VOLUMEII

DOCUMENTS CONTAININIG TECHNICAL SPECIFICATION FOR ITEMS AND WORKS

Certified that this document contains 159 (One hundred fifty nine ) page excluding cover and index pages.

INDEX SL.NO
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DETAILS
SECTION - I: Specifications for Horizontal Francis Type Hydraulic Turbines, Inlet Valves, Governing Equipment and Auxiliaries. SECTION - II: Specifications for Pelton / Turgo Impulse Type Hydraulic Turbines, Inlet Valves, Governing Equipment and Auxiliaries. SECTION - III : Specifications for Cross Flow Turbine. SECTION - IV : Specifications for Electronic Governors, Oil Pumping Unit and Inlet Valves. SECTION - V : Specifications for Alternating Current Generators, Exciters, Voltage Regulators and Accessories. SECTION - VI : Specifications for Transformer SECTION - VII :Specifications for Servicing & Overhauling of Power Transformers SECTION - VIII : Specifications for Generator Control, Metering and Protection Panel. SECTION - IX : Specifications 33 kV Switchyard Equipment/Works SECTION - X : Specifications 11 kV Switchyard Equipment/Works SECTION - XI : Specifications for Power House Auxiliaries. SECTION - XII : Specifications for Erection, Testing & commissioning.

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SECTION I SPECIFICATIONS FOR HORIZONTAL FRANCIS TURBINE

SECTION- I SPECIFICATIONS FOR HORIZONTAL FRANCIS TYPE HYDRAULIC TURBINES, INLET VALVES, GOVERNING EQUIPMENT AND AUXILIARIES
1.1 SCOPE This section of the specifications covers the design, manufacture, tests at works, supply, delivery at site, erection, testing at site and commissioning of Horizontal Francis hydraulic turbines and associated auxiliary and ancillary equipment, main inlet valve, equipment for auxiliary systems such as compressed air, Cooling water, draft tube dewatering, station drainage, centralized grease lubrication system, oil, water and air piping with valves and fittings, instrumentation, Controls and safety devices(as required): speed increasing gear box (if required): spares for five year operation of the plant, special tools etc., as described and detailed in the specification and listed in the schedule of requirements. The scope of supply shall include all parts, accessories, spares etc., which are essential for construction, operation and maintenance of the complete prime mover even though these are not individually or specifically stated or enumerated. Corresponding components, of all the turbines and associated equipment and spares shall be of the same material, dimensions and finish and shall be inter-changeable. The turbine manufacturer shall co-ordinate with the generator supplier so that the generator to be coupled to the turbine is matched in respect of speed, runaway speed, moment of inertia, overload capacities, coupling and other relevant requirements. 1.2 TYPE AND RATING The turbine shall be of the Horizontal shaft Francis suitable for coupling directly/through speed increaser (gears) to horizontal shaft synchronous generator. The direction of rotation shall be clock-wise when viewed from drive end. The turbines shall be capable of giving outputs higher than rated outputs to match the overload capability of the generators. Each turbine shall be designed to give a rated output at rated head at generator terminals with guide vane opening of about 80-85 Percent. The turbine shall have adequate capacity commensurate with the 10 % continuous overload capacity of the generators. The turbine would have output higher than the rated output when operating at heads higher than the rated head. The supplier may offer his nearest standard design. The maximum output both at maximum and minimum heads shall be stated in the offer.

The specific speed of the turbine shall be as per the best modern practice and of proven design and operation. Manufacturer shall confirm the head and discharge data from the Executive Engineer concerned before actual manufacturing of the turbine starts. 1.3 OUTPUTS AND EFFICIENCY GUARANTEES AND PENALTIES 1.3.1OUTPUT AND EFFICIENCY GUARANTEES The rated output of the turbine at rated head shall be stated and guaranteed. The efficiency of the turbine at rated head for 100%, 80% and 60% rated output shall also be guaranteed. These figures shall be applicable for purpose of penalties, rejection limits and bid evaluation as defined in following clauses 1.3.2, 1.3.3 and 1.9. In addition, the output of the turbine at full gate opening at net head and rated head shall be stated in the tender. 1.3.2 PENALTIES Penalty for Shortfall in Weighted Average Efficiency and Output For any shortfall in the tested values of rated output and weighted average efficiency (as determined on the basis described in clause 1.3.4) from the guaranteed values penalty shall be applied at rate of 0.5 (Half) percent of ex-works price of turbine including governing system for every 0.1(one tenth) percent or part there of by which test figure is less than the corresponding guaranteed figure. The penalties for output and efficiency shall be computed separately and the total amount of penalty shall be the sum of these two. No tolerance shall be permissible over the test figures of rated output. In case of efficiency, tolerance will be allowed as per appropriate IEC test code. The ceiling on the total amount of penalty on account of shortfall in the weighted average efficiency and output shall be 10% of the total unit price of turbines and governing system. 1.3.3 REJECTION LIMIT

The purchaser has the right to reject the turbine if the test value of either weighted average efficiency or the rated output is less than the corresponding guaranteed value by 2(two) percent or more after allowing tolerance in computation of efficiency.

1.3.4 WEIGHTED AVERAGE EFFICIENCY The weighted average efficiency of the prototype turbine shall be determined from the field test or model test values of efficiency at rated head in accordance with the following formula for purpose of penalty and rejection limit and bid evaluation. Tav =k1 x T100 +k2 xT80+ k3 x T60 Where Tav Weighted average efficiency of the turbine, T100, T80 and T60 are efficiencies of turbine at 100%, 80% and 60% rated output at rated head respectively. The value of k1, k2 and k3 are to be decided as per flow duration curve and discharge dependability. 1.3.5 RECTIFICATION TO MEET GUARANTEES The contractor shall be given 4 months or mutually agreed time to improve/modify the design of turbine or to carry out rectifications, etc., as may be required so that the guarantees are met in case the tests prove unsuccessful in meeting the guarantees. If the second meeting is also unsuccessful, penalty or rejection of the equipment, as the case may be, shall be applied. However, no delay in the original delivery schedule shall be allowed if the model test results do not meet the guarantees and rectifications are made by the contractor thereafter within a period of 4 months or mutually agreed period as stated above. 1.4 CAVITATION GUARANTEES The tenderer shall guarantee the runner against excessive pitting caused by cavitation for 18 months from the date of commissioning or 8000 hours of operation, whichever is more. If the 18 months of guarantee period expires before completion of 8000 hours of operation, the guarantee shall apply to the actual hours of operation proportionately. Excessive pitting shall be defined as the removal of metal from the runner of a weight of W= 0.15 D2 per 1000 hours of operation, where, D = Discharge diameter of the runner and W = weight in Kg. In case of cavitation pitting exceeding the guarantee, the turbine supplier shall, at his cost, take corrective measures such as modification of design, finish, replacement, repair, etc., and the turbine after modification, etc. shall be subject to cavitation guarantee as for the original equipment. In determining whether or not excessive pitting has occurred metal removal by erosion, corrosion or by the presence of injurious elements in water, etc., shall be excluded.

1.5

CRITICAL AND PLANT SIGMA

Values of critical sigma as determined from cavitation model tests as per IEC 193A shall be given in the forms of curves for different heads of operation. Plant sigma curves as recommended by the manufacturer shall also be plotted on it clearly to show the safety margin available. 1.6 SPEED RISE AND RUNAWAY SPEED

The moment of inertia of the unit and the normal wicket gate closing time and runner blade angle shall be so adjusted that the maximum momentary speed rise of the unit shall not exceed 35% and the maximum pressure rise in the penstock shall not exceed 25% of the maximum rated head under any condition of operation. The turbine manufacturer shall coordinate with the generator manufacturer for limiting the speed and pressure rise values. The maximum runaway speed of the unit, both off cam and on- cam, under any combination of head and load conditions shall be stated in the tender. The turbine shall be capable of running safely at maximum runaway speed without any damage to its parts for a period of not less than 15 minutes for every such occurrence, with cooling water supply on. 1.7 NOISE LEVEL Maximum noise level resulting from any of the operating conditions shall not exceed 90 db (A) at any place 1.0 m away from operating equipment in the machine hall. 1.8 STRESS AND FACTOR OF SAFETY

All parts of turbine shall be designed and constructed to safely withstand the maximum stresses during the normal running and runaway and short circuit conditions, out of phase synchronizing and brake application. The maximum unit stresses of the rotating parts shall not exceed two-thirds of the yield point of the material. For other parts, the factor of safety based on yield point shall not be less than 3 at normal conditions. For over-load and short circuit conditions, a factor of safety of 1.5 on yielding point shall be permitted. 1.9 BID EVALUATION

In the comparison of the tenders; the equalization on account of differences in the efficiencies of various offers will be made on the basis of weighted average efficiency as calculated by the formula given below: Tav = K1 x T100 + K2 x T80 + K3 x T60 at rated head. Where Tav = weighted average efficiency and T100, T80, and T60 are efficiencies at 100%, 80% and 60% outputs, respectively, at rated head. The highest figures of weighted

6 average efficiency will be the basis for comparison of prices of turbines with lower efficiencies and will be loaded at the rate of 0.5% of their ex-works prices for each 0.1% difference in weighted average efficiency as compared with the highest weighted average efficiency. The weighted average efficiency of the turbine will be multiplied by the efficiency of the gear box (if provided) for obtaining overall weighted average efficiency which will be used for bid evaluation. The basis for selection of the offers shall be the overall economy to the purchaser considering power house civil works, monetized values of efficiencies, prices of matching generator, prices of powerhouse crane required, etc. The speed and setting of the turbine and its design shall be such as to result in the installation of the best generating unit at least cost. 1.10 MODEL TEST

The rates for model test as per relevant standards may be quoted separately. The purchaser shall have the option to get the model test performed by the contractor at an extra cost after the award of the contract. In that event, the manufacture of any part of prototype turbine shall be started only after the efficiency and other guarantees and requirements of the turbine are established and fulfilled on the basis of model tests. In case the contractor has already performed model tests on homologous models, the purchaser may, at his discretion, permit the contractor to proceed with the manufacturer after approval by the purchaser of the model test report. The performance of the model tests either afresh or that had been done earlier shall be as per IEC 193 and 193A in all respects. Hydraulic performance tests shall be made at various guide vane openings to determine machine characteristics including regimes of safe operations, zones of cavitation and vibration, etc. The phenomenon of cavitation and vibration, particularly at lesser guide vane openings shall be specially investigated. These tests shall include determination of capacity, cavitation limits, hydraulic thurst, runaway speed, wicket gate torque relationship, etc., and such other details as covered in IEC 193 and 193A. Prototype efficiencies shall be derived from model tests by Moodys step-up formula as contained in IEC 193 for Francis turbines. Model tests shall simulate all possible normal operating conditions of the prototype for entire range of foreby/reservoir and tailrace levels. The tenderer shall clearly mention the time within which the model tests including manufacture of a new model, if required, will be completed. The delivery schedule given by the tenderer shall be reckoned from the date of approval of model tests or model test report or from the time of permission to proceed with the prototype manufacture. If the model test is already available, this shall be submitted within 1(one) month after the award of the contract if required by the purchaser.

1.11

GENERAL ARRANGEMENT AND CONSTRUCTION

The turbine shall be of spiral casing type so constructed as to allow all the removable parts to be dismantled conveniently. The design shall also permit removal of rotating parts without disturbing the guide apparatus. The design shall also permit horizontal/vertical* movement of runner shaft by an amount sufficient for adjustment of bearings and for clearing the joint at the coupling between the turbine and the generator. All equipments in the turbine pit shall be neatly arranged and shall be readily and easily accessible for operation and maintenance. Necessary walkways, ladders, hand rails, chequered plates, platforms, etc., required in the turbine pit shall be provided by the contractor. 1.11.1 Runner The runner shall be of 13/4 chromium-nickel stainless steel. The composition of the material and the source of runner casting shall be stated in the tender. The runner shall be cast integrally of stainless steel. The runner will be a one-piece construction. The runner will have adequate number of blades which shall be polished and ground smooth and shall be free from roughness, cracks, high spots, etc. The finished machine and ground runner shall be dynamically balanced in the works before dispatch. For runner of diameter more than 1000 mm., renewable wearing rings shall be provided. 1.11.2 Shaft And Coupling The turbine shaft shall be forged carbon steel or alloy steel conforming to IS or other equivalent international standards. Wherever the flanges are integral with the shaft, the same should be conform to American standard ANSI-49.1, 1967. For long larger size shafts, tubular construction of proven design will also be considered. The turbine shaft shall be connected to the runner on one side and to the gear box/flywheel generator shaft on the other side. It shall be of ample size to transmit torque at rated speed without excessive vibration or any distortion. A renewable and removable sleeve of stainless steel shall be provided wherever the shaft passes through a shaft seal or a gland. The turbine manufacturer shall co-ordinate and co-operate with the generator manufacturer for proper design and construction. The final alignment of the shaft at site shall be the responsibility of the generator manufacturer.

8 1.11.3 Bearings The turbine bearings can be: (i) The pad type or sleeve type or Babbitt lined, oil/grease lubricated either selflubrication or forced lubrication type. (ii) Anti-friction ball, roller bearings, oil or grease lubricated. These bearings shall be guaranteed for a minimum continuous operation of 100,000 (one hundred thousand) hours and the design and performance shall be well proven and established. The turbine shall be provided with adequate number of bearings. The bearings shall be designed to withstand operation at maximum runaway conditions with cooling water supply on (if cooling water is provided) for a period of not less than 15 minutes and also for operation at normal speed without cooling water supply for 15 minutes. The bearings shall be provided with a dial type or resistance type thermometer and a pressure gauge with provision for alarm annunciation/shut down on excessive bearing temperatures. The number and type of bearings shall be stated in the tender. 1.11.4 Shaft Gland The shaft gland shall be of the stuffing box/carbon ring type with self-lubricated packing and lantern ring. Any other suitable type of shaft gland will also be considered. The gland shall effectively prevent leakage of water along the shaft under all operating conditions and at standstill and prevent entry of air. In case the location of the gland is below maximum tail water level, an inflatable rubber seal shall be provided for attending the main gland without dewatering the draft tube. A stainless steel sleeve shall be provided on the shaft where it passes through the gland.8 Arrangement for providing clean water supply to the gland, if required, shall be made by the contractor. 1.11.5 Spiral Casing And Speed Ring The spiral casing shall be fabricated from welded steel plate/mild steel plates and shall have suitable sections for ease of shipment and to be within transport limitation. The spiral case shall be designed to withstand maximum water pressure including water hammer and shall be complete with anchors, supports, sole plates, turn buckles, hold-down rods, all types of clamps, etc. The speed ring shall be low alloy cast steel or of welded plate steel and shall be in suitable number of sections. The assembled stay ring shall be suitable for welding on to the casing.

1.11.6 Draft Tube Each turbine shall be provided with a draft tube liner/suction bend of welded construction of structural steel. The draft tube cone shall have machined flange for bolting with the runner chamber. Drain box and drain pipes for dewatering the draft tube (if applicable) shall be included in the scope of supply. The design of the draft tube shall be such as to ensure the best overall efficiency for the turbine and stable and pulsation-free operations of the machines.

1.11.7 Guide Vanes The guide vanes shall be made from stainless steel. Sleeves of stainless steel at the bearing and sealing surfaces shall be provided, if required. The guide vane bushes shall be of the selflubricating type with protective seals or shall be suitable for grease lubrication. In case of grease lubrication, arrangement for manual and automatic grease lubrication to all bushes shall be made. 1.11.8 Operating Mechanism The operating mechanism shall have ample strength to withstand the maximum load that can be imposed on it by the most severe operating condition. All working points with relative motion shall be bronze bushed, grease lubricated/ self lubricated. Means shall be provided for adjusting the position of the individual guide vanes to ensure close contact with adjacent guide vane in the closed position. Each guide vane shall be individually connected to the regulating ring through suitable levers and links. Shear/ breaking link or some other suitable arrangements shall be provided on each guide vane to protect guide vane and to provide alarm on foreign body getting wedged between guide vanes. The regulating ring shall be fabricated from welded steel plates. It shall be supported on the outer casing of top/side cover on bronze strips with provision for grease/ self-lubrication. Guide Vane Servomotor The guide vane shall be operated by two double acting oil operated servomotors of adequate capacity. The servomotors shall be capable of moving guide vanes smoothly during full opening and closing in required time. Standard available hydraulic cylinders of approved make, proven design and of suitable material can also be used as a servomotor.

10 1.11.10 Top Cover/ Side Cover

The top/side cover shall be of cast steel or welded plate construction. Suitable stainless steel labyrinth rings or similar sealing arrangements shall be provided in the covers. 1.11.11 Turbine Platform, Walkways, Handrails Etc Necessary platforms, walkways, handrails, chequered plates, ladders, etc., complete with supporting steel structure, shall be supplied. 1.12 INLET VALVES

The main inlet valves of the turbines shall be butterfly valve type suitable for Gross Head and discharge required for over load capacity of the turbine / generator and connecting to the proposed penstock. The valve shall be suitable for all operating conditions of transient and maximum water hammer. The valves shall be operated by oil, pressure and closed by oil pressure/counterweight, so that it is capable of being closed under all emergencies. All associated equipments such as servomotors, oil pressure units, counterweights, etc., shall be included in the offer. The valve shall close automatically under normal and emergency shut down conditions. The valve will be complete with inlet pipe, outlet pipe, with expansion joint, by-pass arrangement if required for equalization of pressure on either side of the valve, etc. 1.13 GOVERNING EQUIPMENT

Each turbine shall be equipped with suitable electronic governor conforming to IEC No. 308/ Hydro Mechanical Governor complete with all accessories . The governor shall be of proven design capable of maintaining control of speed under all conditions of heads and loads. Such governing system shall be complete with actuator unit comprising speed responsive element, restoring mechanism having adjustable temporary and permanent droop setting, load limiting device, speed level control, etc. The speed responsive element of the governor can be operated by a toothed wheel mounted on the generating unit shaft with speed pick-ups or its equivalent is normally used as an input to speed sensing device. Standard protections like overspeed device, brake control, emergency shut down and alarms, etc., shall be provided in the governing systems.

11 1.14 PRESSURE OIL SYSTEM

Oil pressure Units system shall comprise a sump tank and a pressure tank separate for each generating unit. Two numbers of electrically operated governor oil pumps will be provided, one for normal running and the other acting as standby for each unit. Provision for emergency shut down of the unit without any oil pump running shall be made. Gauges, pressure switches etc., will be provided as may be necessary. 1.15 COMPRESSED AIR EQUIPMENT

A centralized high pressure compressed air system common for all the units, if applicable, shall be provided for charging the governor oil pressure vessels. The system shall comprise two numbers of high pressure compressors of suitable capacity, one of them being a standby, a common air receiver and necessary pipes, fittings, valves, pressure switches, etc. The capacity of the system shall be sufficient to cater to all the generating units. The compressed air system shall be of the automatic start-stop design operating under pressure switches control sensing the pressure in the receiver. The high pressure system shall also be used to supply low pressure air requirements for generator brakes, inflatable seals and the centralized grease system, if required. Suitable outlet connections shall be provided for the above purpose and pressure reducers wherever necessary shall be supplied by the turbine contractor to meet the turbine requirements. For generator brakes, pressure reducer, and air-lines will be arranged by the turbine contractor. The compressors and receivers shall have necessary fittings, mountings, safety devices, etc. The tenderer may also quote as an alternative for providing necessary equipment and devices including nitrogen filled cylinders requires for pressuring the oil pressure vessels with nitrogen gas. 1.16 DEWATERING AND DRAINAGE SYSTEM Complete equipment for the draft tube dewatering system common for all the units and the station drainage system shall be supplied by the contractor. The equipment for each of the dewatering and the drainage system shall include two motor driven dewatering pumps, necessary piping fittings/gate valve/non-return valves/float switches, controls, accessories, etc. 1.17 COOLING WATER SYSTEM The cooling water for generator air coolers (if applicable) generator and turbine bearing coolers, turbine shaft seal if applicable and for other equipment in the powerhouse needing cooling water shall be provided by tapping the penstock. If a higher pressure is needed at low

12 head conditions, booster pumps to obtain the required pressure shall be provided for each tapping. In case the pressure at the tapping is high, suitable pressure reducer shall be provided. The system shall be complete with required number of duplex strainers, fine mesh filters, flow meters, flow indicators, flow relays, pressure gauges, etc. 1.18 GEAR BOX (OPTIONAL)

A gearbox of suitable gear ratio to match the turbine and generators shall be supplied. The speed increasing gear box shall be connected to the turbine and to the generator flywheel. The gear box shall be designed to be capable of withstanding runaway operation for 15 minutes and shock loads due to load variation and due to pressure pulsations in the turbine. The gear efficiency shall be as high as possible and shall be considered in evaluating the turbine efficiency for purpose of bid evaluation. 1.19 TURBINE INSTRUMENTATION, CONTROL AND SAFETY DEVICES

Each turbine shall be provided with a complete set of instruments, gauges, controls and safety devices on unit control board, if provided, for monitoring the conditions of the unit during normal running and emergencies. These shall permit the unit to be started and brought upto speed at the governor location and control during normal running. The instruments and gauges for the turbines include, inter alia, pressure gauges, level indicators, temperature and flow indicators, position indicator, indicating lamps for status indication etc. These shall be placed near the locations of apparatus or in the UCB or both. The safety devices shall comprise equipment and devices for sensing abnormal operating conditions, for giving visual and audible annunciation and shut down the unit, if required. A list of these instruments, controls and safety devices are given in Tables A, B, & C. The items, quantities and location are to suit the requirements for safe and satisfactory operation of the generating units and the auxiliary systems. All the instruments, indicator, gauges, controls, safety devices, etc., shall be complete with necessary detecting element, auxiliary relays, etc. 1.20 SPECIAL TOOLS, SLINGS, CONSUMABLES ETC.

All special tools, slings, lifting devices, jacks, turn buckles, foundation plates/ bolts, etc., required for erection of the equipments shall be listed and supplied. First filling of oil and grease (if applicable) with 10% extra quantity is included in the overall scope shall be and supplied along with equipment. Welding electrodes as required for site welding and paint for finishing coat shall be supplied by the contractor.

13 1.21 SPARES

The spare parts for the turbine and associated equipment considered necessary for 5 years of operation of the generating units shall be supplied by the contractor along with the turbines. The unit prices of the spares shall be indicated as per enclosed Table D and additional spares if considered necessary by the Engineer i/c shall be provided by the contractor within the overall contract price. Over and above those listed in Table D and list provided by contractor. 1.22 SHOP ASSEMBLY AND TESTS

The following assemblies and tests shall be carried out on the turbines and associated equipment at the manufacturers works before dispatch in the presence of the purchasers representatives if desired by the purchaser and test certificates shall be submitted whether or not the tests were witnessed by the purchaser. (i) (ii) (iii) One turbine, manufactured first, shall be assembled in the shop to the extent possible. Static and dynamic balancing of runners. Hydrostatic testing at 1.5 times the maximum working pressure including water hammer for not less than 15 minutes for the main inlet valve, spiral case, servomotors, etc. Non-destructive testing of welds. Performance tests for individual auxiliary equipment. Complete assembly and operational tests of governors. Assembly of spiral case and draft tube liner. All motors/pumps/compressors, etc., shall be tested as per relevant Indian or other standards. FIELD ACCEPTANCE TESTS

(iv) (v) (vi) (vii) (viii)

1.23

The turbines shall be tested at site for establishing fulfillment of guarantees in respect of turbine output and efficiencies including weighted average efficiency. The tests shall be carried out as per IEC 41 for Field Acceptance Tests of hydraulic turbines. The arrangements for these tests will be made, including the testing devices, by the contractor.

14 1.24 COMMISSIONING TESTS

The contractor shall carry out the commissioning tests in accordance with IEC 545. The turbine, after continuous operation during the trial operation of one month, shall be free from problems of leakages, overheating, failure, damage etc. The machine will be handed over to purchaser thereafter. Subject to fulfillment of all other conditions laid down in the contract elsewhere. 1.25 ERECTION

The contractor shall depute experts in erection, testing and commissioning of turbines, governors and associated equipments for erection, testing and commissioning of these.

1.26

TENDER DRAWINGS

The following drawings shall be furnished by the tenderer for vetting and approval : (a) Drawings of the main cross section of the turbine showing the various components, parts/assemblies of the turbine to the extent possible. (b) Layout drawings of the power house showing the overall dimensions and layout of turbines, etc., clearly indicating unit spacing dimensions of spiral casing, draft tube and all important elevations. (c) Schematic drawings of piping system, control system and instrumentation. (d) Physical and schematic drawings and descriptive literature on the governor and governor mechanism. (e) Charts/curve showing performances and cavitation characteristic of the turbine (f) Curve showing areas and velocities at different sections of draft tube. (g) A list of tests to be performed at site on sub-assemblies and equipments. (h) A complete list of equipments auxiliaries, etc. covered in the quotations. (i) Model Test Report (j) Quality Assurance Plan 1.27 GUARANTEED TECHNICAL PARTICULARS

The tenderer shall furnish all the data, information and other particulars called for in the schedule at the end of section under guaranteed technical particulars along with the offer.

15 1.28 SCHEDULE OF REQUIREMENTS

(i) Horizontal Francis turbines to provide power at generator terminals with essential auxiliaries like lubrication equipment oil, water and air piping, instruments, controls, safety devices as per detailed specifications. (ii) Governing equipment including governor actuator, oil pressure pumping units, etc. (iii) Inlet valves with complete operating mechanism. (iv) Turbine control instruments, indicating and metering systems and switches etc for (control panels shall be provided by generator supplier) (v) One set of equipment for common auxiliary system like compressed air draft tube dewatering and station drainage, cooling water, etc. (vi) One set of special tools, slings, consumables. (vii) One set of spares for 5 years of operation.

16 TABLE-A SCHEDULE OF INDICATING/RECORDING INSTRUMENTS

Sl. No. 1. 2. 3. 4. 5 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. Description Device Type Total Quantity per unit Location

Pressure of shaft seal cooling water Gate limit and gate position indicators Unit speed indication (speed indicator) Speed level setting indicator Speed droop setting indicator Unit output meter Pressure of governor oil pressure system on panel, pressure accumulator & Governor separately Level of oil in oil pressure vessel Level of oil in sump tank Standby oil pump in operation indication Penstocks Pressure Pressure of turbine casing Pressure of draft tube Turbine bearing temperatures Indication of runner blade position cooling water pressure Oil level in Turbine bearings Oil level in oil leakage unit Level of leakage water in turbine core Turbine discharge Servomotor locked/unlocked G.V. Shear pins fail

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TABLE-B

CONTROLS
Sl. No. 1. 2. 3. Description Total Quantity per unit Location

Gate Limit Control Auto-manual selection switch Speed level controller Speed droop controller Manual turbine gate controller Control for oil pump motor Control for compressor Turbine shut down control etc.

4
5. 6. 7. 8.

TABLE-C SAFETY DEVICES (FOR ALARM/SHUT DOWN) Sl.No. 1. 1. 2. 3. 4. 5. Governor oil pressure low Unit over speed shut down Manual emergency shut down Turbine bearing temperature high Trubine bearing oil low/high Type 2 Device Qty. per unit 3 4 5 Annunciation at

18 TABLE -D LIST OF SPARES

Sl. No. Item of Spare Qty Unit price Remarks

1 2 I. TURBINE 1. Wearing rings (stationary) if any 2. Wearing rings (moving) if any 3. Shaft seal packings 4. Guide vane stem packings 5. Shear pins/friction clutch components 6. Guide vanes 7. Shaft sleeves 8. Piston rings for servomotor cylinder 9. Packings and sealings, all types and sizes 10. Guide vane bearing bushes 11. Bushes/bearings for regulating mechanism

3 1 set 1 set 2 set 1 set set 4 Nos. 1 set 2 sets 2 sets 1 set 1 set

II. GREASE LUBRICATING SYSTEM (if required) 1. Grease feeders 1 set 2. Timer equipment 2 sets III. GOVERNING EQUIPMENT (a) In case of electronic governor 1. PCBs 2. Electronic Cards (b) Oil Pressure Vessel Sump Tank and Pumps 1. Oil pump for pressure oil supply 2. Seals/packings (all types) 3. Twin filter for oil 4. Solenoids/coils 5. Level relays 6. Pressure switches 7. Pump unloader 8. Safety relief valve IV. INSTRUMENTS AND SAFETY DEVICES 1. Resistance type temperature detectors 2. Level switches 3. Dial type thermometers 4. Coils/contacts/springs for auxiliary relays solenoids and switches, etc.

1 Set 2 Sets each One 1 Set One 1 Set 1 Set 1 Set 1 Set 1 Set 2 Nos. 1 Set 1 Set 1 Set

Note :-

Final list shall be finalised in consultation with the Engineer-in-Charge.

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SECTION II SPECIFICATIONS FOR PELTON / TURGO IMPULSE TURBINE

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SECTION- II SPECIFICATIONS FOR PELTON / TURGO IMPULSE TYPE HYDRAULIC TURBINES, INLET VALVES, GOVERNING EQUIPMENT AND AUXILIARIES
2.1 SCOPE This section of the specifications covers the design, manufacture, tests at works, supply, delivery at site, erection, testing at site and commissioning of. horizontal Pelton / Turgo Impulse type hydraulic turbines and associated auxiliary and ancillary equipment, main inlet valve, equipment for auxiliary systems such as compressed air, Cooling water, draft tube dewatering, station drainage, centralized grease lubrication system, oil, water and air piping with valves and fittings, instrumentation, Controls and safety devices(as required): speed increasing gear box (if required): spares for five year operation of the plant, special tools etc., as described and detailed in the specification and listed in the schedule of requirements. The scope of supply shall include all parts, accessories, spares etc., which are essential for construction, operation and maintenance of the complete prime mover even though these are not individually or specifically stated or enumerated. Corresponding components, of all the turbines and associated equipment and spares shall be of the same material, dimensions and finish and shall be inter-changeable. The turbine manufacturer shall co-ordinate with the generator supplier so that the generator to be coupled to the turbine is matched in respect of speed, runaway speed, moment of inertia, overload capacities, coupling and other relevant requirements. 2.2 TYPE AND RATING The turbine shall be of the vertical/Horizontal shaft Pelton type suitable for coupling directly/through speed increaser (gears) to vertical/horizontal shaft synchronous/induction generators. The direction of rotation shall be clock-wise when viewed from top/drive end. The turbines shall be capable of giving outputs higher than rated outputs to match the overload capability of the generators. The tentative layouts of the powerhouse will be given by tenderer. Each turbine shall be designed to give a rated output at rated head with nozzle opening of about 80-85 Percent. The turbine shall have adequate capacity commensurate with the 10 % continuous overload capacity of the generators. The turbine would have output higher than the rated output when operating at heads higher than the rated head. The supplier may offer his nearest standard design. The maximum output both at maximum and minimum heads shall be stated in the offer.

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The specific speed of the turbine shall be as per the best modern practice and of proven design and operation. 2.3 OUTPUTS AND EFFICIENCY GUARANTEES AND PENALTIES 2.3.1OUTPUT AND EFFICIENCY GUARANTEES The rated output of the turbine at rated head shall be stated and guaranteed. The efficiency of the turbine at rated head for 100%, 80% and 60% rated output shall also be guaranteed. These figures shall be applicable for purpose of penalties, rejection limits and bid evaluation as defined in following clauses 2.2.2, 2.2.3 and 2.9. In addition, the output of the turbine at full nozzle opening at net head and rated head shall be stated in the tender. 2.3.2 PENALTIES Penalty for Shortfall in Weighted Average Efficiency and Output For any shortfall in the tested values of rated output and weighted average efficiency (as determined on the basis described in clause 2.2.4) from the guaranteed values penalty shall be applied at rate of 0.5 (Half) percent of ex-works price of turbine including governing system for every 0.1(one tenth) percent or part there of by which test figure is less than the corresponding guaranteed figure. The penalties for output and efficiency shall be computed separately and the total amount of penalty shall be the sum of these two. No tolerance shall be permissible over the test figures of rated output. In case of efficiency, tolerance will be allowed as per appropriate IEC test code. The ceiling on the total amount of penalty on account of shortfall in the weighted average efficiency and output shall be 10% of the total unit price of turbines and governing system. 2.3.3 REJECTION LIMIT

The purchaser has the right to reject the turbine if the test value of either weighted average efficiency or the rated output is less than the corresponding guaranteed value by 2(two) percent or more after allowing tolerance in computation of efficiency.

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2.3.4 WEIGHTED AVERAGE EFFICIENCY The weighted average efficiency of the prototype turbine shall be determined from the field test or model test values of efficiency at rated head in accordance with the following formula for purpose of penalty and rejection limit and bid evaluation. Tav =k1 x T100 +k2 xT80+ k3 x T60 Where Tav Weighted average efficiency of the turbine, T100, T80 and T60 are efficiencies of turbine at 100%, 80% and 60% rated output at rated head respectively. The value of k1, k2 and k3 are to be decided as per flow duration curve and discharge dependability. The weighted average efficiency of turbine will be multiplied by the efficiency of gear box (if provided) for obtaining overall weighted average efficiency of turbine. 2.3.5 RECTIFICATION TO MEET GUARANTEES The contractor shall be given 4 months or mutually agreed time to improve/modify the design of turbine or to carry out rectifications, etc., as may be required so that the guarantees are met in case the tests prove unsuccessful in meeting the guarantees. If the second meeting is also unsuccessful, penalty or rejection of the equipment, as the case may be, shall be applied. However, no delay in the original delivery schedule shall be allowed if the model test results do not meet the guarantees and rectifications are made by the contractor thereafter within a period of 4 months or mutually agreed period as stated above. 2.4 CAVITATION GUARANTEES The tenderer shall guarantee the runner against excessive pitting caused by cavitation for 18 months from the date of commissioning or 8000 hours of operation, whichever is more. If the 18 months of guarantee period expires before completion of 8000 hours of operation, the guarantee shall apply to the actual hours of operation proportionately. Excessive pitting shall be defined as the removal of metal from the runner of a weight of W= 0.15 D2 per 1000 hours of operation, where, D = Discharge diameter of the runner and W = weight in Kg. In case of cavitation pitting exceeding the guarantee, the turbine supplier shall, at his cost, take corrective measures such as modification of design, finish, replacement, repair, etc., and the turbine after modification, etc. shall be subject to cavitation guarantee as for the original equipment. In determining whether or not excessive pitting has occurred metal removal by erosion, corrosion or by the presence of injurious elements in water, etc., shall be excluded.

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2.5

RUN AWAY SPEED

The maximum runaway speed shall be stated and guaranteed by the Bidder. The machine shall be capable of running continuously at runaway speed without any damage to any part for a period of not less than 15 minutes for every such occurrence with cooling water supply on. The critical speed of the unit shall be more than 1.2 times the runaway speed.

2.6

SPEED RISE AND PRESSURE RISE

The moment of inertia of the unit and the normal deflector closing time and runner blade angle shall be so adjusted that the maximum momentary speed rise of the unit shall not exceed 35 % and the maximum pressure rise in the penstock shall not exceed 25 % of the maximum rated head under any condition of operation. The turbine manufacturer shall coordinate with the generator manufacturer for limiting the speed and pressure rise values. If necessary, adequate flywheel shall be provided and included in generator section. 2.7 NOISE LEVEL

Maximum noise level resulting from any of the operating conditions shall not exceed 90 db (A) at any place 1.0 m away from operating equipment in the machine hall. 2.8 STRESS AND FACTOR OF SAFETY

All parts of turbine shall be designed and constructed to safely withstand the maximum stresses during the normal running and runaway and short circuit conditions, out of phase synchronizing and brake application. The maximum unit stresses of the rotating parts shall not exceed two-thirds of the yield point of the material. For other parts, the factor of safety based on yield point shall not be less than 3 at normal conditions. For over-load and short circuit conditions, a factor of safety of 1.5 on yielding point shall be permitted. 2.9 BID EVALUATION

In the comparison of the tenders; the equalization on account of differences in the efficiencies of various offers will be made on the basis of weighted average efficiency as calculated by the formula given below: Tav = K1 x T100 + K2 x T80 + K3 x T60 at rated head. Where Tav = weighted average efficiency and T100, T80, and T60 are efficiencies at 100%, 80% and 60% outputs, respectively, at rated head. The highest figures of weighted average efficiency will be the basis for comparison of prices of turbines with lower

24 efficiencies and will be loaded at the rate of 0.5% of their ex-works prices for each 0.1% difference in weighted average efficiency as compared with the highest weighted average efficiency. The weighted average efficiency of the turbine will be multiplied by the efficiency of the gear box (if provided) for obtaining overall weighted average efficiency which will be used for bid evaluation. The basis for selection of the offers shall be the overall economy to the purchaser considering power house civil works, monetized values of efficiencies, prices of matching generator, prices of powerhouse crane required, etc. The speed and setting of the turbine and its design shall be such as to result in the installation of the best generating unit at least cost. 2.10 MODEL TEST

The rates for model test as per relevant standards may be quoted separately. The purchaser shall have the option to get the model test performed by the contractor at an extra cost after the award of the contract. In that event, the manufacture of any part of prototype turbine shall be started only after the efficiency and other guarantees and requirements of the turbine are established and fulfilled on the basis of model tests. In case the contractor has already performed model tests on homologous models, the purchaser may, at his discretion, permit the contractor to proceed with the manufacturer after approval by the purchaser of the model test report. The performance of the model tests either afresh or that had been done earlier shall be as per IEC 193 and 193A in all respects. Hydraulic performance tests shall be made at various guide vane openings to determine machine characteristics including regimes of safe operations, zones of cavitation and vibration, etc. The phenomenon of cavitation and vibration, particularly at lesser guide vane openings shall be specially investigated. These tests shall include determination of capacity, cavitation limits, hydraulic thurst, runaway speed, wicket gate torque relationship, etc., and such other details as covered in IEC 193 and 193A. Prototype efficiencies shall be derived from model tests by Moodys step-up formula as contained in IEC 193 for Francis turbines. Model tests shall simulate all possible normal operating conditions of the prototype for entire range of forebay/reservoir and tailrace levels. The tenderer shall clearly mention the time within which the model tests including manufacture of a new model, if required, will be completed. The delivery schedule given by the tenderer shall be reckoned from the date of approval of model tests or model test report or from the time of permission to proceed with the prototype manufacture. If the model test is already available, this shall be submitted within 1(one) month after the award of the contract if required by the purchaser.

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2.11

GENERAL ARRANGEMENT AND CONSTRUCTION

The turbine shall be constructed as to allow all the removable parts to be dismantled conveniently. The design shall also permit removal of rotating parts without disturbing the deflector-nozzle assembles. The design shall also permit horizontal movement of runner shaft by an amount sufficient for adjustment of bearings and for clearing the joint at the coupling between the turbine and the generator. 2.11.1 Runner The runner shall be of 13/4 chromium-nickel stainless steel. The composition of the material and the source of runner casting shall be stated in the tender. The runner shall be cast integrally of stainless steel. The runner will be a one-piece construction. The runner will have adequate number of buckets which shall be polished and ground smooth and shall be free from roughness, cracks, high spots, etc. The finished machine and ground runner shall be dynamically balanced in the works before dispatch. 2.11.2 Shaft And Coupling The turbine shaft shall be forged carbon steel or alloy steel conforming to IS or other equivalent international standards. Wherever the flanges are integral with the shaft, the same should be conform to American standard ANSI-49.1, 1967. For long larger size shafts, tubular construction of proven design will also be considered. The turbine shaft shall be connected to the runner on one side and to the gear box/flywheel generator shaft on the other side. It shall be of ample size to transmit torque at rated speed without excessive vibration or any distortion. The turbine manufacturer shall co-ordinate and co-operate with the generator manufacturer for proper design and construction. The final alignment of the shaft at site shall be the responsibility of the generator manufacturer. Mounting of runner on extended generator shaft (if offered by any tenderer) shall be allowed. 2.11.3 Turbine Bearings The turbine bearings can be: (iii) The pad type or sleeve type or Babbitt lined, oil/grease lubricated either selflubrication or forced lubrication type. (iv) Anti-friction ball, roller bearings, oil or grease lubricated.

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The turbine shall be provided with adequate number of bearings. The bearings shall be designed to withstand operation at maximum runaway conditions with cooling water supply on (if cooling water is provided) for a period of not less than 15 minutes and also for operation at normal speed without cooling water supply for 15 minutes. The bearings shall be provided with a dial type or resistance type thermometer and a pressure gauge with provision for alarm annunciation/shut down on excessive bearing temperatures. The number and type of bearings shall be stated in the tender. These bearings shall be guaranteed for a minimum continuous operation of 100,000 (One Hundred Thousand) hours and the design and performance shall be well proven and established. 2.11.4 TURBINE HOUSING The turbine housing shall be cast fabricated in low alloy Mn. Steel in two parts upper and lower. The wall thickness shall be sufficient to ensure adequate rigidity. Housing shall provide adequate support to guide bearing. Adequately sized air admittance piping enabling the turbine to draw air from atmosphere shall be provided. Each turbine housing shall be equipped with the necessary lugs to facilitate easy handling by a hoist / crane. Necessary foundation shall be provided for securing the housing on turbine floor. Turbine housing and generator stator shall be supported on a common foundation frame. The bearings of turbine and generator shall be aligned in manufacturing shop. 2.11.5 NOZZLE AND DEFLECTOR ASSEMBLY Nozzles shall be of the straight-flow type with internal hydraulic servomotors. Adequate adjusting rings shall be provided for each nozzle to ensure correct alignment of the nozzles. The needles shall have self-closing tendency due to penstock pressure and spring action. Needle servomotors shall be double acting hydraulic jacks with spring assistance. The needle tips and seat ring will be made of erosion resistant stainless steel. Jet deflectors shall be provided on each nozzle and shall be regulated by governor. The nozzle body will be adequately reinforced to support the jet deflector. The deflector and the supports will be designed to prevent any harmful vibrations during operation, including complete load rejection and to ensure that no deflector can contact the runner in the event of operating mechanism breakdown. The deflectors will be of rigid design integrally cast or forged in 13 Cr 4 Ni, erosion and cavitations resistant stainless steel. Each deflector will turn on a shaft of stainless steel, supported in two self-lubricating type bearings. All components of the deflector will be inside the turbine housing and shall be of corrosion resistant materials. Each deflector shall be provided with an external position indicator.

27 The deflector servomotors will be double-acting, hydraulically operated on opening, but closed by spring action. The servomotors will have sufficient capacity to operate the deflectors under all conditions of operation and to move them through full opening or closing stroke in the minimum time specified. The servomotors will be equipped with a mechanical position feedback mechanism, for connecting to the governor restoring mechanism. 2.11.6 BRAKE JET ASSEMBLY Each turbine will be fitted with one nozzle intended to emit a brake jet, to be automatically operated during shutdown of the turbine. The brake nozzle will be fed from a pipe tapped from penstock upstream of the turbine inlet valve with a manual shutoff valve for maintenance. The operation of brake jet shall be controlled through a solenoid operated control valve with over riding manual operation facility. 2.12 GOVERNING SYSTEM

Each turbine shall be equipped with suitable electro-hydraulic governor conforming to IEC No. 308. The governor shall be of proven design capable of controlling speed / output under all operating conditions. The governing system shall comprise oil pressure system, governor actuator (Mechanical), governor electronic regulator, speed signal generator, oil pipe lines and deflector position restoring mechanism. The electronic regulating functions of governor i.e., speed / gate setting, deflector limit setting, start, stop, main circuit breaker position, shutdown etc. shall be operate the unit in manual mode in case governor electronic regulator is non-operative. Local control unit have the indicators for deflector position, speed of the unit and power generated by the unit. a) GOVERNOR REGULATOR The speed sensing shall be achieved through speed signal generator and line PT. The governor shall control, with stability, the turbine at any speed between 85 and 105% of rated speed when operating isolated from the system and while connected to the system at any load between zero and the load corresponding to maximum opening of the nozzles with both nozzles operating. Partial Shutdown/Controlled Action Shutdown device shall be used for automatically shutting down the turbine to the speed-no-load position by the operation of certain protective devices. It should be possible to operate deflector position manually at the local control unit. b) GOVERNOR ACTUATOR Governor actuator shall have the following provisions : Adequate capacity to operate the deflector servomotor and the needles through complete opening or closing strokes in desired time under all operating conditions.

28 Hand control device for stroking of deflectors followed by needles so as to operate the machines manually even if electronic regulator is non-functional. Relationship between deflector position and needle stroke may be achieved through mechanical linkage utilizing a cam. Necessary data for relationship between deflector opening and needle stroke shall be given by turbine designer to the governor manufacturer. It should be possible to control the needles for off-cam position. Emergency shut down device, which can be operated manually at the actuator. Auto - clean double element filter to ensure that clean oil is supplied to control valves. The change over to standby filter and cleaning of clogged filter must be possible while unit is under operation. Means of independent adjustment of the opening and closing times of the deflectors and needles. The time for deflector closing under full load throw off shall be adjustable to limit the speed rise and pressure rise within guaranteed values. Speed Signal Generator (SSG)

c)

A toothed wheel type speed signal generator shall feed speed signal to the governor electronic circuits for speed regulation and operation of speed relays. The toothed wheel shall be mounted on the shaft and two magnetic pick-ups shall be mounted near the toothed wheel. One of the two pickups will work as redundant. The output signal of the magnetic pick-up shall be fed to the governor electronic cubicle. d) Over Speed Device

A centrifugal type over speed protection device with provisions for electrical/ mechanical tripping shall be mounted on the turbine shaft (outside the turbine housing). The tripping points shall be adjustable independently for speed higher than the maximum speed; the turbine can develop with loss of full load. The mechanical tripping device shall directly actuate the governor actuator shut-down valve through a hydraulic connection. The electrical tripping contact shall be wired to the turbine terminal cubicle. The rotating parts of the over speed protection shall be protected by a guard. e) Oil Pressure System

Each turbine will be provided with one independent oil pressure unit to supply oil under pressure to deflector and needle servomotors through governor actuator. Oil pressure system shall consist of one oil sump, two positive displacement pumps driven by AC motors, set of valves, pressure accumulator and accessories. The pressure accumulator can be installed over the sump or separately. The capacity of the pressure accumulator shall be sufficient to operate the deflector servomotor and needle servomotors with minimum pressure of normal operating range and under other normal operating conditions, through three complete servomotor strokes (3 x sum of deflector and needle servomotors volume) with the oil pump not operating. Design calculation of capacity of oil pressure system shall be furnished.

29 The pressure tank shall be constructed in accordance with ASME Code for Unfired Pressure Vessels, Section VIII, for the maximum working pressure of the governing system. Necessary safety / control devices shall be provided on the accumulator. f) Oil Pipe Lines Oil pipe lines of adequate size along with necessary valves, connecting flanges, fittings and fasteners shall be supplied for interconnection between different hydraulic elements. All pipes above 15 mm internal diameter shall be carbon steel seamless pipes and up to 15mm size, will be stainless steel / copper pipes. 2.13 GEAR BOX

A gearbox of suitable gear ratio may be used to match generator of higher speed. The speed increasing gear box shall be connected to the turbine and to the generator shafts. The gear box shall be designed to be capable of withstanding runaway operation for 15 minutes and shock loads due to load variation and due to pressure pulsations in the turbine. The gear efficiency shall be as high as possible and shall be considered in evaluating the turbine efficiency for purpose of bid evaluation. 2.14 TURBINE INSTRUMENTATION, CONTROL AND SAFETY DEVICES

Each turbine shall be provided with a complete set of instruments, gauges, controls and safety devices for unit control board for monitoring the conditions of the unit during normal running and emergencies. The instruments and gauges for the turbines include, inter alia, pressure gauges, level indicators, temperature and flow indicators, position indicator, indicating lamps for status indication etc. The safety devices shall comprise equipment and devices for sensing abnormal operating conditions, for giving visual and audible annunciation and shut down the unit, if required. A list of these instruments, controls and safety devices are given in Tables A, B, & C. The items, quantities and location are to suit the requirements for safe and satisfactory operation of the generating units and the auxiliary systems. 2.15 TURBINE INLET VALVE Turbine inlet valve shall preferably be spherical type. Valve shall be operated through a hydraulic cylinder with pressure oil supply from turbine oil pressure unit. Opening of valve shall be performed by oil pressure and closing by dead weight. Necessary control panel with solenoid operated control valves shall be provided. Provision of manual control from local control panel shall be provided. Inlet valve shall be provided with metal to metal working seal operated by upstream water pressure. Arrangement for releasing working seal before opening the main inlet valve shall be provided. One hand operated rising spindle gate valve shall be used before inlet valve for maintenance purpose.

30 2.16 PENSTOCK DRAINAGE SYSTEM Necessary piping with fittings and steel gate valves shall be supplied for draining both the penstocks into tail race channel. 2.17 COOLING WATER SYSTEM

The cooling water for generator air coolers (if applicable) generator and turbine bearing coolers, turbine shaft seal if applicable and for other equipment in the powerhouse needing cooling water shall be provided by tapping the penstock. If a higher pressure is needed at low head conditions, booster pumps to obtain the required pressure shall be provided for each tapping. In case the pressure at the tapping is high, suitable pressure reducer shall be provided. The system shall be complete with required number of duplex strainers, fine mesh filters, flow meters, flow indicators, flow relays, pressure gauges, etc. 2.18 COMPRESSED AIR EQUIPMENT

A centralized high pressure compressed air system common for both the units shall be provided for charging the governor oil pressure vessels. The system shall comprise two numbers high pressure compressors of suitable capacity, one of them being a standby, a common air receiver and necessary pipes, fittings, valves, pressure switches, etc. The capacity of the system shall be sufficient to cater to both the generating units. The compressed air system shall be of the automatic start-stop design operating under pressure switches control sensing the pressure in the receiver. Nitrogen filled cylinders as an alternative system for pressurizing the oil pressure vessels shall not be accepted.. 2.19 SPECIAL TOOLS, SLINGS, CONSUMABLES ETC.

All special tools, slings, lifting devices, jacks, turn buckles, foundation plates/bolts, testing devices etc., required for erection and commissioning of the equipments shall be listed and supplied. First filling of oil and grease (if applicable) with 20% extra quantity shall be included in the offer and supplied along with equipment. Welding electrodes as required for site welding and paint for finishing coat shall be supplied by the contractor. 2.20 ONE SET OF LEVEL TRANSMITTER AND RECEIVER DEVICE FOR WATER LEVEL IN FOREBAY RESERVOIR,

Forebay Water Level measurement device shall be supplied suiting its installation in Forebay tank. Electronic part of the measuring device should be housed in a hermetically sealed case/panel. This device shall have one local indicator (digital) for indicating water level. Output signal for the device should be made available for unit control panels. Necessary cable between Powerhouse and Forebay, installation of this device and laying of cable shall be included in the priced offer.

31 2.21 SPARES The spare parts for the turbine and associated equipment considered necessary for 5 years of operation of the generating units shall be supplied by the contractor along with the first turbine. The unit prices of the spares shall be indicated in the enclosed Price Schedule Format and additional spares if considered necessary shall be quoted separately.

2.22

SHOP ASSEMBLY AND TESTS ( AT MANUFACTURING WORKS)

The Tenderer shall submit the quality plan indicating the tests to be performed and witnessed by Purchaser and acceptance criteria for the same. The Contractor shall get the quality plan approved from Purchaser as per Contract Conditions. For inspection and tests to be witnessed by Purchaser, requirements elaborated in Conditions of Contract shall be followed. 2.22.1 The following assembly and testing requirements in Contractors works shall

essentially be included in quality assurance plan :

Deflector and Needle Servomotors hydraulic testing, stroke checking, minimum oil pressure required for movement and oil leakage past piston and piston rod. Turbine Runner Dimensional checks, bucket profile checking, casting soundness tests, static and dynamic balancing. Deflector and Needle Assemblies : Free movement, minimum pressure required for movement, and stroke relationship Complete assembly of turbine in the shop for matching Oil Pressure System Performance testing of pumps, U/T of weld joints and hydrostatic testing of pressure vessels. Governor Assembly and complete performance testing as per relevant IEC code Turbine Inlet Valve : Assembly, hydraulic testing and Operational tests

2.22.2 Material Tests - Material tests for important components such as runner, turbine shaft, deflector, needles, nozzles, deflector bushes, turbine housing, bearing sleeve/shell and other important components shall be carried out as per agreed quality plan. Purchasers Engineer shall review the test certificates during inspection. 2.22.3 Tests on Bought out Components : All motors, pumps and compressors etc. shall be tested as per relevant Indian Standards.

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2.23

PRE-COMMISSIONING FIELD TESTS

2.22.1 Following measurements/tests in addition to tests recommended by Contractor shall be included in quality plan for pre-commissioning tests : Characteristic - Servomotor stroke Vs Deflector Opening Characteristic Deflector opening Vs Needle stroke Deflector and Needle opening and closing times and servomotor cushioning time. Insulation Resistance Tests on all electrical motors as per relevant Indian Standards Operational tests on oil pressure system to verify : Setting of pressure relays for automatic control of pump Setting of pressure relay for emergency low pressure Test to verify pumps capacity Tests to verify number of close/open operations with oil pump not operating 2.22.3 The governor shall be assembled, adjusted and tested in the field for optimum performance. Specifically, the following tests/checks will be performed : Verify logic control scheme from local/remote including start/stop, load control, emergency shutdown, controlled action shutdown, locking and other feature Verify stability and response of governor during 10% to 20% step change in load (acceptance and rejection or a combination of these). Verify setting range of permanent droop, on/off-line temporary speed droop, derivative time constants, frequency dead band, speed setting limits, gate setting limits, no load gate limit, speed relays etc. 2.24 COMMISSIONING TESTS Following commissioning tests shall invariably be included in tests recommended by Contractor before putting the machine on 72 hours continuous trial run for handing over: Logic control scheme from local/remote including start/stop, speed control, load control, level control, emergency shutdown, controlled action shutdown and other features, Automatic starting, stopping, synchronizing, loading and emergency shut down by simulating emergency conditions, Checking the setting of over speed trip device by actually over speeding the machine, Checking speed rise and pressure rise at 100% sudden load rejection of individual generating unit and simultaneously from both units,

2.22.2

The Contractor shall carryout the commissioning test in accordance with the agreed procedures. The turbine will be handed over to the purchaser after continuous operation for 72 hours free from problems of leakage, overheating, failures, damages, etc. Tests for meeting performance guarantee can be performed after handing over the machine for commercial operation but before final acceptance in agreement with the Purchaser.

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2.25

FIELD ACCEPTANCE TESTS

The turbines shall be tested at site for establishing fulfillment of guarantees in respect of turbine output and efficiencies including weighted average efficiency. The tests shall be carried out as per IEC 41 for Field Acceptance Tests of hydraulic turbines. The arrangements for these tests will be made, including the testing devices, by the contractor. 2.26 DRAWINGS/ DOCUMENTS TO BE SUPPLIED : 2.26.1 DRAWINGS/ DOCUMENTS TO BE SUPPLIED WITH TENDER Performance characteristics of the turbine with respect to output and efficiency against various discharge and head. Model test report, specifically the Hill Chart of a model based on which prototype will be manufactured & supplied and detailed parameters of projects where turbines based on the same model are working satisfactorily. Cross section of turbine showing the various components, parts/assemblies of the turbine to the extent possible. Layout drawings of the power house showing the overall dimensions and layout of turbines, etc., Overall arrangement drawing, schematic drawing and descriptive literature of electro-hydraulic governor, emergency closing device, return motion gear, speed signal generator and over speed trip device. Schedule of indicating and recording instruments and safety devices. Quality Assurance Plane 2.26.2 Following Drawings, data and information shall be supplied after award of Contract as per Contract Conditions for purchasers approval and record : Overall arrangement drawings of turbine runner, deflector assembly, needle assembly, needle control device, brake jet assembly & inlet valve. Overall arrangement drawings, schematic drawings and descriptive literature of electro-hydraulic governor, emergency closing device, return motion gear, speed signal generator and over speed trip device. Schematic drawings of oil pressure system, Quality plan for tests at suppliers / vendors works indicating customer hold points and acceptance criteria.

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Operation & Maintenance Manual and Erection & commissioning Manual of turbine, governor and inlet valve. Tentative list of vendors for major purchase items and instruments. Catalogues of pumps, valves and other purchased items

2.27.6 GUARANTEED TECHNICAL PARTICULARS The tenderer shall furnish all the data, information and other particulars called for in the schedule at the end of section under guaranteed technical particulars. 2.28 SCHEDULE OF REQUIREMENTS (1) Horizontal Pelton Turbines each consisting of : One Turbine housing One Pelton Runner One turbine shaft One turbine guide bearing Two jet deflectors ( interlinked ) with one deflector servomotor Two nozzles each with needle servomotor and needle operating device One Brake jet assembly including piping One Governing system including digital electro-hydraulic governor, speed signal generator, over speed trip device, emergency shut down device, restoring mechanism, One oil pressure unit and oil pipe lines One set of inlet valve (spherical type) Necessary air and water piping alongwith valves and fittings Necessary electrical wiring and terminal boxes Set of Instruments for temperature, pressure and water flow Any other parts and accessories required to make the turbine complete. (2) Following items/materials shall be supplied as common for both the units : One set of level transmitter and receiver device for water level in Forebay reservoir, One set of Cooling Water System, if required One set of Compressed Air System One set of Penstock drainage system All special tools required for assembly, dismantling, maintenance and handling of the equipment, including templates for repair of runner buckets and deflectors and one set of Pressure pump and other accessories for site hydrostatic tests. Site consumables, lubricating oils and grease for first filling with 20% extra quantity, welding electrodes, brazing materials, paints, insulating materials, cleaning agents etc. One set of spare parts for five years trouble free operation as per schedule of mandatory spares,

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TABLE-A SCHEDULE OF INDICATING/RECORDING INSTRUMENTS Sl. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 Description Penstocks Pressure Pressure of water after inlet valve Deflector position and limit indicators Needles position indicator Speed indicator Speed level setting indicator Unit output meter Pressure of governor oil pressure system on panel and pressure accumulator Pressure of air in air receiver Level of oil in oil pressure vessel Level of oil in sump tank Turbine bearing temperatures Cooling water pressure, if cooling water system provided Water level in Forebay TABLE-B CONTROL DEVICE Description Device Type Deflector Position Control (Electrical) Governor Auto-manual selection switch Speed level controller Manual turbine gate controller Inlet Valve Control Manual Control of Brake Jet Pressure Switches for control of oil pump motors Pressure Switches for control of compressors Turbine Over speed Tripping Device Turbine Guide bearing temperature high (for shut down command) Turbine emergency shut down command Control of cooling water pumps, if provided Device Type Total Quantity per Unit Location

Sl. No. 1 2 3 4 5 6 7 8 9 10 11 12

Total Quantity per Unit

Location

36 TABLE-C SAFETY DEVICES (FOR ALARM/SHUT DOWN) Sl. No. 1 2 3 4 5 Description Governor Oil pressure too low Turbine bearing temperature too high Oil level in pressure receiver too low Unit over speed Manual emergency shut down Device Type Quantity per Unit Annunciation

37 TABLE D LIST OF MANDATORY SPARES Sl. No. TURBINE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Sl. No. 18 19 20 21 22 23 24 25 26 27 Needle Nozzle Bush of needle assembly Deflector Bush of Deflector assembly Seals of nozzle assembly Springs (each type) Piston rings (if used) INLET VLAVE Seals of Inlet valve Piston rings (if used) Journal Bushes GOVERNING SYSTEM Speed pick up Actuator Transducer / proportional valve Oil filter element Emergency solenoid valve Return motion Potentiometer / LVDT PCBs of electronic regulator Item OIL PRESSURE UNIT Oil Pump-motor set Idler / Unloader Valve Safety Valve Pressure Gauge INSTRUMENT AND SAFETY DEVICE Resistance temperature detector Dial type thermometer Pressure gauges (each type) Differential pressure relay (each type) Solenoid operated valve (each type) Level Switches 1 No. 1 No. 2 Sets 1 Set 2 Sets 2 Sets 2 Each 1 Set each 1 No. 1 Set 1 Set 2 Nos. 2 Nos. 2 Nos. 1 No. 2 Nos. 1 Set Quantity Item Quantity

1 Set 1 No 1 No 2 Nos. 2 Nos. 2 Nos. 2 Nos. 2 Nos. 1 No. 1 Each type

38

SECTION III SPECIFICATIONS FOR CROSS FLOW TURBINE

39

SECTION III SPECIFICATIONS FOR CROSS FLOW TURBINE

3.1 HYDRAULIC TURBINE SCOPE: The specification covers the design, engineering, manufacture, supply, installation, testing and commissioning of a complete hydro-power generating powerhouse of..KW capacity comprising of ONE/TWO units turbine units suitably coupled to Synchronous generator The system shall also include Electronic Load Controller for each turbine for load governing and regulation of turbine speed/generated frequency and electrical power distribution panel with necessary protection against over-current, earth fault, under-voltage and over-voltage. Provision for synchronizing of generated output to Grid/ second turbine- generator output must be available in the panel with necessary protection. It is preferred that a common base frame for turbine and generator be provided for ease of alignment of generator with the turbine/ for drive pulley alignment, as may be required. 3.1.1 TYPE & RATING:

3.1.1.1 Turbine: The turbines offered shall be cross-flow type or axial flow or Francis or Pelton or Turgo impulse or any other type to match with the specifications. A penstock adaptor must be provided at the inlet suitable for connecting the penstock pipe of appropriate size at the turbine inlet. (Manufacturer must specify the inlet penstock pipe size and flange details for which the penstock adaptor has been designed.) The penstock adaptor must be provided with matching flanges with necessary fasteners for fixing of the penstock pipe. The turbine should be capable of generating power so that specified kW of power can be measured at the generator terminals. The turbine should be capable of operating between 110% to 40 % variation of rated discharge and capable of synchronization with other machines and with the grid. The turbine shall be so constructed as to allow all the removable parts to be dismantled conveniently. All the components shall be neatly arranged and shall be easily accessible for O& M.

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RUNAWAY SPEED All parts and bearing should be capable of withstanding continuous runaway speed attained under any combination of head and load conditions with inlet valve fully opened, generator disconnected and unexcited. The occurrence of runaway condition should not damage the turbine parts. NOISE LEVEL Maximum noise level resulting from any of the operating condition shall not exceed 90 dB (A) at any place 1.0 m away from operating equipment in the machine hall. GENERAL ARRANGEMENT AND CONSTRUCTION RUNNER The runner shall be of stainless steel with approximate content 13% chromium & 4 % nickel. It should be either casted or fabricated .The runner would have adequate number of smooth blades. It should be dynamically balanced in the works. SHAFT AND COUPLING The turbine shaft should be forged carbon steel or stainless steel or alloy confirming to Indian standard or equivalent International standard. The turbine supplier shall collaborate with the generator supplier for the coupling arrangement. The flexible rubber coupling shall be preferred. CASING The casing shall fabricate from welded steel plate/ mild steel plates and shall have suitable sections for ease of transport and its limitations. THE TURBINE BEARINGS The turbine bearings should be Anti-friction ball, roller bearing, oil or grease lubricated, pad type or sleeve type. These bearings shall be guaranteed for a minimum continuous operation of 100000 (one lack) hours and the design and performance shall be proven and established. SHAFT GLAND The gland shall effectively prevent leakage of water along the shaft under all operating conditions and at stand still prevent entry of air. Arrangement of cooling water supply of shaft gland will have to be made by the contractor.

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DRAFT TUBE (if applicable) The draft tube can be either straight or elbow shaped. The design of draft tube shall be such as to ensure the best over all efficiency for the turbine, stable and pulsation free operation of the machines. GUIDE VANE SYSTEM ( if applicable) Water admission to the turbine is controlled by suitable number guide vanes. The guide vane shall be made from cast steel alloy. The guide vanes are adjusted individually through linkages by an automatic and manual control system. SHOP ASSEMBLY AND TESTS The following assemblies and tests shall be carried out on the turbine and associated equipment at the manufacturer's works before dispatch in the presence of representative of the Owner, if desired by the Owner, and test certificate shall be submitted. i) ii) iii) iv) v) vi) vii) viii) ix) x) xi) The turbine, manufactured first, shall be assembled in the shop to the extent possible. Dynamic balancing of runner. Hydrostatic testing at 1.5 times the maximum static/ working pressure including water hammer for not less than 15 minutes for the spiral case, servomotors, etc. Non-destructive testing of welds. Performance tests for individual auxiliary equipment. Complete assembly and simulation test of governors. Assembly of spiral case and draft tube liner. All motors/ pumps/ compressors, etc. shall be tested as per relevant Indian or other standards. Runner Mechanism (checking of proper motion of blades, oil leakage and clearances). For Main turbine assembly, Top cover, Pivot ring, shall be assembled and checked. Routine test reports of all the bought out items shall be furnished before approval for dispatch.

3.1.1

Pressure Gauge Two pressure gauge shall be provided in the P.H. to read the pressure of water just before it enters the turbine. It shall have scale to read approximately half- scale at gross head and shall be mounted at 45o with vertical.

3.1.2Manifold The manifold to carry water from penstock to the turbine inlet and runner shall be designed so as not to introduce large additional head losses. This can be verified by following thumb- rules:

42 i. ii. Do not allow the velocity of water in the penstock to increase as it passes through the penstock, Velocities in the manifold should not exceed: a. 3 m/s in straight pipes, b. 2.5 m/s in bends up to 45 degrees, c. 2.0 m/s in bends up to 90 degrees.

3.1.3

Inlet Valve A inlet valve (a valve at the foot of penstock) shall be provided unless: a. It is possible to quickly, safely and in a routine manner divert water away from the turbine or the mouth of the penstock in order to shut down the turbine (e.g. on some low head sites it may be possible to divert water at the mouth of the penstock as to close a valve), b. If a jet deflection system is fitted to a Pelton turbine, c. If a multi- jet Pelton turbine has valves on every branch of the manifold, d. If the guide vane of a Cross flow or a propeller turbine closes off the Flow sufficiently.

ii.

Location The inlet valve shall be located in the P.H. and be easily accessible. It shall be rated at maximum penstock pressure. Operational Speed The valve must be slow closing type or should have an apparatus which shall prohibit fast closing e.g.: a. Fitting of a much smaller second valve in parallel to the manifold valve, which shall be pad-locked in the open position and kept open when the main valve is closed. b. A gearing mechanism to ensure very slow closing operation. Safety Guards All moving parts shall be shielded by a strong and durable wire mesh. The size of the mesh shall be small enough to prevent the entry of hands and arms of the children. The guards shall be electrically earthed and kept permanently secured by locks. . Minimum Weighted Average Efficiency (wav) The weighted average efficiency of the turbine generator unit, calculated by the following expression should not be less than 60% wav = 0.5 { t100 g 100 + t 50 g 50}, where t100, g 100, t 50, g 50 are efficiencies of turbine and generator at 100% and 50% rated outputs, respectively at rated head.

iii.

3.1.4

3.1.5 i.

ii.(a)

For efficiency of turbine, the performance curves of similar offered turbine manufactured by the manufacturer of which turbines are being quoted by the bidder,

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(b)
3.1.6

(tested by independent institution), be provided, OR the value obtained as per the field tests on the turbine carried out as specified in IEC or equivalent international or national code shall be taken. For efficiencies of generator the value obtained as per field tests as specified in above codes shall be taken.
Bid Evaluation Equalization for Short Fall in wav: For each 1 (one)% or part thereof by which wav (Sub clause 3.1.6.i) is lower than the highest offered wav in any of the bids received, 3(three)% of total price of turbine generator unit offered in the bid under evaluation shall be added to the offered price of each turbine-generator unit . Cavitation Guarantee

3.1.7

The bidder shall guarantee the runner against excessive pitting/ cavitation for Eighteen (18) months from the date of commissioning or 8000 (Eight thousand) hours of operation, which is earlier.
3.2 Generator: A suitably rated brushless type synchronous generator in four-pole design (preferred) in horizontal foot-mounted configuration with forced cooling shall be provided for generation of electrical power having the following parameters: Voltage: 415 volts Three-phase, Four-wire. Frequency: 50 Hz. Rpm: to be specified by the system manufacturer. Power Factor: 0.8.

Voltage Regulation (with Electronic AVR): + 2%. The generator shall be supplied complete with electronic AVR which may be generator mounted/panel mounted with arrangement for providing adjustment and voltage setting potentiometer on the control panel door for adjustments during synchronizing and operation of the turbine alternator system on load. Generator supplied shall be of standard make and conforming to IS-4722 and IEC 34-1. The enclosure protection class should be IP-23S and the insulation levels for Main stator & rotor as well as Exciter stator & rotor shall be Class F.
Generator shall be to with stand continuous run way speed. The generators shall also have provision for possible grid connection in future. Generators shall be suitable for continuous duty operation at full load. They should be suitably de-rated, if necessary, for operation at higher altitudes depending on the location of the site.

Following operating parameters for the turbine generator system shall be specified: Net operating Head (in Meters): Operating Discharge (in litres/sec or Cumecs):

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Desired Electrical Power generation: Minimum Turbine efficiency: 75%. Minimum Generator efficiency: 89%.
Electrical Power Distribution & Control Panel:

3.3

A composite electrical power distribution shall be provided for the installation which shall house suitably rated incoming and outgoing feeders, electronic load controllers (one for each turbine system) complete with water-cooled dump loads, provision for synchronising for running TG sets as well as synchronising with Grid in future and necessary protection relays for system protection. Control panels may have simple PLC based system to make operation simple by the local operators. The Composite electrical panel shall be free-standing, floor mounting and fabricated out of 14/16 SWG MS CRCA sheet steel having cable entry from the bottom. The panel shall have a pleasing appearance and all components and metering/relays on the panel door shall be neatly and conveniently located. The panel shall be powder coated in IS631 or Siemens Grey shade or any other approved shade after de-rusting and application of primer. The panel shall house the following: Incomer feeder (One no. for Single turbine unit/ two nos. for Two turbine units separated by a Bus Coupler) each comprising of: 1no. MCCB of suitable rating complete with short circuit, over-current and shunt trip release. 1no. 0-500V Voltmeter SIF96 complete with control fuses and selector switch. 1no. 45-55 Hz Reed type frequency meter. 1no. Multi-function digital indicator to read Current, KW, KWh, PF, KVA & KVAR. 3nos. BPL type current transformers Class 1.0 having 5A secondary, 10VA for metering. 3nos. BPL type current transformers Class 5P10 having 5A secondary, 15VA for protection. 1no. IDMT Over Current and Earth Fault relay. 1no. Voltage relay for Over Voltage and Under Voltage protection. 1 no Over frequency and Under frequency relay 1no. Reverse Power Protection relay. 1no. Synchronising Contactor of suitable rating. Any other relays required for proper functioning & safety of the system. Outgoing feeders: (One no. for Single turbine unit/ two nos. for Two turbine units) each comprising of: 1no. MCCB of suitable rating for Utility Load transformer/Grid supply. 1no. 0-500V Voltmeter SIF96 complete with control fuses and selector switch. 1no. Multi-function digital indicator to read Current, KW, KWh, PF, KVA & KVAR. 3nos. BPL type current transformers Class 1.0 having 5A secondary, 10VA for metering. 1no. 6-way three phase MCB DB, for power house lighting load etc., comprising of: 1no. Four pole MCB incomer. 6nos.MCB outgoings (2nos. per phase) Synchronising section comprising of: 1no. 0-500V double voltmeter.

45

1no. 45-55 Hz double frequency meter. 1no. Synchroscope. 1set Dark Lamp arrangement. 1no. Synchronising switch. 1no. Turbine selector switch. 1set ON/OFF Push buttons for Synchronising Contactor. 1no. Frequency set potentiometer for each turbine unit. 1no. Voltage set potentiometer for each turbine unit.
3.4 Electronic Load Controller :

Electronic Load Controller for load governing and regulation of generated frequency ONE set for each turbine Generator system. The system will be a continuous load monitoring system operated through a set sensing electronics controlling the flow of current through a set of electronic power devices. The salient functional features desired are being enumerated below:

Governing of the turbines for regulation of the output electrical parameters is achieved by providing an Electronic Load Controller across the generator output terminals to provide constant loading equivalent to the total power generation capacity of the turbine-generator system at any point of time. The Electronic Load Controller is designed to control the dissipation of the generated power into a set of resistive loads called the Dump Load depending on the generated voltage level as compared to the desired pre-set value. The system is designed to maintain the following power equation:
Total generated Power = Utility Load + Power dissipated in Dump Load. The loading of the generator is maintained within over-current limit by sensing the current flowing in each phase in case of unbalanced load conditions. However, for reasonably balanced load conditions i.e. within 10-15% imbalance a mean phase sensing can also be resorted to for cost economics.

In addition to the above the system is provided with a frequency monitoring arrangement (in case of Synchronous Generators) by sensing of the generated frequency or turbine rpm. In case of rise in the frequency vis--vis the shaft rpm, the system shall divert the generated power to the dump loads and thus reduce the rpm to the set value. This monitoring arrangement restricts the turbine from driving up to run-away speeds. Provision should be made to restrict the runaway speed of the generator within maximum 2 minutes. A stainless steel tank with provision for inflow and outflow of water houses a set of resistive dump loads. The flow of water in the tank is maintained to restrict rise in temperature of the discharged water from the tank.

46 Ballast i. ii. Location

Ballast shall be located in the P.H. so that it is never disconnected.

Disconnection-proof

Cables to the ballast shall be short to be secure and temper-proof and there should be no method of disconnection.
iii.

The design shall ensure that water flow is not impeded so that the ballast may not over-heat and fail and must include reliable protection against the effects of water flow blockage e.g. a. Alarms for high water temperature and low level of water shall be provided for automatic disconnection of the generator field. a. Ballast tanks shall be made from corrosion-proof materials. b. Arrangement for easy flushing out of silt deposits. c. Provision of over flow channel to direct spill water away from electrical apparatus in case of out flow blockage.

3.5

Lightning Protection of Power House

To protect the power house and the consumers, lightning arrestors shall be provided on each phase as below: i. 1 arrestor on the first pole out side the P.H. and 1 arrestor per km of distribution line, An additional arrestor if a consumer is more than 500 m away from the arrestor
3.5.1 Earthing i. The following shall be effectively earthed:

ii.

a. The neutral of the generator. b. All the metal casings of the electrical equipment etc. Precaution shall be taken to prevent corrosion due to electrochemical effects, which can be done by using copper conductor/ electrode for earthing, avoiding bi-metal joints, or by maintaining air and water exclusion from bi-metal joints. ELCB (RCD) shall be used for electrical safety. The earth conductor (connection from the earth terminal to the earth electrode) should have a minimum cross-sectional area of not less than 25 sq. mm. A permanent level Safety Electrical Connection DO NOT REMOVE shall be provided. Earthing of all indoor & outdoor equipment and transformer neutral will be as per IS: 3043 and Indian Electricity Rules , 1956 as amended up to date

iii. iv.

3.5.2

Lighting of Power House, Switchyard and Appurtenant Works

i.

The P.H. shall be provided with adequate safe illumination: minimum 50 watts / sq. m. of floor area, if incandescent, or 20 watts / sq. m., if fluorescent.

47

ii. iii.

Two battery-charged type lantern (emergency light) shall be provided on display board. A weather proof HPSV flood light (100W) shall be provided on all the four sides of the power house for tailrace, switchyard , lighting/area lighting on suitable fixtures. Street lighting/Road shall be provided with 20 Lux illumination using Approved type lighting equipment & fixure (s).

iv.

3.6

POWER & CONTROL CABLES:

All LT power cables will be 1100 volts grade, stranded Aluminium conductor, PVC insulated, PVC sheathed armoured. All control cable shall be of stranded 2.5 sq.mm copper conductor except for CT which will of 4 sq. mm. The cables shall conform to IS: 1554 i. ii. iii. iv. v. Strong conduits, physically secured to all enclosures by means of threaded connectors, shall be used to protect all cables. The conduits shall be sealed to the enclosure entrances. Since the cable inside the conduit from generator to panel board is not protected from over currents and earth faults, adequate physical strength of conduit shall be ensured, The current carrying capacities of the cables, after taking in to account the derating required for use of conduit and multiple cables, shall not be less than 140% of the rating of the over current protection device(s), If the cables are felt over- warm on touching, it is an indication of these being under-sized. The cables shall be doubled or replaced in such cases.

3.6.1. Sockets

Two or more sockets (outlets) shall be provided for use of electrical appliances. The sockets shall be placed at least 1 m above the floor.
3.6.2 Shielding

i. ii. iii.

Cables and their connections to Units shall be shielded both by conduit and by their insulation. The connections shall be with in the closed casings. All live surfaces and points shall be fully and reliably shielded from human contact. Door interlock isolators shall be provided on control gear with voltages above 50 V so as to ensure safe working.

3.7

Fire Protection

Suitable, adequate and Approved fire protection equipment / system shall be provided for the plant / equipment.

48 3.7.1 Safety Guards

Appropriate and approved safety guards shall be provided.

3.8 TECHNICAL SPECIFICATION FOR 11 KV OUTDOOR SUBSTATION SCOPE:

The scope of work includes design, detailed engineering, manufacture of equipment, testing at manufacturers works before dispatch, packing transportation, loading, unloading, supply and delivery at site, storage at site, erection, testing and commissioning of the following equipments and works including preliminary acceptance tests and performance guarantee. i) ii) iii) iv) v) vi) vii)
3.8.1

0.415/11 KV step up transformer as specified in the schedule of quantities. 11 KV Gang Operated Disconnecting Switch as required. 11 KV Drop Out Fuse Unit as required. Earthing Power and control cable. 11 KV Lightning Arrestors.

TRANSFORMER:

1.1 Make: The transformer shall be of reputed make 1.2 Codes & Standards: The transformer shall conform to IS: 2026 -Part I,II & III (latest edition), IEC 354 & IEC 76. 1.3 Service condition: The transformer shall be installed outdoor.Altitude & the range of temperature variation will be intimated by the concerned EE(EM). 1.4 Transformer Ratings: S/No Description 1. Continuous rating Overload capacity 2. 3. 4 5 6 7 8 Type Frequency No. of Phases Maximum Voltage (HV side) Maximum voltage (LV side) Vector group Connections i) HV windings ii) LV windings .. KVA As per IEC354 Oil Immersed 50 Hz +/- 3% Three 12 KV (rms) 0.440 KV (rms) Ynd11 Star, neutral earthed Delta solidly

49

9 10

Off-circuit taps on HV side Suitability of Bushings

11 12
3.8.2

Type of cooling Oil

+2.5% to (-)7.5% in steps of 7.5% LV side suitable for cable connection HV side suitable for overhead bushing connection (as per IS:3347 & IS:2029 ONAN As per IS 335

Fittings & accessories:

The transformer will be fitted with the following accessories: i. Dehydrating silicagel breather ii. Cooling radiators iii. Lifting lugs 2 nos iv. Off circuit tap changing switch with position indicator & locking device v. Drain valve with plug vi. Filter valve with plug vii. Earthing Terminals 2 Nos viii. Underbase mounting channels with 4 nos. uni-directional rollers ix. Thermometer pocket with thermometer x. Air release plug on top cover xi. Oil conservator with oil level gauge, oil filling hole with cover, oil drain plug xii. Rating & terminal marking plate xiii. HV outdoor type bushing terminals xiv. LV bushing suitable for cable connection
Tests:

All tests shall be carried out as per IEC:76, IEC:354 & IS:2026
3.8.3 GANG OPERATED AIR BREAK SWITCH /DO FUSE UNIT etc.:

Three phase 11KV outdoor triple pole Gang Operated Air Break Switch suitable for vertical mounting with complete operating mechanism, and drop out fuse of suitable rating complete with barrel fuse with metal parts,11 KV hooke stick,handgloves and rubber insulation mats. The scope will include the structure required for mounting the GOAB switches, Dropout Fuse Unit, lighting arrestors etc.fabricated out of structural steel and galvanized. The GOAB will conform to IS: 9920/1985
3.8.4 EARTHING:

Earthing of all outdoor equipment and transformer neutral will be as per IS: 3043 and Indian Electricity Rules , 1956 as amended up to date.

50 3.8.5 POWER & CONTROL CABLES: All LT power cables will be 1100 volts grade, stranded Aluminium conductor, PVC insulated, PVC sheathed armoured. All control cable shall be of stranded 2.5 sq.mm copper conductor except for CT which will of 4 sq. mm. The cables shall conform to IS: 1554 3.8.6 LIGHTNING ARRESTOR:

The lightning arresters shall have line terminals and ground lead terminals accommodating copper or aluminium conductor sizes from 13.3mm sq (6AWG) through 53.49mm sq.(1/0 AWG). The lightning arresters shall be furnished with a galvanized steel-mounting bracket suitable for steel channel cross arm mounting. Voltage rating Creepage distance Minimum Impulse withstand voltage Minimum power frequency withstand Wet Dry Power Frequency Spark over Front of Wave 1.2 x 50 Wave Maximum Discharge voltage at 10 KA

9 KV 229 mm 105 KV 45 KV 70 KV 15 KV 39 KV 34 KV 35 KV

The lightning arresters shall be manufactured and tested in accordance with IS 3070 (latest edition)
3.8.7 ACSR CONDUCTOR AND HARDWARE: ACSR conductors, connectors and all necessary hardware shall be provided to connect the HV terminals of the transformer to the Gang operated Air Break switch. All such hardware, conductors etc. shall be of reputed make and conform to Indian Standards. 3.9 3.9.1 TESTING AND COMMISSIONING TESTING

Testing of equipment and works shall be carried out as may be required as per the relevant I.S./ I.E.C. Standards.
3.9.2 COMMISSIONING

After the erection and testing of the equipment/works as per above, commissioning of the plant and works shall be carried out and here the term Commissioning shall mean the activities of functional testing of the complete system after erection and testing, including tuning or adjustment of the equipment for optimum performance

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and demonstrating to the Purchaser that the equipment performance meets the requirements of the specifications.
3.9.3 ACCEPTANCE TESTS AT SITE

The contractor shall carry out tests to obtain the guaranteed out put and efficiency at the site as per the plan prepared by him and submitted to the Purchaser before hand.

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SECTION IV SPECIFICATIONS FOR ELECTRONIC GOVERNOR

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SECTION- IV SPECIFICATIONS FOR ELECTRONIC GOVERNERS, OIL PUMPING UNIT AND INLET VALVES
4.1 SCOPE

This section of the specifications covers the design, manufacture, tests at works, supply, delivery at site, erection, testing at site and commissioning of electronic governors, OPU, butterfly valves complete with all associated auxiliary and ancillary equipment ,one set each for existing turbine sets alongwith necessary lubrication system, oil, water and air piping with valves and fittings, instrumentation, Controls and safety devices(as required), spares for five year operation , special tools etc. This section also includes the specification for re-wiring of Generator Control Panel for two nos. units. The scope of supply shall include all parts, accessories, spares etc., which are essential for satisfactory operation and maintenance of the complete system even though these are not individually or specifically stated or enumerated. Corresponding components, of all the equipment and spares shall be of the same material, dimensions and finish and shall be interchangeable. The contractor shall co-ordinate with the manufacturers of each of the above equipments supplier so that those are perfectly compatible to the existing turbines and match with all other relevant requirements.
4.2 INLET VALVES The main inlet valves of the turbines shall be butterfly valve type suitable for Gross Head and discharge required for over load capacity of the turbine / generator and connecting to the proposed penstock. The valve shall be suitable for all operating conditions of transient and maximum water hammer. The valves shall be operated by oil, pressure and closed by oil pressure/counterweight, so that it is capable of being closed under all emergencies. All associated equipments such as servomotors, oil pressure units, counterweights, etc., shall be included in the offer. The valve shall close automatically under normal and emergency shut down conditions. The valve will be complete with inlet pipe, outlet pipe, with expansion joint, by-pass arrangement if required for equalization of pressure on either side of the valve, etc.

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4.3

GOVERNING EQUIPMENT (DIGITAL ELECTRONIC GOVERNOR)

Each turbine shall be equipped with suitable electro-hydraulic governor conforming to IEC No. 308. The governor shall be of proven design capable of controlling speed / output under all operating conditions. The governing system shall comprise oil pressure system, governor actuator (Mechanical), governor electronic regulator, speed signal generator, oil pipe lines and deflector position restoring mechanism. The electronic regulating functions of governor i.e., speed / gate setting, deflector limit setting, start, stop, main circuit breaker position, shutdown etc. shall be operate the unit in manual mode in case governor electronic regulator is non-operative. Local control unit have the indicators for deflector position, speed of the unit and power generated by the unit.
a) GOVERNOR REGULATOR

The speed sensing shall be achieved through speed signal generator and line PT. The governor shall control, with stability, the turbine at any speed between 85 and 105% of rated speed when operating isolated from the system and while connected to the system at any load between zero and the load corresponding to maximum opening of the nozzles with both nozzles operating. Partial Shutdown/Controlled Action Shutdown device shall be used for automatically shutting down the turbine to the speed-no-load position by the operation of certain protective devices. It should be possible to operate deflector position manually at the local control unit.
b) GOVERNOR ACTUATOR

Governor actuator shall have the following provisions : Adequate capacity to operate the deflector servomotor and the needles through complete opening or closing strokes in desired time under all operating conditions. Hand control device for stroking of deflectors followed by needles so as to operate the machines manually even if electronic regulator is non-functional. Relationship between deflector position and needle stroke may be achieved through mechanical linkage utilizing a cam. Necessary data for relationship between deflector opening and needle stroke shall be given by turbine designer to the governor manufacturer. It should be possible to control the needles for off-cam position. Emergency shut down device, which can be operated manually at the actuator. Auto - clean double element filter to ensure that clean oil is supplied to control valves. The change over to standby filter and cleaning of clogged filter must be possible while unit is under operation. Means of independent adjustment of the opening and closing times of the deflectors and needles. The time for deflector closing under full load throw off shall be adjustable to limit the speed rise and pressure rise within guaranteed values.

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c)

Speed Signal Generator (SSG)

A toothed wheel type speed signal generator shall feed speed signal to the governor electronic circuits for speed regulation and operation of speed relays. The toothed wheel shall be mounted on the shaft and two magnetic pick-ups shall be mounted near the toothed wheel. One of the two pickups will work as redundant. The output signal of the magnetic pick-up shall be fed to the governor electronic cubicle. d)
Over Speed Device

A centrifugal type over speed protection device with provisions for electrical/ mechanical tripping shall be mounted on the turbine shaft (outside the turbine housing). The tripping points shall be adjustable independently for speed higher than the maximum speed; the turbine can develop with loss of full load. The mechanical tripping device shall directly actuate the governor actuator shut-down valve through a hydraulic connection. The electrical tripping contact shall be wired to the turbine terminal cubicle. The rotating parts of the over speed protection shall be protected by a guard. e)
Oil Pressure System

Each turbine will be provided with one independent oil pressure unit to supply oil under pressure to deflector and needle servomotors through governor actuator. Oil pressure system shall consist of one oil sump, two positive displacement pumps driven by AC motors, set of valves, pressure accumulator and accessories. The pressure accumulator can be installed over the sump or separately. The capacity of the pressure accumulator shall be sufficient to operate the deflector servomotor and needle servomotors with minimum pressure of normal operating range and under other normal operating conditions, through three complete servomotor strokes (3 x sum of deflector and needle servomotors volume) with the oil pump not operating. Design calculation of capacity of oil pressure system shall be furnished. The pressure tank shall be constructed in accordance with ASME Code for Unfired Pressure Vessels, for the maximum working pressure of the governing system. Necessary safety / control devices shall be provided on the accumulator. f)
Oil Pipe Lines

Oil pipe lines of adequate size along with necessary valves, connecting flanges, fittings and fasteners shall be supplied for interconnection between different hydraulic elements. All pipes above 15 mm internal diameter shall be carbon steel seamless pipes and up to 15mm size, will be stainless steel / copper pipes.

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4.4 TURBINE INSTRUMENTATION, CONTROL AND SAFETY DEVICES Each turbine shall be provided with a complete set of instruments, gauges, controls and safety devices for unit control board for monitoring the conditions of the unit during normal running and emergencies. The instruments and gauges for the turbines include, inter alia, pressure gauges, level indicators, temperature and flow indicators, position indicator, indicating lamps for status indication etc. The safety devices shall comprise equipment and devices for sensing abnormal operating conditions, for giving visual and audible annunciation and shut down the unit, if required. A list of these instruments, controls and safety devices are given in Tables A, B, & C. The items, quantities and location are to suit the requirements for safe and satisfactory operation of the generating units and the auxiliary systems.

TABLE-A SCHEDULE OF INDICATING/RECORDING INSTRUMENTS

Sl. No. 1. 4. 3. 4. 5 6. 7. 8. 9. 10. 11. 14. 13. 14. 15. 16. Description Device Type Total Quantity per unit Location

Pressure of shaft seal cooling water Gate limit and gate position indicators Unit speed indication (speed indicator) Speed level setting indicator Speed droop setting indicator Unit output meter Pressure of governor oil pressure system on panel, pressure accumulator & Governor separately Level of oil in oil pressure vessel Level of oil in sump tank Standby oil pump in operation indication Penstocks Pressure Pressure of turbine casing Pressure of draft tube Turbine bearing temperatures Indication of runner blade position cooling water pressure

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17. 18. 19. 20. 21. 24. Oil level in Turbine bearings Oil level in oil leakage unit Level of leakage water in turbine core Turbine discharge Servomotor locked/unlocked G.V. Shear pins fail TABLE-B

CONTROLS
Sl. No. 1. 4. 3. Description Total Quantity per unit Location

Gate Limit Control Auto-manual selection switch Speed level controller Speed droop controller Manual turbine gate controller Control for oil pump motor Control for compressor Turbine shut down control etc.

4
5. 6. 7. 8.

TABLE-C SAFETY DEVICES (FOR ALARM/SHUT DOWN)

Sl.No. 1. 6. 7. 8. 9. Governor oil pressure low Unit over speed shut down Manual emergency shut down Turbine bearing temperature high Type 2

Device Qty. per unit 3

Annunciation at 4 5

10. Turbine bearing oil low/high

58 TABLE -D LIST OF SPARES

Sl. No.

Item of Spare

Qty

Unit price

Remarks

I. GOVERNING EQUIPMENT (a) In case of electronic governor 1. PCBs

1 Set

(b) Oil Pressure Vessel Sump Tank and Pumps 1. 4. 3. 4. 5. 6. 7. 8. Oil pump for pressure oil supply Seals/packings (all types) Twin filter for oil Solenoids/coils Level relays Pressure switches Pump unloader Safety relief valve One 1 Set One 1 Set 1 Set 1 Set 1 Set 1 Set

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SECTION V SPECIFICATIONS FOR ALTERNATING CURRENT GENERATOR

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SECTION -V SPECIFICATIONS FOR ALTERNATING CURRENT GENERATORS, EXCITERS, VOLTAGE REGULATORS AND ACCESSORIES
5.1 SCOPE

This section of the specifications covers the design, manufacture, test at works, supply, delivery at site, erection, testing at site and commissioning of Horizontal AC generators complete with excitation system, voltage regulating equipment, neutral grounding and generator terminal equipments including CTs. PTs, (as per protection schemes) surge protection equipment, etc., and auxiliaries such as CO2 generator fire fighting equipment (if required), lubrication system (if required), oil, water and air piping with valves and fittings, instrumentation, controls and safety devices (as required), spares for 5 years operation of the plant, special tools and testing devices as described and detailed in the specifications and in the annexed schedule of requirements. The scope of supply shall include all parts, accessories, spares etc., which are essential for construction, operation and maintenance of the complete generator even though these are not individually or specifically stated or enumerated. Corresponding components of all the generators and associated equipments and the spares shall be of the same material, dimensions and finish and shall be interchangeable. The generator manufacturer shall co-ordinate with the turbine supplier so that the generators to be coupled to the turbine is matched in respect of speed direction of rotation, runaway speed, moment of inertia, overload capacities, coupling and other relevant requirements
5.2 TYPE AND RATING

The generators shall be of the horizontal shaft water wheel driven alternating current type. The direction of rotation shall be in accordance with turbine. The generator shall be capable of delivering maximum continuous output of 110% of the rated output at rated power factor. The tenderer may offer his nearest standard. The generator will be connected to the turbine directly or through speed increaser which will be supplied by the turbine supplier. All generator terminals shall be brought out of the stator frame for insertion of current transformer for protection, metering and surge protection apparatus. The generator neutral shall be grounded suitably and the generators shall be designed to safely withstand any mechanical/magnetic stresses resulting from either a three phase or a single phase fault.

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Each generator shall comply in all respects with the requirement of the latest issue of Indian Standard IS:4722 except where specified otherwise.
5.3 SPEED RISE AND RUNAWAY SPEED

The moment of inertia of the generator together with the moment of inertia of the turbine and flywheel (if any) shall be such that the maximum momentary speed rise on full load rejection shall not exceed 35 % of the rated speed. The generator manufacturer shall co-ordinate with the turbine manufacturer to limit the speed rise to this value. Each generator shall be designed and constructed so as to be capable of running for a period of 15 minutes at the maximum runaway speed. The runaway speed test shall be considered successfully if after undergoing the test no injury is apparent. The runaway speed test may be carried out at site for which the purchaser would provide suitable foundations that will withstand the test.
5.4 NOISE LEVEL

The noise level shall not exceed 90 db (A) when measured at a distance of 1m from any component of the generator.
5.5 INSULATION AND TEMPERATURE RISE

Insulation shall be provided as follows: (i) Stator winding (ii) Rotor winding

material corresponding to class F. material corresponding to class F.

The generator shall be capable of delivering rated output continuously at any voltage and frequency in the operating range at rated power factor without exceeding the following values of temperature rise over ambient temperature (30oC) (a) Stator winding 60o C (b) Rotor winding 60o C Stator Core 55o C The maximum temperature rise when the generator is delivering maximum output corresponding to continuous overload capacity for conditions stated above shall not exceed 60o C for both stator and rotor windings.

62 5.6 EFFICIENCY AND OUTPUT GUARANTEES

Within the limits of temperature rise specified in clause 6.5 above, the rated continuous output of the generator shall be guaranteed under penalty with a rejection limit of minus 2% for the rated generator terminal conditions. The weighted average efficiency of the generator shall be guaranteed under penalty with a rejection limit of minus 2%. The efficiencies shall be determined by the summation of losses method as specified in latest Indian Standard IS:4889. For any shortfall in the test value of output and weighted average efficiency (as determined below) from the guaranteed figures, the penalty shall be at the rate of 5% of the ex-works value of generator per generator for every 1% by which the test figure is less than the guaranteed figure. The weighted average efficiency = 0.30 x efficiency at full load + 0.50 x efficiency at 80% full load + 0.20 x efficiency at 60% full load. The penalty on account of output and efficiency shall be computed separately and the total amount of penalty shall be the sum of the two. The ceiling on the total amount of penalty on account of shortfall in the weighted average efficiency and output will be 10% of the total unit price of the generators. No tolerance shall be permitted over test figures of output. Tolerance in determination of efficiency shall be as per relevant Indian Standard.
5.7 BID EVALUATION

For the purpose of comparison of tenders, the equalization on account of differences in the weighted average efficiencies between various offers will be made on the same basis as indicated for penalties, i.e., the prices of generators with lower efficiencies will be loaded at the rate of Rs. 50,000.00 (Rupees Fifty Thousand) each 0.10% (one tenth) difference in weighted average efficiency as compared with the highest weighted average efficiency.
5.8 STRUCTURAL DETAILS

5.8.1 STATOR 5.8.1.1 Stator frame Frame shall be fabricated from M.S. plates and to be rigid enough to take the stresses transferred during core assembly. Ventilating ducts of suitable dimensions with wire mesh shall be provided on outer periphery of the frame. The frame shall have its own foundation plate, which shall be fixed with the existing foundation bolts if possible. The bidder shall coordinate with turbine supplier for details of centerline of stator frame to be kept. If necessary, suitable fabricated structure to be provided to fix the generator sole plates with the existing foundations.

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Stator core Stator core material shall be of high quality Electro technical sheet sheets of grade 50C 270 as per IS 648. Core punching may be in one piece or in segments. Punching shall be degreased cleaned & dried before varnishing. Core plate varnish with class `F properties shall be applied and over dried. Both side thickness of the varnish shall be restricted to 67 microns. Insulation resistance shall be measured and recorded. The segments shall be assembled in stator frame with the help of wedges. In case punching are in segments these shall be staggered in alternate layers. The punching shall be pressed between pressing plates welded with fingers as per bidders shop specifications. However, no looseness in core assembly shall be permitted. Bidders shall ensure monolithic stator core frame inside to outside. Assembled core shall be tested for core losses & hot spots if any. Proper record shall be kept for the test procedures & observations. After completion of core loss test, stator slot portion shall be painted with conducting varnish.
5.8.1.3 Stator Windings

Windings shall be multi turn with tip to tip class `F insulation system, manufactured by VPI system. The copper for elementary conductors shall be ETP as per IS 191. The section shall be rectangular in shape. The self insulation of elementary conductor shall be glass braiding with class `F varnish. Other insulation details like liners, packers & slot wedges shall also be of class `F material. Over hang portion of the winding on both sides shall be supported on suitable binding rings and lashed properly with packers of suitable thickness to provide adequate rigidity to the over hanging portion against dynamic forces . Three main & 3 neutral terminals shall be brought out.
5.8.2 ROTOR

5.8.2.1 Shaft & Spider

Generator shaft shall be of forged steel in one piece including extension for mounting the turbine runner. The shaft shall be heat-treated & accurately machined. Spider shall be of fabricated type with central bush to be shrink fitted on the shaft. Suitable arrangements shall be provided to fix the poles on the rotor body. Generator supplier shall coordinate with turbine manufacturer for mounting the turbine runner on the extended portion of the generator shaft and flywheel required for turbine governing. If any additional flywheel is required excluding generator rotor effect, it shall also be mounted on the generator shaft. The high frequency generator shall also be mounted on the generator shaft.
5.8.2.2 Poles

The field poles shall be laminated from stamped sheets of suitable thickness, and fixed between iron plates and fitted to the rotor rim/spider/rotor body. The form of pole shoe shall be such that sine wave of voltage at no load performance of the generator is achieved. Field windings shall be made of copper bends on edges. The subsequent turns shall be insulated with pretreated Nomex paper of suitable thickness of class `F properties.

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The body of the poles shall be isolated with glass insulation. Temperature limits for field windings shall be 60oC which shall ensure the reliability of operation and long life of insulation system. Pole coil connections shall be soldered with suitable grade of material.
5.8.2.3 Current carrying leads Suitable arrangement from diode wheel shall be provided for transferring power from diode wheel to the field poles. The field current shall be fed directly from diode wheel to the rotor winding through cable. The cable /current carrying leads shall be insulated with class `F insulating material. The leads shall be secured perfectly for any slippage due to centrifugal forces. 5.8.2.4 Bearings

There shall be two bearings one on either side of the generator, the bearing shall be of pedestal type with bearing sleeves in two half. The bearings shall be cooled by circulating oil coolers mounted in the oil bath. Suitable temperature measuring devices viz. RPT&TSD with two contacts shall be provided for measurement of bearing metal temperature. Suitable flow relays in water flows system with alarm & tripping for low water supply shall also be provided. Bidder shall furnish the complete details of bearing being provided alongwith the offer. The bearing metal temperature rise shall not exceed 20-25oC. The bearing shall be capable to withstand forces due to earthquake of magnitude 0.3g in both the directions.
5.8.3 Ventilation System

Cooling system for the generator shall be open ventilating type. Two fans of suitable design shall be provided at both ends of the generator rotor. These fans shall suck the cold air from sides and hot air after cooling stator winding & core shall be exhausted form the ducts provided on the stator frame.
5.8.4 Heating Of Generator In Stand Still Conditions

At each end of the generator heating elements of suitable capacity shall be installed to avoid condensation when the unit is under shutdown. The temperature to be maintained shall be 5oC above the surrounding temperature. Necessary thermostat to be provided for auto on/off of the heating elements.
5.8.5 Bearing Oil Coolers

Coolers shall be manufactured with cupro-nickel tubes grade Cu Ni 30 as per IS 1545. Adequate surface shall be provided to evacuate the bearing losses. These shall be plugged to the oil bath. Necessary cooling water flow arrangement shall be provided for oil cooling. Oil temperature at full load shall be less than 25oC.

65 5.9 FIRE PROTECTION FOR GENERATOR (OPTIONAL)

An automatic carbon dioxide fire protection system complete with CO2 cylinders, ring headers, discharge nozzles, temp. detectors etc., shall be provided as a common system for all the generators. The temperature detectors shall be of the rate of the rise of temperature type. Automatic control shall be arranged to discharge CO2 into the generator in the event of operation of temperature detector or of the differential relay of the generator (if provided). The system shall be complete with manual operation arrangement to release CO2 and with all necessary pipes, fittings, directional valves, etc.
5.10 OIL AND GREASE

The tenderer shall indicate this requirement and give his recommendations with detailed specifications regarding type of oil/grease to be used for lubrication of generator bearings. The oil if used for generator bearing lubrication, etc., shall be identical with that used for the pressure oil system of governor. The generator and turbine manufacturers shall cooperate to ensure that their recommendations regarding oil are identical. The first filling of oil with 20% extra shall be supplied alongwith the generator.
5.11 THE FLYWHEEL

A separate flywheel of ample dimensions shall be supplied in case the required moment of inertia for limiting the speed rise/runaway speeds in case not available from the generator rotor (through the speed increaser, if envisaged). Necessary provision for receiving the piston of the brake cylinder on application of brakes shall be made in the flywheel.
5.12 EXCITATION SYSTEM 5.12.1 General

The excitation system of static type consisting of high performance fully controlled solid state converter bridge, dry type excitation transformer of suitable capacity, static voltage regulator, field breaker, field flashing unit, field discharge resistor, etc., conforming to acceptable relevant international standards may be supplied. The excitation shall be completely described in the tender. Brushless excitation system or self-excited self-regulated excitation may also be offered.

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5.12.2

Generator Field Discharge Equipment

A totally enclosed field air circuit breaker, drawout type, complete with auxiliary contacts, capable of breaking, without generating dangerous overvoltage, the maximum field current that can occur under conditions of normal operation or when interrupting the transient D. C.. component of the field current due to a three-phase fault at generator terminals, shall be furnished with each set of excitation equipment. The field circuit breaker shall be suitable for both manual and electrical operation. Alternatively, an A. C. circuit breaker on the secondary side of the rectifier transformer instead of D. C. field circuit breaker may be offered. The field circuit breaker discharge contacts, discharge resistors, or other equipment shall be mounted together to form a self-supporting assembly of the excitation control equipment of each generator. A suitable hinged door, locking handle, inspection windows, foundation bolts etc., shall be provided with each excitation cubicle.
5.12.3 Automatic Voltage Regulator (If Not Already Included In the Excitation System)

An automatic voltage regulator, complete with an enclosed master element, voltage adjusting rheostat, contactors, etc., shall be provided with each generator for the automatic control of the generator exciter. The voltage regulator shall be anti-hunting. The voltage regulator shall be capable of maintaining the generator terminal voltage at and pre-set value and at the same time sharing the reactive kVA of the load between the two similar units. The voltage regulator shall be sensitive to the charge of plus or minus 0.5 (one half)% 0f normal voltage (average of three phases) of the generator when operating under steady load conditions for any load or excitation within operating range and shall initiate corrective action without hunting. After the initial maximum voltage following any load rejection up to 110 (One hundred and ten)% of rated load, the automatic voltage regulator shall restore the terminal voltage to a value not more than 5(five)% above or below the voltage being held before the load rejection and shall maintain the voltage within these limits throughout the period of generator overspeed. The voltage regulator shall be provided with cross-current compensating devices for parallel operation of generators.

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A voltage adjusting rheostat suitable for manual and also for motor operation by remote control shall be furnished with each voltage regulator equipment. The range of the voltage control shall extend from 90 (ninety)% to 110 (One hundred and Ten)% of rated voltage of generator.
5.13 LINE TERMINAL AND NEUTRAL GROUNDING CUBICLES

The generator suppliers shall supply 1 no. terminal cubicle for each machine housing surge capacitor, potential transformers, current transformers, lightning arresters, cable boxes, etc., as given in the enclosed drawing. The cubicle shall be complete with necessary tappings for excitation system, etc. The rating of the CTs for AVR shall be decided by the supplier taking into account the requirements of AVR. The generator supplier shall neutral grounding cubicle one for each machine housing single phase distribution transformer, secondary loading resistor, current transformer, cable boxes, etc., as shown enclosed drawing. The cubicles shall be sheet suitably compartmentalized with doors and shall be furnished complete with base mounting arrangement, foundation bolts, etc. The internal illumination for cubicles shall be provided with guarded lamps with on/off switches. Copper/Alluminium conductors of appropriate size shall be used for bus bars and connections in the cubicles. The bus bar and main connecting conductors shall be suitably insulated to make them compatible with generator temperature rise and insulation. The support insulators for the bus connection will be provided as necessary. GI earth bus of adequate cross section will be provided in the cubicle.
5.14 POTENTIAL TRANSFORMERS

The potential transformers will be single phase, epoxy cast, dry type units. Potential transformer will be protected on primary and secondary side by current limiting fuses. The PT shall conform to IS:3156. The potential transformers shall berated as given in the drawing.
5.15 CURRENT TRANSFORMERS

The current transformer will be epoxy cast, dry type unit conforming IS:2705. The current transformer shall be designed to withstand the thermal and magnetic stresses resulting from the maximum short circuit current.

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The technical requirement and location of the CTs are given in the drawing. The generator suppliers shall supply suitable transformer for the protection scheme and these shall be installed in the neutral grounding and line terminal cubicles. The current transformers should be suitable for metering and protection. The following protections are recommended: (i) Three-pole differential relay (87 G)-3 CTs on the neutral of the generator and 3 CTs on the phase. (ii) Over-current and earth fault relay (50/51 and 64) (iii) Rotor earth fault protection single stage ( 64 R) (iv) Stator earth fault protection (64 G) (v) Over voltage protection (59) (vi) Field failure protection (40) (vii Negative phase sequance (46) (viii) Reverse Power Protection (32) (ix) Over speed frequency protections (81) (x) Voltage restrained over current relay (SIV)

In case the generators are provided with static excitation system with excitation transformers, high set instantaneous over-current relay (50) IDMT and over-current relay (51) would be provided in the tapping for excitation transformer for protection of excitation transformers.
5.16 LIGHTNING ARRESTORS

The lightning arrestors shall be heavy duty indoor station class non-linear resistor type suitable for repeated operation to limit voltage surges on alternating current power circuits and to interrupt power follow current. The arrestors shall conform to IS:3070 (latest edition) Part-I. The nominal discharge current of lightning arrestor shall not be less than 10KA.
5.17 SURGE CAPACITORS

The surge capacitors shall conform to the latest edition of IS:2834 and shall be rated 0.25 microfarad. The capacitors shall be connected in parallel with lightning arrestors and shall be provided with a built-in discharge resistor. The capacitor shall be suitable for indoor mounting.

69 5.18 UNIT CONTROL BOARD AND GENERATOR INSTRUMENTATION AND CONTROL

The generator supplier shall supply all equipment and devices for control, instrumentation and safety relating to the generator. These together with the equipment supplied by the turbine supplier shall constitute a complete and coordinated set of instruments, gauges, and control and safety devices for control of the units during normal running and in emergencies. Indicating instruments, gauges, control and safety devices will be mounted on the unit control board to be supplied by the generator supplier. The turbine supplier shall supply necessary loose items for mounting on the unit control board. The generator manufacturer shall fully coordinate with the manufacturer of turbine to ensure a neat and functional arrangement of the cubicles. A tentative list of indicating instruments, controls and safety devices to be supplied by the generator supplier is given in Tables A. The generator manufacturer may increase/decrease items according to requirements to suit the type and design and also for proper and satisfactory operation of the units. The alarm and annunciation panel with all necessary annunciation relays, aux relays, alarm bell, terminal bolts etc., and adequate number of alarm annunciation fascia windows for both turbine and generator shall be provided. The generator manufacturer shall fully co-ordinate with the turbine manufacturer in this regard.
5. 19 SPARES The unit rates shall be quoted for the spares as listed in Table-B The tenderer shall also indicate in the tender any additional spares that he would recommend for 5 years operation and furnish item wise unit prices for the same. 5.20 TESTS The first generator shall be completely assembled at works and types tests as specified below shall be conducted on the assembled unit and auxiliaries as per the latest edition of IS:4722. 5.20.1 Type Test on First Generator

(a) (b) (c) (d) (e) (f)

Temperature rise test. Dielectric test. Efficiency test. Excess current test. Runaway speed test. Moment of inertia of rotating parts (by mutual agreement between the purchaser and the contractor)

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(g) (h)

Wave form Determination of characteristic: (i) Reactances Synchronous, transient, subtransient, negative phase sequence and zero phase sequence. (ii) Rated current, zero power factor lagging saturation curve. (iii) No load and short circuit saturation curve.
Routine Tests on all the Generators

5.20.2

(a) (b) (c) (d) (e) (f)

High voltage test on stator coils and stator sections and on assembled stator. High voltage test on field coils and poles. Insulation resistance tests. Impedance and voltage test on field coils. Accuracy test for RTDs and dial type thermometers. Hydraulic tests on oil, and air coolers.

5.20.3 Tests on Exciters and Regulating Equipment (For Rotating Exciters) (a) High voltage test.

(b) (c) (d) (e) (f) (g) (h)

Temperature rise test. Measurement of resistances. Measurement of insulation resistance. Regulation test. Commutation test. Excitation response ratio. Routine tests on static excitation equipment.

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5.20.4 Additional test, if any, as recommended by the supplier. 5.20.5 Tests At Site

Site test for each generator shall include the following: (a) Mechanical run. (b) Measurement of stator and rotor winding insulation resistance. (c) High voltage dielectric test. (d) Measurement of shaft voltage (if applicable) (e) Measurement of stator and rotor winding resistance. (f) Phase sequence test. (g) Load acceptance and rejection test at selected loads from no load to full load. (h) Overall response of machine and excitation system to system voltage changes. (i) Adjustment of AVR. (j) Synchronising test. (k) Checking and commissioning of various other auxiliary equipment.
5.20.6 Test on other equipment like CTs, PTs, Las shall comply with the routine tests, etc., as per relevant standards.

Test report for all type tests on the generator, CTs, PTs, etc., carried out on similar equipment already supplied shall be furnished for approval.
5.21 TESTING EQUIPMENT

A list of field testing equipment along with item-wise rental prices rental prices shall be indicated in the tender.
5.22 SPECIAL TOOLS

The contractor shall supply a complete set of special tools and other equipment that may be necessary or desirable for operation and maintenance of the generator and auxiliary equipment of his supply. The tenderer shall submit a list of the above and include the price in tender. Any special reamers or broaches and brazing equipment for all work which must be done in the field, shall be provided by the contractor.

72 5.23 DRAWINGS

In addition to the drawings called for in Section II the following drawings and data shall be submitted with the tender. The drawings containing all the information required for designing the civil works shall be supplied within 60 calendar days of the placement of letter of intent: (i) The general arrangement and overall dimensions of the generators, exciters (where applicable) and bearings, and showing positions of main and neutral terminals. Description of lubrication system alongwith drawings. Physical and schematic drawings of excitation system and AVR alongwith descriptive literature. Graphs showing predicted characteristic of the generator. Generator layout drawings showing overall dimensions and layout of all ducts, cables, piping, relative positions of auxiliaries, etc.

(ii) (iii)

(iv) (v)

5.24

GUARANTEED TECHNICAL PARTICULARS

The guaranteed and technical particulars of generator and associated auxiliary and ancillary equipments shall be furnished in the tender as per schedule of Guaranteed Technical Particulars.
5.25 SCHEDULE OF REQUIREMENT

0.8 Pf 3.3kV 50Hz +3%, 3 phases horizontal synchronous generators with excitation system. Each generator shall be equipped as follows and in accordance with the specifications described in the preceding clauses. One No. One No. One set Generator stator complete with frame, soleplates, core, winding with accessories and terminals. Generator rotor complete with shaft, spider rim, poles with windings and accessories. Bearings.

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One set One set One set One set One set One No. One One One set One set One set One

Anti-condensation space heater. Excitation and voltage regulation equipment. Fabricated base plate for generator and its bearings (for horizontal machines). Resistance type temperature detectors. Dial thermometer with electric contacts for alarm and trip for bearings. Multi-point temperature indicator cum recorder. Neutral grounding cubicle. Line terminal cubicle. Unit gauge panel with instruments, controls and safety devices for generators Mechanical overspeed devices with electrical contacts. Bearing oil coolers Dome light.

COMMON EQUIPMENT FOR BOTH GENERATORS i) One set of special tools. ii) iii)

One set of testing devices. One set of spares for five years normal operation of the generator.

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TABLE A
SCHEDULE OF INSTRUMENTS AND SAFETY DEVICES FOR EACH UNIT Sl. No. Purpose Type of Qty. Remarks instruments

01 02 03

Temperature of stator windings Temperature of stator core Temperature of pedestal bearings

PRT PRT

3 3

PRT shall be 100 platinum resistance & 3 wire system for indication & recording PRT shall be 100 platinum resistance & 3 wire system for indication & recording PRT shall be 100 platinum resistance & 3 wire system for indication & recording Indication / recording Alarm / Trip Indication / Record Control Indication / Alarm Indication / Alarm

Bearing sleeves 04 05 06 07 Temperature of cooling water outlets for bearings Control of stator heaters Flow of water in oil coolers of bearings Level of oil in oil baths for bearings

PRT TSD PRT Thermostat Flow Relay Level Relay (Low & High)

2 2 2 1 1 1

TABLE B
LIST OF MANDATORY SPARES

1.

2.

3. 5.

5. 6.

1/3rd of stator windings of one generator with necessary slot insulation including wedges. Two Nos. complete field coil with connecting clamps and all necessary insulation. Set of shells of bearing One of each type of PCB, auxiliary relay contained in the excitation system Diode wheel complete with diodes. Oil cooler for bearing

1 Lot

2 Nos.

1 Set 1 Set

1 No. One

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SECTION VI SPECIFICATIONS FOR TRANSFORMERS

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SECTION VI TECHNICAL SPECIFICATIONS TRANSFORMERS

6.1 SCOPE

The scope of work includes design, detailed engineering, manufacture of equipment, testing at works, assembly at manufacturers works before dispatch, packing transportation, loading, unloading, supply and delivery F.O.R. destination, storage at site, erection, inspection, testing and commissioning of following equipment/system and works including preliminary acceptance tests and performance guarantee. i.
6.2

.4/33 kV or .4/11 kV as the case may be.

CODES AND STANDARDS

A list of applicable Codes of Practice and Standards has been given in Annexure-5/1. These shall be the latest editions including all applicable official amendments & revisions as on date of opening of bid.
6.3 SERVICE CONDITIONS

The equipment to be supplied under this specification will be installed outdoor at an altitude below 2000 meters and shall be suitable for satisfactory operation under the site conditions as described in Project Details.
6.4 6.4.1
Sl. No. 1. 2. 3. 4. 6. 6. 7. 8. 9. 10. 11.

GENERATOR- TRANSFORMERS TRANSFORMER RATINGS/CHARACTERISTICS The ratings/characteristics of the transformers shall be as below:
Particulars Continuous KVA rating Type Frequency No. of Phases Maximum voltage on H.V. side Maximum voltage on L.V. side Vector group Connections i. H.V. windings ii. L.V. windings Off-load taps on H.V. side (for H.V. variation) Suitability of bushings Type of cooling Ratings/Characteristics As required in schedule of works Oil immersed 50 Hz + 3% Three 36 kV (r.m.s.) / 12 3.6 kV (r.m.s.) / .416 kV Y n d 11 Star, neutral solidly earthed Delta (+) 2.5% to (-) 7.5% in steps of 2.5% L.V. side suitable for cable box/connections. H.V. side : condenser bushings ON

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6.4.2

DESIGN AND CONSTRUCTION

i.

The transformer shall be 3-phase, oil immersed with core type of construction, tank mounted radiators, and suitable for outdoor service as step-up transformer. Adequate Ceramic ball/spacers shall be provided in the core/winding for circulation of oil so as to ensure proper cooling. All apparatus shall be designed to ensure satisfactory operation under such sudden variations of load, frequency and voltage as may be met-with under system working conditions including those due to short circuits. To minimize the eddy current losses in the windings, CTC shall be used wherever required. Similarly, for minimizing the stray losses, magnetic shield in yoke, magnetic shunt in tank walls, bushing turrets, clamps, flitch plates etc. shall be provided, wherever required. The design value of eddy current losses and stray losses shall be indicated by the manufacturer as a % of load losses.

ii. iii.

All materials used in the manufacture of the transformers shall conform to Codes and Standards as above. Design of all outdoor apparatus, including bushing insulators with their mountings shall ensure that no pockets be formed wherein collection of water can take place. Corresponding parts, interchangeable.
RISE,

iv.
6.4.3

which

are

liable

for

replacement,
&

shall

be

TEMPERATURE RATING

OVER-LOAD

CAPACITY

CONTINUOUS

i.

Each transformer shall be capable of operating continuously on any tap at normal rating under service conditions given in Clause 6.6.1 without exceeding following temperature rises, over maximum ambient temperature of 45 deg. C: a. b. c. 50 deg. C in winding (by resistance) 45 deg. C in oil (by thermometer) The temp. of hot spot in the winding not to exceed 90 deg. C when calculated over max. annual weighted average temp. of 40 deg. C & 105 deg. C at worst ambient of 45 deg. C.

ii. iii.

Transformer shall be capable of delivering rated current at an applied voltage upto + 10% of rated voltage without exceeding the temperature limit. The limits of temperature rise mentioned above and over-load capacity as per IEC-354 (1993) shall be satisfied by the manufacturer by carrying out the heat run test at the lowest negative tap. This test shall be carried out by feeding the following losses : (Total max. losses at 75 deg. C at highest current tap ) x 1.1

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iv.

Safe over-load capacity of the transformer and the duration of over-load for ON cooling under maximum temperature conditions (Clause 6.6.3(i) above) without any damage to the winding or harmful effects on the insulation shall be as per IEC 354 and shall be clearly stated in the tender. The transformers shall be operable without exceeding temperature rises, winding gradients and hot spot at any particular tapping at the rated MVA for 10% of the voltage corresponding to that tapping.

v.

6.4.4

TAP CHANGER

The range of transformer taps shall be as per serial no. 9 of table under clause 6.6.1. OFF - circuit tap changer having local manual control and with following features shall be provided: i. ii. iii. iv. v.
6.4.5

Designed for sustained over current of not less than 150% of rated current of the winding. It shall not occupy any intermediate position between clearly marked tap positions. It shall be capable of repeated operation and withstanding S.C. forces. It shall have integral handle with pad-locking facility at every tap position. The tap charger shall have tap position indicator.
CORE

i.

Working flux density under rated voltage shall not exceed 1.55 Tesla at normal voltage, frequency and voltage ratio. Overfluxing shall be as per relevant standards. Tenders with higher flux density than specified shall not be considered. The core shall be built up with thin laminations of high grade, non-ageing, low loss, high permeability, cold rolled super grain oriented silicon steel, known as HIBIMOH or low loss CRGO silicon steel of maximum 0.27 mm or low lamination thickness specially suitable for transformer cores. The laminations shall be annealed in a non-oxidizing atmosphere to relieve stresses and restore original magnetic properties of material after cutting and punching operation. The laminations shall be treated after cutting etc. to remove all burrs and checked during stage inspection. These shall be coated with baked enamel insulation coating. The insulation shall be inert to the action of hot transformer oil and be perfectly adhesive. Paper and varnish insulation shall not be accepted. Particulars of proposed insulation shall be stated in the tender.

ii. iii.

iv.

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v.

The core shall be rigidly clamped and/or bolted to ensure adequate mechanical strength and to prevent vibrations during operation. The bolts used in the assembly of the core shall be suitably insulated and the clamping structure be so constructed that the eddy currents will be minimum. The design of magnetic circuit shall be such as to avoid static discharges, development of short circuit paths within itself or to the earthing clamping structure and the production of flux components at right angles to the plane of the lamination which may cause local heating. Number of steps in the limb and yoke shall be matching and dimensionally identical to minimize the effect of cross-fluxing and for better mechanical strength. The core shall be provided with lugs suitable for lifting complete core and coil assembly of transformer and be fixed in the tank so that its shifting will not occur when the transformer is moved or when a short circuit occurs. Every care shall be exercised in selection treatment and handling of core steel to ensure that the laminations are flat and that finally assembled core is free from distortions. Supporting frame of the core shall be so designed as to avoid presence of pockets which would prevent complete emptying of the tank through the drain valve or cause trapping of air during filling. Oil ducts, where necessary, should be formed across the plane of the lamination and be given a suitable slope to assist oil circulation. The overall design of core and winding should ensure free flow of oil without obstruction. Frame work and clamping arrangement shall be earthed by connecting to the tank body through a copper strip. Yoke bolt area should be compensated if bolts are used for fastening of the core. Also, flitch plate area will not be counted in core area. The insulation of core to bolts and core to clamp plates shall be able to withstand a voltage of 2 kV (RMS) for one (1) minute. Core and winding shall be capable of withstanding shocks during transport, installation, service etc. and adequate provision shall be made to prevent movement of core and winding relative to tank during these conditions.

vi.

vii.

viii.

ix.

x.

xi.

xii.

xiii.

xiv.

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xv. xvi. xvii.

All steel sections used for supporting the core shall be thoroughly sand blasted after cutting, drilling and welding. CRGO used shall be procured from reputed vendor. The tenderer shall indicate the maximum flux density allowable continuously, as well as for time intervals of 1 minute and 5 secs. and the limit of flux density at which core material used by them saturates.

xviii. The name of the core material must be mentioned in the tender. The successful tenderer shall be required to furnish magnetization curves of the core material/design calculations and such other data/documents deemed fit by the purchaser for being satisfied that flux density is as desired. xix. Purchaser may inspect the built-up core for verification of flux density for which all facilities shall be provided. Core may also be inspected during horizontal assembly, built up assembly.

NOTES:

i.

The above flux density has been specified to meet with the over fluxing of the core due to temporary over voltage of the order of 31% for 1 min., 44% for 5 sec. that may appear in abnormal conditions such as those following sudden loss of large loads/ tripping of Generator-breaker. Yoke bolt area and flitch plate areas shall not be counted in the net core area, if these are provided for fastening of core. The design of limb and yoke shall be so coordinated that there is no cross fluxing at the joints.

ii.

iii.
6.4.6

WINDINGS

i. ii.

The conductor used for the winding shall consist of solid drawn high conductivity electrolytic grade copper free from scale and burrs. In case of copper strip, the corners shall be rounded-off to eliminate risk of injury to internal insulation during winding & other operations. No strip Conductor wound on edge should have width, exceeding six times its thickness. All permanent current carrying joints in the windings and leads shall be welded or brazed. Preference shall be given to a winding with a continuous conductor. The windings shall be pre-shrunk during manufacture so as to avoid any chances of any further shrinkage taking place during service. Provision shall be made so that it will be possible to take up this shrinkage by means of adjustable clamping screws and end rings in case of occurrence of shinkage.

iii.

81

iv.

The voltage between adjacent coils shall be kept as low as consistent with the given design. The windings shall be so designed that all coil assemblies of identical voltage ratings shall be interchangeable and field repairs to the windings can be made readily without special equipment. The coils shall be supported between adjacent sections by insulation used in the assembly of the windings. The windings shall be arranged so as to ensure free circulation of oil and to reduce hot spots in the windings. All threaded connections shall be provided with locking facilities. All leads from the windings to the terminal board and bushings shall be rigidly supported to prevent injury from vibration. Guide tubes shall be used wherever practicable. The winding shall be designed to reduce the out of balance forces in the transformer to a minimum at all voltage ratios. The windings shall be clamped securely in place so that they will not be displaced or deformed during short circuits. The assembled core and winding shall be dried and suitably impregnated before removal from the treating tanks. The insulation of the coils shall be treated suitably to develop full electrical strength of the windings and for this, hot oil vacuum impregnation process shall be used for improving the electrical and thermal properties of insulating paper. All materials used in the insulation and assembly of the windings shall be insoluble, non-catalytic and chemically inactive in the hot transformer oil and shall not soften or otherwise be adversely affected under the operating conditions. The conductors shall preferably be CTC, transposed at sufficient intervals in order to minimize eddy current and equalize the distribution of current and temperature along the winding. Windings shall preferably be made in dust proof condition. Tappings shall be so arranged as to preserve the magnetic balance of transformer at all voltage ratios. Tapping winding shall be provided separately from the main HV winding.

v.

vi. vii. viii.

ix. x.

xi.

xii.

xiii.

xiv. xv.

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xvi. xvii.

Coil assembly and insulating spacers shall be so arranged as to ensure free circulation of oil and to reduce the hot spot of the winding. Inter-coil and inter-turn insulation shall be designed to ensure that di-electric stress is uniformly distributed through out the windings under all operating conditions.

xviii. The insulation of transformer windings and connections shall be free from insulating compound which are liable to soften, ooze out, shrink or collapse and be non-catalytic and chemically inert in transformer oil during service. xix. The windings shall be braced to withstand shocks due to rough handling and forces due to short circuits, switching or other transients.

6.4.6.1 Reinforced Insulation

At each end of HV winding an electrostatic shield and/or cap & ring shall be provided so as to increase the ratio of the electrostatic capacity between turns as compared with the electrostatic capacity of the high voltage winding to earth and to the low voltage winding. HV winding shall preferably be interleaved.
6.4.6.2 Current Density

The design of the transformers shall ensure that the current density of the HV windings at the lowest tap does not exceed 250 A/cm2, and that of the LV windings 200 A/cm2.
6.4.7 INSULATION LEVEL

6.4.7.1 The insulating material to be used, shall be of class F as specified in the latest relevant standards. 6.4.7.2 The dielectric strength of winding insulation and of the bushings shall conform to values given in IS: 2026/1981 part-III amended upto date except for the changes made in this specification. 6.4.7.3 The impulse test and power frequency test voltage shall be as per the relevant IS/Standards followed. 6.4.7.4 Short Circuit Strength and Provision of Separate Tapping Coil for Regulation

Transformers shall be designed and constructed to withstand without damage the thermal and dynamic effects on external short circuits for 5 seconds under conditions specified in IS: 2026 (Part-I)- 1977. The transformers shall be provided with separate tapping coil to limit the short circuit forces.

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The position of the tapping coil shall be so arranged that at extreme negative tap, the percentage regulation is less than at normal tap. The bidders shall submit test certificates of short circuit test, if already done on the offered design and rating. However, the thermal and dynamic ability to withstand short-circuit forces shall be demonstrated by calculations.
6.4.8 IMPORTANT TECHNICAL PARTICULARS

Important technical particulars of the transformers to be guaranteed by the tenderers shall be as per formats given in the concerned section.
6.4.9 TOLERANCES

Various tolerances on technical parameters shall be as under :i. Impedances: Maximum tolerance allowed on impedances at all taps shall be as per IS:2026 (Latest edition). Over-Load Transformers shall be tested for over-load conditions as specified in latest edition of IEC-354/1993 , which shall be read with IEC-76/1993. Weights No negative tolerance shall be allowed on Weight of Copper, Weight of CRGO & Weight of Oil etc. Losses No positive tolerance shall be allowed on guaranteed No load losses, Load Losses and Auxiliary Losses individually at rated voltage, current, principal tap & 75oC temp. Temperature Rise Test No positive tolerance shall be allowed on Temperature Rise of Oil, Windings, Windings Temperature Gradients & Hot-Spot Temperature than the Guaranteed Values.
6.4.10 COOLING

ii.

iii.

iv.

v.

Transformers shall have ON type of cooling. Radiators shall be of pressed steel, tank mounted, bolted type. Bolted, gasketted and flanged connections shall be used for connecting the radiators to the tank. Radiators shall be designed to withstand the pressure conditions specified for the tank and shall be designed so as to be accessible for cleaning and painting to prevent accumulation of water on the outer surfaces.

84

Radiator shall be provided with: i. ii. iii. Top and bottom shut-off valves and blanking plates. Bottom drain plug, top filling plug and air release plug. Lifting lugs. Valves and connections shall have following features: i. ii. iii.
Insulating Oil

Sluice type valves with hand wheels. Clear indication of open and closed positions. Provided with blanking plates and screwed plugs.

i.

Sufficient insulating oil of NAPTHENIC TYPE (Made from NAPTHENIC CRUDE) conforming to BS: 148/IEC:296 class-I/IV shall be supplied for first filling of each transformer. An extra quantity of transformer oil equal to 10% of the total quantity of oil shall also be supplied. If the transformer is to be supplied gas filled, particular attention shall be paid to deliver the oil at site free from moisture and of uniform quality through out in non-returnable epoxy coated steel drums. The quantity of oil for first filling of each transformer shall be stated in tender along with manufacturer of the oil to be supplied.

ii.

iii.

iv.

v.
6.4.11

Use of inhibitors in oil shall not be resorted to.

SUPPRESSION OF HARMONICS

The transformer shall be designed with particular attention to suppression of harmonic voltages especially the 3rd and 5th harmonics. Percentage of harmonics at normal voltage and at maximum system voltage shall be stated in the tender.
6.4.12 TRANSFORMER TANK

The transformer tank and cover shall be oil tight and fabricated from good commercial grade low carbon steel of adequate thickness. The weld procedure and performance shall be in line with ASME-BPV-9 /IS:2062. The tank and the cover shall be of welded construction. All seams shall be welded and where practicable they shall be double welded. The tank shall be designed and constructed for vacuum filling of oil and be capable of withstanding without leakage or distortion continuous internal gas pressure of 0.7 atmosphere with oil at operating level. The tank cover shall be bolted with the lower position of the tank and the transformer

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design shall make it possible to move the complete transformer unit by skidding in any direction without injury when using plates or rails. . Where the design of the tank is such that the bottom plate will be in direct contact with the surface of the foundations, the bottom plate thickness shall not be less than 20mm. Man holes/inspection covers with welded flange and bolted covers shall be provided on the tank cover. The inspection covers shall be of sufficient size to afford easy access to the lower ends of bushings, terminals etc. All bolted connections to the tank and connections between sections of the tank shall be provided with suitable flanges, with properly spaced bolts and suitable oil tight gasket which shall give satisfactory service under operating conditions. The thickness of M.S plate for bottom, sides and top of the tank shall be adequate as per CBIP recommendations. The main body including tap changing compartments, radiators and coolers shall be capable of withstanding full vacuum of 760mm of mercury when empty of oil. The design of tank, its shape, proportions, weight of material and construction shall be such as to best facilitate oil circulation and to ensure against transmission or magnification of noise or vibration, which might be injurious or objectionable. The transformer tank alongwith radiators and other accessories shall be tested for vacuum and pressure test as per CBIP recommendations. Suitable guides shall be provided for positioning the various parts during assembly or dismantlement. Adequate space shall be provided between the cores and windings and the bottom of the tank for collection of any sediment. Lifting eyes or lugs shall be provided on all parts of the transformer requiring independent handling during assembly or dismantlement. In addition, the transformer tank shall be provided with lifting lugs and bosses properly secured to the sides of the tank for lifting the transformer by using hydraulic or screw jacks. As far as possible, the transformer tank and its accessories shall be designed without pockets so that gasses may not collect. Where pockets cannot be avoided, pipes shall be provided to vent the gas into the main explosion pipe. The vent pipes shall have a minimum inside diameter of 15mm except for short branch pipes which may have 6mm minimum inside diameter. The tank cover shall be provided with pockets one for mercury in glass thermometers and two pockets for the bulbs of oil and winding temperature indicators. Minimum depth of the thermometer pockets shall be 10'' from top oil level. Protection shall be provided where necessary, for each capillary tube. The thermometer pockets shall be fitted with a captive screwed top to prevent ingress of water. The pockets shall be located in the position of maximum oil temperature at CMR and it shall be possible to remove the instrument bulbs without lowering the oil in the transformer tank.

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Each transformer tank shall be fitted with the following valves/plugs with standard screw connections for external piping: i. ii. iii. iv. v. One filter-cum-oil drain valve with plug or blanking flange (size 80mm/ 100mm/ dia) and so placed as to completely drain the oil of the transformer. One no. top filter valve of size 50mm near the top of the tank diagonally opposite to filter-cum-drain valve. At least two nos. 15 mm/ dia air release plugs suitably located on top of cover. One pressure relief valve/device to operate at a pressure below the test pressure for the tank. Suitable no. of jacking bolts shall be provided on tank cover and inspection covers.

The design of the tank, the lifting lugs and bosses shall be such that the complete transformer assembly filled with oil can be lifted with the use of these lugs without any damage or distortion. All bolts and nuts used in connection with tank and fittings shall be galvanized/Zinc plated & passivated. The tank shall be provided with suitable lugs for the purpose of grounding with a mild steel flat.
6.4.13 CONSERVATOR TANK

i. ii.

iii. iv. v. vi. vii. viii.

An oil conservator tank preferably air cell type complete with sump, filling hole and drain valve shall be mounted above the radiators and located so as not to obstruct taking of bare connections from the transformer terminals. The capacity of the conservator tank shall be adequate to meet the requirements of expansion of the total cold oil volume in the transformer and cooling equipment from minimum ambient temperature of minus 5 deg.C. to 115 deg.C. The minimum indicated oil level shall be, with the feed pipe from main tank cover, under not less than 15mm depth of oil and the indicated range of oil level shall be from minimum to maximum. One magnetic type oil level gauge with alarm contacts shall be mounted at a convenient height to be read from ground level. Prismatic oil level gague shall also be provided. Oil level at 30 deg.C. shall be marked on the gauge. The conservator tank shall have one oil filling hole with cap at the top and drain valve of appropriate size at the bottom. A shut off valve shall be provided at the conservator to cut off supply to the transformer. The conservator tank will be designed to withstand strong wind pressure. Adequate stiffeners may be added, if necessary. Each conservator shall be fitted with a double compartment breather with oil seal in which silica gel is the dehydration agent and designed so that :a. The passage of air is through the silica gel.

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b. The external atmosphere is not continuously in contact with the silica gal c. The moisture absorption is indicated by change in colour of the tinned crystals and can be observed from distance. d. All breathers shall be mounted at approximately 1400 mm above ground level. e. The breather should be made of superior quality see-through material and should consist of two compartments placed in parallel. f. The conservator shall be of air cell type, if possible, having provision for rubberized air cell so that air does not come in contact with oil in the conservator.
6.4.14 OFF-CIRCUIT TAP-CHANGER

Each transformer shall be provided with an off - circuit tap changing switch suitable for varying its effective ratio of transformation whilst the transformer is de-energized and without producing phase displacement. The off - circuit switch handle will be provided with a locking arrangement along with tap position indicator, thus enabling the switch to be locked in position. A warning plate, indicating that switch shall be operated only when the transformer is de-energized, shall be fitted.
6.4.15 ELECTRICAL CLEARANCES

The electrical clearance in air between live conducting parts and live conducting parts to each structure shall be as per the relevant IS/Standards followed.
6.4.16 FITTINGS AND ACCESSORIES

Each transformer shall be complete with the following fittings and accessories : i. ii. One 150 mm (6'') dial type indicating thermometer (OTI) of robust pattern mounted on the side of the transformer at a convenient height to read the temperature in the hottest part of oil and fitted with alarm and trip contacts. 1 No., 150 mm dial type winding hot spot temperature indicator (WTI) placed in HV/LV winding, as described below: It shall be indicating type responsive to the combination of top oil temperature and winding current calibrated to follow the hottest spot temperature of transformer winding. The device shall have a additional pointer to register the highest temperature reached. Winding temperature indicator should have two sets of contacts. Contacts of the WTI shall be used for trip and alarm purpose, wiring of which will go to the main control and relay panel of the transformer (external control cables from the Marchalling kiosk to the Control & Relay panel are covered in separate section.) One explosion vent on transformer tank cover. Inspection covers with jacking bolts in the top cover plates of the tank. One filter - cum - oil drain valve with plug or blanking flange size 80mm. One filter valve at top of transformer tank size 50mm.

iii. iv. v. vi.

88

vii.

One double float gas/oil surge detecting (Buchholz) relay in the pipe connecting the conservator with tank, complete with alarm/tripping contacts to detect accumulation of gas and sudden rise of oil pressure, complete with two shut - off valves on conservator side as well as tank side and a coupling to permit easy removal without lowering flanges/oil level in the main tank. The size of shut - off valve shall be 80mm. viii. Two grounding terminals on breadth side of tank ix. Skids and pulling eyes on both sides. x. One Marshalling box housing dial type thermometers for winding and oil temperature indicators. xi. Thermometer pockets for mercury in glass thermometer of minimum 25 cm depth from top level. xii. A set of universal type bi-metallic multi-bolt double grooved conductor clamps for HV side capable of receiving single ACSR conductor (DOG) for bushing of 33 kV side of transformer. xiii. Suitable bi-metallic flexible connectors for neutral terminals. xiv. One set of terminal bushings each for HV & LV winding xv. One set of Neutral bushing (s) with ring type CT of ratio 40/5, 5P15 15 VA for earth fault protection. xvi. Suitable size bi-directions wheels for rail gauge to suit existing tracks in both directions-4 Nos. along with locking and bolting devices. xvii. The following plates, marked in English, shall be fixed to the transformer tank at about 1750mm above ground level: a. Rating plate bearing date as specified in IS: 2026/1977, it must contain insulation levels of various windings, impedance at normal & extreme taps short circuit duration, WTI ratio besides other information. b. Terminal marking plate showing the internal connections & voltage vector relationship of various windings in accordance with IS: 2026: 1977 (Latest Edition). c. Diagram plate showing the location and function of all valves and air release cocks or plugs. xviii. Oil conservator (for main tank) complete as per 6.6.13. xix. One no. spare pocket on tank cover for thermometer. xx. Off-circuit tap changer xxi. De-hydrating breather xxii. Any other item, which is not included above but is essential for the satisfactory operation of the equipment.

6.4.17 ANTI-EARTHQUAKE CLAMPING DEVICE

A clamping device shall be provided for fixing the transformer to the foundations to prevent transformer movement during earthquake. The contractor shall supply necessary bolts for embedding in the concrete. The arrangement shall be such that the transformer can be fixed to or unfastened from these bolts as desired. The fixing of transformer to the foundation shall be designed to withstand seismic events to the extent that a static coefficient of 0.3g applied in the direction of least resistance to that of loading will not cause the transformer or clamping device as well as bolts to be over stressed.

89 6.4.18 EARTHING TERMINALS

Two earthing pads suitable for connecting 50x 8mm mild steel flat shall be provided at positions close to the two diagonally opposite bottom corner of tank. These grounding terminals shall be suitable for bolted connection. Two earthing thermals shall also be provided on marshalling box and any other equipment mounted separately.
6.4.19 UNDER CARRIAGE The transformer shall be supported on a strong structural steel base equipped with forged steel or cast steel, single flanged, bi-directional wheels suitable for moving the transformer completely filled with oil. Jacking pads shall be provided to make it possible to change the direction of wheel through 90 degree when the transformer is lifted on jacks and permit movement of the transformer both in the longitudinal and transverse direction. Track gauge in both longitudinal and transverse direction shall match with the existing track at power house switchyard site. Means shall be provided for locking the swivel movement in position parallel to and at right angles to longitudinal axis of the tank.

Pulling eyes and skids shall be provided to facilitate moving of the transformer. These shall be suitably braced in the vertical direction to avoid bending when the pull has a vertical component.
6.4.20 BUSHING INSULATORS AND TERMINALS

i.

Transformer shall be fitted with bushing insulators as follows :a. HV Bushings: 36 kV b. LV Bushings: 3.6 kV c. HVN Bushings: 36 kV Bushing shall be suitable for 25 times rated current for 5 seconds. Short time current withstand capability of bushing shall be 17.5 kA for 3 seconds for HV bushing and 40 kA for LV bushing. The electrical characteristics of bushings shall be in accordance with IS:3347 and IS:2029. All bushings shall be equipped with suitable terminals of approved type and size and all external current carrying surfaces shall be adequately silver plated. All ends as well as all tappings on the windings shall be brought to terminals. Bushings which pass through the cover shall be removable without disturbing the transformer cover. The bushings shall have high factor of safety against leakage to ground and shall be so located as to provide adequate electrical clearances between bushings of various voltages and between bushings and grounded parts. Bushings of identical voltage shall be interchangeable. The insulating class of the high voltage neutral bushings shall be properly co-ordinated with the insulation class of neutral of the high voltage winding. Clamps and fittings shall be galvanised.

ii. iii. iv. v.

vi. vii. viii.

90

ix.

x.

Each bushing shall be so co-ordinated with the transformer insulation that all flash covers will occur outside the tank. All bushings shall have puncture strength greater than dry flash over value. Any stress shield shall be considered as integral part of bushing assembly. Only condenser type bushing shall be accepted. Neutral bushings shall be provided as required for earthing of neutral point alongwith ring type of CT ratio 40/5, 5P15, 15 VA.

6.4.21 CENTRE OF GRAVITY

The center of gravity of the assembled transformer shall be low and as near the vertical center line as possible. The transformer shall be stable with or without oil., if the center of gravity is eccentric relative to track either with or without oil, its location shall be shown on the outline drawings.
6.4.22 JOINTS, GASKETS AND VALVES

i. ii.

All gasket used for making oil tight joints shall be of proven material such as granulated cork bonded with synthetic rubber. The material used should not deteriorate under the action of hot oil. All valves upto and including 100 mm shall be of gun metal or of cast steel. Larger valves may be of gun metal or may have cast iron bodies with gun metal fittings. They shall be of full way type with internal screw and shall open when turned counter clockwise when facing the hand wheel. Means shall be provided for padlocking the valves in the open and closed position. Every valve shall be provided with flanges having machined faces. The drilling of valves flanges shall comply with the requirement of IS: 2026/IS: 3639.

6.4.23 CLEANING AND PAINTING

All corrodible parts and surfaces shall be of such material and shall be provided with such protective finish that no part of the installed equipment is injuriously affected by atmospheric conditions. The whole of the exposed portion except bright parts shall be thoroughly cleaned by sand blasting and painted with two primary coats of approved rust resisting paint in dark admiralty grey colour. Inside surface shall be clean, smooth, free from voids and of best construction. The nature of coatings, provided inside, shall be specified and it shall be ensured that it does not react with transformer oil or deteriorates its electrical/chemical properties. Some paint suitable for primary and secondary coats shall also be supplied to cover the damage to paint work which may be experienced during transportation.
6.4.24 MARSHALLING KIOSK

Made of sheet steel of minimum 3mm thickness, vermin proof, well ventilated and weather proof marshalling box of a suitable construction shall be provided for the transformer ancillary apparatus. Wiring up to marshalling box shall be with PVC/SWA, PVC copper cable 660/1100 volts grade IS certified/marked.

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The marshalling box shall accommodate the following equipment: i. ii. Temperature indicators. Terminal board and glands for incoming and out going cables.

The temperature indicators shall be so mounted that the dials are not more than 1600 mm from the ground level and the door(s) of the compartment(s) shall be provided with glass window of adequate size to prevent internal condensation. An approved type of metal clad heater with thermostat shall be provided, controlled by water tight single pole iron clad rotary switch mounted on outside of the box. The ventilation louvers, suitably padded with felt, shall also be provided. All outgoing connections from the transformer viz.: Buchholz relay, temperature indicators, level indicators, etc. shall be wired to marshalling kiosk. All incoming cables shall enter the kiosk from the bottom and the gland plate shall not be less than 450 mm from the base of the box. The gland plate and associated compartments shall be sealed in suitable manner to prevent the ingress of moisture from the cable trench.
6.4.25 CONTROL CONNECTION, INSTRUMENT WIRING, TERMINAL BOARDS & FUSES

All wiring connections, terminal boards, fuses and lines shall be suitable for tropical atmosphere. Any wiring liable to be in contact with oil shall have oil resisting insulation. There shall be no possibility of oil entering connection boxes used for cables and wiring. When 415 volts connections are taken through junction boxes of marshalling boxes, they shall be adequately screened and 415 volts danger notice must be affixed to the outside of junction boxes or marshalling boxes. All wiring shall be with stranded copper of 1100 volts grade and 4.00 sq. mm for CT leads and not less then 2.5 Sq.mm for other connections. All wiring cables shall be ISI- marked/certified and in accordance with the relevant ISS. All wires on panels and all multicore cables shall have ferrules bearing same number at both ends. Same ferrule numbers shall not be used on wires in different circuits, on the same panels. Ferrules shall be of white insulating material and be provided with glossy finish to prevent adhesion of dirt. They shall be clearly and durably marked in black and shall not be effected by dampness or oil. Wiring shall, in general be accommodated on sides of the box and wires for each circuit shall be separately grouped. Back of panel wiring shall be arranged so that access to the connecting stems of relays and other apparatus is not impeded. All the cables and capillary types of OTI and WTI etc are to be wired properly on cable trays with the help of suitable cleats upto the marshalling box. The cable trays shall be kept minimum 100 mm away from the tank body to avoid excessive heating of cables/wires. Wires shall not be joined or tied between terminal points. Wherever possible, all circuits in which the voltage exceeds 125 volts, shall be kept physically separated from the remaining wiring.

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The function of each circuit shall be marked on the associated terminal boards. Where apparatus is mounted on panels, all metal cases shall be separately earthed by means of copper wire. No live metal part shall be exposed at the back of terminals boards. All fuses shall be of cartridge type and links shall be labelled. All wiring diagrams for control panels shall preferably be drawn as viewed from the back. The overall design of wiring shall be such that various wires and ends of the same wire can be traced easily and there is convenience to access the terminations and ferrule number shall be readable with convenience.
6.4.26 DRAWINGS

The tenderer shall submit with his tender, one set of dimensional drawings of the equipment offered, alongwith illustrated and descriptive literature for scrutiny. The successful bidder after the award of the contract, shall supply four copies of the following drawings documents within 30 days after the receipt of purchase order, which will describe the equipment in detail for approval by the Purchaser. i. Detailed outline General Arrangement drawing showing plan, front elevation, side elevation with all fittings and accessories etc. Following information must be specifically included on this drawing:

a. Make of transformer oil. b. Electrical clearances, minimum as well as actual. c. The no. of radiator elements, width, thickness of sheet & height of each radiator. d. A sketch showing detailed procedure for dismantling. e. Thickness of transformer tank bottom, side & top plates. f. Type, shade, shade no. and thickness of transformer paints. g. Roller, rail gauge sketch. h. Weight of oil; Bare copper windings, core, un-tanking mass, transportation mass and dimension etc. ii. Detailed drawing of bushing, showing plan & elevation, terminal details, mounting details, make and type, number, incorporating electrical characteristics, description of various parts, total creepage/protected creepage distance, weight of oil, total weight of bushing, dimensions, short time rating etc. iii. Transportation sketch showing dimensions and weights of the heaviest package and the shipping arrangements of the transformer. iv. Rating and diagram plate.
NOTE: Bushing CTs for WTIs are to be provided on HV side.

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v. vi. vii.

Detailed structural drawings for the transformer tank, under carriage, conservator, radiators, supporting structures for cooling fans etc. Dimensional drawings of multi bolt bimetallic connectors for line ends and flexible connectors for the neutral ends. Roller Stopper arrangement drawing.

6.4.27 ADDITIONAL DRAWINGS

Following drawings shall be supplied for reference and record in addition to the above listed drawings. i. Large scale drawing of high and low voltage windings of transformer showing the nature and arrangement of insulation and terminal end connections. ii. Drawing showing sectional view of the HV and LV windings when viewed from top. iii. Detailed drawings of conservator and pressure relief device (explosion vent) mounted in position. iv. Foundation plan of the transformer including auxiliary equipment. v. Any other drawing considered necessary by the Purchaser. vi. A schedule showing the requirement of set of spare gaskets.
6.4.28 INSTRUCTION MANUALS

The successful tenderer shall be required to supply 6 (six) sets of instruction manuals per transformer, each properly bound in hard cover.. Each set shall consist of the following:i. ii. iii. iv. v. All the approved drawings listed above.. Erection, Operation & Maintenance manual for transformer and pamphlets for all spare parts e.g. OIL, WTI, Off- load tap-changer Buchholz relay, Silica-gel breather / Pressure relief valve. Instructions for dehydration, if any. Precautions prior to vacuum application, if any. Any other information/data/documents/instructions considered necessary by the manufacturer for efficient functioning of the transformer.

6.4.29 GUARANTEED DATA AND OTHER PARTICULARS

Guaranteed data and other technical particulars of the transformers offered shall be furnished by the tenderer in accordance of this specification for all the transformers.
6.4.30 PLACE OF MANUFACTURE, TESTING AND INSPECTION

The tenderer shall state in his tender, the place (s) of manufacture, testing and inspection of various portions of the work included in the tender. The place of manufacturing shall not be allowed to be changed at a later stage. The purchaser or his duly authorized representative shall have access to the manufacturers works at any time during working hours for the purpose of inspecting the manufacture &

94

testing of materials, equipment and completed plant and the supplier shall provide necessary facilities for inspection.
6.4.31 INSPECTION AND TESTING

The successful tenderer shall submit complete set of drawings as already brought out in this specification within 30 days from the receipt of purchase order. The suppliers will furnish schedule of manufacturing of the transformer alongwith the drawing. Purchaser can inspect the raw material, manufacturing process at sub-supplier's works for which advance intimation of manufacturing activities shall be given.
i. Radiators

Radiators shall be routine/type tested at supplier works as per relevant standards.

ii. Routine Testing All routine tests shall be carried out on each transformer as per IS- 2026/ IEC-76 & IEC- 354

iii. Type testing

Following type tests and T/F withstand capacity beyond name plate as per IEC-354 shall be carried out as per IEC-76/IEC- 354 & IS- 2026 on the transformers :i. ii. Temp. Rise Test with 2x50% radiators only. Impulse Voltage withstand test on all the three phases with chopped impulse.

6.4.32 FOUNDATIONS AND FIXINGS

All plant and equipment shall be provided with a complete set of foundation bolts, washers, nuts, plates and other fixtures as may be required and these shall be supplied by the supplier. These fittings shall be fixed by the purchaser in the foundations, unless otherwise specified. All foundations, bolts, fixtures etc. shall be supplied as soon as possible after the contract drawings have been approved.
6.4.33 PACKING, DESPATCH AND DELIVERY

The supplier shall be responsible for suitable packing of all equipment and marking of the consignments so as to avoid any damage during transit, storage and to ensure correct dispatch to the destination. Damages to equipment/material in transit due to improper packing shall be to suppliers account. All parts requiring protection from moisture shall be especially packed to prevent ingress of moisture. No parts of any kind shall be packed inside other larger parts. Heavy parts shall be so mounted that there is no difficulty in attaching slings etc. for unloading at destination. All parts shall be adequately marked to facilitate field erection. Boxes and crates shall be marked with contract number and shall have packing list enclosed, showing the parts contained therein.

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In case the transformers are despatched gas filled and oil for first filling is despatched separately, sufficient quantity of gas in NON RETURANABLE Cylinders shall be supplied to maintain the pressure of the gas in the tank at site before it is filled with oil.
6.4.34 TOOLS

The transformers shall be supplied with a set of special tools, if considered necessary for assembling and dismantling of transformer. The details of the tools etc. included in the offer shall be given.
6.4.35 SPARES

All the spare parts of the equipments shall be interchangeable and shall be of same material and workmanship as the corresponding parts furnished with main equipment. Unit prices of any additional spares considered necessary may be indicated separately. The F.O.R. destination prices shall be mentioned clearly against each item given above. Further, voltage & current rating of each spare bushing should be clearly indicated and should be same as that of bushing provided on the transformers.
6.4.36 DRYING-OUT AND ERECTION

The transformer shall be dried-out by an appropriate method at the manufacturers works and so arranged for transportation and storage that it may be put into service without further drying out at site. For any subsequent drying out which may be necessary at site the manufacturer shall give details of the method recommended for using the same. The transformer shall be designed to withstand pressure and vacuum tests as specified by CBIP specification for power and distribution transformers :i. ii. iii. Vacuum as per CBIP manual to be applied to tank and cooling equipment when empty of oil. Pressure of 1 kg/cm2 mercury applied to tank and cooling equipment when empty of oil. Pressure of 0.5 kg/cm2 to be applied at conservator on fully assembled transformer when full of oil.

Clear instructions shall be given in the maintenance manual regarding special precautionary measures e.g. stucking up of tap changer barrier or tank cover which must be taken before applying the specified vacuum treatments. The maximum vacuum which the complete transformer filled with oil, can safely withstand without any special precautionary measures being taken shall also be stated in the maintenance manual. The bushings shall be capable of withstanding vacuum operation when drying out the transformer.

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Annexure-6/1 STANDARDS, SPECIFICATIONS AND CODES OF PRACTICE 1. POWER TRANSFORMERS

Hot dip galvanized cooling on threaded fasteners. Code of practice for maintenance of insulating oil. Specification for Power Transformers Current transformers Dimensions of porcelain transformer bushings for use in lightly Polluted Atmospheres IS: 3637 Gas operated relays IS: 3639 Fitting & accessories for Power Transformers IS: 6600 Guide for loading of oil immersed transformers IS: 9434 Guide for sampling and analysis of free and dissolved gas in oil filled Atmosphere. IS: 10028 Code of practice for selection, installation and maintenance of transformer IS: 12371 Technical requirements for single action telescopic tipping cylinders for agriculture trailers IEEE: 32 IEEE standard requirement terminology and test procedure for neutral Grounding device. CBIP: Manual of Transformer. Equipment complying with other internationally accepted standards such as IEEE, IEC, BS, USA, VDE etc. will also be considered if they ensure performance and constructional features equivalent or superior to standards listed above. In such a case the Bidder shall clearly indicate: i. ii. iii. The standards adopted, The bidder shall clearly bring out salient features for comparison with the standards listed under serial 1 above. Furnish a copy (in English) of the relevant standards adopted (along with the latest revision of standard and copies of all official amendments and revisions in force as on date of opening of bid).

IS: IS: IS: IS: IS:

1367 1866 2026 2705 3347

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SECTION VII SPECIFICATIONS FOR SERVICING & OVERHAULING OF POWER TRANSFORMERS

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SECTION VII SPECIFICATIONS FOR SERVICING & OVERHAULING OF POWER TRANSFORMERS

7. 7.1. PROCEDURE AND SPECIFICATION FOR OVERHAULING OF .4 KV / 33 KV OR 0.415/11 KV POWER TRANSFORMER The overhauling of transformer shall consist of the following but not limited to: -

1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11)

12) 13) 14) 15) 16) 17)

7.2

Inspection of core assembly, winding & internal inspection. Cleaning of the conservator tank. Replacement of gaskets. Checking of the body of tank for leakages. Examination of bushings for cracks, dirts deposits and replacement if required, adjustment of arching horns for alignment and proper gaps. Checking of breather for air passage and replacement of silicagel. Examination and replacement of broken earth leads. Checking for acidity and sludge and cleaning the tank & windings in case of depositing of sludge. Replacement of insulating oil and its dehydration. Checking of tap changing gear and repair / replacement as per requirement. Replacement of oil temperature thermometer, replacement of winding temperature thermometer with maximum pointer, alarm contacts i/c trip contacts and necessary capillary tubing, replacing of Bucholz relay (gas oil actuated relay) with both alarm and trip contacts / signals. Checking of pressure relief vent. Checking of filter valves. Checking of lifting lugs, Jacking lugs and earthing terminals for the tank. Checking & cleaning of oil level indicator. If required coils should be rewound by replacing insulating materials. Painting of transformer.
INSULATING OIL (SPECIFICATIONS AND DEHYDRATION AT SITE )

The insulating oil used for transformers shall meet the following requirements as per IS 335 : 1983 and as amended up to date:(a) (b) (c) (d) (e) (f) (g) (h) Provide a high electric strength. Permit good transfer of heat. Have low specific gravity. Have a low viscosity. Have low pour point. Have a high flash point. Not attack insulating materials and structural materials. Have chemical stability to ensure lifelong service.

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Characteristic 1. Appearance

Requirement The oil shall be clear and transparent and free from suspended matter or sediments.

2. Corrosive sulphur (in terms of classification of copper strip) 3. Electric strength (breakdown voltage) Min. (a) New unfiltered oil (b) After filteration 4. Presence of oxidation inhabitor. 5. Water content, Maz.

Non-corrosive.

30 kV (rms) if the above value is not attained the oil shall be filtered. 60 kV (rms). The oil shall not contain antioxidant additives. 50 ppm.

7.3

DRYING OUT

Drying out, dehydration of the transformer shall be carried out most carefully and correctly. The main aim of the dehydration process shall be to remove the moisture completely from the insulation of the transformer and that the value of insulation resistance itself should not be taken as an indication of the state of dryness.
7.3.1 PROCEDURE TO BE ADOPTED FOR DRYING OUT

7.3.1.1. DRYING OUT BY CIRCULATING HOT OIL

In this method the transformer is filled with oil to cover core and windings. The oil filtration valves, if provided on the transformer, or the filling and drain valves at top and bottom are connected through an oil filtration plant fitted with heating elements. The temperature of the oil should be maintained at 85oC. To reduce losses of heat the tank should be blanketed and oil prevented from circulation through the coolers or radiators. It is essential to provide ventilation of the air space above the oil in order that moisture may get away. The time of drying can be reduced by application of vacuum to the surface of oil. This should, however, be done with all main gaskets under oil as otherwise there is the risk of drawing in moisture through gaskets.
7.3.1.2. CONDITION DURING DRYING OUT

There is no definite length of time for drying out. A period that may be required shall be depending on the size of the transformer, its voltage rating, its conditions and the method of drying out used. The stage to which the transformer may be assumed to have been dried depends on the experience and judgement of the Engineer-in-charge of the dehydration process. The conclusion is based primarily on the readings of temperature and insulation resistance recorded regularly throughout drying. It may be added that the value of insulation resistance itself is no indication of the state of dryness. The insulation resistance before

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starting the dehydration process may be quite high. As drying out proceeds the insulation resistance may fall due to (i) increase in temperature, and (ii) release of moisture. When constant temperature is reached the resistance will commence to rise, the rate of increase slowing down as drying out nears completion until flattening out to a constant value indicates completion. It is a good practice to plot the curve of insulation resistance against time as the readings are obtained. Temperature measurements should also be recorded. The temperature may be checked by measuring the increase in resistance of the windings. Situations may arise when damage to the sealing of the transformer may not have existed long enough to allow the entry of the moisture seriously to affect the insulation. If this is so, when the drying process is carried out, the insulation resistance will fall only because of the temperature rise and will then remain practically constant. When this value is reasonably high and is approximately the same for three days such a transformer can be assumed to be dry.
7.4 ACIDITY & SLUDGE

While in service the existing transformers insulating oil may have developed acidity and sludge. The contractor shall check the transformer oil for acidity and accumulation of sludge. If the acidity reach 0.5 and there are traces of accumulation of sludge, then it should be removed by working all parts with a pressure jet of clean new oil. Should the acidity reach 1.5, the transformers core and windings should be lifted and all other parts worked with clean new oil assisted, if necessary, by dismantling.
7.5 INSULATION RESISTANCE

The resistance of insulation depends on its temperature, therefore, when testing insulation, the temperature should also be measured. In oil-immersed transformers, the temperature of the top oil is conventionally taken as the insulation temperature, while in drytype transformers, it is the ambient temperature that is taken as the insulation temperature. The results of the insulation resistance measurements should be checked against the manufacturers specifications or against the results of the previous tests. If there are no such data, the check should be made against the values specified in the pertinent standards. For new oil-immersed transformers of Soviet make, the 60-second insulation resistance as a function of the winding temperature and voltage class is given in Table 7.5.1
7.5.1 MINIMUM PERMISSIBLE INSULATION RESISTANCE R60 (in M) FOR OIL-IMMERSED TRANSFORMER WINDINGS.

Transformer voltage class, kV

Winding temperature, o C 10 450 900 20 300 600 30 200 400 40 130 260 50 90 180 60 60 120 70 40 80

Up to 35 110

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The values of R60 given in the table refer to all the windings of a given transformer,. They also apply to transformers that have underwent overhauling with the replacement of the windings and insulation. The magnitude of the insulation resistance is not always indicative of the degree of dryness of the transformer, therefore, use is made of an additional characteristic, known as absorption coefficient (designated Ka b s) which is the ratio of the 60-second insulation resistance to the 15-second insulation resistance, i.e., Ka b s = R 60 / R 15. For power transformers with dry insulation, the absorption coefficient at a temperature of 10 to 30oC must not be lower than 1.3. Before measuring the insulation resistance of an assembled transformer, its terminal bushings must be carefully wiped with a piece of dry cloth. When handling a megohmmeter, one should observe accident prevention rules. Transformer windings possess a substantial capacitance, therefore, the current-carrying parts can only be touched after electric charge has been removed from them. For this purpose, these parts should be connected to the earthed tank. When doing this, one should wear rubber gloves. It is absolutely prohibited to use a megohmmeter to test a transformer under voltage.
7.6. REQUISITE CONDITIONS FOR PUTTING OVERHAULED TRANSFORMER INTO SERVICE WITHOUT DRYING-OUT OR TEST DRYING

Transformer voltage class and capacity Up to 35 kV inclusive with capacity of up to 10000 kV A inclusive

Insulation characteristics
R60" - must not decrease during repair by more than 50% of the value specified by the manufacturer, or must not be lower than indicated in Table 7.4.1 R60"/R15" - must not be lower than 1.3 at a temperature of 10 to 30oC

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SECTION VIII SPECIFICATIONS OF GENERATOR CONTROL, METERING AND PROTECTION PANEL

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SECTION - VIII SPECIFICATION OF GENERATOR CONTROL, METERING AND PROTECTION PANEL

8. SCOPE OF SUPPLY AND DESIGN CRITERIA

Design, manufacture, testing, erection & commissioning of control, metering and protection system which includes Electrical protection by conventional relay; manual control and metering of energy generated by the units, energy drawn through individual outgoing feeders, and energy consumed in the Power House. The control panel shall also have provision of back up protection of the generating units etc. from faults occurring on main HT/LT outgoing feeders. Arrangements Manual synchronization of the machines with each other and the power station and with the grid shall be provided in addition to the Auto Synchronisation system. This control panel should be compatible in size and dimensions with the 33 kV or 11 kV breaker indoor remote control panel. The scope of supply shall also include all arrangements parts, accessories, spares etc., which are essential for operation of the whole system even though these are not individually stated or enumerated.
8.1 DESIGN CRITERIA

The control panels will have provision as required for the safe and efficient working of the system. Common tripping relays for similar functions shall be provided with lock-out facilities. All these relays shall have potential free contacts for trip and alarm purposes and externally hand reset type of flag indicators. They should preferably be housed in drawout type of cases with tropical finish. All the protective equipment including HT breaker remote control panel will be housed in the Power Plant control room. The details of C.T.s for all the unit protection and metering shall be subject to approval by purchaser. C.T.s and P.T. may be mounted on switchgear panels alongwith indicating meters like ammeter, voltmeter and kW meters etc.
8.2 CONSTRUCTIONAL FEATURES

i) ii) iii) iv) v) vi)

All control panels shall be of standard construction, dimensions, materials and sheet thickness. Control panels shall be of simplex types (devices mounted on the front panel and double door on the back side). Panels shall be painted by dry electro-static powder coating process. All accessories mounted on the front panel shall be flush mounting type. Each control panel will have mimic diagram painted or embossed on its front. Each panel will have arrangements for internal lighting and heating.

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vii)
8.3

The wires and wiring accessories, terminations etc. shall be as per relevant Indian Standards.

Details of Switchgear, Control and Relay Panels

Floor mounted, sheet steel simplex type control and relay panels with the following equipment mounted on them shall be supplied.
8.4 Generator Control / Relay panels
Sl. No. Description of Items

Control Panel for specified nos. of incoming supplies separated by Bus Coupler and specified nos. of outgoing feeder each equipped with
1 415 V ACB of suitable rating Microprocessor based with all accessories, thermomagnetic releases ,O/L,S/C,E/F, 4NO+4NC auxiliary contact, spring charging motor-240 Volts , Under voltage release-415 V AC, shunt trip & closing coil-24 V DC Safety shutter, Door Interlock etc. Aux. Contact Block, 2NO+2NC , Coil-240 V AC Analog Ammeter of appropriate range flush mounting type with 3 way ammeter selector switch having off position. Analog Voltmeter range 0-500 V flush mounting type with 3 way voltmeter selector switch having off position. Power factor meter range 0.5-1-0.5 flush mounting type only in incoming panels Reed type frequency meter range 45-50-55 Hz flush mounting type only on incoming panels Kw meter of suitable range flush mounting type size suitable for 3 phase, 3 wire system Kwh meter flush mounting type suitable for 3 phase, 4 wire system. (Digital Type microprocessor based Trivector meter) on each incoming panel. KVAR meter flush mounting type suitable for 3 phase, 4 wire system.

2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19

Three-pole differential relay (87 G)-3 CTs on the neutral of the generator and 3 CTs on the phase
Triple pole over current relay & Earth fault relay for protection of alternators Negative phase sequence relay. Relay for Over voltage and Under voltage protection. Relay for Field failure protection. Relay for Reverse power protection. Relay for Over speed frequency protection Relay for Rotor earth fault protection Relay for Stator earth fault protection

Voltage restrained over current relay (SIV) In case the generators are provided with static excitation system with excitation transformers, high set instantaneous over-current relay (50) IDMT and over-current relay (51) would be provided in the tapping for excitation transformer for protection of excitation transformers.
Any other equipment / relay necessary for the system protection & operation. 16 window alarm annunciation panel shall be provided for the above Faults and balance windows shall be as spare windows.

20 21

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22 23 24 25 26 27 Lightning arrestor 1.5KA,Metal Oxide,Gapless,600V system with solidly earth neutral Surge capacitor,0.25 Microfarad Panel space heater,80 W, 220V with thermostat 18 Watt CFL Panel Lamp with door switch Control fuse with base All necessary provisions should be made so as to enable the power station to operate in isolated as well as in synchronization with grid.

Controls The following controls will be provided:

a) b) c) d) e) f) g) h) i)

Generator anti-condensation heater ON & OFF switch. Panel heater ON and OFF switch. Alarm acknowledge push button. Healthy trip circuit test push button. Reset push button. Breaker ON/OFF push buttons. Voltage raise/lower spring return switch. Panel light ON/OFF Switch Any other control as deemed fit.

Indication Lamps

The following indicating lamps LED type will be provided on the control panel: i) Phase indication lamps on incoming and outgoing panels ii) Unit circuit breaker on iii) Unit circuit breaker off iv) Auto trip-electrical fault v) Spring Charged vi) Healthy trip circuit vii) DC supply fail viii) Generator anti-condensation heater ON ix) Any other indication as required
8.5 33 kV or 11 kV Indoor Control Panels for remote operation of required VCB for outgoing feeders and for protection of Generator Transformerseach consisting of :Quantity 1 Set Description Ammeter ,Volt meter, kW meter, kWh electronic trivector meter with selection switches etc. Over current, Earth fault relays, Reverse Power Relay and any other relay required to make the system safe Annunciations System Switch ON and OFF of breaker ON and OFF indication of breaker

1 Set 1 Set 1 No. 1 No.

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1 No. 1 No.

Healthy Trip Circuit indication DC supply fail indication

The remote relay control panels for the VCBs installed for safety of power transformers shall contain all such relays necessary for total protection of the transformers from internal and external faults. Following protective systems should invariably be applied for transformer protection:(i) Gas and Oil Pressure Relays (Buchholz relay). (ii) Over current and earth fault (un restricted)- (IDMT relays or definite time relays). (iii) Restricted earth fault. (iv) Frame leakage Protection. (v) Differential relay. (vi) Any other relay as deemed suitable The Contractor shall also provide the following scheme for bus bar protective viz (i) Frame leakage Protection and (ii) Differential Protection (a) Current differential and (b) Voltage differential. For radial feeders (i.e. Outgoing feeder) instantaneous pilot wire protection and time graded over current and earth fault shall be provided as back up protection.

N.B: The equipments supplied i/c the remote relay control panels shall be so

designed to make the whole system enable to operate in isolated as well as grid mode.

8.6

Auto Synchronising Panel :The synchronizing bracket will be mounted on left hand side of the panel and shall be of swinging type and will have following provisions: Quantity Description 1 Synchroscope 1 Double voltmeter 1 Double frequency meter 1 Synchronising check relay (25) with guard relay 1 Synchronising selector switch 1 set Auxiliary relays 1 Synchronising lamp 415 VOLTS AC DISTRIBUTION BOARD FOR UTILITIES

8.7

i) ii) iii)

1 No. 100 Amps TPN Switch Fuse unit complete with necessary protection through HRC Fuses and all other accessories for receiving incoming supply from main Power Control Panel Board i/c 2 Nos. energy meters (electronic static). 1 No. 100 Amps. 4 Pole Change Over Switch to select incoming power from Turbo Generating Power Control Panel and utility DG Set or any other source. 1 No. MCB distribution board having following arrangement :-

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(a) (b) (c) (d) (e) (a) (b)

2 Nos. 32 Amps. Outgoing feeders provided with 32 Amp. SPN Motor duty MCBs. 1 Nos. 32 Amps and 1(one) no 63 Amp. Outgoing feeders provided with 32 Amp. 4 Pole Motor duty MCBs 6 Nos. 10 Amps. Outgoing feeders provided with 10 Amps. SPN Motor duty MCBs. Necessary indicating and metering instruments including indication lamps. Any other item / equipment required to make the system complete (KW meter, Voltmeter, Ampere meter). The distribution board shall be completely wired. The scope of power and control cables is also included. This distribution boards shall be attractive in design, mechanically strong, robust in construction and shall be totally enclosed in a mild steel cabinet of 3 mm. thickness. It shall have specified sets of MCBs and shall be vermin and dust proof complete with double door, lock and key arrangement. The doors shall be properly hinged. Cable entry shall be through suitable conduit pipe. The interior and exterior shall be painted with two coats of red oxide primer after 7 tank treatment and two coats of approved colour paint as per IS: with a minimum thickness of 60 microns. This distribution board shall be suitable to be mounted on concrete wall/columns or it may be mounted inside the wall so that its top surface is flush with the wall as the case may be. Suitable fixing arrangement such as nuts, bolts, washer, anchors shall be provided at suitable places for its proper fixing. The isolator / MCBs units shall be of reputed make only and shall be complete and fully comply with latest edition of IS:2516-1977, IEC 157-1983. The operating handle shall be properly insulated from the live portion of MCCBs/MCBs and shall always be easily accessible. The MCCBs/MCBs used for A.C. supply and D.C. supply shall be designed for a fault level of 10 KA for 1 second. These S.D.B.'s shall be suitable for voltage variations as per latest relevant I.S.S. Suitable earthing arrangement shall also be provided with sub distribution boards. The above description is a broad outline of the control, metering and protection system. Drawing of the above control panel showing layout arrangement of various measuring, indicating, protection equipments and annunciation system shall have to be got approval from the Engineer-in-Charge prior to its manufacture. Contractor shall have detailed discussion with the Engineer-in-Charge about the actual functional requirements of the panel board before designing the control panel boards.

(c)

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SECTION IX SPECIFICATIONS FOR 33 KV SWITCHYRAD EQUIPMENTS

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SECTION IX TECHNICAL SPECIFICATIONS: 33 kV SWITCHYARD EQUIPMENT/WORKS

9.1 SCOPE

Design, detailed engineering, manufacture of equipment, shop testing, packing, transportation, loading & unloading, delivery, storage at site handling, erection, precommissioning tests and commissioning of the following equipment/system including preliminary acceptance test and performance guarantee for the following 33 kV switchyard equipment of the powerhouse. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
9.2

Isolators Circuit Breakers Lightning Arrestors Potential Transformers Current Transformers Bus Bars & Bus Connections Grounding/Earthing Lighting of switchyard Lightning Protection System for power house and switchyard Structures Fencing Any other equipment necessary to complete the job

CODES OF PRACTICE

List of Codes of Practice and Standards is given in Annexure9/1. All Codes of Practices and Standards shall be the latest editions including all applicable official Amendments & Revision as on date of opening of bid.
9.3 9.3.1 ISOLATORS Application

These are to be used for: i. Breaker isolation/connection on no load ii. Line connection/isolation/ on no load
9.3.2 Type And Construction

i. ii. iii. iv.

Triple pole gang operated suitable for outdoor installation in open yard under the specified site conditions. Common actuating mechanism for all three poles. Motor operated from Remote/local and also manually operable. Interchangeable single pole units

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v. vi. vii. viii.

9.3.3

Switch blades shall be of copper and of one solid piece construction. Adequate Inter-phase clearance and mounting height. Speed of operation during opening or closing shall ensure minimum arcing. 33 kV isolator shall be horizontal double break type mounted on structure.

TECHNICAL PARTICULARS

i. ii. iii. iv.

Nominal system voltage Highest system voltage Rated frequency Type

: : : :

v. vi. vii. viii.

ix. x. xi. xii. xiii. xiv. xv.

Continuous current rating Short time rating 1 sec Rated peak withstand current Insulation level of a. Impulse withstand voltage (1.2/50 micro sec.) b. Between poles to earth Across Isolating distance c. One min. power freq. Withstand voltage (both dry & wet) d. Between poles to earth Across Isolating distance Min. creepage distance Operating mechanism Termination Earthing switch Auxiliary contacts Installation Interlocks

: : : : : : : : : : : : : :

33 kV 36 kV 50 Hz Outdoor station type, double break, triple pole double throw with turn and twist mechanism, with earth switch (on feeder isolator only) 630 A 750 MVA 17.5 kA Peak 170 kV 195 kV 70 kV 80 kV 2.54 cm/kV Gang operated, Auto and manual/motorized ACSR conductor both sides Mechanically inter-locked with isolator. Rating of earthing Switch same as that of isolator 3 NO + 3 NC Pole structure with padlocking facility i. With upstream circuit breaker/isolator ii. Mechanical interlock with earthing switch for correct sequence of operation 48 V DC/230 V AC 50C

xvi. xvii. a.

Control voltage Temperature rise above 45 ambient

: :

Disconnecting blades shall be capable of carrying rated current continuously as well as specified short circuit current for the duration indicated above without causing mechanical damage to any part or temperature rise which may damage the insulation.

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b. c.

The switches shall be capable of making on to faults specified and withstanding the dynamic stress involved. The isolator shall be suitable for interrupting small inductive and capacitive currents such as those occurring while disconnecting lines at no load, bus bars or voltage transformers under energized condition.
CONTACTS

9.3.4

i. ii. iii.
9.3.5

High pressure self-aligning adjustable type. Contacts shall be well protected all round by a metal cover to provide not only electrostatic screening but also to prevent coarse dust from entering between the contacts. Contacts shall be of high grade high conductivity heat resisting copper and silver plated.
OPERATING MECHANISM

i. ii. iii. iv.

It shall be suitable for motorized and also manual operation. Operating mechanism and its controls shall be so designed that under no circumstances the travel of the switch blades is interrupted before it reaches the fully closed or open position. Provision for padlocking the mechanisms in either the open or closed position shall be provided. Housing for the operating mechanism and its control shall be of sheet steel, weather and dust proof construction, with rubber gaskets conforming to enclosure protection class IP-55.
EARTHING SWITCHES FOR LINE ISOLATORS

9.3.6

i. ii. iii.

Disconnecting switches shall be provided with earthing switches on the line side forming integral part. Rating of earthing switch shall be same as that of the main isolator/disconnecting switch with respect to rated short time current and dynamic peak withstand current. Earthing blade shall be operated by a separate mechanism on manual and motorized mode but interlocked so that it can be closed only when the main disconnecting switch is open and vice-versa.
INTERLOCKS

9.3.7

ii. iii. iv v.

i. To be interlocked with associated isolators and circuit breakers through castle key and electrical interlock arrangement. Earthing switch and isolator interlocking. For closing of isolators main blades, associated earthing switches shall have to open and it is also to ensure that isolators are not used for on load closing. Final wiring or contact multiplication relay, blocking solenoid etc. shall be provided as per approved logic diagram. Breaker can be closed if associated earthing switches are open and isolators are in closed position.

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9.3.8

TERMINAL CONNECTION

Shall be provided with high conductivity terminal connecting suitable for ACSR conductors.
9.4 9.4.1 33 kV CIRCUIT BREAKERS TYPE

i. ii. iii. iv.

9.4.2

Outdoor type Vaccum Circuit Breaker suitable for installation in open yard. Three identical single pole units linked together for simultaneous operation, complete with supporting frames and tie-rods. Capable of interrupting small inductive currents caused by switching of unloaded transformers and low capacitive current without causing undue over-voltage. The circuit breakers are to be supplied complete with their control and relay panels for operation from remote i.e. inside the power house.
TECHNICAL PARTICULARS

i. ii. iii. iv. v. vi. vii.

Nominal system voltage Highest system voltage BIL Power Frequency withstand voltage Rated frequency Rated continuous current Closing mechanism a. Closing coil/tripping coil (2 nos.) b. No. of Poles Symmetrical short circuit withstand capacity Temperature rise Operating duty Dead time of breaker System neutral Min. creeping distance Control supply voltage Auxiliary, contacts with each circuit breaker Accessories a. ON/OFF/TRIP b. Emergency tripping mechanism c. Termination suitable with connectors

: : : : : : : : : : : : : : : : : : : :

viii. ix. x. xi. xii. xiii. xiv. xv. xvi.

33 kV 36 kV 170 kV 70 kV 50 Hz 1250 A Electrical spring charging with 230 V AC motor and local manual closing. 48 V DC 3 750 MVA for 1 sec. Not to exceed 50oC above ambient temp. of 45oC. 0-3 min. CO-3 min.-CO. Adjustable between 0.3 sec. to 15 sec. Solidly Earthed 900 mm 48 V DC 6NO+6NC Interchangeable at site Mechanical as well as Electrical Mechanical ACSR Conductor

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d. e.
9.4.3

Anti-pumping operation Spring charge indicator

: :

To be provided To be provided

OPERATING MECHANISM

i. ii. iii. iv. v. vi. vii. viii. ix. x.

9.4

Electrically / Manually operated mechanism. Breaker shall be provided with trip free mechanism. It shall be suitable for remote operation / control from the control room. The operating mechanism shall be of spring charging type by electrical control under normal conditions. The mechanism shall be trip free electrically and mechanically. The motor for spring charging shall be suitable for operation on 230 V AC supply and shall have overload protection. A local control switch with locking arrangement shall be provided for each breaker for local operating i.e. tripping and closing during maintenance, test etc. Local/remote selector switch and Trip/Normal/Close control switch shall be provided in the mechanism cabinet. An operation counter for each breaker shall be provided. Cabinet for operating mechanism and its accessories shall be as per relevant standards with padlocking facility. Cabinet shall be simplex type, all equipment mounted on front side and wiring on back in proper wire ways. Panel illumination and anti-condensation heater shall be provided in the local and remote control panel with MCB and thermostat. Closing circuit to operate satisfactorily from 85% to 110% of the rated control voltage and tripping from 50% to 110% of the rated voltage.
33 kV LIGHTNING ARRESTORS

9.5.1 TYPE i. Station class, 10 kA, heavy duty, non-linear resistance, metal oxide type gapless lightning arrestor for 33 kV system. ii. Self-supporting type in single pole assembly. iii. Suitable for pedestal mounting. iv. Outdoor type suitable for installation in open yard. v. Shall be designed to provide maximum protection against lightning and switching surges. 9.5.2 TECHNICAL PARTICULARS i. Nominal system voltage ii. Highest system voltage (rms) iii. Rated arrestor voltage (rms) iv. Continuous operating voltage (rms) v. Frequency vi. Power frequency with stand test voltage vii. Impulse voltage (peak) viii. System neutral connection ix. Nominal discharge current for 8/20 micro sec. x. Long duration discharge class as per IEC-99-4 xi. Maximum residual voltage at nominal discharge current of 8/20 micro sec wave

: : : : : : : : : : :

33 kV 36 kV 30 kV 24 kV 50 Hz 70 kV 170 kV Solidly earthed 10 kA (peak) 3/2 100 kVP (peak)

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xii. xiii.

xiv. xv.

Maximum steep current impulse (1/20 micro sec.) residual voltage at nominal discharge current Arrester Housing a. One minute power frequency withstand voltage (rms) b. Lighting impulse withstand voltage Prospective Symm. Fault current for pressure relief test (rms) Disconnecting device :

110 kV (peak)

: : :

70 kV 170 kV (peak) 40 kA

xv.
9.6 9.6.1

Minimum creepage distance of porclain housing (mm)

Disconnecting devices as per IS: 3070 (Part-II) shall be connected in series with ground lead. : 900

POTENTIAL TRANSFORMERS TYPE i. ii. iii. iv. v.

33 kV outdoor type Epoxy moulded dry type for 33 kV kV sealed type self cooled Single phase design Independently mounted Suitable for operation on 33 kV kV, 3 phase, 50 Hz AC systems

9.6.2

TECHNICAL PARTICULARS

i. ii. iii. iv. v. vi. vii.

Standard Nominal system voltage Highest system voltage Rated frequency System neutral earthing Number of secondary Voltage ratio

: : : : : : :

viii. ix.

x. xi. xii. xiii.

Class of insulation Insulation level a. One minute power Frequency withstand Voltage (wet and dry) b. Impulse withstand voltage For rating/other details Temperature rise Limits of voltage error & phase displacements Accuracy & burden etc.

: : : : : : : :

IS-3156 (1992) 33 kV 36 kV 50 Hz Solidity earthed One 33kV 110 V / 3 3 F

70 kV 170 kV Refer single line diagram As per IS 3156 PartI/1992 As per IS 3156 PartI/1992 As required

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.
9.6.3 WINDING CONNECTION

i. ii. iii.
9.6.4

Any three single phase units shall be suitable for three phase connection in star/star formation on three phase system. The positive, negative and zero sequence impedances shall all be equal. Secondary winding to be used for metering.

LIMITS OF TEMPERATURE RISE i. Limits of temperature rise specified in technical particulars shall correspond to 1.2 times the rated primary voltage applied continuously at rated frequency and at rated burden connected to both the secondary windings simultaneously. ii.. Temperature rise when 1.5 times the rated primary voltage is applied for 30 seconds after achieving stable thermal conditions followed by application of 1.2 times the rated voltage continuously, shall not exceed by more than 10C from the values specified above. TERMINAL ARRANGEMENT

9.6.5

i. ii. iii.

Bi-metallic (Cu/Al) terminal connector shall be suitable for ACSR conductors. Suitable earth terminal connector to be supplied for connections to earth. Secondary terminals to be housed in weather and dust proof cabinet with provision for terminating PVC insulated, armoured and PVC sheathed control cables.

9.7 9.7.1 9.7.2

CURRENT TRANSFORMERS TYPE 33 kV outdoor type TECHNICAL PARTICULARS i. Standard ii. Nominal system voltage iii. Highest system voltage iv. CT Ratio v. Rated frequency vi. System neutral earthing vii. Short time thermal current rating for 1 sec. duration viii. Class of insulation ix. Insulation level a. Peak impulse withstand voltage b. Rated one minute power frequency wet and dry withstand voltage x. Terminal

: : : : : : : : : : : : : :

IS-2705 (1992) 33 kV 36 kV As per Annexure-8/2 50 Hz Solidly earthed 25 kA F 170 kV 70 kV Suitable for ACSR conductor IP-55 enclosure As required and shown in Annexure

xi. xii.

Marshalling kisok For rating, ratio, class of accuracy and VA burden etc.

116

9.8 BUSBARS AND BUSBAR CONNECTIONS 9.8.1 TECHNICAL PARTICULARS i. Nominal system voltage : ii. Nominal current rating : iii. Bus conductor : iv. Short time rating : for 3 (three) seconds 9.8.2 CLEARANCE

33 kV 800 A ACSR DOG 750 MVA (17.5 kA)

The net clearance in air of bus bars, jumpers etc. shall not be less than that given in CBIP manual.
9.8.3 ACSR CONDUCTOR i. Construction a. Conforming to IS 398 (Part-III)-1996 b. Aluminum wire made from at least 99.5% pure electrolytic aluminum rods of EC grade with copper content less than 0.04%. c. Steel wires uniformly coated with electrolytic high grade 99.95% pure zinc. d. Steel strand hot dip galvanized with minimum coating of 250 gm/sq.m. e. No joints permitted in the individual aluminum strands and steel core of the conductor. f. No Joints permitted in bus bar and jumpers conductor. TECHNICAL PARTICULARS Sl. No. 1. Description Wire diameter Aluminum (mm) Steel (mm) Sectional area of aluminum (sq.mm) Total sectional area (sq.mm) Overall diameter (mm) Approximate weight (kg/km) Maximum calculated D.C. resistance at 20C (ohms/km) Ultimate tensile strength (kN) Final modulus of elasticity (Kg/Sq.m) Coefficient of linear expansion x 10-6 per C Type of Conductor

9.8.4

2. 3. 4. 5. 6. 7. 9. 9.
9.8.5 Hardwares

6/4.72 7/1.57 103.6 119.45 14.15 394 0.2745 32.99 0.735x106 Kg/cm2 19.53

The bolted tension fittings complete with U-bolts arcing horns etc. shall be provided suitable for 33 kV bus bar. Clamps and connectors for connecting ACSR conductor shall be made of alloy casting.

117

Bi-metallic connectors shall be used for connecting equipment terminals made of copper or brass. Bolts, nuts and washers for connectors shall be made of mild steel and electro-galvanized and passivated to make them corrosion resistant conforming to requirements of BS 1706.
9.8.6 INSULATORS

The insulators shall conform to the relevant latest IS standards (IS 2544, 731, 1248) and made of hard porcelain. Creepage distance shall be adequate for polluted outdoor atmosphere. Glazing of the insulator shall be uniform brown color, free from blisters, burns and other similar defects. The insulators shall have technical particular as detailed below: i. ii. iii. iv. v. vi. vii. viii.
9.9

Type Nominal system voltage kV (rms) Highest system voltage kV (rms) Wet power frequency one minute withstand voltage kV (rms) Power frequency puncture kV (rms) Impulse withstand voltage kV(peak) Creepage distance in mm (minimum) Minimum failing load

Post/Disc/Pin 33 36 70 1.3 times the actual voltage dry flash over voltage 170 580 10 kN (45 kN for disc insulators)

GROUNDING / EARTHING OF SWITCHYARD

Earthing system of the S/yard and power station shall be designed as per IS: 3043 and IEEE: 80. Earthing system network/earthmat shall be interconnected mesh of mild steel rods buried in ground in the switchyard area and/or earthing electrode type earthing system for the power house area as may be most suited to the existing power house. All off-site areas shall be interconnected together by minimum two parallel conductors. The contractor shall furnish the detailed design and calculations for Owner's approval. Contractor shall obtain all necessary statutory approvals for the system. The grounding resistance of the grounding system for power house and switchyard together shall not be more than 0.5 Ohms. The step and touch potentials shall be with in safe limits. The earthing system of the power station and switchyard shall be joined together. The grounding and lightning protection shall include complete grounding of PH and switchyard area including the equipment, earthing of all steel structures & bodies of all equipment. The equipment/work shall have following features: i. ii. iii. All earthing connections shall be sufficient to carry the fault current of 25 kA for 1 sec. Soldered joints shall not be used. All joints shall be made pressure type fitting or welded. The earth resistance of yard shall be not be more than that indicated above.

118

iv. v. vi. vii. viii. ix. x.

9.10

Touch and step potential shall be maintained in a safe value by grounding mat in accordance with IEEE-80 for a fault current of 25 kA for 1 sec. Fencing around the yard shall be earthed separately. Earth electrodes shall have facilities for measurements of resistance and watering during dry season. Earth mat shall be extended 150 cm beyond fencing. All structures and buildings shall be provided with lightning protection as per IS-2309. Complete earthing of transformer neutrals, L.A. earthing of all steel structures, earthing of bodies of all equipment etc. Any other item/work required for efficient completion of work.

SWITCHYARD STRUCTURES ETC.

Galvanized main and auxiliary structures for the equipment to be installed in the switchyard shall be provided alongwith other material e.g. conductors, clamp and connectors, insulators and hardware etc. complete as required.
LIGHTNING PROTECTION The lightning protection system shall be designed as per IS: 2309. It shall cover all buildings and structures in the plant, and switchyard areas. It shall comprise horizontal/vertical air terminations, down conductors, test links and earth connections to the station earthing grid. All conductors shall be of minimum 25x6 mm size and shall be of galvanised steel only. The down conductors of lightning protection system shall have a test joint at about 1500 mm above ground level. Each down conductor shall be connected to a 40 mm dia, 3 m long mild steel earth electrode as well as station earthing grid. The lightning protection system shall not be in direct contact with under ground metallic service ducts and cables, and shall not be connected above ground level to other earthing conductors. All joints in the down conductors shall be of welded type. 9.11

Pulser system for lightning shall not be accepted. Hazardous areas handling inflammable/explosive materials and associated storage areas shall be protected by a system of aerial earths as per IEEE: 142.
9.12 PAINTING AND FINISHING The colour code for the electrical equipment shall be as follows: Sl.No. Item Transformer Outdoor equipment Outdoor structures, bolts, nuts etc. H.T. Switchgear panels L.T. board etc. Panels, Dist. Boards etc. Junction Boxes Earthing Colour Paint Shade No. (as per IS:5,1991) 632 632 --

1. 2. 3. 4. 5. 6. 7. 9.

Dark admiralty grey Dark admiralty grey Galvanised Light gray Light admiralty grey Light admiralty grey Light grey Bus Greas

631 697 697 631 --

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The painting shall be, as per relevant IS. It shall be ensured that there will be no rusting, no peeling-off of the paint. The painting shall be long lasting type. The contractor shall ensure sufficient spare supply of paint for any touch-up required later on.
9.13 FENCING

The 33 kV / 11 kV switchyard shall be secured by surrounding it with 2 meters high M.S. pale fencing consisting of 2.3 m long 50 x 50 x 6 mm M.S. angle upright supports and two numbers 40 x 40 x 5 mm M.S. angle runners. The supports shall be spaced at 3 m interval and 75 mm vide pale strips shall be fixed on runners through G.I. bolts/nuts/washers at a clear spacing of 75 mm. The corner upright shall be supported with similar angle struts. The supports and struts shall be properly grouted.

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Annexure-9/1 CODE OF PRACTICE AND STANDARDS

IS-3231 IS- 1248 IS-722 IS-2705 IS-3156 IS-4237 IEC-157 IS-375 IS-8686 IS: 1248 IS: 2516 IEC 529

Electrical relays for power system protections Indicating Instruments Energy meters, control switches (LV switching devices for control and Auxiliary Circuits) Current transformers Voltage transformers General requirements for Switchgear and control gear for voltage not exceeding 1 kV Marking and arrangements for switchgear busbars, main connection and auxiliary wiring Specification for static protective relays Specification for direct acting electrical indicating instruments Specification for alternating current circuit breakers (Part I&II) Classification of degrees of protection provided by enclosure (IP code)

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SECTION X SPECIFICATIONS FOR 11 KV SWITCHYARD EQUIPMENTS

122

SECTION X TECHNICAL SPECIFICATIONS: 11 kV SWITCHYARD EQUIPMENT/WORKS

10.1 SCOPE

Design, detailed engineering, manufacture of equipment, shop testing, packing, transportation, loading & unloading, delivery, storage at site handling, erection, precommissioning tests and commissioning of the following equipment/system including preliminary acceptance test and performance guarantee for the following 11 kV switchyard equipment of the powerhouse. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12.
10.2

Isolators Circuit Breakers Lightning Arrestors Potential Transformers Current Transformers Bus Bars & Bus Connections Grounding/Earthing Lighting of switchyard Lightning Protection System for power house and switchyard Structures Fencing Any other equipment necessary to complete the job

CODES OF PRACTICE

List of Codes of Practice and Standards is given in Annexure10/1. All Codes of Practices and Standards shall be the latest editions including all applicable official Amendments & Revision as on date of opening of bid.
10.3 ISOLATORS 10.3.1 Application

These are to be used for: i. Breaker isolation/connection on no load ii. Line connection/isolation/ on no load
10.3.2 Type And Construction

i. ii. iii. v.

Triple pole gang operated suitable for outdoor installation in open yard under the specified site conditions. Common actuating mechanism for all three poles. Motor operated from Remote/local and also manually operable. Interchangeable single pole units

123

v. vi. vii. viii.

Switch blades shall be of copper and of one solid piece construction. Adequate Inter-phase clearance and mounting height. Speed of operation during opening or closing shall ensure minimum arcing. 11 kV isolator shall be horizontal double break type mounted on structure.

10.3.3 TECHNICAL PARTICULARS

i. ii. iii. iv.

Nominal system voltage Highest system voltage Rated frequency Type

: : : :

v. vi. vii. viii.

ix. x. xi. xii. xiii. xiv. xv.

Continuous current rating Short time rating 1 sec Rated peak withstand current Insulation level of a. Impulse withstand voltage (1.2/50 micro sec.) b. Between poles to earth Across Isolating distance c. One min. power freq. Withstand voltage (both dry & wet) d. Between poles to earth Across Isolating distance Min. creepage distance Operating mechanism Termination Earthing switch Auxiliary contacts Installation Interlocks

: : : : : : : : : : : : : :

11 kV 12 kV 50 Hz Outdoor station type, double break, triple pole double throw with turn and twist mechanism, with earth switch (on feeder isolator only) 630 A 750 MVA 12.5 kA Peak 75 kV 85kV 28 kV 32 kV 2.54 cm/kV Gang operated, Auto and manual/motorized ACSR conductor both sides Mechanically inter-locked with isolator. Rating of earthing Switch same as that of isolator 3 NO + 3 NC Pole structure with padlocking facility i. With upstream circuit breaker/isolator ii. Mechanical interlock with earthing switch for correct sequence of operation 48 V DC/230 V AC 50C

xvi. xvii.

Control voltage Temperature rise above 45 ambient

: :

124

d. e. f.

Disconnecting blades shall be capable of carrying rated current continuously as well as specified short circuit current for the duration indicated above without causing mechanical damage to any part or temperature rise which may damage the insulation. The switches shall be capable of making on to faults specified and withstanding the dynamic stress involved. The isolator shall be suitable for interrupting small inductive and capacitive currents such as those occurring while disconnecting lines at no load, bus bars or voltage transformers under energized condition.

10.3.4 CONTACTS

i. iv. v.

High pressure self-aligning adjustable type. Contacts shall be well protected all round by a metal cover to provide not only electrostatic screening but also to prevent coarse dust from entering between the contacts. Contacts shall be of high grade high conductivity heat resisting copper and silver plated.

10.3.5 OPERATING MECHANISM

i. ii. iii. iv.

It shall be suitable for motorized and also manual operation. Operating mechanism and its controls shall be so designed that under no circumstances the travel of the switch blades is interrupted before it reaches the fully closed or open position. Provision for padlocking the mechanisms in either the open or closed position shall be provided. Housing for the operating mechanism and its control shall be of sheet steel, weather and dust proof construction, with rubber gaskets conforming to enclosure protection class IP-55.

10.3.6 EARTHING SWITCHES FOR LINE ISOLATORS

iv. v. vi.

Disconnecting switches shall be provided with earthing switches on the line side forming integral part. Rating of earthing switch shall be same as that of the main isolator/disconnecting switch with respect to rated short time current and dynamic peak withstand current. Earthing blade shall be operated by a separate mechanism on manual and motorized mode but interlocked so that it can be closed only when the main disconnecting switch is open and vice-versa.

10.3.7 INTERLOCKS

i. ii. iii.

To be interlocked with associated isolators and circuit breakers through castle key and electrical interlock arrangement. Earthing switch and isolator interlocking. For closing of isolators main blades, associated earthing switches shall have to open and it is also to ensure that isolators are not used for on load closing.

125

iv v.

Final wiring or contact multiplication relay, blocking solenoid etc. shall be provided as per approved logic diagram. Breaker can be closed if associated earthing switches are open and isolators are in closed position.

10.3.8 TERMINAL CONNECTION

Shall be provided with high conductivity terminal connecting suitable for ACSR conductors.
10.4 11 kV CIRCUIT BREAKERS

10.4.1 TYPE

v. vi. vii. viii.

Outdoor type Vaccum Circuit Breaker suitable for installation in open yard. Three identical single pole units linked together for simultaneous operation, complete with supporting frames and tie-rods. Capable of interrupting small inductive currents caused by switching of unloaded transformers and low capacitive current without causing undue over-voltage. The circuit breakers are to be supplied complete with their control and relay panels.

10.4.2 TECHNICAL PARTICULARS

i. ii. iii. iv. v. vi. vii.

Nominal system voltage Highest system voltage BIL Power Frequency withstand voltage Rated frequency Rated continuous current Closing mechanism a. Closing coil/tripping coil (2 nos.) b. No. of Poles Symmetrical short circuit withstand capacity Temperature rise Operating duty Dead time of breaker System neutral Min. creeping distance Control supply voltage Auxiliary, contacts with each circuit breaker Accessories

: : : : : : : : : : : : : : : : :

viii. ix. x. xi. xii. xiii. xiv. xv. xvi.

11 kV 12 kV 75 kV 28 kV 50 Hz 1250 A Electrical spring charging with 230 V AC motor and local manual closing. 48 V DC 3 750 MVA for 1 sec. Not to exceed 50oC above ambient temp. of 45oC. 0-3 min. CO-3 min.-CO. Adjustable between 0.3 sec. to 15 sec. Solidly Earthed 900 mm 48 V DC 6NO+6NC Interchangeable at site

126

a. b. c. d. e.

ON/OFF/TRIP Emergency tripping mechanism Termination suitable with connectors Anti-pumping operation Spring charge indicator

: : : : :

Mechanical as well as Electrical Mechanical ACSR Conductor To be provided To be provided

10.4.3 OPERATING MECHANISM xi. Electrically / Manually operated mechanism. Breaker shall be provided with trip free mechanism. xii. It shall be suitable for remote control from the control room. xiii. The operating mechanism shall be of spring charging type by electrical control under normal conditions. The mechanism shall be trip free electrically and mechanically. xiv. The motor for spring charging shall be suitable for operation on 230 V AC supply and shall have overload protection. xv. A local control switch with locking arrangement shall be provided for each breaker for local operating i.e. tripping and closing during maintenance, test etc. xvi. Local/remote selector switch and Trip/Normal/Close control switch shall be provided in the mechanism cabinet. xvii. An operation counter for each breaker shall be provided. xviii. Cabinet for operating mechanism and its accessories shall be as per relevant standards with padlocking facility. Cabinet shall be simplex type, all equipment mounted on front side and wiring on back in proper wire ways. xix. Panel illumination and anti-condensation heater shall be provided in the local and remote control panel with MCB and thermostat. xx. Closing circuit to operate satisfactorily from 85% to 110% of the rated control voltage and tripping from 50% to 110% of the rated voltage. 10.5 11 kV LIGHTNING ARRESTORS 10.5.1 TYPE i. Station class, 10 kA, heavy duty, non-linear resistance, metal oxide type gapless lightning arrestor for 11 kV system. ii. Self-supporting type in single pole assembly. iii. Suitable for pedestal mounting. iv. Outdoor type suitable for installation in open yard. v. Shall be designed to provide maximum protection against lightning and switching surges. 9.5.2 TECHNICAL PARTICULARS i. Nominal system voltage ii. Highest system voltage (rms) iii. Rated arrestor voltage (rms) iv. Continuous operating voltage (rms) v. Frequency vi. Power frequency with stand test voltage vii. Impulse voltage (peak) viii. System neutral connection ix. Nominal discharge current for 8/20 micro sec.

: : : : : : : : :

11 kV 12 kV 30 kV 24 kV 50 Hz 28 kV 75 kV Solidly earthed 10 kA (peak)

127

x. xi. xii.

Long duration discharge class as per IEC-99-4 Maximum residual voltage at nominal discharge current of 8/20 micro sec wave Maximum steep current impulse (1/20 micro sec.) residual voltage at nominal discharge current Arrester Housing a. One minute power frequency withstand voltage (rms) b. Lighting impulse withstand voltage Prospective Symm. Fault current for pressure relief test (rms) Disconnecting device

: : :

3/2 100 kVP (peak) 110 kV (peak)

xiii.

: : : :

28 kV 75 kV (peak) 40 kA Disconnecting devices as per IS: 3070 (Part-II) shall be connected in series with ground lead. 900

xvi. xv.

xvii.

Minimum creepage distance of porclain housing (mm)

10.6 POTENTIAL TRANSFORMERS 10.6.1 TYPE i. 11 kV outdoor type ii. Epoxy moulded dry type for 11 kV sealed type self cooled iii. Single phase design iv. Independently mounted v. Suitable for operation on 11 kV, 3 phase, 50 Hz AC systems 10.6.2 TECHNICAL PARTICULARS i. Standard ii. Nominal system voltage iii. Highest system voltage iv. Rated frequency v. System neutral earthing vi. Number of secondary

: : : : : : : : : : : : : :

vii. viii. ix.

Voltage ratio Class of insulation Insulation level a. One minute power Frequency withstand Voltage (wet and dry) b. Impulse withstand voltage For rating/other details Temperature rise Limits of voltage error & phase

IS-3156 (1992) 11 kV 12 kV 50 Hz Solidity earthed One 11kV 110 V / 3 3 F 28 kV 75 kV Refer single line diagram As per IS 3156 PartI/1992 As per IS 3156 Part-

x. xi. xii.

128

xiii.

displacements Accuracy & burden etc.

I/1992 As required

10.6.3 WINDING CONNECTION

i. ii. iii.

Any three single phase units shall be suitable for three phase connection in star/star formation on three phase system. The positive, negative and zero sequence impedances shall all be equal. Secondary winding to be used for metering.

10.6.4 LIMITS OF TEMPERATURE RISE

i. ii..

Limits of temperature rise specified in technical particulars shall correspond to 1.2 times the rated primary voltage applied continuously at rated frequency and at rated burden connected to both the secondary windings simultaneously. Temperature rise when 1.5 times the rated primary voltage is applied for 30 seconds after achieving stable thermal conditions followed by application of 1.2 times the rated voltage continuously, shall not exceed by more than 10C from the values specified above.

10.6.5 TERMINAL ARRANGEMENT

iv. v. vi.

Bi-metallic (Cu/Al) terminal connector shall be suitable for ACSR conductors. Suitable earth terminal connector to be supplied for connections to earth. Secondary terminals to be housed in weather and dust proof cabinet with provision for terminating PVC insulated, armoured and PVC sheathed control cables.

10.7

CURRENT TRANSFORMERS

10.7.1 TYPE 11 kV outdoor type 10.7.2 TECHNICAL PARTICULARS i. Standard ii. Nominal system voltage iii. Highest system voltage iv. CT Ratio v. Rated frequency vi. System neutral earthing vii. Short time thermal current rating for 1 sec. duration viii. Class of insulation xiii. Insulation level a. Peak impulse withstand voltage c. Rated one minute power frequency wet and dry withstand voltage xiv. Terminal

: : : : : : : : : : : :

IS-2705 (1992) 11 kV 12 kV As per Annexure-8/2 50 Hz Solidly earthed 25 kA F 75 kV 28 kV Suitable for ACSR conductor

129

xv. xvi.

Marshalling kisok For rating, ratio, class of accuracy and VA burden etc.

: :

IP-55 enclosure As required and shown in

10.8 BUSBARS AND BUSBAR CONNECTIONS 10.8.1 TECHNICAL PARTICULARS vi. Nominal system voltage : vii. Nominal current rating : viii. Bus conductor : ix. Short time rating : for 3 (three) seconds

11 kV 800 A ACSR DOG 750 MVA (12.5 kA)

10.8.2 CLEARANCE The net clearance in air of bus bars, jumpers etc. shall not be less than that given in CBIP manual. 10.8.3 ACSR CONDUCTOR ii. Construction

g. h. i. j. k. l.

Conforming to IS 398 (Part-III)-1996 Aluminum wire made from at least 910.5% pure electrolytic aluminum rods of EC grade with copper content less than 0.04%. Steel wires uniformly coated with electrolytic high grade 910.95% pure zinc. Steel strand hot dip galvanized with minimum coating of 250 gm/sq.m. No joints permitted in the individual aluminum strands and steel core of the conductor. No Joints permitted in bus bar and jumpers conductor.

10.8.4 TECHNICAL PARTICULARS Sl. No. 1. Description Wire diameter Aluminum (mm) Steel (mm) Sectional area of aluminum (sq.mm) Total sectional area (sq.mm) Overall diameter (mm) Approximate weight (kg/km) Maximum calculated D.C. resistance at 20C (ohms/km) Ultimate tensile strength (kN) Final modulus of elasticity (Kg/Sq.m) Coefficient of linear expansion x 10-6 per C Type of Conductor

2. 3. 4. 5. 6. 7. 8. 10.

6/4.72 7/1.57 103.6 118.45 14.15 394 0.2745 32.99 0.735x106 Kg/cm2 110.53

130 9.8.5 Hardwares

The bolted tension fittings complete with U-bolts arcing horns etc. shall be provided suitable for 11 kV bus bar. Clamps and connectors for connecting ACSR conductor shall be made of alloy casting. Bi-metallic connectors shall be used for connecting equipment terminals made of copper or brass. Bolts, nuts and washers for connectors shall be made of mild steel and electro-galvanized and passivated to make them corrosion resistant conforming to requirements of BS 1706.
9.8.6 INSULATORS

The insulators shall conform to the relevant latest IS standards (IS 2544, 731, 1248) and made of hard porcelain. Creepage distance shall be adequate for polluted outdoor atmosphere. Glazing of the insulator shall be uniform brown color, free from blisters, burns and other similar defects. The insulators shall have technical particular as detailed below: ix. x. xi. xii. xiii. xiv. xv. xvi. Type Nominal system voltage kV (rms) Highest system voltage kV (rms) Wet power frequency one minute withstand voltage kV (rms) Power frequency puncture kV (rms) Impulse withstand voltage kV(peak) Creepage distance in mm (minimum) Minimum failing load Post/Disc/Pin 11 12 28 1.3 times the actual voltage dry flash over voltage 75 580 10 kN (45 kN for disc insulators)

10.9

GROUNDING / EARTHING OF SWITCHYARD

Earthing system of the S/yard and power station shall be designed as per IS: 3043 and IEEE: 80. Earthing system network/earthmat shall be interconnected mesh of mild steel rods buried in ground in the switchyard area and/or earthing electrode type earthing system for the power house area as may be most suited to the existing power house. All off-site areas shall be interconnected together by minimum two parallel conductors. The contractor shall furnish the detailed design and calculations for Owner's approval. Contractor shall obtain all necessary statutory approvals for the system. The grounding resistance of the grounding system for power house and switchyard together shall not be more than 0.5 Ohms. The step and touch potentials shall be with in safe limits. The earthing system of the power station and switchyard shall be joined together. The grounding and lightning protection shall include complete grounding of PH and switchyard area including the equipment, earthing of all steel structures & bodies of all equipment.

131

The equipment/work shall have following features: xi. All earthing connections shall be sufficient to carry the fault current of 25 kA for 1 sec. xii. Soldered joints shall not be used. All joints shall be made pressure type fitting or welded. xiii. The earth resistance of yard shall be not be more than that indicated above. xiv. Touch and step potential shall be maintained in a safe value by grounding mat in accordance with IEEE-80 for a fault current of 25 kA for 1 sec. xv. Fencing around the yard shall be earthed separately. xvi. Earth electrodes shall have facilities for measurements of resistance and watering during dry season. xvii. Earth mat shall be extended 150 cm beyond fencing. xviii. All structures and buildings shall be provided with lightning protection as per IS-23010. xix. Complete earthing of transformer neutrals, L.A. earthing of all steel structures, earthing of bodies of all equipment etc. xx. Any other item/work required for efficient completion of work.

10.10 SWITCHYARD STRUCTURES ETC.

Galvanized main and auxiliary structures for the equipment to be installed in the switchyard shall be provided alongwith other material e.g. conductors, clamp and connectors, insulators and hardware etc. complete as required.
10.11 LIGHTNING PROTECTION

The lightning protection system shall be designed as per IS: 23010. It shall cover all buildings and structures in the plant, and switchyard areas. It shall comprise horizontal/vertical air terminations, down conductors, test links and earth connections to the station earthing grid. All conductors shall be of minimum 25x6 mm size and shall be of galvanised steel only. The down conductors of lightning protection system shall have a test joint at about 1500 mm above ground level. Each down conductor shall be connected to a 40 mm dia, 3 m long mild steel earth electrode as well as station earthing grid. The lightning protection system shall not be in direct contact with under ground metallic service ducts and cables, and shall not be connected above ground level to other earthing conductors. All joints in the down conductors shall be of welded type. Pulser system for lightning shall not be accepted. Hazardous areas handling inflammable/explosive materials and associated storage areas shall be protected by a system of aerial earths as per IEEE: 142.

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10.12 PAINTING AND FINISHING

The colour code for the electrical equipment shall be as follows:

Sl.No. Colour Paint Shade No. (as per IS:5,1991) 632 632 --

1. 2. 3. 4. 5. 6. 7. 8.

Item Transformer Outdoor equipment Outdoor structures, bolts, nuts etc. H.T. Switchgear panels L.T. board etc. Panels, Dist. Boards etc. Junction Boxes Earthing

Dark admiralty grey Dark admiralty grey Galvanised Light gray Light admiralty grey Light admiralty grey Light grey Bus Greas

631 697 697 631 --

The painting shall be, as per relevant IS. It shall be ensured that there will be no rusting, no peeling-off of the paint. The painting shall be long lasting type. The contractor shall ensure sufficient spare supply of paint for any touch-up required later on.
10.13 FENCING

The 11 kV switchyard shall be secured by surrounding it with 2 meters high M.S. pale fencing consisting of 2.3 m long 50 x 50 x 6 mm M.S. angle upright supports and two numbers 40 x 40 x 5 mm M.S. angle runners. The supports shall be spaced at 3 m interval and 75 mm vide pale strips shall be fixed on runners through G.I. bolts/nuts/washers at a clear spacing of 75 mm. The corner upright shall be supported with similar angle struts. The supports and struts shall be properly grouted.

133 Annexure-10/1 CODE OF PRACTICE AND STANDARDS

IS-3231 IS- 1248 IS-722 IS-2705 IS-3156 IS-4237 IEC-157 IS-375 IS-8686 IS: 1248 IS: 2516 IEC 529

Electrical relays for power system protections Indicating Instruments Energy meters, control switches (LV switching devices for control and Auxiliary Circuits) Current transformers Voltage transformers General requirements for Switchgear and control gear for voltage not exceeding 1 kV Marking and arrangements for switchgear busbars, main connection and auxiliary wiring Specification for static protective relays Specification for direct acting electrical indicating instruments Specification for alternating current circuit breakers (Part I&II) Classification of degrees of protection provided by enclosure (IP code)

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SECTION XI SPECIFICATIONS FOR POWER HOUSE AUXILLARIES

135

SECTION- XI SPECIFICATIONS FOR POWER HOUSE AUXILIARIES

11.

Power house auxiliaries shall consist of the following systems: 1 2 3 4 Batteries, Charging Equipment and D.C. Board Fire Protection System for Power House Lighting in Power House, switchyard & appurtenant works Lightning Protection of Power House & Switchyard - 1 Lot - 1 Lot - 1 Lot - 1 Lot

11.1 BATTERIES, CHARGING EQUIPMENT AND D.C. BOARD ETC. 11.1.1 GENERAL 11.1.1.1This specification broadly covers manufacture, supply, installation and commissioning of (a)Battery bank built of lead acid 2 volts cells of tubular plante type of suitable voltage and ampere hour as per calculation (b) one set of float and boost charger for quick and trickle charging of the batteries and for supplying required continuous DC load as per calculation and (C) one no. D.C. distribution board. 11.1.1.2 The batteries shall be used for supplying power to essential services where instant availability and reliability of D.C. supply are most important such as: 11.1.1.3 The battery and charger shall meet following load requirement: Continuous load for three hours Emergency load for one hour Intermittent load for 1/60 hour The tenderer shall give actual load requirement based on specification of the equipments offered and based on that sizing calculation i.e. voltage and amperehour shall be done and the calculation sheet shall be submitted compulsorily. 11.1.1.4 The charging arrangement for main batteries shall comprise installation of one sets of float and boost battery charger. The boost charger should be capable of quick charging the battery in 10 hrs. from the fully discharged condition. The charger shall be connected to the batteries through D.C. distribution board, which shall have a charger load bus, load bus, emergency load bus contactors, MCCBs, and MCBs. By means of MCCBs, it shall be possible to connect any of the charger or Battery to the load bus. Under normal operating conditions, battery charger shall be connected to load bus, float charger shall be ON while boost charger shall be OFF, to keep the battery floating. 11.1.1.5 The float charger shall be capable to trickle charge the batteries at 1.3 volt/cell, while supplying a permanent load as arrived as per calculation/requirement. Boost charger shall be capable of quick charging the batteries upto 1.7 volt/cell. The charger shall be provided with controls for adjusting the voltage between suitable range, so as to make them suitable for trickle charge as well as boost charge duty. For distribution of D.C.

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supply, a D.C. distribution board shall be installed with two incoming circuits from chargers one circuits from batteries and 12 outgoing circuits. One outgoing circuits shall feed the emergency lighting board, through emergency lighting contactors. The emergency lighting contactor shall supervise the A.C. supply to normal lighting boards and shall switch on D.C. lighting in the event of A.C. failure.
11.1.2 REQUIREMENT

i) ii) iii) i) ii) iii) iv) v) vi) vii) i) ii) iii) iv) v) vi) vii) viii) ix) x) xi) xii) i) ii) i) ii) iii) iv) v)

One no. battery bank as described above complete with stands, insulators, inter-row, inter-tier and inter-cell connectors. One set of automatic voltage regulated, static type full wave battery charger for batteries complete with filters, rectifier, AVR, voltmeter (0-100 V DC), ammeter 0100 Amps, moulded case circuit breaker, fuses etc. One no. D.C. distribution board equipped with: One positive and one neutral charger load bus. One positive and one neutral for load bus One positive and one neutral for emergency load bus One outgoing circuit controlled by MCCB from the charger load bus connecting load bus. Three incoming circuits of moulded case circuit breaker type, two from battery charger and one from battery. 14 outgoing circuits of miniature circuit breaker type, one of which shall feed emergency lighting board through emergency lighting contactors and remaining to the other D.C. loads. The D.C. distribution board shall be equipped with protective relays to give visible and audible alarms with buzzer silencing facility etc. under the following conditions: Over voltage at bus bar Under voltage at bus bar Battery ground (positive bus, negative bus) A.C. supply failure annunciation D.C. over load Earth leakage Float output D.C. fuse failure/MCCB trip Boost output D.C. fuse failure/MCCB trip Controller card defective Float charger failure Boost charger failure Alarm annunciation scheme for the above protections with "Alarm accept, reset and test push buttons." One No. 415V/230V A.C. emergency lighting contactor. Instrument for measuring Voltage for 415V A.C. supply D.C. output voltage of float and boost charger D.C. output current of float and boost charger Trickle charging current of battery and discharging current from battery Four outgoing circuit of miniature circuit breaker type from emergency load bus.

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vi)

An internal lamp with a door switch shall be provided. The distribution panel shall be physically matching with the charger panel in all respect and its construction will be similar to the charger cubicles. 11.1.3 TECHNICAL PARTICULARS
11.1.3.1 Connectors

Battery cells shall be accommodated in double row single tier arrangement on wooden stands. Sufficient No. of inter-row, inter-tier and inter-cell connectors shall be provided.
11.1.3.2 Potassium Hydroxide

It shall strictly comply with relevant ISS and shall be sufficient for one filling with 10% spare.
11.1.3.3 Water

The distilled water shall be sufficient for one filling and charge-discharge-recharge operations with 10% spare. It shall conform to IS:1069-1964 (revised).
11.1.3.4 Stand

The stand shall be constructed from seasoned teak wood and shall be robust enough to take the full load of batteries. The stand shall have bolted connections and should be supplied in pieces to facilitate entry in the battery room. The stands shall be coated with three coats of paints as per IS requirements.
11.1.3.5 Bolts & Nuts

Bolts and nuts for connecting the cells shall be effectively lead coated to prevent corrosion.
11.1.4 Float & Boost Charger For Battery Bank 11.1.4.1 Type

It shall be static type, full wave, suitable for boost charging and trickle charging to keep required nos.of cells battery floating under normal operating conditions while supplying permanent load upto 30 Amps.
1. 2. 3. 4.

Type of Rectifier No. of Units Manufacture type and designation and standard applicable A.C. Supply required

1 PH, SCR controlled Separate Boost and Float Charger Any reputed brand as per relevant IS specification

138 5. 6. a) b) 7. a) b) 8.

Percentage taps provided on the transformer Rated D.C. output for Boost Charger Float Charger Rated DC output Voltage for Boost Charger Float Charger

+ / - 5 % + / - 10 % As per calculation As per calculation

D.C. output voltage regulation +/-1% from no load to full load Maximum ripple current +/-3% 11. Overall efficiency 70 % 11. Unit dimension 1200 (L) x 550 (D) x 1500 (H) 11. List of major accessories of Please refer Bill of material 12. spares Constructional details 14/16 SWG CR sheets 13. In the event of failure of float charger, boost charger should be capable to boost/trickle charge the batteries and also to supply 30 Amps. permanent load.
11.1.4.2 Regulation

It shall be inherently voltage regulated static type with automatic regulation within plus and minus one percent from 10% of rated load to full load and shall have steep voltage drop beyond 110% full load. Both the chargers will be housed in a sheet steel cubicle of angle iron structure with adequate ventilation for natural air cooling, suitable for floor mounting indoor operation and having door at the rear side with locking arrangement for easy access to all the components housed in side as detailed below. The height of the charger shall be such as to allow easy operation of all the switches and push buttons.
11.1.5 D.C. Distribution Board: 11.1.5.1 D.C. Bus Bars: There shall be one charger load bus, one load bus and one emergency load bus. The charger load bus shall be rated for 200 Amp, 10kA short circuit withstand rating. Load bus bar shall be rated for 100 Amps, 10 kA short circuits withstand rating. The emergency load bus shall be rated for 50 Amps, 5 kA short circuits withstand rating. The charger load bus and load bus shall be connected through 100A MCCB. 11.1.5.2Outgoing Circuits: (12 Nos.) i) ii) iii) iv) v) vi) 1 No. feeder to control and relay panel. 1 No. feeder to L.T. Board. 1 No. feeder for 33 kV or 11 kV switchyard 4 Nos. feeders to Electronic governor panel 4 Nos. feeder to excitation panel 3 Nos. feeder as spare.

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One No. feeder for emergency lighting which will comprise of a emergency load bus and 4 Nos. outgoing emergency light circuits having 16 amps MCB in each circuit, each housed in D.C. panel itself. One main lighting feeder shall be connected to emergency load bus through emergency lighting contactors. The contactor will normally keep D.C. supply to the mini bus off, but in case A.C. fails it will automatically switch on the D.C. to emergency lighting. Note:

All above feeders except emergency load bus feeder will be connected through 32 amps MCB. Emergency load bus will be connected through 50 Amps MCCB.

11.1.5.3. One no emergency lighting contactor rated for 415/230 V. A.C. and provided with two sets of contacts controlling D.C. emergency contactor. The DC contactor rated for 24 Volt. controls D.C. emergency supply. 11.1.5.4 The board shall be complete with wiring, cable glands, cable lugs for termination of outgoing and incoming circuits, as shown in drawing. This drawing is tentative and tenderer is desired to submit his own drawing for approval of the purchaser. 11.1.6 Instruments

Following instruments may be installed on the charger: 1. 2. 3. 4. 5. 6. AC voltmeter 0-500 V with RY, YB, BR selector switch DC output-voltmeter for float charger DC output-voltmeter for boost charger DC ammeter for float output DC ammeter for boost output DC ammeter (centre zero) to measure trickle charging current to battery as well as discharging current from the battery.

11.1.7 Spares

The technical particulars of the spares shall be identical to those of corresponding components. Tenderer will give list of spares required for five years.
11.1.8 Tools For Battery Bank Cell testing voltmeter Thermometers Hydrometers Alkaline mixing tank Alkaline resistant jugs, funnels, rubber apron, rubber gloves, rubber siphon and rubber syringes, spanners

2 Nos. 2 Nos. 2 Nos. 1 No. 2 Nos. each

140 11.1.9 Design & Construction 11.1.10.1 Wooden stands shall be of first class seasoned teakwood. These shall be mechanically strong and coated with three coats of KOH resistant paint. 11.1.10.2 Charger shall be floor-mounting type totally enclosed in steel cabinet with provision of cable entry from bottom. All the breaker controls and instruments shall be mounted in front of the panel and at a convenient height to facilitate ease of operation. It shall be provided with hinged doors at the rear side. The charger cabinet shall be painted with approved shade colour as per ISS Plastic paint in gloss finish shall be used. 11.1.10.3 DC distribution board shall be floor-mounting type. It shall be totally enclosed in steel cabinet with welded steel work inside so as to make it rugged and all fuses bus bars and switches except their operating handle shall be mounted inside. Bus bars shall be covered with coloured PVC tapes or epoxy insulated and shall be designed for the appropriate current rating. A common ear thing shall be provided for the DC board. Cable glands shall be provided and mounted on the glands plate so as to facilitate easy termination of all the incoming and outgoing cables entering from the bottom. Front of the cabinet shall be hinged type. The cabinet shall be painted with approved shade colour. 11.1.11 Tests

Following tests shall be performed on each battery after installation at site. The tests shall be performed in accordance with IS:1651-1970 and the test results shall strictly conform to the provisions of the above said standard. i) ii) iii) iv) Visual inspection and dimensional check as per Para 11.4 of IS:1651-1970. Capacity test on complete batteries as per Para 11.5 of IS:1651-1970. Test for retention of charger as per Para 11.7 of IS:1651-1970. Potassium hydroxide supplied shall be tested in accordance with IS (revised).

Tests of Chargers Following tests shall be performed on each of the charger: i) General inspection of circuits, associated components and checking of wire etc. ii) Capacity test on charger to verify temperature rise of various components. iii) Calibration test of indication instruments. iv) Performance test on voltage regulating equipment both on auto and manual condition. v) Testing of overload and other protective devices.
Tests on DC Distribution Board

i)

General inspection of the board and associated components checking of working etc. Calibration test of indicating instruments provided on the D.C. distribution board.

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ii)

Test of insulation resistance. Test of safety devices such as over voltage, under voltage and ground fault alarms and lighting contactors etc.

11.2

Fire Protection Equipment / System For The Power House

Portable Fire Extinguishers, as per relevant ISS, of following types of requisite capacity shall be located at appropriate locations in the power house and switchyard as below for extinguishing of general fire, electrical fire, chemical fire, oil fire:

a. b. c. d.

Trolley mounted CO2 type : 2 cylinders CO2 type fire extinguishers : 2 Nos. Carbon Tetra-Chloride type : 1 No. forGeneral electrical installations, Any other type as required for different types of fire mentioned above.

The fire protection scheme / plan shall be got approved by the Department.
11.2.1 Fire buckets. Two sets of fire buckets, each set comprising 6 buckets filled with sand, shall be provided on covered steel stand at various places in the power house area. 11.3 Lighting in Power House, Switchyard and Appurtenant works:

11.3.1 Scope

These specification covers design, manufacture, supply, installation, testing and commissioning of the lighting system at the project. The scope covers lighting arrangement inside & around the powerhouse, switchyard, tailrace, forebay and other appurtenant works like bye pass, approach road near the power house and trash rack, etc. Including wiring as required.
11.3.2 Standards

IS: 3646 IS: 694 IS: 732

Illumination and glass index Wires Wiring installation conditions

11.3.3 General Requirements

A comprehensive illumination system shall be provided in the entire project i.e. all areas within the plant boundary. The system shall include lighting fixtures, distribution boards, lighting panels, junction boxes, receptacles, switchboards, cables and wires, conduits, etc. The system shall cover all interior and exterior lighting such as area lighting, yard lighting, street lighting, security lighting including wiring as per standard norms.

142 11.3.4 Design Criterion

The illumination system shall be designed on basis of best engineering practice and shall ensure uniform, reliable, aesthetically pleasing, glare free illumination. The design shall prevent glare/luminous patch seen on VDU screens, when viewed from an angle. Power supply shall be fed from 415/240 V normal ac power supply, station service board, and 24 V dc supply for emergency lighting. Lighting panels shall be located at different convenient locations for feeding various circuits. These panels shall be robust in construction with lockable arrangements and MCB for different circuits. 24V DC emergency lighting shall be provided in following areas: a. Machine hall 20 lux b. Control room 100 lux c. Exit points One light fixture each d. All other strategic locations for safe personnel movement during any emergency. DC lighting shall come on automatically on failure of normal ac supply. These shall be switched off automatically after the normal ac supply is restored and luminaries have attained their full glow. Lighting panels, fixtures, receptacles, distribution boards, switch boxes, conduits, junction boxes etc. shall be properly installed and earthed. All outdoor fixtures shall be weather proof type. Fluorescent fixtures, installed in other than control room areas shall have electronic ballasts. For control rooms, the ballasts shall be copper wound inductive, heavy duty type, filled with thermo-setting insulating moisture repellent polyester. All luminaries and their accessories and components shall be of the type readily replaceable by the available Indian makes. All fixtures and accessories shall be of reputed make and non-corrosive type. Acrylic covers/louvers shall be of non-yellowing type. The constructional features of lighting distribution boards shall be similar to AC/DC distribution boards described elsewhere. Outgoing circuits shall be provided with MCBs of adequate ratings. Wiring shall be by multi-stranded PVC insulated colour code cable laid in GI conduits. Wiring for lighting circuits of ac, and dc systems shall be run in separate conduits throughout. Minimum size of the wire shall not be less than 1.5 sq.mm copper or 4 sq.mm aluminium. Wire shall conform to IS: 694 and wiring installation shall be as per IS: 732. Conduits shall be of heavy duty type, hot dip galvanised steel conforming to IS: 9537. In corrosive areas, conduits shall have additional suitable epoxy coating. At least one 5/15A, 240 V universal socket outlet shall be provided in offices, stores, cabins, control room, switch gear room etc. 20A, 240 V ac industrial type receptacles shall be provided strategically in all other areas including switch gear room and control room. All these receptacles shall be 3 pin type and controlled with a switch. Suitable numbers of 63 A, 3 phase, 415 V ac industrial type receptacles with control switches shall be provided for the entire plant for welding and other purposes, particularly near all major equipment and at an average distance of 50 m.

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11.3.5

Illumination Levels And Type of Fixtures And Luminaries

Location i) Machine Hall ii) Control room iii) Offices iv) Switchyard, tailrace, around the power house, bypass channel v) Street lighting in the approach road near the power house vi) Outdoor storage handling vii) Garage/Car parking

Average Type of Fixture Illumination level (Lux) HPSV high/medium bay 200 Industrial trough type fluorescent Decorative mirror optics type -Do300 300 10 (general) 50 (on equip.) 20 20 70 HPSV flood light, weather proof HPSV street lights HPSV flood light, weather proof. Industrial trough type fluorescent

The lighting plan shall have to be got approved by the contractor from the Department. 11.4 LIGHTNING PROTECTION OF POWER HOUSE & SWITCHYARD.

The lightning protection system shall be designed as per IS: 23011. It shall cover all buildings and structures in the plant, and switchyard areas. It shall comprise horizontal/vertical air terminations, down conductors, test links and earth connections to the station earthing grid. All conductors shall be of minimum 25x6 mm size and shall be of galvanised steel only. The down conductors of lightning protection system shall have a test joint at about 1500 mm above ground level. Each down conductor shall be connected to a 40 mm dia, 3 m long mild steel earth electrode as well as station earthing grid. The lightning protection system shall not be in direct contact with under ground metallic service ducts and cables, and shall not be connected above ground level to other earthing conductors. All joints in the down conductors shall be of welded type. Pulser system for lightning shall not be accepted. Hazardous areas handling inflammable/explosive materials and associated storage areas shall be protected by a system of aerial earths as per IEEE: 142.

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11.5

GROUNDING/ EARTHING OF SWITCHYARD AND POWER HOUSE EQUIPMENTS

Earthing system of the S/yard and power station shall be as per IS: 3043 and IEEE: 80. Earthing system shall be individual copper earthings of all equipments in the switchyard area and the power house as may be most suited. Contractor shall ensure that the grounding resistance of the grounding system for power house and switchyard together shall not be more than 0.5 Ohms. The step and touch potentials shall be with in safe limits. Individual earthing by copper plate and copper strip of any equipments inside the power house like alternators, control panels, LT distribution board, not attaining the above values is to be redone by the contractor. The scope covers providing all materials required for earthing i/c civil works like digging of pits etc i/c any other item/work required for efficient completion of work. The earthing system of the power station and switchyard shall be joined together if possible. The grounding and lightning protection shall include complete grounding of PH and switchyard area including new earthing for the equipment, earthing of all steel structures, bodies and neutrals of all equipment in the Switchyard as the Switchyard is being constructed new. The equipment/work shall have following features: xxi. xxii. xxiii. xxiv. xxv. xxvi. xxvii. xxviii.
11.6

All earthing connections shall be sufficient to carry the fault current of 25 kA for 1 sec. Soldered joints shall not be used. All joints shall be made pressure type fitting or welded. The earth resistance of switch yard and Power house shall be not be more than that indicated above. Touch and step potential shall be maintained in a safe value by grounding in accordance with IEEE-80 for a fault current of 25 kA for 1 sec. Fencing around the yard shall be earthed separately. All earth electrodes shall have facilities for measurements of resistance and watering during dry season.. All structures and buildings shall be provided with lightning protection and shielding as per IS-23011. Any other item/work required for efficient completion of work. Earthing should conform to relevant IS specification.

PAINTING AND FINISHING

The painting shall be, as per relevant IS. It shall be ensured that there will be no rusting, no peeling-off of the paint. The painting shall be long lasting type. The contractor shall ensure sufficient spare supply of paint for any touch-up required later on. Colour shades for different equipments inside the Power House and Switchyard shall be approved by purchaser.

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SECTION XII SPECIFICATIONS FOR ERECTION, TESTING AND COMMISSIONING

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SECTION XII SPECIFICATION FOR ERECTION, TESTING AND COMMISSIONING

12.1 MAIN POWER PLANT AND POWER HOUSE AUXILIARIES

The turbine, generators their auxiliaries and other common auxiliaries of the power house shall be erected at site in most professional way and proper sequence in coordination with civil works. The main equipment to be erected are as follows:
Sl. No. Item Unit

1. 2. 3. 4. 5. 6. 7. 8.

Turbines & their auxiliaries Generators & their auxiliaries including excitation AVR and terminal equipment Main inlet valves and oil pressure units etc. Governors with electronic cabinets complete Control and Relay Panels Station auxiliaries as detailed in Section-XI Transformers (.4/33 kV or .4/11 kV as the case may be ) 33 kV or 11 kV (as the case may be) switchyard equipment, bus bars etc. as detailed in Section IX & X Other remaining items

Set Set Set Set Set Lot Nos. Lot As mentioned in Schedule of Quantities of respective works.

9.

12.1.1 Test At Site

The contractor shall prepare and submit to the engineer for approval site testing manual not later than two month before commissioning is due to commence. The manual shall list in detail the tests to be performed during commissioning taking into consideration field tests to be performed for turbines, generators, transformer, breakers, control and protection equipment, switchyard equipment and auxiliary. The contractor shall provide all testing instruments and shall perform the tests set out in the manual in the presence of the engineer. The testing requirements are briefly described below.

147 Tests Prior to First Rotation

The contractor shall demonstrate to the engineer that the following items of equipment operate satisfactorily and where applicable are correctly adjusted or calibrated. Tests shall include but not be limited to: a) b) c) d) Polarity testing, ratio testing and magnetizing curves of all current transformers Polarity testing, ratio and insulation testing of voltage transformers Initial charging, commissioning and testing of batteries. High voltage insulation testing of the following : a) Cables b) Transformers c) Generators d) Switchgear Full functional checking and setting up of the following All ancillary AC apparatus All ancillary DC apparatus chargers/ distribution boards etc. All alarms and trip All electrical protection All hydraulic systems All cooling systems Switchgear ( 415V, 33 kV ) All associated turbine and generator control protection and miscellaneous items
Initial Run, Test Runs and Test Service Period

e)

The procedure for initial run, and test runs including testing of speed and pressure transients on load acceptance and rejection shall be in accordance with IEC Publication 545 Guide for Commissioning, Operation and Maintenance of Hydraulic Turbines or relevant IS or standards of the country of origin.
Field Acceptance Test

All field acceptance test as detailed for Turbine, Generator, Transformer, Breakers, Control and Protection Equipment, Switchyard Equipment and Auxiliary etc. shall be performed.

148 12.1.2 Tests for turbine output

The guaranteed range of outputs for each scheme shall be tested. The testing shall be in accordance with IEC Publication. No. 41 International Code for the Field Acceptance Tests of Hydraulic Turbines of relevant IS or standard of the country or origin. The Contractor shall calibrate the pressure gauges with a mercury manometer prior to the testing. The turbine output in each test will be determined by measuring the electrical output of each unit and subtracting generator losses calculated from the generator works test results. When comparing the site test results with the Contractors guaranteed performance, the error in the test results shall be assumed to be as allowed in IEC Publication No. 41 or relevant IS or standards of the country of origin.
12.1.3 Generator Output and Temperature Rise

The generator output in relation to guaranteed temperature rise shall be tested at site by performing a heat run in accordance with relevant IS. The resistance temperature detector installed in the generator stators shall be used to measure machine temperature.
12.1.4 Generator Transformer Losses

Test for determining transformer Losses guaranteed under penalty shall be performed.
12.1.5 Tests on Completion and Handing Over

The tests described in the foregoing subsection entitled Field Testing shall be the Tests on Completion. The tests must be completed to the Engineers satisfaction and the equipment retested where necessary before the taking over certificate will be issued For successful completion of field tests of the mechanical equipments, the calibration of various instruments shall be done by authorized agencies only as approved by the owner. A separate handing over certificate will be issued in respect of each set of generating equipment.
12.1.6 Commissioning

The term COMMISSIONING shall mean the activities of functional testing ofcomplete system after erection, including tuning or adjusting the equipment for optimum performance meets the requirement of the specifications
12.2 12.2.1 SWITCHYARD EQUIPMENT General

i.

All electrical installation shall conform to the Indian Electricity Act, IE Rules and Regulations in force, in the State, as laid down Electrical Inspectorate.

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All works under this contract including the installation of the equipments shall be got inspected and approved by the relevant authorities like Electrical Inspectorate etc. iii. The switchgear, current transformers, lightning arresters, power transformer, etc., shall be examined on receipt for damages. The contractor shall assemble, install and connect the equipment, wherever necessary, as per manufacturers recommendations. The assembly of the unit including their operating mechanism, site adjustments shall also be carried out as per guiding instructions from the manufacturer. The equipment shall be placed and leveled carefully on their respective structures. All the preparatory works such as civil foundations, any concrete channels etc., shall be completed prior to this. iv. The operating mechanism and control circuit of the equipment shall be tested for proper opening, closing and position indication. The opening and closing tests shall be made from control points as in service operation. v. Earthing of supporting structures and metal parts of operating mechanism, operating cabinets, operating handles at ground potential shall be ensured. Where moving parts are involved, flexible copper conductors shall he used. vi. Before charging the equipment, contractor shall submit the completion report for each equipment indicating rectifications/modifications carried out during erection, site test certificates with observations if any. Contractor shall also indicate the correctness of operational and safety interlocks. Site test certificates shall also indicate the corresponding values obtained in the factory test. vii. The conductor/jumpers shall be correctly and effectively connected to the terminals of equipment. The faces shall be cleaned with fine cloth and lightly coated with petroleum jelly before use. However, if contacts are silver plated, they shall not be cleaned with emery paper. The connection shall be flexible to withstand stresses during switching operation. viii. The control cabling shall be effectively crimped to the cable lugs which shall be bolted tight after ensuring that the contact faces are clean. Small wiring that is necessary between units in accordance with the diagram of connection shall be made complete. ix. The contractor shall be responsible for completion of the system necessary for successful operation as a whole and would provide any equipment which may be required but may not have been specifically mentioned in this specification. x. The civil works required at switchyard for installation of various equipment/structure/cables etc is not covered in the scope of this tender. ii.
12.2.2 Scope

It covers all the works related to Erection, Inspection, Testing & Commissioning etc. of all the equipment .
12.2.3 Installation of Transformer

i.

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.

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ii.

iii. iv. v.

vi.

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 upto 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 general sequence of erection of transformers: a. Unpacking of closed/packed cases and comparing with the packing list. b. Physically checking and inspecting, paying particular attention to the following components to ensure that the same are in sound conditions;

Tank sides or cooling tubes Protruding fittings Oil sight glass Bushings Tightness of Bolts Oil leakage. Transportation to erection site. 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 suppliers/ engineers instructions. IS 1886 and manufacturers recommendations. Submission of completion report. Charging of transformer. Loading of transformer. Handing over to engineer/owner

c. d. e. f. g. h. i. j. k. l. m. n. o. p. q. r. s. t. u.

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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 (latest revision). 12.2.4 Installation of Isolators

i. ii. iii. iv. v.

The poles of the isolators shall be aligned accurately and levelled on the supporting structures. Sequence of installation of isolator parts shall be carried out as recommended by manufacturer. Perfect operation of isolators, earthing switches shall be ensured after erection by normal operation. Working clearance between adjacent structures and switch blades in open position shall be checked. The isolators shall be adjusted so as to permit operation with ease by one man. Laying, termination of power and control cables, checking of internal wiring connections. The contractor shall also check for the key interlocking of the earthing switch with the main disconnect switch. Earthing between units, earthing terminals to structure, operating handle to structure and ground mat should be effective and neatly taken through structures and foundation. Ground mat shall he positioned right below the operating handle of the disconnect switch.

12.2.5 Installation of Lightning Arresters

The lead connecting lightning arrester with line should be direct without any splice or other joint and the connection should be effective to carry the lightning discharge currents. The lightning arrester shall be positioned in such a way that short and straight leads can be run from the earthing terminal of the arrester to the earth electrode specifically provided for this purpose. The arrester exhaust ports should be directed away from the equipment and other arrester.
12.2.6 Interconnection of Equipments

i. 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. e) 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. f) 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. g) 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.

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h)

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.

12.2.7 Installation of Switchgear Panels

i. 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. ii. 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. ii. 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 two panels, wherever disconnected for transport, shall also be connected.
12.2.8 Installation of Grounding/Earthing

i.

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, so that the values of the step and touch potentials in case of faults are kept within safe permissible limits. ii. The principal requirements of the grounding are: a. Low resistance and adequate current carrying capacity. b. 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 for the network of outdoor yard under all conditions. 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. All equipment located at switchyard, shall have 2 separate distinct earth connections. Switchyard fencing shall be earthed at every alternate section.

iii. iv. v.

vi.

153

vii. viii. ix. x. xi. xii. xiii. xiv. xv.

Lightning arrestors and transformer neutral shall be connected to two independent earth electrodes as per IS 3043. Air termination rods of lightning protector systems shall be connected to earthing network as per IS 3043. 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 though 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 representativein-charge of the works.

Installation of Earth Pits

i. 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. ii. The distance between two pits shall preferably be 4 to 6 meters. iii. 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. iv. The electrodes shall be well packed with earth, charcoal and salt mix up to the level of connections.
Joints/Terminations Of Earth Strips

i. All joints of bare earth strips shall be welded so as to form rigid earth ring. All such welded joints shall be given necessary coating of cold galvanised paint as per relevant standards and a coat of suitable bitumen compound to prevent corrosion. ii. 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. iii. 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.

154

12.2.9 Installation of Cables i) Scope

The supply, laying, termination and commissioning of all control/protection cable is in the scope of the contractor. He shall also be responsible for providing, laying and commissioning LT cables for switchyard lighting at power station. Cable schedules/termination drawings in respect of above cabling work shall be submitted to the bidder for his approval.
ii) Mode of Cable Installation

Straight through joints shall not be permitted in cables.

iii) Trenches

The maximum depth of all trenches shall normally be 1 .0 metre and the maximum soil cover above the protective slabs shall be 75 cms, unless otherwise agreed. The back filling of the excavation shall be carried out without disturbing the cover slabs or damaging the cables.
iv) Cable Laying In Trenches

a) b)
v)

The cables shall be laid in trenches as steel radis duly clamped in proper and systematic manner. Unless agreed otherwise, all power cables shall be spaced at a distance of 15 cms horizontally.

Markers

a) b)
vi)

Approved cable markers of reinforced concrete shall be provided and fixed to mark each and every deviation of all cable routes. A marker shall also be placed every 50 metres along straight portions of each route. A concrete cable marker shall also be provided and fixed to mark the position of every joint, if any.

Supporting Steel Work For Outdoor Switchyard Equipment

All supporting steel work shall be free from dirt, rust or scale and shall be galvanised.
vii) Cable Supporting Structure

a) b) c)

Cable supporting structures shall use angle of minimum size of 50 x 50 x 6 mm. The structure shall be painted. The cable supporting material shall be fixed to concrete and brick work by the use of anchor bolts. Fibre plugs shall not be used.

155 viii) Cable in Pipe

a) b) c)
ix)

Cable pipes shall be provided to protect the cables, where the cables rise through holes at ground level. Not more than one cable shall be drawn into one pipe unless agreed otherwise. After the cable has been drawn in, the pipe shall be sealed.

Cable Terminations

i.

Cable shall be terminated in accordance with the relevant diagrams. The cable cores from the sealing box or gland, to the terminals of the apparatus shall be neatly dressed & arranged, and shall be of sufficient length to prevent the development of tension or local pressure on the insulation. They shall be suitably supported wherever required.

x)

Identification & Marking

a)

End of each core of every control cable shall be provided with tight ferrules of approved make and white non-flammable plastic insulation material, having the marking engraved in black to correspond with the relevant diagram. Where the ends of one conductor have different markings, each end shall also have white ferrules engraved in red with the remote marking. Distinguishing labels of non-corrodible material marked in accordance with the cable numbers of the cabling diagram shall be permanently attached to each end of every cable. The phase or polarity of each power cable core at the cable ends shall be identified as follows AC System : Phase Neutral Red, Yellow and Blue painted discs Black painted disc

b)

c)

xi)

Connection to Terminals

a) b) c) d) e)
xii)

Power cable connections shall be made with cable lugs of approved type and materials, taking into account the bimetallic actions. All control circuit connections shall be made with the bare conductor with the use of washers crimped lugs etc. The ends of all stranded conductors shall be twisted tightly together. Solid or stranded conductors shall be connected to terminal studs by taking one complete turn around the stud between the flat washers. Connections to an easy wiring terminal shall be made with a straight end conductor.

Protection of Cables

All cables shall be installed such that the risk of damage is minimized.

156 xiii) Sealing The openings of cables passing from are basement to cable trench, basement to cable tunnel/spare ducts etc. to be sealed properly to prevent seepage of water.

12.2.10 Guidelines For Clearances

i)

Clearance from buildings/between equipments shall be decided as per the following guidelines: i) All equipment/panels shall have minimum 1250 mm back clearance all around them (except when the panels are installed adjacent to each other). j) The front to front clearance of switchboards/panels shall be 2000 to 2500 mm as per drawing approved by the purchaser. Clearance between two panels installed in a row shall be minimum 1000 mm. k) Clearance between wall and end of the panels shall be minimum 1000 mm.

ii)

Cable Trenches

a) b) c)
iii)

Cable trenches shall have removable covers for the full width. Minimum working passage of 500 mm shall be provided between cable racks or between cable rack and wall. Shall have suitable drainage facility to avoid accumulation of seepage water.

Safety Partitions and Entries

All the cable openings on the equipment floor shall be sealed.

12.2.11 Inspection and Testing a) b)

The procedure outlined in earlier shall be adhered to in regard to inspection and testing.
Tests, Test Certificates and Documents

For each of the items being manufactured following test certificates and Documents (as applicable for each of the equipment) in requisite copies shall be prepared and submitted to the purchaser for scrutiny & records. Should the result of tests not come within the margin specified, the tests shall, if required, be repeated at contractors cost without any liability to the Purchaser. The site tests and acceptance tests to be performed by contractor are detailed below.
c) Site Tests and Checks

All the equipment shall be tested at site to know their condition and to prove suitability for required performance.

157

Following tests shall be conducted after installation. All tools, accessories and required instruments shall have to be arranged by the Tenderer. Any other test which is considered necessary by the manufacturer of the equipment has to be conducted at site. The tests to be carried out on the equipment at pre-commissioning stage shall include but not limited to the following.

Vacuum Circuit Breaker

i. ii. iii. ii. iii. iv. v. vi. vii. viii.

IR test on each pole by Meggar (Between phases and phase to ground) by 2.5 kV tester. IR tests on control circuits. Functional check of breaker operation on minimum and maximum specified control voltages. Checking of interlocks with Isolators & Earthing switches. Measurement of contact resistance. Checking of operation and tripping of protection release. Checking tightness of termination connectors and earthing connections. Checking of insulators for cracks etc. Check for closing and opening time and simultaneous closing of all poles through oscillograph. Tripping of circuit breaker at reduced or over voltage of 60% & 110%

Isolator/Disconnecting Switches

i. ii. iii. iv. v. vi. vii. viii.

IR test by HV Meggar on main poles. IR test on control circuits. Measurement of Contact resistance for all three phases. Functional checking for manual operation. Checking of interlocking with earth switch Checking of earth switch operation . Checking tightness of earthing connections. Checking of insulators for cracks.

Lightning Arrestors

i. ii. iii. iv. v.

Continuity Check (for metal oxide type only) Check for connection to ground. Check insulators for cracks. HT and IR test of each element. Check reading of leakage current

Current Transformers

i. ii. iii. iv.

IR test on each winding, winding to earth and between windings. Checking of winding ratios by primary injection test set. Polarity check on each winding. Continuity check for all windings.

158

v. vi. vii. viii. x. x.

Check for connections to correct taps. Checking of oil level (if applicable). Checking of continuity and IR values for cables form CT to Marshalling Box. Checking tightness of earthing connections. Checking of insulator for cracks. Check output after loading of the main circuit

Potential Transformer

i. ii. iii. iv. v. vi. vii. viii.

IR test on each winding, winding to earth and between winding. Polarity check on each winding. Continuity check for all windings. Turns ratio test Check for connections to correct taps. Checking of oil level Checking tightness of earthing connections. Checking of insulator for cracks

Power Transformer

i. ii. iii. iv. v. vi. vii. viii. ix. x. ix. x. xi. xii. xiii. xiv. xv.

IR test on each winding to ground and between windings. Turns ratio test on each tap. Polarity and vector group test Measurement of winding group test. IR test of wiring and operational tests on all control devices in control cabinet, oil level indicator, winding and oil temp. indicators etc. Checking of earthing w.r.t transformer tank (flexible from top cover in tank) other parts, neutrals. Testing of Buchhloz relay for alarm and trip conditions. Setting of oil/winding temperature indicators, level gauge and checking of alarm/ trip circuits. Check insulators for cracks. Checking for oil leakage and arresting of leakages (if observed). Checking for open position of all the valves (except drain and filter valves). Filtrations of oil by using fine filter vacuum pump and heater set. BDV test on oil samples from top and bottom. Measurement of magnetizing current and no load loss. Measurement of PI Value. Checking of silica gel breather. Checking of other points given in manufactures commissioning manual.

Insulators

i. ii. iii.

Check for minor damage/cracks after cleaning. Verification of number of disks as per drawings. Check heating at termination point during shut down.

159

ACSR Conductor

i. ii. iii. v.

Check for continuity. Check for tightness of connections for all the termination points. Check for phase sequence marking and for their correctness. Physical verification.

Cables i. Checking of continuity/phasing and IR values for all the cables ii. HV test and measurement of leakage current after termination of cable kits (for H T cables). iii. Checking of continuity for Armour and fourth core (if applicable). Earthing

i. ii. iii. iv.

Check tightness of each connection Check earthing of all metallic equipment, busbar supporting structures, yard fencing, steel structures of yard, rails, gates, building column (if steel) etc. Measurement of earth resistance for each electrode. Measurement of total earth resistance.

Lightning Protection

i. ii. iii.

Check continuity of all the earth strips/shield wire. Check tightness of all connection. Measure earth resistance of each electrode and combined system.

Miscellaneous

i. ii iii. iv.

Checking of continuity of the system. Checking of phase sequence from overhead line to consumer end. Checking safe accessibility of all operating points. Check availability of control/aux supply.

VOLUMEIII

BRIEF DESCRIPTION OF THE EXISTING HYDEL STATIONS PUT TO TENDER

Certified that this documents contains 63 (Sixty three) pages excluding cover and index pages.

INDEX SL.NO
1 2 3 4 5 6 7 8

DETAILS
Chini Afra MHP (1 X 250 kW) Tafragam MHP (1 X 250 kW) Doorah Nallah MHP (4 X 100 kW) Abhapani MHP (1 X 250 kW + 2 X 100 kW) Mechuka MHP (2 X 50 kW + (1 X 250 kW) Ego- Echi (Dali) MHP ( 4 X 100 kW) Silli (Geku) MHP ( 2 X 250 kW) Yingkiong Ph-I MHP ( 3 X 50 kW) & Ph-II (2 X 100 kW) Pasighat MHP ( 2 X 100 kW) Rupa MHP ( 2 X 100 kW) Dulom MHP ( 4 X 100 kW) Rahung MHP ( 3 X 250 kW)

PAGE No.
14 5 10 11 16 17 21 22 27 28 33 34 39 40 45

9 10 11 12

46 50 51 54 55 58 59 - 63

CHINI AHFRA MICRO HYDEL PROJECT (1 X 250 KW) N.I.T No. NIT/R&M/2011-12/01

1.

INTRODUCTION OF THE PROJECT In recent years small hydro electric power has received great deal of attention from many point of view, one, as a sizable and easily utilization source of renewable energy and second, as a moderate investment method for providing electricity to underdeveloped areas. Electricity is most convenient form of energy, which is utilized for lighting and industrial production. Generation of electricity through small hydro electric schemes and its consumption does not pollute the environment and therefore can play important role for protection of the environment and in maintenance of ecological balance, especially for the isolated areas. Department of Hydro Power Development, Government of Arunachal Pradesh is entrusted with the design, construction, operation and maintenance of Power Projects in Arunachal Pradesh State. Arunachal Pradesh is bestowed with hilly terrain and abundant rainfall and has vast potential for harnessing the water of rivers and their tributaries for developing hydro electric power by construction of large, small, micro and mini power projects. The present requirement of electric power is partly met by import from Assam Electricity Board, partly by construction of small and micro-mini hydro-electric schemes in remote and isolated regions and still others through local generation by diesel fuel. Working period is short because of inadequate communication facilities and extended rainy season for seven to eight months in a year. There is no large thermal power station in Arunachal Pradesh. Number of hydel stations are under operation and maintenance in this state, out of which several hydel stations are very old and huge amount is being spent in day to day maintenance work. The power generation has also been reduced from their installed capacity. Hence there is a need for renovation & modernization of these power stations to uplift the Power generation up to their maximum installed capacity. Chini Ahfra MHP installed at Amuli near Anini is one of such projects need renovation and modernization.

2.

SAILENT FEATURES OF THE PROJECT I. 1) 2) 3) 4) GENERAL Name of the Project Name of river Location District Access a) Road: : : : Chini Ahfra MHP (1 x 250 kW) Chini Pani Amuli near Anini in Dibang Valley

2 i) Anini to Amuli ii) Roing to Amuli b) Nearest Rail Head c) Nearest Airport 5) Date of commissioning at Chini Ahfra HYDROLOGY i) Installed capacity ii) Catchment area iii) Type of River iv) Design Discharge III. PROJECT FEATURES 1) Intake i) Type ii) Width iii) Depth iv) Length 2) i) ii) iii) Forebay Tank Size Capacity Type : : : : 1 x 250 kW 72 sq km Perennial 1.6 Cumec : : : : : 13 km 223 km Doom Dooma 363 km from Project site Mohan Bari 348 from Project site 2001

II.

: : : :

RCC Trench Type Submersible 1.20 m 1.00 m 7m

: : :

19m x 9m x 3 m 513 cumec RCC

3) Spillway i) Type ii) Length iii) Section 4) i) ii) iii) iv) 5) i) ii) iii) iv) Feeder Channel Type Length Width Depth Power Channel Type Length Width Depth : : : : RCC 270 m 1.40 m 1.10 m : : : : RCC 21.50 m 1.40 m 1.10 m : : : RCC 30 m 1.3 x 1.00 m

6) i) ii) iii) iv) v) 7) a)

Penstock Pipe Number Length of each row Dia. Thickness Design Discharge E & M Equipments Turbine i) ii) iii) Type Number Capacity : : : : : : : : : Reaction turbine (Kaplan) 1 No. 250 kW Synchronous 1 No. 250 kW RCC Pillar CGI sheet roofing 31 m 10 x 6 m : : : : : 2 rows 340 m 600 mm (ID) 7.3 mm 2.3 cumec

b)

Generator i) Type ii) Number iii) Capacity Power House i) Type ii) Gross head iii) Size

c)

3. 3.1

GENERATING UNITS TURBINE : The turbine-generator set is running on partial load due to various problems. During visit on 08.11.2009, the plant was found running at about 25% load only. Generated current and voltage of 100A and 300V were observed on the ampere meter and voltmeter available on the panel. On trying to increase the load, abnormal sound was observed and therefore load has to be reduced. Following problems were observed in the plant equipment. Water leakage from G.V. bushes and glands. M/s Jyoti make type D Governor is working on manual arrangement. Feedback belt and hydraulic system is defective. Turbine bearing is defective. Coupling shaft may be deformed. Scroll casing of the turbine is damaged. Bearing temperatures meters & sensors are not available.

3.2

GENERATORS : M/s Jyoti make synchronous generator is of class B insulation. The following defects have been observed. The bearing is badly damaged. Shaft may be deformed. The insulation being class B and affected by flood water, may give way on running at rated voltage 415 Volts. Excitation system also appears to be not working properly as low voltage is being observed at the terminals of generator. Stator winding and bearing temperature sensors and indicators are all defective.

TAFRAGAM MICRO HYDEL PROJECT (1 X 250 KW)

N.I.T. No. NIT/R&M/2011-12/02

1.

INTRODUCTION OF THE PROJECT In recent years, small hydro electric power has received great deal of attention from many point of view, one, as a sizable and easily utilization source of renewable energy and second, as a moderate investment method for providing electricity to underdeveloped areas. Electricity is most convenient form of energy, which is utilized for lighting and industrial production. Generation of electricity through small hydro electric schemes and its consumption does not pollute the environment and therefore can play important role for protection of the environment and in maintenance of ecological balance, especially for the isolated areas. Department of Hydro Power Development, Government of Arunachal Pradesh is entrusted with the design, construction, operation and maintenance of Power Projects in Arunachal Pradesh State. Arunachal Pradesh is bestowed with hilly terrain and abundant rainfall and has vast potential for harnessing the water of rivers and their tributaries for developing hydro electric power by construction of large, small, micro and mini power projects. The present requirement of electric power is partly met by import from Assam Electricity Board, partly by construction of small and micro-mini hydro-electric schemes in remote and isolated regions and still others through local generation by diesel fuel. Working period is short because of inadequate communication facilities and extended rainy season for seven to eight months in a year. There is no large thermal power station in Arunachal Pradesh. A number of hydel stations are under operation and maintenance out of which several hydel stations are very old and huge amount is being spent in day to day maintenance work, and the power generation has also been reduced from their installed capacity. One such power station is installed at Tafragam in Lohit District. There is a need for renovation & modernization of Tafragam Mini Hydro Power Station to uplift the Power generation up to its maximum installed capacity. In view of this requirement, Govt. of India and department of Hydro Power Development, Govt. of Arunachal Pradesh decided to execute the R & M of their old and defective hydro electric projects. These authorities entrusted the preparation of detailed project reports for R & M of their old and defective hydro projects to Alternate Hydro Energy Centre, IIT, Roorkee. Besides several other projects, this project is also to be renovated and therefore, AHEC team visited the project site with senior engineers of the department. The data provided by the department and collected by the visiting team of AHEC have been incorporated in the DPR.

2.

SAILENT FEATURES OF THE PROJECT I. GENERAL 1) Name of Project 2) Name of Stream River 3) State 4) District 5) Village : : : : : R & M of Tafragam MHP ( 1 x 250 kW) Doorah Nallah Arunachal Pradesh. Lohit Tafragam Tezu, the district HQ (15 Km) Tezu Road - 182 Km from Dibrugarh to project site 9) Nearest Railway Head : Tinsukia, Assam (132 Km from project site) 10) Nearest Airport 11) Gross head 12) Net head 13) Design Discharge 14) Capacity 15) Date of Commissioning II. CIVIL WORKS A) Weir & Intake B) Headrace Channel 1) Length 2) Bed slope 3) Width of section 4) Height of section 5) Free board 6) Thickness of section : : : : : : 50 m 1 :200 1.20 m 1.50 m 0.30 m 0.20 m : : : : : : : Dibrugarh, Assam (182 Km from site) 120 M 109 M 0.332 cumec/ each 1 x 250 kW 1984 Existing Tailrace of Doorah Nallah

6) Nearest town/township distance : 7) Nearest Administrative Office 8) Access : :

C) Desilting Tank D) Forebay Tank 1) Length of forebay tank 2) Width of forebay tank 3) Height of forebay tank 4) Free board 5) Thickness of section

Desilting tank does not exist

: : : : :

17 m 17 m 3.0 m 0.30 m 0.30 m

E) Spillway Channel 1) Length 2) Bed Slope 3) Width of section 4) Height of section 5) Freeboard 6) Thickness of section F) Penstock Pipe 1) Length of main penstock : : : : : : : 25.0 m 1:200 m 1.20 m 1.20 m 0.30 m 0.20 m Existing 4000 mm 600 mm 1 Row 6.4 mm
300 mm 5.0 m long 300 mm 5.0 m long

Proposed

2) Diameter of main penstock pipe : 3) No. of rows 4) Thickness of pipe 5) Diameter of branch penstock G) Power House 1) Size of power house building 2) Type of power house building H) Tailrace Channel 1) Length 2) Bed Slope 3) Width of Section 4) Height of Section 5) Freeboard : : : : : : : : : :

16.00 x 9.00 x 6.90 m RCC framed structure

30.00 m 1:200 1.20 m 1.20 m 0.30 m

8 6) Thickness of Section III. E & M EQUIPMENT 1. i) ii) iii) iv) v) 2. i) ii) iii) iv) v) vi) 3. i) Turbine Type Number Capacity Make Rated Speed Generator Type Number Capacity Make Power Factor Drive Switch Yard Transformer : 315 kVA 0.415/11 kV, ONAN 630 kVA 0.415/11 kV ONAN : : : : : : Synchronous 1 No. 250 kW, 415V, 1000 rpm M/s Jyoti Ltd. 0.8 Directly Coupled Synchronous 1 No. 250 kW, 415V, 1000 rpm 0.8 Directly Coupled : : : : :
Horizontal Turgo Impulse Horizontal Turgo Impulse

0.20 m

1 No. 250 kW M/s Jyoti Ltd. 1000 RPM -

1 No. 250 kW

1000 RPM

IV. i) ii)

POWER Installed capacity Date of commissioning : : 1 x 250 kW 1984 1 x 250 kW -

3.

GENERATING UNITS; Unit I (Existing)

The turbine and generator installed at site require complete over hauling and proper repair/maintenance of the bearings and nozzle. Butterfly valve and OPU system are not working and these require renovation and replacement of defective parts. The terminal equipment of generator like LA/SC, CT, NGC etc. are defective. After over hauling, the unit needs to be re-installed with adequate care particularly the alignment and levelling. The control, protection and metering system may be provided with the panel as breaker, protection, metering systems and synchronization arrangements are defective. Unit II (Proposed) The equipment for second unit may be procured and installed as detailed below.

3.1

TURBINE, INLET VALVE, GOVERNOR & OPU: Turbine: 250 kW Turgo Impulse type suitable for 109 m net head with inlet and sluice valve in penstock and microprocessor based ELC and ballast conforming to relevant standards may be provided. Inlet valve: The inlet valve shall be of butterfly type operable through oil under pressure and shall be in accordance with IS 7326 1902. Governor: It is recommended to provide the governor by PLC based digital electronic governor with manually operated back up system for integrated unit and plant control. The governor shall be of proven design controlling the turbine by speed sense and load. The governor should provide flexibility in control, alarming, sequence of event recording and provide graphic display. The PLC should be of standard make, open architecture system allowing expansion. The governing system shall be complete-with actuator unit comprising of hydraulic pressure system, restoring mechanism, load adjustment, load limiting device, start / stop capability and emergency closure. The governor shall use PID (Proportional integral derivative) loop control in which three derivatives of speed are used for speed stabilization. Electronic governor shall provide following control: a. Speed Control b. Unit Control c. Suitability for Isolated Operation d. Suitability for Grid Operation Governor shall be fail safe on the failure of the speed sensing element, loss of oil pressure or defects in actuating system, so that under any of these conditions, the machine shall be automatically shut down with alarm and indication. Hand control device for stroking governor shall be provided. Oil Pressure Unit: The hydraulic pressure system shall comprise of two motors driven pumping unit, pressure tank, sump tank and piping etc.

3.2

GENERATOR: 250 kW Salient Pole Synchronous generator, 3 phase, 0.8 p.f., 50 Hz, 415 volts, with other terminal equipments conforming to IS 4722 and class F insulation of modern design with high efficiency suitable to run in isolation and in synchronizm with other machine and grid is recommended for coupling with above new 250 kW turbine.

10 New generator shall be salient poles synchronous generator of 250 kW at 415 V, 0.80 PF, 3 Phase A.C., 50 Hz, natural air-cooled self ventilated with brush less excitation. The generator shall be star connected complete with stator, rotor, bearings, stator and bearing temperature detectors, oil coolers for bearings, brush less excitation system comprising high frequency generator, diode wheel, AVR and protection equipment. The generator shall be designed to with stand the runway speed of the turbine for 30 minutes without any detrimental effect. The generator and excitation system shall be able to operate in isolation and parallel with grid. The generator stator and rotor shall have class F insulation with Class B temperature rise and designed for continuous operation with screen-protected enclosure. The generator shall be designed conforming to IS 4722/1968/IEC-34/BS 4999. The six terminals from three main windings shall be brought out to the terminal box for insertion of current and voltage transformer for protection and metering. The generator neutral shall be directly connected to earth or through low resistance and disconnecting link. The generator shall be capable to operate with either leading or lagging power factor by control of excitation. The power factor commonly ranges between 0.80 and 0.95. The generator shall be designed to safely with stand any mechanical/ magnetic stresses resulting from either a three phase or a single phase fault. The short circuit ratio of generator shall not be less than 0.8. The AVR will have provision for regulating the voltage to the extent of 10% of rated voltage manually. The change in voltage from no load to full load on AVR mode will not exceed 5% of rated voltage. 3.3 Control/Protection and Metering: Control, protection and metering panel having ELCs and various protection / metering systems as indicated in single line diagram suitable for both units shall be provided. The control, protections and metering panel consisting of generator ACB, transformer ACB and other systems may be provided as shown in single line diagram enclosed.

11

DOORAH NALLAH MICRO HYDEL PROJECT (4 X 100 kW) N.I.T. No. NIT/R&M/2011-12/03
1. INTRODUCTION OF THE PROJECT In recent years small hydro electric power has received great deal of attention from many point of view, one, as a sizable and easily utilization source of renewable energy and second, as a moderate investment method for providing electricity to underdeveloped areas. Electricity is most convenient form of energy, which is utilized for lighting and industrial production. Generation of electricity through small hydro electric schemes and its consumption does not pollute the environment and therefore can play important role for protection of the environment and in maintenance of ecological balance, especially for the isolated areas. Department of Hydro Power Development, Government of Arunachal Pradesh is entrusted with the design, construction, operation and maintenance of Power Projects in Arunachal Pradesh State. Arunachal Pradesh is bestowed with hilly terrain and abundant rainfall and has vast potential for harnessing the water of rivers and their tributaries for developing hydro electric power by construction of large, small, micro and mini power projects. The present requirement of electric power is partly met by import from Assam Electricity Board, partly by construction of small and micro-mini hydro-electric schemes in remote and isolated regions and still others through local generation by diesel fuel. Working period is short because of inadequate communication facilities and extended rainy season for seven to eight months in a year. There is no large thermal power station in Arunachal Pradesh. A number of hydel stations are under operation and maintenance out of which several hydel stations are very old and huge amount is being spent in day to day maintenance work, and the power generation has also been reduced from their installed capacity. There is one such project installed on Doorah nallah river with capacity of 4 x100 kW. There is a need for renovation & modernization of Doorah Nallah Power Station to uplift the Power generation up to its maximum installed capacity. In view of this requirement, Govt. of India and department of Hydro Power Development, Govt. of Arunachal Pradesh decided to execute the R & M of their old and defective hydro electric projects. These authorities entrusted the preparation of detailed project reports for R & M of their old and defective hydro projects to Alternate Hydro Energy Centre, IIT, Roorkee. Besides several other projects, this project is also to be renovated and therefore, AHEC team visited the project site with senior engineers of the department. The data provided by the department and collected by the visiting team of AHEC have been incorporated in the DPR. 2. SALIENT FEATURES OF THE PROJECT I. (i) (ii) (iii) GENERAL Name of Project Name of Stream River State : : : Doorah Nallah MHP ( 4 x100 kW) Doorah Nallah Arunachal Pradesh

12 (iv) (v) (vi) (vii) (viii) (ix) District Village Ref. of Toposheet Nearest town Township with distance Nearest Administrative Office Access : : : : : : Lohit Tafragam 92 A/1 Tezu, the district Head Quarter (15 Km) Tezu Road 195 Km from Dibrugarh to project site Tinsukia, Assam (145 Km from project site) Dibrugarh, Assam (195 Km from project site) 350.00 Sq. Km. 1.15 Cumecs 55.00 M 50.00 M 0.260 cumec per each machine 4 x 100 kW = 400 kW 25.05.1976

(x)

Nearest railway head

(xi) (xii) (xiii) (xiv) (xv) (xvi)

Nearest airport Catchment Area Discharge Gross Head Net Head Design Discharge

: : : : : : : :

(xvii) Capacity (xviii) Date of Commissioning II. (i) (ii) (iii) (iv) (v) (vi) (vii) (viii) (ix) WEIR & INTAKE Length of diversion Top width of trapezoidal section Side slope Height Thickness of section Length of U/s apron Length of D/s apron Total length of apron Height of apron

: : : : : : : : :

8.00 M 0.90 m 1:0.5 1.00 M 0.70 M 5.00 M 0.70 M 8.00 M 2.00 M

13

III. (i) (ii) (iii) (iv) (v) (vi) IV. V. (i) (ii) (iii) (iv) (v) VI. (i) (ii) (iii) (iv) (v) (vi) VII.

HEAD RACE CHANNEL Total length Bed slope Width of section Height of section Free board Thickness of section DESILTING TANK FOREBAY TANK Length Width Height Free board Thickness of section SPILLWAY CHANNEL Length Bed slope Width of section Height of section Free board Thickness of section PENSTOCK PIPE : : : : : : 25.00 M 1:200 1.20 M 1.20 M 0.30 M 0.20 M : : : : : 24.00 M 10.50 M 3.00 M 0.30 M 0.30 M : : : : : : : 1355.00 M 1:400 1.20 M 0.90 M 0.30 M 0.15 M Not exist

MAIN PIPE (i) (ii) (iii) (iv) (i) (ii) Length of penstock pipe Diameter of penstock pipe No. of rows Thickness of pipe Length of penstock pipe Diameter of penstock pipe : : : : : : 78.00 M 450.00 MM 2 Rows 6.4 MM 6.00 M 250.00 MM (ID)

BIFURCATION PIPE

14 (iii) (iv) HEAD (i) (ii) Gross head Net head : : 55.00 M 50.00 M No. of rows Thickness of pipe : : 4 Rows 6.0 MM

VIII. POWER HOUSE (i) (ii) Size of power house building : Type of power house building: 18.50 M x 9.00 M x 6.90 M RCC framed structure with CGI sheet roofing (iii) IX. (i) (ii) (iii) (iv) (vi) X. XI. (i) (ii) (iii) (iv) (v) XII. (i) (ii) (iii) (iv) (v) Capacity TAILRACE CHANNEL Length Bed slope Width of section Height of section Free board SUSPENSION BRIDGE TURBINE Type Number Capacity Make RPM GENERATOR Type Number Capacity Make RPM : : : : : Synchronous 4 Nos. 125 kVA each Jyoti Ltd. 1000 RPM : : : : : Vertical shaft francis 4 Nos. 100 kW each Jyoti Ltd. 750 RPM : : : : : : 50.00 M 1:200 1.20 M 1.50 M 0.30 M 95.00 M Span : 4 x 100 kW

15 (vi) Drive : : Gear driven 2 Nos. 250 kVA, 0.415/11 kV, pf 0.8

XIII. TRANSFORMER

3. 3.1

GENERATING UNITS TURBINE, INLET VALVE, GOVERNOR & OPU Turbine: The turbine generator sets are reported to be in working order. Only unit 4 was running. The other units were not found running due to non- availability of water as water conductor system require maintenance works. The turbine, generator and their auxiliaries may be got checked and necessary maintenance works may be done. The defective parts are proposed to be repaired/replaced after inspection before water is made available. The defective ACBs, meters etc. may be replaced with new one of proper rating alongwith the protective relays meters. Protection relay as shown in the single line diagram annexed, may be procured. New control, protection and metering panels with breakers, digital meters, relays etc. may be provided with synchronizing arrangement for all the four machines. Inlet Valve : The inlet valves of butterfly type operable through oil under pressure and in accordance with IS 7326 1902 are proposed to be replaced with new sets. The sluice valves also to be replaced. Governors : It is recommended to provide the PLC based digital electronic governors with manually operated back up system for integrated unit and plant control. The governors shall be of proven design controlling the turbine by speed sense and load. The governors should provide flexibility in control, alarming, sequence of event recording and provide graphic display. The PLC should be of standard make, open architecture system allowing expansion. The governing system shall be complete-with actuator unit comprising of hydraulic pressure system, restoring mechanism, load adjustment, load limiting device, start / stop capability and emergency closure. The governor shall use PID (Proportionate integral derivative) loop control in which three derivatives of speed are used for speed stabilization. Electronic governor shall provide following control: a. b. c. d. Speed Control Unit Control Suitability for Isolated Operation Suitability for Grid Operation

16 Governor shall be fail safe on the failure of the speed sensing element, loss of oil pressure or defects in actuating system, so that under any of these conditions, the machine shall be automatically shut down with alarm and indication. Hand control device for stroking governor shall be provided. Oil Pumping Unit : The hydraulic pressure system shall comprise of two motors driven pumping unit, pressure tank, sump tank and piping etc.

17

ABHAPANI MICRO HYDEL PROJECT (1 x 250 kW + 2 x 100 kW) N.I.T. No. NIT/R&M/2011-12/04
1. INTRODUCTION OF THE PROJECT In recent years small hydro electric power has received great deal of attention from many point of view, one, as a sizable and easily utilization source of renewable energy and second, as a moderate investment method for providing electricity to underdeveloped areas. Electricity is most convenient form of energy, which is utilized for lighting and industrial production. Generation of electricity through small hydro electric schemes and its consumption does not pollute the environment and therefore can play important role for protection of the environment and in maintenance of ecological balance, especially for the isolated areas. Department of Hydro Power Development, Government of Arunachal Pradesh is entrusted with the design, construction, operation and maintenance of Power Projects in Arunachal Pradesh State. Arunachal Pradesh is bestowed with hilly terrain and abundant rainfall and has vast potential for harnessing the water of rivers and their tributaries for developing hydro electric power by construction of large, small, micro and mini power projects. The present requirement of electric power is partly met by import from Assam Electricity Board, partly by construction of small and micro-mini hydro-electric schemes in remote and isolated regions and still others through local generation by diesel fuel. Working period is short because of inadequate communication facilities and extended rainy season for seven to eight months in a year. There is no large thermal power station in Arunachal Pradesh. A number of hydel stations are under operation and maintenance out of which following hydel stations are very old and huge amount is being spent in day to day maintenance work, and the power generation has also been reduced from their installed capacity. One such power station is installed at Simari (Roing) in Lower Debang Valley District. There is a need for renovation & modernization of Abhapani Mini Hydro Power Station to uplift the Power generation up to its maximum installed capacity. In view of this requirement, Govt. of India and department of Hydro Power Development, Govt. of Arunachal Pradesh decided to execute the R & M of their old and defective hydro electric projects. These authorities entrusted the preparation of detailed project reports for R & M of their old and defective hydro projects to Alternate Hydro Energy Centre, IIT, Roorkee. Besides several other projects, this project is also to be renovated and therefore, AHEC team visited the project site with senior engineers of the department. The data provided by the department and collected by the visiting team of AHEC have been incorporated in the DPR. 2. SALIENT FEATURES OF THE PROJECT I. GENERAL 1) Name of Project 2) Location

: :

Abhapani MHP ( 1X250 + 2X100 KW) SIMARI Village in Lower Dibang Valley

18 District, Arunachal Pradesh. 3) Access a) Road b) Nearest Rail Head c) Nearest Air Port II. HYDROLOGY 1) Name of river 2) Catchment area 3) Type of river 4) Design discharge 5) Rated Head III. DIVERSION WEIR 1. Type 2. Shape 3. Length 4. Material : : : : : : : : : : Abhapani 35 Sq km Perennial 517 L/Sec (0.517cumec) 110 m Temporary Trench weir Trapezoidal 15 mtr. R.C.C. : : : : 15 KM Roing Town 155 Km from Dibrugarh Doom Dooma 85 Km from site Mohan Bari 140 Km

IV. FEEDER /POWER CHANNEL 1. Length 2. Shape V. DESILTING TANK VI. FOREBAY TANK 1. Size 2. Free board 3. Type : : : 57 X 23 X 3m 0.60m RCC (Trapezoidal) : : : 300 m Temporary earthen feeder channel Temporary proposed RCC Tank

VII. PENSTOCK PIPE 1. Number 2. Dia. 3. Length : : : One row of M.S pipe 600 mm 4980 m (4mm HR sheet Pen stock pipe) 1000 m to be replaced.

19

VIII.

POWER HOUSE : : : SPT 19.90 x 8.60 m 1 x 250 kW + 2 x 100 kW

1. Type 2. Size 3. Capacity IX. E & M EQUIPMENT 1. i) ii) iii) TURBINE Type Number Capacity

: : :

Turgo impulse (M/S Jyoti Ltd) 3 Nos. 2 Nos. of 100 kW 1 No. of 250 kW

2. i) ii) I ii)

GENERATOR Type Number Capacity : : : Synchronous (Jyoti make) 3 Nos. 2 Nos. of 100 kW 1 No of 250 kW

3. i) ii) iii) X. i) ii)

SWITCH YARD Transformer Make Type POWER Installed capacity Date of commissioning : : 2 x 100 kW + 1 x 250 kW December 1983. : : : 2 Nos. 315 and 100 kVA 0.415/11 kV Kirlosker Step-up ONAN

3. 3.1

GENERATING UNITS TURBINE, INLET VALVE & GOVERNOR Turbine:The 250 kW turbine-generator set is running on partial load due to various problems. During visit on 07.11.2009, the this machine was found running at about 30% load only. Following problems were observed in the plant equipment and R & M works are proposed accordingly. 250 kW

20 Gaskets and packings may be replaced. M/s Jyoti make Governor is working on manual arrangement. Hydraulic system is defective. The electronic governor may be provided. Defective bearing may be repaired. Defective Coupling may be repaired. Bearing temperatures meters & sensors may be repaired. Other maintenance works required in the parts found defective on opening the machine including general overhauling may be got done. 2 x 100 kW

These sets are not in working condition and repairs are beyond economic consideration therefore, these way be replaced with new unit of 250 kW capacity. Turbine of parameters as per existing 250 kW turbine is proposed to be installed in place of 2 x 100 kW defective sets alongwith the electronic governing system and main inlet valve etc. Inlet valve: The inlet valve shall be of butterfly type operable through oil under pressure and shall be in accordance with IS 7326 1902. Governor : It is recommended to provide the governor by PLC based digital electronic governor with manually operated back up system for integrated unit and plant control. The governor shall be of proven design controlling the turbine by speed sense and load. The governor should provide flexibility in control, alarming, sequence of event recording and provide graphic display. The PLC should be of standard make, open architecture system allowing expansion. The governing system shall be complete-with actuator unit comprising of hydraulic pressure system, restoring mechanism, load adjustment, load limiting device, start / stop capability and emergency closure. The governor shall use PID (Proportional integral derivative) loop control in which three derivatives of speed are used for speed stabilization. Electronic governor shall provide following control: e. f. g. h. Speed Control Unit Control Suitability for Isolated Operation Suitability for Grid Operation

Governor shall be fail safe on the failure of the speed sensing element, loss of oil pressure or defects in actuating system, so that under any of these conditions, the machine shall be automatically shut down with alarm and indication. Hand control device for stroking governor shall be provided Oil Pressure Unit : The hydraulic pressure system shall comprise of two motors driven pumping unit, pressure tank, sump tank and piping etc.

21

3.2

GENERATORS: 250 kW set

The Synchronous generator defects may be removed through adequate maintenance and overhauling including repair of the following parts. Defective bearing. Generator shaft. The windings with insulating paints. Excitation system and AVR. Stator winding and bearing temperature sensors and indicators. 2 x 100 kW sets

Both generators need to be replaced with one generator of 250 kW, 0.8 pf, 415V and 1000 rpm rating matching with the existing generator parameters of 250 kW set. The generator with class F insulation of modern design with high efficiency suitable to run in isolation and in synchronizm with the grid is recommended for above new 250 kW turbine. New generator shall be salient poles synchronous generator of 250 kW at 415 V, 0.80 PF, 3 Phase A.C., 50 Hz, natural air-cooled self ventilated with brush less excitation. The generator shall be star connected complete with stator, rotor, bearings, stator and bearing temperature detectors, oil coolers for bearings, brush less excitation system comprising high frequency generator, diode wheel, AVR and protection equipment. The generator shall be designed to with stand the runway speed of the turbine for 30 minutes without any detrimental effect. The generator and excitation system shall be able to operate in isolation and parallel with grid. The generator stator and rotor shall have class F insulation with Class B temperature rise and designed for continuous operation with screen-protected enclosure. The generator shall be designed conforming to IS 4722/1968/IEC-34/BS 4999. The six terminals from three main windings shall be brought out to the terminal box for insertion of current and voltage transformer for protection and metering. The generator neutral shall be directly connected to earth or through low resistance and disconnecting link. The generator shall be capable to operate with either leading or lagging power factor by control of excitation. The power factor commonly ranges between 0.80 and 0.95. The generator shall be designed to safely with stand any mechanical/ magnetic stresses resulting from either a three phase or a single phase fault. The short circuit ratio of generator shall not be less than 0.8. The AVR will have provision for regulating the voltage to the extent of 10% of rated voltage manually. The change in voltage from no load to full load on AVR mode will not exceed 5% of rated voltage.

22

MECHUKA MICRO HYDEL POWER PROJECT (2 X 50 KW) + (1 X 250 KW) N.I.T. No. NIT/R&M/2011-12/05
1. INTRODUCTION OF THE PROJECT The Mechuka valley is situated on Indo China boarder and Micro hydel project was commissioned in Feb 1989 with a installed capacity of 2 x 50 kW (Two nos. vertical double jet Pelton Turbine) on Tsingrung Thuchu nallah near Mechuka town. This project meets up the power requirement of entire Mechuka town and nearby villages. Later on to meet additional Power demand of town and Army base one no. 250 KW horizontal Francis Turbine was added. This machine was taken out from some other power station which was renovated and installed at Mechuka MHP. This power station has thus two vertical Pelton turbine coupled with synchronous vertical synchronous generators and one horizontal Francis turbine coupled with horizontal synchronous generator and runs in isolated mode. The third machine can not be synchronised with other two units and can not generate more than 80 KW. Due to paucity of funds when third machine was added work on modification of water conductor system could not be taken up as such present section of power channel is not capable to carry requisite discharge to generate power to full capacity of all the three machines. It is expected in near future grid will be available as such it is proposed by Project Authorities that provision of grid connection should be made in the R&M proposal. 2. SALIENT FEATURES OF THE PROJECT

I.

GENERAL : : Mechuka MHP (2 x 50kW+1x250 kW) 1989 with capacity of 2x50 kW, 1x250kW was added later on, old machine taken out from some other Project was installed

1. (a) Name of the Project (b) Year of commissioning

2. i) ii) iii) iv)

Location State District Town/Village Access Nearest Rail Head Nearest Air Port : : : : : : Arunachal Pradesh West Siang Mechuka 180 Km from Along by road 316 Km form Silapather Lilabari, Assam

23 3. (a) (b) 4. (a) (b) II. Details of Site Name of stream Head (Gross) Hydrology Max. discharge Mini. discharge : : 2.00 Cumec 0.22 Cumec : : Tsigrung Thuchu Nallah 81 m

PROJECT FEATURE 5. Intake Trench weir Width 6. Intake Chamber Size 7. Intake Gate Size 8. (a) (b) (c) (d) Intake and Power Channel Shape Width Depth Length : : : : trapezoidal Top=0.85 m, Bot.=0.6 0.85 m, 1500 m : 1.2 m x 1.4m : 3.9m x 3.10m x 2.85(h) m : : 14.0 m long 1.0m

9.

Desilting tank Length Width Height Type : : : :

Existing 1.80 m 1.70 m 2.85 m RCC

Proposed 10.0 m 4.0 m 1.1 m RCC

10. Forebay Tank (a) Size (b) Depth (c) Type : : : 11.70 m x 8.8 m 2.27 m RCC

24 11. Spillway channel Length Width Depth Type 12. Penstock (a) Material (b) Length and dia. : : Steel 155.0 m 400mm dia. which reduces to300mm dia. about 65.0 m upstream of common header 13. Power House Type : G.C sheet Roofing is supported by wooden truss. RCR masonry walls, RCC columns are there. Size 15 m x 6 m x 5.5 m : : : : 70 m 1.7 m 0.6m RCC

14. Tailrace (a) Length (b) Depth : : : 30 m existing (50 m to be extended ) 0.8 m Top=1.5 m, Bot.=1.0

(c) Width

15. Turbine (a) No. of turbine (b) Make (c) Type : : : Three Nos. M/S Flovel Ltd M/s Jyoti Ltd. Francis (d) Capacity (e) Speed (f) Net head 16. Generator/Alternator (a) No. of Generator (b) Make : : : : Vertical 2 Nos., M/S Kirloskar Horizontal 1No. M/s Jyoti Ltd. 2x50 kW 1000 rpm 90 m 1x250 kW 1500 rpm 77 m 2 xVertical Pelton 1 x Horizontal

25 (c) Type (d) Speed (e) Out put (f) Phase (g) Frequency (h) Power Factor (i) (j) Generator Voltage Insulation Synchronous 1000 rpm 62.5 kVA (each) 3 50 Hz 0.80 415 V Class F Synchronous 1500 rpm 250 kW 3 50 Hz 0.80 415 V Class F

17. Power evacuation Feeder-1 18. Power transformer No. Capacity Voltage ratio : : : Two 125 KVA 0.415/11 KV 315KVA 0.415/11 KV : 11 kV To Mechuka town

3.

INFORMATION AND DATA

i. ii. iii. Sl. No. 1 2 3 4 5 No DPR provided. No history or major/ special maintenance data were available O&M expenditure incurred during last five years is given in following table : Year 2005 2006 2007 2008 2009 Rs. In lacs 6.10 6.80 7.70 8.62 9.15 Remark Rs.21.00 lac have been incurred on special maintenance

4. 4.1

GENERATING UNITS TURBINE , INLET VALVE & GOVERNOR. Turbine Inlet Valve: It is recommended to provide butterfly valve, operated by oil servomotor in both the units. They should be able to be opened by hand operated oil pump and closed by counter weight by releasing the oil pressure through DC operated solenoid coil or hand operated knob.

26 The valve shall be suitable for slow opening and closing so as to avoid water hammer pressure rise/drop in the penstock. The valve shall close automatically under normal and emergency shut down conditions. The valve shall be complete with inlet pipe, outlet pipe with dismantling joint, by pass arrangement if required for equalization of pressure on either side of the valve etc. The valve shall meet all requirements specified in IS 7326-1902. Turbines: It is proposed to provide 2 No. turgo impulse turbine each to deliver 150 kW at generator terminals with 10% continuous over load capacity. New turbines will have provision of regulating the flow of water by nozzles/deflector through DC operated electrical actuator in addition to manual operation. The journal bearings should be oil bath/ball bearing type, water cooled and shall have provision of temperature indicating device. Speed indicating device and centrifugal type over speed mechanical switch shall be provided to stop the machine at over speed. Flywheel of suitable inertia will be coupled with turbine shaft. Flywheel inertia should be selected to keep the speed rise and pressure rise on sudden full load rejection within limits and stabilize the frequency at load variations effectively. During sudden load throw- off condition, the speed rise and pressure rise should not exceed 35% and 25% respectively. One pressure gauge must be mounted on each penstock before turbine to indicate pressure in penstock. Governor : It is recommended to provide PLC based digital electronic governor with manually operated back up system for integrated unit and plant control. The governor shall be of proven design controlling the turbine by speed sense and upstream water level. The governor should provide flexibility in control, alarming, sequence of event recording and provide graphic display. The PLC should be of standard make, open architecture system allowing expansion. The governing system shall be complete-with actuator unit comprising of hydraulic pressure system, water level sensor, restoring mechanism, load adjustment with level, load limiting device, start stop capability and emergency closure. The governor shall use PID (Proportional integral, derivative) loop control in which three derivatives of speed are used for speed stabilization. The hydraulic pressure system shall comprise of two motors driven pumping unit, pressure tank, sump tank and piping etc. Electronic governor shall provide following control: a. Speed Control b. Unit Control c. Forebay level control d. Suitability for Isolated Operation e. Suitability for Parallel operation f. Suitability for Grid Operation Governor shall be fail safe on the failure of the speed sensing element, loss of oil pressure or defects in actuating system, so that under any of these conditions, the machine shall be automatically shut down with alarm and indication. Hand control device for stroking governor shall be provided.

27

4.2

GENERATORS: New generator shall be salient poles synchronous generator of 150 kW at 415 V, 0.80 PF, 3 Phase A.C., 50 Hz, natural air-cooled self ventilated with brush less excitation. The generator shall be capable of delivering 10% continuous over load. The generator shall be star connected complete with stator, rotor, bearings, stator and bearing temperature detectors, oil coolers for bearings, brush less excitation system comprising high frequency generator, diode wheel, AVR and protection equipment. The generator shall be designed to with stand the runway speed of the turbine for 30 minutes without any detrimental effect. The generator and excitation system shall be able to operate in parallel with other generator and with grid also. The generator stator and rotor shall have class F insulation with Class B temperature rise and designed for continuous operation at 10% over load with screen-protected enclosure. The generator is designed to conform to IS 4722/1968/IEC-34/BS 4999. The six terminals from three main windings shall be brought out to the terminal box for insertion of current and voltage transformer for protection and metering. The generator neutral shall be directly connected to earth or through low resistance through disconnecting link. The generator shall be capable to operate with either leading or lagging power factor by control of excitation. The power factor commonly ranges between 0.80 and 0.95. The generator shall be designed to safely with stand any mechanical/ magnetic stresses resulting from either a three phase or a single phase fault. The short circuit ratio of generator shall not be less than 0.8. The AVR will have provision for regulating the voltage to the extent of 10% of rated voltage manually. The change in voltage from no load to full load on AVR mode will not exceed 5% of rated voltage.

28

EGO ECHI (DALI) MICRO HYDRO POWER PROJECT (4 X 100KW) N.I.T. No. NIT/R&M/2011-12/06 1. INTRODUCTION OF THE PROJECT The Ego-Echi MHP was commissioned in 1988 with a installed capacity of 4 x 100 kW on Echi nallah of Dali village in Basar Administrative sub division . This project meets up the power requirement of entire Basar town and nearby villages. This power station has four horizontal Turgo impulse turbines coupled with synchronous generators and runs in isolated mode. It is expected in near future grid will be available as such it is proposed by Project Authorities that provision of grid connection should be made in the R&M proposal. 2. SALIENT FEATURES OF THE PROJECT I. 1. GENERAL (a) Name of the Project : EGO-ECHI (DALI) MHP (4x 100 kW) (b) Year of commissioning 2. i) ii) iii) iv) Location State District Town/Village Access Nearest Rail Head Nearest Air Port 3. (a) (b) 4. II. 5. Details of Site Name of stream Head (Gross) Ref. Toposheet No. PROJECT FEATURE Intake Type Length U/S apron width D/S apron width : : : : Trench weir 20 m long 2.5 m 3.0 m : : : Echi Nallah 87 m 83 I/13 : : : : : : Arunachal Pradesh West Siang Basar 75 Km from Along 65 Km Sila pather Lilabari, Assam : 1988

29 Trash rack width 6. Intake Gate Size 7. Intake Chamber Size 8. (a) (b) (c) (d) Intake and Power Channel Shape Width Depth Length : : : : Trapezoidal B1=0.62 m, B2=0.75 1.3 m, 2200 m : 3.3m x 3.05m x 3.5(h) m : 1.7 m x 2.0 m : 1.5 m

9.

Desilting Tank Length Width Depth : : : 23 m 3.2 m 1.2 m

10. (a) (b) (c) 11. (a) (b) (c) (d) 12. (a) (b) (b)

Forebay Tank Size Depth Type Spillway Channel Type Length Width Depth Penstock Material Length Diameter : : : Steel 245 m 600 mm : : : : RCC Rectangular 275 m (Extend up to 320 m) 1.5 m 0.6 m : : : 50 m x 25 m 3.6 m RCC

30

13.

Power House Type Size : Steel framed structure with GC sheet roof and walls 24 m x 9.9m x h=5.5m

14. (a) (b) (c)

Tailrace Length Depth Width : : : 40 m 0.60 m 1.50 m

15. (a) (b) (c)

Turbine No. of turbine Make Type : : : 4 No. M/s Jyoti Ltd. Horizontal Turgo impulse

(d) (e) (f) (g) 16. (a) (b) (c) (d) (e) (f) (g) (h) (i) (j)

Capacity Speed Design Discharge/Unit Design head Generator/Alternator No. of Generator Make Type Speed Out put Current Phase Frequency Power Factor Generator Voltage

: : : :

100 kW (Each ) 750 rpm 185 lit/sec. for each unit 78 m

: : : : : : : : : :

4 Nos. Make M/s Jyoti Ltd. Synchronous 750 rpm 125 kVA (each) 174 amp 3 50 Hz 0.80 415 V

31 (k) Insulation : Class F

17.

Power evacuation Feeder - 1 : 33 kV To Ichi and Padi town Feeder 2 Feeder 3 : : : : : : 33kV to Igo town Spare 33 kV 415 V to Dali village Three 250 KVA 0.415/33 KV

18.

Feeder - 4 Power transformer No. Capacity Voltage ratio

3.

INFORMATION AND DATA

i. ii. No DPR provided. No civil, electrical or mechanical drawings were available. However project layout power house building plan and single line diagram got prepared iii. iv. Sl. No. 1 2 3 4 5 No history or major/ special maintenance data were available O&M expenditure incurred during last five years is given in following table: Year 2005 2006 2007 2008 2009 Rs. In lacs 12.76 13.71 17.21 16.96 17.80 Remark Expenditure on special maintenance is of Rs.35 lacs Rewinding of alternator , replacement of slip rings in two units and remetalling of bearings got done

4. 4.1

GENERATING UNITS TURBINE INLET VALVE & GOVERNOR. Inlet Valves: The existing butterfly type inlet valves of all the four units may be replaced by new valves operated by oil servomotor. They should be able to be opened by hand operated oil pump and closed by counter weight by releasing the oil pressure through DC operated solenoid coil or hand operated knob. The valve shall be suitable for slow opening and closing so as to avoid excessive water hammer pressure rise/drop in the penstock. The valve shall close automatically under

32 normal and emergency shut down conditions. The valve shall be complete with inlet pipe, outlet pipe with dismantling joint, by pass arrangement if required for equalization of pressure on either side of the valve etc. The valve shall meet all requirements specified in IS 7326-1902. Turbines: It is recommended to overhaul all the units by replacing old worn out components like deflector with bushes and seals, needle-nozzle assembly, needle operating mechanism and labyrinth/water-thrower etc. Thrust and guide bearings, turbine shaft, runner, turbine casing etc. may be got repaired or replaced depending upon the condition of the respective item. Specially runner of all the turbines should be inspected thoroughly against any metallurgical defect. If major repair is involved in any runner, it should be replaced. Following indicators and devices may be provided during renovation: - Pressure gauge on penstock before and after inlet valve to show water pressure, - Temperature indicator for thrust and guide bearing, (if possible) - Speed indicator to show speed of turbine, - Scale showing opening of deflector and needle, - Provision of emergency stopping, - Brake jet for bringing the unit to standstill during stopping Mechanical Governors: It is recommended to retain these mechanical governors after overhauling as they do not require much skilled manpower for operation and maintenance. It is expected that these governors will give trouble free service for long period after renovation. During overhauling of these governors, worn out / defective components may be replaced by genuine spares and adjustments may be done by specialist. It is recommended that renovation work of these governors may be given to original equipment supplier (M/S Jyoti Ltd. Baroda) or to any established governor supplier company independent of turbines renovation work. After renovation of governors, index testing must be performed at different loads to find out optimum relationship between deflector and needle opening. This relationship should be adhered to during operation to avoid wastage of water. Following features should be added in Governors during renovation: Adjustment of deflector and needle opening/closing timings Mechanical indicators for deflector and needle opening on respective servomotor. Automatic shut down of unit and closure of inlet valve in case of over speed and electrical faults. 4.2 Generators: All the four generators may be dismantled and overhauled. Following items nay be changed or repaired depending on the condition of the item: - Cleaning and varnishing of windings, - Replacement of journal bearings if worn out otherwise cleaning and filling with fresh grease/oil, - Machining of slip rings and change of carbon brushes,

33 Provision of new bearing temperature indicators in case of pad type bearings, Provision of new over speed centrifugal switch for stopping unit on abnormal speed. Checking tightness of foundation bolts, Realignment of generator with respect to turbine shaft. Painting of stator body and Terminal box.

34

SILLI MICRO HYDRO POWER PROJECT (2 X 250KW) N.I.T.No. NIT/R&M2011-12/07

1.

INTRODUCTION OF THE PROJECT The Silli Micro Hydel Project at Geku was commissioned in the year 1993 with a installed capacity of 2 x 250 kW. This project meets up the power requirement of entire Geku and Katan Circles. This power station has two horizontal Turgo impulse turbine coupled with synchronous generators and runs in isolated mode. It is expected in near future grid will be available as such it is proposed by Project Authorities that provision of grid connection should be made in the R & M proposal.

2.

SALIENT FEATURES OF THE PROJECT I. 1. GENERAL (a) Name of the Project (b) Year of commissioning (c) Purpose : : : Silli, Geku MHP (2 x 250 kW) 1993 Generation, stand alone, meets entire power requirement of Geku and Katan circle Arunachal Pradesh Upper Siang Geku 150 km from Pasighat 185 km Murkoselek, Assam Lilabari

2. i) ii) iii) iv)

Location State District Town/Village Access Nearest Rail Head Nearest Airport : : : : : :

3. (a) (b) II. 4. (a) (b) (c) (d) (e)

Details of Site Name of stream Head (Gross) PROJECT FEATURE Diversion Weir Type Length Width Trash Rack Width Material : : Silli River 113m

: : : : :

Trench Weir 8.1 m 0.8 m 1.5 m RCC

35 5. (a) (b) Intake chamber Size Material : : : L= 3.3, H= 3, W= 3.0 m RCC

6. (a) (b) 7. (a) (b)

Intake Gates Size Material Desilting tank Size Material : : 20.0 m x 2.5 m x 0.75 m CC : : H= 3m, w= 1 m Fabricated steel

8. (a) (b)

Power Channel Shape Width : Trapezoidal : B1 = 1.1 m, B2 = 1.8 m Depth 1.1 m

(c) (d) 9. (a) (b) (c)

Type Length Forebay Tank Size Depth Type

: CC : 216 m+40 m+20m

: L= 17.1 m, B= 10.1 m, : 4m : RCC

10. (a) (b) (c) (d) (e)

Spillway Shape Length Width Depth Type : Rectangular : 57 m : 1.1 m : 1.1 m : CC

36 11. (a) Penstock Material : Steel pipe (One no., Bifurcated near power house building) (b) Length 562.9 m +20m going to each unit after bifurcation (b) 12. (a) (b) (c) 13. (a) (b) (c) Diameter Power House Length Breadth Height Tailrace Length Width Depth : 22.5 m, : 1.3m, : 1.3 m, : : : 20 m 10 m 6.6 m : 600 mm

14. (a) (b) (c)

Turbine No. of turbine Make Type : 2 Nos. : M/s Jyoti Ltd. : Horizontal Turgo impulse, double jet

(d) (e) (f) (g) 15. (a) (b) (c)

Capacity Speed Design Discharge/Unit Design head Governor Type Capacity Sl No.

: 250 kW : 1000 rpm : 40 lit/ sec per unit : 90 m

: B : 125 kg.m : 282/489

37 16. (a) (b) (c) (d) (e) (f) (g) (h) (i) (k) (l) (m) Generator/Alternator No. of Generator Make Type Speed KVA Current Phase Frequency Power Factor Generator Voltage Insulation Excitation (i) Current (ii) Voltage 17. (a) (b) (c) 18. Power transformers Capacity Voltage Ratio No. of Transformer Power Evacuation (stand alone ) i. Feeders 3. Feeder I Feeder-II : 33 kV Yingkong 33 kV Geku : 630 kVA : 0.415/33 kV : 2 No. 315 kVA 0.415/33 kV 1No. : 2 Nos. : M/s Jyoti Ltd. : Synchronous : 1000 rpm : 312.5 KVA : 435 Amp : 3 : 50 Hz : 0.80 : 415 V : Class F : : 2.2 A : 36 V

INFORMATION AND DATA

i. ii. No DPR provided. No civil, electrical or mechanical drawings were available. However project layout power house building plan and single line diagram got prepared iii. iv. No history or major/ special maintenance data were available O&M expenditure incurred during last five years is given in following table

38

Sl. No. 1 2 3 4 5 4. 4.1

Year 2005 2006 2007 2008 2009

Rs. In lacs 13.07 13.97 15.12 16.62 18.63

Remark On special maintenance Rs. 18.0 lacs (approx) were spent. Main work done rewinding of generator and replacement of bearings.

GENERATING UNITS TURBINE , INLET VALVE Turbines: It will be difficult to incorporate some new features in the existing turbines. The efficiency of existing runners is very poor since they have been repaired a number of times. Procuring and replacing vital components of turbine including runners from original manufacturer may cost more than the new ones. It is, therefore, proposed to replace the old turbines by new horizontal turgo impulse turbines of existing rating. New turbines should have provision of regulating the flow of water by needle/deflector through DC operated electrical actuator in addition to manual operation. The journal bearings should be oil bath/ball bearing type, water cooled and shall have provision of temperature indicating device. Speed indicating device and centrifugal type over speed mechanical switch should be provided to stop the machine at over speed. Turbine shaft shall carry a suitable pulley with V-belts at one end for driving the generator and flywheel on the other end. Alternatively rigid coupling of turbine and generator may be adopted. Flywheel inertia should be selected to keep the speed rise and pressure rise on sudden full load rejection within limits and stabilize the frequency at load variations effectively. One pressure gauge must be mounted on each penstock before turbine to indicate pressure in penstock. Inlet Valves: It is recommended to provide butterfly valve, operated by oil servomotor. They should be able to be opened by hand operated oil pump and closed by counter weight by releasing the oil pressure through DC operated solenoid coil or hand operated knob. The valve shall be suitable for slow opening and closing so as to avoid water hammer pressure rise/drop in the penstock. The valve shall close automatically under normal and emergency shut down conditions. The valve shall be complete with inlet pipe, outlet pipe with dismantling joint, by pass arrangement, if required, for equalization of pressure on either side of the valve etc. The valve shall meet all requirements specified in IS 7326-1902.

39 4.2 GENERATORS: In order to ensure trouble free operation of the machines after renovation, it is proposed to replace the generators of both the units. New generator shall be salient poles synchronous generator of 250 kW at 415 V, 0.80 PF, 3 Phase A.C., 50 Hz, natural air-cooled self ventilated with brush less excitation. The generator shall be capable of delivering 10% continuous over load. The generator shall be star connected complete with stator, rotor, bearings, stator and bearing temperature detectors, oil coolers for bearings, brush less excitation system comprising high frequency generator, diode wheel, AVR and protection equipment. The generator shall be designed to with stand the runway speed of the turbine for 30 minutes without any detrimental effect. The generator and excitation system shall be able to operate in parallel with other generator and with grid also. The generator stator and rotor shall have class F insulation with Class B temperature rise and designed for continuous operation at 10% over load with screen-protected enclosure. The generator are designed to conform to IS 4722/1968/IEC-34/BS 4999. The six terminals from three main windings shall be brought out to the terminal box for insertion of current and voltage transformer for protection and metering. The generator neutral shall be directly connected to earth or through low resistance through disconnecting link. The generator shall be capable to operate with either leading or lagging power factor by control of excitation. The power factor commonly ranges between 0.80 and 0.95. The generator shall be designed to safely with stand any mechanical/ magnetic stresses resulting from either a three phase or a single phase fault. The short circuit ratio of generator shall not be less than 0.8. The AVR will have provision for regulating the voltage to the extent of 10% of rated voltage manually. The change in voltage from no load to full load on AVR mode will not exceed 5% of rated voltage.

40

YINGKIONG PHASE-I (3 x 50 KW), PHASE-II (2 x 100 KW) MICRO HYDEL PROJECT N.I.T. No. NIT/R&M/2011-12/08 & N.I.T. No. NIT/R&M/2011-12/09 1. INTRODUCTION OF PROJECT Yingkiong phase-I having three machines of 50 KW each was commissioned in the year 1980-81 and Yingkiong phase-II having 2 machines of 100 KW each was commissioned in the year 1992-93 respectively. The tail water and spillway water of phase-I goes to Forebay tank of phase-II. Both the power stations have horizontal Turgo impulse turbine coupled with synchronous generator. These power stations meet the power requirement of Yingkiong town which is district headquarter of upper Siang district and nearby villages. These power stations run in isolated mode. Availability of grid is expected in near future as such project authorities proposed to keep provision of synchronizing of machines with grid also. 2. SALIENT FEATURES OF THE PROJECT I. 1. GENERAL (a) Name of the Project (b) Year of commissioning Phase -I Phase -II (c) Purpose : : : : : 1980-81 1992-93 Generation, stand alone meets power requirement of Ying Kiong Town and near by villages Arunachal Pradesh Upper Siang Yingkiong Ying Kiong Phase I & II

2. i) ii) iii) iv)

Location State District Town/Village Access By Road Nearest Rail Head Nearest Airport : : : : : : : 2 km from Ying Kiong 225 km from Murkoselek, Lilabari, Assam

3. i) ii)

Geographic Coordinates Longitude Latitude : : Phase I Phase - II 2803910.8N 2803910 N 950113.44E 9501.06E

41 4. (a) (b) Details of Site Name of stream Head (Gross) Phase I Phase II 5. Hydrology Maximum discharge II. 6. (a) (b) (c) (d) (e) 7. (a) PROJECT FEATURE Diversion Weir Type Length Width Trash rack width Material Intake chamber Size Length Width Depth Material Intake Gate Type Size Width Height Desilting tank Size Length Width Depth Material Flushing Pipe dia Length Sluice valve : : : Steel fabricated manually operated 1.2 m 2.0 m : : : : : Trench Weir with trash rack 14.6 1.2 m 1.5 m RCC : : 1.40 cumec : : : : 70 m 53 m Sikking

(b) 8. (a) (a)

: : : :

3.40 m 3.10 m 3.00 m RCC

9. (a)

(b) (c)

: : : : : : :

17 m 3.9 m (at entry) 1.5 m RCC 200 mm dia. 3.0 m 200 mm dia.

42

10 (a) (b)

Power channel Shape Size Length B1 B2 Depth Forebay Tank Size Length Width Depth : : : : Phase I L1=34.6 m L2=29.6 m 7m 2.1 m Phase II 12.5 m 7.5 m 2.25 m : : : : : Trapezoidal 2100 m 1.2 m 0.5 m 0.9 m

11 (a)

12

Spillway Size Length Shape Section B1 B2 Depth Penstock Length Material dia Sluice valves Near Forebay Near P.H. Building Tailrace : Draft tube out let is connected to Forebay tank of Phase II Trapezoidal shaped B1= 1.8 m B2= 0.6 m D=0.85 m L=250 m : : 1 no. 600 mm 3 nos. 300 mm 1 no. 600 mm dia 2 nos. 300 mm dia : : : 140 m Steel pipe 600 mm 215 m Steel pipe 600 mm : : : : : : : Phase I 170 m Trapezoidal 1.2 m 0.5 m 0.75 m Phase-II 130 m Trapezoidal 1.2 m 0.5 m 0.75 m

(a) (b) (c)

13 (a) (b) (c) 14 (a) (b) 15

43

III 1. 2 (a) (b) (c) (d) (e) (f) (g) 3.

ELECTRO MECHANICAL WORKS Capacity Turbine No. of turbine Make Type : Speed Design discharge/ head Capacity Design head Inlet valve : : : : : : : : : Phase-I 3x50 kW 3 M/s Jyoti Ltd. Horizontal Turgo impulse 750 RPM 144 lit/sec. 50 kW 53 m BFV hydraulically operated Phase II 2x100 kW 2 M/s Jyoti Ltd. Horizontal Turgo impulse 750 RPM 190 Lit/sec. 100 kW 70 m BFV hydraulically operated

4 (a) (b) (c) 5. (a) (b) (c) (d) (e) (f) (g) (h) (i) 6 (a) (b) (c) (d) 7

Governor Make Type Capacity Generator Make Type Capacity Speed Current Frequency Voltage P.F. Insulation Control panels Make Incomer Outgoing Synchronizing Power transformer

: : : : : : : : : : : : :

M/s Jyoti Ltd. B 125 kg.m

M/s Jyoti Ltd. B 125 kg.m

M/s Jyoti Ltd. Synchronous 62.5 kVA 750 RPM 87 Amp 50Hz 0.415 kV 0.8 Class B

M/s Jyoti Ltd. Synchronous 125 KVA 750 RPM 174 Amp 50Hz 0.415kV 0.8 Class B

: : : : :

M/s Jyoti Ltd. 3 2 1 1 No. 200 KVA 0.415/11 kV

M/s Jyoti Ltd. 2 2 1 1 No. 400 KVA 0.415/11 Kv

44

8 (a) (b) 3.

Power Evacuation Feeder Mode

: : : 11 kV to Phase-II LT nearby village Stand along 11 kV to Ying Kiong LT nearby village Stand along

INFORMATION AND DATA

i. ii. No DPR could be made available. No civil, electrical or mechanical drawings were available with them however project layout power house, building layout and single line diagram were got prepared at site iii. iv. A. Sl. No. 1 2 3 4 5 B. Sl. No. 1 2 3 4 5 No history or major/ special maintenance data was available O&M expenditure incurred during last five years is given in following table Ying Kiong Phase -I Year 2005 2006 2007 2008 2009 Rs. In lacs 12.20 13.70 14.35 16.10 19.95 Remark Alternator rewinding and replacement of bearing Expenditure incurred on special maintenance is Rs. 12.00 lacs (Approx)

Ying Kiong Phase II Year 2005 2006 2007 2008 2009 Rs. In lacs 12.34 13.74 14.49 16.24 20.13 Remark Alternator rewinding and replacement of bearing Expenditure incurred on special maintenance is Rs. 10.00 lacs (Approx)

4. 4.1

GENERATING UNITS TURBINE , INLET VALVE Inlet Valves: Main inlet valve shall be butterfly valve, operated by oil servomotor. It should be able to be opened by hand operated oil pump and closed by counter weight by releasing the oil pressure through DC operated solenoid coil or hand operated knob. The valve shall be suitable for slow opening and closing so as to avoid excessive water hammer pressure rise/drop in the penstock. The valve shall close automatically under normal and emergency shut down conditions. The valve shall be complete with inlet

45 pipe, outlet pipe with dismantling joint, by pass arrangement if required for equalization of pressure on either side of the valve etc. The valve shall meet all requirements specified in IS 7326-1902. Turbine: The turbine for phase I shall be horizontal turgo impulse, to deliver 50 kW at generator terminal with shaft, runner, bearings etc. with 10% continuous over rating. The turbine should have provision of regulating the flow of water by needle/deflector through DC operated electrical actuator in addition to manual operation. The journal bearings should be oil bath/ball bearing type, water cooled and shall have provision of temperature indicating device. Speed indicating device and centrifugal type over speed mechanical switch should be provided to stop the machine at over speed. Turbine shaft shall carry a suitable pulley with V-belts at one end for driving the generator and flywheel on the other end. Alternatively rigid coupling of turbine and generator may be adopted. Flywheel inertia should be selected to keep the speed rise and pressure rise on sudden full load rejection within limits and stabilize the frequency at load variations effectively. One pressure gauge must be mounted on each penstock before turbine to indicate pressure in penstock. 4.2 GENERATORS: The generator for phase I shall be salient poles synchronous generator of 50 kW at 415 V, 0.80 PF, 3 Phase A.C., 50 Hz, natural air-cooled self ventilated with brush less excitation. The generator shall be capable of delivering 10% continuous over load. The generator shall be star connected complete with stator, rotor, bearings, stator and bearing temperature detectors, oil coolers for bearings, brush less excitation system comprising high frequency generator, diode wheel, AVR and protection equipment. The generator shall be designed to with stand the runway speed of the turbine for 30 minutes without any detrimental effect. The generator and excitation system shall be able to operate in parallel with other generator and with grid also. The generator stator and rotor shall have class F insulation with Class B temperature rise and designed for continuous operation at 10% over load with screen-protected enclosure. The generator shall be designed to conform to IS 4722/1968/IEC-34/BS 4999. The six terminals from three main windings shall be brought out to the terminal box for insertion of current and voltage transformer for protection and metering. The generator neutral shall be directly connected to earth or through low resistance through disconnecting link. The generator shall be capable to operate with either leading or lagging power factor by control of excitation. The power factor commonly ranges between 0.80 and 0.95. The generator shall be designed to safely with stand any mechanical/ magnetic stresses resulting from either a three phase or a single phase fault. The short circuit ratio of generator shall not be less than 0.8. The AVR will have provision for regulating the voltage to the extent of 10% of rated voltage manually. The change in voltage from no load to full load on AVR mode will not exceed 5% of rated voltage.

46

PASIGHAT MICRO HYDEL PROJECT (2 X 100 KW) N.I.T.No. NIT/R&M/2011-12/10

1. INTRODUCTION OF THE PROJECT Pasighat Micro Hydro Project commissioned in 1972 has two nos. Vertical Francis turbine coupled with synchronous generator of 100 kW, Generating at 415 Volts. The power station runs in isolated mode and supplies power to Pasighat town alongwith some near by villages. 2. I. SALIENT FEATURES OF THE PROJECT GENERAL 1. (a) Name of the Project (b) Year of commissioning 2. Location i) State : : : : : Arunachal Pradesh East Siang Pasighat Pasighat (HQ.)-Powerhouse-12 km : : Pasighat MHP (2 x 100 kW) 1972

ii) District iii) Town/Village iv) Access Nearest Rail Head 3. Details of Site (a) Name of stream (b) Head (Gross) 4. Hydrology (a) Minimum discharge II. PROJECT FEATURE 5. Intake Type Length Width

: :

Sille 62 m

0.283 m3/ sec

: : :

Trench weir 16.8 m long 9.8 m (Include U/s & D/s apron and trash rack )

47 Trash rack 6. Intake Gate Size 7. Intake Chamber Size 8. Power Channel : : : : 4.5 m x 2.2m x 4.2 m Partly hume pipe of 1000 mm dia and partly open channel (a) Shape : : : Rectangular 2.0 m 1.2 m, wall thickness 300 mm (d) Type (e) Length : : RCC Total 1600 m (a) hume pipe =1473 m (b) open channel = 127 m 9. (a) Forebay Tank Size : : 32 m x 27 m 5.6 m 1.2 m x 1.5 m : 1.2 m

(b) Width (c) Depth

(b) Depth 10. Spillway Channel (a) Length

: : :

80 m 2.0 m 1.3 m

(b) Width (c) Depth

[[

11. Penstock (a) Material Steel 120 m 600 mm (b) Length (c) Diameter

12. Power House (a) Type : RCC columns with G.C sheet Roofing and walls

48

(b) Length (c) Width

: : :

11.0 m 7.70 m 4.50 m I II 10 m 0.8 m 1.0 m RCC Common 50 1.2 2.0 RCC

(d) Height 13. Tailrace (a) (b) (c) Length Depth Width : : : :

10 m 0.8 m 1.0 m RCC

(d) Type 14. Turbine (a) (c) No. of turbine Type

: 2 No. : M/s Jyoti Ltd. : Vertical Francis : 100 kW (Each ) : 1000 rpm : 0.283 m3/sec. : 56 m : : 2 Nos. : Make M/s Jyoti Ltd. : Synchronous : 1000 rpm : 125 kVA (each) : 3 : 50 Hz : 0.80 : 415 V

(b) Make (d) Capacity (e) (f) Speed Design Discharge/Unit

(g) Design head 15. Generator/Alternator (a) No. of Generator

(b) Make (c) Type

(d) Speed (e) (f) kW Phase

(g) Frequency (h) Power Factor (i) Generation Voltage

16. Power evacuation Both generator are connected to 0.415 V bus through 25Amp ACB Feeder-1 : 11 kV to Pasighat town :

49 Feeder-2 : 0.415 V directly connected to generator Bus though 100 Amp HRC Fuse to staff complex & nearby village

17. Power transformer No. Capacity Voltage ratio : One : 315 KVA : 0.415/11 KV

3.

INFORMATION AND DATA i. No DPR could be made available. ii. iii. iv. No civil electrical or mechanical drawings were available with them No history or major/ special maintenance data was available O&M expenditure incurred during last five years is given in following table Remark An expenditure of Rs. 15.6 lacs was incurred on special maintenance during last five years. It is mostly on rewinding and remetalling of bearings.

4. 4.1

Sl. Year Rs. In lacs No. 1 2005 14.58 2 2006 15.48 3 2007 17.73 4 2008 18.26 5 2009 21.79 GENERATING UNITS TURBINE & INLET VALVES : Inlet Valves:

It is recommended to provide butterfly valve, operated by oil servomotor. They should be able to be opened by hand operated oil pump and closed by counter weight by releasing the oil pressure through DC operated solenoid coil or hand operated knob. The valve shall be suitable for slow opening and closing so as to avoid water hammer pressure rise/drop in the penstock. The valve shall close automatically under normal and emergency shut down conditions. The valve shall be complete with inlet pipe, outlet pipe with dismantling joint, by pass arrangement if required for equalization of pressure on either side of the valve etc. The valve shall meet all requirements specified in IS 7326-1902.

50 Turbines: It will be difficult to incorporate some new features in the existing turbines. The efficiency of existing runners is very poor since they have been repaired a number of times. Procuring and replacing vital components of turbine including runners from original manufacturer may cost more than the new ones. It is therefore, proposed to replace the old turbines by new vertical francis turbines of existing rating. New turbines should have provision of regulating the flow of water by guide vanes through DC operated electrical actuator in addition to manual operation. The journal bearings should be oil bath/ball bearing type, water cooled and shall have provision of temperature indicating device. Speed indicating device and centrifugal type over speed mechanical switch should be provided to stop the machine at over speed. Turbine shaft shall carry a suitable pulley with V-belts at one end for driving the generator and flywheel on the other end. Alternatively rigid coupling of turbine and generator may be adopted. Flywheel inertia should be selected to keep the speed rise and pressure rise on sudden full load rejection within limits and stabilize the frequency at load variations effectively. One pressure gauge must be mounted on each penstock before turbine to indicate pressure in penstock. 4.2 GENERATORS : In order to ensure trouble free operation of the machines after renovation, it is proposed to replace the generators of both the units. New generator shall be salient poles synchronous generator of 100 kW at 415 V, 0.80 PF, 3 Phase A.C., 50 Hz, natural air-cooled self ventilated with brush less excitation. The generator shall be capable of delivering 10% continuous over load. The generator shall be star connected complete with stator, rotor, bearings, stator and bearing temperature detectors, oil coolers for bearings, brush less excitation system comprising high frequency generator, diode wheel, AVR and protection equipment. The generator shall be designed to with stand the runway speed of the turbine for 30 minutes without any detrimental effect. The generator and excitation system shall be able to operate in parallel with other generator and with grid also. The generator stator and rotor shall have class F insulation with Class B temperature rise and designed for continuous operation at 10% over load with screen-protected enclosure. The generator are designed to conform to IS 4722/1968/IEC-34/BS 4999. The six terminals from three main windings shall be brought out to the terminal box for insertion of current and voltage transformer for protection and metering. The generator neutral shall be directly connected to earth or through low resistance through disconnecting link. The generator shall be capable to operate with either leading or lagging power factor by control of excitation. The power factor commonly ranges between 0.80 and 0.95. The generator shall be designed to safely with stand any mechanical/ magnetic stresses resulting from either a three phase or a single phase fault. The short circuit ratio of generator shall not be less than 0.8. The AVR will have provision for regulating the voltage to the extent of 10% of rated voltage manually. The change in voltage from no load to full load on AVR mode will not exceed 5% of rated voltage.

51
RUPA MICRO HYDRO PROJECT (2 X 100 KW )

N.I.T. No. NIT/R&M/2011-12/11 1. INTRODUCTION OF THE PROJECT Rupa Micro Hydro Power Station has two nos. cross flow turbines coupled to synchronous generators of 100 kW, 415 Volts, 1500 rpm through belt drive. Generators are delivering power to isolated grid of 11 kV. The project was constructed by Rural Works Department, Government of Arunachal Pradesh and funded by Department of Science and Technology. It was commissioned in 1997-98. 2. SALIENT FEATURES OF THE PROJECT I. 1. GENERAL (a) (b) 2. i) ii) iii) iv) Name of the Project Year of commissioning : : Rupa MHS (2x100 KW) 1997-98

Location State District Town/Village Access : : : : Arunachal Pradesh West Kameng Rupa By Road 16 km. before Bomdila and 145 km from Tezpur (Assam) Nearest Rail Head Nearest Airport : : Bhalukpong 86 km from site Tezpur 145 km from site

3. (a) (b) (c) 4. (a) (b) 5. (a)

Geographical co-ordinates Latitude Longitude Reference Topo Sheet Details of Site Name of stream Catchments Area Hydrology Water Availability : 0.89 Cumecs : : Dinik Kho River 77.00 sq. km : : : 26o 54 N 91o 30 E 83 A/8

52 (b) II. 1. Maximum Flood Discharge PROJECT FEATURES Diversion / Intake : Trench Type Weir : Trapezoidal : Bottom Width - 1.00 m. - 1.60 m : 10.20 Cumecs

(a) Type (b) (c) Shape Dimension

: Top Width : : : (d) Material

Maximum Depth - 0.80 m Minimum Depth Length - 0.60 m - 18.00 m

: RCC : 0.90 Cumecs : 400 mm dia steel pipe with Sluice Gate

(e) Design Discharge (f) 2. (a) (b) (c) (d) Silt Excluding arrangement Feeder Channel Shape Size Bed Slope Length

: Rectangular : Width 1.60 m., Depth 0.80 m : 1:300 : 185 m. : R,C.C. M-15 : 0.89 Cumec : 0.30 m.

(e) Material (f) Design Discharge (g) Free Board 3. (a) (b) (c) (d) Power Channel Shape Size Bed Slope Length

: Rectangular : Width 1.60 m., Depth 0.80 m : 1:400 : 790 m. : RCC M-15 : 0.89 Cumec : 0.30 m

(e) Material (f) Design Discharge (g) Free Board

53

4. Desilting Arrangement (a) Size of Tank : Length 20.00 m, Width 5.60 m, Depth 2.50 m (b) Material (c) Free Board : R.C.C. : 0.20 m : 0.20 mm.

(d) Particle size elimination 5. Forebay Tank & Spillway

(a) Size of Tank

: Length 5.00 m, Width 6.25 m, Depth 3.75 m

(b) Free Board (c) Material (d) Overflow Arrangement (e) Spillway Length 6. (a) Penstock Number

: 0.30 m. : Steel Fabricated : Spillway : 70.00 m

: 1 No. : Spirally welded Steel pipe : 110 m. , 500 mm dia. : 0.89 Cumec

(b) Type / Material (c) (d) 7. Length / Diameter Design Discharge Power House

(a) Type

: Surface power hosue, Bricks masonry walling, intermediate RCC column and CGI sheet roofing : 12.35 m x 8.00 m x 3,60 m : 38.00 m : 36.00 m. : 2 x 100 Kw

(b) Size of Power House (c) Gross Head (d) Net Head (e) Capacity 8. (a) (b) (c) Turbine Type Nos Capacity `

: Cross Flow : 2 No. : 100 KW each

54

9. Generator/Alternator 10. Tail Race Channel (a) Shape (b) (c) (d) Size Length Material

: Synchronous : Rectangular : Width 1.60 m, Depth 0.80 m, : 30.00 m : R.C.C.

3. 3.1

GENERATING UNITS TURBINE: Both turbines are in working condition and generating 100 KW each when required discharge is available and load demand is there. However, their general condition is very poor and they require frequent maintenance. The runners and guide plates get eroded frequently due to higher silt content in water. The efficiency of turbine has gone down considerably due to repair of runner blades a number of times. In the absence of spare runners, bearings and guide plates, capital maintenance of turbine takes longer time. There is no provision for indication of speed during idle run and also for sensing over speed of the turbine. Guide plate for controlling the flow of water is manually operated and machine can not be stopped automatically in case of emergency situation. There is no provision of disc valve before turbine to stop the machine automatically. Sluice valves provided on penstock before entry in the power house are manually operated. Spindle of one sluice valve is broken and bypass valves of both units are not operative. Both these valves need replacement.

3.3

GENERATORS: The generators are self excited synchronous machines driven through belt. The spare components of excitation system are not available. The condition of generators too is very poor and needs reconditioning / complete overhauling. There is no provision of voltage control, measuring and indicating temperature of stator winding and journal bearings and sensing over speed. Alarm and shut down action in case of high temperatures or over speed is not possible.

3.4

ELECTRONIC LOAD CONTROLLER : Provision of shunt/ballast load along with its electronic controller had been given for governing of turbines but the system is not functional as most of the components are defective. Speed / load control is carried out by controlling flow by adjusting opening of regulating plate

55

DULOM MICRO HYDEL PROJECT ( 4 X 100 KW) N.I.T. No. NIT/R&M/2011-12/12

56

57

4.

INFORMATION AND DATA

58

59

RAHUNG MINI HYDRO PROJECT ( 3 X 250 KW ) N.I.T. No. NIT/R&M/2011-12/13

1. INTRODUCTION OF THE PROJECT Rahung Mini Hydro Power Station has three nos. Turgo Impulse turbines directly coupled to synchronous generators of 250 kW, 415 Volts, 1000 rpm rating. Generators are supplying power to isolated grid of 11 kV. Unit 1 & 2 were commissioned in 197273 and unit 3 in 1982-83. 2. SALIENT FEATURES OF THE PROJECT I. 1. GENERAL (a) (b) Name of the Project Year of commissioning : Rahung MHS (3x250 KW) : Unit 1 & 2 - 1972 73 & Unit 3 - 1982-83. 2. i) ii) iii) iv) Location State District Town/Village Access : : : : Arunachal Pradesh West Kameng Rahung By Road 16 Km. from Bomdila and 176 Km from Tezpur (Assam) v) vi) 3. (a) (b) (c) 4. (a) (b) 5. (a) (b) (c) Nearest Rail Head Nearest Airport Geographical co-ordinates Latitude Longitude Referance Topo Sheet Details of Site Name of stream Catchments Area Hydrology Water Availability Maximum Design Flow Discharge Minimum Design Flow Discharge : : : 0.750 Cumecs 0.85 Cumecs 0.425 Cumecs : : Rahung 25.90 sq. km : : : 27o 17 09N 92o 22 E 83.A/7 : : Bhalukpong 135 Km from site Tezpur 176 Km from site

60

II. 1. (a) (b) (c)

PROJECT FEATURES Diversion / Intake Type Shape Dimension : : : : : : : : : : Trench Type Weir Trapezoidal Bottom Width Top Width Maximum Depth Minimum Depth Length RCC 0.75 Cumec Sluice Gate - 0.85 m. - 1.50 m - 0.70 m - 0.50 m - 19.5 m

(d) Material (e) (f) 4. (a) (b) Design Discharge Silt Excluding arrangement Feeder Channel Shape Size

: :

Trapezoidal Bed Width 0.45 m. Water depth 0.72 m

(c) (d) (e)

Bed Slope Length Material

: : : : :

1 : 250 50.00 m. R.M.M. 0.75 Cumecs 0.30 m.

(f) Design Discharge (g) Free Board

5. (a) (b)

Power Channel Shape Size : : Trapezoidal Bed Width 0.60 m. Top width 1.44 m. Depth 0.82 m

(c) (d)

Bed Slope Length

: : : : :

1 : 500 800 m. RCC M-20 0.75 Cumec 0.30 m.

(e) Material (f) Design Discharge (g) Free Board

61 4. Desilting Arrangement (e) Size of Tank : Length 20.00 m, Width 2.60 m, Depth 2.70 m (f) Material : : R.C.C. 0.20 m

(g) Free Board

5. Forebay Tank & Spillway (a) Size of Tank : : : : : (i) 43.00 m x 23.00 m x 2.50 m (ii) 18.80 m x 6.20 m x 3.00 m 0.30 m. R.C.C. M-20 Spillway 2.75 m

(b) Free Board (c) Material

(d) Overflow Arrangement (e) Spillway Crest Level

6. (a)

Penstock Number : : : : 1 No. Spirally welded Steel pipe 210 m., 450 mm diameter 0.75 Cumec

(b) Type / Material (c) Length / Diameter

(d) Design Discharge

7. (a)

Power House Type : Surface PH, bricks masonry walling with RCC column and CGI sheet Roofing

(b) Size of Power House (c) Gross Head

: : : :

19.00 m x 8.00 m 140.00 m 120.5 m. 3 x 250 kW

(d) Net Head (e) Installed Capacity

8. (a) (b) (c)

Turbine Type Nos. Capacity : : : Turgo Impulse 3 No. 250 KW each

62 (d) Speed : 1000 RPM

9. Generator/Alternator (a) (b) (c) (a) (b) Type Rating Speed Shape Size : : : : : Synchronous 312.5 kVA, 415 V, 0.8 PF, 3 Phase 1000 rpm Trapezoidal Top width 0.72 m. Bed Width 0.45 m. Depth 0.60 m (c) (d) (e) Length Material Slope : : : 25.00 m R.R.M. 1: 250

10 Tail Race Channel

3. 3.1

GENERATING UNITS TURBINE & INLET VALVES : Inlet Valves: Butterfly type turbine inlet valves provided in unit I & II do not operate satisfactorily as their servomotors are water operated and get jammed. Inlet valve has not been provided in Unit-3. Turbines & Governors: Three numbers Turgo Impulse turbines of M/S Jyoti Ltd. Vadodara, Gujarat have been installed. Belt driven hydro-mechanical governors have been provided to regulate deflectors and needles are controlled manually by hand wheel. Unit - 1 is under shut down / breakdown since Sept. 2005 as most of its vital components are defective and need replacement. This unit needs immediate overhauling. Unit-2 is under capital maintenance since April 2009 and is expected to be ready soon. Unit-3 is under operation and was generating around 170 kW during the visit of the team to meet isolated load demand. It was informed by operating staff that the unit is capable of generating 250 kW during peak load hours. Starting, stopping and synchronizing of the unit is done manually. There is no provision of emergency stopping. Following indicators have not been provided; - Pressure gauge on penstock to show pressure of water. - Temperature indicator for bearing temperature - Speed indicator to show speed of turbine - Scale showing opening of deflector and needle

63 Drawing and O&M instruction manual for turbine and governor is not available in the power house. Operating staff has no knowledge of deflector needle opening relationship for optimum opening of needle. 3.2 GENERATORS: Generators are synchronous machines directly coupled with turbine shaft alongwith flywheel in between. No flywheel has been provided in unit-3. Power supply items of excitation system have been installed on top of generator stator. Control part of excitation system has been installed in excitation panel. The condition of generators seems to be poor and needs reconditioning / complete overhauling. Following items / indicators have not been provided; - Temperature indicator for bearing temperature - Temperature of stator windings - Overspeed centrifugal switch