading conditions.
Memory shall be non-volatile, preferably EEPROM type. Memory shall be
provided with adequate capacity with 40% spare capacity under worst loading
condition. All dynamic memories shall be provided with buffer battery backup
up which shall be for at least 360 hours. The batteries shall be lithium or Ni-Cd
type.
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The healthiness of processor hardware and software shall be continuously
monitored by watchdog timer.
PLCs shall be provided as a minimum with dual redundant processor subsystem
including CPU, memoryand power supply. Redundancy shall be provided such
that, in case of failure of the main processor, the standby processor shall take
over automatically and vice - versa.
The changeover shall be bumpless (less
than 50 m/s or better) and shall not result any process or system upset.
In case of failure of complete processor system i.e., both processors, outputs
shall take fail safe state automatically.
The scan time of programmable controller shall be of the order of 100-250
milliseconds or better for OLCS and CLCS. Scan time/response time of PLC is
defined as the cycle time taken by the system to read input, process input
executing logic and update control output for all the logics configured within the
system.
Other activities like diagnostic routines, output / dump of data to
peripherals, or any other activity which consume processor time shall also be
accounted while computing scan time.
4.3.4.4
Communication subsystem
The redundant communication subsystem shall provide reliable and high speed
data transfer between the processor subsystem, I/O subsystem, PLC cubicles,
PLC and operator work station and other devices connected to the system.
Redundancy in communication subsystem shall be provided, such that on the
failure of the active device, communication link or bus, the redundant device
communication link or bus shall take-over automatically without interrupting
the system operation and same shall be suitably alarmed /logged. The
communication bus shall be of coaxial / fibre optics type.
Information about the failed device shall be displayed locally as well as on the
PLC console. It shall be possible to manually switch-over the communication
from main bus device to redundant bus device without interrupting the PLC
functions.
Design Requirements
a)
The control, interlock and protection, monitoring, mimic displays, Alarm
reporting (on HMI monitors /window facia) etc shall be achieved through
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PLC based automation system and Operating Station provided at the
control room.
b)
The PLC based automation system shall be capable of acquiring the status
of equipment, acquiring the analog and digital signals, displaying of
status in the form of mimic diagram, video trend, bar graph, bar chart,
over view, group over view, loop overview, alarm overview display,
periodic display, logs such as hourly/ shift/daily logs, log on request,
alarm logs etc. with the help of TFT monitor and key board and mouse.
c)
Process control and monitoring for each PLC based system listed earlier
shall be envisaged through operators station, keyboard and mouse.
However, direct local switching of individual drives and actuators shall be
possible for maintenance purpose with the necessary basic protection
d)
incorporated.
Wherever sequential operation is envisaged, the operator shall pre-set the
operating steps and sequences as required for the implementation of the
automatic operation of the plant. Subject to completion of the necessary
permissive and sequence interlocks operator Start initiations of the
appropriate lines would automatically select and start the programmed
operation sequences.
e)
Once started, the systems shall continue in automatic operation as
programmed. It shall be possible for the operator to make on-line
adjustments to timings, routings, selections etc., with appropriate
selection
checks
before
Command
initiation.
Also
programme
interruption shall be possible to effect unscheduled or out of sequence
extractions before return to the original programme.
f)
g)
The PLC system shall be designed for fully automatic operation of the
entire system in both auto and manual operation.
The following functional requirements shall be provided.
1.
Complete
control
of
system
operations
with
protection,
interlocking, alarm functions, sequential operation and closed loop
2.
controls.
system shall have provisions to modify the logic system, control
system, graphic display etc.
3.
For operator request display the response time shall be 1 to 2
4.
On the operators station all dynamic parameters shall be updated
seconds under all loading condition.
in 1 sec. interval
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4.3.4.5
PLC Console
PLC Console shall be provided as operator Interface station for control and
monitoring of the plant. This shall be done through dynamic mimic displays and
control displays.
The PLC console shall also be used for program storage, display, fault diagnostic
and alarm monitoring.
It shall be possible to modify, add or delete the
application program on-line without affecting the outputs. It should be possible
to modify or create new displays from PLC Console.
Each console unit shall have latest configured CPU with 24 TFT monitor, bulk
memory, DVD read/write disk drive, keyboard and mouse.
PLC Console shall consist of color TFT monitor of 24 size, mouse, the
programming keyboard, operating keyboard and laser printer. The TFT Monitor
and Laser printer shall meet the specification requirement indicated in the
specification.
Isolation shall be provided between programming terminal and related
subsystems, if there is any possibility of high voltage from monitor being
transmitted to other subsystems.
Bidder shall provide necessary modular control desk and standard make
furniture for installation of Operator Work Station /Engineering Work Station in
the control room.
Displays
The system shall be capable of reading the status of equipment, acquiring the
analog signals, displaying the status in the form of mimic diagram, video trend,
bar graph, periodic display, alarm display, alarm overview display, logs such as
hourly/shift/daily logs, alarm logs etc.
Displays include plant mimic diagrams, which shall include the complete
auxiliary plant system indicating each major components of the system and the
operating status of individual equipment and devices through 2 nos. of 52 thin
bezel industrial grade LCD/TFT monitor with dedicated controller.
Alarm Monitoring on Operators station:
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The system shall display history of alarms in chronological order of occurrence
on the Operator Station.
At least three (3) levels of alarm priority shall be
available which shall be displayed in different colours. It should be possible to
display and print alarms. System shall have all alarm related functional keys like
acknowledge, reset etc. Other design features like set point / dead band
adjustment,
alarm
priority,
manual
and
automatic
inhibition
based
on
predefined logic etc. shall be provided, which shall be as finalised during detail
engineering.
The alarm display shall be built bottom up with the most recent alarm at the top
of the list. When a point returns to normal, the associated alarm line shall
change colour suitably and on acknowledgement, the line shall be blanked out.
The alarms below the blank lines shall move upward to fill the empty lines. If
the capacity of the monitor display page is exceeded, alarm history shall be
stored in memory to accept the over- flow. This alarm history shall be displayed
upon operator demand. The format and details of alarm displays shall be
finalised during detail engineering.
When a point goes into an alarm state and appears on the alarm screen, the time
of alarm shall flash until acknowledged by the operator. Acknowledgement by
the operator shall cause the time to stop flashing. All alarm initiations and
return to normal, shall be logged on a printer.
4.3.4.6
System Software
The system software shall include all programs for the PLC and PLC console
which are required to perform all the PLC functions including communication
and self-diagnostics.
Diagnostic software shall have the capability to provide information about the
failed module / system either in the form of a system configuration display or
provide information in the form of a statement.
The Bidder shall provide software license for all the software provided for the
project and shall not be machine specific. All software licenses shall be valid for
the continuous service life of the plant and equipment. Password security shall
be provided in order to ensure security level to the plant operation.
The bidder shall provide software license for all software being used in the
system. The software license shall be provided for the project and shall not be
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hardware/ machine specific. That is, if any hardware / machine is upgraded or
changed, the same license shall hold good and shall not be necessary for
purchaser to seek a new license/renew license due to upgradation/change of
hardware/machine in system at site. All licenses shall be valid for the continuous
service life of the plant.
All the software listings including source code for application software. All
specific to-project data files etc. shall be submitted by the bidder.
The bidder shall furnish a comprehensive list of all system /application software
documentation after finalisation for owner review and approval.
4.3.4.7
Peripherals
All peripherals shall conform to the minimum requirements indicated in the
specification, the exact make and model number shall be as approved by the
OWNER during detailed engineering stage.
All terminals/Operators stations shall be 24 colour monitor with mouse and
key board and two nos. of 52 thin bezel industrial grade LCD/TFT monitor with
dedicated
controller,
operation
interfacing
unit
with
keyboard,
mouse.
Operators stations shall be provided with graphic and mimic capabilities with
minimum 64 distinct colours. The graphic resolution shall be 1280 x 1024 dots
minimum with 0.25 mm dot pixel and refresh rate shall be 85 Hz or better.
Suitable optical filter for minimum secondary glare shall be provided.
The colour laser printer shall be automatic duplex printing type suitable for
printing both A4 and A3 size paper. Printing speed shall be minimum 6ppm for
colour and 24 ppm for black and white. The printer shall be heavy-duty type
with minimum 50,000 pages/month printing capability, 600 dpi resolution, 128
MB memory and 3000 sheet input capability.
Dot matrix type character printer 132/136 column with minimum speed 400 cps
shall be provided for printing operator requested functions and graphics. Paper
width and line spacing shall be selectable. Noise level shall not exceed 60 db at
a distance of one (1) metre from printer. Sound proof enclosure shall be
provided. Facility to lock or release the printers on demand shall be provided.
Automatic back up facility of printer functions shall be provided. The operator
shall be able to direct logs, reports etc. to any printer from any of the HMI
stations. Furniture for keeping the printer shall be provided. The printer shall
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have self contained test and diagnosis to aid in trouble shooting. The interface
shall be either RS232C or RS422A or any other latest protocol.
4.3.4.8
Alarms & Inter locks for PLC Systems
The Bidder shall provide alarms and interlocks as recommended by the
manufacturer and as felt necessary for safe and smooth running of the process
and equipment offered.
The System Control Panels shall house the controls for the plant including
tripping and status indications. Interlock and protection logics for equipment
and process shall also be provided at the panel. The panel shall accommodate
indicators, annunciators, push buttons, selector switches, indicating lamps,
control switches, auxiliary relays, contactors, PLC etc as required. The location
and design of panel shall be subject to Owners approval.
Bidder shall refer the typical configuration of the PLC systems of Coal Handling
Plant
provided in the following drawing: PLC System Configuration Diagram of
Coal Handling Plant : E072-03-CHP-I-03-08-R1.
4.3.4.9
SOE points for Coal Handling Plant
Some important ON/OFF status and trip signals from different equipment of
Coal Handling Plant shall be connected to plant DCS. Bidder will supply, lay and
terminate all the required cables up to DCS marshalling panel. The termination
of signal at one end of DCS marshalling panel will be under bidders scope.
4.3.4.10 Power Supply System
Separate independent UPS system shall be provided for PLC system located in
CHP control rooms. UPS system shall consists of 2 x100%, 1-Phase, 240 V, 50
Hz parallel redundant UPS with 50% load sharing mode and stand by servo
stabilizer to supply power at full load to CPU, Monitor, Printer with 60-minute
battery back-up shall be provided for PLC. The battery of 2V, plante type with
long life shall be provided. Voltage regulation shall be within 1%. All the
necessary chargers, inverters, isolation transformers, surge protection devices
shall be provided. For CPU / I/O cards power supply shall be derived from UPS
by providing redundant 240V UPS AC/DC 24 V DC convertor for each cubicle.
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4.3.5 Field Instruments
All field instruments shall have microprocessor based transmitter with self
configurable keypad and portable communicator of HART/MODBUS protocol.
4.3.5.1
Pressure Transmitter
Pressure Transmitter shall be provided:
(a) For all control applications and as demanded by the process. It shall be
noted that for all critical control applications, 3 transmitters shall be
provided.
(b) The Drive protection trip due to pressure shall be derived from LVM of
transmitter signal and not through switches.
Specification:
Micro-processor based indicating type (LCD display), rack mounted with
accuracy of 0.1% of span, external zero and span adjustment. Repeatability:
0.05% of FSR or better. Linearity: 0.1% of FSR or better. Hysteresis: 0.1% of
FSR or better. Self diagnostics, temperature sensor for compensation. Powers
supply 24 V DC; output signal of 4-20 mA DC. IP 65 or equivalent degree of
protection. Aluminium housing with epoxy coating, 316 SS sensing element.
Accessories like snubbers
for pump discharge applications
and
chemical
diaphragm with 15 m PVC covered SS armored capillary for corrosive and oil
services, 3 way manifold & name plate, etc. Material for accessories will be SS.
Remote communication with field communicator/ control system. HART protocol
output shall be available in each transmitter.
4.3.5.2
Differential Pressure Transmitter
Differential Pressure Transmitter shall be provided
For the measurements of Diff. pressure, flow, level
Wherever indicating type transmitters are provided, local indicators shall not
be provided.
Specification
Microprocessor based indicating type (LCD display), rack mounted with accuracy
of 0.1% of span, external zero and span adjustment. Self-diagnostics,
temperature sensor for compensation. Powers supply 24 V DC; output signal of
4-20 mA DC. IP 65 or equivalent degree of protection. Aluminium housing with
epoxy coating, haste alloy sensing element. Accessories like snubbers for pump
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discharge applications, chemical diaphragm with 10 m PVC covered SS armoured
capillary for each limb for corrosive and oil services and 5 way manifold & name
plate, etc. Material for accessories will be SS. Accuracy: 0.25% of FSR or better.
Repeatability:
0.05% of FSR or better. Linearity: 0.1% of FSR or better.
Hysteresis: 0.1% of FSR or better. Remote communication with field
communicator/ control system. HART protocol shall be available in each
transmitter.
4.3.5.3
Flow Transmitters
For most applications the transmitter shall be DP type measuring differential
pressure across the primary flow element orifice / flow nozzle / aerofoil.
The transmitter shall provide suitable 4-20mA dc output signal for control and
indication/recording. Converters if necessary shall be provided to generate the
4-20mA signal.
4.3.5.4
Level Transmitter
Level transmitters shall be provided on process equipment where
continuous
remote monitoring and/or control of level are envisaged. The transmitter shall
provide suitable 4-20mA dc output signal for control and indication/recording.
The instrument will be displacer type for tanks normally under vacuum. For all
other tanks the instrument will be differential pressure type.
4.3.5.5
Temperature Indicators
Temperature indicators (Thermometers) shall be provided:
(a)
On all process lines where local indication is warranted by the system
either for monitoring or testing.
(b)
On the inlet/outlet of equipment such as desuper-heaters, Heat
Exchangers & Coolers for both the fluid media.
(c)
Capillary type temperature indicators shall be used in vibration prone
areas.
(d)
Thermowell shall be provided for all temperature indicators.
(e)
Local indications/gauges shall be provided as per approved P&IDs during
detail engineering.
Thermometersshall be Indicating type, field mounted, filled system with ten (10)
metres SS capillary with SS armour and six (6) inch dial (white dial with black
numerals with micrometer pointer) housed in aluminium casing (epoxy coated)
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with an accuracy of 1% of span, response time of 2-4 seconds, auto
temperature
calibration, linear calibration over the range and SS bulb with 316
SS, thermowell having a process connection of M33 x 2 thread or 150 RF
flanged. Material of accessories (name plates, mounting brackets, etc.) will be
SS. IP 65 or equivalent degree of protection for enclosure.
4.3.5.6
Thermowells
Pipe/equipment mounted temperature / test wells of 316 SS with a process
connection of M33 x 2 threads or 150 RF flanged. Accessories like name plate,
plugging with chain, etc. shall be provided. Material of accessories will be SS.
Thermowell shall be hex head of bar stock assembly. In case flanged wells are
required for any specific application, the same shall be supplied as required. The
thermowell construction shall meet the ANSI 19.3-1994 (latest) requirements.
4.3.5.7
Temperature Elements
All RTDs as required for implementation of control & monitoring shall be
supplied
Thermowells shall be provided for mounting of all temperature elements.
The elements shall be duplex type with integral thermowell (except for metal
temperature thermocouples).
Resistance Temperature Detectors (RTDs) shall be provided for all 6.6/3.3 kV
motors, for winding temperature monitoring.
types, duplex with thermowell assembly.
Each element shall be 3 wire
All temperature elements shall be supplied with associated junction box with IP
65 protection class.
1 no. duplex RTD shall be provided for each bearing of HT equipment.
4.3.5.8
Resistance Temperature Detectors (RTD)
Duplex PT-100 type with accuracy of 0.5% of span, response time 1-2
seconds; Spring loaded mineral insulated three (3) wire RTD assembly housed in
aluminium
casing (epoxy coated), IP 65 or equivalent degree of protection for
enclosure.
RTD shall be supplied as an assembly complete with thermowells
meeting ANSI 19.3-1994 (latest) requirements. Thermowell shall be 316 SS
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having a process connection of M33 x 2 thread or 150 RF flanged. Thermowell
with hex head with screwed cover & SS chain, bar stock assembly. Element lead
size will be 18 AWG. The insulation resistance at 540oC shall not be less than 5M
ohms. Repeatability over full range shall be better than 0.02%. RTDs shall be
ungrounded. Material of accessories (name plate, etc.) will be SS.
4.3.5.9
Pressure switches
Pressure Switches shall be provided
(a) On all process lines/equipment where parameter abnormality / status
including pre trips alarms are to be communicated to the operator in control
room.
(b) For all permissive conditions governed by safety operation of the equipment
e.g. pressure adequate conditions.
(c) For all interlock conditions which govern starting of standby equipment or
subsequent equipment for safety operation of the system.
(d) Inlet and outlet of filters/strainers.
Specification:
Non indicating type, field mounted Pressure Switches of aluminium casing
(epoxy coated), and 316 SS element and accuracy of 1% of span, including
accessories
like siphons for steam services, snubber for pump
applications
and chemical diaphragm for
corrosive
and oil
discharge
services, name
plate & mounting brackets. Material of accessories will be SS. Auto reset micro
switch with internal adjustment for set values with 2 SPDT contacts rated for 0.2
A at 220 V DC. IP 65 or equivalent degree of protection for enclosure. Over
range protection 50% above maximum pressure.
provided.
Scale for setting shall be
4.3.5.10 Differential Pressure Switches
Differential Pressure Switches (Indicating type) shall be provided across
filters/strainers for remote monitoring.
Specification
Bellows or diaphragm operated indicating field mounted type; aluminium casing
(epoxy coated); 316 SS pressure element nylon movement; an accuracy of 1%
of span with
adjustable contact, including
accessories
like snubbers for
pump discharge applications, chemical diaphragm with 15 m capillary for each
limb for all corrosive and oil services and 5 way manifold, name plate
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&mounting brackets, etc. Material of accessories will be SS. Auto reset micro
switch with tamper proof external adjustable set values with 2 SPDT contacts
rated for 0.2 A at 220 V DC. IP 65 or equivalent degree of protection. Over range
protection will be 50% above maximum pressure. Repeatability shall be 0.5%
FSR.
4.3.5.11 Level Switches
Level Switches shall be provided on Tanks for remote monitoring and interlocks.
Level switches shall be Float or Displacer type for water tanks.
The instrument shall be external float type with SW connection with isolation
facility for surface mounted tanks and top mounted with still pipe for all sumps.
Still pipes will be provided with adequate supports.
Specification
Float or Displacer type with dual process connections. an accuracy of 1% of
span with
adjustable contact, Auto reset micro switch with tamper proof
external adjustable set values with 2 SPDT contacts rated for 0.2 A at 220 V DC.
IP 65 or equivalent degree of protection. Repeatability shall be 0.5% FSR.
4.3.5.12 Pressure indicator/gauges
Pressure indicators shall be provided for
(a)
Suction and discharge lines of pumps, including on header section, if two
or more pumps are employed for the same service.
(b)
Suction and discharge lines of fans, including on header section if 2 or
(c)
All input and output lines of process equipment.
(d)
Inlets and outlets of heat exchangers and desuperheaters.
(e)
more fans are employed for the same service.
Local gauges shall be provided as per approved P&IDs during detail
engineering.
Specification
Direct reading, pipe mounted Pressure gauges of aluminium casing (epoxy
coated) with 4 1/2 inch / 6 inch phenolic dial (white dial with black numerals),
316 SS Bourdon tube, AISI 304 movements and micrometer type adjustable
aluminium pointer, an accuracy of 0.5% of span including accessories like
siphons for
steam services, snubbers for pump discharge applications and
chemical diaphragm for corrosive and oil services and name plate, etc. Material
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of accessories will be SS. IP65 or equivalent degree of protection for enclosure.
Over range protection will be 50% above maximum pressure. Armoured capillary
of 15 M shall be provided as required.
4.3.5.13 Differential Pressure Indicators
Direct reading type, pipe / rack mounted, bellows or diaphragm operated
differential pressure indicators; aluminium casing (epoxy coated) with six (6)
inch dial (white dial with black numerals), with micrometer type pointer, 316 SS
pressure element; an accuracy of 0.5% of span including accessories like
snubbers for pump discharge application, chemical diaphragm with 15 m PVC
covered SS armoured capillary for each limb for corrosive and oil services and 5
way manifold & name plate, mounting brackets, etc. Material of accessories will
be SS. IP 65 or
equivalent degree of protection. Over range protection will be
50% above maximum pressure.
4.3.5.14 Level gauges
Level gauge glasses shall be provided on all tanks and the maximum length of
one gauge glass shall not exceed 1 meter. The gauge glasses shall be stacked
to cover the complete height of the tanks including over flow level. There shall
be an overlap of minimum 150 mm, when more than one level gauge is
required.
Suitable
platforms
shall
be
measurements and during maintenance.
provided
for
purpose
of
taking
Specification
Tubular type level gauges for low-pressure up to 7 kg/cm2 & reflex type for
high-pressure water & steam services & vacuum services with automatic ball
check
valves, illuminator (240 AC) Pyrex/ borosilicate glass, mica shield, brass
guard rods & brass holders. Material of accessories (name plate, etc.) will be SS.
Tubular glass OD will be 5/8. Vent & drain valves shall be provided. Connection
shall be screwed or flanged (ANSI class 150 RF).
4.3.6 Drive Control Philosophy
Interface of the system with M.C.C / Switchgears, AC Solenoids, DC Solenoids
and contactors (AC&DC) shall be in the form of potential free contacts via
interposing relay modules mounted in the respective switchgear or MCC unit. All
other interfacing relays shall be mounted in a separate cabinet or a separate
section of the cabinet. For AC solenoids and contactors directly driven from
output cards, arc suppressors shall be provide across the coil.
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The Drive control Philosophy is as follows:
Sl.
Type of
Description
No.
I/O
No of I/O
PLC INTERFACE FOR UNIDIRECTIONAL HT DRIVE / LT BREAKER
1.
CONTROL DRIVE (Signal Exchange has been envisaged between PLC
and switchgear)
a.
Start Command
DO
b.
Stop Command
DO
c.
ON Feedback
DI
d.
OFF Feedback
DI
e.
Swgr Disturbance (Overload relay operated/
DI
DI
DI
control supply fail/Emergency LPBS stop)
f.
Electrical Trip (Motor Protection Relay)
g.
Switchgear
Available
(breaker
in
service
position, switchgear in remote & breaker
spring charged)
h.
Pump / Fan bearing temperature measurement
RTD
i.
Motor Bearing temperature measurement
RTD
j.
Motor Winding temperature measurement
RTD
k.
Current Transducer input
AI
2.
PLC INTERFACE FOR UNIDIRECTIONAL LT DRIVE (Signal Exchange has
been envisaged between PLC and PMCC/MCC)
a.
Start Command
DO
b.
Stop Command
DO
c.
ON Feedback
DI
d.
OFF Feedback
DI
e.
Swgr/MCC
relay
DI
Switchgear/MCC Available (switchgear/MCC in
DI
Disturbance
(Overload
operated/ control supply fail/Emergency LPBS
stop)
f.
remote)
3.
PLC INTERFACE FOR BIDIRECTIONAL LT DRIVE- For Integral starters
(Signal Exchange has been envisaged between Actuator and PLC.)
a.
Open Command
DO
b.
Close Command
DO
c.
Integral starters Fault
DI
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Sl.
Type of
Description
No.
I/O
No of I/O
d.
Open limit switch feedback
DI
e.
Close limit switch feedback
DI
f.
Open Torque switch feedback
DI
g.
Close Torque switch feedback
DI
h.
Position Transmitter (For inching type Drive)
AI
PLC INTERFACE FOR BIDIRECTIONAL LT DRIVE-For Non-Integral
4.
starters (Signal Exchange has been envisaged between Actuator and
a.
Open Command
DO
b.
Close Command
DO
c.
Swgr/MCC
DI
DI
PLC.)
Disturbance
(Overload
relay
operated/ control supply fail/Emergency LPBS
stop)
d.
Switchgear/MCC Available (switchgear/MCC in
remote)
e.
Open limit switch feedback
DI
f.
Close limit switch feedback
DI
g.
Open Torque switch feedback
DI
h.
Close Torque switch feedback
DI
i.
Position Transmitter (For inching type Drive)
AI
4.3.7 Instrumentation Cables, Wiring & Terminals
Please refer Electrical specification for Instrumentation Cables.
4.3.8 Instrumentation Interconnection Philosophy
Cable interconnection philosophy is to be adopted such that extensive grouping
of signals at field shall be done by use of junction boxes, transmitter racks so
that multi pair cables can be used from junction boxes to marshalling
cabinets/RTU.
4.3.9 Junction Box (JB)
Junction Boxes shall have following features:
Double door type with cable entry from bottom.
12/24/36/48/64/72/96/128 way with 20% spare terminals.
Spring-loaded terminals shall be used.
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4mm thick fiberglass reinforced polyester.
Door shall be screwed at all four corners. Door handle shall be self-locking
with common key. Door gasket shall be of synthetic rubber.
Suitable for mounting on walls, columns, structures etc. The brackets, bolts,
nuts, screws, glands and lugs required for erection shall be of brass, included
in C&I Vendors scope of supply.
Terminals shall be rail mounted cage-clamp type suitable for conductor size
up to 2.5 mm2. An M6 earthing stud shall be provided.
Enclosure shall be minimum IP: 55 or better for all applications except CHP.
For CHP application the protection class shall be IP 65 minimum.
4.3.10
Installation / Erection
Instrumentation and Control, Erection, Field Testing and Commissioning
Requirements
Erection requirements
The actual location of transmitters, junction boxes and other instruments
shall be decided depending on the site conditions considering the layout and
maintenance aspects.
The Vendor shall get prior approval as per approved quality assurance plan of
the Owner / Consultant before any installation work starts.
Impulse / sample piping, air supply and pneumatic tubing, cable trays and
equipment shall be supported rigid enough to prevent vibration and anchored
sufficiently to prevent strains on equipment installed.
Supporting clamps
shall be provided at least at every one metre distance for better rigidity.
Impulse / sampling piping shall be provided with adequate slope, (preferably
1:10). Hangers and supports shall be so installed as not to interfere with free
expansion and contraction of the piping and tubing between anchors.
Suitable vibration dampeners, etc., shall be provided wherever necessary. In
addition, care should be taken that the arrangement of impulse piping, air
supply and pneumatic tubing shall be safe from mechanical injury. Impulse
pipes joints shall be welded type unless otherwise specified.
Argon arc
welding shall be employed. Impulse tubing / pneumatic tubing joints shall
use double compression fittings.
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All the panels, desk, cabinets supplied by the Vendor shall be bolted to the
floor channel.
Testing requirements
The Vendor shall set up his own instrument laboratory.
The calibration
equipment shall cover complete range and shall have the desired accuracy of
not less than 0.1%.
All the calibration equipment shall have the certification
from National Physical Laboratory (NPL) or IDEMI for the duration of Contract
Period.
The Vendor shall follow the standard procedures for calibration of various
instruments and as set by the manufacturer of instruments and as instructed
by the Owner including any requirements of field calibration.
First, the
calibrations shall be carried out independently by the Vendor and later in the
presence of Owner who shall certify the same. Proper documentation in this
regard shall be maintained and handed over to the Owner.
All the instruments shall be calibrated for the entire range of the instrument
for which it is designed. Calibration shall include test for repeatability.
All switches shall be tested for the actuation of both normally open and
normally closed contacts at the desired set points and also for the fixed /
differential settings.
All the float operated level switches shall be tested for the movement of the
float and linkages to make to break the switch contacts by filling up with
water before installation. For such tests, necessary testing set up required
shall be arranged by the Vendor.
All the conductivity type probes and
switches shall be tested for functionality before installation.
Air leak tests shall be performed on all impulse lines, air supply and
pneumatic
lines.
Necessary
equipment
such as
portable
compressor,
connecting pipes, materials, cables and test gauges shall be provided by the
vendor.
For all electrical actuators of the valves, functioning, setting and performance
of limit switches / torque switches of various positions shall be checked
before and after installation of the actuators. The position transmitters for
inching applications shall also be calibrated.
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Pneumatic actuators shall be calibrated at site.
Commissioning requirements
Prior to taking the instruments in service, all impulse lines, sampling lines and
air supply lines shall be blown as required with the establishment of adequate
line pressure and temperature conditions to keep the lines thoroughly clean.
On-line i.e., without removing control valves from the pipe calibration of the
positioners and stroking of control valves / control dampers shall be carried
out as required during control system tuning.
After delivery of the equipment, the Vendor shall locate all the equipment
including electronic cards in final position, check all the power wiring,
grounding and interconnection cables, all in accordance with manufacturers
recommendations. The Vendor shall perform initialisation of system power, field
loading of system configuration / software and data base, demonstration of
system functionality to verify conformance with manufacturers instructions and
specifications, tuning of control loops, implementation of any configuration
changes including hardware, software and additional tappings / instruments,
cabinets as required and providing general trouble shooting and final solutions
to application and / or instrument problems.
Training
Further
to
relevant
clauses
regarding
training
specified
elseware,
The
manufacturer/supplier has to provide the technical training to Owners technical
team (10 members including both maintenance & operational personal) in the
following areas:
Operator training
Hardware /Software maintenance training
Any other specialized training as required for system operation and
maintenance.
4.4
CIVIL
4.4.1 General
The works to be performed under this specification include execution of
complete civil, architectural and structural works for foundations for equipment,
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buildings, facilities, substructures, superstructures including structural steel
fabrication and erection and infrastructure works for the entire coal handling
system. The works shall generally comprise (but not limited to) carrying out
detail engineering, design computations, preparation of detail construction
drawings & design reports and getting the same approved by owner/ consultant
including
all
necessary
survey,
tests,
studies,
investigations
including
geotechnical investigation work as may be required for design, construction or
erection up to the specified terminal points mentioned elsewhere, including
supply of all materials, consumables, tools & plants and labour etc as per
approved drawings and these specification for the following:
clearance, leveling and grading to achieve FGL as per
requirement: for complete coal handling plant area.
Coal Crushing and screening system Includes crushers and
Site
screens.
Main CHP control room and MCC Room
Wagon tippler control room and MCC Room
Wagon Tippler shed and allied works
Wagon Tippler (WT) & side arm charger- 5 nos.
Conveyor tunnels from tipplers
Conveyor tunnels from Manual Reclaim hoppers
Transfer Towers (TT) Nos. as per mechanical specification.
Transfer House (TH) Nos. as per mechanical specification.
Stacker Reclaimer foundations
Coal stack yard
Manual Reclaim Hopper (MRH)
Bulldozer Shed.
Pent House Nos. as per mechanical specification.
Dust suppression system as per mechanical specifications
Dust extraction system as per mechanical specifications
Works related to transformers and other electrical facilities for CHP
area (As per Electrical specification & scope)
Foundations and Support columns(as and where required ) for Belt
Conveyors/Gallaries etc.
All main roads in CHP area and approach roads connecting all
facilities in the Coal Handling package to the nearest main roads,
including drains and culverts wherever required.
Civil works required for illumination of the facilities in the Coal
Handling package and connecting approach roads.
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Any other work necessary for completion of coal handling plant.
Water Tanks and pump houses for Dust Suppression System
Tunnel Ventilation System
Emergency Reclaim Hopper/Mill reject Handling system; Quantity
as per Mechanical Specification
No of stacks/stacker reclaimer as per Mechanical specification
Garland Drains, Decantation tanks, Coal pile run off pond, Coal
sampling room andOffice Complex for O & M staff for CHP
For detailed civil work specifications, Part C of this document shall be referred.
This specification covers the methodology to be followed for design and
construction of all civil, structural and architectural works for the complete Coal
handling system. Description of various items of work and nature of work
involved under this specification are given hereinafter. The items, though not
specifically mentioned, but are needed to make the system complete shall be
treated as though included and the same shall also be furnished and erected /
constructed unless otherwise specifically mentioned as excluded.
The work shall be carried out according to the design/ drawings to be developed
by the Contractor and approved by the Owner/Engineer. For all buildings,
facilities, systems, structures, etc., necessary layout and details are to be
developed by the Contractor keeping in view the statutory and functional
requirements and providing enough space and access for operation, use and
maintenance. The Contractors work shall cover complete requirements as per IS
codes, fire safety norms, requirements of various statutory bodies, International
Standards, best prevailing practices and to the complete satisfaction of the
Owner / Engineer.
The Contractor shall make the layout and levels of all structures from the
general grid of the plot and the nearest GSI benchmark or other acceptable
benchmark
of
Government
department
as
per
the
directions
of
the
Owner/Engineer. Certain minimum requirements that are indicated in this
specification are only for guidance purpose. However, the Contractors offer
shall cover the complete requirements as per the best prevailing Engineering
Standards and Practices and to the complete satisfaction of the Owner.
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The Contractor shall be solely responsible for the correctness of the layout and
levels and shall provide necessary instruments, materials, access to works, etc.,
to the Owner/Engineer for general checking of the correctness of the civil works.
All the quality standards, tolerances, welding standards and other technical
requirements shall be strictly adhered to.
The Contractor shall inspect the site, examine and obtain all information and
data required and fully appraise himself of the prevailing conditions at the
proposed site, access to site, communications, transport, right of way,
availability of local labour, materials and their rates, local working conditions
climatic conditions including monsoon pattern, soil conditions, local conditions
and site specific parameters and shall include for all such conditions and
contingent measures in the bid, including those which may not have been
specifically brought out in the specifications.
In case of any conflict between stipulations in various portions of the
specification, most stringent stipulation would be applicable for implementation
by the Contractor without any extra cost to the Owner/Engineer.
4.4.1.1
Construction Water
The Construction water will be arranged by the owner free of cost at ground
level reservoir
within the plant area. Arrangements for drawing the water from
ground level reservoir and distribution of pipe line network for various locations
as required shall be arranged by the Contractor at his own cost. In case of
shortage of water, the Contractor has to make alternative arrangements at his
own cost.
4.4.1.2
Statutory Requirement
Contractor shall comply with all the applicable statutory rules pertaining to
Factory act, Fire safety rule of Loss prevention association, Water act for
Pollution control, Explosives act etc.
Provisions of Safety, health and welfare
according to Factories act shall also be complied with. Statutory clearances shall
be obtained and norms of State Pollution Control Board shall be followed.
Statutory body /Act requirements shall be fulfilled by the CONTRACTOR and in
case any modifications /additions to the building /Structures are to be made as
per the above, shall be carried out by the Contractor at no extra cost to the
owner.
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4.4.1.3
Submissions
Commencement of fabrication and erection and construction shall be done after
approval of the relevant documents and drawings. All drawings shall be of
standard sizes (Metric System) and shall be made using AutoCAD (latest). All
documents shall be made using MS office. Contractor shall submit two sets of
soft copies of all documents and drawings on CDs along with requisite sets of
hard copies of the same.
In addition to the requirements specified elsewhere in the specification 3D/2D
structural frame analysis and design for the plant structures shall also be
submitted by the contractor for Owner/Engineers review and approval.
The documents and drawings as listed below are to be submitted for the
approval of the Owner/Engineer unless specified otherwise. The list given below
is not exhaustive but indicative only.
i.
A General Layout Plan drawing covering complete Coal handling system
with coordinates of buildings and facilities, roads, railway line (if
applicable), boundary wall, piping/cable corridors etc.
ii.
Drawings showing underground facilities with co-ordinates and invert
levels of the facilities like tunnels, transfer houses, buried pipes, buried
cables, trenches, ducts, sewers, drains, sumps, pits, culverts, manholes,
foundations, etc.
iii.
Architectural floor plans, including conceptual interior/ equipment and
furniture arrangement, elevations, cross-sections and perspective view in
colour for all buildings are in contractors scope. Contractor shall submit
two different schemes along with a report elaborating the underlying
philosophy of the proposed architectural concepts.
iv.
Project design intent document giving the basis of design, which shall
cover all the aspects, parameters, assumptions, references, structural
idealization/ mathematical model, loading cases, load combinations,
analysis and design for all buildings, facilities, systems and structures etc.
v.
Structural analysis, design calculations and drawings of substructure and
super structures for all buildings, structures, facilities, and systems in his
scope.
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vi.
Analysis,
design
calculations
and
drawings
for
pipe
supports,
foundations, culverts, road/ rail crossings / bridges, drains, cable / pipe
trestles, pipe trenches, ducts, etc required to complete the scope of this
specification.
vii.
All architectural drawings required for execution of construction work
such as detail floor plans, detail elevations, detail sections and other
miscellaneous architectural details such as finish schedule, colour scheme
(both internal and external), doors and windows, flooring including
provision of north/ sky light in the roof (if required), false flooring, false
ceiling,
etc.,
architectural
facia
and
projections,
miscellaneous
architectural details, coping, flashing, khurras, water proofing, fillet, roof
decking, wall cladding, surface drains, rain water down comers, sanitary,
plumbing, etc.
viii.
All reports of tests/ studies/ investigations including model studies
carried out by the Contractor.
ix.
Shop drawings/ fabrication drawings of all structural steel works (only for
reference) and design calculations for important joints/ connections.
x.
Construction and erection procedure for all major structures covered
under the Contractors scope.
xi.
Marking
scheme
identifying
the
equipment
lay-down
areas,
with
distinctive colour scheme.
xii.
All other design details/drawings or any other submission as may be
indicated elsewhere in this specification and as required by the
Owner/Engineer.
xiii.
Details of corrosion protection measures for all structures.
xiv.
Construction drawings shall include total quantity of concrete (grade
wise), reinforcement steel and structural steel (section wise).
xv.
Specifications, design & drawings for profiled roof metal deckings and
metal claddings.
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xvi.
Field Quality Plan with procedures.
xvii.
Material test certificates.
xviii. As built drawings with quantities of various items of work system wise,
building wise, structure wise, etc. duly certified by Site after execution of
work for information/ record.
xix.
The contractor has the option to use mild steel as per IS:2062 conforming
to IS:8500 for structural steel works in various buildings/ structures. He
shall submit detailed fabrication and welding procedure along with his
design/scheme drawings.
xx.
One Complete set of applicable standards, references, specifications,
code of practice, other than BIS (Bureau of Indian Standards) etc to the
Owner/Engineer for use at site.
xxi.
Wherever applicable, scheme for dewatering, shoring, strutting/ sheet
piling and scheme for blasting (including controlled blasting) of hard
rock.
4.4.2 Specific Requirements for various components of Coal Handling
Plant
This section stipulates requirements of civil, structural and architectural works
Requirements in respect of major works to be executed by the contractor for
Coal handling system shall be as mentioned below:
4.4.2.1
Plinth level of buildings
Plinth level of the buildings in the coal handling plant, in general and crusher
house, junction towers/houses and MCC / control room in particular shall not be
kept less than 0.5 meter above the finished ground level, except specifically
mentioned otherwise.
4.4.2.2
Crusher houses
Primary and secondary Crusherhouses shallbe of steel structure of framed /
braced design. All the foundations of buildingcolumns shallbe RCC and shall be
connectedbytie/plinthbeams. Topofthepedestalsfor thecolumnsshall beat least
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150 mmabovefinishedgroundfloorlevel. Plinth level of crusher house will be
minimum 0.5 meter above the finished ground level.
Floorsandroofsshallbeof
RCC,
supported
overstructuralsteelbeams.
Sidecladdingshallbeof brickwork up to 3m height from finished ground
floor
level.
metalcladding
Above
shall
3m
be
level,
provided
permanentlycolourcoatednon-insulated
document.Adequately
asspecified
elsewhere
sized
in
this
windows
shallbeprovidedwithsteelglazedsidehungwindowsusingwired glass. At locations,
wheremonorails are provided outside forlifting of equipment, steel slidingdoors
of adequate size shall be provided. Rolling shutters at Main entrance of the
building shall be provided. These shall be of adequatesizeto allow movement of
equipment. Other doorsshall be offlushweldedsteel construction. Ramps and
sunshades shall be provided in frontof main entrance. Toilet block shall be
provided in the Crusher houses at suitable locations.
Grade slab as well as intermediate floors shall be of RCC. Intermediate floor shall
be supportedonsteelbeams/bracings. Handrailsshallbeprovided around all large
floor
openingsand
RCCkerbwallof
kerbplatesshall
minimum
beprovidedaroundall
300mmshallbe
smallopenings.
providedalroundthefloor
with
handrails.
Flooring for crusher house shall be of RCC with non-metallic floor hardner
topping.
The crusher shall be on RCC deck supported on steel helical spring units and
viscous damper (vibration isolation system), which in turn shall be supported on
the independent RCC sub-structure isolated from building floors. Dynamic
analysis shall be done for the top deck together with the springs and dampers to
determine the natural frequencies and amplitudes of vibration. A mathematical
model of the top deck shall be formulated with three-dimensional beam / plate
finite element for the purpose of analysis with the springs idealized with vertical
and horizontal stiffness. The mass of the machine together with that of the top
plate shall be considered for the analysis. Single degree of freedom systems may
be used for evaluating the rigid body modes. Natural frequencies upto at least
20% above the operating frequencies shall be checked. Forced response dynamic
analysis shall be carried out for the unbalanced forces during operating
condition using sinusoidal forcing function. The vibration isolation system shall
be designed for at least 90% isolation efficiency. A ratio of at least 10 (ten) shall
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be ensured between the stiffness of the supporting structure and the stiffness of
the spring system in each direction to achieve decoupling between the two (the
stiffness of the spring system being lower). This ensures that the supporting
structure is relatively Rigid with respect to the springs and the vibration
isolation system can be conveniently assumed to be rigidly supported for the
purpose of dynamic analysis. In addition, the first bending mode frequency of
the top deck shall be at least 20% above the operating speed of the motor.
The building shall be provided with twostaircasesofstructuralsteel oneinternal
and one external. An Elevator shall be located outside the crusher house of
adequately
sized
for
serving
all
the
floors
shall
be
provided.
ElevatorpitshallbeofRCC and permanentlycolour-coatedmetal claddingsystem
shall be provided for covering the shaft for movement of Elevatorcage. Elevator
pitshall bekept atleast 500 mm abovesurrounding gradelevel topreventflooding.
Asump with access ladder shallbe providedinsidethepitfor dewatering.
RCC floor androofshallbe p r o vi de d fo r Machineroom of elevator if applicable.
Sidecladdingof
elevator
shaft
shallbeof
non-
insulatedmetalcladdingabove3mhighbrickwall. Side cladding for machine room
shall
be
of
brick
masonry.
RCCkerbwallof
minimum
300mmshallbe
providedalroundthefloor with handrails. Main entrance door forM/C roomshall be
offlush welded steel construction. Steel glazed windows shall be provided for
adequate ventilation. Access staircase to machine shall also be provided.
Roofshallbelaid withadequateslopefor proper drainage. Roof shallbetreated with
Elastomericliquid membrane waterproofingtreatment as specified elsewhere.
Adequate
arrangementsshallbeprovidedto
therainwaterthroughgalvanisedgutterofmatching/
andHDPEdowncomer pipes asperIS:4985.
4.4.2.3
let
approvedcolour
Junction houses
Junction houses shall be designed and constructed in a manner similar to the
Crusher houses
and the provisions shall be as specified in the Mechanical
section of this document. There shall be one number of staircase in junction
houses, preferably located outside with metal cladding as explained in crusher
house specification.
The junction towers which are supporting the coal conveying galleries to coal
bunkers shall accommodate mill reject silos within the junction towers&structure
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shall be designed accordingly. Further, the sizing of the junction tower shall be
as per the space indicated in the Mechanical G.A.
4.4.2.4
1
Conveyor Galleries and Trestles
Overhead conveyors shall be housed in structuralsteel gallery supported
on structural steel columns / trestles.Maximumspanofgalleryshallnot
exceed24m unlesshigherspan is necessitateddueto site constraints, subject
toapprovalofOWNER.
Forsingleconveyor 1000mm widewalkwaysshall beprovidedoneitherside.
Doublestream conveyor galleries shall be provided with onecentral
walkway of 1200 mm wide and two side walkways of 1000 mm each.
Clearheight of thegallery shallbeasspecifiedinMechanicalsectionof the
document.
Both
sidesof
thecentral
andsidewalkwaysshallbe
providedwithpipe handrails as specified elsewhere in this document.
These Handrails shall not be connectedtoconveyor supporting stringer.
Walkway
shall
be
of
skidarrangement
chequered
along
plate
construction
with
with
kerb
antiplates.
Floorsoftheconveyorgalleryshallbeprovidedwith
sealplatesifspecifiedinMechanical section.
3
Conveyorgalleryshallhavepermanentlycolourcoatedmetalsheet on roof and
side
cladding
shall
be
of
permanently
colour
coated
non-
insulatingmetalcladding.
Roofframingshallbegivenaslopeof1vertical:3horizontal. A continuous slot
opening in the side cladding of 300mm justbelowtheroofsheeting and
150mm height from the floor shall be provided. Adequateprovisionof
windows with wire-meshed glass shall be provided on both sides. Crossovershallbeprovidedatapproximately 100m interval along the conveyor
preferably at 4 legged trestlelocations. Provision of fire escape stair case
shall be provided at four legged trestles at approximately 100m intervals.
4
Fourleggedtrestlesshallbeprovidedata
spacingnot
exceeding
100m
betweentransferpoints. Two-leggedtrestles may be provided between
fourlegged trestles. Trestles shall generally be provided usingrolledsteel
sections.
5
All over ground and on ground conveyor gallery shall be of enclosed type
steel structure with two lattice girders having rigid jointed portal frame at
both ends. The lattice shall be braced together in plan at top and bottom
and roof truss shall be provided at regular interval. The gallery shall be
covered on sides and top with permanently colour coated metal sheeting
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as per system requirement. Any conveyor gallery trestles coming in the
coal stacking heap shall be encased with RCC up to 12 m height with a
minimum clear thickness of 200mm alround the structural steel
members.
6
SlidingPTFEbearingsupportshallbeprovidedatoneendofthe gallery to take
care of forces due to temperature variation. Therefore, one end of the
gallery
shall
be
treatedashingedandthe
otherendonrollers
for
the
purposeof analysis.
7
Transfer
tower
supporting
the
end
of
conveyor
gallery
shallbesomodeledthat,onlyverticalreactionistransferred
fromconveyorgallery. This side of thegalleryshallthereforebe supported on
slidingPTFEsupport.
Thetopofpedestalforthefoundationsshallproject
minimum 300mmabove thegradelevel.
The clearance between top of road/rail and bottom of gallery shall be 8m
minimum.
8
The following requirements pertaining to the Conveyor Galleries shall also
be ensured:
i)
The general parameters for conveyor galleries shall conform to the
provisions of IS: 11592-1985 unless specified otherwise in
Technical Specifications. The structures shall be designed so as to
meet
functional
requirements
and
shall
provide
space
for
operation, maintenance and removal of machinery and give the
workers good and safe environment.
ii)
Gallery floors shall be of minimum 8mm thick Chequered plates
iii)
Steps shall be provided (rise not exceeding 130 mm) along the
supported on steel beams.
walkways if the gallery slope exceeds 12. In case the slope of
gallery is between 6 to 12, suitable ribs shall be provided on
floor (without any sharp edges) at 250 to 300 mm intervals.
iv)
Provisions shall be made for emergency exit from galleries to
ground level preferably at four legged trestles and also for crossover above conveyor at 100 m intervals (maximum). The width of
cross over shall not be less than 750 mm.
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v)
Adequate provision for natural light inside conveyor gallery shall
be made through roof by providing translucent FRP sheets (as per
IS:12866 -1989) at about 20m spacings.
vi)
Protective hand railing shall be provided along gallery walkways,
open platform, stairways, landings, edges of walkways when the
gallery is not enclosed, and around erection openings, if any, to
ensure safety of operating personnel.
x)
Conveyor galleries longer than 150 m shall be provided with
expansion joints with twin trestles/supports. Each expansion block
shall have fixed support /rigid trestle with adequate arrangement
(provision of top chord and bottom chord bracing to gallery girder
etc.) for transferring the transverse and longitudinal forces to the
foundation.
xi)
Gallery girders near junction house shall be preferably supported
on trestle located as close to the junction house as possible, with
part of gallery girder between
junction house and trestle
cantilevered from the trestle. Supporting gallery girders on
junction house shall be avoided.
xii)
The underside of the belt conveyor shall be fully covered with 3
mm sheet in case of conveyor is located within the boundaries of
BTG area. . Outside the BTG boundary, the covering must be
provided, where the gallery crosses roads, railway lines or areas of
public gatherings. Conveyor Gallery truss shall be of latticed type
construction and shall support roof as well as floor deck
supporting conveyor system. The trusses shall be adequately
braced at top and bottom chord level to transfer the horizontal
wind forces to end portals.
4.4.2.5
1
Stacker cum reclaimer
Stackercumreclaimerrailshallbesupportedon
continuous
RCC
beam/
RCC wall type foundations. Expansion joint, preferably at every 30
metres shall be provided in thebeam/wall. Stacker / reclaimer conveyor
support shallalsobeprovided on the RC beam in the transverse directions
connecting the above two beam/wall in longitudinal directions.
2
The entire coal storage area shall be provided with adequately sloped PCC
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paving over rubble soling on hard rolled compacted subgrade. RCC
Garland drains around each of the coal stacks with removable precast
RCC slotted slabs shall be provided.These drains shall be adequately
sized for carrying drainage from coal yard and surrounding areas to
theRCC decantation /settling tank with baffle walls and lead to the coal pile
runoff pond (earthen pond). Decantationtankshallbesized to store about
30 minutes peak runoff. Coal pile runoff pond capacity shall be sufficient
to store about 30 days discharge.
3
RCC supports for dust suppression piping system shall alsobeprovided as
per
design
requirements.
Beyondthestockpileareauptojunctiontowers
oneitherside,foundationsfortrestlesandshortsupportsshall
also
be
provided as per design requirements. Thetopof pedestal shall project
aminimum of 300 mmabovethe finished ground / floorlevel.
4.4.2.6
Wagon tippler Complex
(Consists of tippler platform, hopper, wagon tippler tunnel, wagon tippler shed,
WT control room, MCC room, side arm charger, power pack room etc.)
1
TheWagon tippler hopper and the pit accommodating the sames h a l l
b e o f R C C and designed as water retaining structure. Due care shall be
taken during construction to make the pit & hopper completely
waterproof. Suitable sump shall be provided in the pit for dewatering.
The wagon tippler hopper shall be of RCC construction and adequately
sized to accommodate the coal load for at least three (3) nos. of 8
wheeled wagons (180 tons) of RDSO design used by Indian Railways.
For effective volumetric capacity computation of the hopper, the angle of
repose of coal shall be considered as 37. The minimum valley angle of
the hopper shall be considered as 60.
Steel gratings of mesh size 300 mm x 300 mm over wagon tippler hopper
shall be provided. The hopper and gratings shall be designed for
movement of front end loader/bulldozer over them. Bull-dozer weight
shall be considered. Wet coal column height of 1.5m shall also be
considered for grizzly design under separate load case over entire area of
grizzly.
The lowest level of grizzly shall be at finished floor level for easy removal
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of boulders coming along with the coal. Openings in the wagon tippler
shed shall be provided in such a way that the front end loader can access
the entire area of the grizzly. The minimum height of opening shall be
6m above plinth level. Plinth level of the pit shall be kept at least 500 mm
above graded level with RCC sloped paving on the dozer entry side of
adequate width to enable bulldozer/front end loader movement.
6
RCC access shaft with staircase leading to the bottom of the pit shall be
provided. Minimum width of the staircase shall be 1200mm. To facilitate
equipment/ machinery handling, Monorail with hoist shall be provided in
the access shaft projecting through double-leaf steel sliding door.
The wagon tippler shed shall be covered with permanently colour coated
metal sheets supported on columns. These columns shall be designed as
free standing structure.
Wagon tippler shed floor level shall be kept equal to rail top level.
4.4.2.7
1
Tunnels (Cut and Cover type), Pent houses and Transfer Houses
RCC Tunnels shall be provided for housing conveyors to evacuate coal
from underground hopper. Adequate head room shall be provided with
minimum headroom of 4.0m in tunnels. Tunnels shall be designed as
water retaining structure. Utmost care shall be taken during construction
to make it completely waterproof. On the tunnel floor, PCC M20 screed
with
non-
metallic
floor
hardner
shallbeprovided
sloping
toone/eithersideof the tunnel, where asmall longitudinal trench of
minimum 250 x 250mm deep with grating covers and edge
protection
angles
shallbeprovidedtolead
thedrainage/
seepage
tothenearest dewatering sump of 1.5 m deep. The spacing of sumps in
the tunnel shall be at suitable intervals not more than 200m c/c.
Provision for dewatering pump of appropriate capacity shall be made to
keep the system dry & hassle-free. Sumps of suitable capacity shall be
provided in the transfer house also facilitating the effective drainage.
2
Ventilation shafts shall be provided in a combination of RCC/ brickwork
Wherever
fitted with grills to keep the tunnel adequately ventilated.
the
tunnel
slope
exceeds
tunnelfloorshallbeprovidedwithPCCstepsto
operating
maintenance
caseofdoubleconveyor,suchstepsshall
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12
degrees,
the
facilitate
movement
of
personnel.
In
the
beprovidedin
thecentre
PAGE 292 OF 506
also.
2X800 MW YERMARAS TPS PROJECT
Tunnelshallbeprovidedwithwalkwayoneithersideofthe
conveyor.Handrailshallbe p ro v i de d o n b o th s id e s o f the w a l k w a ys
a s d e ta i l e d f o r c on v ey o r g a l l e r i es . Ho wev e r, the s in gle pi pe
han d ra il can be fixedtothetunnelwallto serveashandrail.
4
RCC
Penthouseshall
beprovided
at
the
l o ca t io n ,
tunnelentersthe
houseshallbeprovidedwithaliftingbeamtofacilitate
w h e re
th e
groundlevel.Pent
movement
of
equipment/ toolsto& from the tunnel.
5
RCC Transfer house shall be provided, at the junction of two tunnels.
Transferhouseis
theconveyors
similar
in
function
toajunctiontower,
meet
exceptthat
belowgroundlevel.
Transferhouseshallbedesignedaswaterretainingstructure and shall have
RCC
floors,
roof,
RCC
access
shaftwith
arrangementfor carrying equipmentup and down.
6
staircaseandmonorail
Properdrainagearrangementshallbeprovided in the lowest floor. Handrails
shall be provided around all floor openings. Plinth protection around
access
shaft
shall
be
provided
with
ramp
towards
the
door.
Onedoubleleafsteelslidingdoor for movement of equipmentand one
single leaf flush welded steel door for entry of personnel shall be
provided.
7
The tunnel or transfer house directly below or adjacent torailway line or
road passes, shall be appropriately designed to withstand the additional
imposed load as per relevant IRC/RDSO. Tell tale / warning signs shall be
provided
above
the
toidentifytheextentoftheundergroundstructure.
8
gradedground
All conveyor tunnels shall be designed for dozer load of approximately 36
tons or to withstand movement of crane with loads of cranes as per
manufactures specification. Suitable inserts at 3 m intervals shall be
embedded in both sides and underside for supporting cables. Drains of
250 x 250 mm deep shall be provided for drainage of tunnels withsumps
of adequate capacity at suitable intervals. The height of tunnels shall not
be less than 4.0 m.
9
All underground structures shall be provided with fillet of size 200 x
200mm between the wall and roof/floor.
4.4.2.8
Electrical / MCC rooms
Size and number of these buildings/ rooms shall be decided based on the
geographical location/arrangement of various components/facilities and their
electrical
load
requirementasmentionedintheElectricalportionofthisdocument.
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These shall generally be of RCC framed structure with cable vault as per
electrical system requirements. Side cladding shall be of brick walls with
provision of minimum two doors of adequate size and windows of adequate
number and size for proper ventilation and lighting. The fire barrier wall, if
required in front of transformer shall be provided as per TAC / LPA regulations.
The control room building shall be complete with toilet, drainage, plumbing,
sanitary etc. Roofshallbeadequatelyslopedpreferably without parapet to prevent
the accumulation of coal dust. However, handrails as specified elsewhere in this
document
shall
be
provided
in
place
of
RCC
abovesunshade,faciashallbeavoidedtopreventaccumulationof
parapet.
Similarly,
dust.
Central
control desk area shall be provided with false ceiling suitable for air
conditioning.Coal yard office & electrical maintenance room shall be provided on
first floor with attached toilets & drinking water facilities. Provision for water tank
of suitable capacity shall also be made. Coal yard office shall be air conditioned.
All electrical buildings/control room shall have a clear head room of 3.50 m
(minimum) at all floors.
4.4.2.9
Dust Suppression, Dust extraction and Ventilation system structures
All works pertaining toabovesystemsshall be provided as per requirement
basedon system design and may consistof RCC reservoirs/tanks, pump houses
with pump foundations, fan rooms with fan foundations etc., spread over the
complete Coal handling area. Location and details of these structures will depend
on requirement based on system design.
4.4.2.10 Bulldozer shed with/ Auto repair shop
This shall be of steel framed structure with permanently colour coated metal
cladding sheeting, with a column free area for bulldozer movement in shed area.
The minimum area for this facility shall be 400sqm. The auto repair shop shall
have sides with colour coated metal cladding sheeting except for bottom three
meters of brick work.
Ventilation and natural lighting shall be provided with
steel glazed side hung windows. Doors shall be of flush welded steel for
personnel movement. Rolling shutters of adequate size shall be provided for
movement of vehicle.
The floor shall be of RCC grade slab designed for heavy duty loading with
granolithic finish and non-metallic hardner. Necessary pit for servicing of
vehicles with all necessary steps etc. shall be provided in the repair area.
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Adequate provision for garland drains, roof drainage, dewatering sump, Plinth
protection etc shall also be made.
4.4.2.11 Emergency reclaim hopper/ Manual unloading hopper with shed
Hoppers shall be RCC construction. The pit shall accommodate the hoppers
along with feeders and conveyors below. The hopper pit shall be of RCC
construction and designed as water retaining structure. During construction,
proper provision shall be made to make the pit completely waterproof. Suitable
sump shall be provided in the pit to affect surface water drainage. RCC access
shaft shall be provided with staircase to the bottom of the pit. Monorail for
taking machinery into and out of the pit shall be provided in the access shaft
projecting through double leaf steel sliding door. Plinth level of the pit shall be
kept at least 500mm above graded level with RCC sloped paving all round to
enable bulldozer movement. Shed of minimum 6m height above hopper pit shall
be of structural steel construction. Two numbers of columns shall be raised at
the centre of the span on opposite sides of the pit and shall be designed as free
standing structure, to support double cantilever only by roof framing, to facilitate
dozer movement. These columns shall be encased with concrete as specified
elsewhere in this document to avoid direct impact to the columns by dozer
movement. Roof shall be provided with permanently colour coated metal
cladding sheeting as detailed elsewhere in this document. Steel gratings of
suitable mesh size over the hopper gratings shall be designed for movement of
front end loader/bulldozer over them. Bull-dozer weight shall be considered as
about 36T.
4.4.2.12 Loco Shed
A shed for locomotive maintenance with two no. of railway tracks shall be
provided. It shall be a steel framed structure with permanently colour coated
metal sheeting for roofing and
Side cladding
as detailed elsewhere in this
document.Bottom three meters of side cladding shall be of brick / solid concrete
block masonry. Ventilation and natural lighting shall be provided with steel
glazed side hung windows. The size and height of the shed shall be as per
railway / RDSO standards, keeping in mind the clearance required for traction
cables and columns. Provision for OHT crane of 15tonne capacity (minimum)
shall be made.
The floor shall be of heavy duty concrete floor with granolithic finish and nonmetallic hardner topping. Necessary guide rails and other items in the floor shall
also be provided as per railway standard / requirement.
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Necessary no. of pits of adequate size for servicing / repair of locomotives shall
be provided in the floor with suitable steps etc as may be required. Adequate
provision for dewatering sump, garland drains, roof drains, Plinth protection etc
shall also be made.
4.4.2.13 Coal sampling room & Coal office building
A coal sampling room shall be provided at a suitable location for preparation and
analysis of crushed coal samples. This shall be a two storied RCC framed building
with RCC roof and brick/solid concrete block masonry walls. Minimum size of the
building shall not be less than 20 x 20m, each in ground & first floor of the
building for keeping coal samples, coal crushing, weighing and other required
equipmentand also to accommodate O & M staff. One smaller enclosure shall be
provided in the building with masonry partition wall where ovens or other
required equipment shall be kept.
The rooms shall have working platforms of adequate width for keeping crushers
and other required equipment and performing routine activities. Adequately
sized shelves shall also be provided in the building. The floor shall be of heavy
duty concrete floor with granolithic finish and non-metallic hardner topping.
Adequate ventilation and natural lighting shall be provided with steel glazed side
hung windows. Doors shall be of flush welded steel for personnel movement. The
building shall be complete with drainage, plumbing, sanitary, plinth protection
etc. Roofshallbeadequatelyslopedpreferably without parapet to prevent the
accumulation of coal dust. However, handrails as specified elsewhere in this
document
shall
be
provided
in
place
of
RCC
parapet.
Similarly,
abovesunshade,faciashallbeavoidedtopreventaccumulationof dust.
4.4.2.14 Important Buildings and Systems
i.
MCC Room / Control Room / Maintenance office
ii.
Pipe racks / Cable racks/ trestle supports/junction towers.
iii.
Foundations, pedestals, trenches, tunnels, transfer houses, pent houses,
crusher houses, wagon tippler complex, stacker reclaimer etc. for entire
coal handling system.
iv.
Cranes/Hoists/monorails in coal handling plant
v.
About 15 nos. of toilet blocks along with adequate size of soak pit /
septic tanks and water tanks and connections are to be provided in the
coal handling area. The location and size of the toilets blocks to be
decided during detail engineering.
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vi.
Any other civil / structural work not mentioned here, but required for
completing the scope of mechanical or electrical works in the coal
handling system.
Structural arrangement, foundation system, cladding interior and exterior
finishes, area paving etc., shall be as per total plant building design and finish
schedule furnished elsewhere in the specification.
The compressors and their associated equipment shall be housed in RCC
building along with requisite MCC and control room. Crane / monorail of
adequate capacity shall also be provided in all pump / compressor house.
4.4.2.15 Codes & Standards
The following Indian codes and standards shall be used for analysis, design and
construction and quality control system of all civil and structural works. In all
cases latest revisions with amendments, if any shall be followed. Apart from the
specific codes mentioned herein, all other relevant and related codes concerning
the specific jobs under consideration and/or referred to in these codes and
technical specification shall be followed wherever applicable. (All codes shall be
latest as on the date of issuing the Tender/Bid document).
EXCAVATION AND FILLING
IS: 9758
IS: 10379
Guide lines for Dewatering during construction
Code
of
practice
PROPERTIES,
BUILDING
IS: 383
for field
control
of
moisture
and
compaction of soils for embankment and sub-grade
STORAGE
AND
HANDLING
OF
COMMON
MATERIALS
Specification for coarse and fine aggregates from natural
sources for concrete
IS: 455
Specification for Portland Slag Cement
IS: 808
Rolled steel Beam channel and angle sections
IS: 1077
Specification for common burnt clay building bricks
IS: 1161
Specification of steel tubes for structural purposes
IS: 1363
Hexagon head Bolts, Screws and nuts of production grade C
IS: 1364
Hexagon head Bolts, Screws and Nuts of Production grade A
&B
IS: 1489 (Part I)
Specification for Portland Pozzolona Cement Fly ash based
IS: 1542
Specification for sand for plaster
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IS: 1786
Specification for high strength deformed bars for concrete
reinforcement
IS: 2062
Specification for steel for general structural purposes
IS: 2116
Specification for sand for masonry mortars
IS : 2185 Part I
Specification for Concrete Masonry, Hollow and Solid
concrete blocks
IS : 2185 Part II
Specification for Concrete Masonry, Hollow and solid Light
weight Solid concrete blocks
IS: 2386
(Parts-I to VIII)
Testing of aggregates for concrete
IS: 3812
Specification for Pulverised Fuel Ash Part I -for use as
(Part I & II)
Pozzolona in Cement, Cement Mortar and Concrete; Part II
IS: 4031
Methods of physical tests for hydraulic cement
for use as Admixture in Cement Mortar and Concrete
(All Parts)
IS: 4032
IS: 4082
Methods of chemical analysis of hydraulic cement
Recommendations on stacking and storage of construction
materials at site
IS: 8112
Specification for 43 grade ordinary Portland cement
IS: 8500
Medium and high strength structural steel.
IS: 12269
53 grade ordinary Portland cement
CAST-IN-SITU CONCRETE AND ALLIED WORKS
IS: 456
Code of practice for plain and reinforced concrete
IS: 516
Method of test for strength of concrete
IS: 650
Specification for standard sand for testing of cement
IS: 1199
Methods of sampling and analysis of concrete
IS: 1791
General requirements for batch type concrete mixers
IS: 2502
IS: 2505
Code of practice for bending and fixing of bars for concrete
reinforcement
General requirements for concrete vibrators, immersion
type
IS: 2645
Specification for Integral cement water proofing compounds
IS: 2750
Specification for Steel scaffolding
IS: 2751
Code of practice for welding of mild steel plain and
deformed bars for reinforced concrete construction
IS: 3370
Code of practice for concrete structures for the storage of
(Part I to IV)
liquids
IS: 3414
Code of practice for design and installation of joints in
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buildings
IS: 3558
IS: 4014
(Parts I & II)
IS: 4326
IS: 4990
IS: 5525
Code of practice for use of immersion vibrators for
consolidating concrete
Code of practice for steel tubular scaffolding
Code of practice for earthquake resistant design and
construction of buildings
Specification for plywood for concrete shuttering work
Recommendations
for
detailing
of
reinforcement
reinforced concrete work
IS: 5624
Specification for foundation bolts
IS: 6461
Glossary of terms relating to cement concrete
IS: 6509
IS: 7861
Code of practice for installation of joints in concrete
pavements
Code of practice for extreme weather concreting. (Parts I &
II)
IS: 9012
Recommended practice for shot concreting
IS: 9103
Specification for admixtures for concrete
IS: 10262
Recommended guidelines for concrete mix design
IS: 11384
IS: 12118
IS: 12200
in
Code of practice for composite construction in structural
steel and concrete
Specification for two-parts poly sulphide
Code of practice for provision of water stops at transverse
contraction joints in masonry and concrete dams
IS: 13311
Method of non-destructive testing of concrete
Part-1
Ultrasonic pulse velocity
Part-2
Rebound hammer
SP:23
Handbook of concrete mixes
SP: 24
Explanatory Handbook on IS: 456-1978
SP: 34
Handbook on concrete reinforcement and detailing
PRECAST CONCRETE WORKS
SP:
7(Part
Sec.7)
VI/ National Building Code- Structural design of prefabrication
and systems building.
Code of practice for design and construction of floors and
IS: 10297
roofs using precast reinforced/prestressed concrete ribbed
or cored slab units.
IS: 10505
Code of practice for construction of floors and roofs using
pre-cast reinforced concrete units
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MASONRY AND ALLIED WORKS
IS: 1905
Code of Practice for Structural Safety of Buildings-Masonry
walls
IS: 2212
Code of Practice for Brickwork
IS: 2250
Code of Practice for Preparation and use of Masonry Mortar
SP: 20
Explanatory hand book on masonry code
SHEETING WORKS
IS:277
IS: 730
IS: 2527
Galvanised steel sheets (plain or corrugated).
Specification for fixing accessories for corrugated sheet
roofing
Code of practice for fixing rain water gutters and down pipe
for roof drainage
IS: 7178
Technical supply conditions for tapping screw
IS: 8183
Bonded mineral wool
IS: 8869
Washers for corrugated sheet roofing
IS: 12093
IS: 12866
IS: 14246
Code of practice for laying and fixing of sloped roof
covering using plain and corrugated galvanised steel sheets
Plastic
translucent
sheets
made
from
thermosetting
polyester resin (glass fibre reinforced).
Specification for continuously pre-painted galvanised steel
sheets and coils
FABRICATION AND ERECTION OF STRUCTURAL STEEL WORK
IS: 2016
IS: 814
IS: 1852
Specification for plain washers
Specification for covered Electrodes for Metal Arc Welding
for weld steel
Specification for Rolling and Cutting Tolerances for Hot
rolled steel products
IS: 3502
Specifications for chequered plate
IS: 6911
Specification for stainless steel plate, sheet and strip
IS: 3757
Specification for high strength structural bolts
IS: 6623
Specification for high strength structural nuts
IS: 6649
High Tensile friction grip washers
IS: 800
IS: 816
IS: 4000
Code of practice for use of structural steel in general
building construction
Code of practice for use of Metal Arc Welding for General
Construction
Code of practice for assembly of structural joints using high
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tensile friction grip fasteners
IS: 9595
IS: 817
IS: 1811
Code of procedure of Manual Metal Arc Welding of Mild
Steel
Code of practice for Training and Testing of Metal Arc
Welders
Qualifying tests for Metal Arc Welders (engaged in welding
structures other than pipes).
IS: 7215
Tolerances for fabrication steel structures
IS: 12843
Tolerance for erection of structural steel
SP: 6
(Part 1 to 7)
IS: 1608
IS: 1599
IS : 2595
IS : 3664
IS : 3658
IS : 5334
Hand book for structural Owner/Engineers
Method of Tensile Testing of Steel products other than
sheets, strip, wire and tube
Method of Bend Tests for Steel products other than sheet,
strip, wire and tube
Code of Practice for Radio graphic testing
Code of practice for Ultra sonic Testing by pulse echo
method
Code of practice for Liquid penetrant Flaw Detection
Code of practice for Magnetic Particle Flaw Detection of
Welds
PLASTERING AND ALLIED WORKS
IS : 1661
Application of cement and cement lime plaster finishes
IS : 2333
Plaster-of-Paris
IS : 2402
Code of practice for external rendered finishes
IS : 2547
Gypsum building plaster
WATER SUPPLY, DRAINAGE AND SANITATION
IS : 458
IS : 554
Specification for concrete pipes
Dimensions for pipe threads, where pressure tight joints are
made on thread
IS : 651
Specification for salt glazed stoneware pipes
IS : 774
Flushing cisterns for water closets and urinals
IS : 775
Cast iron brackets and supports for wash basins and sinks
IS : 778
IS : 781
Copper alloy gate, globe and check valves for water works
purposes
Cast copper alloy screw down bib taps and stop valves for
water services
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IS : 782
Caulking lead
IS : 783
Code of practice for laying of concrete pipes
IS : 1172
IS : 1230
IS : 1536
IS : 1537
IS : 1538
IS : 1703
IS : 1726
IS : 1729
Basic
requirements
for
water
supply,
Cast iron rain water pipes and fittings
Centrifugally cast (Spun) iron pressure pipes for water, gas
and sewage
Vertically cast iron pressure pipes for water, gas and
sewage
Cast iron fittings for pressure pipe for water, gas and
sewage
Ball valves
(horizontal plunger type) including float for
water supply purposes
Cast iron manhole covers and frames
Sand cast iron spigot and socket, soil, water and ventilating
pipes, fittings and accessories
Code of practice for building drainage
IS : 1795
Pillar taps for water supply purposes
IS : 1879
Malleable cast iron pipe fittings
Code of practice for selection, installation and maintenance
of sanitary appliances
IS : 2065
Code of practice for water supply in building
IS : 2326
Automatic flushing cisterns for urinals
IS : 2470
(Part-I & II)
IS : 2548
IS : 2556
(Part 1 to 15)
Code of practice for installation of septic tanks
Plastic seat and cover for water-closets
Vitreous sanitary appliances (vitreous china).
IS : 3114
Code of practice for laying of cast iron pipes
IS : 3438
Silvered glass mirrors for general purposes
IS : 3486
Cast iron spigot and socket drain pipes
IS : 3589
IS : 3989
and
sanitation
IS : 1742
IS : 2064
drainage
Electrically welded steel pipes for water, gas and sewage
(200mm to 2000mm nominal diameter).
Centrifugally cast (Spun) iron spigot and socket soil, waste
and ventilating pipes, fittings and accessories
IS : 4127
Code of practice for laying of glazed stone-ware pipes
IS : 5329
Code of practice for sanitary pipe work above ground for
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buildings
IS : 5382
Rubber sealing rings for gas mains, water mains and sewers
IS : 5961
Cast iron grating for drainage purpose
IS : 7740
Code of practice for road gullies
IS : 8931
Cast copper alloy fancy bib taps and stop valves for water
services
IS : 9762
Polyethylene floats for ball valves
IS : 10446
Glossary of terms for water supply and sanitation
IS : 10592
IS : 12592
IS : 12701
Industrial emergency showers, eye and face fountains and
combination units
Specification for precast concrete manhole covers and
frames
Rotational moulded polyethylene water storage tanks
Hand book on water supply and drainage-Manual on
SP: 35
Sewerage and sewage treatment (Published by CPH & EEO)
As updated
DOORS, WINDOWS AND ALLIED WORKS
IS : 204
Tower Bolts
Part-I
Ferrous metals
Part-II
Nonferrous metals
IS : 208
Door Handles
IS : 281
Mild steel sliding door bolts for use with padlocks
IS : 362
Parliamentary Hinges
IS : 420
Specification for putty, for use on metal frames
IS : 1003
Specification for timber panelled and glazed shutters-Part-I
(Part-I)
door shutters
IS : 1038
Steel doors, windows and ventilators
IS : 1081
Code of practice for fixing and glazing of metal (steel and
Aluminium) doors, windows and ventilators
IS : 1341
Steel butt hinges
IS : 1361
Steel windows for industrial buildings
IS : 1823
Floor door stoppers
IS : 1868
Anodic coatings on Aluminium and its alloys
IS : 2202
Specification for wooden flush door shutters (solid core
(Part-II)
type); particle board face panels and hard board face panels
IS:2209
Mortise locks (vertical type).
IS:2553
Safety glass
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IS:2835
Flat transparent sheet glass
IS:3548
Code of practice for glazing in buildings
IS:3564
Door closers (Hydraulically regulated).
IS : 3614
Fire check doors; plate, metal covered and rolling type
IS:4351
Steel door frames
IS:5187
Flush bolts
IS:5437
Wired and figured glass
IS:6248
Metal rolling shutters and rolling grills
IS:6315
Floor springs (hydraulically regulated) for heavy doors
IS:7196
Hold fasts
IS:7452
Hot rolled steel sections for doors, windows and ventilators
IS:10019
Mild steel stays and fasteners
IS:10451
Steel sliding shutters (top hung type).
ROOF WATER PROOFING AND ALLIED WORKS
IS:1322
IS:1346
IS:1580
IS:3067
IS:3384
Specification for bitumen felts for water proofing and damp
proofing
Code of practice for water proofing of roofs with bitumen
felts
Specification for bituminous compound for water proofing
and caulking purposes
Code of practice for general design details and preparatory
work for damp proofing and water proofing of buildings
Specification for bitumen primer for use in water proofing
and damp proofing
FLOOR FINISHES AND ALLIED WORKS
IS:1237
IS:1443
Specification for cement concrete flooring tiles
Code of practice for laying and finishing of cement concrete
flooring tiles
IS:2114
Code of practice for laying in-situ terrazzo floor finish
IS:2571
Code of practice for laying in-situ cement concrete flooring
IS:4971
Recommendations for selection of industrial floor finishes
IS:8042
Specification for white Portland cement
IS:13801
Specification for chequered cement concrete flooring tiles
PAINTING AND ALLIED WORKS
IS:1477
Code of practice for painting of ferrous metals in buildings
Part-I
Pre-treatment
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Part-II
Painting
IS:1650
Specification for colours for building and decorative finishes
Specification for red oxide-zinc chrome, priming, ready
IS:2074
mixed paint air drying
Part-I
Operations and workmanship
Part-II
Schedules
Code of practice for painting concrete, masonry and plaster
IS:2395
surfaces
Part-I
Operations and workmanship
Part-II
Schedule
Specification of synthetic enamel paint, exterior, under-
IS:2932
coating and finishing
IS:2933
Specification enamel paint, under coating and finishing
Code of practice for hot dip zinc coating on structural steel
IS:4759
and other allied products
IS:5410
Specification for cement paint
IS:5411 (Part-I)
Specification for plastic emulsion paint-for exterior use
IS:6278
Code of practices for white washing and colour washing
IS:10403
Glossary of terms relating to building finishes
PILING AND FOUNDATION
Code of practice for design and construction of simple
IS:1080
spread foundations
Code of practice for design and construction of foundations
IS:1904
in Soils; General Requirements
IS:2950 (Part-I)
IS:2974
to V)
Code of practice for designs and construction of Raft
foundation
(Part-I Code of practice for design and construction of machine
foundations
IS:6403
IS:8009
Code of practice for determination of Allowable Bearing
pressure on Shallow foundation
Code of practice for calculation of settlement of foundation
subjected to symmetrical vertical loads
Part-I
Shallow foundations
Part-II
Deep foundations
IS:12070
Code of practice for design and construction of shallow
foundations on rocks
LOADING
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IS:875 (Pt. I to Code of practice for design loads other than earthquake) for
V)
buildings and structures
IS:1893
Criteria for earthquake resistant design of structures
SAFETY
IS:3696 (Part I &
II)
Safety code for scaffolds and ladders
IS:3764
Safety code for excavation work
IS:7205
Safety code for erection on structural steelwork
IS:7293
Safety code for working with construction machinery
IS:7969
Safety code for handling and storage of building materials
4.4.3 Field Quality Plan
Field Quality Plan detailing out all the equipment, quality practices and
procedures etc to be followed by the Contractor during various stages of site
activities starting from receipt of materials/equipment shall be submitted by the
shall be submitted for Owner/ Engineers approval.
All major bought out items shall be included in the quality plan. The Quality plan
shall inter alia include following works/ Bought out items wherever relevant with
respect to the Technical specifications and drawings.
Earthwork & roadworks including selection of fill material, compaction,
proctor density tests, preparation of subgrade and subbase for
paving/roadworks etc.
Bituminous paints for water proofing & Bituminous concrete's
Cement, reinforcement steel & structural steel procurements
Coarse/ Fine aggregates, ash, water for concrete
Cast-in-situ concrete & allied works
Masonry & allied works
Sheeting & Allied Works
Water supply & sanitation
Structural steel works including approved welding procedures
Floor finishes, tiling etc.
Doors including fire proof doors, windows, ventilators, partitions, louvers,
rolling shutters etc
False ceiling & insulation systems
Roof metal decking/ Wall claddings
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Painting system- Procurement & application
Acid- Alkali lining and tiles: Procurement & application
Electro forged gratings
Concrete Admixtures, chemical injection grouting, waterproofing chemicals
etc.
Anti-termite treatments
Preparation of Concrete joints & joint fill materials
Roof water proofing
Pond/ Hydraulic tests of water retaining structures
Drainage/ Cross drainage works/ Hume pipes
Glazing & aluminium works as specified
3.1.1
i)
IS Codes & References
All the Indian Standards referred to shall be the latest revision (including
all amendments issued thereto) at the time of execution.
ii)
Reference to only some of the codes in this document and various clauses
of design criteria shall not limit or restrict the scope or applicability of
other relevant codes. It shall be ensured that all other codes relevant to a
specific job, in addition to those already mentioned, are followed
wherever applicable.
iii)
Where British / American / DIN or other codes and standards are referred
to in this document, equivalent Indian Standards may be substituted if
available.
iv)
In case of any deviation / conflict between provisions of IS codes, CEA
guidelines and the design criteria, the provisions that are more stringent
v)
shall be followed unless specifically directed otherwise.
The Codes and Standards listed below are applicable for the design and
construction of structures and buildings in general. Codes and Standards
applicable for specific design and construction are listed elsewhere in
reference sections.
vi)
Specifications for materials supplied from India follow the Indian Standard
Specifications.
vii)
Field and laboratory testing procedures for materials follow Indian
Standard Specifications.
viii)
Working stress design can be used as alternative but the approval of
OWNER is a prerequisite.
ix)
A sample design calculation for items like foundations, columns, beams
etc. shall be provided whenever in house software has been used for the
designs to validate the design calculations.(Like MS Excel, Work sheet)
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x)
For detailed civil specifications, Part C of this document shall be referred.
4.4.4 Deliverables
1.
Design Basis Report
2.
Design Calculations input data and output in editable format of soft
3.
Geotechnical investigation report by bidder
4.
Drawings General Arrangement drawings, Equipment and load data
copy and also hard copy
drawings, Detailed RCC Drawings, civil work details, Architectural details &
drawings, Drainage scheme drawings, BOQ, Structural steel design and
fabrication drawings in Auto Cad latest version - editable format.
5.
QA & QC Plan
6.
List of bought out items, quantity & suppliers
7.
List of Field Laboratory Equipment
8.
Schedule of Buildings with their sizes, type of construction, Architectural
details/ finishes etc.
9.
All the drawings/design documents shall be furnished both in soft (editable
format) and hard copies.
10. Standard notes and drawings for steel and concrete structures along with
typical details of handrails, staircase, sunshades, grade slabs etc.
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5.0 OPERATION & CONTROL PHILOSOPHY
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OPERATION & CONTROL PHILOSOPHY
The operation and control of the Coal Handling Plant (CHP) and associated DE DS
plant shall be performed from its own dedicated PLC located in the Coal
Handling Plant Control Room through Three nos. (3) Operator Stations, one (1)
number Operator Station cum Engineering Work Station and color graphic
displays of 2 x 52 thin bezel LCD monitors. The three (3) Nos. 24 LCD/TFT
monitors shall be configured to display alarm and also serve normal operation,
however, hard annunciation facia shall be provided for alarm and annunciation.
The PLC system of CHP shall have redundant MODBUS TCP/IP connectivity with
the Stacker & Reclaimer PLC system through cable reeling drum, further
alternative connection shall be discussed and finalised during detail engineering.
The PLC system of CHP shall have redundant MODBUS TCP/IP connectivity with
the wagon tippler PLC located at the Wagon tippler control cabin.
One (1) no. A3 colour size laser jet printer shall be provided which shall be
connected to the data highway and One (1) no. dot matrix printer shall be
provided which shall be connected directly to the engineering work station. The
required furniture such as operator desk, chairs, etc shall be provided by the
bidder. The CHP PLC shall be linked to DCS through high speed redundant
TCP/IP fast Ethernet connectivity as well as hardwired signals for monitoring
purposes. The following signals as minimum shall be hardwired directly from
CHP PLC to DCS:
Coal Flow Indication
Coal Handling Plant in operation
Coal Handling Plant in trouble
Operation of the coal handling plant shall be based on the coal flow path
selection. The operator shall be able to select from PLC the desired Coal flow
path of the coal delivery, delivering coal from Track hopper/ Wagon Tippler to
the coal bunkers or coal stockyard, or from coal stockyard to the bunkers.
The coal handling plant operator shall select any one of the above paths from
monitor located on the main control desk. The flow stream path is then selected
by positioning different flap gates at the desired position from monitor to select
the conveyors. Once the system is in operation, the gates cant be moved from
their positions and path. After the selected path is in operation the movement of
the path selector will not have any effect on the system. The system shall be in
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operation with a time delay and with a hooter sound. If selection is wrong, PLC
shall generate an audio-visual warning.
The control system will be designed for Auto & Manual operation of the
conveyors in the selected path. Auto / Manual selection shall be done from the
keyboard.
Auto Mode: In the Auto mode, the conveyors and related equipment will start
sequentially when the System Start is activated. During stopping, when the
System Stop is activated, all conveyors will stop sequentially (in the reverse
sequence) allowing time delays for clearing the materials on conveyor.
Manual Mode: In Manual Mode, the operator will start the conveyor system in
the same sequence as in Auto mode by pressing individual Start push buttons.
The operator will also stop the conveyor system, by pressing System stop or
individual Stop push buttons in the reverse sequence.
All the conveyors shall be protected from reverse running due to power failure
by providing mechanical or electrical locking system.
The starting sequence of the conveyors shall follow a direction opposite to that
of flow of material i,e :
1.
In case of direct conveying of coal to boiler bunkers, start from bunker
2.
In case of stacking of coal in stockyard, start from yard conveyor and end
conveyor end up with reclaim conveyor below track hopper/ wagon tippler.
up with reclaim conveyor. However for yard conveyor to start, the stacker reclaimer shall be in operation.
3.
In case of reclamation of coal from stockyard, start from bunker conveyors
and end up with yard conveyor along with stacker reclaimer.
4.
The starting of paddle feeder shall be interlocked with operation of the
reclaim conveyors below track hopper.
Interlocking of yard conveyor with stacker reclaimer boom conveyor shall be
provided.
Any individual equipment (belt conveyor etc.) should not be allowed to start
unless the equipment immediately following the same in the direction of flow of
material is already in operation. Stop / tripping of any equipment from running
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condition shall trip all preceding equipment in the system, but shall not effect
succeeding ones which shall continue to operate except crushers. Interlocking of
various conveyors shall be achieved with Flap gate, Rack & Pinion gate, limit
switches and zero speed switches.
Motors shall start only when the brake / rail clamp if provided, is in not
applied condition.
Crushers shall be provided with fluid coupling oil temperature, speed and
vibration monitoring instruments. Crushers shall trip in case fluid coupling oil
temperature/ speed / vibration are going beyond set limits of design.
Once a conveyor trips, flap gate directing coal from this conveyor shall change
over its position with a time delay and shall come back to the original position
again. This is to prevent jamming of gate. Tripping of the respective conveyor
shall be provided in case of any paddle feeders and mobile trippers start running
along with conveyor belt at speed higher than their rated speed.
It shall be possible to trip bunker conveyor and yard conveyor from paddle
feeder, mobile tripper and stacker / reclaimers respectively.
Stacker & Reclaimer Control: Stacker & reclaimer system shall be operated
through separate redundant PLC based Control panel at stacker cabin and same
shall be interfaced with the Coal handling plant PLC system through cable
reeling drum, further alternative connection shall be discussed and finalised
during detail engineering.
Wagon tippler and side arm charger Control: Wagon tippler & Side arm charger
shall be operated and controlled from the Local Control panel in the Wagon
tippler control cabin. The PLC system of CHP shall have redundant MODBUS
TCP/IP connectivity with the Wagon tippler PLC located at the Wagon tippler
control cabin. Monitoring of the Wagon tippler and side arm shall also be done
from the CHP control room.
Dust Suppression and dust extraction control: The fixed nozzles spraying water
on to coal at the discharge of various conveyors, shall be energised only
when the respective conveyors are operating.
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The DS system of W.T. Hoppers shall have provision for interlocking with the
wagon unloading mechanism. The system shall be controlled from W.T. Hopper
Control Rooms. D.S System for waiting wagon in W.T area shall however be
separately controlled through solenoid valve from W.T Hopper Control Rooms.
Dust suppression system at crushed coal pile area shall be operated through
solenoid valves. The system shall be controlled from central control desk cum
mimic of the coal handling plant.
All dust extraction system shall be started or stopped manually from the central
control desk of CHP in addition to local start/stop push button. The stop P.B.
shall be lockable type with Indication in mimic panel. The Start/Stop system for
dust suppression and ventilation equipment shall also be similar.
Remote electrically operated butterfly type dampers will be provided at each
dust extraction point with multiple extraction point for balancing the air flow.
Ventilation systems shall be started and stopped manually from CHP control
room. Local Start/Stop Push Button shall also be provided. The stop P.B. shall be
of lockable type.
Interlocking: Generally the following conveyors / equipment will come under
interlock scheme:
1)
Conveyors
2)
Flap gates
3)
Rack & Pinion gates
4)
Metal detectors
5)
Magnetic Separators and suspended magnets
6)
Crushers
7)
Vibrating feeders
8)
Paddle feeders
9)
Belt Scale
10) Travelling Trippers
11) Stacker- Reclaimer
The following equipment shall not generally come under interlock of the
conveyor scheme.
1)
All dust suppression systems & service water system
2)
Ventilation systems
Doc. No.: E072-03-CHP-O-02
REV. NO.: R3
PAGE 313 OF 506
2X800 MW YERMARAS TPS PROJECT
3)
Maintenance equipment
All conveyors and equipment shall have local push buttons. Belt scale shall be
started when relevant conveyors are started. The dust suppression systems will
be energized as soon as the conveyors at the transfer points are energized.
Interlock for H.T. Motor: H.T. motors shall continue to run on no load by
disengaging the fluid coupling in the event of failure of any process interlock.
The H.T. motors will however be tripped in the event of any motor fault like O/L,
high motor winding temperature etc.
Safety interlocks to be taken care for conveyors and other equipment as a
minimum.
Conveyors:
1)
Pull chord switch not operated
2)
Belt Sway switch not operated
3)
Under speed switch closed at 90% speed of the conveyor within designed
accelerating time
4)
Motor protection - not tripped
5)
Local stop PB - reset
6)
Chute Block switch not operated
7)
Brakes for conveyor ---not operated
8)
Trip circuit healthy
9)
Temp of fluid coupling oil --- not high
10) Zero speed switch Closed at 90% of belt conveyor speed
Paddle Feeders
1)
Motor O/L --- not tripped
2)
Local stop PB - reset
3)
Stop PB in main CHP control room -- reset
4)
All limit switches -- reset
Travelling Tripper
1)
Motor O/L --- not tripped
2)
Local stop PB - reset
3)
Over travel limit switches not tripped
Magnetic Separators / Metal Detectors/Suspended Magnets
Doc. No.: E072-03-CHP-O-02
REV. NO.: R3
PAGE 314 OF 506
2X800 MW YERMARAS TPS PROJECT
1)
O/L / fault relay - not tripped
2)
Stop PB(Local & Remote ) --reset
3)
Metal detector -- reset
Vibrating Feeder
1)
Motor O/L --- not tripped
2)
Local stop PB reset
Flap Gates and Rack& Pinion Gates
1)
End of travel limit switches -- reset
2)
Torque limit switches - reset
3)
Local stop - reset
Crusher
1)
Zero Speed not operated
2)
Vibration level not high
3)
Temp of fluid coupling oil not high
4)
Local stop push button reset
Doc. No.: E072-03-CHP-O-02
REV. NO.: R3
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2X800 MW YERMARAS TPS PROJECT
6.0 SPARES LIST
Doc. No.: E072-03-CHP-O-02
REV. NO.: R3
PAGE 316 OF 506
2X800 MW YERMARAS TPS PROJECT
SPARES
6.1
MECHANICAL
S.No.
1.0
Description
Quantity
Conveyors
(a) Idlers
10% of the total no. of idlers of
each type subject to a minimum of
ten (10) no.
Pulley bearings
Five (05) nos. of each type / size.
Plummer Blocks
Five (05) nos. of each type / size.
(d)Conveyor gear box complete set
Two (02) nos. of each size
(e)Fluid coupling complete set
Two (02) nos. of each size
(f)Flexible coupling complete set
Three (03) nos. of each size
(g) Thrustor brakes
Two (02) nos. of each size
(h) Thrustor brake liners
10m in each size
(i) Rubber strip for skirt board
100m
2.0
Wagon Tippler
2.1
Rack segments
12 Nos.
2.2
Bushes
03 complete sets
2.3
Bearings except drive gear box
03 complete sets
2.4
Main drive unit
(a) Rack and pinion
06 Nos.
(b) Brake liners
06 sets
(c) Thrusteor for brake
03 Nos.
(d)
Pin & rubber bushes for brake 12 sets
coupling
(e) Hydraulic motor & solenoid 03 complete set
valves
(f) Electric motor for main power 02 Nos
pack pump
2.5
Rubber blocks for assembly of top
03 complete sets
stop clamping device
2.6
Electric motor for SAC power pack
2.7
Snap ring for assembly of
02 Nos
hinge 24 Nos.
pieces
3.0
Apron Feeder
3.1
Carrying rollers
30 Nos.
3.2
Chain link with pins and bushes
30 sets
3.3
Apron pans
30 sets
Doc. No.: E072-03-CHP-O-02
REV. NO.: R3
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2X800 MW YERMARAS TPS PROJECT
S.No.
Description
3.4
Apron spur pinion
3.5
Apron feeder drive
(a)
Quantity
06 Nos.
DC motor with spare carbon 02 Nos.
brushes (9) and slipring (4)/AC
motor if VFD drive is provided.
(b) Thyristor/VFD panel spares
1 No of each type of card, CT,
Transformer etc
4.0
(a) Idlers for Dribble Feeder
10 Nos.
(b) Belt switches
15 Nos
5.0
Rotary Breaker (Primer Crusher)
5.1
Lifting shelves
06 Nos.
5.2
Deflector
03 Nos
5.3
Screen plate
15 Nos.
5.4
Main roller bearings
06 Nos.
5.5
Adapter assembly
06 Nos.
5.6
HT bolts for screen plates
100 Nos
5.7
Guide rollers
03 sets complete
5.8
Gear Box
Bearings (complete for Gear box)
03 Nos. of each size & type
Oil seals
03 Nos. of each size & type
5.9
Chain (complete)
03 sets
6.0
Ring Granulator Crusher
(Secondary crusher)
6.1
Hammer rings (plain / toothed)
Three (03) sets (one set means
complete for one crusher)
6.2
Roller bearings with plumber block
Three (03) sets
6.3
Liners
Three (03) sets
6.4
Kick-off plate
Three (03) sets
6.5
Cage bar
Three (03) sets
6.6
Cage breaker plate
Twelve (12) Nos
6.7
Suspension bars
Twenty four (24) Nos
6.8
Screen plate
Twelve (12) Nos
7.0
Stacker cum Reclaimer
7.1
Drive Bogie
Bogie wheel complete with
06 Nos.
bearings
Spur wheel
Doc. No.: E072-03-CHP-O-02
06 Nos.
REV. NO.: R3
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2X800 MW YERMARAS TPS PROJECT
S.No.
Description
Quantity
Labyrinth seal
12 Nos.
Drive motor, coupling and gear 02 sets
box (complete assembly)
Pinion
7.2
06 Nos.
Non-drive bogie
Bogie wheel complete with
06 Nos.
bearings
Labyrinth seal
7.3
7.4
7.5
7.6
12 Nos.
Reduction gear
Pinion and wheel (1st pair)
06 sets
Bearings complete for Gear box
06 sets
Oil seals
08 sets
Liners for brakes
09 sets
Slewing gear mechanism
Pinion & shaft (1st pair)
02 sets
Slewing ring bearings
02 sets
Oil seals
06 sets
Electric motor for slew power pack
01 No
Reduction gear box for boom
03 Nos.
conveyor (complete)
7.7
Luffing Mechanism
Hydraulic piston & cylinder with
04 sets
bellows
Hydraulic pump complete
03 Nos.
(c) Electrical motor for luffing
2 Nos
mechanism power pack
7.8
Bucket wheel mechanism
(a) Reduction gear
(i) Pinion & wheel (1st pair)
02 sets
(ii) Bearings complete for Gear Box
02 sets
(iii) Oil seals
06 sets
(b) Bucket wheel drive
7.9
(i) Hydraulic motor and pump
03 sets
(ii) Solenoid valves
Three (03) sets complete
(iii) Electrical motor for power pack
01 No
Bucket wheel
complete buckets with teeth
Doc. No.: E072-03-CHP-O-02
REV. NO.: R3
04 Nos.
PAGE 319 OF 506
2X800 MW YERMARAS TPS PROJECT
S.No.
Description
Quantity
7.10
Feed table impact idlers
8.0
Motorised Travelling Tripper
8.1
Bearing for travel wheel
8.2
Travel drive
8.3
9.0
15 Nos.
Six (06) Nos.
(a) Gear box (complete)
Two (02) Nos
(b) Flexible coupling
Four (04) Nos
(c) Electric motor for travel drive
Two (02) Nos
Rollers for seal belt
Eight (08) Nos.
Vibrating screen/Grizzle Feeder
9.1
Bearings
04 Nos. of each type and size
9.2
V-belt
06 sets
9.3
Eccentric disc
06 sets
9.4
Oil seals for gear box
12 sets
9.5
Spacers with discs and shaft (1 set
08 sets
complete for one screen)
10.0
Mechanical vibrating feeder
10.1
Bearing
04 Nos of each type and size
10.2
V-Belt
06 Sets
10.3
Eccentric disc
06 Sets
11.0
Telescopic Chute
11.1
Gear box
03 Nos.
11.2
Sheeves
03 Nos. of each type & size
11.3
Bearings
03 Nos. of each type and size
12.0
Inline Magnetic Separators
12.1
Head pulley
Two (02) sets
12.2
Tail pulley
Two (02) sets
12.3
Idler pulley bearings
Two (02) sets
12.4
Set of sprockets
Two (02) sets
12.5
Endless cleated belt
Two (02) sets
12.6
Rectifier assembly
Two (02) sets
13.0
Bunker Level Indication
13.1
Bunker level indicator (complete)
Two (02) sets
13.2
Bunker level switches (low level)
Two (02) Nos.
14.0
Belt Weigher (Conveyor scale)
14.1
Preamplifier
14.2
Belt weigher console
14.3
Transformer module
Doc. No.: E072-03-CHP-O-02
Two (02) Nos
card used
REV. NO.: R3
of each type of
PAGE 320 OF 506
2X800 MW YERMARAS TPS PROJECT
S.No.
Description
Quantity
14.4
Regulated power supply module
14.5
Convertor modules
15.0
Metal Detector complete with panel
16.0
Dust Suppression System
16.1
Spray nozzles (complete)
etc.
Two (02) sets.
for WT hopper
Eighty (80) Nos.
For conveyors
Forty (40) Nos.
16.2
Sprinkler (complete)
Thirty (30) Nos.
17.0
Sector Gates / Flap gates
17.1
Actuator assembly with electric
Six (06) Nos.
motor
17.2
Seals
18.0
Dust Extraction System
18.1
Filter bags
10% of total quantity
18.2
V-belt
02 sets of each type and size
18.3
Flexible connection between fan
02 sets of each size
18.4
Bearings
03 Nos. of each type and size
6.2
Sl.No
I
Five (5) sets in each size
and duct
ELECTRICAL
Description
Quantity
OneNo.of each type
operating mechanism
and rating
andtruck mounted
2
Closing & Tripping coils
Five Nos. of each
Spring charging motors
Two Nos.
Set of gaskets
Five Sets
Auxiliary contact blocks
6
7
rate
Amount
11 / 3.3 kV Switchgear
Breaker with complete
Unit
Limit position switches
Breaker control switches
Doc. No.: E072-03-CHP-O-02
Five Nos
each
REV. NO.: R3
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Sl.No
8
9
Description
switches
11
Current Transformers:
12
Voltage Transformers:
15
II
1
2
Ten Nos of each
type and colour
Two Nos of each
type and range
Two Nos of each
type and range
Five Nos
type
Transducers of each type
Two Nos
& range
Digital Multi-function
Five nos. of each
Meter
type
415 V Switchgear
Power Contactors and
One No of each
Auxiliary contactors
Rating and type
BI-Metallic Thermal
Two Nos of each
Overload Relay
HRC fuses
Control fuses
Protective relays
Trip Relays
MCB
MCCB
10
type& range
Fuses of each rating and
One No of each
Protective relays
Indicating lamps (LED)
14
rate
Amount
Local/remote selector
10
13
Unit
Quantity
Range
Five Nos of each
Rating
Five Nos of each
Rating
Two Nos of each
type
Two
Nos of
each
type
Two Nos of each
rating offered
Two Nos of each
rating offered
415 V Breaker complete
One No of each
with operating mechanism.
rating
Closing coil & Tripping coil
Two Nos each
Doc. No.: E072-03-CHP-O-02
REV. NO.: R3
PAGE 322 OF 506
2X800 MW YERMARAS TPS PROJECT
Sl.No
11
Description
Quantity
Spring charging motor
Bus support insulators
Five Nos
13
Aux. switch assembly
Five Nos
14
Position Limit switch
Five Nos
15
Local/Remote switch
Five Nos
16
Breaker control switch
Five Nos
18
19
20
Clustered type LED
Ten Nos of each
indicating lamps
Interposing Current
Transformers
Transducers
Digital Multi-function
colour
One of each range
Two of each type &
rating
Five nos. of each
Meter
III
3.3 kV HT MOTORS
3.3 kV Motor
Bearings for motors
rate
Amount
Two Nos
complete
12
17
Unit
type
One No of each type
& rating
Two Nos of each
type
Two sets with each
3
Bearings Temperature
Indicators
set comprising
indicators for DE &
NDE
Terminal connector
assembly
Cooling fan
RTD
IV
415 V LT MOTORS
415 V Motors
Doc. No.: E072-03-CHP-O-02
1 No of each type
1 No of each type
1 Set for each rating
of motor
One No of each type
& rating
REV. NO.: R3
PAGE 323 OF 506
2X800 MW YERMARAS TPS PROJECT
Sl.No
Description
Quantity
Bearings for motors
Power Transformer
Gaskets(One
rate
Amount
Two nos of each type
Number
of
1 set
each type & size)
Bushing of each type
1 set.
CT of each type
1 No.
Cooler fan with Fan motor
1 No.
Pressure relief device
1 No.
Magnetic Oil level Gauge
1 No.
Buchholz relay
1 set
Dial type WTI with Capillary
8
Unit
Complete
for
HV
&
1 No each.
LV
winding
9
10
Dial type OTI with Capillary
Complete
RTD ,CCU Unit with remote
1 set
indicator for OTI
RTD ,CCU Unit with remote
11
1 No.
1 set each
indicator for WTI for HV &
LV
12
13
14
Valves of each type and
1 set
Silica Gel Breather
1 No.
Motor contactors, Over load
1 Set
size
relay,
timers,
Switches
comprising
MCB,
one
no of each type used in
cooler control cabinet
VI
1
Service Transformer
Gaskets(One
Number
each type & size)
of
1 set
Bushing of each type
1 set.
CT of each type
1 No.
Explosion
4
diaphragm/Pressure
vent
1 No.
relief
device as applicable
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REV. NO.: R3
PAGE 324 OF 506
2X800 MW YERMARAS TPS PROJECT
Sl.No
Description
Quantity
Magnetic Oil level Gauge
1 No.
Buchholz relay
1 set
Dial type WTI with Capillary
7
Complete
for
HV
&
Unit
rate
Amount
1 No each.
LV
winding
8
9
10
11
Complete
Remote
Oil
Temperature
remote
1 set
Valves of each type and
1 set
CCU
Unit
with
indicator for WTI
size
Silica Gel Breather
VII
Battery Chargers
1 set
indicator Complete
12
1
1 No.
Dial type OTI with Capillary
1 No.
Fuses including
FiveNos of each
semiconductor fuse
rating
Control Cards(PCB with
One No of each type
components)
Thyristors
One No of each type
Diodes
One No of each type
Meters
One No of each type
LED Lamps
Five No of each type
Switches
One No of each type
MCB & MCCB
VIII
HT bus duct
1
2
One no of each type
and rating
Bus support insulator
2 nos
Bolted disconnect link
1 set each
Complete with hardware
Flexible
equipments
terminal
Connector
1 set each
complete with Hardware
4
Seal off bushing
Doc. No.: E072-03-CHP-O-02
1 set each
REV. NO.: R3
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2X800 MW YERMARAS TPS PROJECT
Sl.No
Description
Quantity
Expansion bellow
1 set each
IX
LT bus duct
Bus support insulator
2 nos
Bolted disconnect link
1 set each
Unit
rate
Amount
Complete with hardware
3
Flexible
terminal
equipments
1 set each
Connector
complete with Hardware
4
Seal off bushing
1 set each
Expansion bellow
1 set each
Illumination
Illumination spares
10% of supplied
quantity
XI
Miscellaneous
10% for each type or
Interposing Relay
minimum Two nos
whichever is higher
Ten Nos of
Fuses
eachType and
Rating
6.3
CONTROL AND INSTRUMENTATION
PLC Control System
S.No.
1)
Description
Quantity
Power supply
20% / 02 Nos. of each type &
model, whichever is more
2)
Input / Output Modules
20% / 02 Nos. of each type &
model, whichever is more
3)
Central Processing Unit
20% / 02 Nos. of each type &
model, whichever is more
4)
Interface /communication Unit
20% / 02 Nos. of each type &
(including lower & higher bus
model, whichever is more
cable)
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REV. NO.: R3
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2X800 MW YERMARAS TPS PROJECT
5)
Memory Unit
20% / 02 Nos. of each type &
6)
Push Buttons & Control Switches
20% / 02 Nos. of each type &
model, whichever is more
model, whichever is more
7)
8)
Cooling Fan in PLC System /
10% / 02 Nos. of each type &
cabinet
model, whichever is more
Audible device
20% / 02 Nos. of each type &
model, whichever is more
9)
Cooling Fan in PLC System
10% / 02 Nos. of each type &
model, whichever is more
10)
Battery
10% / 02 Nos. of each type &
model, whichever is more
11)
Key Board
10% / 02 Nos. of each type &
model, whichever is more
12)
Annunciation Facia
20% / 05 Nos. of each type &
model, whichever is more
13)
Connectors for Pre-fab cable
02 Nos. of each type and model
14)
Interconnecting cables
1 Run length of each type &
15)
Indicating Lamps of all type
50%
size
Measuring Instruments
1
Electronic Transmitters
(i)
Transmitters of all type, range 10% or 1 no. Of each type and
and
model
no.
measurement
of
(for
the model whichever is more. (To be
Pressure, divided into various ranges in
differential pressure, flow, level, proportion to main population)
etc.)
(ii)
Electronic cards / PCB's for each 10%
type and model of transmitters.
or
nos.
of
each
type
whichever is more.
Temperature elements
(i)
RTD's of each type and length
10% or 2 nos. Whichever is more
(ii)
Thermocouples of each type and 10% or 2 nos. Whichever is more
length
Indicators
(a)
Digital Indicators of each model,
10% or 2 nos. whichever is more.
type & range (including relevant
Doc. No.: E072-03-CHP-O-02
REV. NO.: R3
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2X800 MW YERMARAS TPS PROJECT
digital
system)
(b)
indicators
of
electrical
Vertical Indicators
Vertical indicators of each model
5% or 2 nos. of each model
whichever is more.
(c)
Electrical Metering Instruments
Electrical
meters
including 5% or 1 no. Of each model and
voltmeter (analog), motor current type whichever is more.
ammeter,
semaphore
indicator,
frequency
meter
(analog),
synchroscope
Doc. No.: E072-03-CHP-O-02
REV. NO.: R3
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2X800 MW YERMARAS TPS PROJECT
7.0 DRAWINGS AND DOCUMENTS TO BE
FURNISHED BY BIDDER
Doc. No.: E072-03-CHP-O-02
REV. NO.: R3
PAGE 329 OF 506
2X800 MW YERMARAS TPS PROJECT
DRAWINGS AND DOCUMENTS TO BE FURNISHED BY BIDDER
7.1
DATA TO BE FURNISHED WITH THE BID
Completely filled in DATA SHEET-B as given in this specification.
Project execution network schedule.
Technical write-up of the system.
Features provided in the system to achieve guarantee availability.
Flow Diagrams.
Drive list with motor rating of each drive
List of recommended spares
List of special tools and tackles
Write-up on control philosophy of Coal handling plant
In addition to above, drawings/data/information as called elsewhere in the
specification shall also be submitted along with the bid.
ELECTRICAL
1. Deviation from the tender specification
2. Completely filled in Data Sheet-B.
3. QAP format
4. List of sub-vendors with their credential.
CONTROL & INSTRUMENTATION
Clause wise confirmation / deviation list with respect to I&C requirement as
per specification.
P&ID (Process and Instrumentation drawings) indicating primary and
secondary Instruments and the destination/functionality of the signals.
Control
philosophy
operation
philosophy
Design
philosophy
Redundancy philosophy.
PLC system configuration drawing with write-up.
Power supply scheme for PLC system including Peripheral & Remote I/O.
Completely filled in Data Sheet-B.
QAP format
List of sub-vendors with their credential.
Doc. No.: E072-03-CHP-O-02
REV. NO.: R3
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2X800 MW YERMARAS TPS PROJECT
7.2
DATA TO BE FURNISHED AFTER AWARD OF CONTRACT
The Contractor shall submit the following data / information documents /
drawings to the Purchaser, who in turn will review and furnish comments on only
important drawings / documents.
Contractor shall furnish a list of data /
drawings / documents which will be submitted to the Purchaser with due dates
of submission immediately after award of Contract.
The list shall be updated
by the Contractor on fortnightly basis. Drawings, documents and calculations as
required for review shall be submitted by the contractor to owner/consultant on
case to case basis.
All drawings shall be generated in AUTO CAD 2004 edition.
Equipment general arrangement drawings including, elevation and cross
section of the equipment with major dimensions and all connection
details and other relevant data.
Foundation design, criteria including loading details of individual
equipment system.
Complete load list for the system
Instrument set points.
Sub Vendor List.
Design Data
Drive motor schedule with motor rating of each drive
Design basis report.
Sizing calculation for coal handling plant
Technical data sheet of all equipment
Sequence interlocks and block logic diagram
Drawings
Key plan of Coal handling system
General arrangement - Plan and section of the following subsystems:
(a)
Complete Coal handling Plant
(b)
Primary and secondary crusher house
(c)
Conveyor gallery
(d)
Conveyor tunnel
(e)
Wagon tippler complex
(f)
Dust extraction system
(g)
Dust suppression system
(h)
Tunnel and Bunker bay ventilation system
Doc. No.: E072-03-CHP-O-02
REV. NO.: R3
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2X800 MW YERMARAS TPS PROJECT
(i)
Conveyors
Detailed dimensional GA drawings showing supporting details, cross
sectional details, loading details, foundation /insert details along with parts
list major
parameters and test certifications for material of construction;
detail drawings for various components; operation and maintenance
instruction manuals for the following equipment / items :
(a)
Idlers
(b)
Pulleys
(c)
Primary and secondary crushers
(d)
Vibrating screens
(e)
Vibrating feeders
(g)
Rack & Pinion Gates
(i)
Chutes
(h)
(j)
Drives including gearbox, couplings, motors
(l)
Metal Detector
(m)
Belt weigher
(n)
Coal sampling unit
(K)
ILMS
(o)
Apron feeder
(p)
Dribble feeder
(q)
Wagon tippler and side arm charger
(s)
Travelling tripper
(t)
Belt switches
(u)
Take-up arrangement
(v)
Pumps
(r)
Flap Gates
Stacker/Reclaimer
Characteristic curves for
(a)
All type of pumps
(b)
Motors
(c)
Fluid couplings
Doc. No.: E072-03-CHP-O-02
REV. NO.: R3
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2X800 MW YERMARAS TPS PROJECT
ELECTRICAL
1. POWER TRANSFORMER
S. No
Description
Dimensional general arrangement drawing
Terminal arrangement details
GA of Marshalling Box , Cooler control panel, OCTC cabinet, as applicable
Drawings of major components like bushing, etc
Test certificates of transformer and auxiliary equipment
Control schematics
Wiring diagrams
Rating and Diagram Plate
Oil filling instruction plate
10
Valve schedule plate
11
Cable Interconnection Diagram and Cable schedule
12
Quality Assurance Plan
13
Instruction manuals on transformer and its various fittings. The manual shall
clearly indicate method of installation, check-ups and tests to be carried out
before commissioning of the equipment.
14
Design calculations for short circuit forces
15
Cooling calculation
16
Foundation details
17
Roller assembly
18
Customer inspection test Schedule
19
Vender List
20
Technical leaflets on major components and fittings
22
Any other relevant drawing or data necessary for satisfactory installation,
23
Field quality Plan
operation and maintenance
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REV. NO.: R3
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2X800 MW YERMARAS TPS PROJECT
2. HT SWITCHGEAR
S. No
Description
Dimensional general arrangement drawing showing disposition of various
Foundation plan and loading
Bill of material
Control schematic
Wiring diagrams
Quality assurance plan
Instruction manuals on circuit breakers and its accessories (The manual shall
fittings
clearly indicate method of installation, checkups and tests to be carried out
before commissioning of the equipment)
8
9
Any other relevant drawing or data necessary for satisfactory installation,
operation and maintenance
Relay settings with detailed calculation
10
Detailed relay manuals
11
Type test certificates
3. LT Switchgear
S. No
Description
Typical general arrangement drawing of the equipment and foundation plan.
Bill of material
Type test certificates of similar Equipment. In case type test certificates as
per IS or IEC of identical Equipment of the offered items are not submitted,
the Bidder shall have to conduct the type test on the offered Equipment
before delivery free of charge to the Owner or Bidders testing charges are to
be mentioned.
4
Proposal sheets duly filled in.
Leaflets on equipment and other accessories explaining their constructional
details, principle of operation, special features etc.
4. Segregated /Non Segregated Phase Bus Duct
S. No
Description
General Arrangement Drawing - Plan and Sections.
Typical details of space heater cubicles, bus-insulator assembly, conductor/
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2X800 MW YERMARAS TPS PROJECT
S. No
Description
enclosure connections rigid & flexible, seal-off bushings, connections with
switchgear and transformer terminals etc.
Bill of Materials
Technical leaflets / Write-ups on various pieces of equipment offered
Calculation for temperature rise for bus and enclosure as per IEEE No. 298
Calculation for short circuit forces justifying the proposed arrangement.
Type test reports on similar equipment.
Bus duct layout - plan and sections.
Foundation plan
10
Structure layout
5. HT MOTORS
S. No
Description
Write-up on the proposed procedure of overhauling the HT Motor
Complete list of all tests to be carried out, with code/standard followed and
brief description of test procedure, for
a)
Tests at works
b)
Tests during erection &commissioning.
d)
Reliability demonstration tests
c)
Operational & flexibility tests
Acceptance tests
Extended performance tests
List of spares
Consumable spares (for day to day maintenance, inspection & overhaul of plant
Overhaul spares (for planned overhauls to ensure the required availability)
Strategic spares (generally high cost and/or long lead-time spares required
Manufacturing drawings for those spare parts going out of production beyond
& equipment requiring regular attention)
infrequently, may be once in the plant's life time)
10
three (3) years of plant operation
Engineering and master drawing schedule indicating when the
drawings
and data will be submitted for review within four (4) weeks from the date of
issue of notice of proceed
11
Write up on the design and construction features control philosophy of the
12
All different characteristic curves of motor for 100%, 90% and 80% of the
Motor
supply voltage
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6. LT Motors
S. No
Description
Dimensional General Arrangement drawing
Foundation Plan & Loading
Cable end box details
Space requirement for rotor removal
Thermal withstand curves hot & cold
Starting and speed torque characteristics at 80% & 100% voltage
Complete motor data
Erection & Maintenance Manual
Test reports
7. HT power, LT power, Control & Instrumentation cables
S. No
1
Description
Confirmed cable data
Test reports
Guaranteed Technical Particulars
Quality assurance plan
Shop Test reports
8. DC System
S. No
Description
Guaranteed technical particular and quality assurance plan
Duty cycle diagram and battery sizing calculation in the format of IEEE-485
Battery and charger sizing calculation
Fault current calculation for battery and battery charger
Sizing calculation of charger and main equipment viz SCRs, rectifier
Detailed bill of materials
Transport/shipping details such as method of packaging, Dimensions & Weight
Instruction manuals on battery,battery charger and battery discharge resistor
Dimensional battery layout diagram in plan & section
transformer etc
of package, part list etc
unit.
10
Connection details of take-off terminals
11
Dimensional general arrangement drawings of battery charger, clearly showing
12
Sectional views of battery charger panels
13
Charger foundation plan and loading
device dispositions, cable entry, space requirement, etc
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S. No
14
Description
Charger schematics and wiring diagrams
15
Test reports
16
Any other relevant drawing or data necessary
operation and maintenance
for satisfactory installation,
9. Erection Package
S. No
Description
A network showing the proposed construction schedule specifically indicating
Consolidated Bill of Materials.
Loadings of all equipment and structures.
Cable / conduit routing, cable schedule & interconnection
Data Sheet and technical leaflets on cable trays, conduit, junction boxes,
Dimensional drawings and data sheets for different equipment supplied under
Technical leaflets and data sheet on each piece of equipment/device
the milestone event.
grounding material etc.
the specification.
CONTROL & INSTRUMENTATION
Document/Drawing to be furnished under Approval Category
Process & Instrumentation Diagram (PID) indicating primary sensors and
secondary instruments, destination reference (alarm, control etc).
PLC BOQ
Calculation of data bus, processor, memory loading.
PLC configuration drawing / system architecture drawing including HMI and
peripherals.
Control Room Layout
Factory Acceptance Test (FAT) procedure / Availability test procedure /PG
test procedure for C & I equipment (including PLC).
Input/output List
List of instruments / drive / solenoid valve.
Control
philosophy
operation
philosophy
Design
philosophy
Redundancy philosophy.
Instrument Installation drawings
Control panel/desk GA and layout
Power distribution scheme
Panel heat dissipation data
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Process mimics
Control schemes / logic diagrams
List of logs with point assignment
Earthing schemes
Cable grouping and Marshalling philosophy
QAP along with test certificates
Data sheets of PLC equipment and all field Instruments
As built drawing after commissioning and O&M manual
Wiring diagrams for panel, local panel, junction boxes, actuators, starters
etc.
Document/Drawing to be furnished under Information Category
Cabinet / Panel wiring diagrams and internal layout drawings
Cabinet / Panel terminal details
Cable schedule and interconnection drawing
a. Between field to PLC
b. Between field to MCC
c. Between PLC to MCC
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8.0 PERFORMANCE & AVAILIABILITY
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PERFORMANCE AND AVAILABILITY
8.1
SYSTEM PERFORMANCE REQUIREMENTS
The coal handling system and equipment shall perform satisfactorily to meet the
guarantee requirements specified in the following chapter and also those
specified in this specification.
After the coal handling system is ready, the same shall be tested at rated
capacity within six (6) months from the date of initial operation preferably
during the monsoon season to prove the performance of the system and
equipment. The capacity figures specified for the equipment shall have to be
achieved with tolerance on the positive side. The guarantee requirements shall
be made without undue vibrations in the conveyor supports, junction towers,
crusher houses, transfer houses, etc.
The wagon unloading system shall be capable of unloading the designed
number of wagons on continuous basis to achieve the specified capacity.
The coal handling system from stockpile to bunkers shall operate continuously
at an average capacity as specified over a period of 24 hours. The 24 hours
boiler requirement of coal shall be handled in a maximum 14 hours.
Each crusher shall be capable of crushing rated capacity with specified
maximum lump size of coal even while handling damp and sticky coal having
20% moisture (including surface moisture) during monsoon season. The largest
size of output particles shall not exceed those specified in the specification.
Screens shall screen out 95% of material having dimension of (-) 20 mm even
during rainy seasons.
Stacker reclaimer shall be stable under specified design condition and shall meet
all the requirements specified. The bucket wheel shall reclaim coal at the rated
capacity specified while handling well compacted, damp and sticky coal during
rainy seasons. The capacity shall be arrived at on working for 4 hours over
complete cross section of the coal pile. Also, the stacker shall stack coal at the
rate capacity specified. The stacker reclaimer shall have the facility for bypass
operation while conveying coal directly to bunkers via yard conveyor.
The capacities of all equipment / conveyors / feeders shall be equal to or more
than the specified.
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All drive motors shall be suitable for direct-on-line starting and capable of
starting fully loaded conveyors / feeders.
Noise level produced by any rotating equipment (other than crusher) individually
and collectively should not exceed 85 dBA at a distance of 1.5 meter from it in
any direction under any load condition.
Vibration level of equipment at bearings shall not exceed the following limits for
different equipment.
Vibration levels shall conform to the limits specified below and shall be
measured as per VDI 2056 / BS 4675.
Equipment
Peak to peak limit
a) At the bearing of drive pulley, motor and gear box for the following
equipment:
i)
Boom conveyor of stacker /
115 microns
75 microns
Reclaimer
ii)
All other equipment /
Conveyors / feeders etc.
Equipment
Peak to peak limit
b) On the floors and columns of JTs, crushers
200 microns
Houses and conveyor gallery walkways
c) Crusher
160 microns for corresponding rated
speed of 750 rpm. For any other
lower speeds, the vibration limit
shall be calculated as per VDI
2056 / BS 4675
Magnetic separator shall separate the magnetic material of the sizes and shapes
mentioned in this specification effectively.
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Accuracy of belt weigh scale shall be 0.5% of actual weighment.
The flow of coal in the transfer chutes and coal bunkers shall be smooth without
any plugging / rat holding even with worst moisture and fines content.
8.2
ILLUMINATION LEVELS
Minimum illumination levels specified for lighting shall be achieved during
normal operation of the plant with dust laden environment.
8.3
EARTHING RESISTANCE
An earthing resistance of less than 0.5 ohm shall be achieved when measured
after isolating CHP earthing system.
8.4
DUST CONTROL SYSTEM
At the outlet of dust extraction system, the dust concentration should not
exceed 100 mg/Ncu.m.
8.5
ENDURANCE TEST
Each stream and each path shall be tested at rated capacity for 24 hours to
prove that the system functions satisfactorily without any trip due to overload or
system fault.
All necessary instruments including walkie-talkies etc. for carrying out
performance testing of coal handling system shall be provided by the
Contractor.
The specified performance figures of the equipment shall be proved by the
Contractor during the performance tests. Should the results of the tests show
any vibration from the specified values, the Contractor shall modify the
equipment as required to enable it to meet the requirements.
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9.0 LAYOUT & MAINTAINANCE REQUIREMENT
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LAYOUT AND MAINTAINANCE REQUIREMENT
Minimum clearance between the bottom of the tail pulley and floor in junction
tower / crusher house / tunnel shall be 500 mm.
Centre lines of WT hopper, junction towers, transfer houses, crusher house and
elevation of bunker floor shall be finalized by the Contractor. The sizes of the
junction towers, transfer houses and crusher house and the floor elevations shall
be finalized by the Contractor considering a minimum clear walkway space of
1200 mm around the equipment in each floor. The clear distance between the
floors shall be minimum 3000 mm and head room shall be suitable for handling
/ removing the equipment at the head end and tail end. The floor of junction
towers, transfer houses and crusher house shall be designed for keeping the
heaviest part of the equipment anywhere on the floor for maintenance of
equipment shall be provided. The length and elevation of the conveyors shall be
finalized by Contractor based on the limitations for the inclination furnished in
the specification.
A clear width of 4 M shall be provided at the end of the bunker bays on each
side of boiler for maintenance purpose.
Adequate space around the crusher in the crusher house shall be provided for
opening the cage of the crusher and for removal of the shaft.
Partitions with slide doors shall be provided in the crusher house between the
crushers to enable maintenance of standby crusher when the other crusher is
operating. Adequate maintenance space and handling facilities shall be provided
on both sides of the partition wall separately.
All conveyor galleries shall be provided with dust sweeping hopper covered with
removable chequered plates. There shall be one dust hopper for each walkway
of gallery and the same shall be provided at each trestle location. Similarly 2
nos. dust hoppers shall be provided for each floor or junction towers / crusher
houses. These dust hoppers shall be connected to a dust chute to enable the
dust swept to be led to the ground level.
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10.0
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VENDOR LIST
PAGE 345 OF 506
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VENDOR LIST
The successful bidder shall furnish sub vendor list for Mechanical, Electrical and
C&I, items / equipments / systems for RPCL review and approval along with
credentials of the firm and performance certificates of the items / equipments /
systems.
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11.0
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DATA SHEETS
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DATA SHEETS-A: SPECIFIC DATA SHEET
Mechanical
Sl. No
Description
Units
Values
1.
Belt Conveyors
1.1
Horizontal centrer distance
As per the layout and
between Drive and Tail pulley of
flow diagram.
each conveyor
1.2
Lift of each conveyor
As per the layout and
flow diagram
1.3
Capacity of each conveyor
1.3.1
Rated and Designed
The capacities of
conveyors from Wagon
tippler to bunker
including yard
conveyors are, Designed
2200 TPH and Rated
2000 TPH. Except
manually unloaded coal
conveyor BCN-23, which
has a capacity of
Designed-600 1200 TPH
and Rated- 500 1000
TPH.
1.4
Belt speed
2.8 m/sec or As per IS
11592
1.5
Belt
1.5.1
Belt width
1600
mm
conveyors
for
from
all
wagon
tippler to bunker except
manual
unloading
conveyor BCN-23, which
is of 600 mm.
1.5.2
Belt specification
Belt shall be of Nylon Nylon,EP moulded edge
skim coated & fire
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Sl. No
Description
Units
Values
resistance as per spec
type and suitable for 35
degree troughing angle .
The cover shall be Fire
resistant grade type (BS
490 Part-I ). Fire
resistant property shall
conform to Canadian
Bureau of Mines Report
No. FRL 269/CAN/CSA/
M-422- M87 grade C.
1.5.3
Minimum thickness of cover
1.5.4
Minimum no. plies
Top 5 mm
Bottom 3 mm
5 No. for WT to crusher
House &the rest of the
conveyors will be
provided as per IS /
design.
1.5.5
Ratio of working tension to
90 %(maximum)
allowable tension
1.5.6
Conveyor Belt Rating
As per design/ IS
1.6
Pulleys
1.6.1
Shell thickness
16 mm
1.6.2
Disc end thickness
24 mm
1.6.3
Drive Pulley lagging
Hot lagged with
Vulcanized natural
rubber. 12 mm thick
grooved in diamond
pattern with grooves 6
mm wide x 6 mm deep
1.6.4
Other pulley lagging
Hot lagged with
Vulcanized natural
rubber. 12 mm thick
plain
1.6.5
Rubber of lagging
a)
Hardness :55 to 65
durometer (shore A)
b)
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Sl. No
Description
Units
Values
300%
c)
Strength :160-200
kg/cm2
d)
Adhesion loss :250
mm3 as per DIN
53516
e)
f)
Specific gravity : 1.4
to 1.5
Adhesion strength
:10 kg/cm
1.7
Bearings for pulleys
1.7.1
Type
Heavy duty roller type
1.7.2
Casing
Horizontal Split
1.7.3
Sealing
Dust tight with double
labyrinth seals.
1.7.4
Lubrication
Greasing arrangement
with conical head shape
nipples
1.7.5
Bearing life
Min 50,000 hours
1.7.6
Type of Bearing
Double row self aligning
spherical roller
1.8
Pulley width
Belt width + 200 mm
1.9
Pulley Material
Mild steel conforming to
IS : 2062
1.10
Shaft Material
Forged Steel shaft EN-8
or equivalent material
1.11
Maximum allowable
deflection
5 minutes
of shaft at the hubs
1.12
Idlers
1.12.1
Carrying idlers
Carrying idlers shall be
of 3 roll, troughing
angle 35 degree. Roller
dia and thickness shall
be minimum 152.4 mm
&5.4mm, Spacing -1000
mm
1.12.2
Return idlers
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Return idlers shall be of
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Sl. No
Description
Units
Values
2 roll V type. Roller dia
and thickness shall be
minimum 152.4 mm
&5.4mm Spacing 3000
mm
1.12.3
Impact idlers
Shall be of 3 roll type of
190 mm roll dia with
127mm steel tube dia
and 5.4 mm thickness.
Min. 5 Nos. impact idlers
shall be provided at each
feed point @ 500mm
spacing
1.12.4
Self aligning carrying and return
Shall be provided on
idlers
thrust bearing for
swiveling. Side guide
rollers shall be provided.
Spacing shall be 15 m for
Self aligning Carrying
Idler and 30 m for Self
aligning Return Idler
1.12.5
Bearings
Single row deep grove
ball bearing, for carrying,
return & impact idlers
with double labyrinth
seals
1.13
Technological structures
1.13.1
Stringers/Short supports
As required
1.13.2
Deck plate
Min. 3.0 mm for full
1.13.3
Width of Clear walk way on both
length of conveyors
mm
1200
side of conveyor
1.14
Belt Tensioning arrangement
Suitable belt tensioning
arrangement shall be
provided
1.15
Skirt Boards
1.15.1
Length
Min. 5 m for each
feeding point
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Sl. No
Description
Units
Values
1.15.2
Height
As required
1.15.3
Width
2/3 of belt width
1.15.4
Side plate
Min. 10 thk
1.15.5
Top cover
6 mm thk M.S.
2.
Stacker Reclaimer
2.1
Type
Rail
mounted,
bucket
wheel type Stacker-cumreclaimer
2.2
Number required
Nos.
2.3
Location
2.4
Capacity while stacking (Rated)
2.5
Capacity
Three (03)
Outdoor
while
TPH
2000
stacking TPH
2200
(Designed)
2.6
Duty
Machine
shall
be
designed for 24 hours
continuous duty
2.7
Capacity
while
reclaiming TPH
2000(Rated)/2200(Desig
(Rated/Designed)
ned)
2.8
Material handled
Crushed Coal
2.9
Belt
width
of
boom
and mm
As required
intermediate conveyor
2.10
Wind velocity and pressure
As per IS: 875-1987
2.11
Seismic Zone III
As per IS: 1893 Zone III
2.12
Maximum
wheel
load tones
permissible with impact
2.13
Track gauge
To
be
furnished
by
bidder
m
7.0 (minimum)(length of
travel to be furnished by
bidder)
2.14
2.15
Effective stock pile height above m
8.75
Bottom of bucket wheel
8.75
graded level
above
rail
level
(minimum)
2.16
Slewing angle of Boom of stacker deg.
1050 i.e., total 2100
reclaimer
2.17
2.18
Length of the boom
36 m
Traveling speed
m/se
Max. 15 m/min. min. 7.5
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Sl. No
Description
Units
c
2.19
Stability factor
Values
m/min.
In accordance with ISO
5049/1
2.20
For
operating
conditions
of
machine with maxm. Permissible
1.5
(Live
Load
only
considered
wind velocity and maximum live
load
2.21
For
operating
conditions
of
1.5
maximum
wind
machine with maxm. Permissible
pressure shall be as per
wind velocity and without live
IS 875(latest edition)
load
2.22
For non operating conditions of
machine
with
maximum
1.5 (Machine in parking
position)
permissible wind load.
2.23
Material
of
construction
of
Bucket Wheel Assembly
2.23.1
Bucket Wheel
M.S., IS:2062
2.23.2
Bucket
Abrasion resistant steel
2.23.3
Lips
Manganese Steel
2.24
Type of drive
2.24.1
Bucket wheel
Low speed, high torque
type
drive-
speed
suitable
variable
hydraulic
for
operation
drive
inching
(no.
of
buckets-8)
2.24.2
Slewing
Hydraulic
2.24.3
LT drive
VVVFD
2.25
Type of control of SCR
Automatic operation with
PLC shall be provided in
addition
to
manual
control
3.
Primary Crushers
3.1
Type of crusher
Rotary Breaker
3.2
No. required
Four (04) Nos.
3.3
Material to be crushed
Coal size (-)300mm
3.4
Hard grove Index of coal
45
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Sl. No
3.5
Description
Units
Values
Maximum moisture content in
Maximum 20
coal
3.6
Material Temperature
Max. 50
3.7
Ambient Temperature
Max. 50, min 14, (50 for
electrical design)
3.8
Hours of operation per day
Hour
24
s/day
3.9
Bulk density
T/m3
0.8
3.10
Rated capacity
TPH
1000
Designed capacity
TPH
1250
3.11
Output size
(-)150 mm 98%
3.12
Type of Drive
Direct through hydraulic
3.13
Maintenance/inspection door to
Yes
coupling
be provided?
3.14
Material of construction
3.14.1
Shaft (Rotor)
Forged Carbon/Alloy
Steel
3.14.2
Frame
3.14.3
Breaker Plate
Rolled Steel, IS-2062
Mn-Steel
IS : 276
3.14.4
Liner plate
Tiscral C -45/ Abrasion
Resistance
3.15
Bearing
3.15.1
Bearing Type
3.15.2
Life
3.15.3
Lubrication
Oil
3.15.4
Cooling Arrangement
Oil bath
3.16
Enclosure
Dust tight
4.
Secondary Crushers
4.1
Type of crusher
Ring granulator
4.2
No. required
Four (04) nos. for
Anti-friction roller
Hrs
50,000 (Min.)
Secondary crusher house
-1 and Four (04) nos. for
secondary crusher house
-2
4.3
Material to be crushed
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Sl. No
Description
Units
4.4
Hard grove Index of coal
4.5
Maximum moisture content in
Values
45
Maximum 20
coal
4.6
Material Temperature
Max. 50
4.7
Ambient Temperature
Max. 50, min 14, (50 for
electrical design)
4.8
Hours of operation per day
Hour
24
s/day
4.9
Bulk density
T/m3
0.8
4.10
Rated capacity
TPH
1000
Designed capacity
TPH
1250
4.11
Output size
(-)20 mm 98%
4.12
Type of Drive
Direct through hydraulic
coupling
4.13
Maintenance/inspection door to
Yes
be provided?
4.14
Material of construction
4.14.1
Shaft (Rotor)
Forged and heat treated
Carbon/Alloy Steel
4.14.2
Suspension Bar/Ring/Roller
Mn-Steel
IS : 276
4.14.3
Frame
4.14.4
Breaker Plate
Rolled Steel, IS-2062
Mn-Steel Gr III
IS : 276
4.14.5
Cage Assembly
Mn-Steel Gr III
4.14.6
Liner plate
Tiscral C -45/ Abrasion
IS : 276
Resistance
4.15
Bearing
4.15.1
Bearing Type
4.15.2
Life
4.15.3
Lubrication
Oil
4.15.4
Cooling Arrangement
Oil bath
4.16
Enclosure
Dust tight
5.
Flap Gates
5.1
Service requirement
As per flow diagram
5.2
Type
Motorized Actuator type
Doc. No.: E072-03-CHP-O-02
Anti-friction roller
Hrs
REV. NO.: R3
50,000 (Min.)
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Sl. No
Description
Units
Values
5.3
Required numbers
As per flow diagram
5.4
Location
As per flow diagram
5.5
Crushed & uncrushed
Material handled
5.6
coal
mm
Material size
5.7
(-)300 , (-) 150 and (-)
20
Max ambient temperature
0C
50
5.8
Min ambient temperature
0C
14
5.9
Actuator
5.9.1
Type
Motorized
5.9.2
Travel range
As required
5.10
Materials of construction
5.10.1
Gate
IS-2062
5.10.2
Main plate
12 mm
5.10.3
Liner
10 mm thick SS 409
5.11
Bearing
5.11.1
Type
5.11.2
Life
5.12
Method of lubrication
Dust proof antifriction
ball or roller
h
50,000 (min)
Single shot, pressure
lubrication
6.
6.1
Rack and Pinion Gates
Electrically operated
Type
double rack and pinion
type
6.2
Below wagon tippler
hopper, Emergency
Location
reclaim hoppers and
manual reclaim hopper
6.3
5 nos. for wagon tippler
hopper , 3nos. for
Required nos.
Emergency reclaim
hopper and 1nos. for
manual reclaim hopper
6.4
mm
Material handled-coal lump size
Doc. No.: E072-03-CHP-O-02
REV. NO.: R3
Uncrushed (-) 300 for
wagon tippler hopper
and manual reclaim
PAGE 356 OF 506
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Sl. No
Description
Units
Values
hopper , crushed (-) 20
mm for Emergency
Reclaim hoppers
6.5
6.6
Maximum ambient temperature
OC
50
Min ambient temperature
OC
14
T/M3
0.8
6.7
Bulk density
6.8
Moisture content
6.9
Size of opening
As required
6.10
Locking device to be provided
Yes
6.11
Type
of
chain
for
manual
Maximum 20
Endless
operation
6.12
Chain guard to be provided
Yes
6.13
Materials of construction
6.13.1
Slide gate
IS-2062
6.13.2
Rack
IS 210 Gr 260
6.13.3
Pinion
IS 210 Gr 260
6.13.4
Drive shaft
EN-8, Forged steel
6.13.5
Chain, Wheel, Chain guard
M.S.
6.14
Bearing
6.14.1
Type
Dust tight antifriction
ball bearing
6.14.2
Life
6.15
Method of lubrication
50,000 (min)
Single shot, pressure
lubricated
6.16
Type of Seal
6.17
Chain pull to actuate
Double Labyrinth
kg
25 (max) at choked
condition
7.
Chutes
7.1
Material handled
Coal
7.2
Bulk density
T/M3
7.3
Lump size
mm
(-) 300, (-) 150 & (-) 20
7.4
Belt width
mm
As required
7.5
Maximum moisture content
20
7.6
Rated flow rate
TPH
As required
7.7
Belt speed
m/s
As required
7.8
Pulley width
Doc. No.: E072-03-CHP-O-02
0.8
Belt width + 200mm
REV. NO.: R3
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Sl. No
Description
Units
Values
7.9
Min valley angle
60
7.10
Material of chutes
IS-2062
7.11
Thickness of parent material
7.11.1
Liner material
7.11.2
Liner thickness
mm
12
SS 409
mm
10
*Note : Size of the chute shall be 20% more than the designed size
8.
Vibrating Screens
8.1
Location before crushers
8.2
Rated / Designed capacity
TPH
1000 / 1250
8.3
No required
Nos.
1 no. for each secondary
crushers (4 nos. in
secondary crusher
house-1 and 4nos. in
secondary crusher house
-2)
8.4
Material to be handled
Coal
8.5
Max. Lump Size
(-) 150 mm (Input coal)
8.6
Output size
(-)20 mm
8.7
Moisture content (max.)
20%
8.8
Material for construction
As per manufacture
standard
8.9
Bulk density of coal
0.8 T/M3 for volume
calculation.
1.2 T/M3 for structural
design calculation.
8.10
Inclinatioin
100 from Horizontal
8.11
Material of Grizzly bars
wear resistant
8.12
Type of Bearing
Heavy duty
9.
Mono Rail Electric Hoist
9.1
Type
Electric Hoist with
Electrically operated
Traveling trolley
9.2
Capacity
1.25 times of heaviest
part
9.3
No. and location of Hoists
As required
9.4
Duty Class
II as per IS:3938
9.5
Type of trolley.
Electrically operated
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Sl. No
Description
9.6
Type of Rope
9.6.1
Construction
Units
Values
6x37 with Fibre core of
best plough steel having
tensile strength of 160180 kg/cm2
9.6.2
Type of core
Fibre
9.6.3
Factor of safety
9.7
Operating speed
9.7.1
Hoisting
3.0 m/min
9.7.2
Trolley
10.0 m/min or as per
manufacturer standard
9.8
Total lift
As required
9.9
Cross Travel
As required
9.10
Height of bottom of mono rail
As required
beam from operating floor
9.11
Motor
High starting torque,
crane duty
9.11.1
Type
TEFC squirrel cage
induction motor as per
IS:325
9.11.2
Duty/Rating
25% CDF, 16-25
cycles/hour, S4
9.11.3
No. of starts/hr.
150
9.11.4
Degree of protection
IP 54
9.11.5
Class of insulation
F limited to temperature
rise of class-B.
10.
Inline Magnetic Separator
10.1
Location
10.2
Belt Width
10.3
Material
10.4
Bulk weight
T/m3
0.8
10.5
Coal size (mm)
mm
(-) 300 mm, (-) 150 mm
As per Flow Scheme
mm
As required
Coal
and (-) 20 mm
10.6
Flow rate
10.7
Weight of magnetic metal parts Kgs
50 kg MS round Bar of
to be handled (kg) - Maximum
L/D ratio with in 5/M 20
Doc. No.: E072-03-CHP-O-02
TPH
REV. NO.: R3
As required
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Sl. No
Description
Units
Values
bolts & nuts /50 Kg MS
Plates.
10.8
Type
Suspended
10.9
Magnet active face - size
10.9
Type of Magnet
mm
Bidder to Indicate
Electromagnetic
Oil
Cooled type DC with
Selenium Rectifier
10.10
Operating height above conveyor mm
500
belt
10.11
Burden Depth above 1000
10.12
Gauss Strength (Flux Density)
10.13
Accessories
Bidder to decide
Gaus
s
1000
Suspension
lifting
Hooks
Cleated Belt
10.14
Control Panel
Local & Remote provision
required
10.15
Quantity
As per flow scheme
11.
Belt Weighers
11.1
Material
11.2
Temperature
OC
Ambient
11.3
Moisture Content
Maximum 20
11.4
Bulk weight
T/m3
0.8
11.5
Coal size (mm)
mm
(-)300, (-) 150& (-)20
11.6
Flow rate
TPH
As required
11.7
Location
11.8
Quantity
11.9
Belt conveyor characteristic
Coal
As per flow scheme
Nos.
As per flow scheme
As required
Belt width (mm) & Speed
11.10
Belt scale type
Single roller - Electronic
11.11
Load cell
Strain gauge type IP 66
capable of withstanding
200% load
11.12
Control station
with tachogenerator for
speed control
11.13
Control cabinet
Complete with 4 digit
Flow rate indicator and 6
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Sl. No
Description
Units
Values
digit
Totalizer, Remote
Totalizer, Chart Recorder
11.14
Weighing range
20 110%
11.15
Accuracy
0.5% (on weighing
range)
Suitable
device
calibration
&
accuracy
shall
for
testing
be
provided
11.16
Electrical
Wall
mounted
panel
housing DOL starter &
microprocessor
based
controller
digital
flow
with
rates
&
totalized
counts. signals provided
1 no 4-20 mA analog
signal corresponding to
TPH rate for the Clients
PLC
1 no pulse signal output
corresponding
totalized
pulses
to
for
Clients PLC
Power Supply to control
panel AC/3Ph/50 Hz
5% /415V 5%
12.
Metal Detector
12.1
Material handled
Coal
12.2
Capacity (flow)
As required
12.3
Size of material
(-) 300 mm, (-) 150 mm
and (-)20 mm
12.4
Bulk Density
0.8
12.5
Type
Electronic
12.6
Size
To suit
Belt Width of
conveyor
12.7
Location
Doc. No.: E072-03-CHP-O-02
REV. NO.: R3
As per flow scheme
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Sl. No
Description
Units
Values
12.8
Material of Construction
IS : 2062/ Fibre Glass
12.9
Sand Bag Marker
Provided. Marker drops
on detection
12.10
Sensitivity
Should be able to detect
25mm Al sphere at the
conveyor rated capacity
12.11
Hooter / Siren
Provided having range of
300M
12.12
Quantity
As per Flow scheme
12.13
Control Unit/Panel
Local Control Panel, IP-
13.
Vibrating Feeders
13.1
Location and numbers
55
03 nos. for Emergency
reclaim hoppers and 01
nos.
for
Rated
2000/Designed
unloading hopper
13.2
Feeding capacity
TPH
2200
for
reclaim
manual
Emergency
hopper
and
Rated 600/Designed 500
for
Manual
unloading
hopper
13.3
Material handled
13.4
Lump size
Coal
mm
(-)
20
for
Emergency
reclaim hopper and (-)
300
mm
for
Manual
unloading hopper
13.5
Bulk Density of material
T/M3
0.8
13.6
Maximum material temperature
OC
50
13.7
% of inherent moisture
Maximum 20
13.8
Hours of operation
Hour
24
s
13.9
Installation
Indoor
13.10
Type of vibrating feeder
Electro
Mechanical
unbalanced motor type
13.11
Belt width
Doc. No.: E072-03-CHP-O-02
mm
REV. NO.: R3
As required
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Sl. No
Description
Units
Values
13.12
Belt material
Synthetic
13.13
Tray liner
Tiscral/Sailhard
13.14
Whether liner replaceable
Yes
13.15
Local feed rate controller to be
Yes
13.16
Deck slope
By Bidder
13.17
Deck size
By Bidder
13.18
Dimension of discharge opening
By Bidder
14.
14.1
provided
WagonTippler
Type of Wagon Tippler
Rota side (side discharge)
Wagon
clamping
operation: hydraulic
Tippler
operation:
hydraulic with integrated
electronic
weighing
system for each wagon
tippler,
as
per
latest
RDSO G-33 norms.
14.2
Quantity Required
Five (05)
14.3
Required No. of
25tips/hr-
Tippling/hr
(Guaranteed)
Design
22tips/hr- Rated
14.4
Track Gauge
1676mm
14.5
Gross weight of wagon handled
Wagon tippler shall be
designed for 110T Gross
Weight
Wagon
as
per
latest RDSO G-33 norms
14.6
Hours of operation
24
14.7
Min. Factor of safety used in
design
14.8
Type of Wagon to be handled
All types of open box-N
type
wagons
manufactured by
Indian Railways
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14.9
Description
Units
Values
Drive details:
a. Reduction of speed
Through
b.
system, hydraulic motor
Motor
hydraulic
directly coupled to drive
pinion suitable to drive
pinion suitable for duty
specified.
Shoe
brake
integral with hydraulic
motor.
15.
Apron Feeder
15.1
LOCATION
Beneath
Wagon
Tippler
Hopper
15.2
Capacity (Rated/Design)
TPH
2000 / 2200
15.3
Duty
Continuous
15.4
Capacity Range
20% to 110 %
15.5
Number required
Five (05)
15.6
Material to be handled
ROM Coal
15.7
Max. Lump Size
mm
(-)300
15.8
Bulk density
T/M3
0.8 for Vol. Calculation
1.2 for weight calculation
15.9
Length of Apron feeder
To suit the requirement
15.10
Drive
Variable
drive
speed
without
electric
gear
box
coupling etc. & directly
coupled to driven shaft
16.
16.1
Dribble Feeder
LOCATION
Beneath Apron feeder
Type
Belt Type
16.2
Capacity (Rated/Design)
TPH
16.3
Duty
Continuous
16.4
Number required
Five (05)
16.5
Material to be handled
ROM Coal
16.6
Max. Lump Size
16.7
Type of Belt
16.8
Top and Bottom cover thickness
mm
Top 5, Bottom 3
16.9
Width
mm
200 mm more than width
mm
2000 / 2200
(-)300
Nylon-Nylon/EP
of apron feeder
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Sl. No
16.10
17.
17.1
Description
Units
Take-up
Values
Screw type
Integrated weigh bridge
Type
Integral Electronic Load
cell type
17.2
Location
Below
Wagon
Tippler
platform
17.3
Number
17.4
Weighment Position
Static
17.5
Display & Output
Microprocessor
based
control unit with digital
indication and print out
17.6
Location of control console
Wagon
Tippler
Control
Room
17.7
Tare Weight Determination
Automatic & Manual entry
17.8
Type of Wagon
All type of Box Wagons of
Indian Railway
18.
Dust Suppression system
18.1
Type
Dry fog type for
Wagon
tippler area and all coal
transfer point
Plain water type for coal
stock pile
18.2
Location
1) Conveyor transfer
points, Junction
towers/Transfer
house
2) Stockpile
3) Wagon Tippler
18.3
Type of nozzles
Swiveling type for
stockpile,
Fog jet spray type for
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Description
Units
Values
other area
18.4
Spray nozzle tip and housing
SS304 and Aluminum
alloy
18.5
Quantity of water to be sprayed
at
each
feed
and
1.25 ltr of water per hour
discharge
per ton of coal
points of conveyor
18.6
transferred
Quantity of water to be sprayed
6.25 ltrs of water per
at stockpile
hour per tonne of coal
stocked in sections of 90
m length of stockyard.
18.7
Method of operation of each DS
Local panels, Solenoid
system
valves will be provided at
each header and
interlocked with the
respective conveyor
operation.
19.0.
VENTILATION SYSTEMS
19.1
Bunker ventilation systems
For coal bunkers and at
crusher house
19.1.1
Type
Dry Type bag filter (with
reverse pulse jet type)
with cyclone separator
19.1.2
Dust emission level
19.1.3
Capacity
mg/N
m3
50
Based on 12 air changes
per hour
19.2.0
(ii)Tunnel Ventilation System
19.2.1
No of Air Changes/hr
12 (Minimum)
19.2.2
Type of fan
Centrifugal
19.2.3
Location
Tunnels
19.2.4
Velocity of air inside duct
19.2.5
Material of duct
M/s
10 (maximum)
RCC for tunnel portion 18
gauge GI Sheet for others
19.2.6
Grills
GI construction with
louvers
19.3
Pressure ventilation system CHP
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Sl. No
Description
Units
Values
MCC room
19.3.1
Room size
Contractor to decide
19.3.2
Basis of capacity calculation
Based on the heat load in
the switchgear room
allowing a rise in
temperature of 20C over
the ambient temperature.
20
HOPPERS
20.1
Designation
WT hopper, Emergency
Reclaim Hopper and
Manual unloading
hoppers
20.2
Number Required
Five (05) Nos. for Wagon
tippler hopper, Three(03)
Nos. for Emergency
reclaim hoppers and
One(01) No. for Manual
unloading hopper
20.3
Whether grid required on top of
Yes for Wagon tippler
hopper
hopper, ERH and Manual
reclaim hopper
20.4
If grid required, size of opening
To suit the lump size of
coal flow , 300
mmX300mm for Wagon
tippler hopper and
Manual reclaim hopper
To suit the lump size of
coal flow , 20 mm X 20
mm for ERH
20.5
Type of Construction of Hoppers
RCC
20.6
Shed over hoppers required
For wagon tippler hopper
only
20.7
Liner
10 mm TISCRAL /SAILMA
21.0
COAL PILE RUN OFF PIT
21.1
Purpose
Collecting the coal pile
run off water from the
coal stock yard. Coal
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Description
Units
Values
particles
will
settle
down and clear water
will over flow.
21.2
Construction
Earthen type with proper
slope.
22.0
COAL SAMPLING SYSTEM
22.1
Type
Automatic
22.2
Location of sampler
As per the flow scheme
22.3
Capacity of each of the conveyors TPH
AS per Data Sheet
22.4
Type of Primarycutter
Swinging type
22.5
Material of construction
22.5.1
Primary cutter
SS-304/316
22.5.2
Liners for hoppers
SS Conforming to AISI 409 M
22.5.3
Through of screw conveyor
SS-304/316 or MS with
SS liner
23.0
Side Arm Charger
23.1
Type
Rail Mounted with Gear
Teeth
Rack
Traction
Drive
&
&
Pinion
Hydraulic
without
gearbox
and coupling.
23.2
Qty
Five (05)
23.3
Type of wagon to be hauled
BOX N type
23.4
Hauling capacity
60 Nos.
Wagons, each
with gross weight of 110
tons.
23.5
Duty
Continuous ; 24hrs/day
23.6
Operating
Speed (Forward
&
Forward : 0.5 m/s
Reverse)
with
&
Reverse : 1.0 m/s
Load
without Load
23.7
Speed is adequate for
25tips / hr. (Designed ),
23.8
Mode of Control
Automatic
23.9
Type of Lubrication Arrangement
Centralized
23.10
No. of Carriage Wheels
4 Nos
23.11
No. of Guide Rollers
4 Nos. (wheels)
Doc. No.: E072-03-CHP-O-02
22tips/hr (Rated)
REV. NO.: R3
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Sl. No
23.12
Description
Units
Track Gauge
Values
1676 mm
24.0
EOT crane
24.1
No. of Cranes
5 Nos, one no. for each
24.2
Hazardous area classification
Safe
24.3
Type of girder
Double girder box type
24.4
Duty class
M5 Mechanical
24.5
Rated
Crane
wagon tippler shed
M5 Electrical
capacity
(SWL)
20
Tonnes
24.6
Hook type
Shank C. IS 3815 Forged
steel. Safety latch and
swivel lock pin.
24.7
Operation from
24.8
Hoisting Rope
24.8.1
Hoisting rope
Pendant
Flexible plough steel with
lubricated fibre core as
per IS 2266.
24.8.2
Hoist drum
As per IS 3177 minimum
one spare groove when
hook
is
position.
at
highest
24.9
Type of brakes
24.9.1
For hoist
Electro hydraulic Thrustor
24.9.2
No. Required
Two
24.9.3
For long travel
AC Electro hydraulic
thrustor
24.9.4
Cross travel
1 No. AC Electro
hydraulic thrustor
24.10
Speeds
24.10.
Main hoist
3 m/min
24.10.
Cross travel
7.0 m/min
24.10.
Long travel
10.0 m/min
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24.11
Description
Units
Method of achieving creep speed
Values
Through VVVFD
for all motions
24.12
Minimum creep speed
24.12.
Main hoist
10 % of main speed
24.12.
Auxiliary hoist
10 % of main speed
24.12.
Cross travel
10 % of main speed
24.12.
Long travel
10 % of main speed
24.13
Limit switches
24.13.
Cross
Two way lever 2 nos.
24.13.
Long travel
Two way lever 2 nos.
24.13.
Hoisting
Two way rotary & gravity
(1+1)
24.14
Gearboxes
Totally
immersed
horizontal split type with
oil level, drain, breathing
shall be provided
24.15
Types of motors
24.15.
cross travel
Squirrel cage
24.15.
long travel
Squirrel cage
24.15.
hoisting
Squirrel cage
24.16
Maximum hook lift
As required
24.17
Span
As required
24.18
Long travel
As required
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PAGE 370 OF 506
2X800 MW YERMARAS TPS PROJECT
Electrical
Power Transformer
S.No
Description
Particulars
1.
Rating & Quantity
As per SLD
2.
Cooling
ONAN/ONAF
3.
Type
2 Winding
4.
Voltage Ratio
11 kV/3.6 kV
5.
Frequency
50 Hz
6.
Phases
3 (Three phase)
7.
i) ONAN rating
Min. 80% of rated MVA
ii) ONAF rating
Rated MVA
8.
Service
Outdoor
9.
Duty
Continuous
10.
Overload capacity ambient temperature
As per IS: 6600
11.
Temperature rise over 50C ambient
of 50 deg C
i) top oil measured by thermometer
50C
ii)
55C
winding
method
12.
measured
by
resistance
Highest System Voltage
12 kV for 11 kV system and 3. 6
kV for 3.3 kV system
13.
Winding
i)
Rated
power
frequency
withstand
HV: 28 kV, LV: 10 kV
ii) Rated lightning impulse withstand
HV: 75 kV, LV: 40 kV
voltage kVrms
voltage kVp
14.
Bushing
i)
Rated
power
withstand
As per IS 2099
ii) Rated lightning impulse withstand
As per IS 2099
voltage kVrms
frequency
voltage kVp
15.
Clearance in air HV/LV/neutral
16.
Vector group
17.
Tap Changer
HV:130
LV: 50
DyN11
i) Tap range
+/-5% in steps of 2.5% on HV
side
18.
ii) Tap control
OCTC
Type of tank construction
Conventional type
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2X800 MW YERMARAS TPS PROJECT
S.No
Description
19.
Particulars
Noise level
20.
NEMA TR-1
Max. Flux density in any part of core &
Yoke at 110% rated voltage
1.9 tesla
21.
Creepage distance mm
31 mm / kV
22.
Reference standard
IS 2026/IEC60076
23.
System earthing
HV (11 kV)
Non effective earthing (through
LV (3.3 kV)
Non effective earthing (through
24.
Auxiliary supply
415V, 3 ph. 50 Hz
25.
Full power tapping provided(Yes/No)
Required
26.
Type
CFVV
27.
Over fluxing capability
28.
Winding insulation type uniformly or
resistance)
resistance)
of
(CFVV/VFVV/CbVV)
voltage
variation
110% cont. 125% for
140% for 5 second
1 minute
non-uniformly insulated
HV
Uniform
LV
Uniform
Service Transformer
S. No
1.
Description
Particulars
Quantity
As per SLD
Reference standard
IS 2026/IEC60076
3.
Cooling
ONAN
4.
Type
2 Winding
5.
Voltage Ratio
As per SLD
6.
Frequency
50 Hz
7.
Phases
3 (Three phase)
8.
ONAN rating
100% of rated MVA
9.
Service
Indoor
10.
Duty
Continuous
11.
Overload capacity
As per IS: 6600
12
Temperature rise over 50C ambient
i) Top Oil in Deg C
50 C
ii) winding Deg C
55C
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2X800 MW YERMARAS TPS PROJECT
S. No
Description
Particulars
i) Temp Class of Insulation
13.
Insulation Level
a) Impulse
(1.2/50
s)/
frequency
power
withstand
voltage/Induced Over Voltage
Withstand
i) H.V
As per IS
ii) L.V
As per IS
b) Insulation Type(HV/LV)
14
Uniform/Uniform
Bushing Particulars
(i)
Voltage Class HV/LV
As per IS
(ii) Insulation Level
As per IS
(iii) Creepage Distance
31mm/KV
iii) Applicable standard for bushing
IS 2099
15
Clearance in air (minimun) (mm)
HV-130
16
Vector group
17.
Tap Changer
LV-25
DyN11
i) Type
Off-Circuit
ii) Tap range
+/-5%
iii) Tapping step
2.5%
Iv) Tapping power
Full
18
Noise level
NEMA TR-1
19
Max. Flux density in any part of core &
1.9 tesla
21
System earthing
Yoke at 110% rated voltage
HV
Non effectively
LV
Effectively
22
Fault level
50
24
Type of voltage variation
CFVV
25
Over fluxing capability
110%
26
Parallel operation of transformer
Only
kA
(to
match
the
continuous,125%
One
corresponding LT switchgear)
(CFVV/VFVV/CbVV)
Minute and 140% 5 Sec.
momentary
operation with transformers of
similar rating
Notes:
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PAGE 373 OF 506
2X800 MW YERMARAS TPS PROJECT
i)
The Transformer shall be capable of withstanding without damage 1.4 times the
ii)
The specified kVA rating shall be available at the lowest HV winding tap (-5%)
rated voltage at its termination for five (5) seconds.
also.
The transformer should withstand the 3 phase fault current for 3 sec for a fault at the
bushing of the transformer
HT Switchgear
S.No
Description
For 11 / 3.3 kV
Switchgear Assembly
1.
Nominal System voltage
11 / 3.3 kV
2.
Highest System voltage
12 / 3.6kV
3.
Rated Frequency
50 Hz
4.
Type
Metal-clad, draw out
5.
Service
Indoor
6.
Enclosure
IP-42
7.
Number of phases/poles
Three
8.
System neutral earthing
Earthed through Resistance fault
9.
One minute power frequency
By vendor
10.
1.2/50 s Impulse withstand voltage
By vendor
11.
Maximum system fault level
40kA(rms)
12.
Short time rating for bus bars,
40kA(rms) for 3sec
current of 300 Amp. for 10 sec.
withstand voltage
including initial motor contribution
circuit-breakers, current
transformers and switch gear
assembly
13.
Dynamic withstand rating
14.
AC/DC Power Supply
15.
16.
100kA(peak)
i) Control voltage
220 V DC (198V-240V)
ii) Service voltage
240V 10%, 1Ph, 50Hz 5%
Control supply voltage
i) Trip and closing coils
220 V DC unearthed
ii) Spring charging motor
220 V DC/240 V AC
iii) Space heaters
240 V AC single phase
Maximum ambient air temperature
50C
B)
BUSBARS
1.
Temperature rise allowed above
ambient
Doc. No.: E072-03-CHP-O-02
REV. NO.: R3
40C for plain joints 50C for Silver
plated joints
PAGE 374 OF 506
2X800 MW YERMARAS TPS PROJECT
S.No
Description
C)
SWITCH GEAR CUBICLE
1.
Cable entry
For 11 / 3.3 kV
CONSTRUCTIONAL REQUIREMENTS
Power Cables-Bottom
Control Cables- Bottom
2.
Bus duct entry
Top
3.
Main Earthing conductor
Galvanized steel strip
D)
CIRCUIT BREAKERS
1.
The circuit breakers current rating at
2.
Short circuit breaker current
an ambient of 50C
As per requirement
i) A.C. component
40 kA
ii) D.C. component
As per IS:13118 or IEC-56
3.
Short circuit making current
100 kA(peak)
4.
Total break time
Not more than 4 cycles
5.
Total make time
Not more than 5 cycles
6.
Operating Mechanism
Motor wound spring charged stored
7.
Auxiliary Voltage
8.
9.
energy type as per IEC-62271
i) Closing
220 V DC (85%-110%)
ii) Tripping
220 V DC (70%-110%)
iii) Spring Charging
220 V DC (85%-110%)
Duty Cycle
0-3-CO-3-CO
Operation Time
i) Opening time (ms)
Not more than 60
ii) Closing time (ms)
Not more than 100
E)
RELAYS
1.
One minute power frequency
F)
METERS
1.
Accuracy class
0.5S
2.0kV (rms)
2.0kV (rms)
2.
One minute power frequency
G)
CURRENT
1.
Class of insulation
Class E or better
2.
Rated output of each CT
Adequate for the relays and devices
3.
Accuracy class
TRANSFORMER (CT)
connected, but not less than 15VA
i) Protection core
Class PS for differential and core
balance CTs; 5P20 for other protection
CTs
ii) Measurement core
Doc. No.: E072-03-CHP-O-02
0.5
REV. NO.: R3
PAGE 375 OF 506
2X800 MW YERMARAS TPS PROJECT
S.No
Description
For 11 / 3.3 kV
4.
Minimum primary earth fault current
H)
VOLTAGE TRANSFORMER (VT)
1.
Rated voltage factor
1.2 continuous for all VTs , and 1.9 for
2.
Class of insulation
Class E or better
3.
Other parameters
As specified elsewhere
I)
TRANSDUCERS
to be detected by core balance CT
3 Amperes
8 hours for star connected VTs.
1.
CURRENT TRANSDUCERS
2.
Input
0-1A (CT secondary)
3.
Rated Frequency
50Hz
4.
Output
4-20mA (2 Nos. decoupled)
5.
Ammeter withstand capability
6.
Accuracy
6 times CT sec. current of 1A for a
minimum period of 30 seconds
0.5%
J)
VOLTAGE TRANSDUCERS
Input
110V (VT secondary) 50Hz (for
Output
4-20mA (2 Nos. decoupled)
Accuracy
0.5%
K)
VAR TRANSDUCERS
Input
3 PHASE, 3-WIRE (1A CT secondary),
Rated Frequency
50Hz
Output
4-20mA (2 Nos. decoupled)
0.5%
AC)/220V dc (for DC)
110V (VT secondary)
Accuracy
L)
WATT TRANSDUCERS
Input
3 PHASE, 3-WIRE (1A CT secondary)
Rated Frequency
50Hz
Output
4-20mA (2 Nos. decoupled)
Accuracy
0.5%
M)
FREQUENCY TRANSDUCERS
Input
110V (VT secondary)
Rated Frequency
50 Hz
Range
45-55 Hz
Output
4-20 mA (2 Nos. decoupled)
Accuracy
0.5%
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PAGE 376 OF 506
2X800 MW YERMARAS TPS PROJECT
LT Switchgear
S.No
A)
1
Description
Particulars
POWER SUPPLY
AC SYSTEM
Voltage
415V + 10%, 3 Phase, 4 wire, solidly
Frequency
50Hz 5%
Combined variation
frequency)
earthed
(in volts &
Fault Level
2.
3.
B)
10% absolute sum
50 kA(rms)
DC SYSTEM 2 Wire, unearthed
System Voltage
220 V DC
Fault Level
20 kA (indicative only)
CONTROL SUPPLY VOLTAGE
Trip & closing coil of circuit breaker
220 V DC
Spring charging motor
220 V DC
MCC control supply
240 V AC Neutral solidly earthed
Space heater & lighting
240 V AC Neutral solidly earthed
CUBICLE DATA
CB is used as incomer
50kA(rms) for 1 sec.
Dynamic Rating
CB is used as incomer
C)
105kA(peak)
CIRCUIT BREAKER
Type
Air break spring charged stored energy
Operating duty
O-3 MIN-CO-3 MIN-CO
Symmetrical interrupting
50 kA(rms)
Short circuit rating
105kA(peak)
type
Short Circuit Breaking current
D)
AC Component
50kA(rms)
DC Component
As per IS: 13947
Short time withstand
50 kA(RMS) for onesec
No of aux. contacts
4 NO + 4 NC for owner use
METERS
Accuracy class
Minimum as per CEA guidelines for
incomers and for other feeders class
1.0 S
One min. power frequency
2.0 kV (rms)
withstand test voltage
E)
CURRENT TRANSFORMER (CT)
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PAGE 377 OF 506
2X800 MW YERMARAS TPS PROJECT
S.No
Description
Particulars
Type
Cast Resin Bar Primary
Voltage class and frequency
1100V, 50 Hz
Class of insulation
E or better
Accuracy class & burden
For protection
5P-20,VA adequate for application
subject to owners approval
For metering
Minimum as per CEA guidelines for
incomers and for other feeders class
1.0 S
Short time withstand
For CTS Associated with circuit
50 kA (rms) for 1 sec
For CT Associated with fuse
Prospective current of 50 kA(rms) for
breaker
protected feeders
the Fuse clearing time
Dynamic withstand
For CTS Associated with circuit
105 kA(peak)
For CT Associated with fuse
Prospective current of 105 kA(peak) as
breaker
protected feeders
F)
Limited by fuse
BUSDUCT
Type
Non-Segregated
One min. power frequency
2.5 kV
One second short ckt
50 kA(rms)
Momentary dynamic withstand
105 kA(peak)
withstand voltage
withstandCurrent
current
G)
VOLTAGE TRANSFORMER (VT)
Type
Cast Resin
Voltage Ratio
440/110V
Method of construction
Y/Y
Rated Voltage factor
1.1 Continuous, 1.5 for 30 sec.
Class of insulation
Class E or better
One min. power frequency
2.5kV
withstand voltage
I)
CONTACTORS
Type
Air break electro magnetic
Utilizing Category
AC 3 of IS: 13947 for non reversible
AC-4 of IS: 13947 for reversible drives
J)
RELAYS
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PAGE 378 OF 506
2X800 MW YERMARAS TPS PROJECT
S.No
Description
Particulars
Power frequency withstand voltage
K)
CONTROL TRANSFORMERS
Type
Dry/Cast Resin
Voltage Ratio
415/110V, 5% taps in steps of 2.5%
Class of insulation
Class B or better
One min. power frequency
2.5 kV
Rating
1.5 x Adequate for application
withstand voltage
L)
2.5 kV for 1 sec. or 2.0 kV for 1 min.
TRANSDUCERS
CURRENT TRANSDUCERS
Input
0-1 A (CT secondary)
Rated Frequency
50 Hz
Output
4-20 mA (2 Nos. decoupled)
Over current
Transducer for motor current ammeters
shall be capable of withstanding min. 6
times CT sec. current of 1A for a min
period of 30 seconds
Accuracy
M)
0.5%
VOLTAGE TRANSDUCERS
Input
110V (VT secondary) 50Hz (for
Output
4-20mA (2 Nos. decoupled)
Accuracy
0.5%
AC)/220V DC (for DC)
VAR TRANSDUCERS
Input
3 PHASE, 3-WIRE (1A CT secondary),
Rated Frequency
50Hz
Output
4-20mA (2 Nos. decoupled)
Accuracy
0.5%
110V (VT secondary)
WATT TRANSDUCERS
N)
Input
3 PHASE, 3-WIRE (1A CT secondary),
110V (VT secondary)
Rated Frequency
50Hz
Output
4-20mA (2 Nos. decoupled)
Accuracy
0.5%
FREQUENCY TRANSDUCERS
Input
110V (VT secondary)
Rated Frequency
50Hz
Range
45-55 Hz
Output
4-20mA (2 Nos. decoupled)
Accuracy
0.5%
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REV. NO.: R3
PAGE 379 OF 506
2X800 MW YERMARAS TPS PROJECT
MCCB
S.No
A)
Description
Particulars
General
Type
Metal-clad, draw-out
Service
Indoor
Enclosure
In
switchgear
room
and
control
room, all panels shall have degree of
protection of IP-4X.For all other
locations
the
panels
shall
have
degree of protection of at least IP54.
System
AC
DC
i) Voltage
415V 10%
ii) Phase
3-phase
iii) Frequency
50Hz 5%
iv) Combined voltage and frequency
10%
neutral
variation
v) System grounding
sum)
and
(absolute
Solidly
grounded
220V 10%
Ungrounded
Rated current at 50C ambient
i) Switches
16 to 630A
Short circuit rating
AC
DC
i) Interrupting
50kA
20 kA (Values are
ii) Short time for 1 second
50kA
20 kA (Values are
Hipot for 1 minute (min.)
2.5kV
1.5kV
tentative only)
tentative only)
AC/DC Power Supply
B)
i) Control voltage for circuit breaker
220V DC 10%
ii) Control voltage for MCC modules
240V AC 10%, 1Ph, 50Hz 5%
iii) Service voltage
240V AC 10%, 1Ph, 50Hz 5%
CIRCUIT BREAKER
Duty Cycle
0-3-CO-3-CO
Breaking Current
i) A.C. Symmetrical
50 kA for 1 sec
Making Current
105kA(peak)
Auxiliary Voltage
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PAGE 380 OF 506
2X800 MW YERMARAS TPS PROJECT
S.No
C)
Description
Particulars
i) Closing
220V DC (85%-110%)
ii) Tripping
220V DC (70%-110%)
iii) Spring Charging
220V DC (85%-110%)
CONTACTOR DUTY
i) AC
Class
III-Category
AC3
for
unidirectional drives and AC4 for bidirectional/inching duty drives
ii) DC
D)
Class I-Category DC2
SWITCH DUTY
AC
DC
i) Motor feeders
AC23
DC22
ii) Other feeders
AC22
DC22
HT Cables
S. No
1.
Description
Conductor
Particulars
Stranded and compacted aluminium conductor of
grade H2 and class 2 for all sizes, generally
conforming to IS: 8130
2.
Conductor Screen
Extruded semi-conducting compound
3.
Insulation
Extruded cross linked polyethylene (XLPE)
4.
Insulation Screen
Extruded semi-conducting compound with a layer
of non-magnetic metallic tape. For single core the
metallic part of screening. The semi-conducting
tape shall be easily strippable
5.
Core Identification
By coloured strips applied on (For three core
6.
Inner Sheath
Extruded PVC FRLS compound conforming to type
cables) cores or by numerals
ST2 of IS: 5831 for three core cables. Single core
cables shall have inner sheath. Filler material shall
also be of type ST2 PVC
7.
Armour
Galvanized single round steel wire armour for twin
and multicore cables.
Non-magnetic hard drawn aluminium single round
wire conforming to H4 grade for single core
cables.
8.
Overall Sheath
9.
Permissible Voltage and
Extruded FRLS PVC compound conforming to type
ST2 of IS: 5831
frequency variation
Voltage
+/-10%
Frequency
+/-5%
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REV. NO.: R3
PAGE 381 OF 506
2X800 MW YERMARAS TPS PROJECT
S. No
Description
Particulars
Voltage & frequency
10% (absolute)
Permissible conductor
90 deg C
temperature
corresponding to
maximum current
Maximum permissible
conductor temperature
130 deg C
foe emergency
overloading
Conductor temperature
allowed for short circuit
250 deg C
duty
10.
Highest System Fault
40 kA.
11.
Drum/ Length/Tolerance
Wooden/500/1000meter/ 5%
Current
LT power cables
S.No
Description
Particulars
1.
Conductor
Stranded and compacted plain aluminium of grade
2.
Insulation
Extruded XLPE insulation conforming to type C of
3.
Inner Sheath
Extruded PVC compound conforming to type ST2
4.
Armor
Galvanized single round steel wire armour for twin
H2 and class 2 generally conforming to IS: 8130
IS: 5831.
of IS: 5831for multicore cable. Single core cables
shall have inner sheath.
and multicore cables.
Non-magnetic hard drawn aluminium single round
wire conforming to H4 grade for single core cables.
5.
Overall Sheath
6.
Highest System Fault
50 kA for 1 second.
7.
Drum/ Length/Tolerance
Wooden/1000/500metre/ 5%
8.
Permissible Voltage and
Current
Extruded FRLS PVC compound conforming to type
ST2 of IS: 5831
frequency variation
Voltage
+/-10%
Frequency
+/-5%
Voltage & frequency
10% (absolute)
Permissible conductor
90 deg C
temperature
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2X800 MW YERMARAS TPS PROJECT
S.No
Description
Particulars
corresponding to
maximum current
Maximum permissible
130 deg C
conductor temperature
foe emergency
overloading
Conductor temperature
allowed for short circuit
250 deg C
duty
LT Control cables
S.No
Description
Particulars
1.
Conductor
Class 2/stranded, high conductivity annealed plain
2.
Insulation
Extruded PVC compound conforming to type C of
3.
Inner Sheath
Extruded PVC compound conforming to type ST2
4.
Armor
Galvanized single round steel wire armour.
5.
Overall Sheath
Extruded FRLS PVC compound conforming to type
6.
General requirement
copper generally conforming to IS:8130.
IS:5831.
of IS:5831 for multicore cable. Single core cables
shall have inner sheath.
ST2 of IS: 5831
1100 V grade, 90oC rating, XLPE power cable
conforming to requirement and in line with
IS-1554, IS-5831, IS-8130 & IS-3975
Instrumentation cables
Table A: Cable Parameter
Conductor Size
0.5 Sq.mm.
Parameter/ Type
Individual and Overall
Individual and
Compensating
shielded (Type (Type-G)
shielded
(with/without
of Cable
overall
Shielded
F)
Mutual
capacitance at 0.8
120 nF/Km.
Teflon Coated
(Type I)
100 nF/Km.
kHz (max.)
Doc. No.: E072-03-CHP-O-02
overall
REV. NO.: R3
120 nF/Km;
100 nF/Km.
Cables
Teflon
coating)
(Type A, B, C)
200 nF/Km
PAGE 383 OF 506
2X800 MW YERMARAS TPS PROJECT
Conductor
Resistance (max.)
73.4 ohm/km
73.4
Type F
(loop)
(loop) For
73.4 ohm/km
ohm/km
(loop)
Insulation
100 M ohm/
100 M ohm/
100 M ohm/
100 M ohm/ Km
Cross-Talk figure
60 dB
60 dB
60 dB
60 dB
Characteristic
320 ohm
340 ohm
320 ohm; 340
Attenuation at 1
1.2
1.2 dB/Km
1.2 dB/Km
Type F
G/0.8 dB for
resistance
Km
at 0.8 kHz (min.)
impedance (max.)
kHz (max.)
dB/Km for
Km
Km
ohm
for Type
Type E
Description of Various Types of Cables
Description of Various Type of Cables
Type
Conductor Size
Description
0.5 mm2
0.5 mm2
Two pair shielded & twisted T/C extension cable ANSI
0.5 mm2
Two pair shielded & twisted heat resistant Teflon
0.5 mm2
Multi pair individual pair & overall shielded twisted pair
Two pair shielded and twisted pair T/C extension cable,
ANSI type KX, stranded copper conductor.
type SX, stranded copper conductor.
insulation & Outer sheath T/C extension cable ANSI type
KX, stranded copper conductor.
instrumentation cable
(2/4/8/12/16/20/24
pair) for
analog signals with stranded annealed, tinned copper
conductor.
G
0.5 mm2
Multi pair overall shielded & twisted pair instrumentation
cable (2/4/8/12/16/20/24/48 pair) for binary signals
with stranded annealed, tinned copper conductor.
0.5 mm2
Type F cable/type G cable with heat resistant Teflon
insulation
&
outer-sheath
for
high
temperature
application.
S
As per specific
Multi core/ Multi pair shielded cable for system specific
Requirement for
monitoring
Standard /
each application
Doc. No.: E072-03-CHP-O-02
cables. Like conductivity type level switches, Vibration
system
cable,
System
Bus
communications cable etc. as applicable.
REV. NO.: R3
cable,
PAGE 384 OF 506
Bus
2X800 MW YERMARAS TPS PROJECT
DC System
S.N
Description
A)
BATTERY
Application
Ambient temperature
Particulars
Coal Handling Plant
i) Maximum
50C
ii) Minimum
5oC
Type
Lead Acid PLANTE
Battery voltage
220 V
Terminal Connection
1C, copper cables of adequate size
B)
BATTERY CHARGER
Charger
Float-cum-boost
Type
Solid-state (thyristor based), full wave,
Enclosure
Sheet steel enclosure, IP-42
Ambient Temperature
50C
A.C. Input
fully controlled (6 pulse), three phase
bridge for continuous application
i) Supply
415V, 3phase, 50Hz, 4wire
ii) Voltage variation
10%
iii) Frequency variation
5%
iv) Combined volt and frequency
10% (absolute sum)
v) Short-circuit level
50 kA(rms) symmetrical for 1 sec
vi) System earthing
Solidly earthed
variation
D.C. Output
i) Trickle charging mode
(Continuous D.C. load+ trickle
charging battery) plus 25% margin.
Output voltage adjustable between
230-240 Volt
ii) Boost charging mode
Restoring fully discharged battery to
full charging condition in 8 -hours
with 25% margin over maximum
charging rate.
Performance Parameters
i) Output Voltage Regulation (load
Within 1% of the set value
ii) Ripple content in 220V charger D-
1%
variation from 1 to 100%)
C output
Charger Panel
i) Type
Doc. No.: E072-03-CHP-O-02
Free standing floor mounting
REV. NO.: R3
PAGE 385 OF 506
2X800 MW YERMARAS TPS PROJECT
S.N
Description
Particulars
ii) Enclosure
9
Sheet steel (min. 2mm thick CRCA
enclosure conforming to IP-42
Rectifier Transformer
i) Type
10
C)
Dry type, cast resin, double wound,
taps 2x2.5% on primary
ii) Class of insulation
Class-F
iii) Type of cooling
Naturally air-cooled
Maximum temperature rise above
50C ambient
i) Rectifier Transformer
Restricted to class-B
ii) SCR
Limited to 35C rise above ambient
temperature 50C
Controlled Rectifier (SCR)
i) Type
Silicon
ii) Surge protection provided?
Yes
iii) Fast acting HRC fuse provided
Yes
Diode
Peak Inverse Voltage
1200 V
Filter Choke
Insulation Class
Class-F
Contactor
i) Type
Air break heavy duty
ii) Utilization category
AC-3 (for A.C. contactor)
DC-3 (for D.C. contactor)
Meter
i) Size
96 x 96 mm2
ii) Accuracy
1%
Changeover switch
i) Type
3 position 4 pole, load break with
minimum 2 NO + 2 NC auxiliary
contacts
ii) Key interlock furnished?
6
Yes
Terminal Connection
i) A.C. Input
AYWY cable of adequate size
ii) D.C. Output
a) To Battery
1C copper cables of adequate size
b) To Load
1C AYWY cables of adequate size
C)
DCDB
General
Type
Metal clad, Fixed
Service
Indoor
Doc. No.: E072-03-CHP-O-02
REV. NO.: R3
PAGE 386 OF 506
2X800 MW YERMARAS TPS PROJECT
S.N
2
Description
Particulars
System
Voltage
220 V
Phase
2 wire
System
Ungrounded
Rated current at 50 Deg.C ambient
within cubicle
MCCBs
3
16 A to 630 A
Short circuit rating
Short time for 1 sec.
20 kA (indicative only)
Insulation level
1.5 KV for 1 min.
LT Motor
1.
Description
a.
A.C. Motor
2.
Type & Rating
a.
Type of Motor
: Squirrel Cage
b.
Duty Cycle/ Designation
: Continuous
c.
Normal/Energy efficient
: Energy Efficient (EFF1)
d.
Rated Voltage & % Variation
: 415V 10%
: 50Hz 5%
: 415V
e.
Rated Frequency & % Variation
3.
Efficiency at rated Voltage & Frequency
a.
Full Load %
4.
Performance
:>90%
a.
Method of Starting
: DOL
b.
Starting Current at rated Voltage
: <7.2 p.u.
c.
Motor torque at 70% of rated voltage
: Minimum full load torque
d.
Pull out torque of the motor
: Atleast 205% of full load
torque
e.
Motor operation from hot condition without
injurious heating at 85% rated voltage at motor
terminal
: Minimum 5 minutes
5.
Construction
a.
Type of Ventilation
: Self ventilated
Degree of Protection of Enclosure
: IP-55
b.
c.
Method Of Cooling
: Totally enclosed fan cooled
d.
Insulation Class
: Class F with temp. rise
e.
Tropicalized
: Yes
6.
(TEFC)
restricted to class B
Motor Terminal Box
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2X800 MW YERMARAS TPS PROJECT
a.
Short circuit withstand time duration
7.
Accessories
c.
Voltage, phase & frequency
: 0.25 sec
: 240V, 1Phase, 50 Hz
HT Motor
S.No
Description
A.C. Motor
2.
Type & Rating
3.
: 3.3 kV
Type of Motor
: Squirrel Cage
Duty Cycle/ Designation
: Continuous
Normal/Energy efficient
: Energy Efficient
Rated Voltage & % Variation
: Rated Voltage 10%
Rated Frequency & % Variation
: 50Hz 5%
Combined voltage & frequency variation
: 10% absolute
Efficiency at rated Voltage & Frequency
Full Load %
4.
:>90%
Performance
Method of Starting
: DOL
Starting Current at rated Voltage
: 6.0 p.u.
Motor torque at 70% of rated voltage
: Minimum full load torque
Pull out torque of the motor
: Atleast 205% of full load
Motor operation from hot condition without
injurious heating at 80% rated voltage at
motor terminal
5.
7.
torque
: Minimum 5 minutes
Construction
Type of Ventilation
6.
Value
: Self ventilated
Degree of Protection of Enclosure
: IP-55
Method Of Cooling
: Totally enclosed fan cooled
Insulation Class
: Class F with temp. rise
Tropicalized
: Yes
(TEFC)/CACA
restricted to class B
Motor Terminal Box
Type
: Detachable
Time
: 0.25sec
Accessory TerminalBox
Cable glands furnished
: Required
HT Bus Duct
S. No
Description
Doc. No.: E072-03-CHP-O-02
Particulars
REV. NO.: R3
PAGE 388 OF 506
2X800 MW YERMARAS TPS PROJECT
S. No
Description
Particulars
Segregated phase duct
3.3 kV
Reference standard
IS 8084
1.
Nominal System voltage
3.3kV
2.
Highest System voltage
3.6kV
Current rating
As required
3.
Frequency
4.
Service
5.
Number of phase
6.
One
7.
minute
50Hz
Indoor/ Outdoor
power
Three
frequency
withstand
voltage (Dry/Wet)
10 kV
Impulse voltage withstand value with 1.2/50
40 kV
s wave shape
8.
Short time current rating
9.
Dynamic current withstand rating
40kA(rms) for 3 secs
105 kA(peak)
10.
Type of Cooling
Natural
11.
Type of Bus enclosure
12.
Bus bar Material
Aluminum/Al alloy
13.
Enclosure and Partition Material
Aluminum/Al alloy
14.
Minimum thickness of Partition
2mm
15.
Minimum thickness of Enclosure
3mm
16.
Insulators and Bushings
Phase segregated
i) Voltage class
3.6 kV
ii) One minute power frequency withstand
voltage
a) Dry
10 kV
b) Wet
10 kV
iii) Impulse voltage withstand value with
40 kV
1.2/50 s wave shape
v) Material of Insulator
Porcelain
17.
Material of earthing conductor
18.
Design ambient temperature
19.
Maximum temperature rise over an ambient
Galvanized mild steel
50C
of 50C when carrying the rated current
continuously
20.
a) Bolted Joints (Plain or Tinned)
40C
b) Bolted Joints (Silver plated)
40C
ii) Bus duct Enclosure
20C
Degree of protection
Air / Water tightness as per
Doc. No.: E072-03-CHP-O-02
Appendix F of IS 8084.
REV. NO.: R3
PAGE 389 OF 506
2X800 MW YERMARAS TPS PROJECT
LT Bus duct
S. No
Description
Particulars
Non - Segregated phase duct
Reference standard
IS 8084
1.
Nominal System voltage
415 V
2.
Highest System voltage
460 V
Current rating
As required
3.
Frequency
50 Hz
4.
Service
5.
Number of phases
6.
One minute power frequency withstand voltage
8.
Short time current rating
9.
Dynamic current withstand rating
105 kA
10.
Type of Cooling
Natural
11.
Type of Bus enclosure
12.
Bus bar Material
Al/Al alloy
13.
Enclosure and Partition Material
Al/Al alloy
14.
Minimum thickness of Partition
2 mm
15.
Minimum thickness of Enclosure
3 mm
16.
Insulators and Bushings
Indoor/Outdoor
3 phase 4 wire
3 kV
(Dry/Wet)
50 kA for 1 sec
Non segregated
i) Rated Voltage
415 V
ii) One minute power frequency withstand voltage
a) Dry
3 kV
b) Wet
3 kV
iii) Impulse voltage withstand value with 1.2/50 s
wave shape
v) Material of Insulator
Porcelain
17.
Material of earthing conductor
18.
Design ambient temperature
19.
Galvanized mild steel
50 deg C
Maximum temperature rise over an ambient of 50C
when carrying the rated current continuously
a) Bolted Joints (Plain or Tinned)
40 deg C
b) Bolted Joints (Silver plated)
40 deg C
ii) Bus duct Enclosure
20 deg C
Illumination
Lux level requirement - Area wise
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REV. NO.: R3
PAGE 390 OF 506
2X800 MW YERMARAS TPS PROJECT
Sl.
No
1
Area / Structure
Cable vault
Average
illumination
level in Lux
100
Type of
Type of fixture
Luminaire
Indusrial well glass
vitreous enamel reflector
integral mounted control
1 x 70 W
HPSV lamp
gear.
2
All switchgear
room
All Control room
250
300
Indusrial type with vitreous
enamel reflector.
Energy
efficient
lamps
Decorative recessed with
wide angle mirror optic
anti glare type with
diffused illumination and
improved architectural,
civil and aesthetic features
similar to that adopted in
Unit 1 main control room
of BTPS
4
Battery rooms
150
Corrosion proof / Vapour
proof (Epoxy coated).
Energy
efficient
lamps 2 x 28
W FL
Air washer room
and AC plant room
Outside working
Conveyors
areas
enclosed
200
Totally enclosed vapour
Energy
cover.
lamps
proof with clear acrylic
70
Flood light medium beam
100
Dust proof well glass with
reflector wire guard
integral mounted control
efficient
250 W HPSV
lamp
1 x 70 W
HPSV lamp
gear box.
8
Underground
conveyor tunnel
Crusher house,
junction towers
40
Flame proof industrial bulk
head with integral gear
70 W HPSV
box
100
Dust proof / dust tight well
glass with reflector wire
guard integral mounted
1 x 70 W
HPSV lamp
control gear.
10
Coal yard
25
Flood light
1 x 400 W
11
Coal unloading,
50
Flood light
1 x 400 W
Doc. No.: E072-03-CHP-O-02
REV. NO.: R3
HPSV
PAGE 391 OF 506
2X800 MW YERMARAS TPS PROJECT
Sl.
No
Area / Structure
Average
illumination
Type of
Type of fixture
level in Lux
Luminaire
track hopper
HPSV
stacker reclaimer
Road and Yard
lighting
12
Roads and
compounds
10
Street light with clear
acrylic cover cutoff type
with integral mounted
1 x 70 W
HPSV / LED
control gear
13
Parking area
14
Main office areas
15
Office area, cabins
50
General purpose flood
light, high / medium beam
flood light
cabins (air
350
Decorative recessed type
350
Decorative recessed type
conditioned areas)
with false ceiling
but non air -
with mirror optic reflector
with mirror optic reflector
1 x 250 W
HPSV
Energy
efficient 2 x
28 W FL
Energy
efficient 2 x
28 W FL
conditioned
16
Office areas, cabin
non air
350
conditioned
Decorative with wide angle
mirror optic reflector
Energy
efficient 2 x
28 W FL
without false
ceiling
17
Corridors,
walkways, stair
case, etc.,
18
Building periphery
lighting
100
Industrial type with
vitreous enamel reflector /
1 x 28 W FL
channel mounted box
type.
Industrial well glass with
integral mounted control
gear / industrial bulk head
1 x 70 W
HPSV lamp
with integral mounted
control gear.
DC LIGHT
FITTINGS
19
Control room
20
Other areas
Doc. No.: E072-03-CHP-O-02
Decorative recessed type
1 x 100 W
Industrial bulk head or
1 x 100 W
with cylindrical reflector
industrial well glass with
REV. NO.: R3
incandescent
lamp
incandescent
PAGE 392 OF 506
2X800 MW YERMARAS TPS PROJECT
Sl.
Area / Structure
No
21
Average
illumination
level in Lux
Stair case /
landing
Type of
Type of fixture
Luminaire
reflector
lamp
Industrial bulk head or
1 x 100 W
reflector
lamp or CFL.
industrial well glass with
incandescent
Other than above areas, bidder should get approval for Lux level from Owner /
Consultant.
DC lighting percentage
S.No
Area Description
Normal lighting (%)
DC lighting (% of total)
All switchgear room
100
10
Cable vault
100
10
Transformer yard
100
Control room
100
10
Stair case
100
10
Note: Energy Efficient lighting
Fluorescent fixtures with 28 W energy efficient FTL and electronic ballast will be
used for all areas where required Acrylic covers / louvers will be of non
yellowing type. The Acrylic covers will be ultraviolet stabilized. All outdoor
fixtures will be whether proof type with DOP IP55.
Contractor may change the type of fixture to be used in different area against
indicated above, provided minimum illumination level as indicated above is
maintained. Lighting shall appear aesthetically good. Contractor shall measure
the lux levels in the above areas (measured at the working plane) using suitable
devices / meters as per relevant standard to prove the specified values. The
working plant shall include the floor level and also depending on the area.
Lighting transformer details
Sl. No
Description
Particulars
Type
Cast Resin Dry Type
Voltage Rating
433/415V
Cooling
AN
Impedance
Low impedance (To be decided by Bidder)
Voltage Control
Off load tap switch/link, 2 X 2.5%
Class of Insulation
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2X800 MW YERMARAS TPS PROJECT
Temperature Rise Over ambient
70C
Neutral
Solidly Grounded
Mounting
Inside Lighting Distribution Board
of 50 Deg C
Control and Instrumentation
PLC System:
S.No.
Essential/Minimum
Description
Requirements
CPU
1.0
Type
32/64 BIT
2.0
Processor speed
100 MHz
3.0
CPU Memory
1 MB
4.0
Flash Memory
Built in 256 KB
5.0
Drive
DVD read/write
6.0
Boolean Execution Speed
0.4
7.0
Floating Point Maths
Yes
8.0
Embedded Communication
Serial
9.0
Built In Serial Port
Bidder to decide
10.0
Discrete I / O processing
6000
11.0
Analog I / O processing
8 KB
12.0
Protocols Supported
As per Bidders standard
micro
function
sec
Boolean
Discrete Input Module
1.0
Input Module
24 V DC Positive / Negative
2.0
Module Function
Input
3.0
Input Rated voltage
24 V DC Positive / Negative
4.0
Inputs per Module
32/16
5.0
Input Group
Four (4) isolated Groups of
Logic , Intelligent Type
eight (8) input each.
6.0
Channel Indication
LED for each channel
7.0
Fault Indication
Module Fault Indication on the
module
8.0
Discrete Input Voltage Range
0 30V DC
9.0
ON State Voltage
13.5 30 V DC
10.0
OFF State Voltage
05V
Doc. No.: E072-03-CHP-O-02
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PAGE 394 OF 506
2X800 MW YERMARAS TPS PROJECT
S.No.
11.0
Essential/Minimum
Description
Requirements
Isolation between circuit and back 1500 V rms
plane
12.0
Isolation between input circuits
500V rms
13.0
Surge withstand capability
1000V DC/500V AC from point
to point/1000V AC/DC from
point to system ground
14.0
Surge Immunity
1kV peak
15.0
Impedance
20 K Ohms ( Typical )
16.0
Proximity Switch Compatible
Yes
Discrete Output Module
1.0
Module Type
Discrete , Intelligent type
2.0
Module Function
Output
3.0
Outputs per Module
32/16
4.0
Output Group
Four (4) Isolated groups of
eight (8) output each
5.0
Channel Indication
LED for each channel
6.0
Fault Indication
Module Fault Indication on the
7.0
Discrete output voltage range
20 60 V DC
8.0
Response time ON
1 ms Max.
9.0
Response time OFF
1 ms Max.
10.0
Isolation between any output and 1500 V rms
11.0
Isolation between output circuits
500V rms
12.0
Surge withstand capability
1000V DC/500V AC from point
module
back plane
to point/1000V AC/DC from
point to system ground
13.0
Surge Immunity
1kV peak
Output Relay Module
1.0
Module Type
Discrete
2.0
Module Function
Output
3.0
Discrete Output Type
Relay
4.0
Discrete Output Relay Voltage
24V DC
5.0
Outputs per Module
32 Non-Latching Type
6.0
Channel Indication
LED for each channel
7.0
Fault Indication
Module Fault Indication on the
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REV. NO.: R3
PAGE 395 OF 506
2X800 MW YERMARAS TPS PROJECT
S.No.
Essential/Minimum
Description
Requirements
Module
8.0
Response time ON
10
ms
with
ms
typical
bounce time
9.0
Maximum Power
60W Typical
10.0
Maximum Switching Voltage
As 220V DC, 250V AC resistive
load.
11.0
Maximum Switching Current
2 Amps DC, AC resistive load.
12.0
Contact Type
Silver alloy ( gold clad )
13.0
Contact Resistance
50 mw ( by voltage drop 6V DC
1A ) typical
14.0
Built in serial ports
Required.
Analog Input Module
1.0
Module Type
Analog
2.0
Analog Input Type
Current
3.0
Inputs per module
16/8
4.0
Analog Input Current
4-20 mA
5.0
Channel Indication
LED for each channel
6.0
Fault Indication
Module Fault Indication on the
Module
7.0
Response Time
5 ms Typical
8.0
Resolution
0 to 1 micro amp per LSB step
on 4-20Ma
9.0
Accuracy
+ 0.05 % of full scale
10.0
Isolation between any output and 1500 V rms
back plane
11.0
Isolation between output circuits
12.0
Isolation
between
channel
500V rms
to 1000V DC/AC
channel
13.0
Isolation between channel to logic
1000V DC/AC
14.0
Surge Immunity
1kV peak
Analog Output Module
1.0
Module Type
Analog
2.0
Module Function
Output
3.0
Output Type
Current
4.0
Analog Outputs per Module
16/8
5.0
Analog Output
4-20 Ma / 0-20 Ma
Doc. No.: E072-03-CHP-O-02
REV. NO.: R3
PAGE 396 OF 506
2X800 MW YERMARAS TPS PROJECT
S.No.
Essential/Minimum
Description
Requirements
6.0
Channel Indication
LED for each channel
7.0
Fault Indication
Module Fault Indication on the
Module
8.0
Isolation between any output and 1500 V rms
back plane
9.0
Isolation between output circuits
10.0
Isolation
between
channel
500V rms
to 1000V DC/AC
channel
11.0
Isolation between channel to logic
1000V DC/AC
12.0
Surge Immunity
1kV peak
13.0
Impedance
> 10 Mega Ohm, 0- 25 V
14.0
Resolution ( Voltage )
12 Bits
I / O Interface Module
1.0
Module Type
Bus Interface
2.0
Electrical Isolation
Non-isolated
differential
communication
3.0
Built in serial port
Two (2) nos.
Communication Module
1.0
Module Type
Redundant ( Hot Stand by)
2.0
Effective Data Transfer rate
500 KB / sec
3.0
Electrical Isolation
Non-isolated
differential
communication
4.0
Built in serial port
Two (2) nos.
5.0
External communication module
Fibre optic compatible
Power Supply
1.0
Module Function
2.0
Power Source
3.0
Output Power
Power Supply
240 V AC, 50Hz
As per System requirement
Electronic Transmitter -Pressure, D.P., Flow, Level
Sl.No.
Features
Essential/Minimum Requirements
1.
Make
Bidder to state
2.
Model No.
Bidder to state
3.
Type of Transmitter
Microprocessor based, 2 wire type,
HART protocol compatible.
4.
Accuracy
Doc. No.: E072-03-CHP-O-02
0.1% of calibrated span ( minimum)
REV. NO.: R3
PAGE 397 OF 506
2X800 MW YERMARAS TPS PROJECT
Sl.No.
5.
Features
Essential/Minimum Requirements
Output signal range
4-20 mA DC (Analog)
along with
superimposed digital signal
(based
on HART protocol)
6.
Turn down ratio
10:1 for vacuum/very low pressure
applications.
30:1 for other applications.
7.
Stability
0.1% of calibrated span for six
months
for
Ranges
up
to
and
including70 Kg/cm.
0.25% of calibrated span for six
months for Ranges more than 70
Kg/cm (g).
8.
Zero and span drift
+/- 0.015% per deg.C at max span.
+/-0.11% per deg.C at min. Span.
9.
10.
Load impedance
500 ohm (min.)
Housing
Weather proof as per minimum IP-55
with
durable
corrosion
resistant
coating.
11.
Over Pressure
150% of max. Operating pr.
12.
Connection (Electrical)
Plug and socket type
13.
Process connection
1/2 inch NPT (F)
14.
Adjustment/calibration/main
Continuous, tamper proof, Remote as
tenance
well
as
manual
adjustability
from
instrument with zero suppression and
elevation facility.
Centralized
PC
based
system.
In
addition total two (2) no. of handheld type universal calibrators per
unit, compatible with HART protocol,
shall be provided.
15.
Accessories
-Diaphragm
seal,
pulsation
dampeners, Siphon etc. as required
by service and operating condition.
-3-valve manifold for gauge/ vacuum
pressure transmitters and 5 valve
manifold
for
DP/level/flow
transmitters.
Doc. No.: E072-03-CHP-O-02
REV. NO.: R3
PAGE 398 OF 506
2X800 MW YERMARAS TPS PROJECT
Sl.No.
Features
Essential/Minimum Requirements
-For
hazardous
area,
explosions
proof enclosure as per NEC article
500.
16.
Diagnostics
Self Indicating feature
17.
Power supply
24V DC 10%.
18.
Repeatability
+ 0.05% of span or better
19.
Sensitivity
0.05% of span or better
20.
Hand held calibrator
Yes
Notes.
1. LVDT type is not acceptable.
Where the process fluids are corrosive, viscous, solid bearing or slurry type,
diaphragm seals shall be provided. Parts below the diaphragm shall be
removable for cleaning. The entire volume above the diaphragm shall be
completely filled with an inert liquid suitable for the application. For HFO,
LFO Applications, SS capillary with thin wafer element with ANSI RF flanged
ends are to be provided.
For Temperature Gauge
S.N.
Features
Essential/Minimum Requirement
1.
Make
Bidder to state
2.
Model No.
Bidder to state
3.
Sensing Element and
Mercury in steel for below 450C and inert
material
gas actuated for above 450C of SS bulb
and capillary.
4.
Body material
Die-cast aluminum
5.
Dial size
150 mm
6.
End connection
3/4 NPT (F)
7.
Accuracy
1% of span
8.
Scale
Linear, 270 arc graduated in C
9.
Range selection
125% of max. of scale
10.
Over range test
Test pr. For the assembly shall be1.5 to
the max. Design pr. At 38C.
11.
Housing
Weather and dust proof as per minimum
IP-55
12.
Zero/span adjustment
Provided
13.
Identification
Engraved with service legend or laminated
Doc. No.: E072-03-CHP-O-02
REV. NO.: R3
PAGE 399 OF 506
2X800 MW YERMARAS TPS PROJECT
phenolic name plate
14.
Accessories
SS Thermo well
15.
Material of Bourdon/
316 SS / 304 SS
movement
16.
Repeatability
Less than 0.5% of FS.
17.
Response Time
40 seconds
18.
Over range Protection
120% up to 400 Deg. C
115% above Deg. C
19.
Applicable Standard
BS 1401
20.
Others
Capillary and case compensation zero
adjusting by screw from front.
Pressure and D.P. Gauges
S.N.
Features
Essential/Minimum Requirement
1.
Make
Bidder to state
2.
Model No.
Bidder to state
3.
Sensing Element and
Bourdon for high pressure,
material
Diaphragm/Bellow for low pressure Of
316 SS
4.
Body material
Die-cast aluminum
5.
Dial size
150mm
6.
End connection
1/2 inch NPT (F)
7.
Accuracy
1% of span
8.
Scale
Linear, 270 arc graduated in metric units
9.
Range selection
Cover 125% of max. of scale
10.
Over range test
Test pr. for the assembly shall be1.5 to
the max. Design pr. at 38C.
11.
Housing
Weather and dust proof as per minimum
IP-55
12.
Zero/span adjustment
Provided
13.
Identification
Engraved with service legend or
laminated phenolic name plate
14.
Accessories
Blow out disc, siphon, snubber, pulsation
dampener, chemical seal (if required by
process) gauge isolation valve
15.
16.
Material of Bourdon/
AISI 316 SS / 304 SS or non-ferrous for
movement
Phosphor Bronze Bourdon.
Enclosure
Die cast Aluminum, conforming IP 65.
Doc. No.: E072-03-CHP-O-02
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PAGE 400 OF 506
2X800 MW YERMARAS TPS PROJECT
17.
Applicable standard
IS: 3624/PTC 19.2
18.
Accessories
Pulsation dampener, Syphon, Diaphragm
seals, 2 valve manifold etc. as required.
Notes:
Where the process fluids are corrosive, viscous, solid bearing or slurry type,
diaphragm seals shall be provided. Parts below the diaphragm shall be
removable for cleaning. The entire volume above the diaphragm shall be
comp-lately filled with an inert liquid suitable for the application.
For HFO, LFO Applications, SS capillary with thin wafer element with ANSI RF
flanged ends are to be provided.
Level Gauges
Sl.No
Features
Essential/Minimum Requirement
1.
Make
Bidder to state
2.
Model No.
Bidder to state
3.
Sensing Element and
Tempered * toughened Borosilicate
material
gauge glass steel armoured reflex or
transparent type.
4.
Body material
Forged carbon steel/304 SS,
AISI 316 SS (liquid chamber), Tempered
Borosilicate (glass)
5.
Dial size
Tubular covering entire range
6.
End connection
Process connection as per ASME PTC and
7.
Accuracy
2%
8.
Scale
Linear vertical
9.
Range selection
125% of max. of scale
10.
Over range test
Test pr. for the assembly shall be1.5 to
11.
Housing
CS/304 SS leak proof
12.
Identification
Engraved with service legend or
drain/vent 15 NB
the max. Design pr. at 38C.
laminated phenolic name plate
13.
Accessories
Gasket for all KEL-F shields for
transparent type vent and drain valves
of Steel/SS as per CS/Alloy process
Requirement.
14.
Visible Length
Doc. No.: E072-03-CHP-O-02
Shall cover the complete tank height.
REV. NO.: R3
PAGE 401 OF 506
2X800 MW YERMARAS TPS PROJECT
Notes:
Length of gauge glass shall not be more than 1400 mm. If the vessel is
higher, multiple gauge glasses with 50 mm overlapping shall be provided.
Temperature Switches
Sl. No
Features
Essential/Minimum Requirement
1.
Make
Bidder to state
2.
Model No.
Bidder to state
3.
Sensing Element
Vapor pressure sensing, liquid filled
bellow type with SS bulb and capillary
(10 m minimum)
4.
Material
Bourdon, Bulb & capillary-316 SS
Armoring-SS, Movement-AISI 304 SS
5.
End connection
inch NPT (F)
6.
Over range proof pressure
7.
Repeat-ability
+ 0.5% of full range
8.
No. of contacts
2 No.+2NC. SPDT snap action dry
9.
Rating of contacts
60 V DC, 6 VA (or more if required by
contact
DDCMIS or PLC)*
10.
Elect. Connection
Plug in socket
11.
Set point/ dead band
Provided over full range
adjustment
12.
Enclosure
Weather and dust proof as per minimum
IP-55
13.
Accessories
Thermo well of 316 SS and packing
14.
Mounting
Suitable for rack mounting or direct
glands
mounting
15.
Over range Protection
120% upto 400 Deg. C
115% upto 400 Deg. C
Pressure and D.P. Switches
Sl. No
Feature
Essential / Minimum Requirement
1.
Make
Bidder to state
2.
Model No.
Bidder to state
3.
Sensing Element
Piston actuated for high pressure and
diaphragm or bellows for low pr./
Doc. No.: E072-03-CHP-O-02
REV. NO.: R3
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2X800 MW YERMARAS TPS PROJECT
Sl. No
Feature
Essential / Minimum Requirement
vacuum
4.
Material
AISI 316 SS
5.
End connection
inch NPT (F)
6.
Over range proof pressure
150% of max. design pr.
7.
Repeat-ability
+ 0.5% of full range
8.
No. of contacts
2 No.+2NC. SPDT snap action dry
contact
9.
Rating of contacts
60 V DC, 6 VA (or more if required by
DDCMIS or PLC)*
10.
Elect. Connection
11.
Set
point/
dead
Plug in socket
band Provided over full range
adjustment
12.
Enclosure
Weather
and
13.
Accessories
Syphon,
snubber,
minimum IP-55
dust
proof
as
chemical
per
seal,
pulsation dampeners as required by
process
14.
Mounting
Suitable for enclosure/ rack mounting
or direct mounting
15.
Switch Type
Snap acting micro switch, shock &
16.
Accuracy
+1%
vibration proof.
Level Switches
Sl. No
Feature
Essential / Minimum Requirement
1.
Make
Bidder to state
2.
Model No.
Bidder to state
3.
Sensing Element
Radio-frequency/ Ultrasonic type
4.
Material
AISI 316 SS (Float & Wetted )
5.
End connection
Manufacturer standard
6.
Over range proof pressure
150% of max. design pressure
7.
Repeat-ability
+ 0.5% of full range
8.
No. of contacts
2 No.+2NC. SPDT snap action dry
contact
Doc. No.: E072-03-CHP-O-02
REV. NO.: R3
PAGE 403 OF 506
2X800 MW YERMARAS TPS PROJECT
Sl. No
9.
Feature
Essential / Minimum Requirement
Rating of contacts
60 V DC, 6 VA (or more if required
by DDCMIS or PLC)*
10.
Elect. Connection
Plug in socket
11.
Set point/ dead band adjustment
Provided over full range
12.
Enclosure
Weather and dust proof as per
minimum IP-55
13.
Accessories
All mounting accessories
14.
Switch type
Snap acting, magnetically operated
hermetically
sealed,
shock
&
vibration proof.
RF Type Level Switch
Sl.
Essential / Minimum
Feature
No
Requirement
A.
Application
Silo / Bunker level measurement
B.
Electronic Controller
240 V AC, 50 Hz
Input Supply
Body material
Cast Aluminium Housing
Relay Output
Nos.
Relay
Changeover
Potential Free Contacts (2SPDT)
Contact Rating
5A at 240 V AC / 0.25 at 220 V
DC
Class of Protection
IP-66
Ambient Temperature
55 Deg. C (Max)
Local Indication
Local LED Indications
Green
Normal Level
Red
Alarm Level
Yellow
Probe Healthy
Cable Connectio
3/4 ET (2 Nos.) for Supply and
Output 5/8 ET(1 No.) for Probe
Connectionn
C.
Repeatability
Sensing Probe
Type of Probe
Rigid
Material
Stainless steel SS 316
Probe Head Housing
Cast Aluminium
Doc. No.: E072-03-CHP-O-02
REV. NO.: R3
100%
PAGE 404 OF 506
2X800 MW YERMARAS TPS PROJECT
Sl.
Essential / Minimum
Feature
No
Requirement
Insulation (B/W Active& Shield :
PTFE
And Shield& Ground)
Probe Head Protection
IP-66
Mounting
Side Mounted
Cable Connection
5/8 ET(1No.)
Process Connection
40 NB BSP THREADED
Signal Cable
Coaxial
cable
Between
for
Sensing
Connection
probe
and
electronic Controller(@ 10 Mtrs.
Per Level Probe)
Radar Level Transmitter
Feature
Essential / Minimum Requirement
Type
Guided Wave Radar
Application
Bunker / Silo level measurement
Environment Class
Highly abrasive with Gases and Fumes
Orientation
Vertical
Probe Type
Flexible Single lead with chuck
Probe Material
SS 316L
Connection Size & Type
2 Flanged ANSI 150 lb
Connection material
SS 316L
Accuracy
+/- 5 mm
Type(Transmitter)
SMART, 2 Wire
Operating Principle
Time Domain Reflectrometry
Output
4-20 mA, DC
Electrical Connection
NPT
Enclosure Class
IP 66
Electrical Power
11-42 V DC
Housing material
Die Cast Aluminium
Local Display
LCD Display
Units of Measurement
Length mm
Ultrasonic Level Transmitter
Feature
Principle of
Essential / Minimum Requirement
:
Detection of reflected ultrasonic
Operation pulse
Doc. No.: E072-03-CHP-O-02
REV. NO.: R3
PAGE 405 OF 506
2X800 MW YERMARAS TPS PROJECT
Measuring Ranges
Up to 30 meters (typical)
Signal Processing
Microprocessor Controlled Signal Processing
Operating Freq
10KHz to 50 KHz (typical)
Display
Large alpha-numeric back lit LCD/LED
Calibration & Configuration
Accessible from front of panel
Diagnosis
On-line
Status
For power, Hi / Lo / V. Hi / V. Lolevel indication, fault etc.
Construction
Plug-on board
Power supply
240 V AC 50 Hz / 24V DC
Signal Output
4-20 mA DC (isolated) 600 Ohm load.
Hysteresis
Fully adjustable preferred
Output contacts
2SPDT Potential free changeover contacts @
Accuracy & Repeatability
0.25% of span or better
Resolution
0.1% of span
Operating temp
Transmitter-50 o C and Sensor 80 o C
MOC Sensor
Body- PVC and Face Polyurethene
Humidity
1% to 95% non condensing.
Enclosure
IP-65 Epoxy painted die cast aluminium or
8A 230V AC.
Polycarbonate housing.
Cable Connection
3/4" ET
Mounting
2 for sensor and Transmitter on panel.
Accessories
Cable
gland,
prefab
cable,
mounting
accessories.
ZERO SPEED SWITCH
Probe
Type
Magnetic pick up (inductive type)
Size
As per requirement
Protection class
NEMA 4 (IP 65)
Enclosure type
Robust cast aluminum
Supply voltage
240 V AC 10%, 50 Hz.
Speed range
As per process requirement
Electronic unit
Doc. No.: E072-03-CHP-O-02
REV. NO.: R3
PAGE 406 OF 506
2X800 MW YERMARAS TPS PROJECT
Speed setting accuracy
Within 5% of desired value.
Repeatability
Within 1%.
Differential
Within 5% of set value
Output contact type
2 NO + 2 NC
Contact rating
240V, 5A AC/ 220V, 0.5A DC.
Ambient Temperature
0-50 Deg. C.
Preferable features
Red LED for Supply On
Green LED for Relay On
Display of present speed
Belt Sway Switch
Type
Auto reset type
Protection class
NEMA 4 (IP 65)
Enclosure type
Flame proof
Output contacts
2 NO + 2 NC
Contact Rating
Contact roller support
240V, 5A AC/ 220V, 0.5A DC.
Bearing with high relative lubrication &
low Coefficient of friction.
Pull Chord Switch
Type
Manual reset type
Protection class
NEMA 4 (IP 65)
Enclosure type
Flame proof
Output contacts
2 NO + 2 NC
Contact Rating
240V, 5A AC/ 220V, 0.5A DC.
Operating handle
Fitted with spring steel rings at both
Doc. No.: E072-03-CHP-O-02
ends
REV. NO.: R3
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DATA SHEET-B: DATA TO BE FILLED BY THE BIDDER
Mechanical
Sl. No
Description
1.0
Belt Conveyors
1.1
Horizontal centre distance between
Units
Values
Meter
Drive and Tail pulley of conveyor
1.2
Lift of each conveyor
1.3
Maximum angle of inclination
1.4
Capacity of conveyor
1.4.1
Designed
1.4.2
Rated
1.5
Material
1.5.1
Type of material Handeled
1.5.2
Bulk Density of Material
T/cum
1.6
Belt speed of conveyor
M/sec.
1.7
Belt Details
1.7.1
Belt width
1.7.2
Belt specification
1.7.3
Minimum thickness of cover
1.7.3.1
Top
mm
1.7.3.2
Bottom
mm
1.8
Minimum no. plies and braking
TPH
strength
1.9
Belt Tension
1.9.1
Actual
1.9.2
Allowable
1.10
Conveyor Belt Rating
1.11
Weight of Belt per meter length
1.12
Belt Material and Construction
1.13
Length of Belt required including
jointing allowance
1.14
Pulleys of each type for each
1.14.1
Dia of Pulley
1.14.2
Shell thickness
1.14.3
Disc end thickness
1.14.4
Drive Pulley lagging
conveyor
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Sl. No
Description
1.14.5
Other pulley lagging
1.14.6
Rubber of lagging
1.15
Bearings for pulleys
1.15.1
Type
1.15.2
Casing
1.15.3
Sealing
1.15.4
Lubrication
1.15.5
Bearing life
1.16
Pulley width
1.17
Pulley Material
1.18
Shaft Material
1.19
Maximum allowable
Units
Values
deflection of
shaft at the hubs
1.20
Technological structures
1.20.1
Size of Stringers/Short supports
1.20.2
Thickness of Deck plate
1.21
Walk way width on both side of
mm
Conveyor
1.22
Chequered Plate thickness
1.23
Tensioning arrangement
1.23.1
type
1.24
Idlers
1.24.1
Roller Material
1.24.2
Dia and Length of Roller
1.24.3
Thickness of Rubber disk
1.24.5
Spacing
1.24.5.1
Carry ing
1.24.5.2
Return
1.24.5.3
Impact
1.24.5.4
Self aligning Carrying
1.24.5.5
Self aligning Return
1.24.6
Bearing
1.24.6.1
Life
1.24.6.2
Type
1.24.6.3
Make
1.24.6.4
Type of Seals
1.24.6.5
Lubrication arrangment
Doc. No.: E072-03-CHP-O-02
REV. NO.: R3
mm
PAGE 409 OF 506
2X800 MW YERMARAS TPS PROJECT
Sl. No
Description
1.25
Speed Reduction Unit
1.25.1
Manufacturer
1.25.2
Type
1.25.3
Reduction Ratio
1.25.4
Minimum service factor considered
1.25.5
Mechanical efficiency
1.25.6
Material of construction
1.25.6.1
Casing
1.25.6.2
Gear
1.25.6.3
Pinion
1.25.7
Duty Condition
1.25.8
Bearing type, make and life
1.25.9
Hold Back Device
1.25.9.1
Provided
1.25.9.2
Details of hold Back
1.25.10
No. of working hours/day
1.25.11
Location
Units
Values
Yes/No
Indoor /
Outdoor
1.26
Belt Cleaners
1.26.1
Type of External Belt cleaners
1.26.2
Type of Internal Belt Cleaners
1.27
Skirt Board
1.27.1
Thickness of main plate
1.27.2
Material of main plate
1.27.3
Thickness of skirt liner
1.27.4
Material of skirt liner
1.27.5
Skirt height
1.27.6
Skirt weight
1.27.7
Thickness and material on top cover
on skirt
1.27.8
Minimum length of skirt per feeding
point
1.27.9
Adequate dust seal/rubber curtain
provided at exit point of skirt
1.27.10
Thickness and Hardness of Skirt
Rubber
1.27.11
Type of fixing arrangement between
Doc. No.: E072-03-CHP-O-02
REV. NO.: R3
PAGE 410 OF 506
2X800 MW YERMARAS TPS PROJECT
Sl. No
Description
Units
Values
main plate and liner
1.28
Fluid coupling
1.28.1
Make
1.28.2
Type
1.28.3
Rated KW transmitted
1.28.4
Rated input speed
1.28.5
Rated sleep
1.28.6
Whether fusible plug to be provided
1.28.7
Type of cooling
1.28.8
Hours of Operation/Day
1.28.9
Maximum starting torque
1.28.10
Direction of rotation
1.28.11
Balancing
1.29
Flexible Coupling
1.29.1
Make
1.29.2
Type
1.29.3
Power that may be transmitted safely
at rated RPM
1.29.4
Service Factor
2.
Coal Crusher
2.1
Material to be crushed
2.2
Hard grove Index
2.3
Maximum moisture content
2.4
Material Temperature
2.5
Ambient Temperature
2.6
Hours of operation per day
Hours/day
2.7
Bulk density
T/m3
2.8
Capacity
TPH
2.9
Output size
2.10
Material of construction
2.10.1
Rotor
2.10.2
Suspension Bars
2.10.3
Breaker Plate, kick off plate
2.10.4
Screen bars/Screen plates
2.10.5
Middle and end discs
2.10.6
Frame liners
2.11
Bearing
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2X800 MW YERMARAS TPS PROJECT
Sl. No
Description
Units
2.11.1
Bearing Type
2.11.2
Life
2.11.3
Lubrication
2.12
Cooling Arrangement
2.13
Enclosure
2.14
Power Consumption
2.15
Motor Rating
3.
Chutes
3.1
Material handled
3.2
Bulk density
T/M3
3.3
Lump size
mm
3.4
Belt width
mm
3.5
Maximum moisture content
3.6
Flow rate
TPH
3.7
Belt speed
m/s
3.8
Pulley width
3.9
Fabrication
3.10
Material of Construction
3.10.1
Mother Plate Material
3.10.2
Thickness
3.10.3
c) Liner material
3.10.4
d) Liner thickness
3.11
Min valley angle
4.
Electric Hoist
4.1
Quantity and location
4.2
Class of hoist offered
4.3
Capacity
4.4
Travel speed
M/Sec
4.5
Hoisting speed
M/Sec
4.6
Total lift
4.7
Total trolley travel for festooning
MM
Values
Hrs
Site/shop
mm
mm
arrangement
4.8
Applicable standards
4.9
Recommended minimum radius of
curvature
5.
Manual Hoist
5.1
Quantity and location
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REV. NO.: R3
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Sl. No
Description
Units
5.2
Class of hoist offered
5.3
Capacity
5.4
Type of travel
M/Sec
5.5
Maximum manual effort to lift load
Kg
5.6
Total lift
5.7
Applicable standards
5.8
Recommended minimum radius of
Values
curvature
6.
Flap Gates
6.1
Service Requirement
6.2
Type
6.3
Required numbers
6.4
Material handled
6.5
Material size
mm
6.6
Bulk Density
T/M3
6.7
Moisture content
6.8
Hours of operation/day
6.9
Flap Gate Actuator Requirement
6.9.1
No of switching/hr
6.9.2
Travel range
6.9.3
Actuator type
6.9.4
Type of Travel control limit switch
6.9.5
Torque switch provision
6.9.6
Degree of protection
6.10
Materials of Construction and
Thickness
6.10.1
Gate
6.10.2
Liner
6.11
Bearing
6.11.1
Type
6.11.2
Life
6.11.3
Method of lubrication
7.
Rack and Pinion Gates
7.1
Type
7.2
Location
7.3
Required Nos.
7.4
Material handled-coal lump size
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REV. NO.: R3
mm
PAGE 413 OF 506
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Sl. No
Description
Units
7.5
Bulk density
T/M3
7.6
Moisture content
7.7
Size of opening
7.8
Locking device to be provided
7.9
Type of chain
7.10
Chain guard to be provided
7.11
Load on gate (max)
7.12
Materials of Construction
7.12.1
Slide gate
7.12.2
Rack
7.12.3
Pinion
7.12.4
Drive shaft
7.12.5
Chain, Wheel, Chain guard
7.13
Bearing
7.13.1
Type
7.13.2
Life
7.13.3
Method of lubrication
7.13.4
Type of Seal
7.14
Chain pull for manual operations
7.15
Motor rating
Vibrating Screens
8.1
Location
8.2
Rated capacity
8.3
No required
8.4
Material to be handled
8.5
Max. Lump Size
8.6
Output size
8.7
Moisture content (max.)
8.8
Material for construction of all items
Belt Weigher Electronic Type
9.1
Type
9.2
Number and location
9.3
Type of load cell
9.4
Speed sensing device
9.5
Weighing type
9.6
Rate indicator type, Load/remote
9.7
Six Digit Totaliser included in local
Doc. No.: E072-03-CHP-O-02
Values
Kg
TPH
REV. NO.: R3
PAGE 414 OF 506
2X800 MW YERMARAS TPS PROJECT
Sl. No
Description
Units
Values
and remote
9.8
Guaranteed accuracy
9.9
Belt conveyor characteristic
Belt width (mm) & Speed
9.10
Control station
9.11
Control cabinet
9.12
Weighing range
9.13
Electrical
10
In Line Magnetic Separator
10.1
Type
10.2
Number and location
10.3
Maxm, and minm.Size and weight of
MM, Kg
10.4
Operating height of Magnet from
MM
tramp iron that can be lifted
belt top surface
10.5
Flux density of magnet at surface of
Gauss
Magnet and at operating distance
from Magnetic separator under hot
stabilized condition
10.6
Speed of Inline Magnetic separator
M/min
10.7
All accessories included
Yes/No
10.8
Rectifier-Type &material, rating
10.9
Force Index
11
Metal Detectors
11.1
Type
11.2
Number and location
11.3
Detecting capacity
11.4
Annunciation/Hooter provided
11.5
Audible Range of hooter
11.6
Material handled
11.7
Capacity (flow)
TPH
11.8
Size of material
mm
11.9
Bulk Density
T/cum.
11.10
Material of Construction
11.11
Sand Bag Marker
11.12
Sensitivity
12
Dust Extraction System
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2X800 MW YERMARAS TPS PROJECT
Sl. No
Description
Units
12.1
Bag filter
12.2
Type location and Make
12.3
No. of bag filters/DE system
12.4
Volume of dust laden air handled
M3/hr
12.5
Total cloth area
M2
12.6
Air-to-cloth ratio
12.7
Dust concentration of air let out to
Values
Mg/nm3
atmosphere
12.8
Efficiency
12.9
Materials of construction
12.9.1
a) Bags
12.9.2
b) Cage of bags
12.10
Dry Cyclone
12.11
Manufacturer
12.12
Total No. quoted
12.13
Model No.
12.14
Type
12.15
Capacity
12.16
Pressure drop
12.17
Efficiency of collection of dust
13
Dust Suppression System
13.1
Type and location
13.2
Method of working and detailed
M3/hr
%
Yes/No
description furnished?
13.3
Spray nozzles
13.4
Area covered by each spray nozzle
13.5
Material of nozzle tips and housing
13.6
Nozzle Spacing
13.7
Tanks
13.7.1
Number
13.7.2
Material of construction
13.7.3
Capacity
14
Stacker/Reclamer
14.1
Type and Make
14.2
Number required
14.3
Capacity while stacking (Rated)
14.4
Capacity while reclaiming
Doc. No.: E072-03-CHP-O-02
MM
MM
M3
REV. NO.: R3
TPH
PAGE 416 OF 506
2X800 MW YERMARAS TPS PROJECT
Sl. No
14.5
Description
Average Capacity (over a period of 4
Units
Values
TPH
hours) (Rated)
14.6
Peak (Rated)
TPH
14.7
Material handled
14.8
Belt width
mm
14.9
Wind pressure
Kg/m2
14.9.1
Operating
14.9.2
Non-operating
14.10
Maximum wheel load permissible
tones
14.11
Rails for travel of stacker reclaimer
14.11.1
Track gauge
14.11.2
Rail size
14.11.3
Length of runway
14.11.4
Effective length of travel
14.11.5
Effective length of stock pile
14.11.6
Effective stock pile height above
14.12
Bucket wheel
14.12.1
Dia of bucket wheel ring
14.12.2
Number of bucket
14.12.3
Width of bucket
14.12.4
Water fill volume of each bucket
14.13
Material of construction
14.13.1
Bucket wheel
14.13.2
Bucket
14.13.3
Teeth and tips
14.14
Boom Conveyor
14.14.1
Length
14.14.2
Width
14.14.3
Troughing angle
14.14.4
Belt Speed
14.14.5
Range of Luffing
14.14.6
Slewing angle of Boom
14.14.7
Maximum and minimu Slewing speed
14.14.8
Lowering and hoisting Speed
14.14.9
Belt Carcass type
with impact
graded level
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Sl. No
Description
14.14.10
Top and bottom
14.14.11
Drive details with Power
14.15.
Type of drive for
14.15.1
Bucket wheel
14.15.2
Slewing
14.15.3
LT drive
14.16
Type of brakes
14.16.1
Type of control of SCR
14.17
Stability Factor
14.17.1
For operating condition with
Units
Values
maximum operating wind velocity
14.17.2
For non operating condition with
maximum non operating wind
velocity
14.18
Anchoring arrangement for
overturning protection due to storm
14.19.
CRD
14.19.1
Type
14.19.2
No. furnished
14.19.3
Size
14.19.4
Capacity
14.20
Operator Cabin
14.20.1
Type
14.20.2
Location
15
Sump Pump
15.1
Designation
15.2
Number of pumps required
15.3
Design Flow
(m3/hr)
15.4
Head
MWC
15.5
Speed
RPM
15.6
Operation
15.7
Depth of sump
Depth of Minimum water level from
bottom of sump
15.8
Base Frame
15.9
Constructional Features
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Sl. No
Description
15.9.1
Type of pump
15.9.2
Type of Bearing Lubrication
15.9.3
Prime Mover
15.10
Material of Construction
15.10.1
Casing
15.10.2
Impeller
15.10.3
Shaft
15.10.4
Column Pipe
15.10.5
Seal
15.10.6
Coupling type
15.10.7
Coupling
15.10.8
Coupling guard
15.10.9
Base plate
15.10.10
Gaskets
Units
16.
Apron Feeder
16.1
LOCATION
16.2
Capacity (Rated/Design)
16.3
Duty
16.4
Capacity Range
16.5
Number required
16.6
Material to be handled
16.7
Max. Lump Size
mm
16.8
Bulk density
T/M3
16.9
Length of Apron feeder
16.10
Drive
17.
Dribble Feeder
TPH
17.1
LOCATION
17.2
Type
17.3
Capacity (Rated/Design)
17.4
Duty
17.5
Number required
17.6
Material to be handled
17.7
Max. Lump Size
17.8
Type of Belt
17.9
Top and Bottom cover thickness
mm
17.10
Width
mm
17.11
Take-up
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Values
TPH
mm
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Sl. No
18.
Description
Units
Values
Integrated weigh bridge
18.1
Type
18.2
Location
18.3
Number
18.4
Weighment Position
18.5
Display & Output
18.6
Location of control console
18.7
Tare Weight Determination
18.8
Type of Wagon
19.
Dust Suppression system
19.1
Type
19.2
Location
19.3
Type of nozzles
19.4
Spray nozzle tip and housing
19.5
Quantity of water to be sprayed at
each feed and discharge points of
conveyor
19.6
Quantity of water to be sprayed at
stockpile
19.7
Method of operation of each DS
system
20.0.
VENTILATION SYSTEMS
20.1
Bunker ventilation systems
20.1.1
Type
20.1.2
Dust emission level
20.1.3
Capacity
20.2
Tunnel Ventilation System
20.2.1
No of Air Changes/hr
20.2.2
Type of fan
20.2.3
Location
20.2.4
Velocity of air inside duct
20.2.5
Material of duct
20.2.6
Grills
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Mg/Nm3
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Mps
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Sl. No
20.3
Description
Units
Values
Pressure ventilation system CHP MCC
room
20.3.1
Room size
20.3.2
Basis of capacity calculation
21
HOPPERS
21.1
Designation
21.2
Number Required
21.3
Whether grid required on top of
21.4
If grid required, size of opening
21.5
Type of Construction of Hoppers
21.6
Shed over hoppers required
21.7
Liner
22.0
COAL PILE RUN OFF PIT
22.1
Purpose
22.2
Capacity
22.3
Construction
23.0
COAL SAMPLING SYSTEM
23.1
Type
23.2
Location of sampler
23.3
Capacity of each of the conveyors
23.4
Type of Primarycutter
23.5
Material of construction
23.5.1
Primary cutter
23.5.2
Liners for hoppers
23.5.3
Through of screw conveyor
24.0
Side Arm Charger
24.1
Type
24.2
Qty
24.3
Type of wagon to be hauled
24.4
Hauling capacity
24.5
Duty
24.6
Operating
hopper
Cu.m
TPH
Speed (Forward &
Reverse) with Load & without
Load
24.7
Speed is adequate for
24.8
Mode of Control
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Description
Units
24.9
Type of Lubrication Arrangement
24.10
No. of Carriage Wheels
24.11
No. of Guide Rollers
24.12
Track Gauge
25.0
EOT Crane
25.1
GENERAL
25.1.1
Manufacturer
25.1.2
Quantity
25.1.3
Design according to standard service
Values
class/ load class
25.1.4
Nominal load carrying capacity (SWL)
25.1.5
Span
25.1.6
Distance
M
from
operating
floor
to
bottom of beam for long travel
25.2
SPEEDS
25.2.1
Long travelling speed
M/min
25.2.2
Cross travelling speed
M/min
25.2.3
Hoisting speed
M/min
25.3
LOCATION (INDOOR/ OUTDOOR)
25.4.
CLEARANCES
AND
HOOK
APPROACHES, AS PER TENDER (IF NO,
SPECIFY)
25.5
CONSTRUCTIONAL FEATURES
25.5.1
Weight of complete crane unladen
25.5.2
Weight of hoist with travelling trolley
unladen
25.5.3
Maximum wheel load
25.5.4
Wheel loading diagram furnished
25.6
HOISTING SYSTEM
25.6.1
Rope
25.6.2
Rope diameter mm
25.6.3
Rope construction
25.6.4
Rope quality (material)
25.6.5
Rope strength kg/mm2
25.6.6
Number of rope falls
25.6.7
Factor of safety
25.6.8
Rope drum
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Description
25.6.9
Drum diameter and length
25.6.10
Drum material -
25.6.11
Whether stress relieved
25.7
Hook
25.7.1
Hook material
25.7.2
Safety latches provided
25.8
Hoist Brake
25.8.1
Number of brakes
25.8.2
Type
25.8.3
Make
25.8.4
Size
25.9
Limit Switch
25.9.1
Numbers
25.9.2
Type
25.9.3
Make
25.10
CROSS TRAVEL
25.10.1
CT brake
25.10.2
Number of brakes
25.10.3
Type
25.10.4
Make
25.10.5
Size
25.10.6
Wheels
25.10.7
Materials
25.10.8
Hardness
25.10.9
Limit switches
25.10.10
Number
25.10.11
Type
25.10.12
Make
25.10.13
Type of Stoppers
25.10.14
Number of driven wheels
25.10.15
Number of total wheels
25.11
MOTOR (for hoisting)
25.11.1
Make
25.11.2
Type
25.11.3
Rating
25.11.4
Permissible Starts/Hr.
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Units
Values
mm
mm
Mm
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Sl. No
25.12
Description
Units
Values
CRANE CONTROL
Electrical
Power Transformers
S. No
Description
1.
Reference standard
2.
Make& Quantity
3.
Rating
4.
Cooling
5.
Type
6.
Voltage Ratio
7.
Frequency (Hz)
8.
Number of windings
9.
Phases (Nos.)
10.
Particulars
a) Guaranteed Impedance at 75C at principal
tap
b) Percentage impedance in maximum tap
c) Percentage impedance in minimum tap
11.
Service
12.
Rated output (MVA)
i) With ONAN cooling
ii) With ONAF cooling
13.
Duty
14.
Overload capacity
15
Capability of transformer to remain in
operation from hot condition after failure of
forced cooling
a) Full load
b) 80 % load
16.
Voltage withstand time (Sec.)
i) 110% of rated voltage
ii) 125% of rated voltage
iii) 140% of rated voltage
17.
Reference ambient temperature (C)
18.
Guaranteed Maximum Temperature rise over
50C ambient
i) top oil measured by thermometer (C)
ii) winding measured by resistance method
(C) for
a) ONAN
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Description
Particulars
b) ONAF
19.
Winding material
20.
Windings
HV
LV
i) System Fault level (kA)
ii) Winding connection
iii) Insulation
21.
Highest System Voltage
22.
Winding insulation level Impulse/power
frequency (kVp/kVrms)
i) H.V.
ii) L.V.
23.
Bushing HV/LV/LVn
i) Make
ii) Type
iii) Voltage class (kV)
iv) Rated power frequency withstand voltage
(kVrms)
v) Rated lightning impulse withstand voltage
(kVp)
24.
Minimum clearance
a) Between phases
i) In air (mm)
ii) In oil (mm)
b) Between phase and earth
i) In air (mm)
ii) In oil (mm)
25.
Vector group
26.
Tap Changer
i) Type
ii) Tap range
iii) Tap control
iv) Winding tapped (HV/LV)
27.
Guaranteed losses at principal tap, full load
and 75C (kW)with out any Positive tolerence
i) No load losses
ii) Load losses
iii) Cooler losses
28.
Efficiency at 75C and 0.8 power factor lag (%)
i) At full load
ii) At 75% load
iii) At 50% load
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Description
Particulars
iv) Maximum efficiency
v) Load and power factor at which the max.
efficiency occurs
29.
Regulation at full load at 75C
i) At unity power factor
ii) At 0.8 power factor lagging
30.
No load current referred to HV at 100% rated
31.
Maximum flux density
voltage (%)
(A) at 100% rated volts (Tesla)
(B) at 110% rated volts (Tesla)
(C) at 125% rated volts (Tesla)
(D) at 140% rated volts (Tesla)
32
Over fluxing capability
a) Continuous
b) For 1 Minute
c) For 5 Seconds
33.
Maximum current density (A/mm2)
i) H.V.
ii) L.V.
34.
Withstand time for 3-phase dead short circuit
at terminal with rated voltage maintained on
other side (Sec.)
35.
Cooling system
i) Number of Cooler Bank
ii) Capacity of Each Cooler Bank
iii) No of Radiators per Cooler Bank
iv) No of Fans per Cooler Bank
v) Whether Standby Fan for each cooler Bank
Provided
vi) Rating of Fan Motor
36.
Insulating oil
i) Approximate volume (litre)
ii) 10% excess oil furnished (Yes/No)
iii) Type of oil preservation system provided
37
Vacuum withstand capability
a) Main Tank
b) Radiator and accessories
38.
Marshalling box
i) Weather proof, suitable for outdoor duty
(Yes/No)
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Description
Particulars
ii) Degree of protection
39.
Creepage distance of insulators
40.
Noise level (db)
41
Weights
a) Core & Winding
b) Net weight of Copper
HV
LV
Total
c) Oil
d) Tank,Cooler and fittings
e) Total weight
f)
42
Un-Tanking weight
Shipping Section
a) Size of the largest package
b) Weight of the largest package.
Service Transformer
S.No
Description
Particulars
11/0.433 kV
1.
Reference standard
2.
Make
3.
Quantity
4.
Cooling
5.
Type
6.
Voltage Ratio
7.
Frequency (Hz)
8.
Number of windings per phase
9.
Phases (Nos.)
10.
Guaranteed positive sequence impedance at 75 deg C
with 100% rating
a)Principal tap
b) Maximum tap
c) Minimum tap
11.
Service
12.
Rated output (MVA)
13.
Duty
14.
Overload capacity
15.
Voltage withstand time (Sec.)
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S.No
Description
Particulars
i) 110% of rated voltage
ii) 125% of rated voltage
iii) 140% of rated voltage
16.
Reference ambient temperature (C)
17.
Temperature rise over 50C ambient
b.
Top oil deg C
i) For winding over ambient of 50C
ii) Temperature class of insulation
18.
Winding material
19.
Windings
HV
i) System Fault level (kA)
ii) Winding connection
iii) Insulation
i)
Winding insulation type
20.
Highest System Voltage
21.
Winding
(kVp/kV)
insulation
level
Impulse/power
frequency
i) H.V.
ii) L.V.
iii) L.V. neutral
22.
Bushing
HV/LV/LV(N)
i) Make
ii) Type
iii) Voltage class (kV)
iv) Rated power frequency withstand voltage (kVrms)
v) Rated lightning impulse withstand voltage (kVp)
vi) Creepage distance, mm
vii)Short circuit current rating
viii)Rated current
ix) Weight of bushing, kg
x) Applicable standard
24.
Clearances
a) Between phases
i) In air (mm)
ii) In oil (mm)
b) Between phase and earth
i) In air (mm)
ii) In oil (mm)
25.
Vector group
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LV
2X800 MW YERMARAS TPS PROJECT
S.No
26.
Description
Particulars
Tap Changer
i) Type
ii) Tap range
iii) Tap control
iv) Winding tapped (HV/LV)
ii) Provided with caution plate (Yes / No)
iii)
Tap-changer operable at standing height from
ground?
vii) Provided with tap position indicators (Yes/No)
viii) All contacts silver plated? (Yes/No)
27.
Guaranteed losses at principal tap, full load and 75C
(kW)
i) No load losses
ii) Load losses
iii) Tolerance on above mentioned losses (%)
28.
Efficiency at 75C
i) At full load
ii) At 75% load
iii) At 50% load
iv) Maximum efficiency
v) Load and power factor at which the max. efficiency
occurs
29.
Regulation at full load at 75C
i) At unity power factor
ii) At 0.8 power factor lagging
30.
No load current referred to HV and 50 Hz
i) At 90% rated voltage
ii) At 100% rated voltage
iii) At 110% rated voltage
iv) At 125% rated voltage
31.
Maximum flux density (Wb/mm2)
i) At 90% rated voltage, 50 Hz
ii) At 100% rated voltage, 50 Hz
iii) At 110% rated voltage, 50 Hz
iv) At 125% rated voltage, 50 Hz
v) At 140% rated voltage, 50 Hz
32.
Maximum current density (A/mm2)
i) H.V.
ii) L.V.
33.
Withstand time for 3-phase dead short circuit at
terminal with rated voltage maintained on other side
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S.No
Description
Particulars
(Sec.)
34.
Terminal connections
i) H.V.
ii) L.V.
iii) L.V. neutral
35.
Marshalling box
i) Weather proof (Yes/No)
ii) Degree of protection
36.
Noise level (db)
37.
Hot spot temperature in winding limited to ( C)
38.
Reactance at rated current and frequency, %
39.
Resistance at rated current and at 75oC
40.
Zero sequence impedance, % at principal tap
41.
Capacitance between winding and to earth (micro
farads)
HV to tank
LV to tank
HV to LV
42.
Details of core material
i) Core lamination material
ii) Thickness of lamination, mm
iii) Insulation of lamination
iv) Core bolt withstand voltage for 2 kV
43.
Terminal blocks
i) Make
ii) 10% spare terminals furnished? (Yes/No)
44.
Wiring
i) Cable type
ii) Voltage grade, Volt
iii) Conductor size
iv) Current circuits, mm2
v) Other circuits, mm2
45.
Radiator
a)
Overall dimensions l x b x h
b)
Total weight with oil kg
c)
Total weight without oil
46.
Type of mounting
47.
Thickness of radiator tube, radiator sheet steel
48.
Accessories
Each
transformer
accessories (Yes/No)
Doc. No.: E072-03-CHP-O-02
furnished
with
REV. NO.: R3
fittings
and
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S.No
Description
Particulars
MOG with alarm contact (dial type) size
49.
Approximate overall dimensions, mm
i) Length
ii) Breadth
iii) Height
50.
Vacuum withstand capability: main tank, radiators and
51.
Tank pressure withstand capacity
52.
Radiator pressure withstand capacity
accessories
Approximate weights, kg
a) Core and coil
b) Oil
c) Un tanking weight
d) Total weight
53.
Shipping data
q) Weight of the heaviest package, kg
r) Dimension of the largest package (LxBxH), mm
s) Parts detached for transit
54.
Rollers
a) Quantity
b) Whether bi-directional (Yes/No)
c) Gauge
d) Whether lockable in both the positions (Yes/No)
55.
56.
Bushing Current Transformer(s)
a)
Make
b)
Type (Yes/No)
c)
Quantity
d)
Voltage
e)
Current ratio
f)
Burden & accuracy class
g)
Internal resistance at 75C
h)
Knee-point voltage
i)
Short-time
j)
Thermal current rating
k)
Dynamic current rating
l)
Applicable standard
withstand
duration in secs.
current
WTI
in
amps.
NCT
and
Termination Arrangement
a) Details
of
HV
cable
furnished? (Yes/No)
termination
arrangement
b) Details of LV bus duct termination arrangement
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S.No
Description
Particulars
furnished? (wherever applicable) (Yes/No)
57.
Drawing & data are furnished with the bid? (Yes/No)
58.
Paint shade
HT Switchgear
S. No
Description
A)
SWITCH GEAR ASSEMBLY
1.
Make
2.
Type
3.
Reference Standard
4.
Nominal System voltage (kV)
5.
Highest System voltage (kV)
6.
Rated Frequency (Hz)
7.
Number of phases/poles
8.
System neutral earthing
9.
One minute power frequency withstand voltage (kVrms)
9.1
for type tests
9.2
for routine tests
10.
11.
For 11 / 3.3 kV
1.2/50 s Impulse withstand voltage (kVp)
Maximum system fault level including initial motor
contribution (kArms)
12.
Short time rating for bus bars, circuit-breakers, current
13.
Dynamic withstand rating (kApeak)
14.
Control supply voltage
transformers and switch gear assembly (kArms)
i) Trip and closing coils
ii) Spring charging motor
iii) Space heaters
15.
Maximum ambient air temperature (C)
16.
Metal-clad construction?
17.
Degree of Protection
18.
Minimum thickness of sheet metal used (mm)
19.
Switchgear completely assembled, wired and tested at
20.
Service
21.
Enclosure
22.
AC/DC Power Supply
factory
i) Control voltage
ii) Service voltage
B)
Construction
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S. No
1.
Description
For 11 / 3.3 kV
Draw-out feature provided for
1.1
Circuit breaker with SERVICE, TEST and DISCONNECTED
1.2
Voltage Transformer (Yes/No)
1.3
Protective relays (Yes/No)
2.
2.1
2.2
position (Yes / No)
Breaker Cubicle
Cubicle door can be closed with breaker in TEST position
(Yes/No)
Working zone limits from floor level (mm)
3.
All meters, switch and relays flush mounted type (Yes/No)
4.
Minimum clear space required at
4.1
Front for breaker withdrawal (mm)
4.2
Rear (mm)
5.
5.1
Typical vertical section
Overall dimension and weight
a) Incomer/Tie
b) Bus coupler
C) Transformer/ Motor
d) Outgoing feeder
C)
BUSBARS
1.
Make
2.
Material and Grade
3.
Reference Standard
4.
Cross sectional Area (mm2 )
5.
Size (mm)
6.
Skin-effect ratio
7.
Reactance
8.
Continuous current rating at 50C ambient: as per BOQ
9.
Temperature rise allowed above 50C
10.
Short-time current for 3 secs.
11.
DC resistance at 85C (Ohm/m/phase)
12.
Losses-middle phase (W/m/ph)
13.1
KA (rms)
Minimum clearance of bare bus bar and connection
a) Phase to phase (mm)
b) Phase to ground (mm)
13.2
Bus bar provided with
a) Insulating sleeve
b) Phase barriers
C) Cast resin shrouds for joint
14.
Bus Connections
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S. No
Description
14.1
Silver plated
14.2
Made with antioxide grease
15.
Bus bar support spacing (mm)
16.
Bus support insulator
16.1
Make
16.2
Type
16.3
Reference Standard
16.4
Voltage Class (kV)
16.5
Minimum creepage distance (mm)
16.6
Cantilever strength (kg/cm2)
16.7
Net weight (kg)
17.
Bus bar colour coded? (Yes/No)
D)
SWITCH GEAR CUBICLE CONSTRUCTIONAL REQUIREMENTS
1.
Colour finish
2.
Cable entry
For 11 / 3.3 kV
a) Power Cables-Bottom
b) Control Cables- Bottom
3.
Bus duct entry
4.
Main Earthing conductor
E)
CIRCUIT BREAKERS
1.
Make
2.
Type
3.
Reference standard
4.
Rated voltage (kV)
5.
Rated frequency (Hz)
6.
No. Of poles (No.)
7.
Maximum temperature rise over 50C ambient
8.
The circuit breakers current rating at an ambient of 50C
9.
Interrupting capacity at rated voltage and operating duty
9.1
Symmetrical (kArms)
9.2
Asymmetrical (kArms)
10.
Transient Recovery voltage
10.1
Rate of rise
10.2
Peak voltage
11.
Maximum over voltage factor when switching off
11.1
Unloaded transformer
11.2
Loaded transformer
11.3
Unloaded lines
11.4
Induction Motor
12.
Insulation Level
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Description
12.1
Impulse voltage withstand with 1.2*50 s wave (kVp)
12.2
1-minute 50Hz voltage withstand (kV)
13.
Short circuit breaker current
13.1
A.C. component
13.2
D.C. component
14.
Short circuit making current (kApeak)
15.
At 100% interrupting capacity
15.1
Opening time-Max. (mSec.)
15.2
Arcing time-Max. (mSec.)
15.3
Total tripping time (Max.)
16.
Total closing time (Max.)
17.
Total break time
18.
Total make time
19.
Number of breaks per pole
20.
Total length of breaks per pole
21.
Total length of contact travel
22.
Rate of contact travel
22.1
At tripping
22.2
At closing
23.
Type of contacts
23.1
Main
23.2
Arcing
24.
No. Of breaker operations permissible, without requiring
inspection, replacement of contacts and other main parts
24.1
At 100% rated current
24.2
At 100% rated interrupting current
25.
For 11 / 3.3 kV
Material of contacts
25.1
Main
25.2
Arcing
25.3
Whether contacts silver plated
25.4
Thickness of silver plating
26.
Contact pressure at no load (kg)
27.
Minimum clearance in air (mm)
27.1
Between poles
27.2
Between live parts and ground
28.
Type of arc control device provided
29.
Spring charging motor
29.1
Rating (kW)
29.2
Voltage (A.C. or D.C.) (V)
29.3
Permissible voltage variation (%)
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S. No
30.
Description
Closing Coil
30.1
Voltage (V)
30.2
Permissible voltage variation (%)
30.3
Closing current at rated voltage(A)
31.
Tripping Coil
31.1
Voltage (V)
31.2
Permissible voltage variation (%)
31.3
Trip current at rated voltage (A)
32.
For 11 / 3.3 kV
For trip circuit supervision the tripping coil connection
arrangement will be
33.
Operating Duty
34.
Operating Mechanism
34.1
Type
34.2
No. Of breaker operations stored
34.3
Trip free or fixed trip?
34.4
Anti pumping features provided?
35.
Breaker/Cubicle Accessories
36.
Accessories such as control switch, indication lamps,
37.
relays furnished as specified
Breaker/Breaker Cubicle provided with the following
37.1
Mechanical safety interlock
37.2
Automatic safety shutter
37.3
Emergency manual trip
37.4
Mechanical ON-OFF indicator
37.5
Operation counter
37.6
Charge/Discharge indication
37.7
Manual spring charging facility?
37.8
Auxiliary switch with number of NO and NC contacts
37.9
No. Of Cell switch with number of NO and NC contacts
mounted on draw out portion
37.10
Auxiliary switch with number of NO and NC contacts
37.11
Surge protection device?
38.
mounted as stationary parts
Cell/Auxiliary Switch
38.1
Are switch contacts convertible types? (Yes/No)
38.2
Contacting rating at
a) Rated & Making current
b) Interrupting current (Inductive)
c) P.F. for A.C. & L/R for D.C. interruption
39.
Trip circuit supervision relay furnished for each breaker
40.
Net weight of the breaker
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Description
For 11 / 3.3 kV
41.
Impact load for foundation design (to include dead load
plus impact values on opening at maximum interrupting
rating)
42.
Overall dimension (L*B*H)
43.
Auxiliary Voltage
i) Closing
ii) Tripping
iii) Spring Charging
44.
Type test report on identical breaker submitted? (Yes/No)
F)
CONTROL & INDICATIONS
1.
Push Buttons
1.1
Make
1.2
Type and Cat. No.
1.3
Contact rating at 220V D.C.
a) Make and Continuous (Amp.)
b) Break [Inductive] (Amp.)
1.4
2.
2.1
PF for A.C. & L/R for D.C.
Lamps (LEDs)
Make
2.2
Type and Cat. No.
2.3
Watts/voltage
2.4
Series resistance (ohm)
2.5
Lamp & Lens replaceable from front.
3.
Selector Switch
3.1
Make
3.2
Type and Cat. No.
3.3
3-position stay put type?
3.4
Contact rating at 220 V D.C
a) Make and Continuous (Amp.)
b) Break [Inductive] (Amp.)
3.5
Key interlock furnished? (Yes/No)
G)
CURRENT TRANSFORMER (CT)
1.
Make
2.
Type
3.
Reference Standard
4.
CT ratios
5.
Rated frequency (Hz)
6.
Short Circuit Withstand
6.1
Short-time current for 3 secs
6.2
Dynamic current (kA peak)
(kA rms)
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S. No
6.3
Description
Class of insulation
6.4
Temp. Rise over 50C ambient (C)
6.5
Basic Insulation level (kV peak)
6.6
CT magnetization curve furnished (Yes/No)
7.
CT for Differential Protection
7.1
Class
7.2
Secondary resistance at 75C (Ohm)
7.3
Knee point voltage (Volts)
7.4
Excitation current at Vk/2 (mA)
8.
Metering C.T.
8.1
Incomer/Tie feeder V.A Burden class
8.2
Motor feeder V.A Burden class
8.3
Transformer feeder V.A Burden class
8.4
Outgoing feeder V.A Burden class
9.
9.1
Relaying C.T.
Incomer/Tie feeder V.A Burden class
9.2
Motor feeder V.A Burden class
9.3
Transformer feeder V.A Burden class
9.4
Outgoing feeder V.A Burden class
H)
VOLTAGE TRANSFORMER (VT)
1.
Make
2.
Type
3.
Reference Standard
4.
Voltage ratio
5.
Rated frequency (Hz)
6.
Accuracy class
7.
VA burden (VA)
8.
Over voltage factor
8.1
Continuous
8.2
30 seconds
9.
For 11 / 3.3 kV
Class of insulation
10.
Temp. Rise over 50C ambient (C)
11.
Basic Insulation level (kV peak)
12.
Winding Connection
12.1
Primary
12.2
Secondary
I)
FUSES
1.
Voltage class
2.
Rupturing capacity
3.
Rated current
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S. No
Description
For 11 / 3.3 kV
4.
Continuous ratings-H.V./L.V. (Amps)
5.
Symmetrical ratings-H.V./L.V. (kA rms)
J)
RELAYS
1.
Draw-out type with built in test facilities
2.
Numerical multifunctional type (Yes/No)
3.
Type of mounting
4.
Reference standard
5.
All relays furnished as per the Annexures & write up of
6.
All
specification (Yes/No)
relevant
(Yes/No)
relay
leaflets
and
catalogue
furnished
RELAY DETAILS
1.
Incomer/Tie
1.1
Make/Type
1.2
Feeder Management relay [FMR] (Multifunctional)
1.3
Any other discrete relay which is not covered by above
relay
a)
b)
c)
2.
Transformer feeder
2.1
Make/Type
2.2
Feeder Management relay [FMR] (Multifunctional)
2.3
Any other discrete relay which is not covered by above
relay
a)
b)
c)
3.
Motor feeder
3.1
Make/Type
3.2
Feeder Management relay [FMR] (Multifunctional)
3.3
Any other discrete relay which is not covered by above
relay
a)
b)
c)
4.
Power feeder (Multifunctional)
4.1
Make/Type
4.2
Any other discrete relay which is not covered by above
relay
a)
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S. No
Description
For 11 / 3.3 kV
b)
c)
K)
METERS
1.
Make
2.
Type
3.
Reference Standard
4.
Size
5.
Scale
6.
Accuracy class
7.
Digital and Communicator meter (Yes/No)
8.
Meter switch
8.1
Make
8.2
Type
8.3
Catalogue No.
L)
SECONDARY WIRING
1.
Type and Insulation
2.
Voltage grade
3.
Conductor material
4.
Conductor size (minimum)
4.1
Potential circuit
4.2
Control & current circuit
5.
Wires identified at both ends with markers
M)
TERMINAL BLOCK
1.
Make
2.
Type
3.
Catalogue No.
4.
20% spare terminals furnished? (Yes/No)
N)
CABLE TERMINATION
1.
Cable termination & connection arrangement furnished as
O)
CABLE TERMINATION KIT FURNISHED
1.
Make
2.
Type
3.
Complete with all accessories
4.
specified (Yes/No)
Cable Lugs
4.1
Type
4.2
Material
5.
Cable Gland
5.1
Type
5.2
Material
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S. No
5.3
Description
With tappered washer
5.4
With Armour clamp
5.5
Removable Gland Plate
a)
Material for multi-core cable
b)
Material for single-core cable
c)
Thickness of the plate
P)
GROUND BUS
1.
Ground bus furnished
2.
Material
3.
Size
Q)
NAME PLATE
1.
Material
2.
Thickness
3.
Size for (mm)
3.1
Panel
3.2
Equipment/ devices
R)
SPACE HEATER /PLUG SOCKET
1.
Cubicle Heater
1.1
Thermostat controlled?
1.2
Wattage
1.3
2.
Voltage
Plug Socket
2.1
Type
2.2
Rating
3.
Motor Heater
3.1
Provision made for motor heater supply
3.2
Separate contactor furnished
3.3
If so, contactor rating
4.
Cubicle heater, motor heater & plug socket circuit
S)
A.C./D.C. SUPPLY
1.
provided with individual switch fuse unit?
Isolating switches fuse unit for incoming supply: -
1.1
A.C. - type & rating
1.2
D.C. - type & rating
2.
For 11 / 3.3 kV
Isolating switch fuse unit at each cubicle
2.1
A.C. supply - type & rating
2.2
D.C. supply - type & rating
T)
TROPICAL PROTECTION
1.
Any special treatment for tropical protection?
2.
Screens are of corrosion resistant materials?
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S. No
U)
1.
Description
For 11 / 3.3 kV
PAINTING
Finish of switchgear
1.1
Inside
1.2
Outside
V)
NO. OF ACCESSORIES FURNISHED
1.
Earthing equipment
2.
Slow closing device for maintenance
3.
Test cabinet
W)
SURGE ARRESTORS (FOR MOTOR & TRANSFORMER
FEEDERS)
1.
Nominal discharge current (8*20s)
2.
Max. system voltage (rms)
3.
Max. standard impulse spark over voltage (peak)
4.
Residual voltage at nominal discharge current
5.
Temporary over voltage capability (rms)
6.
Installation
X)
CONTACTORS
1.
Nominal System voltage
2.
Highest System voltage
3.
Rated Frequency
4.
Rated Continuous Current at 50C ambient
5.
Control Supply Voltage
6.
Utilization category
7.
Rated operating duty
8.
Rated making current
9.
Rated breaking current
10.
Short time rated current
11.
Asymmetrical current
12.
13.
a)
AC component
b)
DC component
Operating time
a)
Closing time
b)
Opening time
Closing and Opening coil particulars
Y)
TRANSDUCERS
1.
CURRENT TRANSDUCERS
1.1
Input
1.2
Rated Frequency
1.3
Output
1.4
Ammeter withstand capability
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Description
1.5
For 11 / 3.3 kV
Accuracy
2.
VOLTAGE TRANSDUCERS
2.1
Input
2.2
Output
2.3
Accuracy
3.
VAR TRANSDUCERS
3.1
Input
3.2
Rated Frequency
3.3
Output
3.4
Accuracy
4.
WATT TRANSDUCERS
4.1
Input
Rated Frequency
Output
Accuracy
5.
FREQUENCY TRANSDUCERS
5.1
Input
5.2
Rated Frequency
5.3
Range
5.4
Output
5.5
Accuracy
Z)
TESTS
1.
Routine tests to be performed on switchgear
1.1
1.2
1.3
1.4
LT Switchgear
S. No
Description
A)
SWITCH GEAR ASSEMBLY
1.
Make
2.
Type
3.
Reference Standard
Particulars
4.
Nominal System voltage (kV)
5.
Highest System voltage (kV)
6.
Rated Frequency (Hz)
7.
Number of phases/poles
8.
System neutral earthing
9.
One minute power frequency withstand
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S. No
Description
Particulars
voltage (kVrms)
9.1
for type tests
9.2
for routine tests
10.
11.
12.
1.2/50 s Impulse withstand voltage
(kVp)
Maximum system fault level including
initial motor contribution (kArms)
Short time rating for bus bars, circuitbreakers, current transformers and
switch gear assembly (kArms)
13.
Dynamic withstand rating (kApeak)
14.
Control supply voltage
i) Trip and closing coils
ii) Spring charging motor
iii) Space heaters
15.
Maximum ambient air temperature (C)
16.
Metal-clad construction
17.
Degree of Protection
18.
Minimum thickness of sheet metal
19.
Switchgear completely assembled,
used (mm) CRCA
wired and tested at factory
B)
Construction
1.
Draw-out feature provided for
1.1
Circuit breaker with SERVICE, TEST and
DISCONNECTED position
1.2
Voltage Transformer (Yes/No)
1.3
Protective relays (Yes/No)
2.
Breaker Cubicle
2.1
Cubicle door can be closed with
2.2
Working zone limits from floor level
3.
4.
breaker in TEST position (Yes/No)
(mm)
All meters, switch and relays flush
mounted type (Yes/No)
Minimum clear space required at
4.1
Front for breaker withdrawal (mm)
4.2
Rear (mm)
5.
5.1
Typical vertical section
Overall dimension and weight
a) Incomer/Tie
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S. No
Description
Particulars
b) Bus coupler
C) Transformer
d) Motor
C)
BUSBARS
1.
Make
2.
Material and Grade
3.
Reference Standard
4.
Cross sectional Area (mm2 )
5.
Size (mm)
6.
Skin-effect ratio
7.
Reactance
8.
Continuous current rating at 50C
9.
ambient
Temperature rise allowed above 50C
10.
Short-time current for 1 sec.
11.
DC resistance at 85C (Ohm/m/phase)
12.
Losses-middle phase (W/m/ph)
13.1
kA (rms)
Minimum clearance of bare bus bar and
connection
a) Phase to phase (mm)
b) Phase to ground (mm)
13.2
Bus bar provided with
a) Insulating sleeve
b) Phase barriers
C) Cast resin shrouds for joint
14.
Bus Connections
14.1
Silver plated
14.2
Made with antioxide grease
15.
Bus bar support spacing (mm)
16.
Bus support insulator
16.1
Make
16.2
Type
16.3
Reference Standard
16.4
Voltage Class (kV)
16.5
Minimum creepage distance (mm)
16.6
Cantilever strength (kg/cm2)
16.7
Net weight (kg)
D)
SWITCH GEAR CUBICLE
1.
Colour finish
CONSTRUCTIONAL REQUIREMENTS
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2X800 MW YERMARAS TPS PROJECT
S. No
2.
Description
Particulars
Cable entry
a) Power Cables-Bottom
b) Control Cables- Bottom
3.
Bus duct entry
4.
Main Earthing conductor
E)
CIRCUIT BREAKERS
1.
Make
2.
Type
3.
Reference standard
4.
Rated voltage (kV)
5.
Rated frequency (Hz)
6.
No. Of poles (No.)
7.
Maximum temperature rise over 50C
8.
The circuit breakers current rating at
9.
Interrupting capacity at rated voltage
ambient
an ambient of 50C
and operating duty
9.1
Symmetrical (kArms)
9.2
Asymmetrical (kArms)
10.
Transient Recovery voltage
10.1
Rate of rise
10.2
Peak voltage
11.
Maximum over voltage factor when
switching off
11.1
Unloaded transformer
11.2
Loaded transformer
11.3
Unloaded lines
11.4
Induction Motor
12.
Insulation Level
12.1
12.2
13.
Impulse voltage withstand with 1.2*50
s wave (kVp)
1-minute 50Hz voltage withstand (kV)
Short circuit breaking current
13.1
A.C. component
13.2
D.C. component
14.
Short circuit making current (kApeak)
15.
At 100% interrupting capacity
15.1
Opening time-Max. (mSec.)
15.2
Arcing time-Max. (mSec.)
15.3
Total tripping time (Max.)
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Description
Particulars
16.
Total closing time (Max.)
17.
Total break time
18.
Total make time
19.
Number of breaks per pole
20.
Total length of breaks per pole
21.
Total length of contact travel
22.
Rate of contact travel
22.1
At tripping
22.2
At closing
23.
Type of contacts
23.1
Main
23.2
Arcing
24.
No. Of breaker operations permissible,
without requiring inspection,
replacement of contacts and other
main parts
24.1
At 100% rated current
24.2
At 100% rated interrupting current
25.
Material of contacts
25.1
Main
25.2
Arcing
25.3
Whether contacts silver plated
25.4
Thickness of silver plating
26.
Contact pressure at no load (kg)
27.
Minimum clearance in air (mm)
27.1
27.2
Between poles
Between live parts and ground
28.
Type of arc control device provided
29.
Spring charging motor
29.1
Rating (kW)
29.2
Voltage (A.C. or D.C.) (V)
29.3
Permissible voltage variation (%)
30.
Closing Coil
30.1
Voltage (V)
30.2
Permissible voltage variation (%)
30.3
Closing current at rated voltage(A)
31.
Tripping Coil
31.1
Voltage (V)
31.2
Permissible voltage variation (%)
31.3
Trip current at rated voltage (A)
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Description
Particulars
32.
For trip circuit supervision the tripping
33.
Operating Duty
34.
Operating Mechanism
coil connection arrangement will be
34.1
Type
34.2
No. Of breaker operations stored
34.3
Trip free or fixed trip?
34.4
Anti pumping features provided?
35.
Breaker/Cubicle Accessories
36.
Accessories such as control switch,
37.
Breaker/Breaker Cubicle provided with
indication lamps, relays furnished as
specified
the following
37.1
Mechanical safety interlock
37.2
Automatic safety shutter
37.3
Emergency manual trip
37.4
Mechanical ON-OFF indicator
37.5
Operation counter
37.6
Charge/Discharge indication
37.7
Manual spring charging facility?
37.8
Auxiliary switch with number of NO
and NC contacts mounted on draw out
portion
37.9
No. Of Cell switch with number of NO
and NC contacts
37.10
Auxiliary switch with number of NO
and NC contacts mounted as stationary
parts
37.11
Surge protection device?
37.12
Circuit breaker provided with gas
pressure monitoring device (Yes/No)
a) Operating pressure of breaker
b) Alarm & trip setting pressure
38.
38.1
38.2
Cell/Auxiliary Switch
Are switch contacts convertible types?
(Yes/No)
Contact rating at
a) Make or Continuous
b) Break (Inductive)
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Description
Particulars
39.
Trip circuit supervision relay furnished
40.
Net weight of the breaker
41.
Impact load for foundation design (to
for each breaker
include dead load plus impact values
on opening at maximum interrupting
rating)
42.
Overall dimension (L*B*H)
43.
Type test report on identical breaker
submitted? (Yes/No)
F)
CONTROL & INDICATIONS
1.
Push Buttons
1.1
Make
1.2
Type and Cat. No.
1.3
Contact rating at
a) Make and Continuous (Amp.)
b) Break [Inductive] (Amp.)
1.4
2.
PF for A.C. & L/R for D.C.
Lamps (LEDs)
2.1
Make
2.2
Type and Cat. No.
2.3
Watts/voltage
2.4
Lamp & Lens replaceable from front.
3.
3.1
Selector Switch
Make
3.2
Type and Cat. No.
3.3
Contact rating at
a) Make and Continuous (Amp.)
b) Break [Inductive] (Amp.)
3.4
Key interlock furnished? (Yes/No)
G)
CURRENT TRANSFORMER (CT)
1.
Make
2.
Type
3.
Reference Standard
4.
CT ratios
5.
Rated frequency (Hz)
6.
6.1
Short Circuit Withstand
Short-time current for 3 sec
(kA rms)
6.2
Dynamic current (kA peak)
6.3
Class of insulation
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S. No
6.4
Description
Particulars
Temp. Rise over 50C ambient (C)
6.5
Basic Insulation level (kV peak)
6.6
CT magnetization curve furnished
7.
(Yes/No)
CT for Differential Protection
7.1
Class
7.2
Secondary resistance at 75C (Ohm)
7.3
Knee point voltage (Volts)
7.4
Excitation current at Vk/2 (mA)
8.
Metering C.T.
8.1
Incomer/Tie feeder V.A Burden, class
8.2
Motor feeder V.A Burden class
8.3
Transformer feeder V.A Burden, class
9.
Relaying C.T.
9.1
Incomer/Tie feeder V.A Burden, class
9.2
Motor feeder V.A Burden, class
9.3
Transformer feeder V.A Burden class
H)
VOLTAGE TRANSFORMER (VT)
1.
Make
2.
Type
3.
Reference Standard
4.
Voltage ratio
5.
Rated frequency (Hz)
6.
Accuracy class
7.
VA burden (VA)
8.
Over voltage factor
8.1
Continuous
8.2
30 seconds
9.
Class of insulation
10.
Temp. Rise over 50C ambient (C)
11.
Basic Insulation level (kV peak)
12.
Winding Connection
12.1
Primary
12.2
Secondary
I)
HRC FUSES
1.
Voltage class
2.
Rupturing capacity
3.
Rated current
4.
Continuous ratings-H.V./L.V. (Amps)
5.
Symmetrical ratings-H.V./L.V. (kA rms)
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2X800 MW YERMARAS TPS PROJECT
S. No
Description
Particulars
J)
RELAYS
1.
Draw-out type with built in test
2.
Numerical multifunctional type
facilities
(Yes/No)
3.
Type of mounting
4.
Reference standard
5.
6.
All relays furnished & write up of
specification (Yes/No)
All relevant relay leaflets and catalogue
furnished (Yes/No)
RELAY DETAILS
1.
Incomer / Tie
1.1
Make/Type
1.2
Feeder Management relay [FMR]
1.3
Any other discrete relay which is not
(Multifunctional)
covered by above relay
a)
b)
c)
2.
Transformer feeder
2.1
Make/Type
2.2
Feeder Management relay [FMR]
2.3
Any other discrete relay which is not
(Multifunctional)
covered by above relay
a)
b)
c)
3.
Motor feeder
3.1
Make/Type
3.2
Feeder Management relay [FMR]
3.3
Any other discrete relay which is not
(Multifunctional)
covered by above relay
a)
b)
c)
4.
4.1
Power feeder (Multifunctional)
Make/Type
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2X800 MW YERMARAS TPS PROJECT
S. No
4.2
Description
Particulars
Any other discrete relay which is not
covered by above relay
a)
b)
c)
K)
METERS
1.
Make
2.
Type
3.
Reference Standard
4.
Size
5.
Scale
6.
Accuracy class
7.
Digital and Communicator meter
8.
Meter switch
(Yes/No)
8.1
Make
8.2
Type
8.3
Catalogue No.
L)
INTERNAL WIRING
1.
Type and Insulation
2.
Voltage grade
3.
Conductor material
4.
Conductor size (minimum)
4.1
Potential circuit
4.2
Control & current circuit
5.
Wires identified at both ends with
M)
TERMINAL BLOCK
1.
Make
2.
Type
markers
3.
Catalogue No.
4.
20% spare terminals furnished?
(Yes/No)
N)
CABLE TERMINATION
1.
Cable termination & connection
arrangement furnished as specified
(Yes/No)
O)
CABLE TERMINATION KIT FURNISHED
1.
Make
2.
Type
3.
Complete with all accessories
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2X800 MW YERMARAS TPS PROJECT
S. No
4.
Description
Cable Lugs
4.1
Type
4.2
Material
5.
Particulars
Cable Gland
5.1
Type
5.2
Material
5.3
With tappered washer
5.4
With Armour clamp
5.5
Removable Gland Plate
a)
Material for multi-core cable
b)
Material for single-core cable
c)
Thickness of the plate
P)
GROUND BUS
1.
Ground bus furnished
2.
Material
3.
Size
Q)
NAME PLATE
1.
Material
2.
Thickness
3.
Size for (mm)
3.1
Panel
3.2
Equipment/ devices
R)
SPACE HEATER /PLUG SOCKET
1.
Cubicle Heater
1.1
Thermostat controlled?
1.2
Wattage
1.3
Voltage
2.
Plug Socket
2.1
Type
2.2
Rating
3.
Motor Heater
3.1
Provision made for motor heater supply
3.2
Separate contactor furnished
3.3
If so, contactor rating
4.
Cubicle heater, motor heater & plug
S)
A.C./D.C. SUPPLY
1.
Isolating switches MCCB for incoming
socket circuit provided with MCB
supply: -
1.1
A.C. - type & rating
1.2
D.C. - type & rating
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2X800 MW YERMARAS TPS PROJECT
S. No
2.
Description
Particulars
Isolating switch MCCB at each cubicle
2.1
A.C. supply - type & rating
2.2
D.C. supply - type & rating
T)
TROPICAL PROTECTION
1.
Any special treatment for tropical
2.
protection?
Screens are of corrosion resistant
materials?
U)
PAINTING
1.
Finish of switchgear
1.1
Inside
1.2
Outside
V)
NO. OF ACCESSORIES FURNISHED
1.
Earthing equipment
2.
Slow closing device for maintenance
3.
Test cabinet
W)
SURGE ARRESTORS (FOR MOTOR
1.
Nominal discharge current (8*20s)
FEEDERS)
2.
Max. system voltage (rms)
3.
Max. standard impulse spark over
4.
5.
voltage (peak)
Residual voltage at nominal discharge
current
Temporary over voltage capability (rms)
i) For 10,000 seconds
ii) For 5 seconds
6.
Installation
X)
CONTACTORS
1.
Nominal System voltage
2.
Highest System voltage
3.
Rated Frequency
4.
Rated Continuous Current at 50C
ambient
5.
Control Supply Voltage
6.
Utilization category
Y)
TRANSDUCERS
1.
CURRENT TRANSDUCERS
1.1
Input
1.2
Rated Frequency
1.3
Output
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S. No
Description
Particulars
1.4
Ammeter withstand capability
1.5
Accuracy
2.
VOLTAGE TRANSDUCERS
2.1
Input
2.2
Output
2.3
Accuracy
3.
VAR TRANSDUCERS
3.1
Input
3.2
Rated Frequency
3.3
Output
3.4
Accuracy
4.
4.1
WATT TRANSDUCERS
Input
Rated Frequency
Output
Accuracy
5.
FREQUENCY TRANSDUCERS
5.1
Input
5.2
Rated Frequency
5.3
Range
5.4
Output
5.5
Accuracy
Z)
TESTS
1.
Routine tests to be performed on
switchgear
1.1
1.2
1.3
1.4
2.
Type tests quoted
2.1
2.2
2.3
MCCB
S.No
Description
A)
General
1.
Make
2.
Type
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Particulars
REV. NO.: R3
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S.No
Description
3.
Service
4.
No. of poles
5.
Enclosure
6.
System
Particulars
AC
DC
AC
DC
i) Voltage
ii) Phase
iii) Frequency
iv) Combined voltage and frequency
variation
v) System grounding
7.
Rated current
i) Continuous (at 50C ambient &
within cubicle Amp.)
ii) Short time current for 1 sec. (kArms)
8.
No.of break per pole
9.
Type of arc control device
10.
Operating Mechanism
i) Type
ii) Antipumping feature provided
iii) Trip free or fixed trip
11.
Spring charging motor
i) Rating (kW)
ii) Voltage (V)
iii) Permissible voltage variation
Accessories such as control switch,
12.
indication lamps, relays furnished
Breaker/ Breaker cubicle provided with
following
i) Mechanical safety interlock
ii) Automatic manual trip
iii) Emergency manual trip
iv) Mechanical ON-OFF indicator
v) Manual operating handle
vi) Overload release
vii) Short circuit release
viii) Cell switch with 4 NO + 4NC
ix) Cell switch with 4 NO + 4NC circuit
x)
Spare
auxiliary
switch
with
6NO+6NC
xi) Micro switch for release
13.
Short circuit rating
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2X800 MW YERMARAS TPS PROJECT
S.No
Description
Particulars
i) Interrupting
ii) Short time for 1 second
14.
Hipot for 1 minute (min.)
15.
AC/DC Power Supply
i) Control voltage for circuit breaker
ii) Control voltage for MCC modules
iii) Service voltage
B)
CIRCUIT BREAKER
1.
Duty Cycle
2.
Breaking Current
i) A.C. Symmetrical
3.
Making Current
4.
Auxiliary Voltage
i) Closing
ii) Tripping
iii) Spring Charging
C)
CONTACTOR DUTY
i) AC
ii) DC
D)
SWITCH DUTY
AC
DC
i) Motor feeders
ii) Other feeders
Illumination
S.No
Description
Particulars
Technical Particular
1.
Lighting Fixture
2.
LUMINARIES
2.1
Flood Lighting
Housing
Front clamps
Mounting bracket
Reflector type
Gasket
Type of lamp
Lamp wattage
Ballast power consumption
Igniter details (if applicable)
2.2
Indoor Decorative
Housing
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2X800 MW YERMARAS TPS PROJECT
S.No
Description
Particulars
Gear Tray
End Plate
Mirror Assembly
Dimensions
Type of lamp
Wattage of lamp
Type of ballast
Ballast power consumption
Reflector type
Type of fitting
2.3
Indoor
Type of lamp
Wattage of lamp
Type of reflector
Type of Ballast
Ballast power consumption
Type of fitting
Any other information
2.4
Corrosion proof Industrial Lamp
Type of lamp
Wattage of lamp
Type of Ballast
Power consumption of Ballast
Canopy
Gear Tray
Cover
2.5
Indoor Decorative
Rail
Cover
Diffusers
2.6
MS Commercial Rail Lamp
Type of lamp
Wattage of lamp
Type of ballast
Power consumption of ballast
Channel
Cover
2.7
High Pressure Sodium Vapor (70 W) Lamp
Housing
Control gear compartment
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2X800 MW YERMARAS TPS PROJECT
S.No
Description
Particulars
Mounting bracket
Reflector
Gasket
2.8
High Pressure Sodium Vapor (400/70) Watt Lamp
3.
Lighting Panel
Indoor
Outdoor
4.
Receptacle & Power Outlet
RA
RB
RC
5.
Lighting Distribution Board
LDB
6.
Switch Board
i)
ii)
7.
Lighting Tower
i)
8.
Lighting Transformer
8.1
Type
8.2
KVA Rating
8.3
Voltage Rating
8.4
Cooling
8.5
Voltage Control
8.6
Class of Insulation
8.7
Temperature rise over an ambient of 50C
8.8
Neutral
8.9
Mounting
8.10
Impedance
9.
Indoor Lighting
9.1
Make of light fittings
9.2
Make of main DB
9.3
Make of sub-lighting DB
9.4
Type of fitting for periphery lighting and control
9.5
Cable laying method
9.6
Control operations
9.7
Escape lighting
9.8
Type of cable proposed
9.9
Make of cables
for same
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2X800 MW YERMARAS TPS PROJECT
S.No
Description
Particulars
9.10
Type of fittings at various locations
9.11
DC
9.12
Type of incomer for main and sub-DBs
9.13
Type of outgoing for main and sub-DBs
9.14
Second source of supply considered for all the
9.15
i) Degree of protection for main and sub-DB
emergency
lighting
control
necessary contactor
board
with
areas
enclosure
ii) Mounting details for DBs
9.16
Phase to phase and phase to earth clearances in
9.17
Bus bar arrangement in sub-DBs
9.18
Make of ballast
9.19
Make of switches
9.20
Erection
9.21
Make of ceiling fans
main and sub-DBs
accessories
clamps, saddles
such
as
junction
9.22
Make of exhaust fans
9.23
Make
9.24
Rating of exhaust fans
9.25
Deviations, if any, on technical design data
10.
Outdoor Lighting
10.1
Type of fittings envisaged
10.2
Make of fittings
10.3
Lux level to be obtained
10.4
Provision of escape lighting
10.5
Location of main and sub-DBs
of
numbers
flame-proof
fittings
and
boxes,
catalogue
10.6
Control of lighting
10.7
Automatic
10.8
Cable laying above ground
10.9
Deviations, if any, on technical specification
11
Timer details
12
Aviation lamp (Chimney lighting) details
Type of lamp
Wattage of lamp
Colour of lamp
Please mention NA wherever not applicable.
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PAGE 460 OF 506
2X800 MW YERMARAS TPS PROJECT
HT Cables
S.No
Description
A)
GENERAL
1.
Make
2.
Type
3.
Applicable Standard
4.
Manufacturers name and address
5.
Location of factory
6.
Voltage grade
7.
Suitable for system with service voltage
B)
CONDUCTOR
1.
Applicable Standard
2.
Maximum conductor temperature (C)
Particulars
i) Continuous
ii) Short time
3.
Material copper/aluminium/grade
4.
Size
5.
Nominal cross-sectional area
6.
Form of conductor circular/shaped
7.
No. of strands
8.
Nominal dia. of each strand
9.
Whether strands are tinned or not
10.
Temperature co-efficient of resistance at 20C
11.
Overall diameter of the cable
12.
Weight of cable per km.
C)
SHIELDING ON CONDUCTOR
1.
Material
2.
Type/Applicable Standard
3.
Minimum thickness
4.
Whether extruded
5.
Tolerance of thickness
D)
INSULATION
1.
Material
2.
Type/Applicable Standard
3.
Thickness
4.
Negative tolerance of thickness
5.
Diameter of core over insulation
6.
i) Minimum volume resistivity at 27C
ii) Minimum volume resistivity at 70C
7.
Color scheme of identification of cores
8.
Average dielectric strength
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2X800 MW YERMARAS TPS PROJECT
S.No
9.
Description
Particulars
Suitability with regard to moisture, ozone, acid, oil
and alkaline surroundings
E)
SHIELDING ON INSULATION
1.
Material
2.
Type/Applicable Standard
3.
Thickness
4.
Whether extruded semi-conducting screen is applied
5.
Whether extruded under triple extrusion process
6.
Whether copper type screening is applied
7.
Thickness of the copper tape
8.
For braided screen material and diameter of screen
wire and min. % coverage
F)
INNER SHEATH
1.
Material
2.
Type/Applicable Standard
3.
Thickness
4.
Whether extruded
5.
Approximate outside diameter over sheath
6.
Whether the inner sheath and the filling material are
7.
Whether flame retardant low smoke compound is
suitable for the operating temperature of the cable
added in inner sheath
G)
ARMOURING
1.
Material
2.
Type/Applicable Standard
3.
Calculated diameter over inner sheath (under armour)
4.
Size
5.
D.C. resistance at 20C
6.
Short circuit current carrying capacity
H)
OVERALL SHEATH
1.
Material
2.
Type/Applicable Standard
3.
Thickness
4.
Colour
5.
Tolerance of thickness
6.
Whether extruded
7.
Calculated diameter under sheath over armour
8.
Whether anti-termite treatment has been given in the
9.
Whether flame retardant low smoke compound added
outer sheath
in outer sheath
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PAGE 462 OF 506
2X800 MW YERMARAS TPS PROJECT
S.No
I)
Description
Particulars
Approximate overall diameter
J)
Standard drum length with tolerance
L)
Net weight of cable
M)
Approximate weight of empty drum
N)
Continuous current rating for Standard IS
Condition laid Direct
i) In ground
ii) In duct
iii) In air
O)
Is the cable guaranteed to safely withstand
continuous current for temperature of 90C and also
withstand temperature of 130C for duration of 500
hrs. per year
LT Power and Control Cables
S.No
Description
A)
GENERAL
1.
Make
2.
Type
3.
Applicable Standard
4.
Manufacturers name and address
5.
Location of factory
6.
Voltage grade
7.
Suitable for system with service voltage
B)
CONDUCTOR
1.
Applicable Standard
2.
Maximum conductor temperature (C)
Particulars
i) Continuous
ii) Short time
3.
Material copper/aluminium/grade
4.
Size
5.
Nominal cross-sectional area
6.
Form of conductor circular/shaped
7.
No. of strands
8.
Nominal dia. of each strand
9.
Whether strands are tinned or not
10.
Temperature co-efficient of resistance at 20C
11.
Overall diameter of the cable
12.
Weight of cable per km.
C)
INSULATION
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PAGE 463 OF 506
2X800 MW YERMARAS TPS PROJECT
S.No
1.
Description
Particulars
Material
2.
Type/Applicable Standard
3.
Thickness
4.
Negative tolerance of thickness
5.
Diameter of core over insulation
6.
i) Minimum volume resistivity at 27C
ii) Minimum volume resistivity at 70C
7.
Colour scheme of identification of cores
8.
Average dielectric strength
9.
Suitability with regard to moisture, ozone, acid, oil
D)
INNER SHEATH
1.
Material
2.
Type/Applicable Standard
3.
Thickness
4.
Whether extruded
5.
Approximate outside diameter over sheath
6.
Whether the inner sheath and the filling material are
and alkaline surroundings
suitable for the operating temperature of the cable
E)
ARMOURING
1.
Material
2.
Type/Applicable Standard
3.
Calculated diameter over inner sheath (under armour)
4.
Size
5.
D.C. resistance at 20C
6.
Short circuit current carrying capacity
F)
OVERALL SHEATH
1.
Material
2.
Type/Applicable Standard
3.
Thickness
4.
Colour
5.
Tolerance of thickness
6.
Whether extruded
7.
Calculated diameter under sheath over armour
8.
Whether anti-termite treatment has been given in the
9.
Whether flame retardant low smoke compound added
G)
Approximate overall diameter
H)
Standard drum length with tolerance
H)
Net weight of cable
outer sheath
in outer sheath
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2X800 MW YERMARAS TPS PROJECT
S.No
Description
I)
Approximate weight of empty drum
J)
Continuous current rating for Standard IS
Particulars
Condition laid Direct
i) In ground
ii) In duct
iii) In air
K)
Is the cable guaranteed to safely withstand
continuous current for temperature of 90C and also
withstand temperature of 130C for duration of 500
hrs. per year
Instrumentation Cables
S.No
Description
A)
GENERAL
1.
Make
2.
Type
3.
Applicable Standard
4.
Manufacturers name and address
5.
Location of factory
6.
Voltage grade
7.
Suitable for system with service voltage
B)
CONDUCTOR
1.
Applicable Standard
2.
Maximum conductor temperature (C)
Particulars
i) Continuous
ii) Short time
3.
Material copper/aluminium/grade
4.
Size
5.
Nominal cross-sectional area
6.
Form of conductor circular/shaped
7.
No. of strands
8.
Nominal dia. of each strand
9.
Whether strands are tinned or not
10.
Temperature co-efficient of resistance at 20C
11.
Overall diameter of the cable
12.
Weight of cable per km.
C)
INSULATION
1.
Material
2.
Type/Applicable Standard
3.
Thickness
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2X800 MW YERMARAS TPS PROJECT
S.No
Description
4.
Negative tolerance of thickness
5.
Diameter of core over insulation
6.
i) Minimum volume resistivity at 27C
Particulars
ii) Minimum volume resistivity at 70C
7.
Colour scheme of identification of cores
8.
Average dielectric strength
9.
Suitability with regard to moisture, ozone, acid, oil
D)
INNER SHEATH
1.
Material
2.
Type/Applicable Standard
3.
Thickness
4.
Whether extruded
5.
Approximate outside diameter over sheath
6.
Whether the inner sheath and the filling material are
E)
ARMOURING
1.
Material
2.
Type/Applicable Standard
and alkaline surroundings
suitable for the operating temperature of the cable
3.
Calculated diameter over inner sheath (under armour)
4.
Size
5.
D.C. resistance at 20C
6.
Short circuit current carrying capacity
F)
OVERALL SHEATH
1.
Material
2.
Type/Applicable Standard
3.
Thickness
4.
Colour
5.
Tolerance of thickness
6.
Whether extruded
7.
Calculated diameter under sheath over armour
8.
Whether anti-termite treatment has been given in the
9.
Whether flame retardant low smoke compound added
G)
Approximate overall diameter
H)
Standard drum length with tolerance
outer sheath
in outer sheath
H)
Net weight of cable
I)
Approximate weight of empty drum
J)
Continuous current rating for Standard IS
Condition laid Direct
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2X800 MW YERMARAS TPS PROJECT
S.No
Description
Particulars
i) In ground
ii) In duct
iii) In air
K)
Is the cable guaranteed to safely withstand
continuous current for temperature of 90C and also
withstand temperature of 130C for duration of 500
hrs. per year
HT, LT Power, Control & Instrumentation Cables Other Accessories
Details
Sl.
Description
No
A)
DRUM
1.
Drum length
2.
Tolerance on drum length
3.
Total weight of the drum
4.
Dimension of the drum
B)
ELECTRICAL PROPERTIES
1.
DC resistance at 20C
2.
AC resistance at 20C
3.
Reactance at 50 C/S per km.
4.
Capacitance at 50 C/S per km.
5.
Impedance at 50 C/S per km.
6.
Maximum permissible conductor temperature
Value
i) Under continuous full load
ii) Under transient conditions
7.
Volume resistivity at rated operating temperature
8.
Loss tangent at normal frequency
9.
Partial discharge value at 1.5 times rated voltage
10.
Charging current at normal operating voltage
11.
Short Circuit Current for 1 sec.
C)
OTHER DETAILS
1.
Recommended minimum installation radius
2.
Maximum safe pulling force
3.
Derating factor for following ambient temperature in
Air/Ground
i) At 30C
ii) At 35C
iii) At 45C
iv) At 50C
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2X800 MW YERMARAS TPS PROJECT
Sl.
Description
No
4.
Value
Group factor for following Nos. of cables laid
touching/2x diameter center to center apart
i) Single core cable
2 Nos.
3 Nos.
4 Nos.
ii) Multi core cable
3 Nos.
4 Nos.
5 Nos.
6 Nos.
D)
CABLE TRAYS
1.
Make
2.
Type/Material/Size
3.
Manufacturers name and address
4.
Location of factory
5.
Applicable Standard
6.
Thickness
i) Trays
ii) Supports
iii) Brackets
7.
Earthing System
8.
Weight per 100 m
i) Trays
ii) Supports
iii) Brackets
9.
10.
Distance between parallel layer of trays
Galvanization of
i) Trays
ii) Nuts & Bolts
11.
Painting of support system
12.
Supporting arrangement system
E)
CABLE CLAMPS
1.
Material
2.
Type
3.
Thickness
U)
CABLE TERMINATION KIT
1.
Make
2.
Type/Size
3.
Applicable Standard
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2X800 MW YERMARAS TPS PROJECT
Sl.
Description
No
4.
Suitable for voltage grade
5.
Complete with all accessories
6.
AC withstand voltage (Ph/Ground & time duration)
7.
Partial discharge at1.1 Ph/ground volt (Pc)
8.
Impulse withstand 1.2/50 s (kV)
9.
Short circuit current for 1 sec (KA)
Value
(kV)
10.
Dynamic short circuit withstand
11.
Type test report for above tests plus for humidity and
12.
Kit particulars
salt-fog tests furnished (Yes/No)
i) Material of tubling / moulded part
ii) Method of stress control
iii) Method of environmental seal
iv) List of items included in the kit furnished (Yes/No)
a) For terminations
b) For splices
F)
CONDUITS
1.
Make
2.
Type/Material
3.
Applicable Standard
4.
Gauge
i) Upto 25mm dia.
ii) Above 25mm dia.
5.
Catalogue furnished?
G)
JUNCTION BOX
1.
Make
2.
Type/Material
3.
Applicable Standard
4.
Degree of protection
5.
Catalogue furnished?
Outdoor/Indoor
6.
Thickness of sheet material
H)
TERMINAL BLOCK
1.
Make
2.
Type
3.
Applicable Standard
4.
Current rating
5.
Catalogue furnished?
6.
20% spare terminals provide?
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2X800 MW YERMARAS TPS PROJECT
Sl.
Description
No
Value
H)
FERRULES
1.
Make
2.
Type/Material
3.
Applicable Standard
4.
Color
5.
Interlocked type?
I)
TREFOIL CLAMPS
1.
Make
2.
Type/Material
3.
Dynamic force withstand capacity
4.
FIRE STOP MORTAR SEAL
5.
Make
6.
Type
J)
Fire resistance (hrs.)
1.
Approval of CPRI
2.
Material of fire stop
3.
Pressure withstand capacity of fire stop system
4.
Weight of fire stop assembly
5.
Shelf life of fire stop material
6.
Life of fire stop material
K)
Fire Retardant Coating Compound
1.
Make
2.
Type
3.
Fire resistance (hrs.)
Approval of CPRI
5.
Shelf life in years
Instrumentation cable
Conductor Size
S.No.
(a)
0.5 sq.mm
Parameter/Type
Type E,F
Type-G,I
Type A,B&C
Mutual capacitance at
0.8kHz(max.)
(b)
Conductor Resistance (max.)
(c)
Insulation Resistance
(min.)
(d)
Cross-talk figure at
0.8kHz(min.)
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(e)
Characteristic
(f)
Attenuation at 1kHz(max.)
Type
Conductorsize in sq.mm
impedance(max.) at 1 kHz
0.5
0.5
0.5
0.5
0.5
0.5
0.5
As per specific standard/
Remark
requirement for each
application
DC System
S. No
Description
A)
BATTERY
1.
General
1.1
Make
1.2
Type
1.3
Catalogue No.
1.4
Application
1.5
Reference Standard
2.
Rating
2.1
Rated Voltage (Volt)
2.2
10 hour rating at 27C to 1.85 volt per cell (AH)
2.3
1-hour discharge rate to
Particulars
i) 1.85 volt per cell (Amp.)
2.4
1-minute discharge rate to
3.
Performance
3.1
Is the duty cycle curve of battery furnished (Yes/No)
3.2
Cell voltage characteristics during duty cycle
3.3
Minimum cell voltage during duty cycle (Volt)
3.4
AH efficiency at 10-hour discharge rate (%)
3.5
Expected life of Battery (Hour)
4.
Battery Characteristics
i) 1.85 volt per cell (Amp.)
furnished? (Yes/No)
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S. No
4.1
Description
Particulars
Recommended charging rate for
i) Trickle charging
ii) Equalizing Charge
iii) Boost charging in 10 hrs
a) Start
b) Finish
4.2
Recommend specific gravity at 27oC
i) For first filling
ii) At full charge
iii) At end of 10-hour discharge
4.3
Short circuit current for a dead-short across battery
terminals, when
i) Trickle charge at 2.15 Volt/Cell (kA)
ii) Boost charge at 2.75 Volt/Cell (kA)
4.4
Battery internal resistance (ohm)
4.5
Cell voltage characteristics during charging
5.
Cells
5.1
Number of cells per battery
5.2
Type of the cell
5.3
Cell designation as per I.S.
5.4
Material of the container
5.5
Overall dimension of each cell (mm)
5.6
Weight of complete cell
furnished?
i) Without acid (kg)
ii) With acid (kg)
5.7
Internal resistance of cell (ohm)
6.
Inter cell Connector
6.1
Inter cell connector furnished?
6.2
Type of inter cell connector bolted/burned
6.3
Material of inter cell connector
7.
Plates
7.1
Number of positive plates per cell
7.2
Type of positive plate
7.3
Type of negative plate
8.
Separator
8.1
Type
8.2
Material
8.3
Thickness
9.
Electrolyte
9.1
Amount of electrolyte for first filling
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S. No
Description
Particulars
i) Per cell (litre)
ii) Per set (litre)
9.2
First filling with 10% extra furnished?
9.3
Electrolyte conform to
10.
Racks
10.1
Number of racks per battery
10.2
Number of cells per rack
10.3
Type of racks (Rows/Tiers)
10.4
Material of rack
10.5
Racks provided with
i) Numbering tags for cells
ii) Teak wood clamps for cables
10.6
Insulator 5% extra furnished for
i) Cell (Yes/No)
ii) Stand (Yes/No)
10.7
Inter-row, Inter-tier connectors and end take-off
furnished?
10.8
Connection hardware with 5% extra furnished
11.
Dimension & Weights
11.1
Dimension (LxBxH) (mm)
11.2
Approx. Weight (kg)
11.3
Battery layout drawing furnished?
12.
Ventilation requirements
12.1
12.2
12.3
13.
Accessories furnished with each battery
13.1
13.2
13.3
13.4
13.5
13.6
13.7
13.8
13.9
13.10
13.11
13.12
14.
Mounting
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S. No
15.
16.
Description
Particulars
Intermediate tapping
Ambient temperature
i) Maximum
ii) Minimum
B)
BATTERY CHARGER
1.
General
1.1
Make
1.2
Type
1.3
Catalogue No.
1.4
Reference Standard
1.5
Charger
2.
A.C. Input
2.1
Supply
2.2
Voltage % variation (Volt)
2.3
Phase (No.)
2.4
Frequency % variation (Hz)
2.5
Combined volt and frequency variation
2.6
Short-circuit level
2.7
System earthing
3.
D.C. Output
3.1
Voltage
3.2
Current (Amp.)
3.3
Trickle charging mode
3.4
Boost charging mode
4.
Type of Cooling
5.
Max. Temp within cubicle above 50oC ambient
i) Rectifier transformer (C)
ii) SCR (C)
6.
Performance
6.1
Regulation for 0-100% rated load with 10% Input
6.2
Ripple content in D.C. output
voltage and 5% input frequency variation (%)
i) With battery (%)
ii) Without battery (%)
6.3
Guaranteed efficiency at rated load (%)
6.4
Power Factor at rated load (%)
7.
Miscellaneous
7.1
Charger provided with following features
i) Automatic voltage regulation
ii) Current limiting circuitry
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S. No
Description
Particulars
iii) Smoothing filter circuit
iv) Soft-start feature
7.2
SCR elements provided with
i) Surge protection
ii) Fast acting HRC fuse
8.
A.C. Switch
8.1
Make
8.2
Type/ Catalogue No.
8.3
Reference Standard
8.4
Rated Current (Amp.)
9.
A.C. Fuse
9.1
Make
9.2
Type/ Catalogue No.
9.3
Reference Standard
9.4
Rated Current (Amp.)
i) Continuous (Amp.)
ii) Interrupting (kA)
10.
A.C. Contactor
10.1
Make
10.2
Type/ Catalogue No.
10.3
Reference Standard
10.4
Rated Current (Amp.)
10.5
Utilization category
10.6
Thermal overload with in-built single-phase
preventor provided?
11.
Rectifier Transformer
11.1
Make
11.2
Type/ Catalogue No.
11.3
Reference Standard
11.4
Ratings
i) KVA
ii) Voltage
iii) % Reactance
11.5
Class of insulation
11.6
Method of cooling
12.
Controlled Rectifier (SCR)
12.1
Make
12.2
Type/ Catalogue No.
12.3
Reference Standard
12.4
Rms Current rating (Amp.)
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S. No
12.5
Description
Particulars
Surge Current
i) One-cycle (Amp.)
ii) Repetitive cycle (Amp.)
12.6
Surge protection provided?
12.7
Peak inverse voltage
i) Continuous (Volt)
ii) Surge (Volt)
12.8
Filter Choke
i) Insulation class
13.
D.C. Contactor
13.1
Make
13.2
Type/ Catalogue No.
13.3
Reference Standard
13.4
Rated Current (Amp.)
13.5
Utilization category
14.
Blocking Diodes
14.1
Make
14.2
Type/ Catalogue No.
14.3
Reference Standard
14.4
Current Rating
i) One-minute (Amp.)
ii) One-hour (Amp.)
14.5
Peak inverse voltage (Volt)
15.
Indication Lights
15.1
Make
15.2
Type/ Catalogue No.
15.3
Reference Standard
15.4
Wattage (Watt)
15.5
Series resistor (Ohm)
16.
Meters
16.1
Make
16.2
Type/ Catalogue No.
16.3
Reference Standard
16.4
Size
16.5
Accuracy
17.
Alarm-Facia
17.1
Make
17.2
Type/ Catalogue No.
17.3
Reference Standard
17.4
No. of window per facia
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S. No
Description
18.
Change-over Switch
18.1
Make
18.2
Type/ Catalogue No.
18.3
Reference Standard
18.4
Rating (Amp.)
18.5
No. of poles
18.6
Key interlock furnished?
19.
D.C. Switch
19.1
Make
19.2
Type/ Catalogue No.
19.3
Reference Standard
19.4
Rating (Amp.)
19.5
No. of poles
19.6
Key interlock furnished?
20.
Charger Panel
20.1
Make
20.2
Type
20.3
Reference Standard
20.4
Enclosure
Particulars
i) Degree of protection
ii) Sheet steel thickness (mm)
20.5
Panel provided with
i) Internal lamp with door-switch
ii) Space heater with thermostat
iii) 5A 3-pin receptacle
21.
Internal Wiring
21.1
Insulation
21.2
Voltage grade
21.3
Minimum conductor size
22.
Power Terminals
22.1
Make
22.2
Size/ Catalogue No.
23.
Control Terminals
23.1
Make
23.2
Size/ Catalogue No.
23.3
20% spare terminal furnished?
24.
MCCB
24.1
Make
24.2
Type
24.3
No. of poles
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S. No
24.4
Description
Particulars
Rated Current
i) Continuous (at 50C ambient & within cubicle
Amp.)
ii) Short time current for 1 sec. (kA rms)
24.5
No. of breaker per pole
24.6
Type of arc control device
24.7
Operating Mechanism
i) Type
ii) Antipumping feature provided
iii) Trip free or fixed trip
24.8
Spring charging motor
i) Rating (KW)
ii) Voltage (Volt)
iii) Permissible voltage variation
24.9
Accessories such as control switch, indication
lamps, relays furnished
Breaker/Breaker cubicle provided with following
i) Mechanical safety interlock
ii) Automatic manual trip
iii) Emergency manual trip
iv) Mechanical ON-OFF indicator
v) Manual operating handle
vi) Overload release
vii) Short circuit release
viii) Cell switch with 4 NO + 4 NC circuit
ix) Spare auxiliary switch with 6 NO + 6 NC circuit
x) Micro switch for release
25.
Ground Terminal furnished?
26.
Overall dimension (LxBxH) (mm)
27.
Approx. Weight (kg)
27.
General Arrangement drawings furnished?
29.
Accessories as specified furnished with battery
charger?
30.
List of Tools & Tackles
C)
Grounding Cubicle (26 V DC)
1.
Make
2.
Type
3.
Reference Standard
4.
Voltage
5.
Construction
5.1
Metal clad air insulated floor mounting (Yes/No)
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S. No
Description
5.2
Suitable for mounting against building wall (Yes/No)
6.
Enclosure
6.1
Degree of protection
6.2
Minimum thickness of sheet metal
Particulars
i) Door
ii) Side Sheet
iii) Base Frame
7.
Panel size (H x D x W)
8.
Bus Bar
8.1
Make
8.2
Material & Standard
8.3
Cross section area in (mm2)
8.4
Continuous Current (at 50C & within cubicle)
D)
INTERCONNECTING COPPER BUS BAR
1.
Make
2.
Material & Standard
3.
Cross section area in (mm2)
4.
Continuous Current Rating (Amps.)
5.
Whether sleeving provided
6.
Bus bar support details
7.
Type of seal off bushing provided at the wall
E)
Terminal Connection
1.
A.C. Input
2.
D.C. Output
crossing
i) To Battery
ii) To Load
F)
Guaranteed technical parameters
LT Motor
S.No.
Description
1.
Manufacturer
2.
Type and frame size & design code no.
3.
Nos. required
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Particulars
PAGE 479 OF 506
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S.No.
Description
4.
Application
5.
Specification & Codes
6.
Capacity for
Particulars
i) for specified climatic conditions (500C)
ii)
At 400C ambient
7.
Location for installation
8.
Type of enclosure & ventilation
9.
Degree of protection
10.
Type of duty
11.
No. of phases, frequency & voltage
12.
Permissible variations in
(a) Voltage
(b) Frequency
13.
(c) Combined
At rated voltage & frequency
(a)
(b)
14.
(c)
Full load current
Full load speed
No load current
Minimum permissible voltage during starting
15.
Maximum
permissible
time
at
minimum
16.
Maximum permissible time at 75% of rated
17.
Whether motor stalls at 70% of rated voltage.
18.
Efficiency & power factor
permissible voltage during running at full load.
voltage during running at full load.
Load
Efficiency
(% of full load)
Power Factor
100
50
25
0
At Start
Duty Point
19.
Stator Winding
i)
Connection
ii) Type & nos. of terminals Brought out
iii) Resistance between terminals at 20oC
iv) Resistance per phase at 20oC
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S.No.
Description
Particulars
v) Inductance per phase
20.
vi) Capacitance per phase
Starting current as % of full load current
i)
With IS tolerance
ii)
Without IS tolerance
21.
Torque at full load in Kgm.
22.
Break away torque in % of full load torque
23.
Pull up torque in % of full load torque
24.
Pull out torque in % of full load torque
25.
Starting time in sec.
Without
mechanism
coupled
or
Mechanism
coupled through hydraulic coupling when it may
be presumed that load is
transferred
to motor shaft only after attaining almost full
speed.
26.
i)
with rated voltage
ii)
with 80% of rated voltage
iii)
with 110% of rated voltage
Starting time in sec.
With
mechanism
coupling.
27.
28.
coupled
through
i)
with rated voltage
ii)
with 80% of rated voltage
iii)
with 110% of rated voltage
Flexible
Safe stall time (hot motor)
i)
At rated voltage
ii)
At 80% of rated voltage
iii)
At 110% of rated voltage
Safe stall time (Cold motor)
i)
At rated voltage
ii)
At 80% of rated voltage
iii)
At 110% of rated voltage
29.
Limiting motor temperature to determine safe
30.
Permissible maximum accelerating time (hot
31.
stall time
motor)
i)
At rated voltage
ii)
At 80% of rated voltage
iii)
At 110% of rated voltage
Permissible maximum accelerating time (cold
motor)
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S.No.
Description
i)
32.
Particulars
At rated voltage
ii)
At 80% of rated voltage
iii)
At 110% of rated voltage
Insulation
i)
Class of insulation
ii)
Material & treatment of insulation
33.
Whether insulation is suitable for 415 V.
34.
Temperature rise under normal conditions over
500C ambient temperature.
i)
ii)
By resistance method
By Thermometer method
35.
Method of starting
36.
Permissible starting duty cycles
37.
Stator thermal time constant
38.
Maximum permissible voltage
During high speed bus transfer & special design
feature
39.
Time required for voltage to decay down to when
driving voltage is removed.
i)
50% of rated voltage
ii)
40% of rated voltage
iii)
25% of rated voltage
iv)
0% of rated voltage
Bearings
i)
Number
ii)
Type
iii)
Lubrication system
iv)
Quantity of lubricant reqd. for both the
v)
Life in hours at rated speed
vi)
Recommended lubricant
vii)
Bearing end play
viii)
Inlet oil pressure
ix)
Temp. rise of oil
x)
Max. permissible temp. of bearing
xi)
Max. permissible temp. of oil
xii)
Permissible running time without forced
bearings.
oil at full load & full speed.
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S.No.
Description
xiii)
Particulars
Whether bearings are provided with 4
wire, platinum RTD having 100-ohm
resistance at 0oC for remote temp.
indication.
xiv)
Whether bearings are provided with
Yes/ No
local temperature indicator having two
adjustable contacts rated for 2A at
240V AC or 0.2A at 220V DC.
40.
Terminal designation correspond to direction of
41.
Terminal
42.
43.
44.
rotation (Facing driving end).
boxes
with
terminal boxes provided.
accessories
i)
Main
ii)
Space heaters
iii)
Winding temp. detectors
iv)
Bearing temp. detectors
v)
Moisture detectors
vi)
Neutral terminals
separate
Main terminal box details
i)
Type & Nos.
ii)
Fault level permissible for 0.25 sec.
iii)
Location
iv)
Cable gland size & no.
v)
Direction of cable entry
Space Heater
i)
Number
ii)
Location
iii)
Capacity of each
iv)
Total power requirement
v)
Voltage
Details of 4 wire platinum RTD having 100 ohm
resistance at 0C for winding temp. detector.
i)
Nos. provided
ii)
Location
45.
Type of mounting
46.
Shaft orientation
47.
Shaft extension
48.
Grounding pads size nos. & location
49.
Method of coupling to driven mechanism
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S.No.
Description
50.
Motor
51.
Lifting device
52.
Weight
i)
Weight of stator (wound)
ii)
Weight of rotor (wound)
iii)
Weight of base plate
iv)
Weight of cooler
v)
Net weight of motor
53.
Shipping dimensions & weight
54.
Characteristic curves furnished.
i)
ii)
iii)
55.
Particulars
GD2
Speed vs. current at rated voltage.
Yes / No
Speed vs. torque at 110%, 100%, 90% and
Yes / No
Thermal withstand curve for hot & cold
Yes / No
80% of rated voltage.
conditions
iv)
Efficiency vs. load
Yes / No
v)
P.F. Vs. load
Yes / No
vi)
Current vs. time
Yes / No
vii)
Negative phase sequence curve
Yes / No
Drawings furnished
i)
General arrangement of motor
Yes / No
ii)
Main terminal box showing the method of
Yes / No
terminating the incoming cables
Yes / No
iii) Instruction manuals
56.
Rotor design as per specs
Yes / No
HT Motor
S. No.
Description
1.
Manufacturer
2.
Type and frame size & design code no.
3.
Nos. required
4.
Application
5.
Specification & Codes
6.
Capacity for
i)
Particulars
for specified climatic conditions (50C)
ii) At 40C ambient
7.
Location for installation
8.
Type of enclosure & ventilation
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S. No.
9.
Description
Particulars
Degree of protection
10.
Type of duty
11.
No. of phases, frequency & voltage
12.
Permissible variations in
(a) Voltage
(b) Frequency
13.
(c) Combined
At rated voltage & frequency
(a) Full load current
(b) Full load speed
14.
(c) No load current
Minimum permissible voltage during starting
15.
Maximum permissible time at minimum
16.
Maximum permissible time at 75% of rated
17.
Whether motor stalls at 70% of rated voltage.
18.
Efficiency & power factor
permissible voltage during running at full load.
voltage during running at full load.
Load
Efficiency
(% of full load)
Power Factor
100
50
25
0
At Start
Duty Point
19.
Stator Winding
i) Connection
ii) Type & nos. of terminals Brought out
iii) Resistance between terminals at 20oC
iv) Resistance per phase at 20oC
v) Inductance per phase
20.
vi) Capacitance per phase
Starting current as % of full load current
i)
With IS tolerance
ii)
Without IS tolerance
21.
Torque at full load in Kgm.
22.
Break away torque in % of full load torque
23.
Pull up torque in % offull load torque
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S. No.
Description
24.
Pull out torque in % offull load torque
25.
Starting time in sec.
Particulars
Without mechanism coupled or Mechanism
coupled through hydraulic coupling when it
may be presumed that load is transferred to
motor shaft only after attaining almost full
speed.
i)
with rated voltage
ii)
with 80% of rated voltage
iii) with 110% of rated voltage
26.
Starting time in sec.
With mechanism coupled through Flexible
coupling.
i)
with rated voltage
ii) with 80% of rated voltage
iii) with 110% of rated voltage
27.
Safe stall time (hot motor)
i)
At rated voltage
ii) At 80% of rated voltage
iii) At 110% of rated voltage
28.
Safe stall time (Cold motor)
i)
At rated voltage
ii)
At 80% of rated voltage
iii)
At 110% of rated voltage
29.
Limiting motor temperature to determine safe
30.
Permissible maximum accelerating time (hot
31.
stall time
motor)
i)
At rated voltage
ii)
At 80% of rated voltage
iii)
At 110% of rated voltage
Permissible maximum accelerating time (cold
motor)
i)
32.
33.
At rated voltage
ii)
At 80% of rated voltage
iii)
At 110% of rated voltage
Insulation
i)
Class of insulation
ii)
Material & treatment of insulation
Temperature rise under normal conditions over
500C ambient temperature.
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S. No.
Description
i)
ii)
Particulars
By resistance method
By Thermometer method
34.
Method of starting
35.
Permissible starting duty cycles
36.
Stator thermal time constant
37.
Maximum permissible voltage
During high speed bus transfer & special
design feature
38.
Time required for voltage to decay down to
when driving voltage is removed.
i)
50% of rated voltage
ii)
40% of rated voltage
iii)
25% of rated voltage
iv)
0% of rated voltage
Bearings
i)
ii)
iii)
Number
Type
Lubrication system
iv)
Quantity of lubricant reqd. for both the
v)
Life in hours at rated speed
vi)
bearings.
Recommended lubricant
vii) Bearing end play
viii) Inlet oil pressure
ix)
x)
xi)
Temp. rise of oil
Max. permissible temp. of bearing
Max. permissible temp. of oil
xii) Permissible running time without forced
oil at full load & full speed.
xiii) Whether bearings are provided with 4
wire, platinum RTD having 100-ohm
resistance at 0oC for remote temp.
indication.
xiv) Whether bearings are provided with local
Yes/ No
temperature indicator having two
adjustable contacts rated for 2A at 240V
AC or 0.2A at 220V DC.
xv) If forced lub. oil system provided
Doc. No.: E072-03-CHP-O-02
REV. NO.: R3
Yes/ No
PAGE 487 OF 506
2X800 MW YERMARAS TPS PROJECT
S. No.
Description
i)
Qty of lubricant required for initial
ii)
Recommended period after which
Particulars
filling.
lubricant should be replaced
iii) Bearing cooling water requirement
iv)
Max. permissible bearing cooling
v)
Max. permissible bearing cooling
water inlet temp. (permissible)
water outlet temp.
39.
Terminal designation correspond to direction
40.
Terminal boxes with accessories separate
of rotation (Facing driving end).
terminal boxes provided.
i)
ii)
iii)
iv)
v)
41.
vi)
ii)
iii)
iv)
v)
Winding temp. detectors
Bearing temp. detectors
Moisture detectors
Neutral terminals
Type & Nos.
Fault level permissible for 0.25 sec.
Location
Cable gland size & no.
Direction of cable entry
Space Heater
i)
ii)
iii)
iv)
43.
Space heaters
Main terminal box details
i)
42.
Main
v)
Number
Location
Capacity of each
Total power requirement
Voltage
Details of 4 wire platinum RTD having 100
ohm resistance at 0C for winding temp.
detector.
44.
i)
Nos. provided
ii)
Location
Whether CTs for differential protection are
provided
Doc. No.: E072-03-CHP-O-02
REV. NO.: R3
Yes / No
PAGE 488 OF 506
2X800 MW YERMARAS TPS PROJECT
S. No.
Description
i)
Particulars
If Yes, no. of CTs supplied alongwith
motors C.T. details
a) C.T. ratio
b) Knee point voltage
ii)
S.C. withstand capacity
45.
Type of mounting
46.
Shaft orientation
47.
Shaft extension
48.
Grounding pads size nos. & location
49.
Method of coupling to driven mechanism
50.
Motor GD2
51.
Lifting device
52.
Weight
i)
ii)
iii)
iv)
v)
Weight of stator (wound)
Weight of rotor (wound)
Weight of base plate
Weight of cooler
Net weight of motor
53.
Shipping dimensions & weight
54.
Thermometer provided
i)
ii)
55.
In cold air path
In hot air path
iii)
For measurement of oil temp.
i)
Speed vs. current at rated voltage.
Characteristic curves furnished.
ii)
Speed vs. torque at 110%, 100%, 90% and Yes / No
iii)
Thermal withstand curve for hot & cold
Yes / No
iv)
Efficiency vs. load
Yes / No
P.F. Vs. load
Yes / No
Current vs. time
Yes / No
v)
vi)
80% of rated voltage.
conditions
vii) Negative phase sequence curve
56.
Yes / No
viii) RTD characteristics
Yes / No
Yes / No
Drawings furnished
i)
General arrangement of motor
ii) Main terminal box showing the method
Doc. No.: E072-03-CHP-O-02
REV. NO.: R3
Yes / No
Yes / No
PAGE 489 OF 506
2X800 MW YERMARAS TPS PROJECT
S. No.
Description
Particulars
of terminating the incoming cables
57.
iii) Instruction manuals
Rotor design as per specs
Yes / No
Yes / No
Please mention NA wherever not applicable.
HT < bus duct
S. No
Description
1.
Make
2.
Type
3.
Reference Standard
4.
Rated Voltage (Volts.)
5.
Highest System voltage (kV)
6.
Phase (Nos.)
7.
Frequency (Hz)
8.
Impulse withstand voltage (kVp / kVrms)
9.
One minute power frequency withstand voltage (kVp
10.
11.
Particulars
/ kVrms)
Degree of protection
Type of Cooling
12.
Rated Continuous Current at 50C ambient
13.
Maximum temperature rise over 50C ambient
temperature (Amp.)
i) Bus Conductor (C)
a) Bolted Joints (Plain or Tinned)
b) Bolted Joints (Silver plated)
ii) Bus Enclosure and supporting structure (C)
14.
Rated short time current
i) Symmetrical kA for 3 sec. (kA) for HT bus duct & 1
sec for LT bus duct
ii) Momentary kA peak (kAp)
15.
Dynamic current withstand rating (kAp)
16.
Weight & Dimensions
i)
Weight per meter run of busduct
ii) Weight of heaviest package (kg)
iii) Dimension of largest package (l*b*h) (mm)
18.
Material
i) Conductor
ii) Enclosure
Doc. No.: E072-03-CHP-O-02
REV. NO.: R3
PAGE 490 OF 506
2X800 MW YERMARAS TPS PROJECT
S. No
19.
Description
Particulars
Conductivity
i) Conductor
ii) Enclosure
20.
Conductor Size
21.
Conductor Shape
22.
Maximum span between bus support insulators
23.
Enclosure Data (phase spacing /thickness /Other
24.
Interphase Barrier plate for Segregated phase
(mm)
details)
busduct
i) Material
ii) Thickness
25.
D.C. Resistance at (micro ohm/meter/phase)
i) 20C
26.
Skin-effect Ratio
27.
50 Cycle Reactance (ohm/meter/phase)
28.
Capacitance to Ground (Microfarad/meter/phase)
29.
Enclosure Finish outside (outdoor/indoor)/outer
30.
Minimum clearance of live parts in Air
surface / inner surface
i) Phase to phase
ii) Phase to earth
31.
Bus Insulator
i) Make
ii) Type
iii) Reference Standard
iv) Number per support
v) Voltage Class (kV)
vi) Rated Voltage (kV)
vii) Creepage distance (mm)
viii) Compression strength (kgf)
ix) Cantilever strength (kgf)
x) Tensile strength
xi) Basic impulse level kV
xii) Material of Insulator
32.
33.
Material of earthing conductor& size
Supporting Steel Structure
i) Hot-dip galvanized
ii) Thickness of galvanizing micron
34
Seal of bushing
Doc. No.: E072-03-CHP-O-02
REV. NO.: R3
PAGE 491 OF 506
2X800 MW YERMARAS TPS PROJECT
S. No
Description
a.
Make
b.
Type
c.
Reference standard
d.
One minute power frequency withstand voltage
e.
Impulse withstand (kVp)
f.
Creepage distance
Particulars
(Dry / Wet)
35
Space heater with thermostat details
36
Rubber bellow details
a) Make
b) Type
c) Reference standard
d) Size
37
Switchgear terminal adaptor box
a)
Material of enclosure
b)
Thickness of enclosure
c)
Material of inter phase barrier
d)
Thickness of inter phase barrier
Note: (i) Bidder to submit the data sheet for each type and rating of bus duct
separately.
(ii) Strike out whichever is not applicable for LT bus duct
Earthing
Sl.No
Description
Value
Material and size of earth strip for various places
Gap between earth mat conductors lengthwise, breadth wise
Size of main buried earth conductor
Galvanizing content on GI strips
Value of earthing resistance (proposed to be achieved)
Standard to be followed for galvanizing
a) Type of electrodes
b) Size of material
Construction of earthing pit as per IS
Riser Connections
Material
Size
Doc. No.: E072-03-CHP-O-02
REV. NO.: R3
PAGE 492 OF 506
2X800 MW YERMARAS TPS PROJECT
Lightning protection
Sl. No
Description
Down conductor material
Down conductor size
No. of down conductors
Air termination details
Value
Value of earthing resistance (proposed to be achieved)
Construction of earthing pit as per IS
Control and Instrumentation
PLC System:
Sl.No.
Features
Bidder Data
1.
Make
2.
Model No.
3.
Type of Transmitter
4.
Accuracy
5.
Output signal range
6.
Turn down ratio
7.
Stability
8.
Zero and span drift
9.
Load impedance
10.
Housing
11.
Over Pressure
12.
Connection (Electrical)
13.
Process connection
14.
Adjustment/calibration/maintenance
15.
Accessories
16.
Diagnostics
17.
Power supply
18.
Repeatability
19.
Sensitivity
20.
Hand held calibrator
Temperature Gauge
Sl.No
Features
1.
Make
2.
Model No.
Doc. No.: E072-03-CHP-O-02
Bidder Data
REV. NO.: R3
PAGE 493 OF 506
2X800 MW YERMARAS TPS PROJECT
Sl.No
Features
Bidder Data
3.
Sensing Element and material
4.
Body material
5.
Dial size
6.
End connection
7.
Accuracy
8.
Scale
9.
Range selection
10.
Over range test
11.
Housing
12.
Zero/span adjustment
13.
Identification
14.
Accessories
15.
Material of Bourdon/ movement
16.
Repeatability
17.
Response Time
18.
Over range Protection
19.
Applicable Standard
20.
Others
Pressure and D.P. Gauges
Sl. No
Features
Bidder Data
1.
Make
2.
Model No.
3.
Sensing Element and material
4.
Body material
5.
Dial size
6.
End connection
7.
Accuracy
8.
Scale
9..
Range selection
10.
Over range test
11.
Housing
12.
Zero/span adjustment
13.
Identification
14.
Accessories
15.
Material of Bourdon/ movement
16.
Enclosure
Doc. No.: E072-03-CHP-O-02
REV. NO.: R3
PAGE 494 OF 506
2X800 MW YERMARAS TPS PROJECT
Sl. No
Features
17.
Applicable standard
18.
Accessories
Bidder Data
Pressure and D.P. Gauges
Sl.No
Features
Bidder Data
1.
Make
2.
Model No.
3.
Sensing Element and material
4.
Body material
5.
Dial size
6.
End connection
7.
Accuracy
8.
Scale
9.
Range selection
10.
Over range test
11.
Housing
12.
Identification
13.
Accessories
14.
Visible Length
Temperature Switches
Sl No.
Features
Bidder Data
1.
Make
2.
Model No.
3.
Sensing Element
4.
Material
5.
End connection
6.
Over range proof pressure
7.
Repeat-ability
8.
No. of contacts
9.
Rating of contacts
10.
Elect. Connection
11.
Set point/ dead band adjustment
12.
Enclosure
13.
Accessories
14.
Mounting
15.
Over range Protection
Doc. No.: E072-03-CHP-O-02
REV. NO.: R3
PAGE 495 OF 506
2X800 MW YERMARAS TPS PROJECT
Pressure and D.P. Switches
Sl.No
Feature
Bidder Data
1.
Make
2.
Model No.
3.
Sensing Element
4.
Material
5.
End connection
6.
Over range proof pressure
7.
Repeat-ability
8.
No. of contacts
9.
Rating of contacts
10.
Elect. Connection
11.
Set point/ dead band adjustment
12.
Enclosure
13.
Accessories
14.
Mounting
15.
Switch Type
16.
Accuracy
Level Switches
Sl. No
Feature
Bidder Data
1.
Make
2.
Model No.
3.
Sensing Element
4.
Material
5.
End connection
6.
Over range proof pressure
7.
Repeat-ability
8.
No. of contacts
9.
Rating of contacts
10.
Elect. Connection
11.
Set point/ dead band adjustment
12.
Enclosure
13.
Accessories
14.
Switch type
Doc. No.: E072-03-CHP-O-02
REV. NO.: R3
PAGE 496 OF 506
2X800 MW YERMARAS TPS PROJECT
RF Type Level Switch
Sl. No
Feature
A.
Application
B.
Electronic Controller
Input Supply
Body material
Relay Output
Contact Rating
Class of Protection
Ambient Temperature
Local Indication
Green
Red
Yellow
Cable Connectio
Repeatability
Sensing Probe
Type of Probe
Material
Probe Head Housing
C.
Insulation
Bidder Data
(B/W
Active& :
Shield And Shield& Ground)
Probe Head Protection
Mounting
Cable Connection
Process Connection
Signal Cable
Radar Level Transmitter
Feature
Bidder Data
Type
Application
Environment Class
Orientation
Probe Type
Probe Material
Connection Size & Type
Doc. No.: E072-03-CHP-O-02
REV. NO.: R3
PAGE 497 OF 506
2X800 MW YERMARAS TPS PROJECT
Feature
Bidder Data
Connection material
Accuracy
Type(Transmitter)
Operating Principle
Output
Electrical Connection
Enclosure Class
Electrical Power
Housing material
Local Display
Units of Measurement
Ultrasonic Level Transmitter
Feature
Bidder Data
Principle of
Measuring Ranges
Signal Processing
Operating Freq
Display
Calibration & Configuration
Diagnosis
Status
Construction
Power supply
Signal Output
Hysteresis
Output contacts
Accuracy & Repeatability
Resolution
Operating temp
MOC Sensor
Humidity
Enclosure
Cable Connection
Mounting
Accessories
Doc. No.: E072-03-CHP-O-02
REV. NO.: R3
PAGE 498 OF 506
2X800 MW YERMARAS TPS PROJECT
ZERO SPEED SWITCH
Probe
Type
Size
Protection class
Enclosure type
Electronic unit
Supply voltage
Speed range
Speed setting accuracy
Repeatability
Differential
Output contact type
Contact rating
Ambient Temperature
Preferable features
Belt Sway Switch
Type
Protection class
Enclosure type
Output contacts
Contact Rating
Contact roller support
Pull Chord Switch
Type
Protection class
Enclosure type
Output contacts
Contact Rating
Doc. No.: E072-03-CHP-O-02
REV. NO.: R3
PAGE 499 OF 506
2X800 MW YERMARAS TPS PROJECT
Operating handle
PC
Sl. No
Feature
1.
Make
2.
Model No.
3.
CPU
4.
Main memory
5.
Drives
6.
Hard disk
7.
Monitor
8.
Graphic accelerator
9.
Communication port
Bidder Data
10. Expansion slots
11. Other Features
12. UPS
13. Accessories
14. Software
Doc. No.: E072-03-CHP-O-02
REV. NO.: R3
PAGE 500 OF 506
2X800 MW YERMARAS TPS PROJECT
12.0
Doc. No.: E072-03-CHP-O-02
LIST OF DRAWINGS ENCLOSED
REV. NO.: R3
PAGE 501 OF 506
2X800 MW YERMARAS TPS PROJECT
LIST OF DRAWINGS ENCLOSED
Sl. No.
Drawing No.
Description
1.
E072-03-CHP-M-03-01-R2
CHP Flow Scheme
2.
E072-03-CHP-M-03-02-R3
CHP layout
3.
E072-03-CHP-E-03-06-R3
CHP Single Line Diagram
4.
E072-03-CHP-I-03-08-R1
PLC Configuration
Note: All the above drawings are only for tender purpose.
Doc. No.: E072-03-CHP-O-02
REV. NO.: R3
PAGE 502 OF 506
2X800 MW YERMARAS TPS PROJECT
13.0
Doc. No.: E072-03-CHP-O-02
REV. NO.: R3
ANNEXURES
PAGE 503 OF 506
2X800 MW YERMARAS TPS PROJECT
ANNEXURE-1: MECHANICAL-COAL ANALYSIS REPORT
A)
Coal Analysis for Indian coal
I)
i)
Coal Parameters (Air Dried Basis)
Proximate Analysis
Moisture %
6-8
Volatile Matter %
22-30
Fixed Carbon %
37-45
Ash %
18-32
Gross GCV (kCal/kg)
ii)
4000 - 5100
Ultimate Analysis
Carbon %
72.3-82.5
Hydrogen %
2.8-5.1
Nitrogen %
1.4-2.0
Oxygen %
11.2-18.3
Sulphur %
0.03-1.3
Total Sulphur
0.73-1.68
HGI
II)
Value
4555
Ash Parameters
Initial Deformation C
1,060
Softening C
1,100
Hemispherical C
1,140
Fluid C
1,200
SiO2
28.29
Al2O3
18.71
Fe2O3
12.42
CaO
10.9
MgO
4.11
TiO2
0.65
Na2O
4.46
K2O
0.87
Mn3O4
0.17
P2O5
0.53
SO3
18.89
Total
100
Doc. No.: E072-03-CHP-O-02
REV. NO.: R3
PAGE 504 OF 506
2X800 MW YERMARAS TPS PROJECT
B)
Indonesian Coal Analysis is as given
Sl.
Particulars
No.
unit
data
< 15
1.0
Proximate Analysis
1.1
Moisture
1.2
Ash
< 10
1.3
Volatile matter
22-45
1.4
Sulphur
<O.6
1.5
Gross FCV
1.6
HGI
Doc. No.: E072-03-CHP-O-02
Kcal/kg
6000
45-55
REV. NO.: R3
PAGE 505 OF 506
2X800 MW YERMARAS TPS PROJECT
ANNEXURE-2: SUMMERY OF SCOPE
SL.
Description
NO.
Quantity
WAGON TIPPLER
5 NOS.
SIDE ARM CHARGER
5 NOS.
APRON FEEDR WITH DRIBBLE CONVEYOR
5 NOS.
BELT CONVEYORS AS PER LAYOUT
1 LOT
BELTING (AS PER LAYOUT)
1 LOT
PRIMARY CRUSHER
4 NOS.
SECONDARY CRUSHER
8 NOS.
VIBRATING SCREEN
8 NOS.
STACKER CUM RECLAIMER
3 NOS.
10
INLINE MAGNETIC SEPARATORS
As per Flow scheme
11
INLINE BELT CONVEYOR WEIGH SCALES
As per Flow scheme
12
METAL DETECTORS
As per Flow scheme
13
TRAVELLING TRIPPER
8 NOS.
14
FIXED TRIPPER
12 NOS.
15
FLAP GATES
As per Flow scheme
16
SUMP PUMP
As per Flow scheme
17
BELT VULCANISER
1 NO.
18
CHUTE & SUPPORTING STRUCTURES
1 LOT
19
COAL SAMPLING UNIT
As per Flow scheme
20
ELECTRIC HOISTS
1 LOT
21
DUST SUPRESSION SYSTEM
1 Lot
22
VENTILATION SYSTEMS
1 Lot
23
HOPPERS (FOR WAGON TIPPLER CIVIL)
As per Flow scheme
24
DUST EXTRACTION SYSTEM
1 Lot
25
GATES
As per Flow scheme
26
DOZER
5 NOS.
27
LOCOMOTIVES
4 NOS.
28
Elevator
2 No.
29
Material Handling Equipment
1 Lot
Doc. No.: E072-03-CHP-O-02
REV. NO.: R3
PAGE 506 OF 506
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