Specifications of HV Switchgear

POWERING TAMIL NADUS PROGRESS
Specification No: ACE/GTS/OT-72/07-08 Volume-III Technical Specification-Electrical
SPECIFICATION E12 HT SWITCHGEAR
CONTENTS
CLAUSE NO. 1.00.00 2.00.00 3.00.00 4.00.00 5.00.00 6.00.00 7.00.00 General Major Components Description Design Criteria
DESCRIPTION
PAGE NO. 1 1 1 2 3 15 15
Specific Requirement Tests List Of Drawings And Documents To Be Submitted With Bid ATTACHMENTS
ANNEXURE-A ANNEXURE-B ANNEXURE-C
Ratings and Requirements Protection Bus Transfer Scheme
17 20 23
500 MW MTPS STAGE-III
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SPECIFICATION E12 HT SWITCHGEAR 1.00.00 GENERAL The AC Power Supply-Medium Voltage (11kV and 3.3KV) System supplies power to plant auxiliaries requiring power on the 11kV and 3.3KV system and includes necessary fault detection & protection devices and annunciation in switchgear. 2.00.00 MAJOR COMPONENTS The AC Power Supply-Medium Voltage (11kV and 3.3KV) System shall consist of the following components: 11kV and 3.3KV switchgears Segregated phase bus duct. Unit/Standby transformer Unit/Station Auxiliary Transformer Neutral Grounding Resistor Raceways, conduits, conductors and conductor accessories This section covers the details on 11KV and 3.3 KV Switchgears The switchgear shall be complete with Autobus transfer panel and base channel frame with hardware. 3.00.00 DESCRIPTION The generation voltage of 21kV will be connected to 400KV system via respective step-up generator transformer. The medium voltage 11 kV system will derive power from two generator bus ducts through respective 21/11kV Unit Transformers and one 230/11 kV Standby Transformer. The two winding unit transformers receive power from their respective generators through the isolated phase bus duct and feed 11kV power to Unit Switchgears from secondary. One no. 230/11 KV, 2 winding Standby Transformers will be fed from 230kV indoor GIS switchyard. This power is transformed to a nominal system voltage of 11kV and delivered to the 11kV station switchgears through segregated phase bus ducts.11KV power will be further stepped down to 3.3KV and 415V for feeding motors and other loads. The 11/3.3KV switchgear distributes power through feeder breakers to the 11/3.3 KV auxiliary loads.
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The AC Power Supply-Medium Voltage (11/3.3KV) System has the following features for redundancy, diversity, and separation of the system:a) Each switchgear has both a main and reserve power supply feed. Each switchgear will have a high-speed Numerical based on-load bus transfer scheme with momentary paralleling facility. b) Breaker control, alarms, and monitoring of the AC Power Supply-Medium Voltage (11/3.3KV) System shall be provided at the main control room from EDMS / DDCMIS monitors. . c) The normal on-line operating conditions of the AC Power Supply-Medium Voltage (11/3.3KV) System allow for the unit auxiliary transformers to provide power to the auxiliary loads. The normal off-line operating conditions of the AC Power Supply-Medium Voltage (11/3.3KV) System allow for the station auxiliary transformer to provide power to the auxiliary loads. In case of unit failure, power supply to 11kV Unit Board will have Fast-bus changeover to station source. In addition, all 11kV & 3.3kV boards will have facilities for synchronized planned manual/auto changeover. 4.00.00 4.01.00 4.01.01 DESIGN CRITERIA The switchgear shall be used to supply power to 11kV and 3.3KV motors and other loads for various plants. Duty involves direct-on-line starting of large induction motors and also under certain emergency conditions transfer of loads from normal to stand-by source of supply. The motor starting current varies from 6 to 8 times the full-load current, with a maximum of 3 starts per hour. 4.01.02 The switchgear shall be located in a clean but hot, humid and tropical atmosphere. The switchgear room shall be provided with necessary air blowing arrangement. Switchgear ratings and requirements are detailed in the enclosed ANNEXURE-A. Equipment shall be furnished in strict accordance with the same. For continuous operation at specified ratings, temperature rise of the various switchgear components shall be limited to the permissible values stipulated in the relevant standards and/or this specification. The Switchgear and components thereof shall be capable of withstanding the mechanical forces and thermal stresses of the short circuit current listed in the annexure without any damage or deterioration of material.
4.01.03
4.01.04
4.01.05
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4.01.05
Circuit breaker shall not produce any harmful over-voltage during switching off induction motors. The surge protective devices of suitable rating as required shall be included in the scope of supply to limit over-voltage. The switchgear shall be suitable for extension on both sides. 11 KV & 3.3 KV Switchgear for CHP and AHP. The motor feeders shall be provided with SF6 circuit breakers /Vacuum contactors. The motor feeders below 600KW with rated current of 400 A, draw out type vacuum contactors shall be provided with a backup HRC fuses for short circuit protection.
4.01.01 4.01.01
5.00.00 5.01.00 5.01.01 5.01.02 5.01.03
SPECIFIC REQUIREMENT Construction The switchgear shall be indoor, metal-clad, floor mounted, draw out type. Design and construction shall be such as to allow extension at either end. The switchgear enclosure shall conform to the degree of protection IP-5X. The minimum thickness of sheet steel used shall be 2 mm. The switchgear assembly shall comprise a continuous, dead-front, line-up of free standing, vertical cubicles. Each cubicle shall have a front-hinged door with latches and a removable back cover. All covers and doors shall be provided with neoprene gaskets. Switchgear cubicle shall be so sized as to permit closing of the front access door when the breaker is pulled out to TEST position. The working zone shall be restricted within 750 mm to 1800 mm from floor level. Circuit breakers, instrument transformers, bus bars, cable compartment etc., shall be housed in separate compartments within the cubicle. The design shall be such that failure of one equipment shall not affect the adjacent units. All relays, meters, switches and lamps shall be flush mounted on the respective cubicle door or on control cabinet built on the front of the cubicle. Dummy panel shall be provided in the switchgear line up, if required, for easy termination access of power and control cables. The motor space heaters shall be controlled from separate module in MCC with necessary interlocks with switchgear. The wiring for space heaters of Switchgear compartments shall be segregated from the control wiring. In each of the 11KV and 3.3 KV switchgear one spare feeder for each type shall be provided
5.01.04
5.01.05
5.01.06 5.01.07 5.01.08 5.01.09 5.01.10
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5.01.11
Each cubicle shall be provided with 230 V AC lamp controlled by limit switches for illumination in the cubicle chamber while opening cubicles for maintenance purpose. Bus and Bus Taps The main buses and connections shall be of high conductivity copper/ aluminum alloy, sized for specified current ratings with maximum temperature limited to: a. For bolted joints (Plain or tinned) : b. For bolted joints (Silver plated) : 90oC (i.e.40oC ambient) 105oC (i.e.55oC ambient) rise rise over over 50oC 50oC
5.02.00 5.02.01
Bus bar temperature rise shall be limited to 35oC even while the ambient is 50oC. Copper bus bars shall be used for bus bar current rating above 2000A. 5.02.02 All bus connections shall be silver plated. Adequate contact pressure shall be ensured by means of two bolts connection with plain and spring washers and locknuts. Bimetallic connectors shall be furnished for connections between dissimilar metals. 5.02.03 Bus bars and connection shall be fully insulated for working voltage with adequate phase/ground clearances. Insulating sleeves for bus bars and castresin shrouds for joints shall be provided. Bus insulator shall be flame-retardant, track resistant type with high creepage surface. 5.02.04 All buses and connections shall be supported and braced to withstand stresses due to maximum short circuit current and also to take care of any thermal expansion. Bus bars shall be color coded for easy identification and so located that the sequence R-Y-B shall be from left to right, top to bottom or front to rear, when viewed from front of the switch-gear assembly. Circuit Breaker Circuit breaker shall be triple pole, single throw Sulphur hexafluoride (SF6) power circuit breaker elements. The Sulphur hexafluoride (SF6) breaker shall be provided with proper device to monitor the gas pressure in the interrupting chamber shall be provided. The device shall initiate a group alarm on DDCMIS and indication on affected
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5.02.05
5.03.00 5.03.01
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breaker panel. In case of loss of pressure to atmospheric pressure, the failed breaker shall be able to break rated load current. SF6 gas cylinder with all filling devices required for site filling shall also be provided. 5.03.02 5.03.03 5.03.04 Circuit breakers shall be horizontal draw out type, having SERVICE, TEST and DISONNECTED positions with positive indication for each position. Circuit breakers of identical rating shall be physically and electrically interchangeable. Circuit breaker shall have motor wound spring charged trip free mechanism with anti pumping-feature and shunt trip. In addition facility for manual charging of spring shall be provided. For motor wound mechanism, spring charging shall take place automatically after each breaker closing operation. One open-close-open operation of the circuit breaker shall be possible after failure of power supply to the motor. Mechanical safety interlock shall be provided to prevent : a. b. 5.03.07 5.03.08 The circuit breaker from being racked in or out of the service position when the breaker is closed. Racking in the circuit breaker unless the control plug is fully engaged.
5.03.05
5.03.06
Automatic safety shutters shall be provided to fully cover the female primary disconnects when the breaker is withdrawn. Each breaker shall be provided with an emergency manual trip, mechanical ON-OFF, indication, an operation counter and mechanism charge/discharge indicator. Each breaker shall be provided with following: a. b. c. Auxiliary switch, with 6 NO + 6 NC contacts, mounted on the draw out portion of the switchgear. Position/cell switch with 4 NO + 2 NC contacts, one each for TEST and SERVICE position. Auxiliary switch, with 8 NO + 8 NC contacts, mounted on the stationary portion of the switchgear and operated mechanically by a sliding lever from the breaker in SERVICE position.
5.03.09
Alternatively electrically reset type latching relay may be used for the purpose. 5.03.10 Switch contact shall be rated 10 A AC. and 2A DC at their respective operating voltage.
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5.03.11 5.04.00
Limit switches shall be convertible type. Control & Indication The circuit breaker shall be provided with Local/ Remote selector switch, wired up for local & remote operation. Each breaker cubicle shall be equipped with following: -
5.04.01 5.04.02 5.04.03
For motor feeders one (1) TEST-NORMAL-TRIAL selector switch stay put type with pistol grip handle and key interlock. Two (2) heavy-duty oil tight, push buttons for TRIP & CLOSE. ALARMS / INDICATIONS / SER POINTS Control room alarms and indications The following indications / alarms are the minimum to be provided in the DCS/EDMS TFT in the control room. Additional indications / alarms considered necessary during the detailed engineering stage shall also be provided. Out of these, some shall be selected for the sequential events recording.For each feeder, grouped alarm for any abnormal condition of that feeder shall be provided on the control panels. The control / interlock schemes for various types of feeders shall be commensurate with their application. (a) Common for each breaker panel (i) Status Indication Breaker on Breaker off Breaker in remote Breaker in service Breaker in test Circuit side earthed Bus side earthed (as applicable) Spring charger indication Local/Remote (ii) Alarms L/O Relay operated SF6 gas pressure low (in case of SF6 CB) Trip circuit unhealthy
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(b) Incomers from unit auxiliary / Standby transformer Sources paralleled beyond preset time Outgoing breaker trip c) VT Panels Bus under voltage L/O relay operated Bus PT fuse failed DC supply 1 failed. DC supply 2 failed Bus PT not in service d) Motor Feeders Overload alarm e) Service Transformer Feeders Oil temp Hi alarm Oil level low alarm Winding temperature Hi alarm Buchholz relay alarm f) Tie Feeders Sources paralleled beyond preset time. g) Analog Parameters All the parameters, for which the transducers are provided, shall be displayed in the DCS/EDMS CRTs in the control room. h) Control ON / OFF control and ON / OFF & fault / discrepancy indication for each of the breakers shall be provided in the CRTs. Control panel in the control room shall be provided with control of all synchronizing breakers i.e., incomers and tie breakers with auto-off-manual switches. i) Indication Lights on the Switchgear compartments Seven (7) indicating lights on front of compartments: GREEN BLUE RED : : : Breaker Open Spring Charged Breaker Closed
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AMBER
Trip Gas Pressure Low ( for SF6) Lock out relay healthy Trip Circuit healthy
ORANGE : YELLOW WHITE 5.04.04 : :
Lamps shall be front loading clustered type LED module pilot lights in thermoplastic enclosure with polycarbonate lens and diffuser. LED shall be protected by in-built fuse with surge suppressor and leakage voltage glow protection. Lamp and lens shall be replaceable from front. LEDs used for indication shall have pick up and drop out voltage within -20% of the operating voltage. The commands from DCS shall be wired to the breakers through interposing relays to be mounted in the switchgear. The scheme of protection shall be as per ANNEXURE-B attached. Bidder shall develop and furnish the wiring and control scheme accordingly. Current Transformer Current transformers shall be cast resin type. All secondary connections shall be brought out to terminal blocks where wye or delta connection shall be made. Accuracy class of the Current Transformers shall be: a. b. c. Class PS for differential relaying (or as required depending on the type of relay selected). Class 5P20 for other relaying. Class 0.5 and ISF <5 for metering. (applicable for C.T. ratio above 75/1 A). For C.T. ratio 75/1 A and below, ISF shall be <10.
5.04.05 5.04.06 5.05.00 5.05.01
5.05.02
5.05.03 5.05.04 5.05.05 5.05.06 5.06.00 5.06.01
Current transformer secondary shall be rated for 1 A or 5 A, depending on requirement. Summation CT of suitable ratio shall be provided in incomers of ST and UT as applicable The fixing and termination arrangement of feeder CTs shall have easy access for testing and changing. CT secondaries shall have terminations with link T.Bs for shorting. Voltage Transformer Voltage Transformers shall be cast-resin, draw out type and shall have an accuracy class of 0.5. Voltage Transformer mounted on breaker carriage or at
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the top of cubicle is not acceptable. Voltage transformer shall be mounted in a separate panel. 5.06.02 High voltage windings of voltage transformer shall be protected by current limiting fuses. The voltage transformer and fuses shall be completely disconnected and visibly grounded in fully draw-out position. Low voltage fuses shall be sized to prevent overload and shall be installed in all ungrounded secondary leads. Fuses shall be suitably located to permit easy replacement while the switchgear is energized. Relays Relays shall be of draw out design with built-in testing facilities and flush mounted at the front of panel. Small auxiliary relays may be in non-draw out execution and mounted within the cubicle. Relays shall be rated for operation on 110V secondary voltage and 1 or 5 A secondary current. Number and rating of relay contacts shall suit the job requirements. Unless mentioned otherwise in the specification, protective relays shall be multifunction type numerical relays of latest version to be approved by owner. Multifunction numerical relays shall be selected to provide an integrated protection measurement and monitoring functions. Features such as selfdiagnosis, Watch dog provision for relay healthiness, facility for different group of setting, disturbance recording, sequence of event recording and time stampings shall be available with the relay. All data shall be stored in nonvolatile memory backed up by battery. The relay shall have front LCD display and menus, fixed function and programmable LEDs, programmable I/Os, keypad etc and they shall be password protected. Communication port for local and remote (with suitable protocol) communication shall be located in the front and rear part of the relay for communication with EDMS/DDCMIS. A laptop loaded with support software shall be provided for local off line programming, measurements, exftracting and viewing of events, disturbance etc. The relay shall be housed in dust tight enclosure, suitable for IP 52 degree of protection. 5.07.05 The Contractor shall furnish, install & co-ordinate all relays to suit the requirements of protection, interlock and bus transfer schemes as broadly indicated in ANNEXURE-C. Meter Indicating instruments (96 x 96 mm) shall be Taut- band type, with 240degree scale, anti-glare glass and accuracy class of 0.5% full scale. Each meter shall have zero adjuster on the front.
5.06.03
5.07.00 5.07.01
5.07.02
5.07.03 5.07.04
5.08.00 5.08.01
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5.08.02 5.08.03
Motor ammeter shall have extended suppressed end-scale range to indicate starting current (6-8 times full load). Energy meter shall be three phase multifunction, digital type with communication port for EDMS/DDCMIS interface. The energy meter shall be located in respective switchgear cubicle of all incomers and outgoing feeders except motor feeders. For motor feeders the energy data shall be generated in DDCMIS. Transducer Transducers shall be provided for conversion of AC electrical quantities such as voltage, current and power. Transducers shall be of low burden type having 4 20 mA DC linear galvanically isolated output compatible with secondary indicating instrument. Transducer shall be dual channel type (slim model, latest version). The transducer shall be mounted in separate transducer panel, which shall be located in UCP area. The transducer panel shall be powered from 240V AC UPS supply and transducers shall be suitable for this UPS supply.
5.09.00
5.10.00 5.10.01
Switch Switches shall be dust protected, heavy duty, switchboard type complete with escutcheon plate. Contacts shall be silver surfaced, rated 10A at operating voltage. Lockable stay-put type switchgear / field / remote selector switch shall be provided as per requirement and mounted on switchgear cubicle. Meter selector switches shall be maintained contact, stay put type with knob handle. Ammeter& voltmeter selector switches shall be four position type. Ammeter selector switches shall have make before break feature to prevent open circuiting of CT secondary. Breaker control switch shall be multistage, spring return to normal, with lost motion device and pistol grip handle. Fuse Fuses shall be HRC, link type, with minimum interrupting capacity equal to the listed short circuit current. Fuses shall be furnished complete with fuse bases and fittings. Visible indication shall be provided on blowing of the fuse.
5.10.02 5.10.03
5.10.04 5.11.00 5.11.01
5.12.00
Push Button Push button shall be heavy duty, shrouded, push to actuate type with colored button and inscription plate. Each push button shall have 2 NO + 2 NC
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contacts, rated 10A and 0.5A at their respective AC and DC operating voltage. 5.13.00 5.13.01 5.13.02 Secondary Wiring The switchgear shall be fully wired at the factory to ensure proper functioning of control, protection, transfer and interlocking schemes. Fuse, links shall be provided to permit individual circuit isolation from bus wires without disturbing other circuits. All spare contacts of relays, switches and other devices shall be wired upto terminal blocks. Wiring shall be done with flexible, 1100 V grade, FRLS insulated switchboard wires with stranded copper conductors of 2.5 mm 2 for control and current circuits and 1.5 mm2 for voltage circuits. Each wire shall be identified, at both ends, with permanent markers bearing wire numbers as per Contractor's Wiring Diagrams. AC / DC wiring shall have separate color coding. Wire termination shall be made with crimping type connectors with insulating sleeves. Wires shall not be spliced between terminals. All spare contacts of relays, timers, auxiliary switches shall be wired up to the terminal block. Terminal Block 650V grade, multi way terminal block complete with mounting channel, binding screws and washers for wire connections and marking strip for circuit identification shall be provided for terminating the panel wiring. Terminals shall be stud type, suitable for terminating 2 nos. 2.5 mm2 stranded copper conductor and provided with acrylic insulating cover. Terminals for C.T. secondary leads shall have provision for shorting and grounding. Not more than two wires shall be connected to any terminal. Spare terminals equal in number to 20% active terminals shall be furnished. Separate terminal blocks shall be used for AC/ DC wiring termination. Terminal blocks shall be located to allow easy access. Wiring shall be so arranged that individual wires of an external cable can be connected to consecutive terminals. Wherever fuse terminal block is used it must be with LED indications. Terminal blocks used for interface with DDCMIS via termination cabinet shall be suitably sized to facilitate proper termination of interconnecting cables. Cable Termination Switchgear shall be designed for cable entry from bottom. Sufficient space shall be provided for ease of termination and connection.
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5.13.03
5.13.04
5.13.05 5.13.06 5.14.00 5.14.01
5.14.02
5.14.03
5.14.04 5.15.00 5.15.01
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5.15.02
All provisions and accessories shall be furnished for termination and connection of cables, including removable gland plates, cables supports, crimp type tinned copper/ aluminum lugs, double compression brass glands with tapered washer (Power cables only) and terminal blocks. Gland plates shall be minimum 3 mm thick. The gland plate and supporting arrangement for 1/C power cables shall be of aluminum. Sufficient space shall be provided between the power cable termination (endboxes) and gland plate. Core balance CTs wherever specified, shall be accommodated within this space. Bus Duct Connection Bus duct connections, when specified on ANNEXURE-A, shall be furnished along with transition panel if required. Unless mentioned otherwise bus duct connections shall generally be from the top. All connecting bus work shall have the same continuous rating as associated switchgear bus and shall be fully braced for the listed short circuit current. All provisions such as matching flange and other accessories shall be furnished for connection to bus duct supplied by other. Necessary details for this purpose shall be furnished later. Ground Bus A ground bus, rated to carry maximum fault current, shall extend full length of the switchgear. The ground bus shall be provided with two-bolt drilling with Cadmium coated bolts and nuts at each end to receive 50 X 6 mm Cu. flat. Each stationary unit shall be connected directly to the ground bus. The frame of each circuit breaker and draw out VT unit shall be grounded through heavy multiple contacts at all times except when the primary disconnecting devices are separated by a safe distance. Wherever the schematic diagrams indicate a definite ground at the switchgear, a single wire for each circuit thus grounded shall be run independently to the ground bus and connected there to. CT and VT secondary neutrals shall be earthed through removable links so that earth of one circuit may be removed without disturbing other. Earthing Truck Earthing trucks shall be suitable for earthing the switchgear bus bars or outgoing cables. The trucks shall have a voltage transformer and an interlock to prevent earthing of any live connection. The trucks shall have audio-visual
5.15.03 5.15.04
5.16.00 5.16.01
5.16.02 5.16.03
5.17.00 5.17.01 5.17.02 5.17.03
5.17.04
5.17.05 5.18.00
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annunciation to warn the operator against earthing of live connections. It shall not be possible to use bus-earthing truck for cable earthing & vice versa. Earthing truck shall be non- fault making type. 5.19.00 5.19.01 5.19.02 5.19.03 5.19.04 5.20.00 5.20.01 5.20.02 Nameplate Nameplates of approved design shall be furnished at each cubicle and at each instruments & device mounted on or inside the cubicle. The material shall be lamicoid or approved equal, 3 mm thick with white letter on black back ground. The nameplate shall be held by self-tapping screws. Nameplate size shall be minimum 20 x 75mm for instrument/device and 40 x 150mm for panels. Caution notice on suitable metal plate shall be affixed at the back of each vertical panel. Space heaters and Plug socket Each cubicle shall be provided with thermostat controlled space heaters and 5A, 3 pin plug socket. In addition, motor feeder cubicle shall be wired-up for feeding the motor space heater through suitable rated breaker auxiliary NC contact and/or contactor. Cubicle heater, Motor heater, Plug/socket circuits shall have individual switch fuse units. A.C/D.C Power Supply The following power supplies shall be made available to each switchgear: A.C. supply D.C. supply 5.21.02 : : Double Feeder Double Feeder
5.20.03 5.21.00 5.21.01
Isolating switch fuse units shall be provided at each switchgear for the incoming supplies, 4-pole, single throw for A.C. and 2-pole, double throw for D.C. Bus-wires of adequate capacity shall be provided to distribute the incoming supplies to different cubicles. Isolating switch fuse units shall be provided at each cubicle for A.C/D.C. supplies. A.C. load shall be so distributed as to present a balance loading on threephase supply system.
5.21.03
5.21.04
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5.22.00 5.22.01 5.22.02 5.23.00 5.23.01 5.23.02 5.23.03 5.23.04 5.24.00
Tropical Protection All equipment, accessories and wiring shall have fungus protection, involving special treatment of insulation and metal against fungus, insects & corrosion. Screens of corrosion resistant material shall be furnished on all ventilating louvers to prevent the entrance of insects. Painting All surfaces shall be sand blasted, pickled and grounded as required to produce a smooth, clean surface free of scale, grease and rust. After cleaning, the surfaces shall be given a phosphate coating followed by 2 coats of high quality primer and stoved after each coat. The switchgear shall be finished in Siemens grade 631 of IS 5 with two coats of synthetic enamel paint, unless other wise stated. Sufficient quantity of touch-up paint shall be furnished for application at site. Auto Bus Transfer (ABT) panel An automatic 32 bit or higher micro processor based real time operated fast backed up by slow transfer scheme shall be provided for change over between unit to station source. All hardwires pertaining to above transfers shall be mounted in Auto Bus transfer (ABT) panel. The bus transfer module shall have features such as graphical user interface, virtual test simulation, object oriented programming, on line viewing, sequence of event logging, self diagnostic features and communication port for remote communication. The ABT panel shall be indoor, simplex type construction, vertical free standing, floor mounted type, metal clad suitable for installation at 50 degree centigrade ambient. Panel enclosure shall be fabricated from 2 mm thick sheet steel and the same shall be IP 52 protected. For further details of scheme, reference may please be made to ANNEXURE-C
5.25.00 5.25.01
Accessories Following accessories shall be furnished along with the Switchgear : a. Earthing equipment suitable for earthing the bus or outgoing cable.
b. Test cabinet with coupling cables for testing the breaker in draw out position. c. Sufficient quantity of trolley shall be provided with jacking facility to draw out the HT breakers from the cubicle and to transport to the working bench for testing and maintenance purpose. These trolleys shall be arranged for HV and LV Breakers.
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6.00.00 6.01.00 6.02.00 6.02.01
TESTS The switchgear shall be completely assembled, wired, adjusted and tested at the factory as per the relevant standards of IS & IEC. Routine Test The tests shall generally include but not necessarily limited to the following: a. Operation under simulated service condition to ensure accuracy of wiring, correctness of control scheme & proper functioning of the equipment. All wiring and current carrying part shall be given appropriate High Voltage test. Primary current and voltage shall be applied to all instrument transformers. Routine test shall be carried out on all equipment such as circuit breakers, instrument transformers, relays, meters etc. as per relevant standard.
b. c. d.
6.03.00 6.03.01
Type Test Following minimum tests shall be performed on a typical section of the bus assembly: a. Impulse Test b. Temperature rise Test c. Short circuit Test d. STC e. Switching Over voltage Test f. Mechanical Endurance Test
g. Degree of enclosure protection h. Pressure relief device operation test Charges for each of the above tests shall be indicated separately. 6.03.02 All tests shall be carried out at the manufacturers works under his care and expense. All Type and Routine tests shall be witnessed by owners
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representative. Prior notice of minimum four (4) weeks shall be given to the owner for witnessing the tests. 7.00.00 a. List of Drawings and Documents to be submitted with bid Complete assembly drawings of the switchgear showing plan, elevation and typical sectional views and locations of the breaker compartment, cable terminations, busbar chamber, metering and relay compartment and terminal blocks for external connections. Switchgear interface panel drawing showing the layout of terminal block, cabling etc. Drawings of matching flanges and terminals for busducts Typical and recommended schematic diagrams for control and supervision of circuit breakers. Reports of all type tests of representative sections of panel assemblies. Sizing Calculations for bus size selection. Type tests certificates of CT, VT and Breakers
b.
c. d.
e. f. g.
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ANNEXURE-A RATINGS AND REQUIREMENTS 1.0 1.1 SWITCHGEAR General Type Service Enclosure 1.2 System Rated Voltage Phase Rated Frequency System grounding 1.3 KV rms : : : : 11kV and 3.3kV 10% Three 50 Hz 5% Non-Effectively Earthed : : : Metal-clad, draw out Indoor IP 5X
Rated Current inside the cubicle and at an ambient temperature of 50oC : Bus bar Circuit breaker : : *A (for 11kV) and *A (for 3.3kV) *A (for 11kV) and *A (for3.3 kV) * Bidder to furnish
1.4
Short Circuit Rating Rated short time withstand current Duration Rated peak withstand current : : : : : 75KVpeak (for 11kV) & 40kVpeak (for 3.3kV) 40kA minimum. 3 Sec. 100kA minimum.
1.5
Insulation level Rated lightning impulse withstand voltage
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Rated one-minute power frequency : withstand voltage 1.6 AC/DC Power Supply Control voltage Service voltage 1.7 Termination details Incomer/ Tie feeder : : :
35KVrms (for 11kV) & 10kVrms (for 3.3kV)
220 V DC (+10% to 15%) 240V 10%, 1 Ph, 50 Hz 5%
Through bottom entry cable or bus duct, top/bottom depending on requirement. Through bottom entry cable,
Outgoing feeder 2.0 1.0 2.0 3.0 4.0 5.0 CIRCUIT BREAKER Type No. of poles Rated Voltage Rated Frequency Rated normal current at site condition
: : KV rms : Hz Amps : :
SF6 Three 11kV and 3.3kV 10% 50 5% *A(for 11kV) and *A (for 3.3 kV) * bidder to furnish IEC-62271, 60694, 61233, IS-12729 75 kV peak (for 11kV) 40 kV peak (for 3.3kV) 35 kVrms (for 11kV) 10 kVrms (for 3.3kV) M1 E1 C1 As per IEC
6.0 7.0 7.1 7.2
Reference Standard Rated Insulation Level Lightning Impulse withstand voltage Rated one minute power frequency withstand voltage Mechanical Endurance Class Electrical Endurance Class Restrike Probability Class First pole to clear factor
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: : : : : :
8.0 9.0 10.0 11.0
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12.0 13.0 14.0 15.0 15.1 15.2 16.0 16.1 16.2 16.3 16.4
Rated Operating Sequence Operating mechanism % DC Component Operating time Opening time (ms) Closing time (ms) Rated Supply Voltage and frequency for Closing Tripping Spring Charge Motor Heater/Lamp/Socket
: : :
O - 3m - CO - 3m - CO Motor wound Spring charging 35%
: :
Not more than 60 Not more than 100
: : : :
220 V DC, (+10%V to 15%V) 220V DC, (+10%V to 30%V) 220V DC, (+10%V to 15%V) 240V(10%),1 Ph,50Hz( 5%),2W
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ANNEXURE-B PROTECTIONS 1.0 Minimum protections to be provided for different type of circuits are listed below All numerical protection relay shall have communication with EDMS by suitable protocol which shall be hooked up with DDCMIS. The relay shall have self diagnostic features. A. Incomer : 1-multifunction Numerical relay comprising of the following protective elements a. Over current (50/51) for phase fault with timer (2) Over current (50N/51N) for earth fault with timer (2) IDMTL over current (51SN) for stand by earth fault (for incomer from transformer only). Restricted E/F (64) (for incomer from transformer only) Under voltage with time delay (27) VT fuse failure
b.
c.
. d.
e. f. B. Tie feeder :
1-multifunctionNumerical relay with comprising of the following protective elements a. b. Over current (50/51) for phase fault with timer (2) Over current (50N/51N) for earth fault with timer (2) Under voltage with time delay (27) VT fuse failure
c. . d.
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VOL-III/E12/R0
1-numerical synchronizing check relay, if applicable, complete with guard relay and hard wires. 1-multifunction Numerical relay with motor protection relay (99) for protection against a. b. c. d. Thermal overload (49) Phase fault (50) Unbalance (-Ve seq.) (46) Locked rotor (50 LR) (ref. note 6)
C.
Motor feeder
: : D. Auxiliary Transformer :
1-Definite time O/C relay (50G) for earth fault (through CBCT) 1-Differential relay (87) for motor above 1000 KW rating. 1-multifunction Numerical relay comprising of the following protective elements a. b. Over current (50/51) for phase faults with timer (2) Differential protection (for transformers rated 5MVA and above)
: :
1-Definite time O/C relay (50G) for earth fault (through CBCT) Flag relays for transformer gas. oil temperature and winding temperature alarm and trip. 1-multifunction Numerical relay comprising of the following protective elements a. b. Over current (50/51) for phase fault with timer (2) Over current (50N/51N) for earth fault with timer (2)
E.
Line feeder
21
VOL-III/E12/R0
2.0 3.0
In case any trip function is not available in a single relay, separate numerical relays shall be provided to achieve the requirement. Apart from protection relays, each breaker shall be provided with anti-pumping (94), trip annunciation (30), trip supervision (74), electrically reset type breaker contact multiplication (52X) relay and lockout (86) relay. Lockout relay shall be hand reset type. Numerical under voltage relays (27) with time delay relay including VT fuse failure relay shall be provided for Bus VTs. IDMTL relay version shall be decided as per system requirement and the same shall be finalized during detail engineering. Zero-sequence CT and associated relay combination shall be such as to ensure a pick-up sensitivity of 10A primary ground fault current. Separate locked rotor protection relay (50 LR) with auxiliary relay (50 LRX) shall be furnished, if required. All the above Numerical relays shall have communication with EDMS for parameterization and DR upload with necessary password protection, which shall in turn will have connectivity with DDCMIS
4.0 5.0 6.0
7.0 8.0
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VOL-III/E12/R0
ANNEXURE-C BUS TRANSFER SCHEME
1.0
Bus transfer scheme (BTS) shall be provided, when specified, between two switchgears connected through tie-breakers (or bus coupler breaker between two bus sections) and fed independently from two upstream power sources. Bus transfer could be manual (planned transfer) in the event of transfer of load from one source to the other or automatic when fault is characterized by operation of protective relay. The manual and automatic bus transfer shall be arranged in such a way that any of he following mode of operation is possible.
1.1
2.0 2.1
Manual Bus Transfer Without voltage interruption This means by allowing momentary parallel operation of two sources.
2.2
With voltage interruption a) Slow Transfer b) Fast Transfer
3.0 3.1
Automatic Bus Transfer With Voltage Interruption a) Slow Transfer b) Fast Transfer
3.2 4.0 4.1
In Phase Transfer mode The requirement under various modes of bus transfer are further detailed as under : Manual bus transfer without voltage interruption In this mode, two sources are allowed to operate in parallel for short duration. Facility shall be provided to bypass the normal interlock against parallel operation. The changeover involves check synchronizing the two sources whenever the breaker for new source of supply is closed. Closure of new source breaker gives tripping command to the existing source breaker automatically.
23
VOL-III/E12/R0
However, this mode of operation is generally not used in normal course, as it involves paralleling of two sources, however briefly, which may give rise to the fault level beyond the specified withstand and rupturing capacity of circuit breakers. This scheme shall therefore be used, with due precautions, only in case of emergency when other modes of bus transfers are not available. 4.2 Manual bus transfer with voltage interruption Under this condition bus transfer is either Slow transfer or Fast transfer. Slow Transfer This changeover consists in switching off the existing source of supply and allowing the residual voltage of motors connected to the bus to decay sufficiently, (about 20% of the rated voltage) where after only the impulse goes to the breaker of new source of supply for closure. Necessary VTs and voltage sensing relays are used for sensing the appropriate voltage condition for bus transfer. This ensures that at the moment of bus transfer, even if residual voltage of motor is in phase opposition to the voltage of new source of supply, the motors shall not be subjected to magnetic shock. To avoid the excessive voltage drop due to simultaneous restarting of all motors connected to the existing bus, some of the pre selected non-essential motors and other loads are switched off in this scheme along with the existing source breaker. This allows the bus voltage drop during restarting the motors to remain within acceptable limit. The details of selection scheme for automatic tripping of such motors is decided during detail engineering. Fast Transfer In this mode of bus transfer the existing source breaker is switched off and the new source breaker is closed. The switchover is so rapid that the vector difference between motor residual voltage and the new source voltage is very little so that closure of breaker against phase opposition is not encountered. On the other hand, at the time of closure, speed of connected motors drops down only marginally, with the result that at the moment of transfer of motors loads to the new source of supply, there is only a small rise in current as compared to the normal running current of motors. The voltage drop during this transfer is therefore marginal and bus transfer is satisfactory. Since the closing time of breaker is considerably longer than the tripping time, this scheme gives the closing command to the new source breaker first and only after a preset time interval it gives the tripping command to the existing source breaker. The interval between these two commands is so selected that the actual interruption time is limited to few cycles.
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VOL-III/E12/R0
4.3
Automatic bus transfer with voltage interruption As compared to the bus transfer described under 4.2 above, the changeover in this mode of transfer is initiated automatically upon sensing under voltage in the existing bus. Thus with the help of appropriate sensing relays, the bus transfer takes place automatically when the existing bus voltage drops below a certain voltage level (about 85 % of the rated voltage) for a preset time. This scheme initiates bus transfer only in case of external faults responsible for voltage drop. In case of voltage drop due to internal fault, the transfer scheme is locked out. The automatic bus transfer scheme is generally a fast bus transfer scheme and the sequence of operation are similar to that explained in fast bus transfer scheme in manual mode. However, if the fast bus transfer is found not responding to the command-, it shall automatically go for slow bus transfer scheme in a manner explained against slow bus transfer scheme under manual mode.
4.4
In Phase bus Transfer The breaker power contacts shall close when the decaying and drifting bus voltage synchronizes with the incoming source voltage within acceptable voltage and frequency parameters. The bus transfer system shall continuously process the bus voltage and drifting phase angle dynamics to determine using second order predictive algorithm in real-time, the exact moment of sending a command to the breaker-closing coil to achieve the above.
5.0
General requirement The equipment for bus transfer scheme described above shall be wired in separate panels. The equipment shall include selector switches, indicating lamps, transfer circuit, supervising relays, Numerical based fast acting voltage sensing relay and phase comparison relays etc. Necessary voltage transformers of required accuracy class shall be provided in appropriate high voltage switchgear panels. Auxiliary relays shall be incorporated with a view to enable inter panel wiring and easy fault location. Testing facility shall be provided for on line testing of the operating circuits of each bus transfer scheme. However, in case need arises for automatic changeover, when testing of schemes are in progress the automatic changeover operation shall override the testing activities by resetting the test circuits. Necessary selector switches shall be provided to select the mode of transfer i.e., manual or automatic. In case of manual transfer, there shall be additional selector switch for selecting manual without voltage interruption, manual fast and 'manual slow changeover with voltage interruption. Mode selection and bus transfer initiation switches shall be located in the control panel.
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VOL-III/E12/R0
The supervision of operating circuit of each mode of bus transfer shall be duly signalised in the control room. All relevant indication and annunciation with audible alarm, accept and reset facility shall be provided. Facility shall also exist in the form of potential free auxiliary contacts for remote annunciation. Similarly actuation of any mode of bus transfer either manual or automatic shall also be signaled together with an audible alarm in the control room. Certain important information of bus transfer event is to be recorded in the data acquisition system. Necessary potential free contacts shall be kept wired for event logging.
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VOL-III/E12/R0
SPECIFICATION E13 415V POWER CONTROL CENTER (PCC), MOTOR CONTROL CENTER (MCC), AC DISTRIBUTION BOARDS, DC STARTER PANEL & MISCELLANEOUS PANELS AND EQUIPMENTS CONTENTS
CLAUSE NO. 1.00.00 2.00.00 3.00.00 4.00.00 5.00.00 6.00.00 7.00.00 General Description 415V PCC MCC & DB
DESCRIPTION
PAGE NO 1 1 4 13 25 25 27
DC Starter Panel Miscellaneous Panels And Equipments List of Drawing and Document to be submitted with bid
ATTACHMENTS ANNEXURE - A ANNEXURE -B Ratings and Requirements for PCC Ratings and Requirements for MCC & DB 28 30
VOL-III/E13/R0
SPECIFICATION E13 415V POWER CONTROL CENTER (PCC), MOTOR CONTROL CENTER (MCC), AC DISTRIBUTION BOARDS, DC STARTER PANEL & MISCELLANEOUS PANELS AND EQUIPMENTS
1.00.00
GENERAL The AC Power Supply (415 Volt) System shall provide power to 415-volt plant auxiliary loads and include over-current phase and earth fault protection. The AC Power Supply (415 Volt) System shall consist of the following major components:Unit/Station Service Transformers (USTs/SSTs) LT Busduct Unit and Station Service Switchgears (USS/SSS) Power Control Centres (PCCs) & Motor Control Centres (MCCs) 415V AC Distribution Boards (ACDBs) Raceways, Conduits, Conductors and Conductor Accessories. This specification shall cover the requirements of followings. a) Power Control Center (PCC) b) Motor Control Center (MCC) c) AC Distribution Board (ACDB) d) DC Starter Panel (DCSP)
2.00.00
DESCRIPTION The unit & station service transformers (USTs/SSTs) shall transform 11000V three-phase power, supplied by the HV AC Power Supply System, to 3300V & 415V three-phase power. The transformers shall supply 3300V / 415 Volt threephase power to USS/SSS buses through a main breaker. The bus arrangement is shown in attached SLD. The main and bus-coupler breakers shall make it possible for a switchgear bus to be fed from two separate sources with auto & manual live changeover facilities. Normally each half section of the switchgear will be fed by its own incomer with the bus-coupler being open. In case of loss of supply from the incomer, under-voltage actuated dead changeover to the other source shall take place by tripping of affected incomer and closure of bus-coupler breaker. Upon restoration of normal supply, the incomer breaker will be closed after paralleling and the pre-selected breaker will be either automatically or manually tripped thus effecting a live changeover.
VOL-III/E13/R0
The 415V system shall be a solidly grounded wye system. The Motors rated below 160 kW shall be supplied from the 415 volt system. The USS/SSS shall distribute power through feeder breakers to 415V motors rated above 75 KW and to Motor Control Centres (MCC). The MCCs shall distribute power to small 415 volt motors, to AC distribution boards and to intermediate 415 volt loads. The MCCs shall also distribute power to the single phase AC Power Supply (240 Volt) System. The 415 volt AC distribution boards shall distribute power to small 415 volt loads. For offsite areas beyond power block, separate independent PCCs will be provided. All PCCs will be fed through respective 2x100% redundant 11/0.433kV transformers through two incomer breakers. Power to these transformers will be fed from 11kV as shown in SLD. Load centre MCCs in offsite areas will be fed from respective area PCCs through two feeders each. Bidder shall decide the actual number of transformers and LV boards based upon the power distribution arrangement proposed based on geographical location and unit/station loads. Remote control from the control room shall be provided for Unit/station PCC main and bus-coupler breakers from EDMS HMI and remote start, stop and ON/OFF/TRIP, remote/local indication for all motor modules shall be provided from DDCMIS. Monitoring shall be provided for AC Power Supply (415 Volt) System conditions. Abnormal conditions shall be alarmed to EDMS/DDCMIS. The normal operating conditions for the 415V AC System are as listed:a) Unit and/or station transformer supplying power through the 11000 volt buses to the unit/station service transformers. USS bus incomer breakers closed. USS bus bus-coupler breaker open. 415V auxiliary load at level required for full load operation of the unit.
b) c) d)
The Off-Normal or Emergency Operating Conditions include the following: a) b) c) One UST supplying power to two USS buses. One SST supplying power to two SSS buses. Phase-to-ground, phase-to-phase, or three-phase faults on USS, SSS or MCC or distribution board feeder. Phase-to-earth fault currents shall be limited by the UST/SST size i.e. 1600 kVA/2000 kVA/2500KVA. The 415V PCC, MCC with two incomers and one bus coupler (all electrically operated ACB controlled) and as required number of active and spare outgoing feeders for control of various LT drives and loads shall be considered.
VOL-III/E13/R0
All LV switchgears and Motor Control Centres shall be intelligent type utilising feeder management devices for protection, control, monitoring and measurement on each breaker controlled incomer, bus coupler, tie-feeder and breaker-controlled large motor feeders. The data shall be transmitted on a serial fibre-optic cable link to an EDMS/DDCMIS system in the Main Plant Control Room. The feeder units shall provide self-diagnostic and historical data logging facilities. Each 415V switchgear will be served by 2x100% capacity service transformers Each ESP PCC will be fed from 11kV unit switchgear located in powerhouse building via a pair of dry type LT transformers to be installed on either side of ESP PCC. The PCC comprising of two incomer and one bus coupler with adequate number of feeders for ESP, control building lighting, Air conditioning, Ventilation system and equipment handling system (Hoists), fire fighting system load shall be complete in all respect and will serve as power distribution center. The welding power requirement shall be through separate service transformer as shown in SLD. 2.01.00 CONTROL ROOM ALARMS/INDICATION/SER POINTS All switchgear located in the TG building shall be controlled from CRTs (EDMS) in the unit control room, other than those controlled from DCS. The switchgear of ash handling and coal handling systems shall be controlled from the respective system control panels. Other MCCs viz. fuel oil pump house MCC, water treatment plant MCC, clarifier/misc water pump house MCC, ESP MCC, etc shall be locally controlled with synchronization equipment facility mounted on the switchgear. Hese systems shall be monitored from CRTS in CCR. For all switchgear/MCC where auto/manual changeover facility is specified, breakers shall be provided for the incomers and bus coupler. The control room CRTs shall provide indication & alarms for the 415V auxiliary supply as given below. Any additional indications/alarms considered necessary during detailed engineering shall also be provided. Some of these shall be selected for sequential events recording. For each breaker and bus, grouped alarm for any abnormal conditions shall be provided in the control desk. (a) Status indication in CRT (EDMS/DCS) Breaker on Breaker off Breaker fault Breaker service Breaker selected for remote Load current Bus Voltage Trip Circuit Healthy 500 MW MTPS STAGE-III
3 VOL-III/E13/R0
Control DC ON (b) Alarms in CRT Breaker auto tripped/L/O Relay operated Bus under voltage Sources paralleled beyond preset time Common outgoing feeder fault Incoming 220 V DC control supply failed Bus PT fuse failed Bus PT not in service 3.00.00 3.01.00 415V PCC The PCCs shall be indoor, metal clad, floor mounted suitable for location in a clean but hot humid and tropical atmosphere. Degree of protection shall be IP 54. Sheet steel used for the construction shall be minimum 2mm thick for structural load bearing members, doors, covers and partitions. The design and construction shall be such as to allow extension at either end. The PCC shall be rated for 50kA for one (1) second. The PCC shall have sectionalized bus with two incomers and two bus sections. PCC shall be provided with permanent alternative supply for flexibility of operation and to cater for planned or forced outages. PCC cubicles shall be component wise compartmentalized so that failure of one equipment shall not affect the equipment in adjacent compartment or adjacent cubicle. Circuit breaker in switchgear cubicle shall be draw out type and not more than one circuit breakers shall be located in a vertical panel with metallic partitions in between the breakers. The working height shall be limited within 400 mm to 1800 mm from floor level. Each breaker shall be housed in a separate cubicle complete with an individual front access door. Each vertical section shall have a removable back cover. All doors and covers shall be provided with neoprene gaskets. The door shall have self-tightening handle/knob so as to prevent ingress of dust. 3.06.00 PCC cubicle shall be so sized as to permit closing of the front access door when the breaker is pulled out to ISOLATED position. All switches, push buttons, lamps, indicating instruments shall be flush mounted on the respective cubicle door whereas relays and other auxiliary devices may be mounted on a separate cubicle.
3.02.00 3.03.00
3.04.00
3.05.00
3.07.00
VOL-III/E13/R0
3.08.00
The PCC shall have 2 X100% incomer at two extreme end of line up. The incomer, bus couplers, breakers/ isolators for the PCC shall be four- (4) pole type. All breakers shall be compatible for 220 V DC system. 20% spare feeders, minimum one (1) of each rating and type shall be provided.
3.09.00
Bus and Bus Taps i. The main buses and connections shall be of high conductivity Aluminium/Aluminium alloy, sized for specified current ratings with maximum temperature limited to 85oC (i.e., 35oC rise over 50oC ambient) for normal operating condition and 200 0 C for short circuit condition. ii. All bus connections shall be silver-plated. Adequate contact pressure shall be ensured by means of two-bolt connection with plain & spring washers and locknuts. iii. No Bi-metallic should be utilized in the power circuits of bus bar / cable areas. If unavoidable provide suitable Bi-metallic strips in the corresponding zones. iv. Bus bars and connections shall be fully insulated for working voltage with adequate phase/ground clearances. Insulating sleeves for bus bars and shrouds for joints shall be provided. Sleeves shall be non moisture absorbent type. v. Bus insulators shall be flame-retardant, non-hygroscopic, track resistant type with high creepage surface. vi. All buses and connections shall be supported and braced to withstand the stresses due to maximum short-circuit current and also to take care of any thermal expansion. vii. Bus bars shall be colour coded for easy identification and so located that the sequence R-Y-B shall be from left to right, top to bottom or front to rear, when viewed from the front to switchgear assembly. viii. Bolted disconnect links shall be provided for all outgoing feeders for isolation of neutral, if necessary. ix. Heat shrinkable PVC sleeves having flame retardant property shall be provided on each bus bar. x. Vertical neutral bus bar shall be brought for each panel. Neutral bus bars shall have minimum 50% of the rating of main bus bar. xi. The vertical busbar take-off leads shall be provided with adequate clearance to avoid flashovers due to arc jump/ionization of air.
VOL-III/E13/R0
xii. Main buses shall be of aluminium and shall be rated to carry the maximum rated incomer transformer load current. The incomers shall be sized to supply all non-redundant loads on both sections of the switchgear (with one transformer out of service and tie-breaker closed). xiii. CAUTION LIVE BUS BARS inscribed label shall be provided on barriers / covers. 3.10.00 Circuit Breaker i. Circuit Breaker shall be four pole, single throw, air break type with stored energy, trip free mechanism and shunt trip. ii. Circuit breakers shall be draw out type, having SERVICE, TEST & ISOLATED positions with positive indication for each position. iii. Circuit breakers of identical rating shall be physically and electrically interchangeable. iv. Circuit breaker shall have motor wound spring charged trip free mechanism with anti-pumping feature and shunt trip. In addition, facility for manual charging of spring shall be provided. v. For motor wound mechanism, spring charging shall take place automatically after each breaker closing operation. One open-close-open operation of the circuit breaker shall be possible after failure of power supply to the motor. vi. Mechanical safety interlock shall be provided to prevent the circuit breaker from being racked in or out of the service position when the breaker is closed and to prevent racking in the circuit breaker unless the control plug is fully engaged. vii. Safety interlock shall be provided for the followings: a. Operation of CB shall not be possible unless it is fully in service position, fully withdrawn to test position or fully drawnout. b. Compartment door of the breaker shall not open unless the associated breaker is in open position. c. The breaker of specific breaker rating shall be prevented from engaging into the stationary portion of other higher rating. d. The breaker carriage shall be earthed before main circuit breaker contacts are plugged in. The earthing shall be maintained in service position.
VOL-III/E13/R0
viii.
Automatic safety shutters shall be provided to fully cover the female primary disconnects when the breaker is withdrawn. Each breaker shall be provided with an emergency manual trip, mechanical ON-OFF indicator, an operation counter and mechanism charge/discharge indicator. Each breaker shall be provided with followings: a. Auxiliary switch, with 6NO+6NC contacts, mounted on the drawout portion of the PCC. Position/cell switch with 4NO+2NC contacts, one each for TEST and SERVICE position. Auxiliary switch, with 6NO+6NC contacts, mounted on the stationary portion of the PCC and operated mechanically by a sliding lever from the breaker in SERVICE position. Alternatively electrically latching relay may be used for the purpose.
ix.
x.
b. c. d.
xi)
LT circuit breaker provide with in-built over-current, short circuit, under voltage and earth fault releases with shunt trip coil can be adopted instead of providing separate relay for each protection. Limit/auxiliary switches shall be convertible type, that is, suitable for changing NO. contact to N.C. and vice-versa. Switch contact rated for 10A A.C. and 2A D.C. at operating voltage.
3.11.00
Control Modules i. Draw out type control module shall have self-aligning power/control disconnects. All disconnects shall be silver-plated to ensure good contacts. ii. The design shall be such as to permit easy withdrawal/reinsertion of the unit with guide rails to ensure correct alignment. iii. Control Module shall house the control components for a circuit such as switch, fuse, lamps etc. iv. Various module/compartment sizes shall be multiple of one basic unit to facilitate modification at site. Suitable provision for this purpose should also be incorporated in the vertical bus bars. v. Drawout type control modules of same size and type shall be electrically and physically interchangeable.
VOL-III/E13/R0
vi. The commands from DDCMIS/EDMS shall be wired up to the switchgear through interposing relays to avoid mix up of 24 V DC and 220VDC in DDCMIS/EDMS system. vii. The motor space heaters shall be controlled from separate module in MCC with necessary interlocks with the main motor. viii. The wiring for space heaters of Switchgear compartments shall be segregated from the control wiring ix. Double decker lyra contacts for higher capacity LT motors modules and feeder modules for increasing the contacts surface area to avoid flash over of LT motors. 3.12.00 Switches i. Switches shall be three pole, air break, AC22 heavy duty for power feeders. ii. The switch shall have a quick-make, quick-break mechanism operated by a suitable external handle, complete with position indicator. iii. This handle shall have provision for padlocking in ON and OFF position. iv. Barriers shall be provided to prevent inter-phase arcing and live terminals shall be shrouded to avoid accidental contact. v. The compartment door shall be interlocked mechanically with the switch such that the door cannot be opened unless the switch is in OFF position. Means shall be provided for releasing this interlock at any time. vi. Switches shall be capable of withstanding the let-through fault current of back-up fuses or circuit breakers. vii. Outgoing feeders shall be provided with bolted disconnect link for isolation of neutral, if necessary. 3.13.00 The circuit breaker shall be wired up for local & remote operation with Local/Remote selector switch. Each breaker cubicle shall be equipped with following: i. One (1) 'TRIP-NEUTRAL-CLOSE' breaker control switch spring return to neutral type pistol grip handle. ii. One (1) LOCAL REMOTE selector switch stay put type with pistol grip handle and key interlock for all non-motor feeders. iii. Five (5) indicating lamps on front of compartment: 500 MW MTPS STAGE-III
VOL-III/E13/R0
GREEN RED AMBER WHITE BLUE 3.14.00
Breaker open Breaker closed Trip Trip circuit healthy Spring charged
Lamps shall be front loading clustered type LED module pilot lights in thermoplastic enclosure with polycarbonate lens and diffuser. LED shall be protected by in-built fuse with surge suppressor and leakage voltage glow protection. Lamp and lens shall be replaceable from front. LEDs used for indication shall have pick up and drop out voltage within -20% of the operating voltage. Current Transformer i. Current Transformers shall be cast-resin type. All secondary connections shall be brought out to terminal blocks where wye or delta connection will be made. ii. Accuracy class of the current transformers shall be: a. b. Class 5P20 & PS for relaying. Class 0.5 for metering.
3.15.00
3.15.01 3.15.02 3.16.00
The fixing and termination arrangement of feeder CTs shall have easy access for testing and changing. CT secondaries shall have terminations with link T.Bs for shorting. Voltage Transformer i. Voltage transformers shall be cast-resin, drawout type and shall have an accuracy class of 0.5 and 3P. Voltage transformer mounted on breaker carriage is not acceptable. ii. High voltage windings of voltage transformer shall be protected by current limiting fuses. The voltage transformer and fuses shall be completely disconnected and visibly grounded in fully drawout position. iii. Low voltage fuses, sized to prevent overload, shall be installed in all ungrounded secondary leads.
VOL-III/E13/R0
3.17.00
Relays i. Numerical, communicable multi function relay of latest version to be approved by owner shall be provided for all breaker feeders covering all protection. If some functions are not available in the multifunction relay, separate static discrete or electromechanical relays shall be provided. ii. The numerical relay shall have suitable communication port with modbus protocol for connection to EDMS/. iii. Relays shall be rated for operation on 1A secondary current and 110V secondary voltage; number and rating of relay contacts shall suit the job requirements. iv. The bidder shall furnish, install & co-ordinate all relays to suit the requirements of protection and interlock and bus transfer scheme.
3.18.00
Meters & Transducers i. For all incomers and outgoing feeders multifunction digital communicable meter shall be provided with display screen. If some functions are not available in the multifunction meter, separate discrete meters shall be provided. The multifunction meter shall have communication port with modbus protocol for connection to EDMS/DDCMIS. The metering shall cover current, voltage, kW, kVAR, power factor, kWh and frequency. Auxiliary consumption shall be metered. ii. Discrete meters (96 x 96 mm) shall be Taut-band type, with 240o scale, anti-glare glass and accuracy class of 2% full scale. Each meter shall have zero adjuster on the front. iii. Transducers (Slim type), with + 0.5% accuracy, 4-20mA DC linear output & 750 ohm load shall be provided in transducer panel.
3.19.00
Secondary Wiring i. PCC shall be fully wired at the factory to ensure proper functioning of control, protection, transfer and interlocking schemes. ii. PCC shall be provided to permit individual circuit isolation from bus wires without disturbing other circuits. All spare contacts of relays, switches and other devices shall be wired up to terminal blocks. iii. Wiring shall be done with flexible, 1100V grade, PVC insulated switchboard wires with stranded copper conductors of 2.5 mm2 for control & current circuits and 1.5 mm2 for voltage circuits.
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VOL-III/E13/R0
iv. Each wire shall be identified, at both ends, with permanent markers bearing wire numbers as per Contractor's wiring diagrams. v. Wire terminations shall be made with crimping type connectors with insulating sleeves. Wire shall not be spliced between terminals. 3.20.00 Terminal Blocks i. Terminal blocks shall be 660V grade box-clamp type with marking strips, similar to ELMEX 10 mm2 or equal. Terminals for C.T. secondary leads shall have provision for shorting. ii. Not more than two wires shall be connected to any terminal. Spare terminals equal in number to 20% active terminals shall be furnished. iii. Terminal blocks shall be located to allow easy access. Wiring shall be so arranged that individual wires of an external cable can be connected to consecutive terminals. 3.21.00 Ground Bus i. A ground bus, rated to carry maximum fault current, shall extend full length of the PCC. ii. The ground bus shall be provided with two-bolt drilling with Cadmium coated bolts and nuts at each end to receive 50 x 6 mm Cu flat. iii. Each stationary unit shall be connected directly to the ground bus. The frame of each circuit breaker and draw out V.T. unit shall be grounded through heavy multiple contacts at all times except when the primary disconnecting devices are separated by a safe distance. 3.22.00 Space Heaters and Plug Sockets i. Each vertical section shall be provided with thermostat controlled space heater and 5A, 3-pin plug socket. ii. Cubicle heater, Plug-socket circuit shall have individual switch fuse units. 3.23.00 A.C./D.C. Power Supply i. The following power supplies will be made available to each switchgear: A.C. supply: Double feeder D.C. supply: Double feeder
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VOL-III/E13/R0
3.24.00
Isolating switch fuse units shall be provided at each PCC for the incoming supplies, 4-pole, single throw for A.C. and 2- pole, double throw for D.C. Painting i. All surfaces shall be sand blasted, pickled and grounded as required to produce a smooth, clean surface free of scale, grease and rust. After cleaning, the surfaces shall be given a phosphate coating followed by two coats of high quality primer and stoved after each coat. The switchgear shall be finished in Grade 631 of IS 5 with two coats of Epoxy Paint. However, Owner reserves the right to change the color shade at the time of approval of vendor drawings. Sufficient quantity of touch-up paint shall be furnished for application at site.
3.25.00
ii.
iii.
iv.
3.26.00
PROTECTIONS 1.0 The minimum protections to be provided for different types of circuits are listed below : a. Incoming Feeder & Bus Coupler : O/C relays (50/51) for phase fault with timer (2) O/C relay (50N/51N) for Earth fault with timer (2). Under voltage relay (27) Neutral Displacement relay (NDR)
b. Outgoing Bkr. Feeder : O/C relays (50/51) for phase fault with timer (2) O/C relay (50N/51N) for Earth fault with timer (2). 2.0 Apart from protection relays, each electrically operated breaker shall be provided with antipumping (94), trip annunciation (30), lockout (86), lockout supervision (95) and trip supervision (74) relays. Lockout relay shall be hand reset type. Fuse monitoring relay (98) shall be provided on the secondary side of voltage transformer to monitor fuses.
3.0
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VOL-III/E13/R0
3.27.00
TESTS i. The PCC shall be completely assembled, wired, adjusted and tested at the factory as per the relevant standards of IS & IEC in the presence of the owners representative. ii. The following Routine and Type tests shall be performed for each PCC panel. Routine Test The tests shall include but not necessarily be limited to the following : a. Operation under simulated service condition to ensure accuracy of wiring, correctness of control scheme & proper functioning of the equipment. All wiring and current carrying part shall be given appropriate High Voltage Test. Primary current & voltage shall be applied to all instrument transformers. Routine test shall be carried out on all equipment such as circuit breakers, instrument transformers, relays, meters etc.
b.
c.
d.
Type Test The following test shall be performed on a typical section of the bus assembly with breaker in cubicle. a. Temperature rise Test b. Short circuit Test 4.00.00 4.01.00 MCC & DB The MCCs shall be indoor, metal clad, floor mounted suitable for location in a clean but hot humid and tropical atmosphere. Sheet steel used for the construction shall be minimum 2mm thick for structural load bearing members, doors, covers and partitions. MCCs shall be double front draw out type while DB shall be single front fixed type. The design and construction shall be such as to allow extension at either end. The MCC/ DB shall be rated for 50kA for one (1) second. Degree of protection for both MCC and DB shall be IP 54. MCC / DB assembly shall comprise of a continuous line up of dead front, freestanding vertical sections, housing the control modules in multitier formation.
13 VOL-III/E13/R0
4.02.00 4.03.00 4.04.00
4.05.00
The design shall be fully compartmentalized with metal / insulating partitions between compartments. The working height shall be limited within 400 mm to 1800 mm from floor level. Each control module of MCC / DB shall be housed in a separate compartment, complete with an individual front access door. Each vertical section shall have a removable back cover. All doors and covers shall be provided with neoprene gaskets. The door shall have self-tightening handle / knob so as to prevent ingress of dust. All lamps, switches, push buttons, indicating instruments, relays shall be flush / semi-flush mounted on respective module compartment. MCC shall have start and stop facility for all the drives. 20% spare feeders, minimum one of each rating and type shall be provided. Bus and Bus Taps i. The continuous current rating for incomer, bus section and bus bar shall be based on total continuous running load plus highest load during change over of equipment / stream (one at a time) as applicable plus 25% of total connected intermittent loads plus 20% overall margin ii. The main buses and connections shall be of high conductivity Aluminium / Aluminium alloy, sized for specified current ratings with maximum temperature limited to 85oC (i.e., 35oC rise over 50 oC ambient) for normal operating condition and 2000 C for short circuit condition. Vertical bus bars shall be provided for each vertical panel. iii. All bus connections shall be silver-plated. Adequate contact pressure shall be ensured by means of two-bolt connection with plain and spring washers and locknuts. iv. No Bi-metallic should be utilized in the power circuits of bus bar / cable areas. If unavoidable provide suitable Bi-metallic strips in the corresponding zones. . v. Busbars and connections shall be fully insulated for working voltage with adequate phase/ground clearances. Insulating sleeves of non moisture absorbent type for busbars and shrouds for joints shall be provided. vi. Bus insulators shall be flame retardant, track-resistant type with high creepage surface. Busbars & connections shall be supported and braced to withstand the stresses due to maximum short circuit current and also to take care of any thermal expansion.
4.06.00
4.07.00
4.08.00 4.09.00
vii.
14
VOL-III/E13/R0
viii.
Busbars shall be colour coded for easy identification and so located that the sequence R-Y-B shall be from left to right, top to bottom or front to rear when viewed from the front of the assembly. Vertical neutral busbars shall be brought for each panel. Bidder to ensure that for panels, ionized gas travel (due to fault) from module to bus bar chamber or from vertical bus bar to horizontal bus bar chamber or from module/vertical bus bar chamber to cable alley/ compartment shall be effectively restricted to prevent multiple fault/reduce damage. The vertical busbar take-off leads shall be provided with adequate clearance to avoid flashovers due to arc jump/ionization of air. Main bus bar shall run horizontally at the top for easy accessibility. CAUTION LIVE BUS BARS inscribed label shall be provided on barriers/ covers. Adequately rated copper auxiliary bus bars shall be provided for: a. b. c. Panel & motor space heater AC & DC control supply P.T. supply
ix. x.
xi. xii.
xiii.
xiv.
Heat shrinkable PVC sleeves having flame retardant property shall be provided on each bus bar.
4.10.00
Circuit Breaker i. Circuit Breaker shall be four pole for incomer and bus coupler and three pole for out going motor feeders, single throw, air break type with stored energy, trip free mechanism and shunt trip. ii. Circuit breakers shall be drawout type, having SERVICE, TEST & ISOLATED positions with positive indication for each position. iii. Circuit breakers of identical rating shall be physically and electrically interchangeable. iv. Circuit breaker shall have motor wound spring charged trip free mechanism with anti-pumping feature and shunt trip. In addition, facility for manual charging of spring shall be provided. v. For motor wound mechanism, spring charging shall take place automatically after each breaker closing operation. One open-close-open operation of the circuit breaker shall be possible after failure of power supply to the motor. vi. Mechanical safety interlock shall be provided to prevent the circuit breaker from being racked in or out of the service position when the
15
VOL-III/E13/R0
breaker is closed and to prevent racking in the circuit breaker unless the control plug is fully engaged. vii. Safety interlock shall be provided for the followings: a. Operation of CB shall not be possible unless it is fully in service position, fully withdrawn to test position or fully drawnout. b. Compartment door of the breaker shall not open unless the associated breaker is in open position. c. The breaker of specific breaker rating shall be prevented from engaging into the stationary portion of other higher rating. d. The breaker carriage shall be earthed before main circuit breaker contacts are plugged in. The earthing shall be maintained in service position. viii. Automatic safety shutters shall be provided to fully cover the female primary disconnects when the breaker is withdrawn. ix. Each breaker shall be provided with an emergency manual trip, mechanical ON-OFF indicator, an operation counter and mechanism charge/discharge indicator. Each breaker shall be provided with followings: a. Auxiliary switch, with 6NO+6NC contacts, mounted on the drawout portion of the MCC. Position/cell switch with 4NO+2NC contacts, one each for TEST and SERVICE position. Auxiliary switch, with 6NO+6NC contacts, mounted on the stationary portion of the PANEL and operated mechanically by a sliding lever from the breaker in SERVICE position. Alternatively electrically latching relay may be used for the purpose.
x.
b.
c.
xi.
Limit/auxiliary switches shall be convertible type, that is, suitable for changing NO. contact to N.C. and vice-versa. Switch contact rated for 10A A.C. and 2A D.C. at operating voltage.
4.11.00
Control Modules i. Drawout type control module shall have self-aligning power/control disconnects. All disconnects shall be silver-plated to ensure good contacts.
16
VOL-III/E13/R0
ii. Double decker lyra contacts for higher capacity LT motors modules and feeder modules for increasing the contacts surface area to avoid flash over of LT motors iii. The design shall be such as to permit easy withdrawal/reinsertion of the unit with guide rails to ensure correct alignment. iv. Control Module shall house the control components for a circuit such as switch, fuse, lamps etc. v. The equipment layout shall provide sufficient working space in between the components and subject to Owners approval. vi. Various module/compartment sizes shall be multiple of one basic unit to facilitate modification at site. Suitable provision for this purpose should also be incorporated in the vertical bus bars. vii. Drawout type control modules of same size and type shall be electrically and physically interchangeable. viii. Selection and sizing of starter module shall comply with the requirement of IS 8554 Part- I. 4.12.00 Switches i. Switches shall be three pole, air break, AC22 heavy duty for power feeders and AC23 heavy duty for motor feeders. Motor duty switches shall be capable of safety making and breaking the locked rotor current of the motor circuit. ii. The switch shall have a quick-make, quick-break mechanism operated by a suitable external handle, complete with position indicator. iii. This handle shall have provision for padlocking in ON and OFF position. iv. Barriers shall be provided to prevent inter-phase arcing and live terminals shall be shrouded to avoid accidental contact. v. The compartment door shall be interlocked mechanically with the switch such that the door cannot be opened unless the switch is in OFF position. Means shall be provided for releasing this interlock at any time. vi. Switches shall be capable of withstanding the let-through fault current of back-up fuses or circuit breakers. vii. Outgoing feeders shall be provided with bolted disconnect link for isolation of neutral, if necessary.
17
VOL-III/E13/R0
4.13.00
Fuses i. Fuses shall be HRC, preferably link type, with a minimum interrupting capacity equal to the listed Short Circuit Current. ii. Fuses shall be furnished complete with fuse bases and fittings of such design as to permit easy and safe replacement of fuse element. iii. Visible indication shall be provided on blowing of the fuse. iv. Motor fuse characteristics and ratings shall be chosen to ride over starting period without blowing/tripping. The fuse on incoming feeder, if specified, shall be chosen to provide discrimination with motor/feeder fuses. v. All fuses shall be per IS/IEC standards.
In general MCCB shall be used in place of fuses
4.14.00
A.C. Starter Contactors i) The contactors shall be three pole, air break type designed for duty class III - Category AC3 with non-bouncing silver / silver alloy contacts. Each contactor shall be provided with two (2) normally open and two (2) normally closed auxiliary contacts rated 5 A at 240 V A.C. Reversing contacts shall be electrically and mechanically interlocked. Contactors with delayed dropout feature shall be provided for essential auxiliaries. These contactors shall not dropout on power failure if the voltage is restored within 3 seconds. 415V motors of rating upto 75 kW shall be contactor operated. Higher ratings shall be ACB operated.
ii)
iii) iv)
v)
Thermal overload
i)
Thermal overload relay shall be three elements, positive acting, ambient temperature compensated with adjustable settings. Single phase preventor shall be provided as an in-built feature of overload relays. Relay shall be manual reset type with 1 NO + 1 NC Potential free contact. Resetting of relays shall be possible with compartment door closed.
18 VOL-III/E13/R0
ii) iii)
iv)
Relays may be direct acting or C.T. operated depending upon current rating C.T.s shall be included in the scope of supply. Thermal bypass contactor or saturable core C.T. shall be provided with overload relays for motors with longer starting time.
v)
4.15.00 4.16.00
Motor starters shall have type `2 co-ordination according to IEC 947-4. Relays i. Numerical, Communicable, multifunction relay of latest version to be approved by owner shall be provided for all breaker feeders covering all protection indicated in the specification. If some functions are not available in the multifunction relay, separate static or electromechanical discrete relays shall be provided. ii. Relays shall be rated for operation on 1A secondary current and 110V secondary voltage; number and rating of relay contacts shall suit the job requirements. The numerical relay shall have communication port with suitable protocol for connection to EDMS iii. The Contractor shall furnish, install & co-ordinate all relays to suit the requirements of protection, interlock and bus transfer scheme.
4.17.00
Control and Indication i. Push button shall be heavy duty, oil tight, push to actuate type with integral escutche one plate marked with its function. ii. Each push button shall have two (2) normally open and two (2) normally closed contacts rated 5A at 240V A.C. iii. One (1) no. stop (Stay Put) push button and one (1) no. test button shall be provided for each motor feeder. iv. Lamps shall be front loading clustered type LED module pilot lights in thermoplastic enclosure with polycarbonate lens and diffuser. LED shall be protected by in-built fuse with surge suppressor and leakage voltage glow protection. Lamp and lens shall be replaceable from front. LEDs used for indication shall have pick up and drop out voltage within -20% of the operating voltage.
v. For control supply bidder shall provide 415/240V control transformer with 100% standby arrangement. vi. The circuit breaker shall be wired up for local and remote operation. Each breaker cubicle shall be equipped with following: 500 MW MTPS STAGE-III
VOL-III/E13/R0
19
a. One (1) `TRIP-NEUTRAL-CLOSE breaker control switch spring return to neutral type pistol grip handle. b. One (1) LOCAL REMOTE selector switch stay put with grip handle and key interlock for all non-motor feeders. c. One `TEST-NORMAL selector switch stay put type with pistol grip handle and key interlock only for motor feeders. d. Seven (7) nos. indicating lamps on front of compartment. i. ii. iii. iv. v. vi. vii. 4.18.00 Meters & Transducers i. For all incomer and outgoing feeders digital communicable type multifunction meter shall be provided with display screen. If some functions are not available in the multifunction meter, separate discrete meters shall be provided. The multifunction meter shall have communication port with modbus protocol for connection to EDMS/DDCMIS. The metering shall cover current, voltage, kW, kVAR, power factor, kWh and frequency. Auxiliary consumption shall be metered. ii. Discrete meters (96 x 96 mm) shall be switchboard type, with 240o scale, anti-glare glass and accuracy class of 2% full scale. Each meter shall have zero adjuster on the front. Motor feeder rated above 30kW shall be provided with ammeter in module door. Transducers, with +0.5% accuracy, 4-20mA DC linear output & 750 ohm load shall be provided. 4.19.00 Current Transformer Current Transformer shall be cast resin type rated 15 VA, accuracy class 0.5 for metering and 5P20 for relaying. Breaker Open Breaker Closed Trip : GREEN : RED : AMBER
Trip Circuit Healthy : WHITE Spring Charged Service Position Test Position : BLUE : YELLOW : WHITE
20
VOL-III/E13/R0
4.20.00
Voltage Transformer i. Voltage transformer shall be cast-resin, draw-out type and shall have an accuracy class of 0.5 and 3P. Voltage transformer mounted on breaker carriage is not acceptable. ii. Primary winding of voltage transformer shall be protected by current limiting fuses. The voltage transformer and fuses shall be completely disconnected and visibly grounded in fully draw-out position. iii. Secondary winding fuses, sized to prevent overload, shall be installed in all ungrounded secondary leads. Fuses shall be suitably located to permit easy replacement while the MCC is energized.
4.21.00
Secondary Wiring i. Panel shall be fully wired at the factory to ensure proper functioning of control, protection, transfer and interlocking schemes. ii. Fuse shall be provided to permit individual circuit isolation from bus wires without disturbing other devices shall be wired up to terminal blocks. iii. Wiring shall be done with flexible, 1100V grade, PVC insulated switchboard wires with stranded copper conductors of 2.5 mm2 for control & current circuits and 1.5 mm2 for voltage circuits. iv. Each wire shall be identified, at both ends, with permanent markers bearing wire numbers. v. Wire terminations shall be made with crimping type connectors with insulating sleeves. Wire shall not be spliced between terminals.
4.22.00
Terminal Blocks i. Terminal blocks shall be 660V grade box-clamp type with marking strips, similar to ELMEX 10 mm2 or equal. Terminals for C.T. secondary leads shall have provision for shorting. ii. Not more than two wires shall be connected to any terminal. Spare terminals equal in number to 20% active terminals shall be furnished. iii. Terminal blocks shall be located to allow easy access. Wiring shall be so arranged that individual wires of an external cable can be connected to consecutive terminals.
21
VOL-III/E13/R0
4.23.00
Ground Bus i. A ground bus, rated to carry maximum fault current, shall be extend full length of the panel. ii. The ground bus shall be provided with two-bolt drilling with Cadmium coated bolts and nuts at each end to receive 50 x 6 mm Cu. flat. iii. Each stationary unit shall be connected directly to the ground bus. The frame of each circuit breaker and draw out modules shall be grounded through heavy multiple contacts at all times except when the primary disconnecting devices are separated by a safe distance. iv. Wherever the schematic diagrams indicate a definite ground at the switchgear, a single wire for each circuit thus grounded shall be run independently to the ground bus and connected thereto. v. C.T. & V.T. secondary neutrals shall be earthed through removable links so that earth of one circuit may be removed without disturbing others.
4.24.00
Space Heaters i. Each vertical section shall be provided with thermostat controlled space heater. ii. In addition, motor feeder cubicle shall be wired-up for feeding the motor space heater through suitably rated breaker auxiliary NC contact and/or contractor. iii. Cubicle heater & Motor heater circuit shall have individual switch fuse units. A.C./D.C. Power Supply i. The following power supplies will be made available to each switchgear:
4.25.00
A.C. supply: Double feeder D.C. supply: Double feeder 4.26.00 Isolating switch fuse units shall be provided at each MCC for the incoming supplies, 4-pole, single throw for A.C. and 2- pole, double throw for D.C.
4.27.00
Painting i. All surfaces shall be sand blasted, pickled and grounded as required to produce a smooth, clean surface free of scale, grease and rust.
22 VOL-III/E13/R0
ii.
After cleaning, the surfaces shall be given a phosphate coating followed by two coats of high quality primer and stoved after each coat. The switchgear shall be finished in grade 631 of IS 5 with two coats of Epoxy Paint. However, Owner reserves the right to change the color shade at the time of approval of vendor drawings. Sufficient quantity of touch-up paint shall be furnished for application at site.
iii.
iv.
4.28.00
PROTECTIONS 1.0 The minimum protections to be provided for different types of circuits are listed below : a. Incoming Feeder : O/C relays (50/51) for phase fault with timer (2) O/C relay (50N/51N) for Earth fault with timer (2). Under voltage relay (27)
b. Outgoing motor Feeder
: O/C relays (50/51) for phase fault with timer (2) O/C relay (50N/51N) for Earth fault with timer (2).
c. Contactor operated unidirectional motor feeders i. Short circuit protection by MCCB. ii. Thermal over load relay (hand reset type) with built in single phasing preventor. Adjustable time delay earth fault relay operated from zero sequence CTs for motor rated 75kW and above.
iii.
d. Contactor operated valves/ damper feeders i. ii. e. Short circuit by MCCB Thermal overload relay (hand re set type) Feeders protected by MCCB (Short circuit and over current by MCCB)
23
VOL-III/E13/R0
2.0
Apart from protection relays, each electrically operated breaker shall be provided with antipumping (94), trip annunciation (30), lockout (86), lockout supervision (95) and trip supervision (74) relays. Lockout relay shall be hand reset type. Fuse monitoring relay (98) shall be provided on the secondary side of voltage transformer to monitor fuses.
3.0
4.29.00
TESTS i. The MCC/DB shall be completely assembled, wired, adjusted and tested at the factory as per the relevant standards of IS/IEC. ii. The following Routine and Type Test shall be performed for each MCC/DB panel. Routine Test The tests shall include but not necessarily be limited to the following : a. Operation under simulated service condition to ensure accuracy of wiring, correctness of control scheme & proper functioning of the equipment. All wiring and current carrying part shall be given appropriate High Voltage Test. Primary current & voltage shall be applied to all instrument transformers. Routine test shall be carried out on all equipment such as circuit breakers, instrument transformers, relays, meters etc.
b.
c.
d.
Type Test The following test shall conducted on a typical section of bus assembly with breaker in cubicle. a. Temperature rise Test b. Short circuit Test 4.30.00 Essential service Modules During auto changeover of the supply, the contactors in the affected bus would have dropped off. The services, which shall be restarted immediately without time lapse to keep the unit running, are considered as essential services. ( For e. g. Seal oil pumps, Lub oil pumps, Aux cooling water pumps etc.) Such auxiliaries shall start automatically without any action by the operator after an auto-change over. These modules shall have additional hardware like timer, Aux 500 MW MTPS STAGE-III
24 VOL-III/E13/R0
contactors and associated circuitry in the module. Such essential services shall be identified during the detailed engineering stage and suitable scheme/module shall be provided. 5.00.00 DC STARTER PANEL (DCSP) DC starter panels for DC Motors will be fixed resistance type, designed to provide fast acceleration during starting. The starter will be complete with switch fuse units, contactors, resistors, relays, meters, push buttons, lamps etc. The starter will be in totally enclosed, floor mounting, and sheet steel cubicle completed with a hinged front access door. The cubicle enclosure will be provide dust and damp protection, the degree of protection will be no less than IP-52. The cubicle space heater will be provided to maintain internal temperature above dew point. The other feature will be similar to 415V MCC. 6.00.00 6.01.00 MISCELLANEOUS CONTROL PANELS AND ELECTRICAL EQUIPMENT Indoor control panels provided for control of miscellaneous systems in the plant viz., air conditioning, evaporative air cooling, fire protection system, etc and outdoor control cabinets for 400 kV circuit breakers, isolators, transformers etc. shall comply with the requirements outlined in Clause 6.02.00 below. All the meters provided on the panel shall be minimum 96 sq.mm with an accuracy class of 1.5 unless otherwise specified. For motor circuits, ammeters shall have a suppressed extended scale to indicate the motor starting current. The required 240V, 1 phase AC supply required for panel illumination, receptacle and for space heating of panel shall be derived in the control panel itself. Technical Requirements Sl.No. 1 2 3 4 5 6 7 8 8.1 8.2 DESCRIPTION Location Type of mounting Cable entry Paint Finish: Outside/Inside Supply voltage Control transformer Space heater, lighting supply voltage Applicable Standards Switchgear general requirements Factory built assemblies of
25
6.01.01
6.01.02
6.01.03
6.02.00
REQUIREMENTS Indoor/outdoor Wall/Floor Top/bottom depending on layout Later/ glossy white. 415V 3 phase 3 wire Required to derive 110V control supply 240V, 1 phase AC
IS 4237 IS 8623
VOL-III/E13/R0
8.3 8.4 8.5 8.6 8.7 8.8 8.9 8.10 8.11 8.12 8.13 8.14 8.15 8.16
switchgear and control gear for voltages up to and including 1000VAC & 1200V DC Air break switches Miniature circuit breakers HRC cartridge fuses Contactors Control switches/push buttons Current transformers Voltage transformers Relays Indicating instruments Arrangement for bus bars, main connections and accessories Degree of Protection Climate proofing of electrical equipment Code of practice for phosphating iron & steel Wrought aluminium and aluminium alloys for electrical purposes
IS 13947 Part 1 & 2 IS 8828 IS 9224 IS 2959 IS 6875 IS 2705 IS 3156 IS 3231 IS 1248 IS 375 IS 2147 IS 3202 IS 6005 IS 5082
6.03.00
The following miscellaneous equipment are to be supplied:

I. II. III. IV.
Local push button stations Junction boxes (JBs) Danger boards Rubber mats.
6.04.00 6.04.01
LOCAL PUSH BUTTON STATIONS (LPB) Local push button station shall be provided for all the drive motors of the plant (415V motors and 6.6 kV motors) (start stop push buttons for all motors; only start push button for emergency motors). The degree of protection of LPBs shall be IP55 with canopy for outdoor and IP54 for indoor applications. All PBs shall be push to actuate type and the stop PB shall be lockable in off position. All push buttons shall be provided with 2 nos. NO and 2 nos. NC contacts for various interlocking purposes. One contact of stop PB shall be directly wired to the switchgear module for direct tripping and another contact to the control system. JUNCTION BOXES (JBs) Junction boxes as required for the power plant shall be supplied. The JBs used in outdoor areas shall be of weatherproof type. Sheet steel
6.04.02
6.04.03
6.04.04
6.05.00
26
VOL-III/E13/R0
thickness of the JBs shall be minimum 2 mm; the sheet steel shall be hot dip galvanised. 6.05.01 Junction boxes/marshalling boxes (JB/MB) shall be provided to enable running large core cables from/to control panels, terminal cabinets, etc. Junction boxes shall be used for marshalling each CT/CVT core from the switchyard CTs/CVTs so as to use 4 core cables from JB to the relay panels/ control panels. In case of 400 kV CTs, CVTs & EMVTs, marshalling boxes shall form part of the respective equipment package. Danger boards shall be provided in line with statutory requirements. Rubber mats shall be provided to meet the safety and other statutory requirements. List of Drawings and Documents to be submitted with bid a. General arrangement cross-sectional drawings showing constructional features, space required in front for withdrawals, disposition of various accessories, power and control cable entry points etc. Board wise single line diagrams Typical control schematics Drawings of matching flanges and terminals for bus termination Sizing Calculations for selection of CT and VT Bus bar sizing calculation Reports of all type tests of representative sections of panel assemblies Technical leaflets of following a. b. c. d. e. f. Relays, meters, switches, push-buttons, selector switches Moulded case circuit breakers Transducers Instrument Transformers Contactors Glands / Terminal Blocks
6.05.02 6.05.03
7.00.00
b. c. d. e. f. g. h.
The bidder may note that the drawings, data and manuals listed are minimum requirement only. The Tenderer shall ensure that all other necessary write-ups, curves, and information required to fully describe the equipment offered are submitted with this Tender.
27
VOL-III/E13/R0
ANNEXURE-A RATINGS & REQUIREMENTS FOR PCC 1.0 1.1 PCC General Type : Metal-clad, ACB feeder Draw out type, electrically operated. Fuse switch feeder Draw out type. Indoor IP-54
Service Enclosure 1.2 System Voltage Phase Frequency Combined variation System 1.3.
: :
: : : :
415 Volt 10% 3 50 Hz 5% 10% (Absolute)
Solidly grounded.
Rated Current at 50oC Bus bar Circuit breaker : : Bidder to decide Bidder to decide
1.4
Short Circuit Rating Interrupting Short Time for 1 Second : : 50 kA 50 kA
1.5 1.6
Insulation Level
2.5 kV for 1 min.
A.C./D.C. Power Supply Control Voltage Service Voltage : : 220 VD.C. (+10%V to 15%V) 415V, 3Ph , 4 wire , 50 Hz & 240V 1Ph.
28
VOL-III/E13/R0
2.0 2.1 2.2
CIRCUIT BREAKER Duty Cycle Breaking Current A.C. Symmetrical A.C. Asymmetrical : : : 50 kA As per IEC 105 kA Peak : O-3'-CO-3'-CO
2.3 2.4
Making Current Operating Time Break Time Make Time
: :
Not more than 3 cycle Not more than 5 cycle
2.5
Auxiliary Voltage Closing Tripping Spring Charging : : : 220V D.C. (+10%V to 15%) 220V D.C. (+10%V to 30%) 220V D.C.(+10%V to 15%) 50oC
2.6
Design Ambient Temperature
29
VOL-III/E13/R0
ANNEXURE-B RATINGS & REQUIREMENTS FOR MCC & DB
1.0 1.1
PANEL General Type : Metal-enclosed, drawout MCC (drawout type), double front DB (Fixed type), single front Indoor IP-54
Service Enclosure 1.2 System Voltage Phase Frequency Combined variation System 1.3.
: :
: : : :
415 Volt 10% 3 50 Hz 5% 10% (Absolute)
Solidly grounded.
Rated Current at 50oC Bus bar Circuit breaker : : Bidder to decide Bidder to decide
1.4
Short Circuit Rating Interrupting Short Time for 1 Second : : 50 kA 50 kA
1.5 1.6
Insulation Level
2.5 kV for 1 min.
A.C./D.C. Power Supply Control Voltage : 220V(+10V% to 15V%) D.C. for breaker feeder
VOL-III/E13/R0
30
240 V AC within the panel for non-ACB feeders Service Voltage : 415V(10%, 3Ph, 4W, 50Hz + 5% & 240V(10%, 1Ph , 50Hz +5%
2.0 2.1 2.2
CIRCUIT BREAKER Duty Cycle Breaking Current A.C. Symmetrical A.C. Asymmetrical : : : 50 kA As per IEC 105 kA Peak : O-3'-CO-3'-CO
2.3 2.5
Making Current Operating Time Break Time Make Time
: :
Not more than 3 cycle Not more than 5 cycle
2.6
Auxiliary Voltage Closing Tripping Spring Charging : : : 220V D.C. (+10%V to 15%V) 220V D.C. (+10%V to 30%V) 220V D.C.(+10%V to 15%V)
2.6
Design Ambient Temperature Duty of starter Contactor Switch for a) Motor Feeder b) Other Feeder
50o degC
3.0
: : : : :
Class III -Category AC3* AC23 AC22 240V ( 10% ,1(, 50 Hz ( 5%
4.0
Control / Service Voltage
* For inching duty Contactor shall have category AC4.
31
VOL-III/E13/R0

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POWERING TAMIL NADUS PROGRESS

Specification No: ACE/GTS/OT-72/07-08 Volume-III Technical Specification-Electrical

SPECIFICATION E12 HT SWITCHGEAR

ANNEXURE-A ANNEXURE-B ANNEXURE-C

Ratings and Requirements Protection Bus Transfer Scheme

500 MW MTPS STAGE-III

POWERING TAMIL NADUS PROGRESS

Specification No: ACE/GTS/OT-72/07-08 Volume-III Technical Specification-Electrical

500 MW MTPS STAGE-III

POWERING TAMIL NADUS PROGRESS

Specification No: ACE/GTS/OT-72/07-08 Volume-III Technical Specification-Electrical

500 MW MTPS STAGE-III

POWERING TAMIL NADUS PROGRESS

Specification No: ACE/GTS/OT-72/07-08 Volume-III Technical Specification-Electrical

5.00.00 5.01.00 5.01.01 5.01.02 5.01.03

5.01.06 5.01.07 5.01.08 5.01.09 5.01.10

500 MW MTPS STAGE-III

POWERING TAMIL NADUS PROGRESS

Specification No: ACE/GTS/OT-72/07-08 Volume-III Technical Specification-Electrical

500 MW MTPS STAGE-III

POWERING TAMIL NADUS PROGRESS

Specification No: ACE/GTS/OT-72/07-08 Volume-III Technical Specification-Electrical

500 MW MTPS STAGE-III

POWERING TAMIL NADUS PROGRESS

Specification No: ACE/GTS/OT-72/07-08 Volume-III Technical Specification-Electrical

5.04.01 5.04.02 5.04.03

500 MW MTPS STAGE-III

POWERING TAMIL NADUS PROGRESS

Specification No: ACE/GTS/OT-72/07-08 Volume-III Technical Specification-Electrical

500 MW MTPS STAGE-III

POWERING TAMIL NADUS PROGRESS

Specification No: ACE/GTS/OT-72/07-08 Volume-III Technical Specification-Electrical

ORANGE : YELLOW WHITE 5.04.04 : :

5.04.05 5.04.06 5.05.00 5.05.01

5.05.03 5.05.04 5.05.05 5.05.06 5.06.00 5.06.01

500 MW MTPS STAGE-III

POWERING TAMIL NADUS PROGRESS

Specification No: ACE/GTS/OT-72/07-08 Volume-III Technical Specification-Electrical

500 MW MTPS STAGE-III

POWERING TAMIL NADUS PROGRESS

Specification No: ACE/GTS/OT-72/07-08 Volume-III Technical Specification-Electrical

5.10.04 5.11.00 5.11.01

500 MW MTPS STAGE-III

POWERING TAMIL NADUS PROGRESS

Specification No: ACE/GTS/OT-72/07-08 Volume-III Technical Specification-Electrical

5.13.05 5.13.06 5.14.00 5.14.01

5.14.04 5.15.00 5.15.01

500 MW MTPS STAGE-III

POWERING TAMIL NADUS PROGRESS

Specification No: ACE/GTS/OT-72/07-08 Volume-III Technical Specification-Electrical

5.17.00 5.17.01 5.17.02 5.17.03

500 MW MTPS STAGE-III

POWERING TAMIL NADUS PROGRESS

Specification No: ACE/GTS/OT-72/07-08 Volume-III Technical Specification-Electrical

5.20.03 5.21.00 5.21.01

500 MW MTPS STAGE-III

POWERING TAMIL NADUS PROGRESS

Specification No: ACE/GTS/OT-72/07-08 Volume-III Technical Specification-Electrical