Volume 3B PTS

GMR (BADRINATH) HYDRO POWER GENERATION PVT. LTD.
Alaknanda Hydroelectric Project (300 MW) (UTTARAKHAND, INDIA)

BID DOCUMENTS FOR
Bid No: GBHPL/LOT-5: Design, Manufacture, Supply, Transportation to Site, Handling, Erection, Testing & Commissioning works of Generators, Turbines, Transformers, GIS equipment, Control and Protection System, Switching and Auxiliary equipment, EOT Crane and 220 kV Pothead yard Equipment etc complete along with Auxiliary Electrical and Mechanical Equipment
Volume-3B
(Particular Technical Specifications)
October 2009
Table of Contents
Volume- 0
Notice Inviting Bids (NIB) Instructions to Bidders (ITB)
Volume- 1
Information for Bidders
Volume - 2
General Conditions of Contract (GCC)
Volume- 3A
General Technical Specifications (GTS)
Volume- 3B
Particular Technical Specifications (PTS)
Volume- 3C
Technical Data Sheet
Volume- 3D
Quality Assurance and Testing Specification
Volume- 4
Drawings
Volume- 5
Forms and Procedures
Volume- 6
Bill of Quantities (BOQ)
PARTICULAR TECHNICAL SPECIFICATIONS
Alaknanda Hydroelectric Project (300 MW) Particular Technical Specification
Volume 3B(PTS)
TABLE OF CONTENTS 1. 2. INTRODUCTION ............................................................................................................. 1 TURBINE AND ACCESSORIES .................................................................................... 2 2.1 Scope of Work .................................................................................................... 2 2.2 Turbine Rating and Design Requirements ......................................................... 5 2.3 Design considerations ...................................................................................... 11 2.4 Design and construction ................................................................................... 24 2.5 Construction ..................................................................................................... 26 2.6 Quality Control and assurance ......................................................................... 42 2.7 Drawings, Documents and Design Calculations............................................... 43 2.8 Delivery, Installation and Commissioning ......................................................... 44 2.9 Spare Parts....................................................................................................... 45 2.10 Special tools ..................................................................................................... 46 2.11 Shop Tests ....................................................................................................... 47 2.12 Installation and commissioning......................................................................... 49 GENERATOR ............................................................................................................... 53 3.1 Scope of Work .................................................................................................. 53 3.2 Rating and Design Considerations ................................................................... 56 3.3 Design provisions ............................................................................................. 64 3.4 Design and Construction .................................................................................. 69 3.5 Control and monitoring ................................................................................... 114 3.6 Quality control and assurance. ....................................................................... 114 3.7 Drawings, Documents and Design Calculations............................................. 114 3.8 Spare Parts..................................................................................................... 122 3.9 Special tools ................................................................................................... 124 3.10 Testing ............................................................................................................ 126 3.11 Installation and commissioning....................................................................... 128 STATIC EXCITATION SYSTEM ................................................................................. 129 4.1 Scope of Work ................................................................................................ 129 4.2 Rating and design requirements..................................................................... 131 4.3 Design considerations .................................................................................... 134 4.4 Quality control and assurance ........................................................................ 147 4.5 Drawings and documents and design calculations......................................... 147 4.6 Spare Parts..................................................................................................... 147 4.7 Special tools ................................................................................................... 148 4.8 Testing ............................................................................................................ 148 4.9 Delivery, Installation and Commissioning ....................................................... 148 DIGITAL GOVERNING SYSTEM AND ACCESSORIES ........................................... 149 5.1 Scope of Work ................................................................................................ 149 5.2 Rating and design requirements..................................................................... 151 5.3 Design considerations .................................................................................... 159
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5.4 Construction ................................................................................................... 160 5.5 Quality control and assurance ........................................................................ 168 5.6 Drawings, Documents and Design Calculations............................................. 168 5.7 Spare Parts..................................................................................................... 169 5.8 Special tools ................................................................................................... 170 5.9 Testing ............................................................................................................ 172 5.10 Delivery, Installation and Commissioning ....................................................... 172 MAIN INLET VALVE ................................................................................................... 173 6.1 Scope of Work ................................................................................................ 173 6.2 Specific Codes and Standards ....................................................................... 175 6.3 Rating and functional characteristics .............................................................. 175 6.4 Lifting and handling fixtures ............................................................................ 183 6.5 Oil and water piping ........................................................................................ 184 6.6 Quality Control and assurance ....................................................................... 184 6.7 Drawings, Documents and Design Calculations............................................. 184 6.8 Spare Parts..................................................................................................... 185 6.9 Special tools ................................................................................................... 186 6.10 Shop Tests ..................................................................................................... 187 6.11 Installation and commissioning....................................................................... 188 PENSTOCK BUTTERFLY VALVE AND AUXILIARIES ............................................ 191 7.1 Scope of Work ................................................................................................ 191 7.2 Specific Codes and Standards ....................................................................... 192 7.3 Rating and functional characteristics .............................................................. 194 7.4 Design and Construction ................................................................................ 195 7.5 Quality Control and assurance ....................................................................... 202 7.6 Drawings, Documents and Design Calculations............................................. 202 7.7 Spare Parts..................................................................................................... 203 7.8 Special tools, tackles and devices .................................................................. 205 7.9 Shop Tests ..................................................................................................... 205 7.10 Installation and commissioning....................................................................... 207 ISOLATED PHASE BUS DUCT AND ASSOCIATED ACCESSORIES..................... 209 8.1 Scope of Work ................................................................................................ 209 8.2 Rating and design requirements..................................................................... 211 8.3 Design considerations .................................................................................... 218 8.4 Construction ................................................................................................... 219 8.5 Quality control and assurance ........................................................................ 222 8.6 Drawings, Documents and Design Calculations............................................. 222 8.7 Spare Parts..................................................................................................... 222 8.8 Special Tools .................................................................................................. 223 8.9 Testing ............................................................................................................ 223 8.10 Delivery, Installation and Commissioning ....................................................... 223 GENERATOR STEP UP TRANSFORMER ................................................................ 224 9.1 Scope of Work ................................................................................................ 224
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9.2 Rating and design requirements..................................................................... 224 9.3 Design Considerations ................................................................................... 227 9.4 Performance Guarantee ................................................................................. 227 9.5 Construction ................................................................................................... 229 9.6 Quality control and assurance ........................................................................ 238 9.7 Drawings, Documents and Design Calculations............................................. 238 9.8 Spare Parts..................................................................................................... 239 9.9 Special tools ................................................................................................... 240 9.10 Testing ............................................................................................................ 240 9.11 Delivery, Installation and Commissioning ....................................................... 241 10. 220 KV GAS INSULATED SWITCHGEAR ................................................................ 242 10.1 Scope of Work ................................................................................................ 242 10.2 Rating and Design requirements .................................................................... 244 10.3 Design Considerations ................................................................................... 248 10.4 Construction ................................................................................................... 259 10.5 Quality control and assurance ........................................................................ 263 10.6 Drawings, Documents and Design Calculations............................................. 263 10.7 Delivery, Installation and Commissioning ....................................................... 264 10.8 Spare Parts..................................................................................................... 264 10.9 Special tools ................................................................................................... 265 10.10 Testing ............................................................................................................ 266 11. 220 KV XLPE CABLES .............................................................................................. 267 11.1 Scope of Work ................................................................................................ 267 11.2 Rating and Design requirements .................................................................... 268 11.3 Construction ................................................................................................... 272 11.4 Quality control and assurance ........................................................................ 276 11.5 Drawings, Documents and Design Calculations............................................. 276 11.6 Delivery, Installation and Commissioning ....................................................... 277 11.7 Spare Parts..................................................................................................... 277 11.8 Special tools ................................................................................................... 278 11.9 Testing ............................................................................................................ 278 12. CONTROL, MONITORING AND DATA ACQUISITION SYSTEM ............................. 279 12.1 Scope of Work ................................................................................................ 279 12.2 Rating and Design requirements .................................................................... 281 12.3 Design Considerations ................................................................................... 289 12.4 Design ............................................................................................................ 291 12.5 Construction ................................................................................................... 299 12.6 Quality control and assurance ........................................................................ 318 12.7 Drawings, Documents and Design Calculations............................................. 319 12.8 Delivery, Installation and Commissioning ....................................................... 319 12.9 Spare Parts..................................................................................................... 319 12.10 Special tools ................................................................................................... 320 12.11 Testing ............................................................................................................ 320
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13. PROTECTION SYSTEM ............................................................................................. 321 13.1 Scope of Work ................................................................................................ 321 13.2 Rating and functional requirements ................................................................ 322 13.3 Design consideration ...................................................................................... 323 13.4 Construction ................................................................................................... 324 13.5 Quality control and assurance ........................................................................ 328 13.6 Drawings, Documents and Design Calculations............................................. 328 13.7 Delivery, Installation and Commissioning ....................................................... 328 13.8 Spare Parts..................................................................................................... 329 13.9 Special tools ................................................................................................... 330 13.10 Testing ............................................................................................................ 330 14. COMMUNICATION SYSTEM ..................................................................................... 331 14.1 Scope of Work ................................................................................................ 331 14.2 Rating and design requirements..................................................................... 332 14.3 Design considerations .................................................................................... 334 14.4 Construction ................................................................................................... 335 14.5 Point to Point VSAT communication between Power house and Intake ........ 347 14.6 Quality control and assurance ........................................................................ 354 14.7 Drawings, Documents and Design Calculations............................................. 354 14.8 Delivery, Installation and Commissioning ....................................................... 355 14.9 Spare Parts..................................................................................................... 355 14.10 Special tools ................................................................................................... 355 14.11 Testing ............................................................................................................ 356 15. AC STATION AUXILIARY SUPPLY SYSTEM ........................................................... 357 15.1 Scope of Work ................................................................................................ 357 15.2 Rating and design requirements..................................................................... 359 15.3 Design considerations .................................................................................... 365 15.4 Construction ................................................................................................... 366 15.5 Quality control and assurance ........................................................................ 372 15.6 Drawings, Documents and Design Calculations............................................. 373 15.7 Delivery, Installation and Commissioning ....................................................... 373 15.8 Spare Parts..................................................................................................... 373 15.9 Special tools ................................................................................................... 374 15.10 Testing ............................................................................................................ 374 16. STATION DC SUPPLY SYSTEM ............................................................................... 376 16.1 Scope of Work ................................................................................................ 376 16.2 Rating and design requirements..................................................................... 377 16.3 Design considerations .................................................................................... 380 16.4 Construction ................................................................................................... 380 16.5 Quality control and assurance ........................................................................ 381 16.6 Drawings, Documents and Design Calculations............................................. 381 16.7 Delivery, Installation and Commissioning ....................................................... 382 16.8 Spare Parts..................................................................................................... 382
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16.9 Special tools ................................................................................................... 383 16.10 Inspection and Testing ................................................................................... 383 DIESEL GENERATING SET ...................................................................................... 385 17.1 Scope of Work ................................................................................................ 385 17.2 Rating and design requirements..................................................................... 386 17.3 Design considerations .................................................................................... 388 17.4 Construction ................................................................................................... 389 17.5 Quality control and assurance ........................................................................ 394 17.6 Drawings, Documents and Design Calculations............................................. 394 17.7 Delivery, Installation and Commissioning ....................................................... 394 17.8 Spare Parts..................................................................................................... 395 17.9 Special Tools .................................................................................................. 395 17.10 Testing ............................................................................................................ 396 ILLUMINATION SYSTEM ........................................................................................... 398 18.1 Scope of Work ................................................................................................ 398 18.2 Rating and design requirements..................................................................... 400 18.3 Design Considerations ................................................................................... 403 18.4 Construction ................................................................................................... 404 18.5 Quality control and assurance ........................................................................ 407 18.6 Drawings, Documents and Design Calculations............................................. 407 18.7 Delivery, Installation and Commissioning ....................................................... 408 18.8 Spare Parts..................................................................................................... 408 18.9 Special Tools .................................................................................................. 409 18.10 Testing ............................................................................................................ 409 CABLES AND CABLE TRAYS .................................................................................. 410 19.1 Scope of Work ................................................................................................ 410 19.2 Rating and design requirements..................................................................... 410 19.3 Design considerations .................................................................................... 413 19.4 Construction ................................................................................................... 414 19.5 Quality control and assurance ........................................................................ 418 19.6 Drawings, Documents and Design Calculations............................................. 418 19.7 Delivery, Installation and Commissioning ....................................................... 419 19.8 Spare Parts..................................................................................................... 419 19.9 Special Tools .................................................................................................. 420 19.10 Testing ............................................................................................................ 421 ELECTRICAL WORKSHOP ....................................................................................... 422 20.1 Scope of Work ................................................................................................ 422 20.2 Ratings and design requirements ................................................................... 424 20.3 Design consideration ...................................................................................... 433 20.4 Quality control and assurance ........................................................................ 433 20.5 Drawings, Documents and Design Calculations............................................. 433 20.6 Delivery, Installation and Commissioning ....................................................... 433 20.7 Spare Parts..................................................................................................... 434
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20.8 Testing ............................................................................................................ 434 POT HEAD YARD EQUIPMENT ................................................................................ 435 21.1 Scope of Work ................................................................................................ 435 21.2 Ratings and design requirement..................................................................... 436 21.3 Design consideration ...................................................................................... 437 21.4 Construction ................................................................................................... 437 21.5 Quality control and assurance ........................................................................ 439 21.6 Drawings, Documents and Design Calculations............................................. 439 21.7 Delivery, Installation and Commissioning ....................................................... 440 21.8 Spare Parts..................................................................................................... 440 21.9 Special Tools .................................................................................................. 440 21.10 Testing ............................................................................................................ 441 GROUNDING SYSTEM .............................................................................................. 442 22.1 Scope of Work ................................................................................................ 442 22.2 Rating and design requirements..................................................................... 443 22.3 Design Considerations ................................................................................... 444 22.4 (Not in Use) .................................................................................................... 444 22.5 Construction ................................................................................................... 444 22.6 Drawings, Documents and Design Calculations............................................. 447 22.7 Delivery, Installation and Commissioning ....................................................... 447 22.8 Spare Parts..................................................................................................... 448 22.9 Testing ............................................................................................................ 448 ELECTRIC OVERHEAD TRAVELLING CRANES ..................................................... 449 23.1 Scope of Work ................................................................................................ 449 23.2 Specific Parameters and layout conditions..................................................... 451 23.3 Rating and functional characteristics .............................................................. 452 23.4 Design and Construction ................................................................................ 457 23.5 Performance Guarantee ................................................................................. 467 23.6 Safety requirements ....................................................................................... 467 23.7 Drawings, Documents and Design Calculations............................................. 468 23.8 Shop and site tests ......................................................................................... 469 23.9 Installation and Commissioning ...................................................................... 471 23.10 Spare Parts and Special Tools ....................................................................... 471 23.11 Tools and testing Instruments ........................................................................ 476 23.12 Inspection and Testing ................................................................................... 476 HEATING, VENTILATION AND AIR CONDITIONING SYSTEM (HVAC) ................. 477 24.1 Scope of Work ................................................................................................ 477 24.2 Specific Codes and Standards ....................................................................... 481 24.3 Rating and functional Characteristics ............................................................. 482 24.4 Performance Guarantee ................................................................................. 487 24.5 Design and Construction ................................................................................ 487 24.6 Quality control and Quality Assurance ........................................................... 506 24.7 Drawings, Documents and Design Calculations............................................. 506
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24.8 Shop Testing .................................................................................................. 507 24.9 Installation and Commissioning ...................................................................... 507 24.10 Field testing .................................................................................................... 507 24.11 Spare Parts..................................................................................................... 507 24.12 Tools and Instruments .................................................................................... 508 25. FIRE FIGHTING SYSTEM .......................................................................................... 509 25.1 Scope of Work ................................................................................................ 509 25.2 Specific Codes and Standards ....................................................................... 510 25.3 Rating and Functional Characteristics ............................................................ 511 25.4 Performance Guarantee ................................................................................. 519 25.5 Quality control and Quality Assurance ........................................................... 519 25.6 Drawings, Documents and Design Calculations............................................. 519 25.7 Shop Testing .................................................................................................. 520 25.8 Installation and Commissioning ...................................................................... 520 25.9 Field Test ........................................................................................................ 521 25.10 Spare Parts..................................................................................................... 521 25.11 Tools and Instruments .................................................................................... 522 26. COOLING WATER SYSTEM ..................................................................................... 523 26.1 Scope of Work ................................................................................................ 523 26.2 Special Design and layout conditions ............................................................. 523 26.3 Basic Dimension and ratings .......................................................................... 525 26.4 Specific Codes and Standards ....................................................................... 525 26.5 Ratings and Functional characteristics ........................................................... 526 26.6 Design and Construction ................................................................................ 527 26.7 Performance Guarantee ................................................................................. 529 26.8 Drawings, Documents and Design Calculations............................................. 529 26.9 Shop Tests ..................................................................................................... 530 26.10 Installation and Commissioning ...................................................................... 530 26.11 Field testing .................................................................................................... 530 26.12 Quality control and Quality Assurance ........................................................... 531 26.13 Spare Parts..................................................................................................... 531 26.14 Tools and Instruments .................................................................................... 532 27. LOW PRESSURE COMPRESSED AIR SYSTEM ..................................................... 534 27.1 Scope of Work ................................................................................................ 534 27.2 Specific Codes and Standards ....................................................................... 534 27.3 Rating and Functional Characteristics ............................................................ 535 27.4 Performance Guarantee ................................................................................. 539 27.5 Quality Control and Assurance ....................................................................... 539 27.6 Drawings, Documents and Design Calculations............................................. 539 27.7 Shop Tests ..................................................................................................... 540 27.8 Installation and Commissioning ...................................................................... 540 27.9 Field Tests ...................................................................................................... 540 27.10 Spare Parts..................................................................................................... 541
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27.11 Tools and Instruments .................................................................................... 541 OIL HANDLING SYSTEM .......................................................................................... 542 28.1 Scope of Work ................................................................................................ 542 28.2 Specific Codes and Standards ....................................................................... 543 28.3 Rating and Functional Characteristics ............................................................ 543 28.4 Performance Guarantee ................................................................................. 546 28.5 Drawings, Documents and Design Calculations............................................. 546 28.6 Shop Tests ..................................................................................................... 547 28.7 Installation and Commissioning ...................................................................... 548 28.8 Field testing .................................................................................................... 548 28.9 Quality control and Quality Assurance ........................................................... 548 28.10 Spare Parts..................................................................................................... 548 28.11 Tools and Instruments .................................................................................... 549 28.12 Special Tools .................................................................................................. 549 MECHANICAL WORKSHOP ..................................................................................... 550 29.1 Scope of Work ................................................................................................ 550 29.2 Specific Codes and Standards ....................................................................... 551 29.3 Rating and Descriptive Data ........................................................................... 551 29.4 Performance Criteria Guarantee .................................................................... 557 29.5 Drawings, Documents and Design Calculations............................................. 558 29.6 Shop Tests ..................................................................................................... 558 29.7 Quality control and Quality Assurance ........................................................... 558 29.8 Installation and Commissioning ...................................................................... 558 29.9 Field testing .................................................................................................... 559 29.10 Spare Parts..................................................................................................... 559 29.11 Tools and Instruments .................................................................................... 559 ELEVATOR ................................................................................................................. 560 30.1 Scope of Work ................................................................................................ 560 30.2 Specific Codes and Standards ....................................................................... 560 30.3 Rating and Functional Characteristics ............................................................ 561 30.4 Performance Guarantee ................................................................................. 566 30.5 Drawings, Documents and Design Calculations............................................. 566 30.6 Shop Testing .................................................................................................. 567 30.7 Installation and Commissioning ...................................................................... 567 30.8 Field Tests ...................................................................................................... 567 30.9 Quality control and Quality Assurance ........................................................... 568 30.10 Spare Parts..................................................................................................... 568 30.11 Inspection and Testing ................................................................................... 569 DEWATERING CUM SILT EJECTION SYSTEM ....................................................... 570 31.1 Scope of Work ................................................................................................ 570 31.2 Specific Codes and Standards ....................................................................... 570 31.3 Special Design and Layout conditions............................................................ 571 31.4 Rating and Functional Characteristics ............................................................ 571
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31.5 31.6 31.7 31.8 31.9 31.10 31.11 31.12
Performance Guarantee ................................................................................. 574 Quality control and Quality Assurance ........................................................... 574 Drawings, Documents and Design Calculations............................................. 575 Shop Tests ..................................................................................................... 575 Installation and Commissioning ...................................................................... 575 Field testing .................................................................................................... 575 Spare Parts..................................................................................................... 576 Tools and Instruments .................................................................................... 577
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1.
INTRODUCTION
Particular Technical Specifications (PTS) elaborated in various sections specify the detailed technical requirements for the design, manufacture, quality assurance, quality control, shop assembly, shop testing, transportation , delivery at site, site storage , preservation, installation, commissioning, performance testing, acceptance testing, training of Owner s personnel, handing over of commissioned equipment to Owner and guarantee for one year of the Electrical & Mechanical works covered under this contract for GMR (Badrinath) Hydroelectric project. This section provides the technical requirements applicable to all sections hereafter specifying the detailed technical specifications for respective equipment/ system forming part of E& M equipment for this project.
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2. 2.1
TURBINE AND ACCESSORIES Scope of Work
Scope of work under this section covers the provision of labour, tools, plants, materials and performance of work necessary for the design, manufacture, quality assurance, quality control, shop assembly, shop testing, delivery at site, site storage and preservation, installation, commissioning, performance testing, acceptance testing, training of Owners personnel, handing over to Owner and guarantee for one year of three (3) sets of vertical shaft Pelton Turbines as per the specifications hereunder, each complete with all auxiliaries, accessories, spare parts and warranting a trouble free safe operation of the installation. The scope of work shall be a comprehensive functional system covering all supply and services including but not be limited to following: Vertical shaft Pelton turbine and accessories Three (3) sets of vertical shaft Pelton Turbines complete in all respects. Each turbine shall comprise of following main components a) b) Turbine distributor along with its Fixed / embedded parts and foundation items etc. Turbine discharge pit liner along with Fixed / embedded components and foundation items etc. c) d) e) f) g) h) i) j) k) l) Turbine / runner housing along with its embedment and foundation items etc. Runner. Turbine shaft. Runner - turbine shaft and turbine shaft - generator shaft coupling bolts. Turbine guide bearing. A set of nozzles with its needles and needle servomotors. A set of deflectors and deflector operating servomotors. Deflector and nozzle operating mechanism and necessary instrumentation. A brake jet assembly. Flow meter for measuring turbine discharge with necessary piping, sensors, transducer cable / wires etc. and associated accessories.
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m) n)
One mechanical and one hydraulic over speed protection devices for each unit. Penstock and distributor drainage system including pressure reducing valve, piping guard valve and isolating valves etc,
o) p) q) r) s)
Air release valve assembly. Necessary water, air and oil pipes / valves / fittings / accessories etc. for each unit Necessary air piping and fitting for aeration of turbine discharge pit. Necessary electrical wires and terminal boxes with in turbine pit for each unit. Handling devices for runner, nozzle assembly and deflector, platforms, walkways, handrails, stairs, cover plates etc. for each unit.
t)
All necessary control, monitoring, safety and metering instruments / devices / system for temperature, pressure, water flow and vibration etc. including interfacing with plant SCADA
u) v)
Turbine gauge panel for each unit Inspection platform in discharge pit for inspection of runner, nozzle assemblies and other turbine components.
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One set of water level transmitter and indicator / recording instruments (compatible with DAS) for headrace and tailrace along with required panels and accessories (common for all units)
Following items common for all units shall also be supplied i. One set of bulk head cover, nozzle plates, pressure pump motor set and other accessories for site hydrostatic test of turbine distributor. ii. iii. Three (3) Sets of runner bucket profile checking templates for repair of runner profile. One set of tools required for assembly, dismantling, maintenance and handling of equipment. iv. One set of necessary handling devices for maintenance and repair of turbine guide bearing comprising of mono-rail chain pulley block, spanners, trolley and handling devices. v. One set of erection devices for nozzle and deflector assemblies, turbine shaft and runner.
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One Runner cart along with runner handling devices for runner removal. One hydraulically operated runner dismantling device and platform including scaffolding etc.
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Three (3) sets of runner spraying assembly. Three (3) sets of hatch covers of bearing capacity 1 ton /m2 in turbine floor, generator floor & main floor to cover openings of runner / spherical valve.
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One (1) set of spare parts in accordance to clause 2.9 Spare Parts of this section.
Necessary provisions shall be made on all the units for conducting field efficiency and output tests. Any other item not specified above but necessary to complete the work shall also be included in the scope. 2.1.1 Turbine Type and Description
The turbine shall be vertical shaft, and single runner, four (4) jet Pelton type turbine with a set of nozzles and deflectors. The turbine shall be suitable for direct coupling to the synchronous generator with a rated output of 100 MW (with continuous over load of 15%), 0.9 power factor and 300 RPM. 2.1.2 Turbine Specific Standards
The system and equipment shall be designed, manufactured, tested and installed in accordance with the latest revisions of the following applicable standards. In the event of other standards being applicable they shall be compared for specific requirement and specific approval shall be obtained during detailed engineering for the purpose: Standards IEC 60193 Description Hydraulic turbines, storage pumps and pump-turbines Model acceptance tests. Cavitation pitting evaluation in hydraulic turbines, storage pumps and pump turbines. Field acceptance tests to determine the hydraulic performance of hydraulic turbines, storage pumps and pump- turbines.
IEC 60609
IEC 60041
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Standards IEC 60308 IEC 60545
Description Hydraulic Turbine testing of control system. Guide for commissioning, operation and maintenance of hydraulic turbines. Guide for field measurement of vibrations and pulsations in hydraulic machines (Turbine, storage pumps and pump turbines). Determination of the prototype performance from model acceptance tests of hydraulic machines with the consideration of scale The following standards and codes are referred to in this section: Mechanical vibration Evaluation of machine vibration by measurements on rotating shafts - machine sets in hydraulic power generating and pumping plants. Mechanical vibration Balance quality requirements for rotors in a constant (rigid) state part -1: Specification and verification of balance tolerances. Mechanical vibration evaluation of machine vibration by measurements on non rotating parts Machine sets in hydraulic power generating and pumping plants. IEEE standard for hydraulic turbine and generator integrally forged shaft coupling and shaft run out tolerances. Specification for shock and vibration measurements; characteristic to be specified for seismic pick-ups. Specification for inspection of steel castings for hydraulic machines.
IEC 60994
IEC 60995
ISO 7919 part-5
ISO 1940 - 1
ISO 10816 5
IEEE - 810
BS 7119
CCH 70 3 2.2 2.2.1
Turbine Rating and Design Requirements Turbine Rating
Turbine shall be capable of delivering 103 MW of power at rated head and discharge. Turbine shall also be capable of delivering continuous overload of 15% (118.45MW) at rated head and rated speed. The maximum stresses in rotating parts shall not exceed the provisions as per clause 2.4.1
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Turbines shall be installed in an under ground power house with runner centre line at an elevation of EL 2295.5 m. The general arrangement of power house and turbines has been outlined in the layout drawings. Centre line of the turbine distributor / runner has been fixed at EL 2295.5 m corresponding to maximum tailrace water level of EL 2291.85 m when the unit is running. Rated Turbine Output at rated net head Maximum continuous output of turbine at rated net head Rated net head Turbine speed Turbine rotation 103 MW 118.45 MW 587.59 m 300 rpm Clock wise rotation viewed from above when
2.2.2
Operating Net Head Range
With the horizontal centre line of the unit axis as shown on the tender drawings the operating range imposed on the turbines is expected to be as follows: Maximum net head Minimum net head Rated discharge (Total) 2.2.3 Design Pressure 7.46 MPa (including water hammer) 606.81 m 575.75 m 64 cumecs
Normal Internal design pressure:
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2.2.4
Hydraulic Conditions
Head Water Levels Full Reservoir Level (FRL) Minimum Drawdown level Turbine Centre Line Centre Line of Distributor Tail Water Level Tail water Level (All units running) Maximum Tail water Level (one unit running) Gross Heads Maximum gross head Minimum gross head Design Head including water hammer Maximum pressure rise 608.00 m 605.50 m 760 m 25% of max. static head 2291.85 2291.85 2295.5 m 2903.50 m 2901.00 m
Maximum speed rise on full load rejection by all 15% of rated speed three units simultaneously Water density and acceleration due to gravity 2.2.5 Operating conditions As per IEC 60041
The GMR (Badrinath) Hydro electric project is a run of the river project and non peaking type. Project is envisaged to generate 300 MW at generator terminals when all the units are in operation. It is not possible to provide storage for the diurnal peaking at barrage site due to steep river slopes, and accordingly the power station will work as a base load station. During monsoon months when inflow into reservoir will be high; the units will be running at maximum output continuously for 24 hours. During non-monsoon period the units will be
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operated at maximum / rated / part load depending upon the inflow into the reservoir and load demand conditions. The turbine shall be designed to operate safely for the above operating conditions. 2.2.6 Sediments and Petrographic analysis
The project is situated in Himalayan region where the silt content during high flow period shall be excessive. De-silting arrangement will be provided to eliminate larger silt particles (0.2 mm and higher up to 90%), but the water going to the turbines would be containing considerable quantity of hard and coarse silt / sand particles particularly during monsoon season. The water would also contain some amount particles of 0.2 mm and larger size. The Petrographic analysis of silt in water and chemical analysis of water is enclosed as annexure I and recently observed silt data in annexure - II. The supplier shall critically study the silt data, PPM content limits and chemical analysis of water and will take the same into account in designing the turbine and auxiliary equipment susceptible to abrasion. The supplier shall make all such specific provisions and measures including selection of material, coatings and paintings which will help to resist silt abrasion and enable easy and quick maintenance / replacement of worn out components. The supplier shall furnish details of the specific provisions proposed and offer by them in turbine design along with past cases and experience under similar sand / silt conditions. 2.2.7 Special design considerations
The turbine shall be designed to provide the following design features Nozzle assemblies with internal hydraulic servomotors. Servicing and removal of runner, nozzles and deflectors shall be through the turbine discharge pit. The turbine guide bearing lubricating oil and governor oil shall be of the same specification as the generator bearing oil. The weight of turbine rotating parts and axial hydraulic thrust from turbine shall be supported by the generator thrust bearing. The turbine shaft and bearing shall be designed to operate safely under any combination of needle openings.
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An arrangement shall be made in turbine to support the rotating parts of turbine when turbine shaft is uncoupled from the generator shaft.
All bushes used in turbine and spherical valve shall be self lubricated type. Means shall be provided which permit selection of the number of nozzles in operation. For better efficiency at part load, turbine may be designed to operate with two nozzles. Selection of number of nozzles shall be automatic self-selection type at part load. When two nozzles are out of service, the remaining two nozzles shall still be properly controlled by governor.
All equipment shall be neatly arranged in the turbine pit in such a way that shall facilitate easy operation and maintenance.
Suitable provision against silt erosion i.e. protective coating against hydro-abrasion for parts subjected to erosion shall be made.
For short circuit and other abnormal running conditions, stresses shall not exceed (one half) of minimum yield strength.
Centre line of distributor has been proposed at 3.65 m above the maximum tail water level. The supplier shall examine the setting of turbine to ensure that runner is not submerges in froth / water over the entire range of operation including over load on all machines running simultaneously and with maximum TWL in the tail race channel.
The supply may recommend an alternative setting avoid adverse effect on generation, submergence of runner in the froth / water, cavitation or erosion. Better technoeconomic alternative shall be considered. The turbine shall operate for all needle openings and at any head from minimum to maximum without any injury or undue vibration to equipment and power house. Double amplitude of vibration shall not exceed 50 micron under all normal operating and startup conditions. Turbine shall also be designed to give satisfactory, quite and smooth operation, free from excessive noise, vibration, pressure pulsation, power swings, hunting etc in the operative range 25% to 115%
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The supplier shall indicate the limitations, restrictions on safe, stable and trouble free operation of the turbines for various heads and part load operation.
The coupling bolts shall be designed that the stresses in the bolts shall not exceed 75% of maximum allowed tensions as per VDI 2230 standard in the worst case of operation including runaway speed and seismic conditions. This shall also take into account all uncertainty / inaccuracies of assembly and quality control. Supplier shall give detailed Generator-turbine shaft run out procedure to be adopted at side during assembly and checking of run out.
2.2.8
Runner removal arrangement
Runner removal arrangement is proposed to remove the runner from below for repair and maintenance. The runner after dismantling from the turbine shaft shall be lowered axially on the runner handling car for which suitable arrangement shall be provided. The runner handling car shall be pulled on the rails and brought below the runner removal hatch from where the runner shall be lifted up by using power house EOT crane. A runner handling car and oil-operated hydraulic runner elevator with pump shall be supplied with the turbine to facilitate runner removal and installation 2.2.9 Assembly and disassembly
Erosion due to high silt content may require frequent disassembly of the turbines for repair. The Contractor shall design the turbine such that disassembly and assembly of the runner and other components of turbine can be carried out from below without disturbing the generator components. An easy and convenient provision shall be made for dismantling and assembly of Nozzle tip, Needle tip, and Needle tip liner from inside the pit without dismantling of the nozzle assembly. A provision shall be made for easy and quick removal of turbine pit door. 2.2.10 Generator Characteristics The turbine shall be designed for direct coupling to a 100 MW, 0.9 power factor, and 300 rpm synchronous generator. Inertia constant of generating unit at maximum output shall not be less than 3 kW / sec / kVA. The flywheel effect (GD2) required from generator, for turbine regulation i.e. speed & pressure rise / drop consideration, shall be coordinated with generator manufacturer.
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2.2.11 Transient behavior data The units shall be connected to a 220 kV grid having daily frequency excursion of 48 to 51 Hz. The transient behavior of the units shall be designed accordingly and the contractor shall establish and furnish the design behavior data to employer after award of contract and before start of manufacturing. 2.2.12 Stability of system The operation of turbine shall remain stable and smooth in specified operating range and grid conditions. The design shall ensure that the detrimental pulsation (both for pressure and power) do not occur at any load and during transients. The turbine shall be designed for steady and smooth operation from 25% load to 115% over load condition. 2.3 2.3.1 Design considerations Noise level
The maximum noise level at any place at 1.0 m distance from turbine shaft shall not exceed 85 dB. 2.3.2 Vibration
Turbine shall be designed to ensure smooth and quiet operation with low vibrations, pressure pulsation, power fluctuations and noise. The vibration amplitude at shaft near bearing and bearing bracket, when measured under steady state running condition, shall be as Zone A/B according to ISO standard 10816 / edition 2000-04-01, Table A.4. The supplier shall be responsible for adequate supports and bracings to prevent any undue vibrations in hydraulic system and turbine components. The supplier shall coordinate with generator supplier and provide an on line vibration monitoring and recording system with alarm contacts and analogue output, complete with detector. The detector will be mounted on the turbine guide bearing housing in a location best suited to detect excessive vibration of the rotating parts. Provisions for the following will be made; Shaft vibration / run out measurements Turbine bracket vibration measurement
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The vibration monitor with its control accessories shall be located at the gauge panel of generator vibration monitoring panel. The instruments shall be suitable for 230 V AC operation, and a set of two electrically separate contacts shall be available for; i) ii) iii) Vibration first stage alarm Vibration second stage shutdown Loss of control power or malfunction of system alarm
Analogue output shall also be provided. The vibration detector shall be wired up to vibration monitoring cubicle. The system shall contain the latest features. The vibration system for turbine and generator shall be of the same make and integrated together. 2.3.3 Pressure Rise and speed rise
The maximum pressure rise at turbine inlet, considering the effect of water hammer under worst conditions of load acceptance / rejection and governor opening / closing times shall be indicated by the Contractor. However, the pressure rise shall not be more than 25 % of static head acting on the distributor with full reservoir level and speed rise shall not be more than 15% of the synchronous speed under any worst condition. 2.3.4 Runaway speed
The runaway speed of the unit at maximum, minimum and rated net head shall be stated. All the parts of turbine shall be designed to withstand safely for 30 minutes at the maximum runaway speed and any transient over speeds. The temperature of the bearing and the vibration of the unit shall be within permissible limits with cooling water supply on. 2.3.5 Operating temperature limits
The guide bearing metal temperature under permissible operating range of turbine shall not exceed 70 o C with maximum water temperature of 20 o C. 2.3.6 Cooling water failure withstand capacity
The turbine guide bearing shall be designed and guaranteed to withstand operation at maximum continuous rating without any damage or deterioration for a period of at least 15 (fifteen) minutes without cooling water supply
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2.3.7
Safety requirements
The turbine shall be designed to meet the safety requirements in accordance with the IEC 61366 -1. 2.3.8 Performance Guarantee
Turbine efficiency and discharge curves under various head conditions shall be submitted. Guaranteed values of maximum output and efficiency at maximum, minimum and rated net head conditions shall also be furnished along with the bid. The manufacturer shall submit hill curves showing expected turbine performance with all the jets in operation for the entire range of net head indicating the expected efficiency and percentage of needle opening over the range from 25% output to maximum output. The generating units along with all auxiliaries and accessories shall be capable of performing intended duties under specified conditions. The Contractor shall guarantee the reliability and performance of the individual equipment as well as of the complete system. Field tests shall form the final basis to establish fulfillment of guarantee of the turbine and for purposes of liquidated damages and rejection of the plant. Field test shall be carried out as per IEC 60041. The test shall be conducted on any one turbine selected by the employer. The field test shall be conducted as per IEC 60041. 2.3.9 Guaranteed output
The Contractor shall guarantee the turbine output at rated speed of 300 rpm of not less than 103 MW at a rated net head of 587.59 m. The turbine shall also be capable of delivering maximum continuous output of 118.45 MW at rated net and higher heads. Maximum output at maximum, minimum and rated net heads of 606.81.m, 575.75 m and 587.59 m respectively shall be furnished and guaranteed. Field tests as per IEC -60041-1991 shall form the basis to establish fulfillment of guarantees of the turbine and for the purposes of liquidated damages and rejection of plant. 2.3.10 Guaranteed efficiency The guaranteed weighted average efficiency at the rated net head of 587.59 m shall not be less than 92 percent and shall be calculated as follows:
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aw aw
= 0.1 x 115 + 0.6 x 100 + 0.2 x 75 + 0.1 x 50 = Weighted average efficiency
115 = Efficiency at 115 percent of rated output when operating at net head of 587.59 m 100 = Efficiency at 100 percent of rated output when operating at net head of 587.59 m 75 50 = Efficiency at 75 percent of rated output when operating at net head of 587.59 m = Efficiency at 50 percent of rated output when operating at net head of 587.59 m
The efficiency at 50%, 60%, 70%, 80% 90%, 100% and 115% output at maximum, minimum and rated head of 606.81.m, 575.75 m and 587.59 m respectively shall be stated and guaranteed. Liquidated damages shall be imposed as per Clause 2.3.13, Liquidated damages for shortfall in output and efficiency in case of shortfall in weighted average efficiency vis--vis the corresponding guaranteed value. The liquidated damages on account of shortfall in weighted average efficiency shall be computed separately for each unit and the total amount of liquidated damages shall be the sum of all the units. However, tolerance in computation of efficiency shall be in accordance with the IEC 60041-1991 for field acceptance test for hydraulic turbines. 2.3.11 Cavitation pitting guarantee The Contractor shall guarantee the runner against excessive pitting due to cavitation during a period of 24 (twenty four) months from the date of commissioning / commercial operation or 8000 hours of actual operation, which ever is earlier. The cavitation, if any, shall not impair the strength of the runner and detrimental to the efficiency or power output of the turbine. The metal loss shall not exceed the provision under IEC 60609 Part 2. Excessive pitting shall be defined as the removal or loss of metal from the runner, due to cavitation pitting aggregating to If the guarantee period of 24 months expires prior to the completion of 8000 hours of actual operation, the contractor shall guarantee that the weight loss shall not exceed the value proportional for the number of hours actually operated. In case of excessive cavitation being present, the Contractor shall, at his own cost, correct the condition and repairs the pitted area or replaces the parts thus affected. The Contractor
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shall also make the necessary alterations to remove the cause or causes of the pitting or, if necessary, shall replace the runner. Subsequent to repair, the repaired runner and turbine components shall be subject to the same cavitation guarantee as for the original equipment. The guarantee shall be renewed each time the turbine fails to meet the guarantee. Cavitation inspection shall be carried out after 6 months / 2000 hours of operation, 12 months / 4000 hours of operation, 24 months / 8000 hours of operation at which time the Contractor can assess the amount of damage and effect minor corrections. Supplier shall indicate the cavitations free regime of operation for output from 25% to 115% load covering entire head range from minimum to maximum. 2.3.12 Guarantee for Erosion damage of Underwater Parts by Silt / Sand Silt data has been furnished in Project Information. Various under water parts prone to damage by silt shall be adequately protected by adopting the following means: Design features to prevent and minimize damage Protective coatings of suitable quality and thickness to prevent damage to main components. Supplier shall consider latest coating technologies for prevention of damage against cavitation and erosion. This will include Tungsten Carbide Coating, Laser Coating or any other suitable technology which Supplier feels, will provide best results against silt/sand erosion, abrasion and cavitation damage for the given silt conditions. Keeping his design and coatings in view, Supplier guarantee(s) against Hydro-abrasion for following components: Runner Needle tip Nozzle tip liner Nozzle tip Components prone to erosion
The machine shall be guaranteed for trouble free satisfactory operation for given water conditions as given in Annexure II for at least two monsoon seasons.
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2.3.13 Liquidated damages for shortfall in output and efficiency For any shortfall in the tested values of rated output and the weighted average efficiency of turbine vis--vis the corresponding guaranteed values respectively, shall be computed as follows: i) Unit Output For each one tenth of one percent shortfall in tested value of rated output of not less than 103 MW at a rated net head of 587.59 m vis--vis corresponding guaranteed value, ii) Unit Weighted average efficiency For each one tenth of one percent (0.1%) shortfall in tested value of weighted average efficiency vis--vis corresponding guaranteed value, For fractional values of shortfalls in percentage, the liquidated damages amount shall be computed on pro-rata basis. The liquidated damages on account of shortfall of output and weighted average efficiency shall be computed separately. The total amount of liquidated damages shall be the sum of these two multiplied by number of turbines. No tolerance limits shall be permissible over the measured value of rated output. However, tolerance in computation in efficiency shall be in accordance with the IEC 60041-1991 for field acceptance tests for hydraulic turbines. Weighted average efficiency of the prototype turbine will be verified after installation and commissioning of the generating units on the basis of field acceptance tests on any one unit, to be decided by the Purchaser. Keeping principle of homogeneous performance in view, the weighted average efficiency for one unit shall be the basis for acceptance / short fall for calculation of liquidated damages for all units. Maximum continuous output shall however, be verified for each of the three units and this shall be the basis for acceptance / shortfall for calculation of liquidated damages for each unit. As per commercial As per commercial
conditions clause
conditions clause
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Supplier shall also state guarantees for output and efficiencies as mentioned under technical and guaranteed particulars at various load and heads. These efficiencies are not subject to liquidated damages but must not vary by (-) 0.5%. Supplier will be required to take corrective measures in case of defaults. Rectification to meet guarantees after installation Should the first field acceptance test be unsuccessful to meet the guarantees in respect of the turbine output and/or weighted average efficiency as applicable, the Supplier will be entitled to make good and carry out rectification and again conduct the test to meet guarantees. If the second attempt is also unsuccessful, then liquidated damages or rejection shall be applicable as specified. The rectification shall be completed within six months after performance of the first field acceptance test. Not withstanding the above, Supplier shall be responsible for: In case Unit(s) is not taken under commercial operation, liquidated damages for delay as per Conditions of Contract shall be applicable. In case, unit(s) is taken in commercial operation, shutdown period shall be treated and liquidated damages for delay as per Conditions of Contract or cost equal to cost of loss of generation, whichever is less shall be applicable. The Purchaser shall schedule shutdown of the Unit for rectification and retest at the earliest, keeping in view Suppliers readiness for same and grid operating conditions in view. Efficiency at various load points shall be computed in model tests as well as field tests. Method to be used for field efficiency test Supplier shall intimate details of method proposed to be used for field efficiency test keeping into consideration water conductor system layout. Special requirement for field efficiency test to be considered in layout, location of instruments and other relevant details shall be furnished by the Bidder along with his Bid offer. Field efficiency test requirements During field efficiency tests, if rated head condition is not available, test shall be carried out under the prevalent head and correction on basis of model test hill curves shall be applied.
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Instruments selected for field efficiency tests shall be such that the same ensure a minimum accuracy as specified in IEC 60041 (unless specifically agreed otherwise). Accuracy class of instruments to be used for field acceptance test shall be given by the Supplier. The minimum accuracy of measuring instruments will be as follows:Power Measurement Flow Measurement Head Measurement Other instruments 2.3.14 Rejection limit The Owner reserves the right to reject the turbine if the tested values of either weighted average efficiency or the rated output (not less than 103 MW) at rated net head of 587.59 m falls short by Two (2) percent or more of the corresponding guaranteed values during field acceptance tests. 2.3.15 Model acceptance tests If the seller cannot demonstrate that they have successfully developed in the past a similar unit, the Seller shall carry out a model test to verify turbine guaranteed parameters. General The requirement for a model test will be at the option of Purchaser. Within thirty (30) days after date of Notice to Proceed, the Supplier shall submit certified curves from previous tests conducted on similar equipment to demonstrate the expected performance of the proposed equipment. Supplier shall also provide necessary calculations and information to help evaluate the expected performance offered. He will also establish how the model and prototype being offered have required similarity. If, after evaluation of this information, Purchaser decides that a model test is required, the Supplier will be so notified and model test as prescribed herein shall be carried out. Model test shall be performed in presence of Purchaser's representative, comprising one engineer of the Purchaser and one of their consultants, to demonstrate that the efficiency and other guarantees, as well as the requirements of the specifications for the performance of the turbine, will be met. It shall be at the cost of the Supplier. The Supplier shall arrange and meet the expenses of stay of these engineers. Charges for the model tests and the cost
<= <= <= <=
0.2% 0.2% 0.2% 0.2%
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of the model shall be specified in the price schedule. The test shall be completed and 4 copies of test reports submitted for perusal of the Purchaser within six months following the award of contract. The tests shall be as per IEC test code publication No. 60193 and 60193A "International code for model acceptance test of hydraulic turbines". Model test results shall be subject to the approval of the Purchaser; and the Supplier shall commence manufacture of the prototype after approval for the same has been accorded Place of model test Model test shall be conducted in a laboratory well equipped with modern model testing facilities. The laboratories proposed for model testing shall be accredited by reputed agencies. The contractor shall give details of facilities available with him or where he intends to get the model testing done. The contractor shall also suggest alternative independent agency from where model testing can be arranged. The owner reserves the right to get model tested from any of the renowned approved test laboratory or contractors facilities / an independent agency suggested by the contractor. In case model tests are conducted at the Contractors facilities, the Contractor shall guarantee the repeatability of the results within the allowance provided in IEC. Nevertheless the Owner reserves the right to get the model test repeated in presence of both the parties in an internationally recognized independent laboratory at his own cost. The Contractor shall supply his model test data, method of testing from previous tests and turbine model, for each component of turbine, to the laboratory selected for conducting the tests. Requirement for model tests The model shall remain the property of the contractor. The model shall be tested under a net head not less than fifty (50) meters. All pertinent dimensions of test model shall be in geometric proportion to the proposed turbine at a scale not less than one seventh of the dimensions of proposed turbine / according to the IEC norm 60193. The model test including calibration of instruments shall be witnessed by the owners representative and be subjected to the approval of the owner. Tests to be conducted on model
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The model tests shall be conducted in range of unit speeds of 65 % to 125 % corresponding to rated head and Nozzle opening corresponding to no-load to 100%. The Nozzle positions shall be superimposed on the efficiency contours. The model hill diagram shall show unit flow / unit power versus unit speed or head with lines of constant efficiency, power, nozzle position and cavitation limits. The prototype hill diagram shall show prototype power output versus head with lines of constant efficiency, flow, nozzle position and cavitation limits. Prototype curves of efficiency, flow and nozzle position versus power output shall be made for net heads corresponding to unit speeds of 65% to 125% of unit speed at rated head. The efficiency characteristics of the homologous turbine shall also be determined and the complete hill diagrams of both model and prototype shall be incorporated in the report. Runaway speed tests shall be made to determine the maximum runaway speeds under conditions corresponding to prototype net heads with range of 65% to 125% of rated net heads with the nozzle opening that produces the highest runaway speed. The model test shall include but not be limited to the following tests: Efficiency Tests under various head conditions; maximum, minimum and rated head corresponding to 115%, 100%, 75%, 50%, and 40% of rated output. Determination of peak efficiency of the model and estimation of peak efficiency of prototype at maximum, minimum and rated head conditions. Measurement of flow, hydraulic thrust and runaway speed tests at full nozzle opening maximum, minimum and rated net heads. Complete Hill chart, Measurement of head fluctuations Nine point of cavitation at maximum, rated and minimum head at three nozzle opening. Verification of dimensions as per IEC, latest edition.
The model test shall simulate all possible operating conditions of the prototype for the entire range of operation. All equations specified in the relevant clauses of IEC Model Test Code shall be used for discharge and speed. Detailed calculations shall be submitted by the contractor.
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Model test report After completion of the model tests, the Contractor shall submit to the Owner eight (8) copies of the model test reports within one month for approval. The test report shall include, but may not necessarily be limited to, the following: A description of the test equipment and test procedures, Sample calculations for all calculated parameters including efficiency, cavitation and run-away speed for the model and step-up for the prototype, Comparison of test results with the guarantee requirements of specification / contract and technical conclusions, Model test curves for: Unit power, unit discharge, efficiency versus speed for various nozzle openings, Relation of power output, efficiency and discharge to cavitation coefficient-sigma for various nozzle openings and speeds corresponding to the head range to be encountered in service, Relation of runaway speed to nozzle opening at the 65% to 125% of the net head, Hill diagram as specified above.
Prototype turbine curves showing: Relation of efficiency, turbine output and discharge with cavitation limits indicated, Relation of turbine discharge with nozzle opening for the head range of 65% to 125% of the net head, Relation of runaway speed to nozzle opening for the net heads of 65% to 125% of the net head.
Photographs of the runner showing appearance of cavitation during the cavitation test Detailed dimensional drawing of the model turbine, including the runner, nozzle, distributor and discharge pit liner used for the tests,
A sample calculation for each computation from data to final result, Record of calibration of all test instruments and equipment.
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Model Acceptance Within 60 (sixty) days following the receipt of the model test report, the Owner shall communicate his decision of the model test to the Contractor. The Contractor shall commence the manufacture of the prototype only after the approval of the model has been accorded, Should the model fail to meet the requirement of guarantee and other requirements, the Contractor shall modify the same until it complies with the requirements. All expenses involved for the modification and subsequent model tests shall be borne by the Contractor. The contractor shall make good and meet the guarantee again within a period of four (4) months from the date of witnessing the original model tests. No delay, however, will be allowed in the original deliver schedule due to this reason. The final report shall be approved within twelve (12) months from the effective date of the Contract, subject to its submission at least sixty (60) days earlier, 2.3.16 Field acceptance tests General Output and efficiency tests shall be carried out on any one turbine, chosen by Owner at a later date, to verify that the power output and efficiency guarantees have been fulfilled. The field test shall be conducted as soon as possible after the equipment has been placed in operation. The power output and efficiency tests on the turbine shall be made at net effective head as near as practicable to the rated net head. The efficiency test shall be made by the thermodynamic method or other suitable method mutually agreed. The turbine capacity shall be determined from electrical measurements of generator output corrected for generator losses. The generator losses shall be determined from the generator efficiency curves and verified by measurement of air cooler and bearing heat losses. In the event it is necessary to place the equipment in regular service for a considerable period of time, before the acceptance tests are made, the equipment will be inspected carefully and so far as possible restored to its original condition by Purchaser before tests are conducted. Such works by Purchaser shall be witnessed by Supplier. Test Codes
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The turbine efficiency and capacity tests shall be conducted in accordance with the provisions of IEC Publication 60041, International Code for Field Acceptance Tests of Hydraulic Turbines, under the direction of a qualified independent expert to be decided by the Owner, unless otherwise mutually agreed upon by the Contractor and the Owner. The costs shall be borne by the Contractor. Test Instruments The Supplier shall provide all necessary instruments and equipment required to determine the turbine efficiency at site by Thermodynamic method. These instruments will remain the property of the Supplier. Supplier shall give details of the method proposed to be adopted and agency proposed for conducting the tests. All charges of third party agency conducting the tests shall be borne by Purchaser. Rental Charges for test instruments shall be deemed included in supply. Test Supervisor Purchaser may contract for the service of an independent test supervisor, experienced and skilled in the art of conducting turbine efficiency tests. For conducting field acceptance test, the Supplier shall recommend names of a few independent agencies with a good experience in the field and indicate their charges separately for consideration of the Purchaser. The quotation shall include hire charges of equipment, to and fro transit and other incidental expenses. Rates of test engineer, for efficiency test, shall be quoted on per day basis. Number of days, and number of persons, for which services of test engineer shall be required shall be mentioned in offer. Provision for Field Testing The Supplier shall, on all the three turbines, make all necessary provisions (such as pickups, embedded connections, etc.) for the efficiency test, at no additional cost to the Purchaser. Procedure of Field Testing Procedure to be adopted for conducting the field tests shall be submitted well in advance, and shall be subject to approval of the Purchaser. Runaway Speed Test
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The turbine shall be tested for runaway speed for a period of 2(two) minutes to demonstrate ability to withstand successfully the mechanical stress and hydraulic performance incident to maximum runaway at maximum head conditions. After the test, the main parts of the turbine shall be checked for any damage. The test shall be performed by Purchaser and witnessed by Supplier's representative. 2.4 2.4.1 Design and construction Design Stress limits
Under different operating conditions maximum allowable stresses in all components including distributor, nozzle assembly, runner, shaft etc. shall be as under: Maximum Allowable stress (Tension / Compression) of minimum yield strength -do-do-do-do-do-
Loading Condition a) b) c) d) e) f)
Maximum continuous operation up to 115% rated 40% load Dynamic Condition i.e. pressure rise due to load 50% throw off conditions Runaway speed Pressure test of Distributor Hot forged bolts operating condition M.S. Steel bolts operation condition pre-stressed pre-stressed under under 67% 75% worst 75% worst 90%
These maximum allowable stresses will be applied, taking into account stress concentrations using the fourth strength of material theory. The design pressure in the calculations shall be including the pressure rise due to water hammer. Maximum stress in shear shall not exceed 50 percent of the allowable stress. For the peak stresses necessary to achieve the design life of 300,000 fatigue cycles for turbine and main inlet valve pressure retaining boundaries will be adopted during the design process to ensure that defects just large enough to escape detection during the manufacturing inspection did not grow during the fatigue duty of the Power Station to such a size as would cause failure in the event of a fault.
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Stress analysis of major turbine components i.e Distributor, runner, shaft, Nozzle assembly shall be done to demonstrate above. Effect of unbalanced hydraulic loading due to blocking of needle tip on loading of distributor and other components shall be considered. The minimum Charpy V-notch impact strength at 0 Deg.C will be 70 J, to be fulfilled for the runner on all the specimens.
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2.4.2
Material selection and standards Item Manufacturing Method Casting Forging Material Standard ASTM A743 CA6NM ASTM A668 ASTM B23 Carbon / low alloy Steel ASTM A516 Grade 450 plates Steel plates DIN EN 10028 - 3 DIN EN 10283
Runner Turbine Shaft Turbine Guide Bearing Runner Housing and Pit liner Distributor
Nozzle
Casting ASTM A743 CA6NM
Nozzle tip Nozzle Tip Liner Needle Tip
Forging Forging Forging
ASTM A473 UNS S41500 Stellite / HVOF Coated Stellite / HVOF Coated DIN EN 10283
deflector
Casting or forging
ASTM A743 CA6NM ASTM A473 UNS S41500
2.4.3
Normal Internal Design Pressure
The normal internal design pressure for each turbine shall be 7.45 MPa. This pressure includes 25% water hammer effect over the maximum gross head. 2.5 2.5.1 Construction General
Turbine shall be designed in accordance with best modern practice in hydraulic and mechanical design.
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The turbine shall be capable of smooth operation, free of any objectionable vibration, over the specified range of operating head. The design shall be such that cavitation damage / erosion shall be kept to a minimum. Such damage, if it occurs, shall not impair the strength of the runner or other parts of the unit, and shall not measurably contribute to any decrease in efficiency or power output. The design of individual components or sub-assemblies which are subject to erosion wear shall be such as to facilitate removal and replacement. The Design shall provide adequate protection to all surfaces of turbine parts which come into contact with water and against erosion due to silt. In particular, the needle tips, the nozzle seats and runner buckets shall be given particular consideration which will be taken into account during bid evaluation. The turbine shall be capable of withstanding runaway speed for a period of fifteen (15) minutes without damage or need for adjustment. 2.5.2 Runner
The Pelton runner shall be of the integrally cast and made of stainless steel ASTM A743 CA6NM Cr-Ni 13-4 or equivalent material / better composition available at the time of supply. The water faces of the buckets shall be carefully machined and ground smooth to templates and polished. The runner casting shall be free from hollows, depressions, waviness, projections and / or other surface imperfections the might lead to disturbances, erosions and / or cavitations. The disc shall be machined and bored to centre on a male projection at the end of the main shaft ensuring proper centring and alignment of runner. Highly stressed area of runner, the back side of the buckets exposed to water contact and places where fatigue cracks may occur, shall be finished smooth ground and polished. The runner design shall be based on fatigue and steady state conditions. The runner inspection and quality control shall be according to modern engineering. The coupling between the turbine shaft and runner crown shall be flanged type. The buckets shall ensure adequate strength with inlet edges of the cut out smoothly rounded. The conformity of bucket the bucket shape to model shall be verified by using templates or other shop control devices.
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After the runner is completely machined and finished, it shall be statically balanced Quality control during the manufacture of the runner shall include appropriate heat treatment, bar test specimens, non-destructive flaw detection inspection and test for homology with model. 2.5.3 Turbine shaft
The turbine shaft shall be of forged, carbon or alloy vacuum-degreased steel properly heat treated, of ample size and shall meet the specified requirements of C35E according to DIN EN 10083-1 or ASTM A668 Class D or similar material. The shaft shall be have integrally forged skirt / boss for the turbine bearing and upper and lower coupling flanges. A central hole shall be provided which shall allow internal non-destructive inspection and facilitate lower dismantling of runner. The overall shaft length shall be the minimum necessary to provide reasonable access and working space for maintenance and to minimize bending stresses in the shaft. The shaft shall be of ample size to transmit torque at specified speed and maximum load without detrimental vibration or distortion. The maximum tangential shear stress in the main shaft shall not exceed than those specified in the table. The turbine shaft shall operate safely in combination with the generator shaft at any speed up to the maximum runaway speed without detrimental vibration or objectionable distortion. The first critical speed of the combined turbine and generator rotating parts shall be at least 25% greater than the maximum runaway speed. The contractor shall furnish necessary details of turbine directly to the generator manufacturer and shall seek necessary details of generator from generator manufacturer for calculation of critical speed for combined turbine and generator shafts, the calculation shall be submitted along with the drawing of shaft for owners approval. A collar on the turbine shaft or some other suitable arrangement shall be provided to support the shaft and runner on the turbine bearing, during removal of generator rotor. The runner and shaft supporting arrangement shall be approved by the owner. The shaft shall be designed for eccentric loading caused by unbalanced operation, due to any combination of nozzles, in addition to torsional and axial loading on the turbine shaft.
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2.5.4
Turbine Guide Bearings
The turbine guide bearing for radial support of turbine main shaft shall be of oil lubricated, shell or segmental type. The bearing shall be located as near to the runner as possible and shall consist of a bearing housing and removable gearing elements. The lining of bearing shall be of high grade tin base Babbitt material to ASTM B23, alloy No. 2 or 3. The bearing lining shall have sound bondage with the shell or bearing pads. The bearing shall be accurately bored and suitably grooved for oil circulation. The bearing lining shall be polished in the shop to fit properly on the shaft. It shall be the responsibility for the manufacturer to select the bearing arrangement which suits best to the design of the unit. Suitable lifting eyes and backing out bolts shall be provided for use in removing and installing the bearing. The design of bearing shall prevent water from entering to the lubrication system and loss of oil by leakage, creepage up the shaft or overflow from any part of oil system. Bearing shall be capable of the following Continuous operation without any injury and without exceeding normal bearing metal temperature at any speed from 50% to 110% of rated speed. Safe operation for at least 15 (fifteen) minutes at any speed between rated and runaway speed with unbalanced jet conditions without injury, Safe operation for at least 15 (fifteen) minutes with no cooling water flow when starting from normal oil level and temperature without exceeding maximum allowable pad temperature and without damage to bearing surfaces at rated speed and full load. The bearing shall be designed to withstand the side thrust resulting from any possible combination of nozzle operation. The bearing support shall be a part of turbine housing top and designed to transmit the load due to maximum side thrust of the runner to the turbine housing. The internal bearing housing shall be fabricated in halves and welded around shaft to one piece. The bearing housing top shall be provided with a cover to prevent dirt or foreign matter from entering the bearing. The cover shall be split into segments and bolted together and to bearing body. The bearing cover shall be provided with suitable inspection openings with transparent cover.
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The capacity of the oil reservoir shall be sufficient to hold the entire oil required for bearing lubrication system. All circulating devices, strainers and other accessories required for a complete lubricating system shall be provided. Drain and oil filling piping with valves shall also be provided at suitable location for connection to the oil changing / draining and purifying equipment. Lubrication system shall be designed so that the bearing metal temperature shall not exceed 70 o C under continuous operation. A corrosion resistant oil-to-water heat exchanger shall be provided to remove the heat generated during running of the bearing. The heat exchanger shall be of reversal flow type; and shall be designed and located in such a way that it shall be easy to remove without dismantling the turbine. A bearing cooling water flow indicator shall be provided in the cooling water discharge piping. Each bearing shall be provided with required instrumentation for monitoring temperatures of oil, cooling water and bearing pads / elements, oil levels in bearing reservoir and cooling water flow etc. All indicating instruments shall be neatly arranged in Turbine Gauge panel. 2.5.5 Main Shaft Seal
The turbine housing shall be provided with a labyrinth seal or centrifugal water guard or other suitable arrangement to effectively seal the point of entrance of the turbine shaft into the runner housing against any water leakage etc. 2.5.6 Distributor
Distributor shall be designed to withstand, without any support from the concrete, the maximum internal pressure resulting from maximum static head at the distributor centreline including pressure rise due to water hammer. The distributor shall be approximately spiral form. The distributor shall be of cast steel or welded steel plate construction and shall be embedded in concrete. The distributor shall be supplied in segments suitable for transport to site. The distributor segments shall be accurately formed and fitted so that edges of adjoining inside surfaces match together. All circumferential and longitudinal (shop and site) weld joints of the segments shall be 100% radiographically examined. Each segment shall be hydrostatically tested in works before despatch to site. A machined flange shall be provided at the inlet section of distributor for connecting the distributor to main inlet valve.
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The distributor shall be provided with 4 (four) numbers of opening with flange connection for mounting nozzle and deflector assemblies. A suitable arrangement shall be made to adjust the position of nozzle assembly for proper alignment of nozzles with respect to runner position. The distributor shall be provided with necessary stiffener rings, pads of brackets and connections for the application of jacks and tie rods during erection, spider / bracing to prevent distortion of distributor sections during transport and erection. The pads and brackets shall be designed to support and position the distributor segments and extension during all conditions of installation. The distributor shall be provided with following connections / tapping. Four pressure taps of stainless steel with pipe connections on the inlet section suitably located and arranged in accordance with the recommendations of international code for the Field Acceptance Tests of Hydraulic Turbine IEC 60041 1991 for pressure measurements and for connection to the distributor pipe pressure gauge (to be mounted close to distributor inlet) and to pressure transmitter for remote indication on turbine terminal cubicle. A distributor drainpipe connecting the lowest point of distributor with discharge / tailrace pit shall be provided. The arrangement shall have Guard (maintenance) valve & drain valve. Suitable arrangement at drain out let shall be designed to avoid any concrete damage in the discharge pit. The piping shall include a flanged drain valve and an easily removable pipe extension or sleeve-type coupling to facilitate removal of the valve for maintenance and to avoid and bending in the pipe. The distributor shall be provided with a man hole / access door of not less than 600 mm diameter for inspection of distributor. The man hole shall be suitably located on the distributor. The man hole shall have an inward door opening. Inside contour of door shall flush with inside radius of distributor to avoid disturbances to the flow. The distributor shall be provided with an aeration valve to admit / remove air during draining / filling of distributor. The assembly shall include piping, fittings etc. Suitable bosses with flanges to receive bypass valve piping of spherical valve.
The complete assembly of distributor shall be hydrostatically tested at 1.5 times the maximum design pressure at site after erection and before concreting.
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The manufacturer shall supply one set (common for all units) of test bulk head covers for closing inlet section and nozzle openings of distributor during field hydrostatic testing. The bulk head covers shall also be used to maintain the hydrostatic pressure in distributor during concreting. About 50% pressure shall be maintained while pouring the concrete to embed the distributor. The test head covers shall be supplied along with first unit. The test head covers shall be provided with pipe connections for filling & draining the distributor, pressure gauge, thermometer and pressure relief device (if necessary). The bulk head covers shall be provided with lifting lugs / attachments to facilitate handling during testing. 2.5.7 Turbine housing and pit liner
The turbine housing liner shall be of welded steel. The liner thickness shall be sufficient to ensure adequate rigidity during erection and concreting. The liner shall cover completely the inside of the turbine housing down to discharge pit floor and including housing roof. Turbine housing shall be fabricated in least number of sections practicable for handling and shipment. The liner shall not be designed to support any load due to the generator. Necessary concrete anchoring shall be provided. Adequately sized air admittance piping enabling the turbine to draw air from outside of the power house shall be provided. The pit liner shall be provided with energy absorbing baffles to absorb the energy of the deflected jets. Similarly energy absorbing baffle shall also be provided to absorb the water energy from drainage system of distributor / penstock. The turbine pit and tailrace channel shall be provided with rails for a trolley used for removing the runner and nozzle assemblies through the runner removal hatch. The rail shall be extended beyond the turbine housing so that the trolley can be moved to a position underneath the removal opening. 2.5.8 Injectors System
Injectors shall be designed to produce the most uniform jet possible and shall be equipped with servomotor operated needles. Each injector shall be of the straight flow type with internal hydraulic servomotor and needle stem. Injector assemblies shall be designed as an interchangeable part of the turbine to reduce shutdown time to a minimum. However, minor repairs and replacement of nozzle seat and needle tip shall be possible in situ by opening the front section of the nozzle without dismantling the turbine runner and nozzle assembly. The internal moving parts shall be
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manufactured from high corrosion / wear resistant material in order to prevent corrosion, pitting or wear at the points of contact with the various seal rings and the sliding surfaces. The injectors shall have self-closing tendency due to penstock pressure and spring action in the event of failure of governing oil pressure or breakage of any connecting mechanism. Automatic closing of injector shall be at a controlled rate, which shall not result in a pressure rise greater than specified. The servomotor shall be double acting hydraulic jacks with spring assistance. The needle servomotors shall be capable of operating the needles in minimum 30 seconds. The needle tips and nozzle seats shall be made of S.S. forging with stellite massive / HVOF tungsten carbide coating. The needle tips and nozzle seats shall be removable and interchangeable. All hardware and fasteners shall be of corrosion resistant material. Adequate adjusting rings shall be provided for each injector to ensure correct alignment of nozzles. Suitable lifting arrangement shall be made on each assembly for handling during erection and maintenance. 2.5.9 Jet Deflector assembly
Each injector assembly shall be provided with a deflector. The body of the nozzle shall be adequately reinforced to support the deflector. The deflector and its support shall be designed to prevent harmful vibration during its operation. The deflectors shall be of cast steel with a replaceable stainless steel blade / shield. It shall be ensured the no deflector can foul with runner during operation in the entire range and also in the event of breakdown of operating mechanism. Each deflector shall be designed to withstand safely the maximum continuous discharge from its associated nozzle. The deflector shall be rigid construction and the surface subjected to high speed flow shall be adequately lined with a hard stainless steel lining to resist erosion and cavitation. Each deflector shall turn on a shaft made of stainless steel and supported on two self lubricated guide and thrust bearings. All components of deflector inside the casing and subjected to air and water shall be of corrosion resistant materials. Each deflector shall be independently controlled through its own servomotor controlled by the governor oil pressure. Deflectors shall be designed to operate under fully open or fully closed position (On and off) only. The deflectors shall enter the jets only during load throw off and unit trip command.
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The deflector shall also be used during dewatering the entire water passages hence provision shall be provided to open the injectors with deflector in closed position for this purpose. 2.5.10 Servomotor and Control of Turbine Discharge The control of the discharge, necessary to accompany changes in load, shall be accomplished by means of needles, which shall close or open automatically under governor control to meet the load demand. The type of control system shall be through governor actuated needle and deflector servomotors. Each needle and deflector shall be controlled by its own servomotor, thereby maintaining its opening at the selected value or modifying it according to the orders of the electronic governor head into a speed proportional to the oil flow given by the distributing valve. Each needle control valve shall be provided with a manual lock, which can be set to limit needle stroke as a load limit or maintain its respective needle in the closed position regardless of deflector position. The operation of the needles and deflectors shall be such as to accommodate the changes in water supply, with a minimum of oscillation in the output of the unit, and with a minimum of pressure rise in the penstock. For small and slow changes in the load, the deflectors shall not deflect the jets, but for rapid load rejection, the deflectors shall deflect the jets clear of the runner. Under normal speed control the needles shall do governing and water shall not be wasted. Means shall be provided which shall permit selection for the number of nozzles in operation for part load operation and for better efficiency. When one or more nozzles are out of service, the remaining nozzles shall still be properly governed. Selection of number of nozzles shall be automatic self-selection type on part load. The control valve in the governor for controlling deflectors shall be actuated by signal from governor. The deflector servomotors shall be of oil pressure actuated, double acting type with spring bias for closing of sufficient capacity to supply the maximum force required to operate the deflectors through full stroke, with minimum governor operating pressure.
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The cylinders shall be accurately bored and provided with suitable sealing around the operating rods. The operating seals shall be of the automatic pressure actuated type. Provision shall be made so that each needle can be positioned independently by the governor. All the working joints and pin connections throughout the operating mechanism shall be properly bushed and provided with self-lubrication. Means shall be provided to permit adjusting the opening and closing times of the needle stroke to any value within the following limits: Full opening stroke 10 to 30 seconds Full closing stroke 10 to 30 seconds The rate of travel for deflector and needle servomotors shall be independently adjustable for closing and opening directions. Water pressure shall be sufficient to hold the needles in closed position when machine is under shutdown. A calibrated scale shall be provided to indicate deflector / needle servomotor stroke length. Each servomotor assembly shall consist of a cast or welded steel cylinder, cast steel piston, forged stainless steel piston rod, glands and necessary compensating mechanism. The needle servomotors shall be of the oil pressure double acting type with spring bias for closing. Suitable transducer for needle position transmission shall be provided on restoring shaft of each needle. The output (4 20 mA) shall be suitable for static data acquisition and control system. The servomotors shall be equipped with a mechanical feedback position mechanism, for connection with the governor restoring mechanism or transducers, above the turbine casing. 2.5.11 Braking Jet Each turbine shall be provided with one or two braking jet system(s). The system arrangement shall include a nozzle (or nozzles) which will direct a jet of water against the back of the wheel buckets and a water supply pipe which shall branch off from the penstock upstream of the spherical valve. An isolating valve shall be provided at the branch and a control valve shall be provided at an intermediate point outside of the runner pit convenient for maintenance.
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The nozzle and all internals of the valves shall be of high grade stainless steel. The control valve shall be activated automatically during normal or emergency shutdown, and shall be deactivated upon application of the mechanical brakes. The hydraulic brake shall be capable of reducing the speed of the generating unit from one hundred twenty (120) % of rated speed to thirty (30) % of rated speed in approximately eight (8) minutes. Hydraulic brake system shall consist of following principal parts; Pressure water supply outlet from upstream of spherical valve. One set of high pressure piping, valves and necessary fittings. One / two number of needle and nozzle assembly, suitably located to apply the braking jet to the back side of the runner buckets. The needle and nozzle shall be of stainless steel. Oil operated servomotor for needle or valve operation. The oil shall be taken from the governor oil pressure system. One 220 volt DC solenoid operated valve. Two proximity switches for remote indication of position. It shall be preferred to take connection for brake jet from by-pass valve of spherical valve to facilitate inspection and repair of brake jet assembly by closing the guard vale of by-pass arrangement. 2.5.12 Turbine Flow meter Supplier shall provide high quality flow meter for measurement of discharge of the Turbine. The flow meter shall be based on the principle of measurement of acoustic pulse velocities. The system shall be suitable for the penstock layout for accurate measurement of discharge. The system offered shall be complete with digital LCD display of the discharge value. The system shall have provision for integration of the discharge over a period of time as per time set on the flow meter. The flow meter shall provide 4 to 20 mA output corresponding to the flow 0 to 30 m3/sec. The flow meter shall have accuracy better than 1%.
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The flow meter shall serve as a device for index test for relative flow measurement during the life of the project. A system directly measuring efficiency for given power output and head shall be preferred. The system shall conform to discharge measurement method as per IEC 60041 Appendix-I. 2.5.13 Penstock drain system Each penstock shall be drained by means of an independent penstock drainage system consisting of an isolating globe valve, a guard valve, a pressure reducing valve and necessary pipes and fitting. The size of the valve and piping shall be such that the penstock shall be drained in less than 6 hours. Suitable arrangement shall be provided at the outlet to avoid any damage to the concrete. 2.5.14 Runner Removal Hatch Cover A water tight steel cover for runner removal hatch shall be provided as shown in the layout drawings. The cover shall be designed for internal pressure of 1 kg /cm2 and external load of 1.5 MT/m2. 2.5.15 Access door to turbine housing A water tight access door to turbine housing / discharge pit shall be provided for entry to turbine discharge pit during maintenance as shown in layout drawing. The door shall be designed, supplied and installed by the turbine supplier. A provision shall be made for easy and quick removal/opening of access door. 2.5.16 Walkway, access platform and stairs Inspection and maintenance walkways and platforms with floor grating shall be provided and installed for inspection and maintenance work in the turbine housing. All housing walkways, platforms and equipment that can be detrimental to turbine operation shall be easily removable. A removable type structural steel service platform and walkway having opening of ample size for lowering the runner on the trolley, shall be provided by the contractor in runner pit at suitable elevation to permit complete access for inspection and repair / maintenance of the runner, deflectors, and needle / nozzles. The platform shall have pulling eyes and other fixture necessary for maintenance of turbine components in the discharge pit.
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Inspection platform, walkways inside the turbine housing shall be kept during turbine operation; hence the same shall be designed accordingly. Hatch covers, wherever are required, for various openings at turbine, generator and operating floors shall be supplied by the turbine supplier. All hatch covers shall be designed for a loading of 1.5 MT/m2. 2.5.17 Handling devices and lifting fixtures Suitable provisions shall be made in the turbine pit for handling deflector, nozzles and turbine guide bearing. Necessary handling devices, lifting fixtures and special tackles & devices shall be supplied for handling major components of turbine. These components include runner, shaft, turbine cover, injectors, deflectors, servomotors, guide bearing etc. 2.5.18 Turbine Pit Hoist Each turbine-housing shall be equipped with necessary lugs and hooks and a common hoist shall be installed to facilitate easy replacement of all equipment inside the housing. The capacity of the hoist shall be as required for the replacement of complete nozzle assembly. The hoisting system shall permit lowering any nozzle onto the maintenance trolley. 2.5.19 Runner transfer car To facilitate replacement of a runner, a car shall be provided to transfer the runner from the runner pit to the access pit where it shall be in reach of the power station crane. The car shall be robustly designed to accept the weight of the runner and shall be propelled by a reversible ratchet lever on each of two wheels. Permanent rails extending from each pit to the access pit shall be provided. Stops shall be provided at each extremity of the rails. 2.5.20 Control and monitoring The turbine and associated accessories / equipment shall be controlled and monitored at three levels: By respective local control cubicles, By respective Unit Control Boards,
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By Control and monitoring (SCADA) system through Unit Control Boards.
The turbine control shall be based on the following control logic: For starting of machine to spin no load any two opposite injectors will be used, Selection of these injectors shall be automatic / decided by the operator. Other injectors and deflectors shall remain closed. Synchronisation and loading up to 50% load shall be with two injectors. Loading beyond 50% shall be shared with all the four injectors.
2.5.21 Protection devices Bearing Protection The Contractor shall supply sensing devices to sense the following in order generate trip signal: Low oil level; High metal temperature; High oil temperature; High Vibration.
Over Speed Device In addition to an electrical over speed device, the Contractor shall provide a centrifugal type over speed device for mechanical tripping and hydraulic tripping in case of turbine speed exceeding preset limit. The centrifugal over speed device shall be mounted on the shaft of each turbine at a suitable location. The mechanical tripping / hydraulic tripping device shall directly close the deflector servomotors by-passing the governor. The contractor shall supply complete rotating and stationary trip mechanism, guards and necessary supports mounting items. The mechanism shall be completely mechanical / hydraulic and not dependent on electrical equipment for its operation. However, two electrical independent ungrounded changeover contacts shall be provided for alarm and initiating governor shutdown.
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The stationary trip mechanism shall be arrange for convenient manual resetting and shall be provided with an interlocking device to close and prevent reopening the main inlet valve until the fault is clear. The trip connection to the main inlet valve shall be by oil pressure. 2.5.22 Instrumentation The contractor shall consider basic requirement of turbine from operation and maintenance point of view and shall supply suitable instruments and gauges for achieving desired control logic. Indicating instruments as required shall be installed on unit control board. List of instruments to be furnished with the turbine is given below. However, the list is tentative only and scope shall be as per approved drawings / bill of materials during detail engineering. NAME PLATE Penstock Pressure TYPE OF INSTRUMENT Indicating Pressure Gauge QTY 2 LOCATION Unit gauge Panel Local Penstock Pressure Distributor pressure Pressure Transducer Indicating Pressure Gauge 1 2 DACS Unit gauge Panel Local Distributor pressure Turbine bearing temperature Turbine bearing temperature Turbine bearing temperature Pressure Transducer Metal Dial type Thermometer with Alarm / trip contacts Metal Resistance detector oil Resistance detector temperature 1 2 DACS Unit Control Board
Turbine bearing pads
temperature
DACS
Turbine bearing cooling Resistance water outlet temperature detector
temperature
DACS
Turbine bearing thermal Vapour type thermal relay relay Turbine bearing oil level Indicating gauge with high relay and low level contacts
Turbine bearing
Unit gauge panel
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NAME PLATE
TYPE OF INSTRUMENT
QTY 1
LOCATION Turbine bearing
Turbine bearing float Indication for high and low type oil level gauge level Turbine bearing temperature oil Dial type Thermometer with Alarm / trip contacts
Unit Control Board
Turbine bearing cooling Orifice type flow indicator water with low flow alarm contact Turbine bearing cooling Indicating pressure gauge water Turbine Discharge Acoustic as described
Unit Control Board
Local
Unit Control Board or Flow meter cabinet Turbine bearing cooling water piping Transmitter on each needle servomotor and indication in unit control board Indication on control board unit
Turbine bearing cooling Indicating Thermometer water temperature Needle position indicator Position Indicator
Nozzle locked / unlocked Proximity switch indication Deflector position Position Indicator
Transmitter on each deflector servomotor Unit gauge panel DACS
Water in oil detector
Moisture Detector
Tail water Level Barrage water Level Turbine speed in rpm
Level meter Level meter Tachometer Sensor SSG
1 1 1
DACS DACS Unit control Board
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2.5.23 Site test equipment The contractor shall supply on set test equipment for site hydrostatic testing of distributor. The equipment shall include the following; One set (common for all units) of test bulk head covers for closing inlet section and nozzle openings of distributor during field hydrostatic testing. The test head covers shall be supplied along with first unit. The test head covers shall be provided with pipe connections for filling & draining the distributor, pressure gauge, thermometer and pressure relief device (if necessary). The bulk head covers shall be provided with lifting lugs / attachments to facilitate handling during testing. Two numbers of motorised pressure pumps, each of 100% capacity, for hydrostatic testing of distributor. The pump shall be of positive displacement type with internal pressure relief valve. One set of pipes, hose pipe, valves, fittings, pressure gauge, thermometer & other instruments and necessary testing devices. 2.6 Set of hardware, seals, gasket etc. sufficient for three units. Quality Control and assurance
The manufacturer shall supply the equipments of best quality. The manufacturer shall maintain quality control during manufacture of equipment as per the approved quality assurance plans.
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2.7 2.7.1
Drawings, Documents and Design Calculations Drawings
The contractor shall submit all the drawings and documents as per Section 2.12 Reference drawings and documents of General Technical Specification (GTS). These drawing and documents shall include at least the following: Plan, elevation and sections clearly showing arrangement and outline dimensions of inlet valve, distributor, nozzle and needle assemblies, runner, shaft, turbine guide gearing, pit line and turbine housing, dismantling joints etc. Important elevations i.e. centre line of runner, turbine floor. Pit floor, shaft coupling etc. shall be marked in these drawings. Layout drawings of power house with transverse and longitudinal section, floor plans showing overall dimensions and general arrangement of turbine and auxiliaries. Unit spacing, dimensions of pit liner, pipe routing and location of important assemblies shall be located. Schematic drawings of piping systems, control systems and instruments. Graphs / curves showing performance characteristics of the turbine. Model Test report. List of tests to be performed at works and at site. Details of field acceptance tests and methods to be adopted. List of accessories and auxiliaries. Instruments offered with catalogues / pamphlets Detailed quality assurance plan giving complete specifications of materials and specifications relating to inspection and testing of materials and finished products. Comprehensive operation, maintenance and installation instructions in the form of O & M manual for turbine, main inlet valve, governor and auxiliaries. Foundation details and loads including unbalanced forces, their point of application under various normal and most abnormal operating conditions. General arrangement, plan and section of main and sub assemblies.
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Part drawings for all spare indicating dimensions, surface finish and technical requirements for final use.
Any other drawing or information required to specifically check suitability of design and provision of these specifications.
2.7.2
Design calculation
The Contractor shall submit the design calculation covering at least the following, for review / acceptance. Structural and stress analysis of distributor, turbine housing & discharge pit liner, nozzle, deflector and servomotors. Structural and stress analysis of runner. Structural and stress analysis of turbine shaft and coupling bolts, Structural and stress analysis of turbine bearing, Critical speed and bearing arrangement, Speed and pressure rise and GD2 calculation, Hydraulic transient analysis and system stability study, Natural frequency of the unit, Heat calculation and temperature rise calculation for turbine guide bearing, Calculation of Foundation loads including unbalanced forces, their point of application under various normal and most abnormal operating conditions. 2.8 Governor closing and opening times. Delivery, Installation and Commissioning
The supplier shall follow the requirements of Delivery, Installation and commissioning as elaborated in section 2.34 Installation and Supervision of General Technical
Requirements. The seller shall arrange personnel to oversee proper storage of equipment at site, their transshipment to powerhouse, installation and commissioning.
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2.9 2.9.1
Spare Parts Recommended Spare parts
The contractor shall furnish the list of recommended spare parts as per clause 2.36 of Spare Parts and special tools of General Technical Requirements. 2.9.2 Specified spare parts
Following Specified spare parts shall be supplied for turbine and accessories under this section: S. No. 1 Description Runner with protective coating Set of four needle tips and gaskets etc and renewable four nozzle seat rings Set of four jet deflectors Set of four nozzles including servomotors, needle tips and nozzle seat rings Coupling bolts runner to turbine shaft Coupling bolts turbine shaft to generator shaft Turbine guide bearing segments/ pads Set of gaskets / seals (for complete turbine) DTT (Dial Type Temp. Thermometer) of each type RTD (Resistance Temperature Detector) of each type Water flow indicator of each type Pressure gauge of each type Pressure switch / pressure transmitter of each type Quantity 3 nos.
2 3
3 sets 1 set
4 5 6 7 8 9 10 11 12 13
1 set 1 set 1 set 1 set 2 Sets 1 set. 1 set. 1 set. 1 set. 1 set.
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S. No. 14 15 16 17
Description Oil level gauges & relays of each type Limit switches of each type Over speed device Feedback transducers Valves of size 80 mm and above including distributor drain valve each used type
Quantity 1 set. 1 set. 1 set 1 set 1 no.
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Note: One set is defined as the total quantity / number required for one unit. 2.10 Special tools
The Contractor shall provide one set of special tools and maintenance equipment for repair and maintenance of turbine. A list of such tools including their make and detailed specification shall be furnished along with tender and shall be got approved from the Owner during detail engineering. However following special tools shall be included in addition to tools recommended by manufacturer(s) One (1) set of hydraulic torque tensioners with two identical tensioners operated by a common power pack for runner/ turbine shaft flange coupling bolts, as per applicability, Hydraulic wrenches for opening each type of bolt above M-25 size i.e. Head Cover fixing, MIV trunnion bolts etc. These shall be suitable for the bolting arrangement adopted i.e. pre-stressed bolts and/or tightening torque. All accessories including jack, pipes, adopters, hand pumps, extension sockets shall be included in scope as per process requirement / Socket for all sizes above M25 bolts shall be included i) Hydraulic Wrench < 20000 Nm (Hytorc) : : 1 set 1 set
ii) Hydraulic Wrench < 12000 Nm (Hytorc)
Two (2) sets of pneumatic / hydraulic wrenches with sockets and pumps for opening all bolts of the size of M-16 to M-25.
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One set of slings, for handling turbine components i.e. distributor segments, turbine housing, runner, shaft, guide gearing other components etc;
One (1) set of Nylon Sling - round, for handling turbine components, One (1) set of Nylon Sling - Flat, for handling turbine components, Four (4) sets of Eye Bolts of each size (M12 and above) used in the turbine components,
Four (4) sets of lifting D-shackles of each size (M12 and above) used in the turbine components.
2.11
One (1) set special erection tools, instruments and devices. One (1) set of Erection hand tools, wrenches etc. Shop Tests
2.11.1 Assembly The following shall be completely assembled, aligned and fitted in manufacturers works and properly match- marked to ensure correct reassembly and alignment at site Distributor Nozzle and deflector including pressure test and needle stroke movement Runner housing Runner Turbine bearing
2.11.2 Turbine Hydrostatic Test Following assemblies shall be hydrostatically tested in works Distributor segments Each segment of distributor shall be tested for a period of minimum 60 minutes under a hydrostatic pressure not less than 1.5 times the maximum design pressure of distributor. Servomotor assembly The servomotor cylinders and oil pressure system shall be pressure tested for a period of minimum 30 minutes at a pressure of 50% above the maximum working pressure. After test, the equipment and piping shall be thoroughly
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cleaned and protected. The leakage test shall also be performed on these assemblies. Nozzle and deflector assembly Nozzle and deflector assemblies shall be pressure tested at a pressure of 50% above the maximum design pressure for a period of minimum 30 minutes. After hydraulic test, the needle stroke also be tested. Bearing coolers The heat exchanger shall be pressure tested for a period of minimum 30 minutes at a pressure of 50% above the design pressure minimum test pressure shall not be less than 7.0 kg/cm2. 2.11.3 Operational test of Needle Operational test of needle comprising of the following; Alignment and free movement of needle Needle opening by actual stroking of servomotor
2.11.4 Static Balancing of Runner Runner shall be statically balanced in works before dispatch to site. 2.11.5 Tests on subassemblies Tests on subassemblies to verify alignment, soundness and proper functioning, radiograph, magnetic particle, dye penetration, ultrasonic inspections etc shall be performed as required by good standard practice. The contractor shall furnish a list of such subassemblies and tests proposed for quality checks. 2.11.6 Material Tests Material tests for important components such as runner, shaft, needles, nozzles, deflectors, distributor, bearing and other important components shall be carried out and submitted to the owner. 2.11.7 Defects and corrections Any leakage, distortion or other defects developed during or after the tests shall be corrected and retested.
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A record shall be made of shop measurements of all critical and important dimensions, diameters, concentricity, run-out, clearances etc of turbine moving and stationary parts which may affect the field erection and alignment or normal operation of turbine. 2.12 Installation and commissioning
2.12.1 General The contractor shall furnish all labour, tools, supplies, slings and supports and all other provisions and material necessary to assemble, erect, install, test and commission the equipment in a thorough workmanlike manner following the best practices. The equipment and all their components shall be placed with great care and shall be aligned to provide an installation consistent with close tolerances used in the erection of modern equipment. The proper elevation and centrelines to which equipment is to be set shall be established by the contractor. All necessary material and labour for performing all the site tests shall be provided by the contractor. All test equipment and instruments shall be supplied by the contractor. 2.12.2 Installation procedures The contractor shall prepare and submit detail of his proposed site installation procedures. The procedures shall include record sheets on which various alignment checks and test shall be recorded and approved by the engineer as work at site progresses. The installation procedure submitted should specify erection tolerances as per international and or industry standards. 2.12.3 Test during Installation Distributor Assembly The distributor shall be assembled together and pressure tested at 1.5 times the maximum design pressure for a period of minimum 60 minutes. About 50% pressure shall be maintained while pouring the concrete to embed the distributor. Turbine bearing Heat exchanger shall be pressure tested to a pressure of 1.5 times the rated pressure for 30 minutes.
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Bearing oil tank shall be tested for oil leakage with light solvent.
Hydrostatic pressure test, leakage test and operation tests on nozzle and deflectors assemblies.
Hydrostatic pressure test, leakage test and operation tests on sub-assemblies, auxiliaries, valves and piping system etc to the extent feasible shall be carried out.
2.12.4 Field Tests All field tests including operational, pre-commissioning, commissioning and field acceptance tests shall be conducted by the contractor in the presence of owners representative. Procedure to be adopted for conducting the operational, pre-commissioning, commissioning and field acceptance tests shall be supplied well in advance and shall be subjected for approval of the owner. Operational Tests Control logic field tests to prove control logic scheme for operation and interlocks of auxiliaries including annunciation and shutdown scheme shall be done in so far as practical. Calibration Tests all instruments, gauges, sensors, switches, temperature relay and other similar equipment shall be calibrated and adjusted after installation where practical. Where not practical, the calibration and adjustment shall be done just prior to installation. Operational Tests for Protection field tests foe verification of correct operation of protective relays shall be conducted. Pre-Commissioning Test Tests to check all weld joints done at site. Shaft and guide bearing clearance. Shaft rotational checks for alignment. Tests to determine opening and closing time of deflector needle servomotor. To determine deflector v/s needle opening characteristics.
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Bearing run test to determine temperature rise of bearing to determine maximum bearing temperature at no load and maximum overload condition.
Load rejection tests at 25, 50, 75 and 100 percent rated load and at 115% overload to verify speed rise and pressure rise.
Unit starting, stopping, braking and no load no excitation run test, part load and full load and overload operational tests to ensure performance as per specifications.
Measurement of vibrations during various operating conditions. Braking time from 100% speed to 30% speed under brake jet operation. Any other check / tests to ensure that requirements of the specifications are being met. No extra charge for tests shall be payable.
Commissioning Tests Deformation of covers and bearing supports. Noise / vibration in turbine. Water supply pressure for bearing. Turbine safety and signal devices. Operating conditions of all pumps. Oil levels, temperature, pressure, cooling water temperature etc. Shaft run-out at turbine and generator bearings. Brake jet operation. Over speed devices. Load run and load rejection test. Index test Shall be performed on each unit to calibrate the turbine flow meter within 0.2 percent accuracy to assess change in efficiency during operation and to optimize power output. Main Inlet valve closing with full load on the unit.
Field Acceptance Test
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All field acceptance tests in accordance with provision in IEC 60041 1991 shall be conducted at site before acceptance of turbine by the owner. Output and efficiency tests shall be conducted at different heads and needle opening to determine guaranteed efficiency parameters. Any deviation from IEC 60041 1991 shall require approval of the owner. Efficiency shall be measured by thermodynamic or mutually agreed method. Contractor shall furnish details of test methods, agency which will conduct the test, provisions to be made for field testing, calibration of instruments for the purposes of test and all other relevant details in the offer. Contractor shall be under obligation to accept these tests for purposes of liquidated damages. Owner reserves the right to appoint the contractor or any other independent agency or agency recommended by the contractor for conducting these tests.
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3. 3.1
GENERATOR Scope of Work
Scope of work under this section covers the provision of labour, tools, plants, materials and performance of work necessary for the design, manufacture, quality assurance, quality control, shop assembly, shop testing, delivery at site, site storage and preservation, installation, commissioning, performance testing, acceptance testing, training of Owners personnel, handing over to owner and guarantee for one years of three (3) sets of Hydro generators, as per the specifications hereunder, each complete with all auxiliaries, accessories, spare parts and warranting a trouble free safe operation of the installation. The scope of work shall be a comprehensive functional system covering all supply and services including but not limited to the following: 3.1.1 i) Generator and auxiliary systems Three (3) sets of direct driven, vertical shaft synchronous generators, each having a rated output of 111.11 MVA, at rated condition specified hereunder, and capable of 15% continuous overload , complete with air cooled stator, rotor, shaft, thrust and guide bearings, upper bracket, lower bracket and other components etc., conforming to the latest edition of IEC standards, ii) Three (3) sets of water cooled heat exchangers (stator air coolers) complete with valves, interconnection piping, fittings, instruments and anti-condensation lagging etc., iii) Three (3) sets of water cooled heat exchangers (oil coolers) for thrust, lower and upper guide bearings along with complete interconnection piping, fittings, instruments, valves and anti-condensation lagging, iv) v) Three (3) sets of anti condensation heaters and hydrostats for Generator Stator, Three (3) sets of combined brake / jack system along with one portable high
pressure oil pump to operate the jacks along with piping, fittings, valves and instruments. vi) Three (3) sets of high-pressure hydrostatic lubrication system with main (AC drive) and standby (DC drive),
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vii)
Three (3) sets of sole plates, foundation bolts, sleeves ,anchor plates and other embeddments,
viii) Three (3) sets of fire protection system for generators complete in all respects, ix) x) xi) xii) Three (3) sets of brake dust collection system, Three (3) sets of oil fume extraction system Three (3) sets of brushgear assembly with carbon dust collection system, Three (3) sets of shaft current monitoring system complete with sensors, transducers and other accessories with provision of integration with plant SCADA system, xiii) Three (3) sets of all required oil, air and water pipes, fittings, valves, instruments and anti-condensation lagging xiv) Three (3) sets of following miscellaneous items:1. Wiring termination cubicles / connecting boxes / termination boxes / starter panels comprising but not limited to the following: Termination cubicle mounted outside the generator enclosure for all generator Instrumentation and wiring Starter panels for all generator direct related motors to be installed adjacent generator enclosure Termination boxes as per requirement to be provided inside generator enclosure for instruments, heaters etc. 2. Three (3) sets of access doors, stairs, railings, dome with dome light, top cover with insulation and platforms, xv) Oil for the first filling of bearings and jacking system, etc. with 10% extra quantity in non-returnable drums for three (3) units, xvi) Three (3) sets of creep detectors with alarm and tripping contacts as per IEC 125 clause 3.2.26 xvii) Three (3) sets of all necessary control, monitoring, safety and metering instruments/devices/system with provision of extra contacts/ports for SCADA, xviii) Three (3) sets of continuous on-line vibration monitoring system complete with probes/pickup, transducers and cables for shaft vibration / run-out
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measurements. The probes/pickups shall be mounted at suitable locations on Turbine and generator bearings with provision for integration with plant SCADA system, xix) One (1) set of complete equipment handling , lifting and turning devices along with hardware etc. for stator, rotor, rotor poles, shaft, thrust bearing assembly and other components, xx) Three sets (3) of continuous on-line partial discharge monitoring / analyzing system complete with sensors, transducers and other accessories with provision of integration with plant SCADA system, xxi) Three sets (3) of moisture detection system for bearing oil reservoir complete with sensors, transducers and other accessories with provision of integration with plant SCADA system, Common items for all three generators:xxii) One portable laptop of latest configuration with softwares for online monitoring devices xxiii) One (1) set of device for stator bar installations/removal and pushing devices along with power pack and other accessories. xxiv) xxv) Two (2) sets of electrical brazing/soldering equipment / devices, One (1) set of assembly devices like pedestals, stools etc required for stator & rotor assembly in service bay, xxvi) One set of Rotor and stator diameter measuring device and accessories.
xxvii) One (1) set of removal/assembly arrangement devices and tools for thrust and guide bearings, xxviii) One (1) set of spares suitable for 5 years normal operation but not limited to the spares mentioned under clause 3.8 , xxix) One (1) set of tools and devices for handling, assembly, installation, dismantling of the generator comprising but not limited to in the list mentioned under clause 3.9 Special Tools of this section. xxx) Performance test on any one unit including submission of the test report
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Any other item(s) not mentioned specifically but necessary for the satisfactory completion of scope of work defined above, as per accepted standard(s) / best international practices. 3.2 3.2.1 Rating and Design Considerations Rating
The main technical characteristics of the generators are as follows: Type TEWAC( Totally enclosed water and air cooled) 111.11 MVA (Cooling water temperature of 20 C) 127.77 MVA 0.9 11 10% kV 3 phase As per IEC 60034-1, Zone B i.e. 50 +3%, 5% HZ 300 (To match turbine speed ) Star (Wye) High resistance grounding through singlephase transformer 98 % minimum
Rated Power
Maximum continuous power Power Factor Generator Voltage Number of phases Frequency
Speed (r.p.m) Stator Winding connection Grounding
Generator efficiency at 127.77 MVA, 0.9 pf
Direction of rotation (viewed from top) Temperature rise at rated output (111.11 MVA) over and above the cooled air with cooling water temperature not exceeding 25.C and voltage and frequency variation according to Zone B as per IEC 60034-1
Clockwise
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Stator winding Rotor windings Stator Core Collector Rings
70 C 80 C 65 C 85 C 34 C
Maximum cooling air temperature for surface air coolers ( For water temperature of 0-25 C) Minimum temperature of cooling air leaving the coolers (For water temperature of 0-25 C) Temperature rise at maximum continuous output (127.77 MVA) over and above the cooled air with cooling water temperature not exceeding 25 C and voltage and frequency variation according to Zone B as per IEC 60034-1 Stator winding Rotor windings Stator Core Collector Rings
10 C
80C 90 C 75C 85C
Electrical Characteristics Saturated reactance (X=d) direct axis transient not more than 35%
Unsaturated direct axis sub-transient reactance (X@d) Telephone harmonic factor (THF)
more than 15 %
As per IEC 60034-1 Less than 5%
Deviation factor of wave form measured in percent from line to line opencircuit voltage at rated voltage and frequency
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Mechanical characteristics Max. speed rise on full load rejection Maximum runaway speed 35% Not more than 596 rpm 127.77 MVA
To mechanically withstand continuously without exceeding specified normal stresses To withstand seismic forces by all generator components and bearings for peak ground acceleration of Maximum cooling water temperature Inertia constant of Generator, (kW-sec/kVA) (at maximum output) Short circuit ratio Minimum line charging capability Insulation class of stator and rotor winding Maximum permissible temperatures under rated continuous Power (127.77 MVA) with ambient temperature 40C and cooling water inlet temperature 25C : Thrust bearing pads Guide bearing segments
horizontal 0.18g, vertical 0.12g
25 Deg. C
More than 3
Not less than 1.05 70% of continuous power F Absolute Temperature
80C 70C
The design of the generator shall take into consideration daily and seasonal cyclic loading and frequent starting of the units.
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3.2.2
Codes and Standards
The following codes and standards shall be applicable for all the materials, considered for design, manufacturing and construction and testing of the Generator and its components, but not limited to the following:-. ANSI B49.1 C50.10 C50.12 IEC60034 IEC 60137 IS 4722 60545 IEEE 43 62 85 112 115 286 Recommended Practice for Testing Insulation Resistance of Rotating Machinery Guide for Diagnostic Field Testing of Electrical Apparatus Test Procedure for Airborne Sound Measurements on Rotating Electrical Machinery Test Procedure for Polyphase Induction Motors and Generators Guide: Test Procedure for Synchronous Machines Recommended Practice for Measurement of Power Factor Tip-Up of Electric Machinery Stator Coil Insulation Recommended Practice for Voltage Endurance Testing of Form Wound Bars and Coils.
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Shaft Couplings, Integrally Forged Flanged for Hydro-Electric Units Rotating Electrical Machinery Synchronous Machines Requirements for Salient Pole Synchronous Generators and Generator/Motors for Hydraulic Turbine Applications Rotating Electrical Machines Insulating bushing for alternating voltage above 1000V Rotating electrical machine- specification Guide for Commissioning, Operation and Maintenance of Hydraulic Turbines
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1310
Recommended Practice for Thermal Cycling of Form-Wound Stator Bars and Coils for Large Generators Standard for Voltage-Endurance Testing of Form-Wound Coils and Bars for Generators Motors and Generators Safety Standard and Guide for Selection, Installation, and Use of Electric Motors and Generators Large Hydraulic Turbine Driven Synchronous Generators and Reversible Synchronous Generator/Motor Units for Pumped Storage Installations Standard for hydraulic turbine and generator integrally forged shaft coupling and shaft run-out tolerances
1553 NEMA MG-1 NEMA MG-2
MG5.1(ref. Only)
IEE 810
ANSI / IEEE Std. Recommended practice for testing insulation resistance of large AC 433 rotating machinery with high voltage at very low frequency VDI 2059 PART-5 ISO 10816-5-2000 Measurement of shaft vibrations in hydraulic machines Mechanical Vibration Evaluation of machine vibration in machine sets in hydraulic power generating and pumping plants Recommended practice for testing insulation resistance of large AC rotating machinery with high direct voltage
ANSI / IEEE Std. 95
Equipment conforming to any other alternative standard(s) equal or better quality than the above standards shall also be acceptable. However, in such eventuality, the salient points of difference between the standards adopted and the standard mentioned above shall be brought-out by the Supplier. 3.2.3 Material selection and standards
The material specifications and their standards for major components of generator shall be as shown below. The material grade and classification wherever specified are obligatory and proposed equivalent national/international standard for the same shall only be considered if their chemical composition, mechanical properties, manufacturing methods are same / superior and are suitable for proposed use.
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The Contractor shall establish the equivalence/superiority for acceptance by the Owner Sl. No 1 Item Material Material Standard
Structural steel for supports, Structural steel , brackets and sections/plate sections/ plates components Stator frame Fabricated from steel sections/ plate Cold rolled silicon steel with non -oriented grains Rectangular copper conductor Fabricated from steel sections/plate High tensile magnetic steel sheet High permeability magnetic steel sheet Rectangular copper conductor Fabricated from steel plate White metal Carbon Steel Alloy steel Ni Cr Mo Carbon Steel, Fabricated from steel plate Carbon Steel, Seamless
ASTM A 283 GR C
ASTM A 283 GR C
Stator core
Stator coil
Rotor spider
ASTM A 283 GR C
Rotor rim
Rotor pole lamination
Rotor pole coil
Brake ring
ASTM A 283 GR C
10 11 12 13
Bearing Pad lining Generator shaft Coupling bolts Bearing housing
ASTM B 23 No.3 ASTM A 668 Class D ASTM A 434 Class BD ASTM A 283 GR C
14
Pressure Pipes
ASTM A106 GR B / ASTM A53 GR B
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15 16
Cooler tubes
Cupro-nickel 90:10 ASTM A106 GR B / ASTM A53 GR B
All embedded pipes relating Carbon Steel to generating units and auxiliaries Performance Guarantee
3.2.4
The generator along with all auxiliaries and accessories shall be capable of performing intended duties under specified conditions. The Contractor shall guarantee the reliability and performance of the individual equipment as well as of the complete system. The generator shall operate satisfactorily in parallel with each other and with other machines connected to the grid. The generator shall be able to operate on sudden application / or loss of maximum load and during momentary short circuits and sustained ground faults without causing any abnormal vibration or resonant conditions. The generator shall be capable of operating continuously on an unbalanced system such that with none of the phase currents exceeding the rated current, the ratio of negative sequence component of current (I2) to the rated current (In) does not exceed 0.08, and under fault conditions shall be capable of operation with the product of (I2/In) 2 and time in seconds (t) not exceeding 20. Guaranteed output The generator output shall be guaranteed by the Contractor in respect of the following: o Rated output of 111.11 MVA at rated power factor of 0.9 and at any voltage and frequency in the specified operating range without exceeding the maximum permissible temperature limits. Guaranteed efficiency The guaranteed weighted average efficiency, at rated voltage and frequency as determined from the following formula, shall not be less than 98 percent. gAv = 0.1 g115 + 0.6 g100 + 0.2 g75 + 0.1 g50 where, gAv = Weighted average efficiency g115 = Efficiency at 115 percent of rated (111.11) MVA and 0.90 p.f
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g100 = Efficiency at 100 percent of rated (111.11) MVA and 0.90 p.f g75 = Efficiency at 75 percent of rated (111.11) MVA and 0.90 p.f 1 g50 = Efficiency at 50 percent of rated (111.11) MVA and 0.90 p.f Liquidated damage shall be imposed as given below. Liquidated damages for shortfall in output and efficiency in case of shortfall in weighted average efficiency/output vis--vis the corresponding guaranteed value. The liquidated damages on account of shortfall of efficiency shall be computed separately for each unit and the total amount of liquidated damages shall be the sum of all the units. However, tolerance in computation in efficiency shall be in accordance with the IEC 60034-1 for field acceptance test for generators. Liquidated damages for shortfall in output and efficiency For any shortfall in the tested values of rated output and the weighted average efficiency of turbine vis--vis the corresponding guaranteed values respectively, shall be computed as follows: iii) Unit Output For each one tenth of one percent shortfall in tested value of rated output vis--vis corresponding guaranteed value, not to exceed 10% of the contract price iv) Unit Weighted average efficiency For each one tenth of one percent (0.1%) shortfall in tested value of weighted average efficiency vis--vis corresponding guaranteed value not to exceed 10% of the contract price As per As per
commercial clause
commercial clause
For fractional values of shortfalls in percentage, the liquidated damages amount shall be computed on pro-rata basis. The liquidated damages on account of shortfall of output and weighted average efficiency shall be computed separately. The total amount of liquidated damages shall be the sum of these Three multiplied by number of Generators.
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No tolerance limits shall be permissible over the calculated value of rated output. However, tolerance in computation in efficiency shall be in accordance with the IEC 60034-1 for field acceptance tests for generators. Rejection limit The Owner reserves the right to reject the generator if the tested values of either weighted average efficiency or the rated output falls short by three (3) percent or more of the corresponding guaranteed values during field acceptance tests. 3.3 Design provisions
Following design provisions shall be made: a) The generators shall be suspended type with combined thrust and guide bearing located above the rotor and another guide bearing below the rotor. It shall be designed for continuous operation at 115% rated MVA (127.77 MVA) at rated voltage, p.f. & frequency given under clause 3.2.1 without exceeding specified normal stresses. b) The construction of the generator shall be such that the rotor poles, stator coil and generator air coolers can be installed and dismantled without disturbing the upper bracket. c) The thrust bearing housing shall be so designed as to provide easy access to the bearing pads. Openings with removable covers shall be provided for this purpose. The thrust bearing pads and the thrust faces shall be capable of being reached and inspected through the inspection window (after emptying the bearing oil, removal of coolers and with rotor jacked up). d) The guide bearings also shall be of such construction that these can be removed/ dismantled without disturbing the thrust bearing, rotor, stator, etc. e) The stator shall be designed to enable all necessary assembly processes and works to be carried out at site, i.e. v) Building up of core at site including stacking, pressing etc. vi) Assembly of stator winding including installation of bars, jointing, insulation etc.
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f)
The rotor shall be assembled at Site. The rotor construction comprising stacking, pressing, curing of lamination insulation, installation and mounting of rotor poles etc. shall be designed accordingly to suit the assembly at site.
g)
The total length and width of erection bay including unloading bay is 47 m x 21.6 m. The Supplier shall plan simultaneous assembly of 2 rotors and 2 stators. Supplier shall also plan building up of at least one stator in stator pit itself so that sufficient space for other activities is available in erection bay. The Supplier shall submit their proposal keeping in view civil works status, erection activities of turbine and key milestones for completion.
h)
All parts of the generating unit shall be designed mechanically to withstand all electrical, mechanical, seismic and other stresses which may be experienced during the operation of the unit, including short circuit, faulty synchronization, over speed and runaway conditions. Maximum stress of the rotating parts of generators shall not exceed 2/3 of the minimum yield strength under worst abnormal operating condition. Under normal operating conditions the stresses shall not exceed one third of minimum yield strength.
All equipment shall be designed and manufactured considering prevailing transport limitations. j) The design of the Unit, including the relative locations of the rotor, generator thrust and guide bearings shall be such as to cause no resonant conditions. The Unit shall be stable under worst short circuit conditions. k) The supporting brackets will be steel fabricated and shall be rigid enough to support and transmit the loads to the concrete structure/foundation under worst conditions mentioned above. The bearing bracket supporting the brake assemblies shall, however, be designed to withstand the braking of the rotor at 50% normal speed (though normal braking speed shall be max 30% of rated speed). l) Upper and lower guide bearing brackets shall house the upper and lower guide bearings in their hub. m) Rotor field poles shall be arranged in a manner to permit easy removal with the unit rotor in place. Field pole electrical connections shall be located in a position to facilitate ease of inspection, separation and re-connection. The field poles shall be provided with adequate damper winding to reduce voltage distortion etc. The poles shall be interchangeable between units and spares.
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n)
Lubricating oil in all bearings including turbine bearing and the turbine governor shall be of one type only.
o)
The stator bore shall be wide enough to facilitate removal of largest component of turbine.
p) Two sets of tools for assembly of 2 rotors and 2 stators simultaneously and one set of tools for lifting, handling and shifting shall be provided. q) The Supplier shall furnish their erection plan along with complete erection sequence which they propose to follow at site. r) The details of lifting arrangement (General arrangement) proposed for stator and rotor with shaft and the maximum lift required during erection, dismantling, reassembly shall be furnished by the Supplier. The lifting arrangement shall be such that the overall lifting height required is restricted to minimum. s) Design of sole plates and other load transmitting element to concrete shall be such that maximum stresses during normal condition do not exceed 60 kg/cm2 and under worst condition of operation do not exceed 80 kg/cm2. t) The weight of the turbine rotating parts and all hydraulic thrust including any unbalanced thrust shall be supported by the generator thrust bearing. u) Generator housing pit drain to be provided.
Capacity and temperature rise The vertical shaft, synchronous generator, with combined thrust cum upper guide bearing above the rotor and with lower guide bearing below the rotor, and conforming to the latest edition of IEC standards, shall be capable of delivering a guaranteed rated output of 111.11 MVA continuously and continuous overload output of 127.77 MVA at the terminals, as per operating conditions and temperature rise limits mentioned above in clause 3.2.1. Short circuit withstand capability The generator shall be capable of withstanding a three phase short circuit at the generator terminals when operating at overload continuous output i.e. 127.77 MVA and rated power factor with 8% over-voltage (as per IEC 60034-1 Zone B) for a period not less than 3 sec. Generator shall be designed to safely withstand any mechanical/magnetic stresses resulting from either three phase, or single phase faults, or out of phase synchronization, etc.
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Occasional excess current / short time over current The generator shall be capable of withstanding occasional excess current equal to 1.5 times the rated current for not less than 30 seconds each time on each time of occurrence. Wave form and polyphase symmetry a) The wave form of the emf between terminals of the generator on open circuit shall be practically sinusoidal. The wave form shall be accepted as practically sinusoidal if none of its instantaneous values vary from instantaneous value of the same phase of the fundamental wave (50 Hz) by more than 5 percent of the peak value of the fundamental. b) The Polyphase voltage system of each generator shall be practically symmetrical. Polyphase voltage system is considered as practically symmetrical if neither the negative sequence nor the zero sequence component exceeds 5 percent of the positive sequence component. c) Special steps shall be taken to eliminate harmonic voltage wave which may cause inductive interference with communication circuits or resonance in the transmission system. Telephonic harmonic factor shall not exceed 1.5 percent measured in accordance with IEC 60034-1. d) The calculated no-load harmonics in the voltage wave form shall be furnished.
Stability and performance The generator shall operate satisfactorily in parallel with each other and with other machines connected to the grid. The generator shall be able to operate on sudden application / or loss of maximum load and during momentary short circuits and sustained ground faults without causing resonant conditions. Unbalanced current operation The generator shall be capable of operating continuously on an unbalanced system such that with none of the phase currents exceeding the rated current, the ratio of negative sequence component of current (I2) to the rated current (In) does not exceed 0.08, and under fault conditions shall be capable of operation with the product of (I2/In)5 and time in seconds (t) upto 20.
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Runaway speed withstand capability The generator shall be designed and constructed to be capable of safely withstanding maximum runaway speed for a period of 10 minutes (with cooling water flow intact) without incurring damage from stresses under such conditions. The runaway speed test shall be considered successful, if after undergoing the test for two (2) minutes no injury is apparent. A runaway test shall be performed, unless waived by the Purchaser. The generator shall, after undergoing the test, be able to withstand the high voltage test at eighty-five percent of the dielectric test voltage. Severe operating conditions withstand capability The generators shall be capable of safely withstanding maximum stresses during normal operation, seismic conditions, runaway-speed conditions, two phase and three phase short circuit conditions, single phase earth fault, 180 and 120 out-of-phase synchronization, magnetic unbalance with 50 percent of the poles short circuited, and maximum unbalance due to some guide vanes not closing/opening (worst combination) etc. and maximum stresses due to pneumatic brake application at 50% speed. At the time of detailed designing, the above conditions shall be duly considered for calculation of stresses for purpose of civil design. Also calculations for design of various components shall consider these conditions to prove the design provisions given under clause 3.3(h). Speed, runaway speed The unit shall be designed for a nominal speed of 300 rpm. The runaway speed shall be determined in co-ordination with the turbine manufacturer and various parts shall be designed to withstand the same with safety margin allowable under such conditions Maximum shaft displacement and absolute bearing vibrations Maximum shaft displacement in the kinetic shaft orbit (Smax) shall be measured with help of two pickups in each plane for all bearings, ie. generator upper & lower bearings and turbine bearings. This shall be measured at shaft under rated steady state load conditions. The limit of maximum shaft displacement (S max) and the thrust and guide bearing bracket vibration
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(mm/s) shall be as per border line A/B defined in edition dated 01-04-2000 of ISO 7919-5 and ISO 10816-5 (Table A.4). Generator fault condition a) Line-to-ground fault current shall be limited to 10 Amps or less, such that welding of iron does not take place, by using a suitable neutral current limiting device, i.e. distribution transformer loaded by suitable capacity resistor. b) The Supplier shall supply his calculations for capacity rating of neutral earthing transformer and resistor to be supplied under the scope of bus ducts and terminal equipment . Direction of rotation The direction of rotation shall be clockwise when viewed from top. 3.4 3.4.1 a) Design and Construction Stator The stator shall consist of frame, core and windings. Due to shipping constraints the stator frame shall be shipped in sections, and the stator shall be piled and wound at site. The stator frame shall be fabricated of steel plate, suitably ribbed for rigidity and shall be of robust design to withstand maximum forces acting on it under worst conditions of operation. The stator frame shall have robust foundation plates rigidly attached to the frame with provision for leveling, centering and bolting on to foundations. The fastening of the stator frame to the sole plates will have provision for radial movement of the stator due to thermal expansion. Stator frame shall be designed such that, in fully assembled condition, it can be lifted for transfer from erection bay to stator pit. Suitable lifting lugs shall be provided. The stator frame shall be designed to combine stiffness with efficient passage for ventilating air. b) The core shall be built of high grade silicon steel laminations, de-burred and treated with baked enamel. The core shall be ventilated by means of radial air ducts throughout the stack length.
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Core lamination sheets with a loss coefficient of 1.0W / kg at 1 Tesla or lower losses shall be used. The core laminations shall be adequately dovetailed to the Stator frame and securely held in place by clamping together by axially arranged bolts, end plates and radial fingers. To ensure uniform tightness of laminations, full and final clamping pressure shall be applied to successive layers of laminations while being stacked. Depth of layers shall be suitably advised by Supplier as per his standard erection procedures. Final clamping arrangement shall be such as to permit tightening in case of looseness during operation. The clamping fingers shall be of heavy construction, securely attached. There shall be no perceptible buzzing of laminations during operation. Necessary tests i.e core flux test shall be conducted after piling and before winding at site for detection of hot spots. To ensure against shrinkage, coil slot wedges shall be of fabric-base phenolic material or glass reinforced polyester material. The Supplier shall ensure that lamination deformations due to thermal expansion and handling stresses do not occur. The stator bore shall be designed to permit the removal of turbine runner. c) The Stator winding shall be Wye connected with 3 line and 3 neutral leads brought out to the stator terminals. Each phase winding shall be distributed around the Stator such as to minimize unbalanced magnetic pull. The Stator winding and connections shall be insulated with Class F insulation. If the winding is proposed with number of parallel paths per phase the terminal shall be brought out for providing split phase CTs. The required CTs of PS Class for split phase protection shall be included in the scope. Bar type windings shall be used for the stator winding. The stator windings shall be of Roebel copper bar type with strands completely transposed within the slot length with class F insulation. Coil insulation and bracing on the overhang and overall coil tolerances in the slot portion shall be such that coil lifting and replacement shall be possible without damage to the main insulation of adjacent coils when following recommended procedure.
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End winding shall be braced firmly and lashed securely to support rings to withstand short circuit and other abnormal forces. Both ends of each phase winding shall be brought out of the stator winding. Removable links shall be provided in each phase and in each neutral lead to isolate the individual phase from the accessories and external connections for test purposes. The links, when removed, shall provide a clearance of approximately 200 millimeters between adjacent sections. The links shall be located within the barriers specified below and shall be spaced so as to minimize the time required for, and the amount of taping and retaping. Both the neutral and main lead of each phase shall be brought out within the generator air chamber. The Supplier shall also furnish the necessary conductors and hardware for formation of the neutral connection. d) The stator winding shall be protected by earth fault and differential relay, which will be provided by the Supplier as per Technical Specifications. The Supplier shall mount the current transformers as per the scope of busduct & terminal equipment, within the generator air housing/busduct at line end terminal of each phase winding and neutral end of winding. The CTs for Split phase protection, if required shall however be mounted within the generator airhousing. e) Suitable barriers for terminal and neutral ends shall be provided within the air housing around the generator leads to prevent injury to workmen when working on the surface air coolers while the generator is in operation. f) The generator main terminals shall be suitably arranged for connections to the isolated phase bus terminals. Flexible copper connectors between the generator terminals and the isolated phase bus terminals shall be furnished by the Supplier. The Supplier shall furnish all materials required for making joints in field. Consumables will be provided considering 2.5% extra for losses. This shall include silver soldering and brazing material, tapes, varnishes as required. Location of neutral end shall be decided in consultation with the Purchaser. The Supplier will propose suitable location of neutral grounding cubicle considering Purchasers layout drawing. The stator winding, end connections, main & neutral leads shall be insulated with Class F insulation. The bars shall be vacuum impregnated with high-grade insulating varnish so that the insulation becomes a dense, homogeneous mass, free of voids
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and air pockets. The insulation shall become reasonably plastic by the application of heat and shall be of such nature that the bars can be placed in, or removed from the slots without damaging the insulation. The bars shall be form-wound and interchangeable. The coils shall be treated so as to prevent permanent injury from temporary exposure to dampness. g) The stator bars shall be provided with a protective coating and arranged or treated to reduce corona to the lowest practicable minimum, and the slot portions treated with a semi-conducting compound to provide corona shielding. The corona shielding shall extend beyond the core for a sufficient distance to prevent corona damage and shall be graded. h) The bars shall be tightly wedged in the slots with wedges which shall not shrink or buckle and shall have sufficient elasticity. The outer protective taping shall be heatresisting and shall not deteriorate under high temperature. Ripple Springs or other suitable packing shall be provided for slots. Special care shall be taken in insulating and installing the end portions of the bars so that there will be no detrimental effect on the stator insulation level. Slot liner strips if used shall be installed on one side of the slot only and fabricated of approved semi conducting material. The Supplier shall provide detailed instruction for replacement of stator bars, jointing and insulating procedures including heating requirement and testing. i) Winding shall be designed such that it will minimize losses and heating due to circulating currents. The strands shall be of annealed copper, free from splinters, flaws, rough spots, or sharp corners. The end portions of the bars and the connections shall be rigidly supported and braced to prevent vibration and distortion under stresses caused by the most severe short-circuit conditions to which the generator may be subjected. j) Temperature detectors Suitable resistance temperature detectors shall be embedded in the winding, core and tooth portion of core. All connections from temperature detectors upto Generator termination cubicle shall be through shielded cables included in the Suppliers scope.
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k)
Winding insertion at site The stator windings shall be inserted at Site after the stator frame segments are bolted / welded together, and the stator core is stacked. The Supplier shall depute a specialist for supervision of winding. The Purchaser shall provide sufficient skilled manpower having previous experience in winding. The neutral leads shall be brought out in a suitable manner to enable installation of current transformers and formation of neutral in the generator housing. The generator neutral lead shall extend beyond the generator barrel and terminate at the neutral cubicle which shall contain the grounding transformer, resistor, disconnecting switch and accessories. All necessary connectors, conductors and material for forming the generator neutral inside generator housing shall be furnished by the Supplier. Type and arrangement of the line terminals shall be suitable for termination of fully insulated, single phase isolated bus ducts. The bars shall be packed inside the slots with liners of semi-conducting corrugated and flat glass-cloth base laminates to reduce the vibration and partial discharge between the winding bars and the walls of the slots. Wedges made of high strength fibrous moulding materials shall be used to hold the winding bars tight in the slot. The end winding shall be supported by means of retaining rings of non-magnetic steel. The insulation of the retaining ring and connecting bus bars shall be of glass tape backed mica flakes.
3.4.2
Lower brackets, stator sole plates, coupling and foundation bolts
Sole plates, coupling bolts, foundation bolts, pipe sleeves and dowels for lower bearing bracket and stator frames shall be provided. The stator frame sole plates may be designed with sufficient vertical bearing area to transmit maximum tangential forces under short circuit torque conditions without exceeding stresses in concrete to more than 60 kg/cm2, under normal conditions and 80 kg/cm2 under abnormal conditions. Lower bracket sole plates will be designed with sufficient horizontal bearing area so that maximum stresses in concrete do not exceed 60 kg/cm2, under normal conditions and 80 kg/cm2 under abnormal conditions.
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Each sole plate shall have leveling screws and openings for grouting. The stator dowels and sole plates shall safely withstand stresses and impacts from normal and above specified abnormal conditions and shall transmit forces to the foundation. Sole plates, embedded type foundation bolts, levelling screws, sleeves, dowels, etc., shall serve for anchoring and grouting generator parts to the concrete foundations. The fastening of the stator frame to the sole plates shall permit radial movement caused by thermal expansion. Each of three CTs on the neutral side shall have a physical protection. Secondary leads of CTs within the generator housing shall be wired to the generator terminal box. The stator windings shall be equipped with partial discharge detectors. Minimum Four (4) embedded temperature detectors per phase shall be located in the winding. All RTDs shall be wired to the generator RTD terminal box. Adequate space heaters shall be provided to prevent condensation of moisture on windings during shutdown periods. The space between the stator frame assembled with heat exchangers and the concrete sidewalls shall be minimum 0.6m to permit walkway and inspection space for the generator and any accessories. Copper grounding terminals at the generator frame, cover plates, terminal box shall permit the grounding of the generator. 3.4.3 Rotor
General The rotor shall consist of a rotor spider, rotor rim, field poles and winding. The rotor spider shall be fabricated from steel plate and shall be shipped in one piece or in sections to meet shipping limitations. bonded to the shaft. The rotor rim segments shall have Key ways on its inner periphery for fixing the rim on the rotor spider with keys. Poles shall be supported on the outer periphery of rim segment using keys driven into the pole dovetails. The spider hub shall be machined and securely
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The rotor poles shall consist of laminations clamped between steel end plates and held with through studs. The rotor windings shall be fabricated from hard copper strip and shall have class F insulation. Brushes and slip ring material shall be adequate for the specified maximum continuous rating. Brush holders shall be accessible by easily removable panels on brush gear housing. One or more panels shall be transparent to permit examination of brush performance when running. Brush gear ventilation shall be designed so that dust from the brush gear shall not be conveyed into the generator. Where the brush gear is not totally enclosed and uses outside air for ventilation, air filters of a washable type shall be supplied. The rotor shall be built in accordance with the best modern practice. The rotor winding shall be insulated with class F insulation. The brake ring on the rotor shall be supplied in segments which should be readily replaced. The various sections of the brake track shall be interchangeable between each other and with other units. The wearing surface of the brake pads shall be in single asbestos free piece. Adequate provisions shall be made for dissipation of the heat resulting from the application of the brakes and to take care of the expansion of the brake plate. Overspeed due to rejection of maximum load at frequent intervals shall not cause any damage to the rotor or require special maintenance prior to resuming operation. Rim type ventilation shall be provided. The cooling air passing through the inter polar space in the rotor and ventilating ducts in the stator core shall pass on to the generator air coolers. Provision shall also be made for air baffles / air guides at the top and bottom to direct the air to flow in desired direction if necessary. These air guides shall be of Polyster Resin or equivalent material in suitable sections to facilitate removal and inspection of windings. Field poles Construction The construction of the poles shall be such that they may be removed and replaced without lifting the rotor. The connections between poles shall be easily removable and accessible for test.
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The pole pieces shall be built up of thin steel laminations secured in place with studs and bolts. The pole body is secured in place by means of tapered keys. The keys shall be locked in place on both sides of the rotor rim so as to prevent the keys from coming out in the event they should become loose. If tapered keys are used to secure the field poles to the rotor rim, the drive key shall project above the rotor rim a sufficient distance to facilitate removal of this key by means of a key puller and to permit checking for tightness. Suitable keepers shall be supplied in conjunction with the tapered keys to ensure that the keys do not get loose in service. Each field coil shall be so fabricated such that the space between adjacent turns is completely and solidly filled with insulating material. To ensure uniform insulation thickness between conductors throughout the coil, every effort shall be made to avoid excessive deformation or burring of the conductor during forming of the coil. Care shall be taken in undercutting insulation between turns to avoid the possibility of shorting out at turns. The pole of each type shall be interchangeable between units and spares. Their weights shall have close tolerances which shall be specified. Dimensional tolerances for finished product shall be such that the poles require no adjustments at site for their installation. (a) Field pole insulation
The Insulation between the individual turns of field winding shall consist of Class F material. The insulation against the shank of the pole shall consist of glass reinforced resin. Insulating collars shall be provided at the top and bottom of each field coil, and the collars shall be adequately supported at all points. Adequate means shall be taken as necessary to compensate for shrinkage in the insulation and to maintain adequate pressure on the field coil. The windings, insulation and connections between poles shall be capable of withstanding all mechanical stresses to be imposed by the specified maximum runaway speed of the turbine. Special care shall be taken to prevent the end turns from deforming or slipping due to centrifugal stresses on the interconnections. The field winding insulation shall be capable of withstanding the specified dielectric tests. Supplier shall provide detailed procedure for rectification of field winding faults i.e ground faults.
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(b)
Amortisseur windings (Damper windings)
A closed connected Damper winding consisting of several solid copper bars, fitted in grooves below the pole shoe surfaces shall be provided. They will be short circuited at the pole ends by rigid copper rings. It shall be designed for a calculated ratio of quadrature-axis sub-transient reactance to direct-axis sub-transient reactance not to exceed as specified under ratings and to meet guaranteed (I2/In)2t value. Runaway speed conditions The entire rotor shall be designed and built to withstand safely the maximum runaway speed of the unit for not less than 30 minutes. Rotor erection pedestal Pedestal(s), jacks and centering device for simultaneous erection of two rotors at a time shall be provided and despatched with the first generator for supporting the rotor during assembly. Collector rings and field cables The collector rings shall be constant pressure brush holder type and shall be fixed to the upper shaft above the rotor by means of screwed bushing and shall be sufficiently spaced. It shall be insulated with class `F' epoxy glass insulation, Brushes shall be so arranged as to facilitate changing or adjusting the brushes. The maximum runout of the collector rings shall not exceed 0.50 mm. Brush holders for each collector ring shall be spaced around the ring for accessibility in maintaining and inspecting holders and brushes while the generating unit is in operation. The brushes and Collector rings shall be so located that they will not interfere with the removal of the upper thrust cum guide bearing and also to avoid contamination by oil vapors or oil leakage from the bearing. Excitation system to collector ring interconnection shall be through isolated phase d.c. bus duct included in Generator equipment Supplier scope. D.C. connection to collector ring shall be so arranged that the same can be changed to reverse the polarity of collector rings
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without dismantling of incoming d.c. duct. 3.4.4 Carbon Dust collector exhausting arrangement for sucking and collection of carbon, if any
Suitable
produced/emitted by the brushes shall be provided so as to avoid the conduction through carbon deposition resulting in earth faults. Complete information on type; grade and size of brushes used shall be furnished. The filters used shall be metallic and washable type having high efficiency. 3.4.5 Shaft
General The generator shaft shall be made of forged carbon steel, properly heat-treated. It shall be of ample size to operate safely in combination with the turbine shaft at any speed up to and including the maximum runaway speed of the turbine, without detrimental vibration or distortion, and to operate at loads not exceeding 115 MW at normal speed without exceeding the specified normal operating stresses. Shaft requirement shall be coordinated with the turbine manufacturer in order to obtain shafts of the same diameter to satisfy load conditions. Critical speed The critical speed of the combined turbine and generator rotating parts shall be calculated by both the turbine and generator manufacturers. When the necessary design details are established, necessary computation and analysis for critical speed data shall be carried out ensuring that the first critical speed is at least 25% above the runaway speed at maximum head. Necessary calculations shall be supplied to the Purchaser. Generator Supplier shall be responsible for Co-ordination of the critical speed analysis of combined turbine and generator shaft system. The Supplier shall consider unbalanced magnetic pull and bearing support stiffness in the critical speed calculations. Shaft finish and runout The generator shaft shall be free from injurious flaws and imperfections and shall be accurately and smoothly machined all over, and polished at the bearing surfaces, and at accessible points below or above each guide bearing for alignment checks. The shaft shall
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have a hole at least 150 mm in diameter bored axially throughout its entire length to permit inspection. The amount of shaft run out shall be checked, by rotating the finished shaft in a lathe or aligning device in the manufacturers shop, and shall not exceed the tolerances recommended for generator shafts, in IEEE : 810 "Standards for Hydraulic Turbine & Generator integrally forged shaft couplings and shaft runout tolerances". Excessive runout which results in infringement on the bearing and labyrinth/seal clearances will not be permitted. Coupling The turbine manufacturer will deliver the turbine shaft completely machined with coupling bolt holes drilled 3 mm undersize to the generator manufacturers works. The generator manufacturer shall be responsible for the final reaming of the coupling bolt holes and the coupling and aligning of the turbine and generator shaft before shipment to site. The bore and ream coupling holes shall be done using same templates. Any alternate method of coupling shall be subject to Purchasers approval. The Supplier shall cooperate with the turbine manufacturer to provide a neat-appearing coupling and a satisfactory and accurate fit between the two halves of the coupling. The shaft shall be provided with integrally forged female coupling flange. All coupling dimensions shall be as agreed upon by the Supplier with the turbine manufacturer and shall be in accordance with ANSI B 49.1, "Shaft Couplings, Integrally Forged Flange Type for Hydroelectric Units" IEEE : 810 "Standards for Hydraulic Turbine & Generator integrally forged shaft couplings and shaft runout tolerances." The coupling bolts and nuts for attaching the generator shaft to the turbine shaft, suitable metal nut guards on both halves of the coupling for covering the coupling bolt heads and nuts, and motorized /hydraulic / pneumatic operated torque wrenches and gauges necessary for field assembly of the couplings shall be furnished by the Supplier. The coupling bolts shall be provided with locking devices and shall have dimensions and tolerances in accordance with ANSI B49.1/IEEE:810. Not less than three jack screws shall be provided in the generator shaft flange for breaking the joint. The Supplier shall provide suitable coupling guard for the assembly.
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Inspection & Tests on Shaft The Supplier shall be responsible for all tests covering metallurgical strength, crystallographic ultrasonic and boroscopic tests performed on each shaft during manufacturing cycle as per QAP to be approved. Shaft alignment The turbine and generator Suppliers shall exchange templates and / or digital machining data for the coupling flange drillings to ensure accurate fit and assembly at site. The alignment of the complete shaft system will be performed at site by both the turbine and generator Supervisors under the direction and responsibility of the generator Supervisor. The Supplier shall protect the shaft, prior to shipment. Protection for journal surface shall be resistant to moisture, physical impact during transport and storage. Surface finish Supplier shall furnish specifications to be adopted for surface finish of shaft which shall take care of bearing requirements and shall comply to the applicable code. In area where vibration monitoring instruments are installed, suitable burnishing areas shall be earmarked with close surface finish tolerances. 3.4.6 Bearings
Design Basis Thrust bearing The generator shall be provided with a combined thrust and guide bearing arranged on the upper bracket above the rotor. The thrust bearing shall have ample capacity to support the weight of all rotating parts and the hydraulic thrust. The bearings shall be of the Babbitt-metal fully self-lubricating type, amply sized to be capable of safely coping with all operational conditions i.e. start-up / shut-down or runaway speed without cooling water supply as defined below. The arrangement, design and construction of the bearings shall be co-ordinated with the turbine manufacturer. The thrust bearing shall be of the manufacturers standard design, with flexible self adjusting pad, support (spring mattress type), providing sufficient reference for long term satisfactory operation. The oil circulation for lubrication and cooling shall be achieved by drilling in the
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thrust block so that rotation of the unit results in an oil flow through the system (selfpumping). The vertical side of the thrust block will be used as journal surface of the guide bearing. Sufficient details of type of bearing offered, manufacturers experience list shall be furnished. Thrust bearing shall be designed to withstand all loads which can occur in the worst conditions specified. While designing the withstand capacity of the thrust bearing the following shall be considered: Weight of all rotating parts including shaft and runner Max hydraulic thrust (load) for which unit is designed Severest faults Run away speed for 30 minutes
The size of the thrust bearing will be designed by restricting the specific pressure on thrust bearing segments as per IEC. The thrust bearing shall be capable of: Operating continuously without injury at any speed from 50 per cent to 110 per cent of the rated speed. Operating for 30 minutes without injury at any speed, from 110 per cent of the rated speed to the maximum specified runaway speed Operating for at least 30 minutes without injury at normal speed and load, without the cooling water, starting at normal operating temperatures 2 minutes at runaway speed without cooling water supply.
The rotating steel thrust runner disc shall have a mirror sliding surface fastened to the thrust collar by means of bolts and screws. The thrust runner disc shall be insulated from the thrust collar by a sheet glass cloth laminate insulation. The thrust bearing shall be designed so as to permit inspection, adjustments, dismantling, and assembly using rotor jacks and without disturbing or removing the rotor, stator or bearing bracket. Type and quality of the oil shall be the same as for Turbine and Generator guide bearings
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and Governor, spherical valve, BFV system and the same shall be sourced from India. Shaft shall be provided with integral or separate forged thrust block attached to it. Bearing surface shall be given optical finish. The Supplier shall furnish details of fixing thrust block on to shaft. For start-up and shut-down, a high pressure lubrication system shall be provided in accordance with scope of supply. Nevertheless, safe start-up and shut-down shall also be possible in case of failure of this system. The Supplier shall furnish special tool for withdrawal of thrust pads as required for inspection along with tools if any. Suitable tools for attaching thrust block to shaft shall also be provided. Arrangement offered shall be such that disassembly and reassembly should not require any major adjustments. Time required for assembly, disassembly, and sequence details shall be given by the Supplier. Upper & Lower Guide Bearings The guide bearings shall consist of segmental shoe surfaces of babbit metal which shall from a continuous surface around the shaft. The upper combined thrust cum guide bearing and the lower guide bearing shall be arranged on the respective upper & lower bearing brackets. The guide bearing shall be designed and constructed so that it can be dismantled without disturbing the thrust bearing or the generator rotor. Bearing Lubrication System An oil reservoir shall be provided, suitably sized to limit the oil circulation to 15 - 20 times per hour. The entire thrust and the major part of the guide bearing shall be oil-immersed to provide lubrication during starting, normal and abnormal operating conditions and shut-down. Seals and baffles shall be provided to prevent oil leakage and to reduce possible foaming of the oil to a minimum. Self lubricating, self priming arrangement for bearings shall be offered. Bearing Temperature limits Maximum temperature of bearing babbit metal shall not exceed 80C with max. water temperature of 25C under rated load conditions. Expected normal temperature of bearing
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and alarm and trip settings shall be intimated by the Supplier. Bearing shall however be capable for safe operation upto 105C. Bearing Oil Coolers The thrust cum upper guide bearing and the lower guide bearing shall be of the self-lubricated type with oil-to-water coolers. The cooler shall be designed with 150% of the required cooling capacity. The oil - to - water coolers shall be designed to withstand a test pressure of 150% higher than the maximum water pressure expected during operation. The tubes of the oil coolers shall be of Stainless steel / Cupro-nickel and shall have adequate excess capacity to allow for 10% plugging of cooler tubes. All oil circulating devices, strainers, indicators, valves, etc. shall be included. Bearing Oil Treatment / Centrifuging Supply and return line flanges with shut-off valves shall be provided at generator floor level to allow connecting the oil circuits to the oil transfer and treatment system. An overflow with connection to the return line shall be included. Bearing Oil Vapour seal arrangement Special care shall be taken in the design of the bearing seals. No oil Vapour shall enter the generator compartments. The system shall preferably be based on quenching air and vent-pipes with filters. Details of system proposed to be adopted shall be furnished. The generator shall be provided with a complete, self-contained, lubricating system which shall include the latest improvements to eliminate the throwing of oil and the escape of oil Vapour from the bearing and lubricating system. Adequate baffles shall be provided, if necessary, to prevent excessive churning or aeration of the oil. An efficient Oil vapour seal shall be provided for each bearing which shall prevent oil fumes or creepage of oil along the shaft. Oil vapour extraction system complete with all piping, pumps complete in all respect shall be provided to prevent oil vapour escape and deposit on rotor or stator.
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Bearing Shaft current Insulation The bearings shall be adequately insulated to prevent harmful flow of shaft currents induced by the generator field. Test points (Brush holder with brush) shall be arranged at an easily accessible location to allow regular checks for the existence of shaft voltage. Above arrangement can be combined with the auxiliary brush-holder provided for the rotor earth fault protection. Further shaft current monitoring system shall be provided. Bearing Piping Bearing cooling water pipe lines shall include necessary piping, piping insulation and valves as per approved design by the Purchaser. Specifications of valves and piping shall be as defined under clause VALVE & PIPING. Provision for flow reversal in cooling water circuit, including necessary valves, shall be made to prevent silt accumulation in coolers. For this purpose duplex changeover valves shall be used. Piping shall be designed to permit flow measurement during bearing loss measurements using the calorimetric method as per IEC codes. Piping arrangement and location of flow measuring instruments shall be done in conformity with IEC requirements. Piping shall be designed to ensure that there is no turbulence in flow and noise level is below acceptable limit. Instrumentation The thrust bearing shall be equipped with all the necessary indicating and control devices but not limited to the following: One dial type thermometer in each alternate thrust bearing pad. One dial type thermometer for thrust bearing oil reservoir for hot oil temperature. Resistance temperature detectors located in all the pads and two nos. in the oil reservoir. Water flow meter Ultrasonic type for water flow rate and quantity measurement (4-20 mA output). This will provide local controller and/or monitor with visual indication digital and/or analogue. This will also provide separate contacts for low flow for alarm, normal flow contact for start interlock. Oil-level indicator(s) (dip stick type as well as magnetic level indicator or equivalent)
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Oil level monitor providing oil level analogue output 4-20 mA along with potential free signaling contacts for low, very low and high level alarm.
One oil-water contamination detector (for moisture detection upto 10 ppm). All instruments will provide compatible digital / analogue inputs for interface with plant Digital Control System.
The upper and lower guide bearings shall be equipped with all the necessary indicating and control devices but not limited to the following: Oil-level indicator(s) (dip stick type as well as magnetic level indicator or equivalent) Oil level monitor providing oil level analogue output 4-20 mA along with potential free signaling contacts for low, very low and high level alarm. Two dial type thermometers ,one each in two pads of upper and lower guide bearing. One RTD in each pad of upper and lower guide bearing. One RTD in lower bearing oil reservoir One direct-reading water flow gauge, low-flow alarm contact. One oil-water contamination detector (approx 10 ppm moisture detection)
Hydrostatic lubrication system for thrust bearing Hydrostatic lubrication system shall be provided for supplying external high pressure oil to the thrust bearing surfaces during starting & stopping of the machine. It shall include a suitable oil pump driven by a three-phase 415 volt, 50 Hz motor, all necessary protective equipment, high pressure gauges and check valves. A 220 volt DC motor driven oil pump shall also be furnished and installed to act as standby, in case of failure of main AC motor driven pump. The transfer shall be accomplished by automatic devices and manual control shall be provided for testing purposes. The oil-lift pumps shall be controlled automatically during starting, stopping and creeping by speed switches and relays. Motor starter shall also be provided by the Supplier. The oil pump and control equipment shall be mounted in an approved location. Auxiliary contacts shall be provided on the oil-pump motor starter for use as an interlock in Control scheme for start / stop and the brake control circuit and indication. All contacts shall be wired upto terminals and starter shall have adequate provision for termination of cables.
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A pressure device to operate on establishment of a permanent oil film pressure shall be provided for interlocking remote starting of the unit. The pressure device may consist of a combination of pressure switches and relays; and shall provide two contacts which close when a constant pressure, has been established. The contacts shall be suitable for use in ungrounded, 220 volts DC. circuits. Suitable damping devices shall be provided in the highpressure piping system, if necessary, to prevent undue pulsation. The high-pressure oil grooves on the bearing pads shall be so designed that they will not interfere with normal lubrication of the bearing while the high-pressure system is shut down. 3.4.7 Upper bracket
The upper bracket shall have an all welded central part and detachable arms. The upper bracket shall be designed to take the loads from generating unit rotating parts and from the water thrust pressure as well as the radial forces. The central part of the upper bracket shall house the oil reservoir for the upper guide bearing and thrust bearing. All upper bracket arms shall be provided with bracing jacks to absorb the radial forces including the seismic effects. The radial forces including the seismic effects taken up by the upper bearing shall be transmitted by the upper bracket arms to the concrete barrel via the bracing jacks. The supporting bracket shall be designed so that it will not be necessary to remove the collector rings in order to remove the thrust cum guide bearing. Puller bolts should be provided on each bracket arm for adjustment of elevation. The bracket arms shall be bolted to the intermediate plates which are welded to the upper flange of stator frame. Lower bracket with guide bearing The lower bracket shall have an all welded central part and detachable arms which shall be bolted to the central part to form a single unit. The arms shall be bolted to the sole plate concreted in the foundation. The central part houses the oil reservoir for the lower guide bearing. The bearing segments and mounting should be similar in construction to the upper guide bearing. 3.4.8 Braking and Jacking
The generator shall be provided with double acting air-operated brakes of sufficient capacity to bring the rotating parts of the generator and turbine to standstill from 30% normal
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operating speed, within reasonable time after the brakes are applied, and without injurious heating of the braking surface of the brake track. The air pressure shall be less than 7kg /cm. Near each generator barrel, at generator floor level, an outlet from compressed air system with suitable non-return valve and pressure reducing valve shall be provided. Provision for inter connection of brake air system to station air system through isolating valve, pressure reducing valve and non-return valve shall be made. Provision for automatic operation of brakes shall be made in control logic and during normal shutdown in auto mode. However manual brake operation provision shall also be made. Auto operation shall be initiated at speeds recommended by manufacturer. Control logic for application of brakes during shut down and their removal after machine has come to standstill shall be part of the Digital Control System. Air will be supplied from a common air receiver which shall be kept pressurized by the low pressure air compressor. The brakes shall be designed for 150% of normal braking pressure. The capacity of the air receiver shall be sufficient for six (6) full brake operations. The brakes shall also be designed to serve as the hydraulic jacks to lift the generator rotor and the turbine runner for removal or adjustment of the thrust bearing. The amount of lift shall be not less than 20 mm and shall be properly coordinated with the turbine manufacturer. All parts of the generator shall be so constructed as to permit this lifting without dismantling or disconnecting any parts. An approved provision shall be made for locking the brakes in an intermediate position suitable for bearing inspection. The locking device shall be such that maintaining hydraulic pressure on the jacks will not be required while the rotor is in a raised position. Proper air flushing system shall be provided to flush out oil from the brake / jack cylinders effectively. The brakes shall be housed in such a way that braking residues are efficiently sucked by brake dust collector system which is also included in scope of supply. Proper partition from generator coolers shall be ensured. The brake linings shall be of durable, metal-and asbestos-free material, adequately arranged to facilitate inspection and replacement. The minimum lining thickness shall be supervised and an alarm provided. A common compressed air system comprising two compressors (main and standby), air
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cooler, air receiver shall be provided. A pipe header from air receiver to all the unit air receiver(s) shall be provided. The system shall be complete with valves, auto drains, pressure monitor etc. Brake / Jack Headers and piping A header for oil supply to brake/jack units shall be provided and arranged to drain the oil and to prevent oil entry into the air system. High pressure, lock shield valves shall be provided in the oil and air supply lines of header. All piping used in connection with the brakes and jacks shall be capable of withstanding the maximum oil pressure required to lift the combined weight of the rotating parts of generator and turbine. The type of brake in which oil is present in the brake cylinder during braking operation will not be acceptable. Brake shoes The brake shoes shall be provided with suitable moulded asbestos free wearing surface, which shall be renewable. The brake shoes and wearing surfaces shall be keyed or otherwise securely fastened to the jack pistons. The brake shoes shall be equipped with retraction springs to provide positive retraction of the shoes from the braking surface when air pressure is removed. Adjustable means shall be provided for increasing the return force as desired. Limit switches Limit switches shall be provided on each brake shoe to indicate the following status: All brakes ON All brakes OFF Any brake ON
The above brake status shall be interfaced with DCS for sequencing and protection. Portable oil pump for jacking One portable motor-operated high-pressure oil pump for use with the hydraulic jacks shall be furnished by the generator Supplier. The portable pump shall be complete with oil sump, pressure gauge, relief valve, check valve, release valve and flexible hose with swivel nuts etc. High pressure oil piping shall be extended from the brakes to an accessible location on
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the outside of the generator for connection to high-pressure oil pump. Pump shall be supplied complete with motor, MCC/ Starter panel, and control equipment. Motor shall be suitable for 415 volt, 3 phase, 50 hz AC supply. Brakes & jack panel The Supplier shall terminate generator brakes & jack piping into a brake/jack panel mounted on the generator barrel. A solenoid / manual operated 3 way valve shall be provided for braking, jacking and flushing operations. Necessary piping and valves as required shall be included in the scope of supply. Brake Dust Collector Suitable exhausting arrangements for sucking and collection of brake dust, if any, shall be provided during braking operation of the machine. The dust suction motors shall start automatically at the braking speed during shutdown sequence and stop few minutes after release of brakes. The operation of brake dust collector system shall be governed by DCS. Dynamic braking Dynamic electrical braking shall be provided to achieve efficient and fast stopping of machine. Equipments to be provided for this shall be : 3 pole isolator connected across stator terminals Auxiliary excitation system Necessary relays for operation of isolator, field breaker, etc. Electrical brake bypass system.
The sequence of operations of electrical braking shall be as follows : It shall be possible to start the electrical braking manually either from UCB or automatically from the sequential control/DACS. As soon as unit breaker is opened, field breaker is opened, and field suppression is started. The generator voltage shall be detected by a minimum voltage relay and after the voltage reaches to about 3% of normal voltage, the isolating switch shall be closed shorting the generator terminals. The field breaker shall be closed on to the auxiliary excitation
equipment for supplying rated stator current.

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Electrical braking shall switch off automatically as soon as the machine comes to standstill or in the event of any of the following faults: Admissible braking time exceeded Auxiliary AC & DC voltage not available Rotor over voltage protection operated Stator faults Mechanical failure by bearing Excessive vibration (beyond limit)
All equipments necessary for Dynamic braking shall be housed in a cubicle and supplied alongwith the excitation system equipment. 3.4.9 Cooling System for Generator Stator and rotor
General Generator stator shall be provided with a closed, re-circulating cooling system with surface air coolers spaced symmetrically around the periphery of the stator frame. The circulation of air shall be by means of fan action of the generator rotor. The air shall circulate out of the openings in the stator frame, through the coolers, and back into the top and bottom of the rotor and the bearing area as required. Each surface air cooler shall consist of a number of finned tubes, tube sheets and water boxes. The water boxes shall have bolted cover plates to permit inspection and cleaning of cooler tubes. The water headers shall be furnished with the coolers and shall be suitably located. Each connection between coolers and the headers shall be of the flanged type, and a valve shall be provided in each connection between each cooler and each header (supply and discharge) so that any cooler on the generator can be readily disconnected and removed for maintenance or repair without interfering with the operation of the remaining coolers of the Unit. The entire system shall be designed to prevent any accumulation of sediment. Instrumentation as specified shall be provided in the water supply line to the coolers.
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Provision for flushing of coolers and water flow reversal in cooling water piping shall also be made. Necessary piping, pipe insulation against condensation and valves shall be included in the scope of supply upto the termination point. Termination shall be at least 1000 mm outside generator barrel. Generator Air coolers Each air cooler shall be of the straight-tube type with Stainless steel / cupro-nickel, corrosion-resisting, finned tubes expanded into corrosion resisting tube sheets. The water boxes shall be of non-ferrous metal and shall be constructed with removable cover plates, to permit access to all the tubes, and shall be arranged to permit removal of any cover for inspection or cleaning of the tubes without disturbing the water pipe connections. A valve and hose connection shall be provided to permit complete draining of each cooler. A 50 mm copper nipple shall be provided on supply and return manifolds for flushing. Air vents shall be provided at the top of each cooler and at other locations in the system, as required. The air vents shall be connected through valve to a water trap and to a common discharge header. Lifting lugs shall be provided on each cooler. Air coolers discharge piping shall be so arranged that these are always full of water. Valves and piping Valves and fittings shall be minimum class 150. Valves 50 mm and larger shall be flanged iron-body with stainless steel screw and brass/gun metal seats. Valves smaller than 50 mm shall be all bronze with screwed connections. Standard flanged connections shall be provided for all piping and fittings 50 mm and larger. Piping and fittings smaller than 50 mm shall be provided with unions suitably located for assembly. Threaded connections shall conform to ANSI B2.1 (NPT). Gate valves shall be provided at inlet and outlet of coolers. Cooling water piping, including ring header inside generator barrel, and piping for discharge of water, at least upto 1000 mm outside generator housing, shall be supplied by the Supplier. Piping shall be complete with suitable control valves, non-return valves, flow relays, flow meters, orifice plate for adjusting quantity of water flow etc. A temperature controlled
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motorized or solenoid operated throttling valve for water quantity regulation shall be provided at the inlet of the generator, as required, to control cooled air temperature of the generator barrel. Pressure gauge with a gauge cock 6 mm threaded connection will be provided at inlet header. Provision for fitting precision water flow meters for efficiency tests shall also be made. Suitable lagging shall be provided on the cooling water pipes to avoid condensation. Cooler capacity The coolers shall be designed for safe operation at a maximum water pressure of 10 kg/cm2. Each cooler shall be designed to withstand hydrostatic pressure of not less 1.5 times the maximum pressure for one hour. The surface air coolers shall have sufficient cooling capacity. The cooling system shall be able to maintain the temperature of the air leaving the cooler at 35C or less with 10% tubes plugged with the generator delivering continuous overload capacity at rated voltage and water entering the coolers at 0 to 25C. The Supplier shall furnish calculations in respect of number of surface air coolers selected for the generator. The water pressure drop through the coolers and headers shall not exceed 0.51.0 kg/cm measured from the coupling flange of the common discharge header. Cooling system shall be designed to remove one cooler from the generator circuit without effecting operation at rated load. Air circulation The circulation of air shall be by means of rim ventilation system. The air shall circulate out of the openings in the stator frame, through the coolers, and back into the top and bottom of the rotor and the bearing area, as required. The Supplier shall furnish a sectional drawing showing the calculated air flows through the generator.
Temperature and Flow Monitoring Devices

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The cooling system of generator shall be provided with the following: RTDs in each water supply line, to measure the temperature of incoming water. RTDs to measure the temperature of the outgoing water from each cooler. RTDs to measure the temperature of the heated air leaving the stator and entering the air cooler(s) (at least one each for each cooler). RTDs to measure the temperature of the cooled air coming out of the air coolers and entering the rotor (at least one each for each cooler). Water flow meters at inlet and outlet with analogue output 4-20 mA for measuring water flow rate and quantity. The meter shall be ultrasonic type and provide local visual indication and will be connecting to monitoring instrument on generator termination / gauge panel. It shall have facility to provide low water flow and normal flow changeover contacts. Dial type thermometers in the inlet air path entering each cooler and discharge air from cooler (for each alternate cooler) with thermometers mounted on Termination & gauge panel. All instruments shall provide digital/analogue inputs to SCADA as per requirement. Generator top cover The Supplier shall furnish a steel top cover and an adapter ring. Adaptor ring shall be grouted into the concrete housing/barrel of generator air chamber so that an airtight joint is made between the ring and the concrete, and between ring and the generator top cover plates. A steel retainer strip shall be welded to the adapter ring for edging the finished floor. This strip shall be approximately 5 mm thick and 50 mm high. Generator floor and generator top level elevation shall be the same . Top cover shall be of pleasing appearance, neatly constructed and sufficiently rigid to prevent vibrations. The top cover shall be designed for a minimum live load of 488 kg/m and in addition shall be designed so that cover for collector ring housing can be stored on top cover. Painting scheme for top cover, collector housing shall be as approved by Purchaser. Minimum one set of steel door and frame with gaskets and locking arrangement shall be furnished for embedment in the generator barrel. Door shall be airtight to ensure
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closed circuit ventilation. The door shall be painted in approved colour after proper surface treatment. Limit switches shall be provided on each generator housing entrance. It shall have 1 NC contact for annunciation and 1 NO contact for interlock to prevent water discharge during fire if barrel door is open. Removable panels in generator top covering should be so designed that it facilitates complete inspection of generator, removal of field poles, stator bars (besides coolers), and associated piping arrangement.. Suitable lifting arrangement for panels shall be provided. The design of the generator brackets, floor plates and structures in which resonance might become objectionable shall be so proportioned that any possibility of synchronism with the natural frequency, or any of its multiples, of the turbine shall be avoided. The Supplier shall obtain the natural frequency of the turbine from the turbine manufacturer. Suitable guards, over or around all live and moving parts, shall be provided.
Instrumentation Resistance temperature detectors Standard resistance type temperature detectors along with temperature monitoring device for recording and monitoring temperatures shall be provided as per applicable standards. The monitoring devices shall interface with plant SCADA All temperature detector leads shall be three conductor cable with an overall sheath which is oil, moisture and heat resistant. Each detector shall be connected by three leads to terminal blocks located in Terminal Boxes for the purpose. The detector leads shall be color coded and extra flexible to facilitate repeated dismantling without breakage. Detector sheaths shall be insulated where necessary to prevent circulating currents. From unit terminal boxes to termination and gauge panel located on generator floor sheathed screened cables shall be provided. Dial type indicating thermometers 150 mm. square dial type, vapour pressure, flexible copper tubing, indicating thermometers having range of 0 to 150C with 2 NO potential free contacts shall be provided. Bulbs shall be located in bearing pads and oil reservoir, such that hottest
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part temperature is indicated. Thermometers will be mounted on generator gauge panel, and length of tubing shall be as per finalized location, plus 2 metres extra. Bulbs and tubing shall be adequately clamped to prevent breakage due to vibrations. These shall be insulated to prevent stray currents as required. Accuracy of instrument shall be better than 1%
Instruments & gauges General A list of Instruments and gauges for generator shall be submitted by the supplier for approval of the purchaser. All instruments shall have minimum two (2) electrically independent normally open or close contacts of suitable rating as approved and generally as per requirement in the logic control scheme. All junction boxes of instruments/limit switches, where applicable, shall have proper sealing gaskets and covers securely held by screws to make them moisture proof and vermin proof. All interconnecting cables, piping, tubing, orifices, fittings, valves for various devices, H.P. oil pump, indicating instruments, relays and gauges upto generator termination box / gauge panel, as applicable, shall be furnished by the supplier in required sizes and lengths. All instruments shall use metric units of scale. Bearing Oil level transducer & monitor It shall be of magnetic type or capacitive type with 4-20 mA output. Accuracy should be unaffected by working oil temperature upto 105C. Level measurement accuracy shall be better than 5 mm. Indicating instrument shall be mounted on gauge panel and normal bearing oil level, high and low oil level limit shall be marked on instrument. Output shall be compatible with SCADA. Annunciation & control shall be programmed in SCADA. For each bearing oil tank, an oil level indicator at generator gauge panel shall be provided. Water flow meter Analogue flow meter complete with stainless steel orifice plate and flanges,
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manifold, vent, equalizing and shut off valves, and associated piping and hardware shall be supplied for thrust cum upper guide bearing, lower guide bearing and generator air coolers. Remote indicators shall be provided at generator gauge panel. Flow meters shall be interfaced with SCADA hence sufficient number of potential free contacts shall be available for interconnection. Creep detector The creep detector shall be as per . IEC 125 clause 3.2.26 It shall be capable of performing the following functions: It shall detect less than 1 rotation in 8 minutes. Its contact shall be used for disengaging brakes in automatic operation and/or start up of HP lub pump as per logic after set time delay. It shall be disengaged during normal operation and shall remain in continuous operation when unit is shut down. On-line shaft current monitor Suitable shaft current monitor of approved make shall be supplied and installed on unit control board for continuous monitoring. The shaft current transformer shall be located below the rotor and shall be connected to the shaft current monitoring relays in the local control panel. The relays shall provide suitable output for annunciation and trip to SCADA & Protection panels. Maximum level of shaft current permitted by manufacturer shall be furnished in technical particulars. On line monitoring system (generator & turbine) On Line Monitoring System for the generating unit is proposed for monitoring the health of the unit and detect the fault in incipient stage and to help diagnostic facilities to locate the cause of the fault. The Supplier shall offer a suitable composite system for the monitoring of the complete generating unit and also integrate necessary protection and safety measures
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for safe shut down of the unit in the event of a fault. The system shall inter alia include the following:
Vibration Monitoring and Control System; Air Gap Monitoring System; Temperature Monitoring System of the Unit;
Vibration Monitoring System a) General
The Supplier shall provide suitable pickup for vibration monitoring system for on-line monitoring as under: b) Relative Shaft Vibration (s) (2 for each bearing) 1 no. 4 nos. 1 no. (2 for each bearing)
Bearings absolute Vibration (s) Turbine Cover Vibration(s) -
Thrust Bearing Axial Vibration(s) Stator Core Vibrations Stator Bar Vibrations 3 nos.
Stator End Winding Vibrations Relative Shaft Vibration Monitoring
3 nos.
Non-contact Capacitive proximity probes shall be provided to dynamically monitor the motion of the generator / turbine shaft relative to the bearings. The probes shall be insensitive to electrical run-out, magnetic field and shaft mechanical surface imperfections. Two (2) proximity probes shall be provided to monitor radial shaft vibration at each guide bearing (installed at 90 to each other). One (1) proximity probe shall be provided at the thrust bearing to monitor axial shaft vibration. One reference pick-up sensor shall also be provided. c) Absolute Bearing and Turbine Cover Vibration Monitoring
Low-frequency accelerometers shall be provided to monitor the absolute vibration of the bearings and of the turbine cover.
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Two (2) accelerometers shall be installed to monitor absolute radial bearing vibration (x- and y- axes) at each guide bearing. One (1) accelerometer shall be installed on the turbine cover to monitor vertical (z-axis) vibration. d) Air gap monitoring
The Supplier shall provide 8 nos. Capacitive type Air Gap sensor, reliable in operation and immune to magnetic field, dust, oil and carbon particles. Sensors shall be provided to dynamically monitor the generator rotor - stator air gap under all operating conditions from generator standstill up to machine over-speed condition. Sensors must be stator-mounted only. Capacitive proximity probes shall be immune to residual shaft magnetism, shaft scratches, rust and other impurities on the rotor shaft surface. To ensure accurate air gap monitoring, a minimum of 8 air gap sensors (4 nos. each in two planes) shall be installed. The leads for the sensors shall be triaxial cables, which will be brought out and terminated in a wall-mounted enclosure. e) MW, MVAR, Field current, and Stator current monitoring
Interface equipment shall be supplied to capture the MW, MVAR, field current and stator current levels into the monitoring system from SCADA .This interface will provide information about the condition of machine operation at the moment data is taken. f) Guide and Thrust bearing temperature monitoring system
Interface equipment shall be supplied to capture data for bearing temperature into the monitoring system. Minimum one bearing oil temperature and one bearing babbit temperature shall be accommodated for each bearing. This interface will provide information about the condition of machine operation at the moment data is taken. g) Magnetic flux sensor
The magnetic flux between the generator rotor and stator shall be continuously monitored and correlated with the air-gap. One (1) magnetic flux sensor shall be provided per generator and shall be installed upon the stator core. The sensor must not adversely affect the operation of the hydro-generator. The sensor must meet the following minimum requirements: Operate in environment up to 1.5 Tesla
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h)
Be immune to deposits, vibration and temperature variation Minimum operating temperature range of 0 to 125C
Vibration monitoring instrumentation and display rack
A multi channel, multi tasking, on line programmable digital processing unit will be provided for system configuration for processing vibration data from vibration probes as above. i) A front-panel keypad and high visibility display which should permit the modification of all settings without disrupting on line monitoring. Front panel keypad shall be capable for easy, on-site programming of all key settings such as: ii) Alarm and trip levels and delay time Units of measurement Display brightness, etc
A communication interface for vibration signal data to be linked to SCADA and central station for on line system monitoring.
iii)
Front-panel connectors to allow raw vibration signals to be analyzed with portable equipment.
iv)
Capability to calculate and display the maximum resultant vibration vector (S max) for accurate alarming on peak vibration;
v) vi) vii) i)
LCD display that shows dynamic graphical and / or numerical output Suitable Power Supply User configurable display which should provide Time bar graph or numerical values Unit of measurement, scale Alarm thresholds.
Data acquisition unit monitoring hardware
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It shall be designed for the following : capture data Unit-wise; Accept inputs from air gap, vibration, and other sensors as mentioned above plus 10% spare; Provide synchronized measurement of air gap and all connected parameters under conditions of standstill to runaway speed; Permit continuous alarm monitoring capability with user-defined threshold per input; Accept analog signal from frequency sources, sensors and other voltage or process current signal sources; The Supplier shall provide a wall-mounted enclosure that meets the oil and dust tight NEMA 12 standard. Its dimensions shall be sized to accommodate the above data acquisition system with all cable leads. Protective conduits for sensor leads and the AC power line shall be rigidly fixed to the metallic housing. All sensor cable leads shall be labeled to show the associated sensors. A copper wire shall be connected between the ground lug on the system and the generator ground bus. The location of the wall-mounted enclosure shall not interfere with normal operation and maintenance of the generator. Interpretation of system readings The Supplier shall provide interpretation reports of initial system test readings and two subsequent test readings taken during the first year following installation. Partial discharge monitoring Partial Discharge Couplers shall be mounted on the stator windings to monitor the conditions of the stator insulation. Signals from these partial discharge couplers shall be transferred into a portable Monitoring System. Notwithstanding the above provisions, the Supplier may offer suitable configuration which will meet the intent of the above provisions; but offer a better or equivalent techno-economic solution.
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j)
On-line bearing oil moisture detector
Moisture detector as approved by the Purchaser shall be installed on unit control board with transducer/probe in bearing oil tank. It shall detect moisture content in bearing oil. Range of alarm setting shall be adjustable. Detector shall have alarm contacts for annunciation on unit control board and SCADA. The accuracy for measurement shall not be less than 10 PPM. k) Condition based diagnosis system
Requirement for the following Turbine On-line Monitoring System shall also be integrated in the System, in coordination with the Turbine Supplier: l) Relative shaft oscillation; Power [active / reactive]; Penstock pressure; Needle position; Rotational speed.
Other accessories
Generator termination cum gauge panel It shall serve the following purposes:Termination of all wiring and cables (under generator scope) other than for which specific cubicles are provided & wired from Generator barrel. This shall serve as interface for cabling to other equipment (in Purchasers scope). Installation of monitoring instruments for unit level display & monitoring. It shall have adequate capacity power and control cable terminal blocks which shall be arranged in a separate group(s). Terminal blocks of 660 volts grade shall preferably be of cage clamp type. 20 (twenty) percent extra terminal block shall be provided. Lugs for external connections (110%) shall also be provided. Six pressure tools for crimping shall be supplied.
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Cable glands or conduit entrances as approved shall be provided for external cables/wires. Suitable conduit entrances for generator cables/wires shall also be provided as required.
If considered necessary, separate junction box for R.T.D's termination shall be provided as per practice of manufacturer.
m)
The instruments shall be provided with legend plate
Instrumentation for field assembly and tests
The Supplier shall make arrangements for bringing all types of electrical and mechanical instruments required for field assembly of the rotor, stator and all testing equipment for testing and commissioning including field acceptance tests. These shall remain the Suppliers property after fulfillment of all field tests. Piping, tubing, valves General All piping systems within the generator housing to be installed for the coolers, bearings and brakes including ring headers for surface air coolers, valves and fittings shall be designed and furnished with the generator. All piping shall be clean inside and, where ending in open connections for other work, ends shall be capped for protection. Valves and other operating devices shall be easily accessible. Gauges and other indicating devices shall be located where they can be conveniently read from the floor or walkways. Bimetallic fittings shall be used for joining dissimilar material. Arrangement of piping, valves and joints shall be such that minimum disturbance of piping and disturbance with other services when generator is dismantled or parts are removed for inspection or repairs. Brakes and Jack System Piping Pressure piping for brakes shall be of steel of appropriate strength.
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Oil Pipes Any oil piping of black steel shall be flanged and properly pickled. After pickling, pipes shall be capped and sealed for protection until installation. Cooling Water Pipes Galvanized steel pipes of appropriate strength shall be used for supply and discharge pipes. Valves Valves shall have bronze seats and stems except those used in high pressure jacking system. Flange / Union At points where piping may be required to be disconnected, suitable flanges or unions shall be provided. Miscellaneous Piping, Tubing, Valves All piping and valves for the following functions shall be included in the scope of the generator supply: Cooling water inlet, outlet and drain for generator air coolers and Bearing oil coolers H.P. Lubrication oil supply to thrust bearing meant for lubrication during start-up and shut down of the unit. Oil fill and drain connections at the bearings. Piping for brakes and jacks. Tubing for connections between temperature sensing elements (vapour bulbs) to dial type thermometers, pressure gauge tubing. Any other essential piping, tubing, etc. for completion of job(s) under scope of supply of Generator.
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Cabling General The following control and auxiliary power cable and wiring shall be supplied but not limited to by the Supplier. All wiring within the generator housing for the current transformers, PMG/SSG connections, heaters, hygrostats, flow indicators, overspeed switch, fire detection, temperature relays, HP lube pump control, RTDs etc. for all alarm, control and metering circuits associated with the generator. DC busduct between the generator collector rings and the field breaker located at the excitation cubicles. These shall be of adequate cross section. Cables between the generator and termination cum gauge panel. All shielded cable connections from the temperature detectors to the terminal boxes. All 240 V ac wiring, lighting fixtures and convenience outlets within the generator housing. All conduit and cable raceway required for conductors and cables within the generator housing. Any other control / power cable required for completion of system
Control wiring Control wiring shall not be smaller than 1.5 mm. sq. stranded copper class B insulation, 660 Volts grade wires/cables. If wire is in contact with oil, solid core copper cable shall be used. Twenty (20%) percent wires of each type shall be supplied as spare. External wiring by the Purchaser shall also be not smaller than 1.5 mm. sq., stranded copper, 660 volts grade cable. Wire markers Each wire shall be marked or tagged at all terminals with black extruded tubing with deeply heat imprinted designations. The type of wire markers shall be subject to prior approval of Purchaser. Hanging tags from conductors shall not be accepted. Fifty percent (50%) additional wire markers shall be supplied as spare for external wiring.
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Conduits Conduits, within the generator housing shall be galvanized rigid steel with threaded ends. Fittings shall be galvanized with threaded hubs and gasketed covers to ensure that the system shall be water tight. Flexible conduit may be used, where necessary, for vibration or flexibility purposes and where not subject to mechanical damage. Flexible conduit shall be flexible, liquid-tight complete with manufacturer's standard fittings. Conduits shall be arranged, as far as practicable, to make removal unnecessary when the generator is dismantled. Galvanized cable raceways will be used as required. Nameplates and labels Language All nameplates and functional labels shall be in English. Main nameplate A permanent metal nameplate conforming to NEMA standards shall be provided for each major and auxiliary item of the generator in a readily visible location. This shall indicate the designed full load ratings, serial no., type no. date of manufacture and other identification deemed necessary. Instrument transformer identification A separate nameplate shall be furnished for attachment to the housing, which shows current and potential transformer locations, ratios, accuracy class, terminal marking, and phase arrangements. Component nameplates Nameplates of approved sizes and wordings shall be provided on each cubicle identifying each compartment, control device, component and piece of equipment. The nameplates shall be engraved on permanent material and firmly attached with screws. In addition to identification, the nameplates shall give rating of equipment as per relevant IEEE standards. Instruction plates with instructions and diagrams engraved on permanent material shall be attached to equipment in easily accessible location, where required.
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Painting All unfinished surfaces of the generator, auxiliaries and generator housing, and those surfaces which will be embedded in concrete, shall be thoroughly cleaned and painted with an approved priming paint. Any surface which may be subject to corrosion, and will not be accessible for painting after generator assembly, shall be properly cleaned and painted in accordance with the provisions of General technical specifications under Section-2 or as approved by the Purchaser. Flaws in the exterior surface shall be filled with compound or filled by electric welding and ground smooth, before being given the prime coat. Parts to be embedded in concrete and aluminum hand railing and stairs shall be left unpainted. All finished surfaces shall be protected from corrosion by a readily removable, rust preventive compound. Final painting shall be done as per approved colour scheme by the Purchaser. All doors and panels shall be finished with high gloss synthetic enamel paint after surface treatment in shade approved by the Purchaser. Handling provisions Provisions shall be made for readily handling all parts during assembly or disassembly of a generator. Adequate provisions shall be made for attaching lifting devices, slings, eyebolts, and other apparatus. Attachments and lifting devices with pins shall be properly coordinated with the crane hooks and lifting beam. The Supplier shall design the handling device(s) in an optimum manner and submit the lifting arrangement drawing for stator and rotor, field poles, thrust collars, upper bracket, lower bracket and other major assemblies. Generator fire protection system Water spray type fire protection system shall be used for generator, the main components of which shall be as under: Smoke detection system Circular mainfolds with discharge nozzles at top and bottom of the generator connected to water system. Control valve with an emergency mechanical control counterweight. Water Strainers
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Associated piping, valves, instruments with accessories etc. Control Panel housing deluge valve assembly, controls for manual and auto release of water, instruments for monitoring.
Console for monitoring and control of fire detection system. This will be interfaced to meet SCADA requirements.
The water spray type fire protection system shall be complete in all respects. System design General The Automatic water spray extinguishing system shall constitute an effective means of protecting generators against fire. The System shall consist of : a detection system (by thermostatic/smoke detectors/smoke aspiration system) a spray water extinguishing system.
The automatically operated water spray system, complete with the water distribution mains and two ring headers, one at the top of the stator overhang and other at the bottom within the generator housing, spray nozzles, thermostatic temperature detectors and control equipment etc. as required for extinguishing the fire within the generator shall be provided. The distribution system and the spray nozzles shall be designed for effective fog particle formation and dispersion over the surface of the generator. The fire extinguishing system shall be designed for the required discharge rate at the minimum nozzle pressure. Smoke detection system The system shall be activated in one of three ways: action of temperature detectors/smoke detectors / aspiration system located in the generator enclosure action of the unit differential protection manually (in case of emergency) : control wiring for manual points is included under scope of Supplier.
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Extinguishing system According to the area to be protected, a few circular outlet manifolds enable water to be sprayed all over the active parts of the generator : one manifold at the top and one at the bottom of the machine shall direct the water onto the ends of the stator and the end windings. If needed, a third supply manifold located at the top shall direct the spray into the airgap, the rotor end coils and the interpolar zones, and a fourth supply manifold, also located at the top, shall spray water via the spider into the active part of the machine (rotor coils, stator winding and magnetic core) along the same path as that taken by the cooling air. In general, the rate of application shall range from 8 to 12 l/min/m2 (10.2 l/min/m2 according to the NFPA 15 standard), and the application shall last about 20 minutes. The equipment shall comprise of : Control cabinet comprising deluge valve, isolating valves, pressure monitor. Suitable processor for receiving information from detectors and other devices and controlling the deluge valve operation and activating protection in protection panel and SCADA. The thermostatic temperature detectors / smoke detection / smoke aspiration system shall be located at strategic points inside the generator housing. The water sprinkler system shall be operative on receiving signal and alarm on operation of either the detectors or the differential relays of the generator, spraying water by means of nozzles suitably located inside the generator housing. Nozzles shall be specially designed having three pair of holes arranged in such a manner that jet of water flowing out of one hole strikes against the jet of water emerging out of another hole at right angle such that the collision of two high velocity jets result in very high fine fog formation required for extinguishing the fire. For cleaning the water impurities, foreign particles etc., suitable strainer shall be provided. The strainer shall be made of stainless steel and shall be installed in the pipeline itself. Arrangement for cleaning the strainer shall be provided. A drain valve should be provided in the pipeline to drain the water.
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Push button in a breakable glass housing for manual operation of the water sprinkler system shall be provided on the control panel. A suitable control panel with facility for monitoring, testing and annunciation etc. shall be provided. Spare potential free contacts for control & annunciation at Digital Control System shall be provided. There shall also be suitable arrangement for audible alarm at various locations of the different floors in the power house. The system shall comply with provisioning of NFPA 15 or as applicable. The Supplier shall give the drying procedure of the unit after triggering of the water sprinkler system. 3.4.10 Instrumentation All local analogue signals shall be wired to the generator instrumentation panel. The instrumentation as list under Table 1 to be provided:
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LIST OF INSTRUMENTS TO BE FURNISHED BY THE SUPPLIER
Sl. No. 1 (a) (b) (c) (d) (e) (f) (g) (h) (i) (j) (k)
Type of Instrument
Abbre.
Purpose
Qty
Sensor/ Transducer/ transmitter Embedded in stator Winding between bars Embedded in stator core Embedded in stator teeth Each air cooler outlet air circuit Each air cooler inlet air circuit Embedded in all the pads Embedded in all the pads Embedded in all the pads ln combined oil tank for the thrust & lower guide bearing In upper bearing oil tank ln inlet pipe line
Indicating/ Recording instrument SCADA SCADA SCADA SCADA SCADA SCADA SCADA SCADA SCADA SCADA SCADA
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Resistance Temperature Detectors Resistance Temperature Detectors Resistance Temperature Detectors Resistance Temperature Detectors Resistance Temperature Detectors Resistance Temperature Detectors Resistance Temperature Detectors Resistance Temperature Detectors Resistance Temperature Detectors Resistance Temperature Detectors Resistance Temperature Detectors
PT100RTD PT100RTD PT100RTD PT100RTD PT100RTD PT100RTD PT100RTD PT100RTD PT100RTD PT100RTD PT100RTD
Stator Winding Temp. Stator Core Temp Stator teeth Temp. Air Coolers cooled air Temp. Air Coolers hot air Temp. Thrust Bearing pad temperature Upper guide Bearing temp. Lower guide bearing temp. Thrust Bearing oil temp. Upper bearing oil temp. Cooling water Inlet temp. to air cooler
12 Nos 12 Nos 12 Nos 2 Nos 1 No 1 No
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Sl. No. (l) (m)
Type of Instrument
Abbre.
Purpose
Qty
Sensor/ Transducer/ transmitter In outlet pipe line from each cooler In Pipeline
Indicating/ Recording instrument SCADA SCADA
Resistance Temperature Detectors Resistance Temperature Detectors Resistance Temperature Detectors Dial Type Temperature Detector Dial Type Temperature Detector Dial Type Temperature Detector Dial Type Temperature Detector Dial Type Temperature Detector Dial Type Temperature Detector Dial Type Temperature Detector Dial Type Temperature Detector
PT100RTD PT100RTD PT100RTD DTT DTT DTT DTT DTT DTT DTT DTT
Cooling water outlet temp. from air cooler Temp. Of Cooling Water Inlet & Outlet from Thrust-cumlower Guide Brg. Cooler Temp. Of Cooling Water Inlet & Outlet from upper guide Brg. Cooler Thrust Bearing Pad temp. Upper Bearing Pad temp. Lower Bearing pad temp. Thrust cum lower guide Bearing oil temp. Upper Bearing oil temp. Air Inlet temp to coolers Air Outlet temp. from coolers Water Inlet & Outlet from upper G.B. cooler
2 Nos
(n)
2 Nos
In Pipeline
SCADA
2 (a) (b) (c) (d) (e) (f) (g) (h)
4 Nos 2 Nos 2 Nos 1 No 1 No
Embedded in pads Embedded in pads Embedded in pads ln oil tank ln oil tank Alternate air cooler inlet side Alternate air cooler outlet side
Unit Gauge Panel Unit Gauge Panel Unit Gauge Panel Unit Gauge Panel Unit Gauge Panel Unit Guage Panel Unit Guage Panel Unit Guage Panel
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2 Nos
In pipe line
Sl. No. (i) (j)
Type of Instrument
Abbre.
Purpose
Qty
Sensor/ Transducer/ transmitter In pipe line In pipe line
Indicating/ Recording instrument Unit Guage Panel Unit Guage Panel
Dial Type Temperature Detector Dial Type Temperature Detector Temperature Indicator Pressure Gauge Pressure Gauge Pressure Gauge
DTT DTT
Water Inlet & Outlet temp.from L.G.B. cooler Water Inlet & Outlet from Thrust cum lower Guide Bearing Coolers. Rotor temperature Cooling water pressure at generator inlet & Outlet Cooling water pressure at upper bearing Inlet & Outlet Cooling water pressure at Thrust Bearing cum lower guide bearing Cooling water Inlet / Outlet Inlet water for fire protection system H. P. Oil System Compressed air supply for brakes Thrust bearing oil level Upper bearing oil level
2 Nos 2 Nos.
3 4 (a) (b) (c)
T.I PG PG PG
1 No 2 Nos 2 Nos 2 Nos
Insulated brushes across slip rings Local Local Local
Digital excitation regulator Indication Indication Indication
(d) (e) (f) 5 (a) (b)
Pressure Gauge Pressure Gauge Pressure Gauge Oil level indicator and controller Oil level indicator and controller
PG PG PG LIC LIC
1 No 1 No 1 No 1 No 1 No
Pipe line Local Local Combined thrust & lower guide bearing Oil tank Upper bearing Oil tank
Indication Indication Indication Unit Gauge Panel Unit Gauge Panel

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Sl. No. 6 (a) (b) 7.
Type of Instrument
Abbre.
Purpose
Qty
Sensor/ Transducer/ transmitter Combined thrust & lower guide bearing Oil tank Upper bearing Oil tank Cooling water inlet & outlet piping
Indicating/ Recording instrument Unit Gauge Panel Unit Gauge Panel Unit Gauge Panel
Oil level sight gauge Oil level sight gauge Water flow meter indicator with(4-20mA output) Moisture detector Moisture detector Vibration Monitor Vibration Monitor
LG LG WFM
Thrust bearing oil level Upper bearing oil level Water flow inlet / outlet Generator air coolers, thrust cum lower bearing & upper bearing oil coolers Thrust cum lower Bearing Oil tank moisture monitoring Upper Bearing Oil tank moisture monitoring Upper and lower generator bearing Shaft Vibrations
2 No 1 No 1 No each
8 (a) (b) 9 (a) (b)
MD MD VM VM
1 No 1 No 2 each 4 nos (2 on each bearing) 1 no 1 no As per T.S As per T.S
Bearing tank Bearing Tank Displacement pickup Non- Contact pickup
Unit Gauge Panel Unit Gauge Panel Unit Gauge Panel Unit Gauge Panel
10. 11 12 13 14
Shaft Current Monitor Creep Detector Limit switches Pickup transducer Partial discharge coupler
SCM CD LS
Shaft Current Detection Creep detection Brake release & rotor jacking On line air gap monitoring On line partial discharge detector
Shaft Shaft Each Brake shoe Air gap stator terminals
Unit Gauge Panel Unit Gauge Panel Unit Gauge Panel As per T.S As per T.S
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3.4.11 Interface with Other Equipment or Systems Generator phase and neutral terminations shall be connected to Isolated Phase Bus via flexible connectors. After the formation of the neutral, the connection to the grounding transformer shall be accomplished in the neutral cubicle. All the analogue and digital signal terminations located in the instrumentation panel inside the generator barrel shall be interfaced with respective annunciation, control and protection system of the powerhouse. 3.5 Control and monitoring
The generator and associated accessories/equipment shall be controlled and monitored at three levels: vii) By respective local control cubicles, viii) By respective Unit Control Boards, ix) By Control and monitoring (SCADA) system through Central Control Centre. The details of control and monitoring requirement are defined under Control and Monitoring (SCADA) System and Protection System. The Contractor shall make provision of contacts and/or ports in local control cubicles for interfacing with SCADA system for control and monitoring. Local control shall be performed in an independent and stand alone manner, and all information (faults, alarms, measurements, status) necessary for such control shall be displayed locally. If the system consists of redundant subsystems, the priority of operation of such subsystems shall be selectable either from SCADA system or locally. 3.6 Quality control and assurance.
The manufacturer shall supply the equipments of best quality. The manufacturer shall maintain quality control during manufacture of equipment as per the approved quality assurance plans. 3.7 Drawings, Documents and Design Calculations
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3.7.1
Drawings
The contractor shall submit all the drawings and documents as per Section 2.12 Reference drawings and documents of General Technical Specification (GTS). These drawing and documents shall include at least the following:3.7.2 Information to be supplied alongwith the bid
At least the information listed hereunder shall be given alongwith the bid. The Supplier may support advantages in his design of the offered Equipment or special technical features of his offer by additional documents / descriptions. x) Description of proposed construction and procedure for erection at site for the generator stator and rotor keeping in view the transport limitations. xi) Description of applicable stator winding insulation (material, insulation method etc.) xii) Cross section through a slot with winding xiii) Description of rotor pole fitting including type of rotor rim construction xiv) Description of proposed bearing insulation to prevent shaft currents xv) Description of bearing seal system including measures to prevent discharge of oil from bearing xvi) Description of high pressure lubrication system for the thrust bearing xvii) xviii) Description and schematic diagram of the combined brake and jack system Description of the brake dust collection system
xix) Description of the carbon dust collection system xx) Description of vibration monitoring, air gap monitoring and partial discharge measurement system xxi) Proposed arrangement / scheme for draining the fire fighting water from the generator pit xxii) xxiii) Dimensional drawing of the generator with major dimensions Diagrams with electrical characteristics
(a) no load characteristic (b) short circuit curve

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(c) capability curves (power chart) for rated output at nominal power factor and 0.9 / 1.0 / 1.1 x nominal voltage and at 120% rated load. (d) load curves (V-curves) (e) Negative sequence withstand characteristic (f) Calculated no-load harmonics in the voltage wave form
(g) Supporting documents for the guaranteed generator output and efficiencies (references) xxiv) Reference list of comparable generators already supplied and comprising of
at least following information: (a) (b) (c) (d) xxv) rating (MVA) speed (pair of poles) year of delivery name of station and country Complete details of tools included in the scope
Any documentation ( as per list given above), which are not submitted with the Bid shall be submitted alongwith other documentation listed below after award of the Contract. 3.7.3 Information to be supplied after award of contract
The following drawings and data shall be submitted by the Supplier :General Arrangement & Layout Drawings (a) The general arrangement and overall dimensions of the generator showing position of main and neutral leads, bearing arrangement etc. in plan and sections; (b) (c) Dimensional drawing of the generator with major dimensions; Drawings showing assemblies of Thrust and lower guide bearing, and upper guide bearing; (d) Cross section through a slot with winding;
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(e) (f) (g) (h)
Drawings showing arrangement of air coolers, air ducts etc.; Outline of brake and jack system, and its schematic diagram; Drawings showing handling and lifting arrangement for stator/rotor; Proposed arrangement/scheme for draining the fire fighting water from the generator pit;
(i) (j) (k) (l) (m) (n) (o) (p) (q) (r) (s) (t) (u) (v)
Longitudinal and transverse sections of the Generator; Stator winding diagram; Generator cooling diagram; Rating plate; Erection procedure; List of air, water and oil consumers; Pole handling; Slip ring assembly; Upper and lower bracket machining drawings; Pole locking arrangements; Generator Interpolar Connexion Assembly. Generator top cover assembly drawings; Generator lifting jack assembly drawings; Transport sketches for major components [like stator frame, rotor spider, upper and lower brackets, etc.
(w)
Number of air/water coolers for stator and all bearings for normal working pressure drop through coolers;
Electrical Drawings (a) Schematic, drawings of electrical controls for the unit and all associated auxiliaries along with write up; (b) Schematic wiring and termination diagram for all electrical instruments and their connections;
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(c)
Elementary and wiring diagram for all electrical connections, including on-line monitoring devices;
(d) (e) (f)
Low voltage wiring diagram Characteristic Curves, Design Data and Calculations Design calculation giving basis for selection of major parameters of generator such as generation voltage, p.f., short circuit ratio, Inertia constant, moment of inertia, reactances, stator/rotor design parameters, air gap dimensions, etc.;
(g) (h) (i) (j)
(Generator capability curves Generator open circuit characteristic curves (OCC) Generator short circuit characteristic curves (SCC) capability curves (power chart) for rated output at nominal power factor and 0.9/1.0 / 1.1 x nominal voltage;
(k) (l) (m) (n) (o) (p) (q) (r) (s)
load curves (V-curves). Calculated no-load harmonics in the voltage wave form & telephonic harmonic factor; Stress calculation on shaft and rotor; Calculations of the forces on the civil foundations; Pole calculations; Rotor rim and Spider calculations; Stator frame calculations; Calculation of the deceleration and braking times; Combined thrust & lower guide bearing calculations.
Piping Drawings (a) (b) Single line diagram for generator air, water and oil piping 3D-piping layouts for air, water and Oil piping, with plan and sectional views to check for interferences with other equipments; (c) (d) (e) Generator cooler assembly and piping drawings; Upper bearing oil cooler assembly and piping drawings; Combined thrust & lower guide bearing oil cooler assembly and piping drawings.
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Quality Assurance Plan (a) Detailed quality assurance Plan incorporating specifications of the materials and inspection & testing of raw materials, process products, and finished components, equipments sub-assemblies, etc. (b) (c) (d) Shop tests and inspection procedure for the above components. Manuals & Descriptive Documents Descriptive literature and brochures on the following: i) ii) iii) iv) v) procedure for erection at site for the generator stator and rotor; applicable stator winding insulation (material, insulation method etc.); rotor pole fitting including type of rotor rim construction; proposed bearing insulation to prevent shaft currents; bearing seal system including measures to prevent discharge of oil from bearing; vi) vii) viii) ix) x) xi) xii) xiii) high pressure lubrication system for the thrust bearing; combined braking and jacking system [incl. schematic diagram]; brake dust collection system; carbon dust collection system; partial discharge and air gap measurement system; vibration monitoring system; process for shaft aligning at site; process for balancing of rotating parts at site. Supporting documents for the guaranteed generator output and efficiencies (references); Complete details of tools; Painting specifications; Erection manual for generator and its auxiliaries; & M manuals for generator and its auxiliaries;
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Field test procedure for generator and auxiliaries along with write up; Field test procedure for Efficiency Test [on one Unit]; Storage instruction for generator and other components; Mechanical tolerances permissible in the assembly and erection of generator.
Any drawings, data, calculations as per provisions of Conditions of Contract, and other drawings specifically required by the Purchaser during detailed engineering for information as per reasonable demands. For the Generator Fire Protection System the Supplier shall furnish six copies of assembly and detailed drawings and data but not limited to the following: Detailed P & I Diagram of the system Details of piping layout and connections showing location, size, flange dimensions, bolt holes etc. Calculation of water requirement and pressure drop in the system. Characteristics curves for the nozzles. Standard test plan Quality Assurance Plan. Instruction manual for installation, operation and maintenance of all the equipment. Detailed catalogues of the equipments offered for approval of Purchaser.
After approval of the Purchaser, six (6) sets of final drawings along with soft copy on CD, will be submitted to the Purchaser. Training of purchaser's personnel The Supplier shall provide at the manufacturers works, training facilities to Four (4) Engineers of Purchaser/Consultant for a period of 8 man weeks [including training as per clause 9.16.2 below], as per provisions of clause 3.08.13 of Condition of Contract (Section3). The training shall cover various aspects of design, manufacture, test, operation and maintenance.
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In addition to the training provisions at manufacturers works, the Supplier shall also hold training sessions at site to familiarize the Purchaser's Personnel with all aspects of operation and maintenance of the plant before the beginning of dry tests on site. This training shall cover following aspects: Various construction features used in Generator design; Procedures for identification and rectification of faults i.e. rotor earth fault, stator earth fault etc.; Preventive maintenance programme; Unit alignment balancing procedure; On-line Air gap and Vibration monitoring system.
The technical documentation used in the training sessions shall include the Supplier's draft operation and maintenance manuals and test procedure descriptions approved by the Engineer. 3.7.4 Design calculation
The Contractor shall submit the design calculation for review / acceptance of the following: Electrical calculations and characteristics including magnetic circuit, Structural analysis of different generator parts i.e. stator frame, upper and lower brackets, rotor spider, rotoer poles, combined thrust and guide bearing, Foundation loads during various operating conditions including fault conditions, running conditions & seismic conditions, Runaway speed, Critical speeds, Strength of all rotating parts to withstand run away speed and vibration, Number of coolers for stator and all bearings, the normal working pressure and pressure drop through the coolers, GD calculations, Coupling bolts size, Stress calculation on shaft and rotor,
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Calculation to substantiate capability of the generator to withstand the additional stresses resulting from abnormal operation of unit
Size of the thrust bearing, effective surface area / specific load on thrust bearing with respect to total load (static /dynamic) etc. under worst conditions / runaway condition,
Maximum stresses / loads during normal operation, runaway-speed conditions, Three phase and three phase short-circuit conditions or single phase earth fault at maximum output for which generators are capable of, 180 deg and 120 deg out-ofphase synchronization,
Magnetic unbalance at rated speed with 50% of the poles short circuited and brake application etc,
Guide bearing coolers, stator air coolers, temperature rise calculations, Ventilation of generator, Size and no. of brake / jack assemblies. Deceleration and braking time Calculation of water requirement, normal pressure & Pressure drop for water sprinkler type fire protection system
Design calculations giving basis for selection of various parameters of generator i.e. generation voltage p.f., short circuit ratio, inertia constant, reactances etc
The Contractor shall also provide other calculations as required by the Owner for his approval of the Contractors design. 3.8 Spare Parts
Recommended spare parts shall be supplied in accordance to clause 2.36 Spare Parts and tools of General Technical Requirements. Specified spare parts to be supplied under this section are as follows: Sl no 1 2 3 Description Quantity
Set (top & bottom bars) of stator bars complete with winding 1 Set materials and wedges (30% of one machine). Stator winding RTD 1 Set Field coils 4 nos
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Sl no 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
Description Complete rotor pole assembly Pole keys
Thrust bearing springs.( One set of springs used in one 1 Set machine) Collector assembly 1 Set Lower and upper Guide bearing pads Guide bearing cooling coils Collector brushes Collector brush holders Thrust bearing rotating ring. Thrust bearing cooling coils Thrust bearing stationary shoes. Oil seal for thrust and guide bearing 1 Set 1 Set 6 Sets 1 Set 1 Set 2 Set 1 Set 1 Set
Valve and coupling of each type for surface air cooler and air 1 Set oil and water piping. Surface air coolers 2 nos Brakes and jack assembly complete with liner / Brake caliper 2 sets unit Brake lining / brake caliper shoes 2 Sets Dial thermometer of each type Thermostat each type Lamps and fuses. 1 no 1 no 3 Sets
25 Packing
Miscellaneous hardware. 1 piece of each instrument , 1 no pressure gauges, switches, flow meters, level switches, etc. Neoprene rubber >O= seals, rubber chords of all sizes used 3 Sets and gaskets for thrust and guide bearing, top & bottom enclosure seals, door seals, stator, oil injection pumps, oil, water, air piping etc. Motor and fan for brake dust collector equipment 1 no each
All spare parts subject to damage or deterioration by moisture shall be packed in moisture proof containers, or adequately protected by wrapping in moisture proof material; and all spare parts shall be properly identified with weather resistant tags. All spare parts shall be of
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the same materials and workmanship, as the corresponding original parts, and shall be interchangeable therewith. They shall be shipped with the first unit. Spares used in erection Spares used during erection as replacement due to bad workmanship, defect or any other reasons as per decision of generator erectors and/or shortages shall be replaced without any extra charge to the Purchaser. These shall be supplied within agreed time schedule by the Purchaser so that there is no effect on commissioning of any unit. Spare parts for generator fire protection system Following spares shall be supplied by the Supplier Generator Fire Protection System: Deluge Valves Spray nozzle Temperature detector heat Smoke Detectors Pressure Switch (if applicable) : : : : : 1 no. 5 nos. 4 nos. 4 nos. 1 nos.
All spares shall be interchangeable with corresponding part of any unit. 3.9 Special tools
The Contractor shall propose the list of special tools including their make and detailed specification as recommended by manufacturer(s), to be accepted by the Owner. The proposed list of special tools must include the following in addition to tools recommended by manufacturer(s): Stator winding bar pusher. Spider lifting device. Rotor lifting device. Pole lifting device. Lower bracket lifting device. Shaft lifting device.
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Rotor erection pedestal. Generator ground connector. Set of tools with wall panel. Tools and equipment for installation of generator. Portable High pressure rotor jacking pump. Air cooler blanking plate. Temperature logger. Stator piling tools. Stator winding tools. Rim piling tools. Vibration and balancing equipment. Partial discharge analyzer, including laptop and printer. Stator flange fixture. Stator shipping braces. Rotating ring removal device. Set of slings and shackles.
Maintenance management and inventory control system The Supplier shall supply complete database for part list of the equipment, piping, instruments, spares, tools etc. to facilitate control of inventory. Any special software for the purpose used [other than MS-Office Excel] shall be supplied, along with the database. This software shall be loaded on the Server, and shall have the option to be used by multiple users on the LAN. This software shall be similar for all Equipment. Consumables The items of consumables included in the Scope shall cover but not be limited to the following. Oil for first filling of the generator (with 10% extra)
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All consumables for joints of stator bars and field pole connections including 10% extra. Quantity of oil shall be sufficient for flushing of piping, tanks.
3.10
Testing
3.10.1 Assembly The following shall be completely assembled, aligned and fitted in manufacturers works and properly match- marked to ensure correct reassembly and alignment at site Stator frame Upper bracket arms Lower bracket arms Rotor spider arms Generator guide bearing housing Besides above trail assembly, various assembly, equipment, sub-assembly shall be inspected and tested as per approved QAP. The generator assemblies/components shall be subjected at the factory, to the tests as per QAP keeping provision of the Contract & codes in view . The tests shall be witnessed, unless waived in writing, by the Purchaser, and shall be conducted in accordance with the applicable IS, ANSI, IEC/VDE/DIN, IEEE, and NEMA standards. The Supplier shall notify the Purchaser at least thirty days in advance as to when the assemblies/components will be ready for test. The waiver of any test, or the witnessing thereof, shall not release the generator Supplier of the responsibility to meet fully the requirements of the specifications. The test shall interalia include any other test(s) as agreed between the Purchaser and Supplier to ensure quality and to meet performance as per provision of these specification or as provided in applicable IS/ IEEE / Standard Codes. The test shall also include any additional test as per manufacturing practice of the Supplier/manufacturer. Reports The Supplier shall furnish four copies of reports of factory tests. The reports shall include test results, curves, sample calculation and formulae used in determining the
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results of the tests. The factory tests shall include but are not restricted to, those listed in the following sub-paragraphs. 3.10.2 Test on Stator and Rotor Tests on generator components shall be carried out as per section 6 of document Quality assurance plan. The contractor shall furnish a list of such subassemblies and tests proposed for quality checks. 3.10.3 Material Tests Material tests for important components such as core punching, shaft, bearing , upper and lower brackets, brake liner , Thrust runner disc and other important components etc shall be carried out and submitted to the owner. 3.10.4 Defects and corrections Any leakage, distortion or other defects developed during or after the tests shall be corrected and retested. A record shall be made of shop measurements of all critical and important dimensions, diameters, concentricity, run-out, clearances etc of generator moving and stationary parts which may affect the field erection and alignment or normal operation of turbine. 3.10.5 Tests on fire protection system General All tests shall be conducted according to the relevant standards, approved test plan as well as according to the established test procedures of the Supplier. Factory tests Hydraulic test on valves, deluge valve & pipes. Insulation resistance measurements of all electrical coils and contacts, etc. Dielectric test on controls and wiring as per relevant IEC. Other tests as per approved test plan.
Field tests
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The Supplier shall conduct following tests as per relevant specifications. These tests shall be witnessed by the Purchaser, and/or by his authorised agency: Operational and functional tests, without release of water bank to determine whether or not the requirements of these specifications have been fulfilled, and to determine whether or not systems are functioning as intended. Pressure testing of pipelines after assembly Insulation resistance measurements and dielectric tests on all electrical coils and contactors. 3.11 Installation and commissioning
General The contractor shall furnish all labour, tools, supplies, slings and supports and all other provisions and material necessary to assemble, erect, install, test and commission the equipment in a thorough workmanlike manner following the best practices. The equipment and all their components shall be placed with great care and shall be aligned to provide an installation consistent with close tolerances used in the erection of modern equipment. The proper elevation and centrelines to which equipment is to be set shall be established by the contractor. All necessary material and labour for performing all the site tests shall be provided by the contractor. All test equipment and instruments shall be supplied by the contractor. Tests to be carried out during Installation, commissioning and performance are listed in QAP documnent .
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4. 4.1
STATIC EXCITATION SYSTEM Scope of Work
Scope of work under this section covers the provision of labour, tools, plants, materials and performance of work necessary for the design, manufacture, quality assurance, quality control, shop assembly, shop testing, delivery at site, site storage and preservation, installation, commissioning, performance testing, acceptance testing, training of Owners personnel, handing over to Owner and guarantee for one year of static excitation system as per the specifications hereunder, each complete with all auxiliaries, accessories, spare parts and warranting a trouble free safe operation of the installation. The scope of work shall be a comprehensive functional system complete in every respect including but not be limited to following: Static excitation system Three (3) sets of static excitation equipment consisting of: Silicon controlled solid state rectifiers (Thyristors): comprising of parallel, redundant, 3-phase, fully-controlled thyristor bridges, with forced cooling, complete with Gate Pulse Amplifier panel to give positive and negative DC output voltage adjustment. Continuous full load field current rating (n-1 operation) with one bridge out of service shall be possible for 100% redundancy. Automatic voltage regulator (D-AVR): 100% redundant Microprocessor-based digital type which receives generator voltage feedback from 110 volt 3 phase secondary voltage of three (3) generator PTs and 5 amp secondary current of three (3) generator CTs. The regulator shall also be provided with Power system stabilizer and line drop compensation unit. DC field suppression: One (1) dc field breaker, connected in DC output of Thyristor bridges, electrically-operated with two trip and one closing coils. Non linear field discharge resistor of suitable rating and over voltage protection unit. Manual override for tripping the field breaker shall also be provided for isolating the field under emergency conditions. AC and DC field flashing system, including rectifier, transformer, current limiting resistor and DC operated Field flashing contactor.
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Generator terminal shorting breakers and fixed excitation equipment for dynamic braking system.
Control and metering equipment. DC bus duct connecting the rotor to DC field breaker with termination arrangement at both ends.
All hardware and software required to make program changes in the system including a mobile work station.
Three (3) sets of dry type excitation transformers complete with all necessary items such as bushings, CTs, instrumentation, Embedded winding RTDs , fittings , enclosure and external cooling fans ( if required)
Three (3) sets of interconnecting cabling, terminations etc. between various parts of the equipment/components.
Provision of necessary contacts and/or ports for integration with plant SCADA system.
One (1) set of spare parts in accordance to clause Spare Parts of this section. One (1) set of tools and instruments in accordance to clause Tools and Instruments of this section.
Any other item(s) not mentioned specifically but necessary for the satisfactory completion of scope of work defined above, as per accepted standard(s) / best international practices. The Excitation system shall be completely assembled and tested at the manufacturers plant and equipped with but not limited to the following accessories: Static Reference set-point and voltage adjuster.(Auto Channel) Static Reference set-point and voltage adjuster.(Manual Channel) Follow up unit for manual channel for bumpless changeover from auto to manual channel. Maximum field current limiter with adjustable time. Line drop compensator. Volts per hertz limiter. Minimum field current limiter.
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Power System Stabilizer. Rotor earth fault relay Detector AC and DC field flashing Regulated DC power supplies for gating and control derived from 220 VDC station batteries.
Necessary exciter sequences software for starting, stopping, dynamic braking, protection , annunciation and alarms.
4.2 4.2.1
Field voltmeter. Field ammeter. Field volts transducer for remote indication Field current transducer for remote indication Field metering shunt. Generator terminal voltmeter, 0-15 kV. Balance indicator for Auto / manual channel balance. Rating and design requirements Ratings
Excitation transformer Ratings, characteristics, etc. shall comply with the requirements of the IEC 60726. Ratings of the excitation transformers shall be sufficient to meet the duties specified herein. Primary rated voltage Secondary rated voltage Type / Class of insulation Type of cooling Conforming standards Transformer Current Transformers IEC : 60726 IEC 60044-1 To match with the generation voltage - 11 kV Voltage as per excitation requirement not more than 600 V Epoxy cast resin, dry type, / F AN - Indoor type
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Impulse withstand voltage for HV Location HV Terminations LV Termination Temperature monitor Detectors Monitor Temperature Rise Percentage Impedance Excitation system
95 kV Adjacent to thyristor cubicle. Isolated phase busduct, tapped from main busduct between generator and transformer. Non-segregated bus duct to thyristor cubicles
Resistance temperature detector (PT-100) embedded one in each L.V. winding Temperature scanner with annunciation & trip signal to SCADA at preset values Not to exceed 100C, above 30C ambient Not less than 5%
The continuous capacity of the excitation system shall be at least 15% in excess of the actual capacity (in amperes) required to supply the field excitation current of the generator when the latter is operating at maximum continuous output, rated power factor and rated voltage. The excitation system shall be capable of supplying full load collector-ring voltage and corresponding field current down to 70% rated generator terminal voltage. The excitation system shall be able to supply 200% of the rated excitation current for 60 seconds without damage. The nominal exciter response shall be not less than 2. The positive and negative ceiling voltage shall be minimum 200% and 160% respectively of rated excitation voltage at rated output. At maximum kVA, terminal voltage, power factor and speed, the excitation system shall be capable of changing from rated field voltage to 90 percent of ceiling voltage within 25 ms for a sustained drop in generator terminal voltage of 5 percent. The rectifier shall be rated for the following duties: Continuous operation at its maximum rating, Three phase fault adjacent to HV terminals of the generator, Short circuit on the high voltage side of the transformer with duration of 2 sec.
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4.2.2 ANSI
Excitation System Specific Codes and Standards
C37.18 C37.20 C37.20.2 C37.90.1 C37.90A CSA C9 C22.2no 47 C13 IEEE C57.12.01 C57.12.55 C57.12.91 C57.96 421-1 421-2 421-3 421-5 IEC 60439-1 60034-16-1 60726 60129, 62271-102, 60298, 60694
Enclosed Field Discharge Circuit Breakers for Rotating Electric Machinery Metal-Enclosed Low-Voltage Power Circuit Breaker Switchgear Standard for Metal Clad Switchgear Surge Withstand Capability (SWC) Tests for Relays and Relay Systems Associated with Electric Power Apparatus Surge Withstand Tests on Protective Relay and Relay Systems Dry Type Transformers Air-Cooled Transformers (Dry type) Instrument Transformers
General Requirements for Dry-Type Distribution and Power Transformers Dry Type Transformer Used in Unit Installations, Including Unit Sub-stations Conformance Standard Standard Test Code for Dry Type Distribution and Power Transformers Guide for Loading Dry Type Distribution and Power Transformers Standard Definitions for Excitation Systems for Synchronous Machines Guide for Identification, Testing and Evaluation of the Dynamic Performance for Excitation Control Systems. Standard for High-Potential Test Requirements for Excitation Systems for Synchronous Machines Excitation System Models for PS Studies
Low-voltage Switchgear and Control gear Assemblies. Part 1: Type-Tested and Partially Type-Tested Assemblies Excitation System for Synchronous Machines Dry type power transformers Dynamic braking Switch
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4.3 4.3.1
Design considerations Excitation system
The offered solution has a redundant AVR. Each AVR has in one PLC an auto channel and a normal channel. It shall feature a very sensitive, quick acting, fine regulation and control of the generator voltage and reactive power respectively. Second channel will have constant current regulator. The system shall be of reliable design with an adequate record of satisfactorily working reference plants. Digital excitation system shall provide necessary control, annunciation and monitoring output on open field bus standard/Ethernet international standard/TCP-IP and IEC standards compatible with digital control system (SCADA). The Excitation system shall be delivered with Profibus DP communication for transfer of data to SCADA. Control / protection / monitoring shall be provided for at local level with remote control and monitoring from SCADA. The excitation power shall be supplied via a 3-phase dry type excitation transformer directly connected to the generator bus system between generator terminals and generator transformer terminals through busduct tap off. The transformer shall match busduct voltage rating and suitable for bus duct termination. The connection between excitation transformer and thyristor cubicles shall be through LV non-segregated phase bus ducts. The excitation system shall be of the static type and shall have manual and automatic modes of operation. The excitation system shall be provided with all the necessary devices for local and remote operation, condition signalling, alarms and trips. The excitation equipment shall be mounted in freestanding cubicles and shall be located on the generator floor. The excitation equipment for the generator shall include a power supply consisting of silicon controlled rectifiers (Thyristor) supplied from a transformer connected to the generator terminals. Output of Thyristor shall be controlled by a high-speed, continuous acting, digitaltype regulator which adjusts the firing angle of the rectifiers. A double-pole circuit breaker
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and field discharge resistor shall also be supplied to interrupt the field circuit to the generator. The continuous rating of the excitation system shall not be less than the excitation required for the generator when it is delivering the base rating at 0.90 pf, 50 Hz and 105% terminal voltage. The excitation system shall also be capable of operating up to at least 1.6 times rated field current at 110% rated load condition for 30 seconds. The excitation equipment shall be capable of meeting this requirement with one Thyristor Bridge out of service. The equipment shall operate satisfactorily over the following range of voltage and frequency: Voltage: 30 to 125% rated transiently 80 to 110% rated continuously Frequency: 85 to 150% rated transiently 80 to 110% rated continuously a) b) c) Range of voltage control in voltage regulation mode Range of current control in current regulation mode Maximum change in generator voltage for transfer from Auto to manual or vice versa d) e) Reactive drop/line drop compensation range +/- 10% 60 - 110% UN 10 - 110% IN +/- 0.5%
Field voltage response time from nominal to 95% of ceiling <50 m sec voltage
f)
Excitation system response time from nominal to 95% of ceiling voltage
<20 m sec
g) h)
Nominal Excitation System response Ceiling voltage of exciter
not less than 2 not less than 1.6 p.u.
The exciter shall be capable of providing negative ceiling voltage not less than 80% of positive ceiling voltage.
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The regulated voltage shall be readily adjustable over a range of plus 10% and minus 40% of normal, and shall be relatively unaffected by changes in frequency over the range of 45 Hz to 55 Hz continuous. Control of the generator terminal voltage shall be stable within plus or minus 0.5%. The regulator shall have a negligible dead band. The excitation system shall restore stable steady state generator voltage in less than one second following partial or full load rejection, and the sudden rejection or acceptance of reactive power within the capability of the generator. The excitation system must stay operational, and not trip, during any fault on the station service AC power system, during the transfer of power from station services to unit service board, and vice-versa. The excitation system must stay functional and recover after threephase fault on the main AC system which would affect the unit fed station service power supply. The excitation equipment shall be provided with communication ports to interface with the plant control system. Design of excitation system will take into account system fault duty cycle of three phase fault on 220 kV system near to station cleared in 5 cycles, followed by reclosure in 20 cycles on fault, and again cleared in 5 cycles followed by lockout. Components and wiring shall be suitably designed and shielded to prevent excessive noise. The design of the excitation system shall be such that the effect on the balanced and /or residual telephone influence factor (TIF) of the associated generator is normal and shall not cause the TIF to exceed the limits specified Excitation system shall be capable to supply field excitation as required by the generator over the entire range of capability curve of the Generator. The excitation system shall be immune from false operation or failure from high voltage, high frequency transients that may be conducted in the control circuitry and power supplies internal and external to the excitation system. To reduce the transients coupled from external sources, shielded cables shall be used for connection to the external equipment and surge suppression devices shall be installed on inductive devices. Special precautions shall be taken to limit exposure of sensitive excitation system electronic circuits connected to remote equipment.
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These circuits shall be isolated by means of solid state optically coupled or transformer coupled isolation amplifier. The excitation system shall be designed and tested to be insensitive to radiated high frequency interference such as that coupled from portable radio transmitters The regulator shall be compatible with SCADA and be equipped with suitable interface for: Communication interfaces between excitation system processors and SCADA through Redundant Optical Fiber link. Required number of digital / analogue input and outputs with time stamping and clock synchronization with SCADA. Facility of adjustment of set values, limit values and other parameters as per logic control. Self testing facilities Provision for connection of a fast recorder for recording regulator and excitation system response. Provision for data downloading on programmer / laptop (included in scope) for parameterizations, diagnostics, logic modification, etc. Automatic voltage adjusting in conjunction with automatic synchronising equipment for voltage matching. Two sets of thyristor bridges (fixed type) will be provided one is hot standby. Each bridge will have its own cooling fan so that in case of bridge or one fan failure, system can still operate at rated load. Lightning and Switching withstand
The equipment offered shall be provided with an electrostatic shield between excitation transformer windings which shall be capable of withstanding lightning and switching surges and dynamic over voltages to which they may be subjected to and shall meet all the performance requirements and tests as described in these specification. The equipment shall conform to the latest issue of IEEE 421 and IEC 61312 and 61643. The impulse, switching and dynamic withstand voltages shall be stated in the guaranteed particulars and shall take into consideration altitude correction factor. This shall include :-
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De-excitation De-excitation shall be provided using DC field breaker combined with crowbar silicon controlled rectifier shunting circuit and a discharge resistor. On receipt of a tripping signal, field breaker shall trip and the inverter forcing actuated. The system shall allow a rapid decrease in the excitation current by polarity inversion realised by the firing angle of the thyristor bridge (negative excitation voltage). At excitation field breaker opening, the firing circuits will be inhibited and the voltage regulation reset to the initial value. Automatic Voltage Regulator For steady-state conditions with the generator circuit breaker open, the regulator shall maintain the generator terminal voltage at or below 105% of its rated for speeds ranging from rated speed up to an over speed of 120%. An exciter limiting control shall be provided to limit the generator voltage to maximum of125% of rated voltage in the event that the digital voltage regulator is tripped coincidentally with 110% load rejection and the generator speed rising. The voltage regulator shall be provided with over- and under- excitation limiters. The intervention of the limiters shall not cause perceptible deviations or oscillations of the generated active and reactive power. The characteristics of the under-excitation-limiting curve shall match the static and dynamic stability curves of the generator. Such devices shall allow the regulator to reduce the exciter voltage to zero or to negative values in order to prevent over- voltages in case of operation under line reactive load conditions and over speeding of the unit. The following features shall be included: Stator current limiter, Field current limiter, Over fluxing limiter, Power factor regulator, Active and reactive load compensation.
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Dynamic braking of generator from 90% to 30% speed during shutdown sequence.
The field current limiter shall act on DVR with a time delay so as not to disturb transient response of the system during voltage dips/faults. All corresponding protective devices shall be provided, including a generator field earth-fault detector. The voltage regulator shall be equipped with an adjustable voltage droop compensation (compounding) unit. After the generator voltage attaining initial maximum value neglecting the instantaneous rises following any load rejection up to 110% of the rated load, DVR shall restore the generator terminal voltage to a value not more than 5% above or below the voltage being held before load rejection and shall maintain the voltage within these limits throughout the period of the generator over speed. The excitation system shall be capable of operation on joint control maintaining even distribution of the reactive load between machines. Reactive power joint control function devices to ensure satisfactory load sharing during parallel operation of the generators shall be integrated to plant SCADA system. Paralleling of generators shall be achieved on 220kV side of GSU transformers. The voltage regulating system shall include device for improving the damping of active electromechanical oscillations. These devices shall operate to supplement the voltage regulating action through an additional control signal into the excitation system input. This supplemental input signal shall influence the excitation system as to cause a change in field current of the machine for stabilized operation. As an option, adaptive control function feature to the slip stabilizer shall be offered. The function of the control is to optimize the setting of the slip stabilizer to suit the different configuration system. The setting of device shall be determined by the Contractor. The excitation system shall be designed for manual and automatic operation. The changeover from automatic to manual control shall be performed automatically following a failure of the regulator when operating on automatic control. The generator voltage shall be controlled within a range of +10% and 15% of rated voltage. A static follower shall be provided so that, in case of change-over from automatic to manual control, it prevents the excitation current from deviating more than 5% of the excitation current which was flowing in automatic channel before changeover.
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The automatic and manual control circuits shall be fully independent. Local and remote control shall be possible. The voltage setting device shall be of the solid-state digital type providing a range of +10% and 20% for local and remote control and indication. For testing purposes, settings of 0 to 115% shall be adjustable at the DVR cubicle. Field Circuit Breaker The field circuit breaker shall be DC operated, draw out type with three main poles for the field and one secondary pole for switching the field discharge resistor. The field discharge shall be capable of dissipating the full stored energy of the field without exceeding the maximum allowable voltage on the field or circuit breaker. Over voltage protection circuit shall be provided to protect field. Field Flashing The field flashing circuit shall consist of a rectifier supplied from the 415 V auxiliary services board. The field flashing circuit shall be connected to the field circuit with a contactor to initiate field flashing as part of the start-up sequence. The AC field flashing circuit shall include a rectifier bridge, reverse current blocking diodes and resistor to limit field current to a value corresponding to approximately 30% of generator terminal voltage. Backup field flashing circuit using 220 VDC station battery including local and remote-operated transfer switch shall also be provided. Cooling System Forced air cooling shall be provided for thyristor bridges. The cooling system shall be equipped with an air flow switch which shall block the thyristors after a time delay set slightly more than the station supply changeover time. An alarm shall also be initiated to indicate blocking of thyristor bridge and fan failure. 4.3.2 Dynamic braking
The Dynamic Braking Equipment is required to reduce the run down time of the Generator. This is achieved by shorting the stator phase terminals of the generator (Once the unit is tripped) by means of Dynamic braking switch and applying a fixed excitation. The dynamic braking switch shall have the following features:
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High Operating Reliability Simple Maintenance and Inspection Simple and Reliable Driving Mechanism Operable by both Motor and Manual Operation by Bevel Geared Motor, and there by smooth operation Tested in accordance with the IEC
The 3 pole Switch shall consist of frame and contact system comprising stationary and mobile contacts. The switch is made out of rigid framework, with provision for manual operation through operating drive handle. The Switch is equipped with Uni-directional Bevel geared motor for motor operation associated with control circuit and also has arrangement for manual operation. These 3 pole Switch is housed inside Aluminum cubicle and will be connected with Busduct Tap-off. Technical data Rated Voltage No.of poles Rated current Rated Frequency Rated short time current Rated peak current Power frequency voltage( 1 min dry) Impulse withstand voltage (a) To earth (b) Between contacts Making current 11 KV 3 12000 Amps ( Continuous) 50 Hz 230KA rms for 1 sec 575 KA 55KV 125KV peak 145 KV peak 7000 Amps at 1 KV
4.3.3
Cubicles
All the equipment of static excitation shall be suitably housed in sheet metal, dust proof cubicles. Each cubicle shall have thermostatically controlled panel heaters and shall be well illuminated. The panel illumination circuit shall switch off automatically when the panel doors are closed.
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Electronic cards shall be well ventilated by rack mounted fans. All racks and card ground wires shall be terminated on a separate earth bus inside the panel. This earth bus shall be finally connected to a separate electronic grounding system. Each device inside the cubicles shall be identified by labels on front as well as back side. Cubicle swing doors shall be earthed through a separate connection with cubicle grounding bus. 4.3.4 Protection, Control, Alarms, Metering and Instrumentation
The control cubicles shall comprise all controls, limiters, protective devices, fuses, annunciator, power supply monitoring devices, meters, transducers, etc required for the operation of the entire excitation system. At least following quantities shall be available to be displayed on the front panel of excitation cubicle: Rotor current, Rotor voltage, Thyristor bridge current, Stator voltage, Reactive power, The voltage and current set points (accuracy of at least 0.2%), Channel output balance meter of automatic and manual regulating channels.
The exciter shall have all the necessary protections for excitation transformer and the generator field for generator operation within its capability limits. The excitation system shall be equipped with the following protective and indicative devices as a minimum feature: Excitation equipment internal faults, Current asymmetry protection for Thyristor and bridge Over voltage protection for Generated field
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Over current protection for overload and short circuit protection of the excitation transformer and rectifiers,
4.3.5
Overheating protection of the rectifiers, Cooling fan failure (main and reserve), Loss of DC power for Automatic and manual mode of DVRs, Loss of AC power for Automatic and manual mode of DVRs, Failure of Thyristor firing circuit, ( Pulse monitoring unit) Failure of DVRs, Individual cooling fan failure, Rectifier cubicle exit air temperature high alarm / indication Operation of stator current limiter, Operation of slip stabilizing unit, Failure of field flashing circuit equipment, Generator transformer over fluxing preventer ( V / f ), Field breaker trip coil healthiness monitoring Protective changeover from Auto to Manual channel Excitation Transformer winding temperature high alarm and trip. Loss of PT voltage Rotor earth fault Excitation transformer
The excitation transformer shall be of the 3-phase, cast-resin dry type, class H insulated. The L.V. and H.V. windings shall be impregnated and vacuum cast into moulds of glass fibre reinforced epoxy resin. Transformer windings shall be of Copper. The L.V. windings shall be provided with temperature sensors (PT 100) and static alarm and tripping device. The transformer shall be naturally air cooled, installed in a panel, designed and constructed to match perfectly with the common switchgear assembly. The L.V. connections to the rectifier cubicle shall be with copper cable of adequate size.
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The enclosure shall be of at least IP 31 with enclosure thickness of at least 12 gauges. The transformer base shall be of rigid steel welded construction and shall include provisions for lifting, jacking and skidding or rolling in both directions with tapped holes for attaching ground leads one in each diagonally opposite corner of the base. The enclosure shall have provision for mounting external fans for additional cooling if required. These fans shall be controlled by thermostats. The manufacturer shall supply a metal box, which shall enclose the transformer high voltage bushings and terminate the isolated phase bus feeding the transformer. The flexible connectors from the isolated phase bus to the transformer bushing shall be arranged by bus-duct manufacturer. The manufacturer shall provide a flange for bolting the phase bus enclosure to the metal box. To maintain the generator isolated phase bus arrangement, insulated barriers of suitable design to prevent short circuit between phases shall be installed between phases inside the transformer. 4.3.6 Thyristor equipment
This equipment shall essentially consist of silicon power Thyristor bridges and associated equipments for protection and monitoring. Each Thyristor with relevant fast acting semi-conducting fuses shall be mounted on draw-out modules facilitating inspection and replacement. The fuses shall have a blow out indicator and monitored individually or in groups providing alarms and trips as required. Three independent firing circuits shall be provided for the manual and automatic channels respectively The following monitoring and protection features shall be included: Current and Temperature monitoring of Thyristors, Thyristor failure, DC short circuits, Thyristor and field circuit over voltage protection,
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AC system over voltage ,over current and switching surges
The system shall operate correctly with supply voltages up to 120% rated voltage or unbalanced supply voltages. Forced cooling of the Thyristor cubicle shall be provided. The ventilation system shall be automatically controlled and supervised with 100 % stand-by capacity of ventilation fans. Supply to one set of fans shall be from the excitation transformer and the other set of fans from the Unit auxiliary board. Automatic switchover arrangement to other supply in the event of loss of power supply to either set of fans shall be provided. Provision shall be made for manual selection of the bank of fans to be used for cooling. Normal supply for the fans shall be from the excitation transformer. To ensure adequate airflow, suitable temperature detecting devices and loss of airflow detection devices shall be located in the exciter cubicle to indicate complete or partial loss of airflow. The cubicles shall be closed, so that no dust can enter into the inner part. While determining the capacity, effect of ageing shall also be considered. The rectifier PIV (Peak Inverse Voltage) rating shall not be less than four (4) times the maximum RMS voltage of the inputs. 4.3.7 Interface with Unit and Station Control Equipment
The DVR shall be capable to communicate via serial interface and the field bus with unit control boards and station control equipment (SCADA). All signals interchange shall be realised through the bus. Excitation connections Excitation power cable connections between the generator slip rings and the DC field breaker cubicles shall be provided. The cable shall be made of flexible conductors and the cable insulation shall be of the heat-resistant type, taking into account the maximum temperature rise of 65C above ambient temperature in the slip-ring compartment.
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The cables shall be adequately spaced and supported with consideration to the electromechanical forces involved and designed to prevent undue heating during continuous operation. 4.3.8 Performance Guarantee
The static excitation system along with all auxiliaries and accessories shall be capable of performing intended duties under specified conditions. The Contractor shall guarantee the reliability and performance of the individual equipment as well as of the complete system. Automatic operating mode The Contractor shall guarantee the performance of equipment to operate safely under any of the following operating conditions. Performances when uncoupled from the network When the generator is uncoupled from the network and operates within its coupling range, the excitation system shall guarantee to limit the voltage variation to a maximum of 0.25% of rated voltage for any 1% variation in frequency. The system shall be capable of maintaining the generator rated voltage even at maximum runaway speed. Performances on interconnected network Under automatic operating mode, the excitation system shall permit the generator to operate in a stable and safe manner over its entire operating ranges. Thus, the excitation system shall be capable of controlling the field voltage and the field current to allow the generator to operate continuously within: The generator normal operation range, The other operating conditions, provided that the field current shall not overshoot the maximum continuous excitation current i.e.1.1 times of rated generator field current nor the 15 minute operation excitation current i.e. 1.2 times of rated field current. The excitation system shall not de-energize if the generator voltage remains greater than 0.2 times the generator rated voltage. 4.3.9 Excitation losses
Power required for the excitation system shall be included in the losses of the generator for calculation of the guaranteed generator efficiency.
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4.4
Quality control and assurance
The manufacturer shall supply the equipments of best quality. The manufacturer shall maintain quality control during manufacture of equipment as per the approved quality assurance plans. 4.5 Drawings and documents and design calculations
The Contractor shall submit all the drawings and documents in accordance with requirements stipulated in Section 2.12 Reference drawings and documents of General Technical Specification (GTS). 4.5.1 Design calculation
The Contractor shall submit the design calculation covering at least the following, for review / acceptance. Design calculation for the capacity of Thyristor bridges, D.C. Breaker, A.C. Breakers, Discharge resistor, etc. The Contractor shall also provide other calculations as required by the Owner for his approval of the Contractors design. 4.6 Spare Parts
Recommended spare parts shall be supplied in accordance to clause 2.36 Spare Parts and tools of General Technical Requirements. Specified spare parts to be supplied under this section are as follows:
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Sl. No 1
Description All plug in units, printed circuits cards, power supply units, protection devices and transducers for the static excitation equipment including digital voltage regulator (DVR) Set of Thyristors complete with fuses and all accessories used for one unit Rectifier cooling fan complete with motor, air flow meter and accessories Excitation transformer coil complete with all accessories DC Field circuit breaker Field Discharge resistors Relays, contactors, switches, fuses, indication instruments etc Field flashing circuit breaker/ contactor Special tools
Quantity 1 Set
2 3 4 5 6 7 8 4.7
2 Sets 1 Set 2 sets 1 no 1 no 1no each type 1 no.
The Contractor shall propose the list of special tools including their make and detailed specification as recommended by manufacturer(s), to be accepted by the Owner. Proposed list of special tools must include the following in addition to tools recommended by the manufacturer(s): 4.8 One digital Multimeter One dual beam Storage Oscilloscope. Testing
The Contractor shall follow the Inspection and testing requirements in Quality assurance clause 2.31 Factory inspection and testing of General Technical Specifications and section 7 of document QAP for various tests to be conducted in shop and in field. 4.9 Delivery, Installation and Commissioning
The supplier shall follow the requirements of Delivery, Installation and commissioning elaborated in section 2.34 Installation and Supervision of General Technical
Requirements. The supplier shall arrange personnel to oversee proper storage of equipment at site, their transshipment to powerhouse, installation and commissioning.
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5. 5.1
DIGITAL GOVERNING SYSTEM AND ACCESSORIES Scope of Work
Scope of work under this section covers the provision of labour, tools, plants, materials and performance of work necessary for the design, manufacture, quality assurance, quality control, shop assembly, shop testing, delivery at site, site storage and preservation, installation, commissioning, performance testing, acceptance testing, training of Owners personnel, handing over to Owner and guarantee for one year of Digital governing system as per the specifications hereunder, complete with all auxiliaries, accessories, spare parts and warranting a trouble free safe operation of the installation. The scope of work shall be a comprehensive functional system covering all supply and services including but not be limited to following: a) Three (3) sets of digital governors housed in a dust proof steel cabinet with a rack type support system and containing the following: Digital governor control relays, switches, pushbuttons and indicating lamps, terminal blocks etc.; Microprocessor based programmable electronic logic circuits and interface equipments; Display unit to display the parameters and monitoring; Human machine interface for setting / control / monitoring purposes; Local / Remote / Joint control facility; Main and backup power supply; Transducers and indicating instruments; Set point generator circuits/algorithms; Watchdog / Self diagnostic facility; Interface for SCADA / communications etc. Speed measuring unit for regulation and speed relays; Interface facility to transmit and receive electrical signals to distributing and emergency valves installed in the Hydro mechanical cabinet, to activate the
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valves feeding the injector and deflector servomotors for control of speed and load; b) Three (3) sets of Hydro mechanical cabinet consisting of following main components: Electrically operated distribution valve for activation of hydraulic chain of commands of servomotors activating the deflector and injectors. Main oil distributing valve; All hydraulic accessories, i.e., manually; electrically operated or oil operated valves, micro filters, pressure gauges, pressure switches, level switches, gate valves, check valves etc. to complete the system. c) Three(3) sets of oil pressure system comprising of sump tank, motor driven main and standby oil pumps mounted on the sump tank, oil pressure tank with associated accessories, oil piping and valves, instrumentation , high pressure nitrogen bottles. d) Three (3) sets of governor interface cables, terminations etc. between various parts of the equipment/components, e) Three (3) sets of all types of pipes, fittings, valves including mechanical/electrical control for air, oil, water circuits, f) Oil for first filling of governor with 10% extra quantity, in non-returnable drums, for all the three (3) units, g) Three (3) sets ( two probes per unit ) of speed signal generator (SSG) for supplying a signal to the speed sensing element and for supplying voltage for the speed relays h) i) j) k) Three (3) sets of feedback transducers for deflectors and nozzles. Stability studies as defined in clause Stability studies of this section, One (1) set of spare parts in accordance to clause Spare parts of this section, One (1) set of tools and instruments in accordance to clause Tools and Instruments of this section. Any other item(s) not mentioned specifically but necessary for the satisfactory completion of scope of work defined above, as per accepted standard(s) / best international practices.
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5.2
Rating and design requirements
Basic provisions 1 The governor shall be adequate in capacity to close the jet deflectors in 2 seconds under maximum operating head and the turbine needles at the normal rate. It shall meet this performance with minimum permissible oil pressure for normal operation in the oil pressure tank. 2 The governor hydraulic system shall perform in accordance with the requirements of this specification, using same oil as for lubrication of generator and turbine bearings. The supplier shall coordinate with the generator supplier in specifying suitable oil. 3 All bearings in the governor shall be of the grease packed, anti-friction type, where practicable. 4 The arrangement of governor equipment shall be in accordance with the approved Contract Drawings or other drawings, as approved by purchaser. 5 The supplier shall be fully responsible for the capacity of the governing equipment to comply with all operating requirements stipulated herein. 6 Governor shall have provision for local-manual, local-fully automatic, and remote-fully automatic control of the turbine. These auxiliary devices shall permit transfer from one method of control to the other, without disturbing the operation of the turbine. Transfer from local to remote control will be initiated by a two-way position selector switch which will be located on governor cubicle. 7 The operating oil pressure range shall be the manufacturer's standard for the proposed governor and shall have proved satisfactory in similar governors which have been in operation. 8 The electric regulation panel shall preferably be micro processor based digital system of proven design. If other type of electronic regulation panel is offered, same shall also be compatible with Data Acquisition and Control System for which supplier shall co-ordinate with purchaser. control, etc. shall be provided. Facilities such as set point control for limit needle
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Governor shall use PID (Proportional Integral Derivative) loop control in which three derivatives of speed are used for speed stabilization.
10
Control equipment of governor shall be suitable for following auxiliary supply voltages: AC : DC : 415 volts AC 10% 220 Volts DC -15% to + 10%
11
Starting and stopping of the generating unit shall be possible locally from Electronic cabinet/turbine control panel, and also remotely from Control desk.
12
A suitable auto clean filter set shall be provided in governor actuator oil supply circuit to ensure that impurities of 10 microns or above can be removed.
13
Provision for automatic locking out governor, needle control mechanism and adjustable manual limit control for load shall be provided.
14
Governing shall be fail-safe on the failure of the speed sensing element, loss of oil pressure or defect in the actuating system so that under any of these conditions, the machine shall be automatically shutdown, with alarm and indication.
Rating and performance 1 The governor shall meet the requirements of IEEE 125 "Recommended practice for equipment specification for Speed Governing of Hydraulic Turbines intended to drive electric generators". 2 The governor shall control, with stability, the turbine at any speed between 85 and 105% of rated speed when operating isolated from the system and while connected to the system at any load between zero and the load corresponding to maximum opening of the nozzles with two or four nozzles operating. Provision for start of operation with 1st or 3rd nozzle will be preferred. 3 The governor shall be deemed stable: (a) When the generator is operating connected to the system with sustained load demand, the peak to peak magnitude of the sustained speed oscillation caused by the governor, with 2% or more speed droop setting, does not exceed 0.15% of the rated capacity.
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(b)
When the generator is operating connected to the system with sustained load demand, the peak to peak magnitude of the sustained power oscillation caused by the governor, with 2% or more speed droop setting, does not exceed 1.5% of the rated capacity.
Dead Band : With the turbine running at its rated speed the total amplitude of speed variations not resulting in any measurable difference in the deflector servomotor position shall not exceed 0.02% of the rated speed at any deflector opening. The dead band adjustment range shall be 0 to 0.5 Hz.
The governor dead time shall not exceed 0.2 seconds with a sudden load change of 10% or more of the capacity of the turbine.
The governor adjustments shall enable synchronizing over the range of 85 to 105% of rated speed and shall be adaptable for automatic synchronizing and automatic load or frequency control.
The time for the deflectors to cut off the jets from the runner under full load shall be two (2) seconds or less.
The rate of deflector operation and needle closure shall be established by the Supplier to limit generator speed rise to 35 % of rated speed and penstock pressure rise, including surge, to 25% of maximum static head on simultaneous rejection of maximum load from each of three generating units. The needle closing rate shall be slowed near the seated position to reduce turbine discharge at an approximately uniform rate.
The control mechanism shall be equipped with means of independent adjustment of the opening and closing times of the deflectors and of the needles. The adjustments shall be arranged and set securely; so that operation of any control or auxiliary device can not cause the needles to move faster than the time established.
10
The adjustment of permanent speed droop shall have a range from 0 to 10% with the load/frequency setter set to give rated speed at full load.
11
Temporary speed droop of 0 - 100 (hundred) percent range for off line and 0 - 10 (Ten) percent range for on line mode shall be provided. Calibrated knobs for indication shall be provided.
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12
Overload limiter to limit maximum needle opening in any preset position in the stroke range shall be provided. It shall be suitable for manual by hand or Electrically from EHG cubicle or remote from control desk
5.2.1
Governor Cubicle
Provisions in Digital Governor Cubicle The digital governor shall have provisions for setting / adjusting and indication display of the set values of various governor characteristics / parameters with the help of the key board viz. Permanent speed droop Temporary speed droop Temporary speed droop decay time constant Sensitivity Frequency dead band Speed regulation Power regulation Opening limitations Speed set point Output set point Monitoring and supervision of speed, power and position feed back signals Other essential devices for smooth operation, protection and safety of the units. The regulation components, i.e. speed-sensing, comparing, stabilizing and power amplifiers, PID control, dead band and other devices, shall be built of electronic components and shall be assembled on modular printed circuit boards on standard chassis enclosed in a dust tight cubicle.
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The cubicle shall be a neat and attractive steel cabinet with doors for convenient adjustment, test and maintenance. Man machine interface and controls shall be mounted on the front panel in a neat, symmetrical, and convenient arrangement. The cubicle shall be mounted at a suitable location. All electrical wiring shall be neatly concealed inside the cubicle and terminated in readily accessible terminals. Cable entry shall be from below the cubicle. Provision shall be made for ten (10) percent spare wiring terminal blocks. No terminal shall be provided in 300 mm bottom space. Gland plate at bottom shall also be provided. Built-in test circuits and instruments shall be provided to check all circuits. Parameterization facilities for adjustment of various governor setting including speed droop setting shall be provided. Regulation system shall have provision for set reference for load limit, speed and / or gate limit setting as required. OVER SPEED CONTROL a) Hydraulic Overspeed Protection A hydraulic over-speed device shall be provided and mounted on the main turbine/generator shaft to operate automatically at the unit speed slightly above the maximum speed rise allowed on full load rejection (turbine scope). The switch shall also be adjustable and capable of manual operation. The device shall directly act on deflector servomotor. Operation of the switch shall directly lead to closure of the deflectors and initiate shutdown sequence through DCS. Both turbine & governing system Suppliers shall co-ordinate interface. An auxiliary contact switch shall be provided to annunciate operation of the hydraulic over-speed switch. These contacts shall be wired to the governor cubicle for control purposes. b) Speed measurement & Control modules (SMU) The speed signal from SSG shall be converted into desired corrective signals by the digital governor. The hydraulic actuator unit shall convert the electrical signals into mechanical movement to actuate deflector / needle servomotors for fine regulation of
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speed / load. The hydraulic actuator unit shall be provided with protective devices to signal governor failure and initiate emergency closure of the unit. A shrouded manual push button shall be provided on the hydraulic actuator panel to initiate emergency shutdown of the unit. Suitable vapour proof lighting of 240 V, 50 Hz AC to illuminate the interior of all cabinets shall be supplied and fixed in the cabinets. The governor cubicle shall be located near to the Unit Control Board (UCB) and the DCS automatic start-up control cubicles or combined with the latter. The dimensions and appearance of the cubicles shall be compatible as far as possible. The cubicle shall be totally enclosed, naturally ventilated, dust and vermin-proof and to class IP54. Adequate access, for test and maintenance purposes, shall be
provided. Terminal blocks shall be readily accessible for making field terminations from a bottom-entry position. Cubicle swing doors shall be earthed through a separate connection with cubicle grounding bus. Electronic Regulator The digital control system shall be mounted on boards which shall be rack-mounted for easy replacement. The circuits shall be designed and arranged against mal-operation or failure caused by parasitic currents or over voltages which may be internally or externally generated. All circuits shall be subject to a "burn-in" period of not less than 200 hours. Test facilities shall be included so that the equipment may be readily tested in accordance with the manufacturer's instructions. All adjustable pre-set devices for setting the main parameters of the governor shall be calibrated and fitted with a positive means of locking the setting. Turbine speed measurements shall be derived from the output of the speed sensing devices.
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Control Facilities Speed adjustment control with a range of 85 percent of rated speed at no-load and zero speed regulation to 105 percent of rated speed at rated load and maximum speed regulation shall be provided. Control of the speed setting shall be possible from the governor cubicle, from DCS and by the automatic synchronizer. Following synchronisation, which will be detected by the governor monitoring and the circuit breaker status switch, Three modes will be available, pre-selected from the DCS as part of the start sequence: Frequency control mode; Power control mode. Opening limiter control mode
In frequency control mode, the governor will control the power level to correct any deviation from the frequency set point stored in the governor based on the dead band and droop characteristics set into the governor. These settings shall be adjustable using a standard set up procedure independent of the main control characteristic settings of the governor. In power control mode, the governor will control the output power level to the power set point stored in the governor provided the system frequency is between pre-set limits. Outside these limits, the governor shall switch to the frequency control/droop characteristic. The Three modes shall be able to hold a stored set point which can be raised or lowered by pulse commands from the DCS via hard wired interconnections. Adjustable speed regulation (droop setting) having a range from 0 to 10 percent shall be provided. Controls and instrumentation provided shall also include: Local manual adjustment of deflector position. Local and remote adjustment of the deflector opening limits.
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Local and remote adjustment of the speed level set point from 85 percent to 110 percent of rated speed.
Deflector position limit switches Mechanical and electrical over speed switches for control and shutdown.
The unit shutdown function shall be covered by at least one electrical speed sensor and the mechanical speed switch, the mechanical speed switch being set 5 percent above the setting of the electrical speed sensor that is used for electrical trip. The following local and remote indication shall be provided via 4-20 mA transducer outputs for interaction into the DCS in addition to local displays: Deflector position indication Deflector position limit setting indication Turbine speed. (Calibration shall be done between 0 speed, corresponding to 4 mA, and the design run-away speed, corresponding to 20 mA.) Actuator needle balance indication Speed setting Any other indication considered necessary for ensuring proper control.
Remote alarm indications for the following abnormal conditions shall be provided for input to the DCS: Loss of speed signal Over speed ( Mechanical and Electrical) Governor shall accept digital set command from DCS for various controls i.e. speed setting, limit setting, frequency shutdown, and any other signal necessary for proper operation and as per logic control scheme approved by Purchaser.
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5.2.2
Specific Codes and Standards
The system and equipment shall be designed, built, tested and installed to the latest revisions of the following applicable standards. In the event of other standards being applicable they will be compared for specific requirement and specifically approved during detailed engineering for the purpose: Standard IEC 61362 IEC 60308 Description Guide to specification of hydraulic turbine control systems International code for testing of speed governing systems for hydraulic turbines IEEE recommended practice for preparation of equipment specifications for speed-governing of hydraulic turbines intended to drive electric generators Code for unfired pressure vessels Unfired Pressure vessels
IEEE 125
IS - 2825 ASME BPVCSEC VIII Div 1 5.3 5.3.1
Design considerations Stability studies
The Contractor shall simulate, using appropriate methods, the interaction of penstock, turbine, generator, load, and governor in order to prove that the system is stable under all load conditions when adequate adjustments of the governor parameters are set and the pressure and transient speeds after load rejection are within the specified limits when the guide vane closing time is appropriately adjusted. The stability studies shall cover the operating range between maximum and minimum net heads with the discharge corresponding to the full load under each respective net head. Studies shall be conducted for conditions including parallel operation with an infinite system, supply to an isolated resistive load, and supply to isolated loads with special speed regulation characteristics specified. The studies shall indicate the setting range of the governor parameters for which the control circuit remains stable after any disturbance. The quality of regulation shall be demonstrated in diagrams indicating the transient response of
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the frequency of the isolated system to load variations (increase and decrease) for various net heads and the transient response to power changes when supplying an infinite system. 5.3.2 Performance Guarantee
The Digital Governing System along with all auxiliaries and accessories shall be capable of performing intended duties under specified conditions. The Contractor shall guarantee the reliability and performance of the individual equipment as well as of the complete system. 5.4 5.4.1 Construction Speed Sensing Devices
The speed sensing device may be of the static type or of the rotating type mounted around the main shaft of the unit. The output of this device shall be used for a speed monitoring instrument on the turbine generator control panel and for other speed indicators and the electrical over speed protection equipment. The signal from the speed sensing element shall vary directly with the speed of the turbine shaft for all rates of acceleration and deceleration. The signal shall not be affected by variations in the voltage or current of the main generator or exciter or of the power system to which the main generator is connected. Vibration or normal lateral and axial movement of the shaft shall not affect the accuracy of the speed signal. Speed detection and resolution of this information shall be such that the operating points are independent of the voltage on the governor supply circuit. The resetting of the speed switches shall be capable of being adjusted within 1 percent of their operating point. In case of supply of a static type speed sensing device, it shall be connected to the potential transformers which are permanently connected to the generator terminals and shall function reliably with the excitation system off. A dual system shall be provided with 50% of the available speed switches on each system. A minimum of the following speed switches for automatic start/stop logic shall be provided: 0.2 % speed ( Relay Drop out ) for pneumatic brake release and machine creeping indication 10% speed (Relay Pick up) unit turning;
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25% (Relay Drop out) speed during shutdown for application of brakes and start of HP lube pumps. ( The exact speed for application of brakes will be confirmed by the Generator manufacturer
50% (Relay Pick up) speed HP lube pump off; 80% (Relay Pick up) speed excitation on/off interlock; 95% (Relay Pick up) speed ready to synchronize; 120% (Relay Pick up) over speed alarm. The over speed trip setting (electrical) shall be duplicated. An independent 30% mechanical speed switch (Relay drop out) shall be provided to control the emergency manual brake application logic.
Mechanical over speed device A Hydraulic over speed protection device shall be provided to directly actuate the main distributing valve of the governor though a hydraulic connection for closing action in case of turbine speed exceeding preset limit and also to initiate unit emergency shutdown through a micro switch mounted on the hydraulic over speed device.
To cause emergency shut down of the unit through certain specific protection circuits and/or when unit speed increases beyond 110 %.
To cause unit shutdown through the shutdown solenoid via protection circuits at and above 140 percent of rated speed.
In the event of speed rising above 140 % and above, simultaneous command to go to emergency solenoid valve and the spherical valve control cabinet for closure.
Speed signal at required speed for brake system control Speed setting for high pressure lube oil start / stop. Other speed setting as per control logic requirements.
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5.4.2
Speed signal generator (SSG) 1 A tooted wheel type speed signalizer mounted on the generator shaft and a magnetic pick-up mounted near the toothed wheel shall provide the speed signal for the governing system. The square wave output of the magnetic pick-up shall be fed to the frequency-to-voltage converter in governor circuit. The output of this converter shall be fed to the governor regulating circuit, comparator card to energise various speed relays. This output shall also be used in creep detection card for detection of creep and shall be arranged to provide an alarm to apply brakes and supply HP lub. oil. The speed signal generator complete with toothed wheel, magnetic pick-up and internal wiring up to the terminal box on the generator barrel shall be a part of governor supply. The Supplier shall coordinate with the Supplier of generator for
matching the above arrangement with the requirements of governor. 2 The capacity and characteristics of the SSG shall fully match with the requirement of speed responsive elements and governor regulation and control system. It shall be designed to withstand satisfactorily the maximum runaway speed of the turbine. 3 Provision of speed sensing through a potential transformer shall be included in the scope and provision of its mounting in the LAVT cubicle shall be Coordinated. The VA burden and classification of PT as per IEEE shall be furnished. 5.4.3 Servomotor Restoring System (Feedback)
Restoring systems of the electronic type (LVDT) shall be provided. 5.4.4 Hydraulic Power Assembly
General The hydraulic power assembly shall provide oil pressure supply for the governor and the inlet valve. The hydraulic power assembly shall be completely enclosed in a free standing sheet metal cabinet. The cabinet shall be of rigid construction and neat appearance, dustproof, properly ventilated and equipped with adequate vapour-tight light fixtures. Inspection doors shall provide easy access to all equipment. Pressure and Capacity
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Nominal pressure of the governor pressure oil system shall not be less than 100 bars. System shall be so designed to permit maintenance using minimum skilled personnel. The rating of the governor oil pressure system shall not be less than the total capacity of all servomotors. The governor shall be capable of supplying a sufficient quantity of oil to the servomotors so as to operate all deflectors for a complete opening stroke with a minimum oil pressure of 50% of the nominal. The velocity of oil in the pipes shall not exceed 3 m/s. The oil for the governor system shall be of the same grade as that required for the generator and turbine bearings and shall be fully suitable for operation with both. Oil Pumps Two oil pumps shall be provided, one acting as main and the other as standby. Each oil pump for the oil pressure supply system shall be independently driven by a 3-phase 415V AC electric motor and each shall have a capacity sufficient to operate the complete main inlet valve oil pressure system. It shall be possible to run one main pump continuously so that it discharges to the sump or accumulator tank without overheating the oil. A complete pump logic control system shall be provided that will permit the selection of either pump, as the main unit with the other pump acting as a standby, which will cut in automatically to supply the oil and close a set of alarm contacts. Each oil pump shall be of the screw type, with adequate capacity according to DIN 43211987 when operating under the pumping pressure recommended by the Supplier. The capacity of the pump however shall be subject to Owners approval. Each pump shall be self-priming under maximum oil pressure. One jockey pump shall also be provided with capacity equal to 0.1 times the volume of one servomotor. A suitable oil strainer shall be fitted in the suction line of each pump. The motor/pump units shall be mounted on the oil sump tank. Control switches and indicating lamps shall be mounted on the front panel of the actuator. Each pump shall be direct-coupled to a 415 V, 3 phase, 50 Hz, squirrel-cage, low starting current, induction type motor designed for DOL starting and conforming to IEC standards, with Class F insulation. The motor shall have windings with moisture and oil-resistant
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insulation. The windings shall be braced for line start application. The capacity and torque shall be suitable for the pump requirements. Start / stop of the pumps shall be controlled by pressure switches. The starting control equipment shall be arranged so as to start the motor and permit it to reach full speed before the pump loads, and to unload the pump before the motor is disconnected from the power supply. Combination heavy-duty magnetic starting contactors with fused disconnecting switches and thermal overload devices shall be furnished and shall be mounted on or adjacent to the pump units. A 415/240 V control circuit transformer shall be provided within each local starter panel, for power supply requirements of starter accessories. Suitable terminal blocks with marking strips shall be provided in accessible places for the control wiring. All control equipment shall be suitable for operation from the 220 V control circuit transformer. The control logic shall prevent starting of both the pumps when supply interruptions are encountered. The oil pumps shall be supplied with controls to be operated either independently or
together with one pump used for normal operation and the other arranged to start with a drop in oil pressure. A manual control switch shall be provided to select one of the two pumps as the lead pump. An alarm shall be provided to indicate continuous running of the lag pump over an adjustable period of time. Control logic shall be designed to automatically changeover main / standby selection after every 24 hrs. An oil pressure operated unloader valve of sufficient capacity to pass the full delivery of the pump at a pressure of ten (10) percent above the minimum rated pressure of accumulator shall be provided for the pumps. The unloader valves shall be operated by pressure switches and shall be equipped with snap action pilot valves. Hand-operated valves shall be provided to isolate the pumps from the oil pressure system. All valves and mechanisms shall be accurately set and tested in the shop before delivery. Each pump shall be provided with an adjustable temperature switch with two (2) electrically separate contacts suitable for operation at 220 V DC located in the pump suction side for oil temperature high alarm.
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The connections to all pumps shall be arranged so that any pump may be removed for repair or replacement without interfering with the continuous operation of the system. Oil Sump Tank The oil pressure system shall be supplied with a sump tank of sufficient capacity to hold at least 10 percent more quantity of oil required for governing and main inlet valve system including the quantity of oil in accumulator tank and in oil piping. The sump tank shall be designed and have connections for venting and overflow. The minimum thickness of the plate shall be 8 mm. The sump tank shall be provided with a manhole of 600 mm diameter with a suitable oil resistant gasket for access to the interior of the tank. A suitable oil level viewing glass shall be provided to indicate the level of the oil in the tank, with low and high level marks, complete with both hand shut-off valves and automatic means of shutting off oil discharge in the event of breakage. Suitable connections for filling and draining the tank, and connections for an oil purifier shall be provided. The oil purifier connections shall consist of two pipe outlets and valves, one located near the bottom on one side and the other near the top on the opposite side. A vertical filter screen shall be arranged to divide the sump tank into clean and dirty oil compartments. All strainers shall be removable type for cleaning. The outlets of all oil pipes to the sump shall be below low oil level. Any component that requires adjustments shall not be located inside the sump tank. Low and high level switches shall be provided for sump tank, suitable for 220 V DC, which operate alarms whenever the oil level reaches the present level. An oil temperature switch wired to cut off power supply to the oil pumps in the event of high temperature shall also be provided. Pressure Accumulator tank An accumulator tank of adequate capacity shall be provided which shall cater for the pressure oil requirement of the governor and inlet valve. The tank shall be of the hydro-pneumatic accumulator type with integral nitrogen filled bladder.
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CAPACITY The capacity of the pressure tank shall be sufficient to operate the servomotors of the turbine, with minimum pressure of normal operating range and under other normal operating conditions, through four complete servomotor strokes (4 x sum of all servomotor volumes) with the oil pumps and air compressor not operating, and at the remaining pressure the governing mechanism can still operate with a safe margin. One complete servomotor
volume shall be considered to be equivalent to the volume of oil required for one complete opening or closing stroke of both the jet deflectors and needles, and one complete opening or closing stroke of spherical valve servomotors. pressure system shall be furnished. The pressure tank shall be constructed from plate steel in accordance with part UW of the ASME Boiler & Pressure Vessel code, Section VIII Div.1. An adequate sized manhole of 600 mm diameter with a suitable oil-resistant gasket shall be provided on the pressure tank. The tank shall be painted on the inside and on the outside as per approved painting system. Thickness of inside painting shall be such that these do not flake off during operation. Prior to shipping, all threaded openings shall be closed with standard pipe plugs. Flanged openings shall be protected with blind flanges with gaskets bolted in position. All connections to the pressure tanks except connection of safety valve and pressure gauge connections shall be made below the low oil level and shall be designed to prevent foaming. Bypass valves shall be provided to drain the pressure tank into the sump for cleaning or repairs. The pressure tank shall be equipped with a pressure gauge, safety relief valve, air blow-off valve and oil-level sight gauge. The safety relief valve will be set to open at 110 percent of the design pressure of the tank. The sight gauges shall be long enough to overlap the high and low oil levels by at least 150 mm and shall be of the armoured flat glass transparent type with manual shutoff and ball check valves for shutting off air and oil discharge from the pressure tank in the event of breakage of the sight gauge. The safety relief valve should release air to atmosphere in a manner not injurious to personnel or equipment in the vicinity of the tank. Design calculation for capacity of oil
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The pressure tank shall be provided with a float valve assembly to prevent air admission into the main inlet valve piping system under conditions of low oil level. Manufacturer shall supply all necessary piping, fittings, solenoid-controlled valves, pressure and level switches required for this system. The solenoid shall be suitable for operation at 220 V DC and completely wired. The pipe connections for all pressure and level switches shall be independent of the oil supply lines to the servomotors and shall be provided with individual shut off valves and bleed valves as necessary. Oil pressure system and tank shall be provided with pressure switches of approved make. In addition to pressure switches required for main/standby control, the following pressure switches shall be provided and connected to each pressure tank: Normal pressure signal for unit start interlock, Low pressure alarm and Trip One contact for automatic gas admission in pressure tank
Oil pressure system and tank shall be provided with following liquid level devices of approved make mounted externally with piping valves and unions to allow their removal without interruption to MIV operation. High oil level for alarm purpose High oil level for automatic gas admission, Low oil level for alarm purposes, Extreme low oil level for unit shutdown,
In addition to above, one pressure transducer and one level transducer shall be installed for monitoring the oil pressure and level through plant SCADA System. Piping and Valves 1. 2 All piping shall be seamless steel. The entire piping system shall be welded, insofar as practicable, leaving only such flanged connections as may be necessary for erection or possible subsequent
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dismantling for repair.
Whenever straight pipes are provided, tapered flange
connections shall be introduced to ensure leak proof connection. 3 Long radius pipe bends shall be used in lieu of standard pipe elbows, wherever feasible. 4 5 Piping shall be sized so that the oil velocity will not exceed 3 metre per second. An isolating valve shall be provided in the pressure line between the pressure accumulator and the actuator and spherical valve oil system. The valves shall be located near the tank. Valves shall be cast or forged steel valve with rising spindle type and having flanged ends. Standard pipe sizes shall be used. Isolating and relief valves shall be provided to isolate and protect all major pieces of equipment. Governors for each unit shall be hydraulically independent. All oil piping shall be welded except where disassembly is required. 5.5 Quality control and assurance
The manufacturer shall supply the equipments of best quality. The manufacturer shall maintain quality control during manufacture of equipment as per the approved quality assurance plans. 5.6 5.6.1 Drawings, Documents and Design Calculations Drawings and documents
The Contractor shall submit the design calculation covering at least the following, for review / acceptance. Plate thickness calculations for Pressure tanks, Calculation of capacity of oil pressure system,
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5.7
Calculation of size of oil pressure tank, Calculation for capacity of pump and motor. Nozzle Servomotor sizing calculations Nozzle opening and closing time calculation Speed rise / pressure rise calculations Spare Parts
Recommended spare parts shall be supplied in accordance to clause 2.36 Spare Parts and tools of General Technical Requirements. Specified spare parts to be supplied under this section are as follows: Sl. No 1 2 3 4 5 6 7 8 9 10 11 12
Description Complete proportional valve assemblies Main distributing valve Solenoid valve Speed sensing probe and converter
Quantity 1 no. of each used type 1 no. 2 nos. of each used type 2 nos.
Transducer assembly complete of all type used in the 1 set system Signal conditioners Printed circuit card/module Power supply unit Pressure oil pump-motor set Jockey oil pump-motor set Auto clean filter used in the electro hydraulic actuator, Un-loader valve complete assembly 2 nos. of each used type 2 nos. of each used type 2 nos. of each used type 1 no. 1 no. 1 no. 2 nos.
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Sl. No 13 14 15 16 17 18
Description Safety relief valve complete assembly Indicating lamp bulbs for all types
Quantity 2 nos. 100 % quantity 2 nos. 2 nos. of each used type 2 nos. of each used type of installed
Sight glass gauges for pressure and sump tanks Level switches and relays Pressure switches , relays and limit switches
RTDs, Thermometers, pressure gauges used in the 2 nos. of each used type system Indicating instruments/VDU, if the indicating 2 no. of each used type instruments are being provided on display unit Bearing used in the governor hydraulic actuator, 2 nos. of each used type pumps, motors Special tools
19
20
5.8
The Contractor shall supply all necessary tools and instruments etc. for installation, repair and maintenance in accordance to clause 2.36 Spare parts and tools of Section 1 General Technical Requirements. The Supplier shall provide the following instruments:a) b) Programmer/Laptop with software & cables for parameterization and testing - 1 set I/O cards, software, transducers and connecting cables etc. for testing of governing system & spherical valve etc. including measurement of responses & operating times - 1 Set Instruments 1 Instruments as summarised in Table 7.2-1 shall be furnished along with respective equipment. These sensors/instruments shall be mounted by Supplier on respective
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equipment with proper sized fittings, clamping tubes, valves, manifolds piping, and jointing material complete in all respects. 2 Indicating instruments shall be of standard sizes and mounted on electronic cabinet and/or Unit gauge panel (Refer Section-7.4) or locally on equipment as per standard practice of manufacturer and as approved by Purchaser. 3 Input for various analogue and digital values shall be provided for use in data acquisition & control system. Necessary transducers for giving 4 - 20mA output shall be deemed included in scope of supply. These transducers shall be located in
electronic/unit control panel as approved by Purchaser. 4 Digital output for DACS shall, as far as practicable, be through potential free NO/NC contacts. TABLE 7.2.1 LIST OF INSTRUMENTS TO BE FURNISHED WITH GOVERNOR Sl. No. 1. Name Plate Governor transducer Balance Meter Gate Position 3. Gate Limit Millivolt meter scale in rpm and Hz Potential meter with scale in percent Oil pressure switch controller for high/low pressure Oil Pressure gauge (kg/cm2) Sight glass EGC Type of Instrument Voltmeter Location of indicating Instrument Electronic Governor cubicle (EGC) EGC Location of transmitter EGC Remarks
Output for DCS required
2.
Actuator Cabinet Actuator Cabinet EGC
Output for DCS required Output for DCS required Output for DCS required ---
4. 5.
Speed Indicator Load / frequency setter Governor oil pressure
EGC
EGC
EGC
6.
Unit gauge Panel
Oil Pressure tank
Auto control
7.
Governor oil pressure Oil level gauge
Oil Pressure tank Oil Pressure tank
8.
1 - local 1 - Actuator 1 - UGP 1 - local
Pressure indication Level indication

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9. 10.
Oil level gauge Governor oil level high/low
Sight glass
Level Switch
11.
Speed relays
Voltage (speed) relays
Alternative scheme of instruments shall be subject to Purchaser's approval. 5.9 Testing
The Contractor shall follow the Inspection and testing requirements in Quality assurance clause 2.31 Factory inspection and testing of General Technical Specifications and also section 4 of the QAP document. 5.10 Delivery, Installation and Commissioning
Requirements. The supplier shall arrange personnel to oversee proper storage of equipment at site, their transhipment to powerhouse, installation and commissioning.
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6. 6.1
MAIN INLET VALVE Scope of Work
Scope of work under this section covers the provision of labour, tools, plants, materials and performance of work necessary for the design, manufacture, quality assurance, quality control, shop assembly, shop testing, delivery at site, site storage and preservation, installation, commissioning, performance testing, acceptance testing, training of Owners personnel, handing over to Owner and guarantee for one year of main inlet valves, as per the specifications hereunder, each complete with all auxiliaries, accessories, spare parts and warranting a trouble free safe operation of the installation. The scope of work shall be a comprehensive functional system covering all supply and services including but not be limited to following: 6.1.1 Spherical valve and associated components: Three (3) sets of 1600 mm diameter turbine main inlet valves of spherical type for shutting off pressure water supply from penstock to the turbine distributor complete in all respect and comprising of valve body, rotor / plug, trunnions with self lubricated bearing, counter weights, and appurtenances. Three (3) sets of embedded and foundation parts, Three (3) sets of valve body drain along with guard valve and other accessories Three sets of hydraulic operated maintenance seal along with mechanical locking Three sets of hydraulic operated service seal Three (3) sets of hydraulic operating mechanisms each consisting of One/Two double acting servomotor(s), including necessary mechanical linkages, Three (3) sets of by-pass assemblies with, piping, hydraulically operated valve, guard valve and control equipment, Three (3) sets of combined automatic air vent and air inlet valves on the downstream side of the spherical valve along with piping & fittings. The piping shall be wear resistant stainless steel,
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Three (3) sets of upstream extension pieces with penstock drain valve, pressure reducing valve and guard valve,
Three (3) sets of downstream extension pieces with dismantling joint and distributor drain valve and guard valve,
Three (3) sets of Mechanical locking device for MIV Three (3) sets of local control panels including console, electro-hydraulic control, sensing and indicating devices, control piping, and devices for local and remote indication and control,
Three (3) sets of access platforms complete with stairs and guard-rails for access to the bypass and guard valves, locking device and stairs from MIV floor to the top of the valve,
Three (3) sets of piping for oil, water and air. Three (3) sets of Pressure Equalizing Valve for equalizing pressure on both sides of maintenance seal
One (1) set of spare parts, in accordance to clause no. 6.7 spare parts of this section
One (1) set of special tools, in accordance to clause no. 6.8 special tools of this section
One set of test equipment.
Coordination and provision of necessary contacts and/or ports for integration with plant SCADA system, The spherical valve shall be opened / closed by oil pressure. The pressurized oil shall be taken from common oil pressure system for Turbine Governor and Main Inlet valve. Any other item(s) not mentioned specifically but necessary for the satisfactory completion of scope of work defined above, as per accepted standard(s) / best international practices.
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6.2
The system and equipment shall be designed, built, tested and installed to the latest revisions of the following applicable standards. In the event of other standards being applicable they will be compared for specific requirement and specifically approved during detailed engineering for the purpose: 6.2.1 Standards for inlet Spherical Valve Description Spherical valves for Hydropower Stations and Systems
Standard IS 7332 6.2.2 Sl no 1
Standards for material Item Body Material Carbon steel Standard ASTM A216GR WCC ASTM A516GR 60, 70
Rotor / Plug
Carbon steel
ASTM A216GR WCC ASTM A516GR 60, 70
3 4 5
Trunnions Sleeve Seal seat, retainers fasteners, Service Seal Maintenance seal Servomotor cylinder
Carbon steel Stainless steel seal Stainless steel and
ASTM A216GR WCC 13Cr-4Ni ASTM A743 UNS S41500 13Cr-4Ni ASTM A240 UNS S41500
6 7 8
Stainless steel Stainless steel Carbon Steel
13Cr-4Ni ASTM A743 UNS S41500 13Cr-4Ni ASTM A743 UNS S41500 ASTM A216 GR WCC ASTM A516 GR 70
6.3
Rating and functional characteristics

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6.3.1
General 3 1600 mm 21.67 m3/s 24.50 m3/s EL 2295.50 m 608.00 m 760 m 1140 m 60 seconds (adjustable) 60 seconds (adjustable) 50 m3/s
Number of valves Bore nominal diameter Rated flow (100% turbine flow) Maximum flow (with 15% overload) Elevation of valve centre line Maximum Static Head Design head Hydrostatic Test pressure Valve opening time Valve closing time Shut off Discharge 6.3.2 Normal Internal Design Pressure
The normal internal design pressure for the inlet valves shall be 7.46 MPa. This pressure includes 25% water hammer effect. 6.3.3 Duty
Depending upon the requirements, the valve shall be either fully opened or fully closed and partial opening of valve is not envisaged. In closed position the valve shall be leak tight. During normal operation the valve shall be opened under balanced water pressure and closed against 200% of normal flow through the valve. Normal opening and closing shall by oil operated servomotor. Under emergency conditions, due to malfunction of the turbine control, the valves shall be capable of closing by counter weight against maximum discharge. The speed of closure
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shall be such that the internal pressure due to water hammer will not exceed the design pressure 7.46 MPa. The valve shall have a clear passage of not less than 1600 mm diameter and shall be machined to reduce head loss to a minimum. The valve shall be capable of closing against the maximum head, including water hammer, starting from an initial discharge equal to the maximum turbine discharge under full gate generation at net head with normal working stresses in all parts. Resulting pressure rise in penstock shall not exceed 25%. All the valve components shall be designed in accordance with ASME pressure vessel code. Operating servomotors shall be sized for opening and closing of the valve with minimum system oil pressure. Suitable guard valves shall be provided before each valve (i.e. by pass valve, filling valve, decompression valve etc.) to facilitate maintenance. Valve shall meet requirements of IS 7332 - 1991 or equivalent International Standards as applicable. For operation of Main Inlet Valve, control valves for By-pass valve, service seal & maintenance seal and Air release valves, oil from governor oil system shall be used. Water for operation of the seals into the seal chamber shall be fed through duplex filters with 100 microns degree of filtration. The spherical valve and its operating mechanism, extensions, coupling and related bypass, sealing and drain system shall withstand safely the stresses from the following operating conditions, with stresses in the materials not exceeding the allowable stress for normal operation specified: i) Continuous operation with valve in the open position passing the rated discharge of the turbine i.e. 24.5 m3/s under rated head with the turbine running at maximum continuous capacity. ii) With valve in open position withstanding the total maximum water pressure of 7.46 MPa on the valve centre line considering pressure rise on load rejection.
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iii)
With valve in closed position withstanding a maximum water pressure of 7.46 MPa.
The valve and its operating mechanism, extensions, by-pass system, seal, drain and air release valves, and couplings shall withstand the maximum stresses from closing under a flow corresponding to the discharge of 200% design discharge with stresses not exceeding 66% of the ultimate strength. In penstock dewatered condition, suitable means for turning off valve for dry tests [opencloseopen] shall be provided. Suitable arrangement shall be proposed by the Supplier. 6.3.4 Design and Construction
Design for Internal Pressure The design of all parts subject to internal hydraulic pressure shall be in accordance with the requirements of ASME Code Section VIII Division I. The design of branches and their reinforcement, flanges and their bolting shall also be in accordance with ASME Code. Valve body and door shall be robustly designed to minimize deflection and leakage in close condition and at maximum pressure. Valve Body The valve body shall be of either cast steel or welded steel plate construction and shall be made in two sections. The sections shall be jointed with bolted flanges using O seal rings to ensure a watertight joint. The valve body shall be provided with flanges to connect to the upstream and downstream connecting pipes, and a suitable base for support on concrete foundations. The base shall be provided with self-lubricating arrangement in order to allow the spherical valve to move freely to accommodate penstock longitudinal expansion. Provision for drain and air vent shall be made at the lowest and highest point respectively of the valve body. The drain and air vent piping shall be equipped with isolating valves and shall be extended down the drainage trench. Valve door, trunnions and Bearings
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The valve door shall be of cast steel or fabricated from steel plate with forged steel trunnions construction. The trunnion shall be bolted to valve door. Stainless steel seat rings shall be provided on the door and secured to it using stainless steel screws. The material selected of the seat rings shall be compatible with the seal rings. The trunnions shall be faced with stainless steel or hard chrome plating where they will be in contact with the bearings. The bearings shall be of self-lubricating material and shall be secured against rotation in their housings. The trunnions assembly shall be provided with an efficient sealing system and both bearings and seals shall be capable of adjustment or replacement without dismantling the valve rotor from the body. Valve Seals The valve shall be provided with two independent sealing systems; an upstream maintenance seal and a downstream service seal. The down stream seal shall be designed for normal operation and upstream seal shall be designed to be used when downstream seal require adjustment / maintenance. Both seals shall be oil operated with a provision to mechanical lock the upstream seal. The both seals shall be made of stainless steel and carefully machined to ensure proper contact with their corresponding seats. Dismantling joint, upstream and down stream connecting pipes The valve shall be provided with upstream and downstream pipes with dismantling joint on downstream. The upstream and downstream pipes shall be fabricated from steel plate to ASTM A516 Gr. - 70. The upstream pipe shall have flange connection on one side for bolting to spherical valve and welded connection on the other side for welding with penstock. The Upstream pipe shall extend to a minimum distance of 5000 mm from valve centre line including a taper piece and a straight pipe minimum 500 mm long. An extra fitting allowance of 150 mm shall also be provided on upstream end for site adjustment during welding with penstock. Upstream pipe shall also be provided with following connections / tappings;
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One connection for by pass valve One connection for supplying water for spherical valve control One for penstock drain connection Tapping for discharge / flow measurement and pressure gauge / transducer etc. The downstream pipe shall have flange connection on one side and shall be bolted to spherical valve and other side shall be connected to turbine distributor through dismantling joint. The downstream pipe shall be provided a tapping for receiving by-pass valve connection. Valve Servomotor The Spherical valve shall be provided with one or two double acting hydraulic servomotor(s) for opening and closing of the valve. The capacity of servomotor shall be sufficient to open and close the spherical valve in approximately in 30 to 60 seconds. Opening and closing of the spherical valve shall be carried out by supplying the servomotor with pressurized oil from the turbine hydraulic power pack. The piston rod shall be of stainless steel or carbon steel hard chrome plated and the surface of the servomotor in contact with water shall be of a corrosion resistant material. The rod end cylinder head shall be provided with a non-adjustable packing gland to prevent the leakage of oil. Provision shall be made in the servomotor or on the lever to limit the movement of the valve door in each direction so that the door will always terminate its movement in the correct position. The servomotor or valve shall be provided with a hand operated mechanical locking arrangement to lock the valve in open and closed positions. The locking arrangement shall be designed for full servomotor and / or hydraulic load. All pilot and control valves, limit switches and interlocks necessary to coordinate the operation of the main valve and bypass valve shall be provided. When the valve is locked in the closed position, the electric circuits for opening the valve shall be inoperative. Provision shall also be made for padlocking the locking device when in the closed position. At each end of the cylinder, a cushioning device shall bring the moving piston smoothly to rest and avoid damage by impact or pressure waves within the operating system. The cushioning action shall be adjustable.
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Air bleed valves shall also be provided, as required, to release any entrapped air. An indicator giving the position of the rotor shall be mounted on the lever. graduated from 0 to 90. Closed. It shall be
The two extreme positions should be marked Open and
Limit switches or proximity switches shall be mounted on both the extremes
position for Valve position indication. Suitable steel counter weights shall be provided for self closing of valve in shortest possible time under all operating conditions without the help of servomotor. The counter weight shall be properly mounted on the lever of spherical valve. By-pass System The by-pass system with by pass valve and guard valve of suitable sizes shall be provided to fill the turbine distributor for balancing the pressure on upstream and downstream side of the valve before opening the main inlet valve. The by-pass valve shall be of needle type and arranged for automatic operation. The bypass valve shall be provided with a manual guard valve. An indication shall be provided to show the position of by pass valve. Needle and seat of by-pass valve shall be of stainless steel. 6.3.5 Control
The following describes the requirements particular to the inlet valve control. These controls shall be integrated to Unit Control or in a stand-alone cabinet next to it, as applicable subject to approval by the Buyer. The cabinet shall contain all the electric control equipment for the correct operating sequence of the servomotor, bypass valve and seals. The control logic may be hydraulic, relay or programmable logic controller (PLC) and shall provide a high reliable control. The control will be powered from the station 220 V dc battery system. If the control equipment requires supply voltage other than 220 V dc, the voltage source/converters shall be provided by the Seller. The cabinet shall also be equipped with a key operated Local / Remote selector switch, pushbuttons, status indicating lights, and pressure gauges arranged in an approved manner. With the selector switch at Local all remote command signals shall be blocked but remote position status signals shall be maintained.
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With the selector switch at Remote local command signals shall be blocked but local position indication shall be maintained. The Local Control shall be by means of pushbutton for OPEN and CLOSE. Local
indication shall be Red for Valve OPEN, Green for CLOSED, White flashing for Valve in transit. Depressing pushbutton OPEN shall automatically initiate the following sequence of operations; Open by-pass valve and air release valve. Close air release valve after a time delay or when pressure is equalised. After pressure equalisation de-energise service seal. After service seal is withdrawn (no service seal pressure) and spiral pressure equalisation achieved initiate Inlet valve opening command. When valve is fully open, close bypass valve.
Depressing pushbutton CLOSE shall automatically initiate the following sequence of operations; The valve rotor shall rotate into the closed position. The service seal shall be applied after ensuring no valve movement.
It is not intended that valve closure will take place each time the unit is shut down. However, the valve control system shall be integrated with the DCS control so that, in the event a valve is closed during shutdown, the DCS will automatically open the valve following the correct sequence of operation, during next unit start-up. The Remote Control shall be by means of open / close pulse command from the DCS to the valve control. Pulse command shall initiate the same open / close automatic sequence as described above for locally initiated command. In addition to the indication of valve position, service seal position, Bypass valve position, pressure equalisation, signal contacts shall be provided for the DCS to indicate, at the Remote locations, the selector switch position of the local control panel.
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Provision shall be made for emergency closure of the spherical valve by means of the command signal from the Emergency Close pushbutton at the Remote location and from the Unit Protection System. During emergency shutdown the valve will be subjected to close against full flow following the same closing sequence as described for local panel close control. Pressure gauges with 4-20 mA transducer outputs (DCS) shall be provided for monitoring upstream pressure and downstream water pressure. All the components of the hydraulic control system shall be made of stainless steel. Manual valves of the rising stem type shall be provided at all necessary points. Suitable safety mechanisms shall be incorporated into the design of the valve and control systems to ensure proper valve operation and to protect personnel engaged in inspection or maintenance work from the hazards of accidental opening of the valve plug or seals. A mechanical locking device shall be provided to keep the valve rotor in the fully closed position. The locking device shall be designed to hold the rotor positively in this position when the servomotor is disconnected or removed. A limit switch shall also be provided to indicate the application of MIV lock and the same shall be interfaced with SCADA. The maintenance seal control mechanism shall be designed so that, once applied, it is held in contact by the pressure of the water in the penstock and cannot be released unless pressure is applied, by way of the control piping, to release it. 6.4 Lifting and handling fixtures
The Contractor shall provide lifting fixtures and special tackles and devices for handling of major components of main inlet valve i.e. body, rotor, transition sections, servomotors, counterweight, bearings etc. These devices shall include at least the following: One (1) valve handling and lifting device for handling and lifting the assembly of valve in-situ, One (1) valve rotor lifting device and special nylon slings for lifting and handling the valve rotor, servomotors, levers, counterweight etc. One (1) set of special erection tools, instruments & devices and maintenance hand tools, wrench etc.
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6.5
Oil and water piping
Oil piping shall be of seamless steel and shall include all piping to the governor oil pressure supply system as required. The piping shall be of such size that the maximum oil velocity shall not exceed 3.0 m/sec in the pressure lines and 1.5 m/sec in the return lines. Minimum pressure anywhere in the oil piping system during maximum speed of valve operation shall not be less than 0.5 bar absolute. All oil piping shall be thoroughly cleaned, oiled inside, and protected for shipment with flange protectors on all flanges, screwed caps on threaded ends and suitable plugs in plain ends. Water piping shall be made of heavy seamless stainless steel pipe and shall be flanged. 6.6 Quality Control and assurance
The manufacturer shall supply the equipments of best quality. The manufacturer shall maintain quality control during manufacturing, installing and testing and commissioning of equipment as per the approved quality assurance plans. 6.7 6.7.1 Drawings, Documents and Design Calculations Drawings
The contractor shall submit all the drawings and documents as per Section 1.6 Reference drawings and documents of General Technical Specification (GTS). These drawing and documents shall include at least the following: General arrangement, plan and section of Valve, servomotor, by-pass valve etc. G.A assembly drawings of Valve, control valves and other by-pass, air bleeder etc. Control schematic drawings of all devices, piping systems, control systems and instruments illustrating functioning of opening and closing sequences. List of accessories and auxiliaries. Instruments offered with catalogues / pamphlets Detailed quality assurance plan giving complete specifications of materials and specifications relating to inspection and testing of materials and finished products. Comprehensive operation, maintenance and installation instructions in the form of O & M manual for turbine, main inlet valve, governor and auxiliaries.
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Foundation details and loads including unbalanced forces, their point of application under various normal and most abnormal operating conditions.
6.7.2
Design calculation
The Contractor shall submit the design calculation covering at least the following, for review / acceptance. Structural and stress analysis of different parts of spherical valve during all loading conditions. Head loss calculation Torque and hydraulic force coming on door and body during opening and closing of valve 6.8 6.8.1 Calculation of sizing of servomotor. Calculation of Foundation loads. Calculations of sizing of by pass valve, Calculations for oil pressure system. Spare Parts Recommended Spare parts
Following Specified spare parts shall be supplied for Main Inlet valve and accessories under this section: S. No. 1 Description Quantity
Complete set of downstream and upstream moveable 1 set seal assembly including O rings.
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S. No. 2 3
Description Door seat ring
Quantity 1 set
Set of all O ring seals and gaskets for complete 1 set valve including servomotor, by pass valve and other equipment. Coils for each type of solenoid used in valve and 1 set associated equipment One number of each size of valve used By pass valve assembly Air release valve assembly Set of Trunnion bearing Servomotor assembly 1 set 1 set 1 set 1 set 1 set
5 6 7 8 9 10
One set of instruments of all type used for spherical 1 set valve and associated equipment for one complete unit All type of indicating lamps 2 sets
11
Note: - One set is defined as the total number / quantity required for one unit. 6.9 Special tools
The Contractor shall provide one set of special tools and maintenance equipment for repair and maintenance of turbine. A list of such tools including their make and detailed specification shall be furnished along with tender and shall be got approved from the Owner during detail engineering. However following special tools shall be included in addition to tools recommended by manufacturer(s) One (1) set of hydraulic torque tensioners with two identical tensioners operated by a common power pack for tightening bolts valve body halves, One (1) set of Nylon Sling round and flat for handling Valve components,
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Four (4) no. of Eye Bolts of each size (M12 and above) used in the turbine components,
Four (4) no. of lifting D-shackles of each size (M12 and above) used in the turbine components.
6.10
One (1) set of equipment and instruments for site testing of valve One (1) set special erection tools, instruments and devices. One (1) set of Erection hand tools, wrenches etc. Shop Tests
6.10.1 Assembly Major components of valve shall be assembled, match marked and doweled to ensure correct assembly and alignment. The spherical valve shall be hydrostatic tested to demonstrate the strength of valve body and door and to determine leakage through the valve seats. All the associated auxiliaries i.e. bypass valve, control valve, servomotor etc shall also be hydrostatic tested at recommended pressure. The test on spherical valve shall be conducted as follows; Both ends shall be closed with flanged bulkhead and the valve door shall be kept in open position so the hydrostatic pressure can be applied to the body of the valve by suitable connection in the upstream bulkhead. Hydrostatic pressure shall be held for a period of 60 minutes at a pressure not less than 1.5 times the design pressure i.e. 114.00 kg/cm2. After completion of above test, the valve shall be closed and downstream bulkhead shall be removed and same hydrostatic test pressure of 114 kg/cm2 shall be applied. After a period of 15 minutes, the pressure shall be reduced to maximum static head of 608.00 m. The leakage through the closed valve shall than be accurately measured through both the seals to determine whether the valve leakage guarantees has met or not. The leakage through each seal (i.e. service & maintenance seals) shall be determined independently.
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All other tests including performance tests shall be carried out on each valve in accordance with IS: 7332.
Hydraulic testing of servomotors, valve and water and oil piping at two times the normal working pressure.
Leakage and performance tests of all servomotors. Hydrostatic and leakage tests on bypass, drain and air release valves and other valves.
A list of shop assembly and tests required to be carried out shall be as per approved QAP
6.10.2 Material Tests Material tests for important components of valve and servomotor such as valve body, valve door, trunnion bearings, servomotor cylinder, servomotor piston and piston rod, and other important components shall be carried out and submitted to the owner. 6.10.3 Defects and corrections Any leakage, distortion or other defects developed during or after the tests shall be corrected and retested. A record shall be maintained of shop measurements of all critical and important dimensions, diameters, concentricity, run-out, clearances etc of valve moving and stationary parts which may affect the field erection and alignment or normal operation of the valve. 6.11 Installation and commissioning
6.11.1 General The contractor shall furnish all labour, tools, supplies, slings and supports and all other provisions or material necessary to assemble, erect, install, test and commission the equipment in a thorough workmanlike manner following the best practices. The equipment and all their components shall be placed with great care and shall be aligned to provide an installation consistent with close tolerances used in the erection of modern equipment. The proper elevation and centrelines to which equipment is to be set shall be established by the contractor.
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All necessary material and labour for performing all the site tests shall be provided by the contractor. All test equipment and instruments shall be supplied by the contractor. 6.11.2 Installation procedures The contractor shall prepare and submit detail of his proposed site installation procedures. The procedures shall include record sheets on which various alignment checks and test shall be recorded and approved by the engineer as work at site progresses. The installation procedure submitted should specify erection tolerances as per international and or industry standards. 6.11.3 Field Tests All field tests including operational, pre-commissioning, commissioning and acceptance tests shall be conducted by the contractor in the presence of owners representative. Following field tests shall be performed to ensure that the valve meets specification provisions and manufacturers guarantee: Tests to determine opening / closing time during normal and emergency shutdown conditions. Tests to check penstock pressure rise under maximum load throw-off conditions with respect to maximum turbine discharge condition for all the three machines. Tests to determine leakage from each valve seals under specified head conditions with penstock filled with water including operational tests to check maintenance (10 - 15 times). Testing and setting of all relays, limit switches and electrical controls. Dielectric and insulation measurement tests on all electrical items I.e. solenoids, limit switches, wiring etc. as per relevant standards. Operational tests to check sequence of operation and interlocks of by-pass valve, air bleeder valve, valve plug and valve seats as per approved logic diagram.
and
operation
leakage
after
repeated
applications
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Any other tests as recommended by manufacturer or shall be necessary as per the provision of specifications and applicable IS / IEEE standards. Procedure to be adopted for conducting the operational, pre-commissioning and commissioning tests shall be supplied well in advance and shall be subjected for approval of the owner.
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7. 7.1
PENSTOCK BUTTERFLY VALVE AND AUXILIARIES Scope of Work
Scope of work under this section covers the provision of labour, tools, plants, materials and performance of work necessary for the design, manufacture, quality assurance, quality control, shop assembly, shop testing, delivery at site, site storage and preservation, installation, commissioning, performance testing, acceptance testing, training of Owners personnel, handing over to Owner and guarantee for one year of Penstock Butterfly valves, as per the specifications hereunder, each complete with all auxiliaries, accessories, spare parts and warranting a trouble free safe operation of the installation. One butterfly valve shall be provided between the surge shaft and the pressure shaft inlet as shown in the drawing. The valve shall be housed in valve house. The scope of work shall be a comprehensive functional system covering all supply and services including but not be limited to following: 7.1.1 Penstock Butterfly valve and associated components: One (1) set of 3350 mm diameter penstock valve of butterfly type for shutting off pressure water supply from surge shaft to penstock complete in all respect and comprising of valve body, valve door, trunnions with self lubricated bushes, operating lever, counter weights, service seal, maintenance seal and
appurtenances. One (1) set of embedded and foundation parts, One (1) set of hydraulic operating mechanism each consisting of One / Two double acting servomotor(s), including necessary mechanical linkages, One (1) set of by-pass assembly with piping, hydraulically operated valve, guard valve and control equipment, One (1) set of combined automatic air vent and air inlet valves on the downstream side of the BF valve, One (1) set of upstream extension piece, One (1) set of downstream extension piece with dismantling joint,
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One (1) set of Mechanical lock One (1) set control system including sensing and indicating devices, control piping, and devices for local and remote indication,
One set of over speed / penstock rupture device. One (1) set of access platform complete with walkway, stairs / ladder and guardrails for access to the bypass and guard valves, locking device, vacuum breaking valves, and stairs from valve floor to the top of the valve,
One (1) set of piping for oil, water and air. One (1) set of Anti vacuum valve along with pipes and pipe fittings located on down stream of the BF valve.
One (1) set of oil pressure system consisting of sump tank, two motor driven oil pumps, oil pressure tank, high pressure Nitrogen bottles, necessary piping, valves and fittings etc.
Oil for first filling including 10% extra in non returnable drums. One (1) set of spare parts, in accordance to clause no. 7.7 Spare Parts of this section
One (1) set of special tools, in accordance to clause no. 7.8 Special tools and devices of this section
One (1) set of test equipment in accordance to clause no. 7.9 Test equipment. Any other item(s) not mentioned specifically but necessary for the satisfactory completion of scope of work defined above, as per accepted standard(s) / best international practices.
7.2
The system and equipment shall be designed, built, tested and installed to the latest revisions of the following applicable standards. In the event of other standards being applicable they will be compared for specific requirement and specifically approved during detailed engineering for the purpose:
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7.2.1
Standards for inlet Spherical Valve Description Penstock and Turbine Inlet Butterfly Valves for Hydropower Stations and Systems
Standard IS 7326
7.2.2 Sl no 1
Standards for material Item Valve Body Material Carbon steel Standard ASTM A216GR WCC ASTM A516GR 60, 70
Valve Door / Disc
Carbon steel
ASTM A216GR WCC ASTM A516GR 60, 70
3 4 5
Trunnions Sleeve
Carbon steel Stainless steel
ASTM A216GR WCC 13Cr-4Ni ASTM A743 UNS S41500 13Cr-4Ni ASTM A240 UNS S41500
Seal seats, seal Stainless steel retaining cover and fasteners, Seals Metal, solid Rubber or synthetic polymer Carbon Steel
Servomotor cylinder
ASTM A216 GR WCC ASTM A516 GR 70
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7.3 7.3.1
Rating and functional characteristics General 1 3350 mm 64.00 m3/s 73.60 m3/s EL 2867.675 m EL 2863.67 m 55.00 m 82.50 m 120 seconds (adjustable) 120 seconds (adjustable) > 700 m3/sec.
Number of valve Bore nominal diameter Rated flow (100% turbine flow) Maximum flow (with 15% overload) Elevation of valve centre line Elevation of Valve House Design head Hydrostatic Test pressure Valve opening time Valve closing time Catastrophic failure discharge 7.3.2 Normal Internal Design Pressure
The normal internal design pressure for the penstock valves shall be 55.00 m. This pressure includes a water hammer effect also. 7.3.3 Duty
Penstock valve shall be used to shut off water in case of MIV or penstock failure and to permit dewatering of penstock. The penstock valve shall be Lattice type Butterfly valve with horizontal shafts and counter weight closing. The valve shall have provision of maintenance seal to under take repair / removal of service seal without dewatering the upstream section. Depending upon the requirements, the valve shall be either fully opened or fully closed and partial opening of valve is not envisaged.
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During normal operation the valve shall be opened under balanced water pressure and closed against maximum discharge. Normal opening and closing shall by oil operated servomotor. Under emergency conditions, the valves shall be capable of closing by counter weight against maximum head including water hammer, starting from an initial discharge up to maximum turbine discharge or runaway conditions at maximum head. The speed of closure shall be such that the resulting water hammer does not produce a higher internal pressure than normal internal design pressure. Counter weight shall provide sufficient closing torque to enable the valve to close under maximum head with a safety margin of minimum 1.3. Supplier shall furnish discharge vs loss characteristic of the valve. Losses at 64.00 m3/sec and 73.50 m3/sec shall be specifically furnished. Suitable provision for transmission of axial loads to upstream liner (forces to be furnished) shall be made. The feet of valve shall be suitably designed to allow axial movement as per requirement. 7.4 7.4.1 Design and Construction Design for Internal Pressure
The design of all parts subject to internal hydraulic pressure shall be in accordance with the requirements of ASME Code Section VIII Division I. The design of branches and their reinforcement, flanges and their bolting shall also be in accordance with ASME Code. The valve body and door shall be so designed that when fully opened, there shall be minimum obstruction to the flow of water. The design of the valve shall be such as to resist the hydraulic forces acting directly on the body and those resulting from the thrust of the disc when in closed position. Valve body and door shall be robustly designed to minimize deflection and leakage when retaining the design pressure.
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7.4.2
Valve Body
The valve body shall be of either cast steel or welded steel plate construction and shall have a corrosion resistant sealing seat. The body shall be made in two sections. The valve body shall be machine finished where required for matching parts and drilled to receive the shaft bearing. The body shall be provided with drain connection with valve and piping. The valve body shall be provided with flanges for connecting to the upstream and downstream pipes, and a suitable base for support on concrete foundations. The base shall be provided with self-lubricating sole plates, in order to allow the valve to move freely to accommodate penstock longitudinal expansion. Provision for air vent shall be made at the highest point of the valve body. The air vent piping shall be equipped with isolating valves shall extend down the drainage trench. 7.4.3 Valve door
The valve door shall be biplane lattice type. The door shall be made of normalised cast steel or fabricated from steel plate with integral trunnions. The disc shall be so designed and constructed as to produce a minimum of hydraulic loss. The trunnions shall be faced with stainless steel or hard chrome plating where they are in contact with the bearings. 7.4.4 Valve Seals
The valve disc shall be designed to accommodate service and maintenance seals. The seals may be of metal, solid rubber or synthetic polymer. The seal adjustment feature shall be provided either in seal retaining element or in the sealing seating element from the downstream side of the valve. 7.4.5 Trunnion Bearings
The bearings shall be of self-lubricating material. The bearing shall be secured against rotation in the bearing housings. The trunnion assembly shall be provided with an efficient sealing system and both bearings and seals shall be capable of adjustment or replacement without dismantling the valve rotor from the body.
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7.4.6
Dismantling joint, upstream and down stream connecting pipes
The valve shall be furnished with upstream and downstream pipes with dismantling joint on downstream. The upstream and downstream pipes shall be fabricated from steel plate to ASTM A516 Gr. - 70. The upstream pipe shall have flange connection on one side for bolting to the valve and welded connection on the other side for welding with penstock. Upstream pipe shall be provided with following connections / tapping; One connection for by pass valve One for penstock drain connection On the downstream side of the valve a telescopic type dismantling joint shall be provided. The dismantling section shall be flanged on one end for connection to valve body and other end side telescopic joint to downstream connection piece. A manhole of suitable size not less than 700mm dia. shall be provided on the downstream connection pipe at suitable location for the purpose of maintenance. The total length of upstream pipe, downstream dismantling joint and valve body shall not be less than five (5) m. The upstream and downstream pipes shall be provided with additional length (fitting allowance) for site adjustment. 7.4.7 Valve Operating Mechanism
The valve operating mechanism shall consist of one or two double acting hydraulic servomotor(s) for opening and closing of the valve and counter weight. The capacity of servomotor(s) shall be sufficient to open and close the valve in approximately 120 seconds. Opening and closing of the valve shall be carried out by supplying the servomotor with pressurized oil from the nitrogen-oil pressure accumulator. The valve shall be held in open position by oil servomotor. Closing of the valve shall be by counter weight in event of loss of oil pressure. The piston rod shall be of stainless steel or carbon steel hard chrome plated and the surface of the servomotor in contact with water shall be of a corrosion resistant material. The rod end cylinder head shall be provided with a non-adjustable packing gland to prevent the leakage of oil.
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Provision shall be made in the servomotor or on the lever to limit the movement of the valve door in each direction so that the door will always terminate its movement in the correct position. The servomotor or valve shall be provided with a hand operated mechanical locking arrangement to lock the valve in open and closed positions. The locking arrangement shall be design for full servomotor and / or hydraulic load. At each end of the cylinder, a cushioning device shall bring the moving piston smoothly to rest and avoid damage by impact or pressure waves within the operating system. The cushioning action shall be adjustable. Air bleed valves shall also be provided, as required, to release any entrapped air. An indicator giving the position of the door shall be mounted on the lever. graduated from 0 to 90. Closed. It shall be
The two extreme positions should be marked Open and
Limit switches or proximity switches shall be mounted on both the extremes
position for Valve position indication. Adequate counter weight shall be provided for self closing of valve in shortest possible time without the help of servomotor. The counter weight shall be properly mounted on the lever of the valve. Penstock butterfly valve shall be provided with a hydraulic pressure system complete with sump tank, oil pumps, valves, piping, a pressure tank, compressed air system and all electrical and hydraulic control required for complete operation of the valve. 7.4.8 By-pass System
The by-pass system consists of hydraulic pressure operated by pass valve and a manual guard valve, and necessary piping, flanges and fittings etc. The bypass valve shall be of suitable type and size not less than 300 mm. By pass system shall be designed for automatic operation. An indication shall be provided to show the position of by pass valve. The bypass valve shall be able to operate under unbalanced condition. One automatic air release and admission valve shall be provided at the highest point in the downstream dismantling pipe.
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7.4.9
Oil Pressure System
The oil pressure system shall be provided with two motor driven oil pumps along with jockey pump for maintaining the oil pressure. Each pump shall be of adequate capacity to supply the oil required for one normal operation of butterfly valve. It shall be possible to run one pump continuously so that it discharges to the sump during idling or to accumulator tank without overheating the oil. Automatic pressure or level-operated motor controls shall be furnished with the pump running unit, which will start the pump when the oil pressure or level in the pressure tank drops to predetermined point and which will stop the pump when oil pressure or level rises to predetermined point. The two main oil pumps shall be operated either independently or together, with one pump used for normal operation and the other arrangement to start with a drop in oil pressure. A manual selector switch shall be provided to select one of the two pumps as the lead pump. An oil pressure-operated un-loader valve of sufficient capacity to pass the full delivery of the pump at a pressure of 10% above the minimum rated pressure shall be provided for the main pump. The un-loader valve shall be operated from the pressure tank oil pressure by pilot lines, complete with isolating valves & filters or pressure switches, and shall be equipped with snap action pilot valves. Hand operated valves shall be provided to permit isolate either pump from the oil pressure system and its removal for repairs without losing oil pressure. All valves and mechanism shall be accurately set and tested in shop before delivery. Oil pressure station shall be provided with a pressure accumulator tank of sufficient capacity for one opening and one closing of penstock butterfly valve without recharging of the tanks. Sump tank having adequate capacity shall be provided to store oil for operation and drainage of oil for the complete system. The oil sump will have proper provision for duplex strainer, level gauge etc. The scope will also include necessary instrumentation, ie. level monitors, temperature monitors, pressure monitors etc. a) b) Necessary valves, pipes and fittings. Piston type nitrogen accumulators connected to the pressure system having sufficient capacity to maintain the valve in open position and to take care of pressure fluctuations. System shall be suitable for one close - open - close sequence of operations.
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c) d)
Suitable hydraulic controls (48V DC operation) shall be provided Suitable pressure switches for controlling the operation of the oil pumps and monitoring the oil pressure in the servo motor.
e)
Other controls as necessary.
Automatic pressure controlled motor control circuits shall be furnished with the pumping unit which will start the pump while opening of the valve and also start the jockey pump when the oil pressure of the servo motor drops to a pre-determined point and stop when the oil pressure has risen to the required value. 7.4.10 Over velocity Device An automatic shut-off control system shall be provided to close the valve when penstock velocity exceeds a certain percentage over the maximum normal / transient velocity in the penstock. The sensing system shall be of sonic flow measuring system type. The sensing system shall actuate the valve shut-off system when penstock velocity shall exceed the value. This automatic shut off control system shall be operated by electric power with a stored energy backup and mechanically counter weight. This automatic shut off system shall also be controlled remotely from the power house. 7.4.11 Vacuum Breaking arrangement A set of one or two vacuum breaking valves of adequate capacity along with pipes and pipe fittings shall be provided on the penstock to break the excessive vacuum developed in the penstock during closure of Butterfly valve or other wise. The vacuum valves shall be located on the down stream side of the BF valve. The anti-vacuum valve shall be sized considering the following:a) b) Operation is not noisy Air admission rate corresponding to water filling rate by bye-pass or 1% water leakage from BFV. c) All Units running at 120% rated load and BFV closed. In this condition vacuum in penstock should not exceed 4m/w.c. A drain pipe of suitable size shall be provided from outlet of the vacuum breaking valve to drain trench to discharge the leakage water from the valve to drainage. An access platform
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with walkway, ladder and guard-rails shall also be provided around the valves to facilitate maintenance of the valves. 7.4.12 Control and Indications Panel The following describes the requirements of the penstock valve control. The control system shall be compatible with station DCS regarding input and output needed for operation, control and monitoring of butterfly valve. The following control and indication shall be provided in the control panel and remotely at unit control board and the power house control room for penstock valve; A flashing green light to indicate the opening sequence and remain on when valve is open. A flashing red light to indicate the closing sequence and remain on when valve is closed. A light to indicate open / close status of the bypass valve. A light to indicate that the differential pressure across the valve disc is greater than acceptable for opening the main disc. Low / high accumulator level alarm annunciation. Low / high accumulator pressure alarm Extreme low oil level alarm Low level alarm A manually operated switch for closing and opening of the valve. Position, limit, pressure, control and level switches, push-button station, relays and other control devices shall be furnished as required for the proper operation of the penstock valve. 7.4.13 Lifting and handling fixtures The Contractor shall provide lifting fixtures and special tackles and devices for handling of major components of the valve i.e. body, door, upstream & downstream sections, servomotors, counterweight, bearings etc. These devices shall include at least the following:
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One (1) valve handling and lifting device for handling and lifting the assembly of valve in-situ,
One (1) valve door lifting device and special nylon slings for lifting and handling the valve rotor, servomotors, levers, counterweight etc.
One (1) set of special erection tools, instruments & devices and maintenance hand tools, wrench etc.
7.5
Quality Control and assurance
The manufacturer shall supply the equipments of best quality. The manufacturer shall maintain quality control during manufacturing, installing and testing and commissioning of equipment as per the approved quality assurance plans. 7.6 7.6.1 Drawings, Documents and Design Calculations Drawings
The contractor shall submit all the drawings and documents as per Section 2.12 Reference drawings and documents of General Technical Specification (GTS). These drawing and documents shall include at least the following: General arrangement, plan and section of Valve, servomotor, by-pass valve etc. G.A assembly drawings of Valve, control valves and other by-pass, air bleeder etc. Control schematic drawings of all devices, piping systems, control systems and instruments illustrating functioning of opening and closing sequences. List of accessories and auxiliaries. Instruments offered with catalogues / pamphlets Detailed quality assurance plan giving complete specifications of materials and specifications relating to inspection and testing of materials and finished products. Comprehensive operation, maintenance and installation instructions in the form of O & M manual for turbine, main inlet valve, governor and auxiliaries.
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Foundation details and loads including unbalanced forces, their point of application under various normal and most abnormal operating conditions.
7.6.2
Design calculation
The Contractor shall submit the design calculation covering at least the following, for review / acceptance. Structural and stress analysis of different parts of the valve during all loading conditions. Head loss calculation Torque and hydraulic force coming on door and body during opening and closing of the valve 7.7 7.7.1 Calculation of sizing of servomotor. Calculation of Foundation loads. Calculations of sizing of by pass valve, Calculation for Oil pressure system. Spare Parts Recommended Spare parts
Following Specified spare parts shall be supplied for Butterfly valve and accessories under this section: S. No. 1 Description Quantity
Service and maintenance seals with retaining cover 1 set and hardware.
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S. No. 2
Description
Quantity
O ring seals and gaskets for complete valve 1 set including servomotor, by pass valve and other equipment. Piston rings for servomotor, by-pass valve and other 1 set valves Valves one number of each size & type By pass valve assembly Air release valve assembly Bearing / bush for valve trunnion Servomotor assembly All type of indicating lamps Pressure Oil pump motor Set Un-loader Valve assembly Safety relief valve assembly Oil filter Level relay for OPU Glass pipe for sight gauge Pressure relay Resistance temperature detector of each type Limit switches of each type Pressure gauge of each type Dial type thermometer 1 set 1 set 1 set 1 set 1 set 2 sets 1 Set 1 No. 1 No. 1 No. 1 No. 2 Nos. 1 No. 1 set 1 Set 1 Set 1 set
4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20
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S. No. 21 22 23
Description Bearing for motor and pumps Air dryer complete Motor compressor set complete
Quantity 1 Set 1 Set 1 set
Note: - One set is defined as the total number / quantity required for one unit. 7.8 Special tools, tackles and devices
The Contractor shall provide one set of special tools and maintenance equipment for repair and maintenance of penstock valve. A list of such tools including their make and detailed specification shall be furnished along with tender and shall be got approved from the Owner during detail engineering. However following special tools shall be included in addition to tools recommended by manufacturer(s) One (1) set of hydraulic torque tensioners with two identical tensioners operated by a common power pack for tightening bolts of valve body halves, 7.9 7.9.1 One (1) set of Nylon Sling round and flat for handling Valve components, Four (4) no. of Eye Bolts of each size used in the valve components, Four (4) no. of lifting shackles of each size used in the components. One (1) set of equipment and instruments for site testing of valve One (1) set special erection tools, instruments and devices. One (1) set of Erection hand tools, wrenches etc. Shop Tests Assembly Major components of valve shall be assembled, match marked and doweled to ensure correct assembly and alignment.
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The complete assembled valve shall be operated through several opening and closing cycles to demonstrate satisfactory operation.
The valve shall be hydrostatic tested to demonstrate the strength of valve body and door; upstream and downstream pipes and to determine leakage through the valve seals. All the associated auxiliaries i.e. bypass valve, control valve, servomotor etc shall also be hydrostatic tested at recommended pressure. The test on the valve shall be conducted as follows; Both ends of the valve extension pipes shall be closed with bulkheads and the valve door shall be kept in open position so the hydrostatic pressure can be applied to the body of the valve by suitable connection in the upstream bulkhead. Hydrostatic pressure shall be held for a period of 60 minutes at a pressure not less than 1.5 times the design pressure of valve. After completion of above test, the valve shall be closed and downstream bulkhead shall be removed and same hydrostatic test pressure of 8.25 kg/cm2 shall be applied. After a period of 15 minutes, the pressure shall be reduced to a design head of 5.50 kg/cm2. The leakage through the closed valve shall than be accurately measured through both the seals to determine whether the valve leakage guarantees has met or not. The leakage through each seal (i.e. service & maintenance seals) shall be determined independently.
All other tests including performance tests shall be carried out on each valve in accordance with IS: 7326.
Hydraulic testing of servomotors, valves, water and oil piping at two times the normal working pressure.
Leakage and performance tests of all servomotors. Hydrostatic and leakage tests on bypass valve, drain valve, air release valve and other valves.
A list of shop assembly and tests required to be carried out shall be as per approved QAP
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7.9.2
Material Tests
Material tests for important components of valve and servomotor such as valve body, valve door, trunnion bearings, servomotor cylinder, servomotor piston and piston rod, and other important components shall be carried out and submitted to the owner. 7.9.3 Defects and corrections
Any leakage, distortion or other defects developed during or after the tests shall be corrected and retested. A record shall be maintained of shop measurements of all critical and important dimensions, diameters, concentricity, clearances etc of Butterfly valve which may affect the field erection and alignment or normal operation of the valve. 7.10 Installation and commissioning
7.10.1 General The contractor shall furnish all labour, tools, supplies, slings and supports and all other provisions or material necessary to assemble, erect, install, test and commission the equipment in a thorough workmanlike manner following the best practices. The equipment and all their components shall be placed with great care and shall be aligned to provide an installation consistent with close tolerances used in the erection of modern equipment. The proper elevation and centrelines to which equipment is to be set shall be established by the contractor. All necessary material and labour for performing all the site tests shall be provided by the contractor. All test equipment and instruments shall be supplied by the contractor. 7.10.2 Installation procedures The contractor shall prepare and submit detail of his proposed site installation procedures. The procedures shall include record sheets on which various alignment checks and test shall be recorded and approved by the engineer as work at site progresses. The installation procedure submitted should specify erection tolerances as per international and or industry standards.
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7.10.3 Field Tests All field tests including operational, pre-commissioning, and commissioning tests shall be conducted by the contractor in the presence of owners representative. Following field tests shall be performed to ensure that the valve meets specification provisions and manufacturers guarantee: Tests to determine opening / closing time during normal and emergency shutdown conditions. Pressure test of all field piping for oil and air at 1.5 times of the maximum design pressure. Opening and closing of by-pass valve Opening and closing of penstock valve under balanced pressure condition. Testing and setting of all relays, limit switches and electrical controls and interlocks. Dielectric and insulation measurement tests on all electrical items I.e. solenoids, limit switches, wiring etc. as per relevant standards. Operational tests to check sequence of operation and interlocks of by-pass valve, air bleeder valve, valve plug and valve seats as per approved logic diagram. Any other tests as recommended by manufacturer or shall be necessary as per the provision of specifications and applicable IS / IEEE standards. Procedure to be adopted for conducting the operational, pre-commissioning and commissioning tests shall be supplied well in advance and shall be subjected for approval of the owner.
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8. 8.1
ISOLATED PHASE BUS DUCT AND ASSOCIATED ACCESSORIES Scope of Work
Scope of work under this section covers the provision of labour, tools, plants, materials and performance of work necessary for the design, manufacture, quality assurance, quality control, shop assembly, shop testing, delivery at site, site storage and preservation, installation, commissioning, performance testing, acceptance testing, training of Owners personnel, handing over to Owner and guarantee for one year of three (3) sets of three single-phase isolated phase bus ducts along with supporting structures, current transformers, neutral grounding cubicles, potential transformers and surge protection cubicles, as per the specifications hereunder, each complete with all auxiliaries, accessories, spare parts and warranting a trouble free safe operation of the installation. The scope of work shall be a comprehensive functional system complete in every respect including but not be limited to following: Three (3) sets of three single phase isolated phase bus ducts of 8000 Amps, 11 kV rating assembled between Generator terminals and the Transformer connections complete with removable links on the main bus, seal off bushings and flexible connectors etc. Three (3) sets of bus ducts for delta connections for three (3) sets of three single phase step up transformer primary winding, complete with flexible connectors etc. Three (3) sets of tap off bus ducts for excitation transformer complete with removable links on the tap off bus, flexible connectors etc. Three (3) sets of tap off bus ducts for Unit auxiliary transformer complete with removable links on the tap off bus, flexible connectors etc. Three (3) sets of tap off bus ducts for dynamic braking switch complete with removable links on the tap off bus, flexible connectors etc. Three (3) sets of tap off bus ducts for Lightning Arrestor and Voltage Transformer cubicle complete with removable links on the tap off bus, flexible connectors etc. Three (3) sets of bus duct assembly for Generator neutral grounding cubicle complete with all necessary items for neutral formation including flexible connectors, three phase shorting arrangement, Current transformers, seal off bushing etc.
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Three (3) sets of Neutral grounding cubicles complete with dry type neutral grounding transformer of rating 11000 - 240 / 120 V, earthing resistor, single pole single throw disconnect switch with locking arrangement etc.
Three (3) sets of Lightning Arrestor and Voltage Transformer cubicle ,each containing: Three (3) fused withdrawable type PT with single secondary winding; Three (3) fused withdrawable type PT with double secondary winding; Three (3) lightning arrestors; Three (3) 0.25 F surge capacitor;
Three (3) sets of current transformers in phase and neutral side for protection and metering schemes;
Three (3) sets transformer;
of current transformer in the
tap off connection to Unit auxiliary
Three (3) sets transformer;
of current transformer in the
tap off connection to excitation
Three (3) sets of supporting structures, columns, frames, wall plates, hangers, mounting plates, hardware etc.
Provision for necessary contacts and / or ports for integration with plant SCADA system.
One set of spare parts as indicated in clause Spare parts and special tools . of this section
One set of special tools and instruments required for installation, testing and maintenance as indicated in clause 8.7 Spare parts and special tools of this section.
Factory testing of IPB and instrument transformers.
Any other item(s) not mentioned specifically but necessary for the satisfactory completion of scope of work defined above, as per accepted standard(s) / best international practices.
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8.2
The 11 kV bus ducts shall connect each generator to three single phase step-up transformers. The vector group of step up transformer shall be YNd11 and delta formation of three single - phase transformers by bus duct shall match the requirement of the vector group of Generator step up transformer. The tap off connections for unit auxiliary transformer, excitation transformer, Dynamic Breaking cubile, LAVT (lightning arrestor and surge protection panel) and neutral grounding cubicle shall be done with bus duct and necessary flanges at the other end will have to be provided by the contractor. The bus duct shall exit from the generator above the floor at EL 2301.90. The details of bus duct arrangement is indicated in drawing no. 167106-AL00-47DD-0009 The installation being at an altitude above 2307m, the standard voltage and current rating of the IPB will be derated accordingly. Complete bus duct, line and neutral end termination equipment shall be designed to be capable of withstanding without damage all stresses by maximum asymmetrical short circuit (peak) currents in the bus bar. 8.2.1 Rating of Isolated phase bus duct Rating 11 12 50 8000 75
Description Rated Voltage ( kV ) Maximum voltage ( kV ) Rated frequency ( Hz ) Rated continuous current for the main bus (Amps) Lightning impulse withstand voltage 1.5 x 40 microseconds wave peak ( kV peak ) Power frequency withstand voltage ( kV rms ) Short time over current three phase symmetrical for not less than one second for Main bus duct ( KA rms 1 sec)
35 60
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Description Short time over current three phase symmetrical for not less than one second for Tap bus duct ( KA rms 1 sec) Bus conductor temperature rise limit C Bolted joints temperature rise limit C Silver coated bolted joints / Aluminium welded joints temperature rise limit C Enclosure temperature rise limit C Design Provisions
Rating 40
50 50 65
30
All components parts, pieces and accessories of the units shall be identical for the whole set of buses so as to allow interchange of components within units or by new parts as far as practical. Total losses in the complete bus assembly from generator to main step up transformer including losses in conductor, enclosure and supporting structure shall be computed by Supplier based on temperature rise limits, taking altitude correction factor into account. Computations shall be submitted along with offer for purchaser's scrutiny. Losses in tap off and delta buses shall also be separately indicated in the offer. Bus duct shall be installed at an elevation 2306.90 m . Altitude correction factor as per IEEE27-1974 shall be applied to arrive at power frequencies withstand and impulse test values. Altitude correction factor shall also be applied to temperature rise parameters. Bus duct losses listed in guaranteed particulars shall be based on minimum conductor and enclosure temperature for main and delta bus lengths. furnished to Purchaser for his scrutiny. Bus duct losses shall be guaranteed as listed in guaranteed particulars which shall be based on maximum conductor and enclosure temperature for main and delta bus lengths. Computation of losses shall be
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For additional busduct losses liquidated damages shall be imposed on the Supplier @ Rs.1,00,000/- (2,200 US$) per kW additional loss over the guaranteed values. No tolerance over guaranteed losses will be allowed. If during testing, temperature rise for main and delta duct are found more than 5% over guaranteed values, the bus duct can be rejected. Total losses in the complete bus assembly from generator terminations to main step up transformer terminations including losses in conductor, enclosure and supporting structure shall be computed by the Supplier based on temperature rise limits (taking altitude correction factor into account), and the computations shall be submitted for Purchasers approval. Losses in tap off shall also be separately indicated. If the computed losses are found more than 5% over guaranteed figures, bus duct design shall be rejected. Cost of bus duct and generator terminal cubicle shall remain unchanged irrespective of change in bus duct arrangement and / or change of voltage levels. If bus duct length changes more than 10% in total length, rates will be adjusted as per unit rate . Upto 10% variation there will be no extra cost. Construction The bus structures shall be self-supporting, rigid, isolated phase type, insulated, self cooled, non-magnetic, cylindrical, metallic enclosures and separated from adjacent phases by air spaces. The bus structures shall be furnished complete with phase conductors, ground bus, metal housings, isolating barriers, mounting framework, seal-off bushings (provided between outdoor and indoor sections), non-magnetic baffles and frames, gaskets, amortisseur grids for bus passing through openings in the reinforced concrete structures, and shading bands for beams or pipes. Flexible connections for generator terminals, transformer terminals, surge protection and potential transformer cubicle terminals, excitation transformer and unit auxiliary transformer terminals shall be furnished. Details of these connections shall be coordinated with the equipment connected to the bus. The flexible connectors shall be of sufficient length to serve as disconnecting links when removed for that purpose. Temperature rise Temperature and temperature rise of bus and enclosure shall not exceed permissible limits beyond guaranteed parameters with ambient air temperature of 30C. A set of bolted type shorting jumpers rated for the bus duct current shall be provided for the purpose of drying
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out of the equipment before commissioning or for carrying out short-circuit test on the equipment. Such links shall have drilled holes matching those of the bus dis-connecting links. Suitable support insulators shall be provided for such links. Current transformers General Current transformers shall be of the indoor type, dry epoxy cast resin with multi-core secondaries and shall be in accordance with IEC 60044-1. Mechanical stresses The current transformers shall be designed to withstand the thermal and mechanical stresses resulting from the maximum short-circuit current of the unit for one second. Rating Current Transformers shall conform to the following:Rated voltage Highest system voltage Short time thermal current Power frequency withstand voltage Impulse withstand voltage 11 kV*[subject to change as per Generator Voltage 12 kV* 60 kA for one second 35 kV 75 kV
Note: * In case of change in voltage rating selected for busduct the BIL and other ratings shall be modified accordingly. Requirement The quantities and rating of each current transformer shall be offered by the Supplier to suit the requirements of the protective relays, voltage regulator and instruments proposed. The quantities and rating of each current transformer shall not be less than 200 % of the overall computed (design) burden of the connected apparatus. The Supplier shall co-ordinate with the Supplier of protection system described in concerned Section for this purpose. The Supplier shall submit full particulars and information regarding the current transformers he proposes to furnish. Rating of neutral end current transformers
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Function Multifunction relay B for generator protection Multifunction relay A for generator protection Generator differential Metering Spare Rating of phase side current transformers Function Metering to AVR 1 Metering to AVR 2 Multifunction relay B for generator protection
CT ratio 8000 / 5 A 8000 / 5 A 8000 / 5 A 8000/5A 8000/5A
Burden -
Accuracy class Protection Protection Protection
30 VA -
0.5 Protection
CT ratio 8000 / 5 A 8000 / 5 A 8000 / 5 A
Burden 30 VA 30VA
Accuracy class 0.5 0.5 Protection
Rating of Unit Auxiliary Transformer branch line current transformers Function UAT over current protection Generator biased differential CT ratio 300 / 5 A 8000 / 5 A Burden 50VA 50VA Accuracy class Protection Protection
Excitation transformer branch line current transformers Function Excitation transformer over current protection Generator biased differential 8.2.2 CT ratio 100/1 A 8000 / 5 A Burden 10VA Accuracy class Protection Protection
Potential transformer and surge arrester (PTSA) cubicle
General The potential transformers, surge arresters, surge capacitors etc. shall be housed in a three phase draw out type cubicle separated in three compartments corresponding to each phase. Each compartment shall be provided with lockable hinged front door. Cubicle shall be vermin proof and tropicalised. The cubicle will have insulated bus bars. All clearances, where applicable, shall consider altitude correction factor.
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If Supplier offers potential transformers in fixed configuration, the details of the same, inspection and safety features shall be pointed out in the Bid to enable Purchaser evaluate the same. Offers without these details will be rejected. Installation of surge arresters and capacitor in tap off bus duct suspended from main duct can be accepted. Capacitors Surge capacitors shall be single pole, station type and shall be connected in parallel with the surge arresters and shall be in accordance with VDE 0560/3. Each capacitor shall be rated for generator voltage and shall have a capacitance of 0.25 micro farads, or as selected by the generator Supplier and approved by the Purchaser. Two capacitors shall be connected in parallel between each phase conductor and the ground. The capacitors shall be installed so that they may be easily disconnected when measuring the insulation resistance of the generator. Necessary details shall be submitted for approval of Purchaser. Surge arresters Surge arresters shall be of special station class, metal oxide type, moisture resistant, and dust proof and shall be in accordance with IEC 60099-4, Line-to-ground voltage shall be selected by the Supplier and approved by the Purchaser. Arresters shall be suitable for surge protection of generator, neutral grounded through distribution transformer. One fully rated arrester shall be connected between each phase conductor and the ground. In addition, if phase to phase arrester is also required based on surge protection studies keeping in view generator insulation characteristics, the same shall also be provided. Rating of capacitors and surge arresters shall be as per Suppliers design. This shall however be supported by calculations for Purchaser's approval. Potential transformers General Potential transformers shall be fixed mounted dry type, epoxy cast resin and in accordance with IEC 60044-2. Primary fuses of current limiting type, able to withstand maximum energising current, shall be provided. On the secondary side, miniature circuit breaker for protection against overload and short circuit shall be provided. Fuses, terminal blocks as required shall be provided in a normally accessible position.
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Rating Type Rated voltage (kV) Rated transformation ratio Purpose PT A 11/3 11/3KV:110/3V:110/3V: 110/3V: Core-I : Voltage regulator Core-II : Protection Core-III : Syn & metering 0.5 / 3P / 0.2 50VA Star/Star As for busduct 1.9 for 30 seconds 1.2 continuous 50Hz PT B 11/3 11/3KV:110/3V:110/3V: 110/3V: Core-I :Voltage regulator Core-II : Protection Core-III : Governor 0.5 / 3P /0.5 (or as recommended by the governor supplier) 50VA Star/Star As for busduct 1.9 for 30 seconds 1.2 continuous 50Hz
Accuracy class Burden Connections Basic insulation level Rated voltage factor time Frequency Note:
Supplier shall be responsible to ensure that the PTs offered meet the voltage regulator, governor and protection system requirements.
*HV voltage shall be corresponding to bus duct voltage selected and the BIL values etc. shall correspond to that.
Secondary Wiring For external cabling, suitable connecting box/junction box shall be provided on PTSA cubicle or near it at a suitable location. All internal secondary wiring shall be terminated by the Supplier upto these connecting boxes. All wires, conduits and accessories shall be provided by Supplier. Disconnecting type links shall be provided. Secondary devices and their wiring shall be isolated by grounded metal barriers from all primary circuit elements with exception of short lengths of wire at instrument transformer ends. Suitable terminal blocks as approved by Purchaser shall be provided in the cubicle for termination of secondary cables and outgoing cables. Suitable crimped ring tongue type shall be provided for internal wiring. 10% spare lugs and glands for external wiring shall be provided. The wiring shall be flameproof 660 volts grade and shall conform to IEC 60044-2. Minimum conductor size used shall be 2.5 mm2 copper stranded.
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8.3 8.3.1
Design considerations Specific Codes and Standards
Electrical equipment shall be designed and tested according to the latest relevant standards including amendments, or complementary standards mentioned in this document, shall be applied, in particular to the following: ISO 9001 Quality Systems Model for Quality Assurance in design, development, production, installation and servicing Instrument Transformers Short-circuit currents in 3 -phase AC systems Short- circuit currents- calculation of effects Specifications for interconnecting bus-bars for AC voltage above 1 kV up to and including 36 kV Method of measurement of radio influence voltage (RV) of high voltage Apparatus IEEE standard requirement for instrument Transformers High Voltage test techniques Insulation coordination Insulating bushing for alternating voltages above 1000V Characteristics of indoor and outdoor post insulators for transformers and switch gear. Degree of protection provided by enclosures ( IP Code ) Structural welding code. Standard for metal enclosed bus and calculating losses in Isolated Phase Bus.
IEC 60044 IEC 60909 IEC 60865 IEC 8084
NEMA 107
IEEE C57.13 IEC 60060 IEC 60071 IEC 60137 IEC 60273
IEC 69529 AWS D11 ANSI/IEEE C37.23
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8.3.2
Performance Guarantee
The Isolated Phase bus duct along with all auxiliaries and accessories shall be capable of performing intended duties under specified conditions. The Contractor shall guarantee the reliability and performance of the individual equipment as well as of the complete system. 8.4 8.4.1 Construction Isolated Phase Bus Duct
The isolated phase bus duct shall extend from the generator to the main transformer, with tap off connections for LAVT cubicle, excitation transformer, unit auxiliary transformer, dynamic breaking switch and neutral grounding cubicle. The bus duct shall be isolated phase type in which each conductor is supported on epoxy resin insulators at each supporting point and enclosed by an electrically continuous individual aluminium housing separated from adjacent phases by an air space. For connection to generator terminals, main transformer terminals, unit auxiliary transformer, excitation transformer, Dynamic Braking cubicle, neutral grounding cubicle and LAVT cubicle shall be done by flexible copper connections of required rating. Provision shall be made for expansion and contraction of the conductor and the metal enclosure due to temperature changes, short circuit conditions and vibration under operating conditions. Suitable expansion joints for the conductors and for the enclosure should be provided. Bus conductor shall be of aluminium. The protection degree of enclosures shall be IP55. The enclosure shall be made of non magnetic material. Insulators on the bus bars shall support and maintain the bus bars in place without resisting conductor expansion. Seal off bushings at different locations shall be provided wherever necessary. Arrangement shall be made to permit satisfactory connection of misalignment up to 10mm in any direction at site. Disconnecting link with the same rating as that of main bus bar shall be provided in the run of main bus before the tap-off of LAVT, excitation transformer, unit auxiliary transformer and dynamic braking switch. Provision for short circuiting the generator line terminals at suitable locations shall be provided by the contractor for testing of generator protection system. Shorting bars shall form part of supply of bus duct equipment.
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Fire proof floor / wall sealing plates shall be provided for the bus penetration through the Generator barrel. The bus system shall be supplied complete with all necessary supporting steel structures. The support structures shall be sized to maintain the bus duct connections under different working conditions. The structure shall be able to sustain seismic forces; stresses caused by expansion and short-circuit consideration in the most unfavourable circumstances. The support structures shall be manufactured by using steel sections and shall be hot dipped galvanized after manufacturing. The different elements shall be assembled on site by galvanized nuts and bolts. The bus duct shall be mounted on the building structures by metal supports that are isolated from the enclosures to prevent draining currents induced in the enclosures to the earth. Ground bus and ground knobs Aluminium ground bus running the entire length of bus route shall be provided having 50 kA short circuit rating for 1 second. Each enclosure support shall be solidly ground. Ground bus shall be provided with 100 mm x 100 mm ground pads suitable to receive bolted type 100 mm x 10 mm M.S. ground connection. Bolts, nuts and washers as required shall be furnished. Grounding connection with station grounding shall be done at one point only. Grounding system shall be such that induced voltages across insulated joints in the supports is kept as low as possible, and preferably below 2 volts, during rated current operation. A ground knob shall be provied on each phase bus adjacent to each disconnecting link and flexible connector, to permit operating personnel to attach grounding sticks on devices when performing maintenance. Modifications in layout The isolated phase ducts shall be laid out as indicated in drawings mentioned. Tenderers can however suggest modifications in layout which in his view will be more suitable technoeconomically, and/ or will be better from operation and maintenance considerations. If at the time of finalisation of drawings, length of the bus is increased or reduced, the cost of the same shall be adjusted at unit rates mentioned in schedules for bus and bends, etc.
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Earthing terminals shall be provided for connection of bus ducts to the main earthing system. 8.4.2 Neutral Grounding Cubicle
General The neutral grounding cubicle shall be suitable for floor mounting. The generator neutral grounding equipment assembly shall include a distribution transformer, a disconnecting arrangement, a resistor, and accessories, and shall be mounted in a single, ventilated, metal enclosed cubicle. The 11 kV / 220 V neutral grounding transformer and resistor shall be rated as per requirement indicated in IEC-726. The neutral grounding transformer and resistor rating shall be co-ordinated with the generator stator ground fault scheme as also with the generator protection electrical scheme. The connection between the generator neutral and the grounding cubicle shall be through busduct of not less than 200 Amp capacity or higher as determined in fault studies. Rating of distribution transformer and resistor shall be decided based on calculations to be furnished by the Supplier taking generator protection requirement i.e. stator earth fault current be restricted to 10 Amp. The transformer and resistor shall have rating corresponding to short time rating of not less than 1 min. Distribution transformer The transformer shall be a standard single phase distribution transformer, dry type, selfcooled, Class F insulation, suitably rated according to protection requirements as finalised during detailed design and engineering, ratio 11kV/220 volts, 50 Hz, with two high voltage and two low voltage leads brought out of the transformer through bushings. Bushings of identical voltage ratings on all units shall be inter-changeable. Clamp type terminals shall be furnished on all bushings. Necessary calculations for the distribution transformer rating shall be furnished by the Supplier. Resistor The resistor shall be rated as required by the generator Supplier to limit single line-to-ground fault current to a value not greater than 10 amperes. The load resistor shall be selected such that the total kW losses of the resistor are equivalent to the generator/transformers/bus duct system capacitive reactive losses when phase/neutral voltage is applied to the primary side of the transformer. The resistor shall be of the cast iron grid, corrosion resisting, nonbreaking type with low temperature coefficient and shall be securely bolted to the housing.
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The resistor shall be completely insulated from the mounting rods and from ground. Adequate natural ventilation of resistor shall be provided. Necessary calculations for resistor rating according to protection requirements, shall be furnished to the Purchaser for approval. Resistor shall also consider protection requirements i.e. 100% stator earth fault. Resistors shall have suitable taps for adjustment for purposes of protection. Actual value of resistor [measured during test] shall not vary from designed value by more than 5%, or as given in applicable standards whichever is less. 8.5 Quality control and assurance
The Contractor shall submit all the drawings and documents in accordance with requirements stipulated in Section 2.12 Reference drawings and documents of General Technical Specification (GTS) 8.6.2 Design calculation
The Contractor shall submit the design calculation in accordance to Clause 2.12 of General Technical Specification (GTS) covering at least the following, for review / acceptance. Load calculation for supporting structure, Temperature rise calculation used for sizing of bus duct, Calculations in regard to rating of N.G. transformer and resistor to be provided in the N.G. cubicle, 8.7 Calculations verifying the burden and knee point voltage in respect of CT(s). Spare Parts
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Sl no 1 2 3 4 5 6 7 8 9
Description Epoxy resin insulators used for main bus Epoxy resin insulators used for delta connection Epoxy resin insulators used for tap-off connection Voltage transformers Current transformers Surge arrestors Capacitors Seal off bushings
Quantity 10% of installed quantity 10% of installed quantity 10% of installed quantity 6 Nos 6 Nos 6 Nos 6 Nos 3Nos
Complete set of gaskets used in bus duct assembly 2 sets for one unit Special Tools
8.8
The Contractor shall supply all necessary tools and instruments etc. for installation, repair and maintenance in accordance to clause 2.36 of General Technical Requirements. 8.9 Testing
The Contractor shall follow the Inspection and testing requirements in Quality assurance clause 2.31 Factory inspection and testing of General Technical Specifications and section 8 of document Quality assurance and testing specification. 8.10 Delivery, Installation and Commissioning
The supplier shall follow the requirements of Delivery, Installation and commissioning elaborated in section 2.34 Installation and Supervision of General Technical Requirements. The supplier shall arrange personnel to oversee proper storage of equipment at site, their transhipment to powerhouse, installation and commissioning.
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9. 9.1
GENERATOR STEP UP TRANSFORMER Scope of Work
Scope of work under this section covers the provision of labour, tools, plants, materials and performance of work necessary for the design, manufacture, quality assurance, quality control, shop assembly, shop testing, delivery at site, site storage and preservation, installation, commissioning, performance testing, acceptance testing, training of Owners personnel, handing over to Owner and guarantee for one year of GSU transformers as per the specifications hereunder, each complete with all auxiliaries, accessories, spare parts and warranting a trouble free safe operation of the installation. The scope of work shall be a comprehensive functional system covering all supply and services including but not be limited to following: Ten (10) Single-phase generator step-up transformers, 43 MVA, 11/220 /3 kV, 50 Hz, ODWF having off-load tap changers, complete with HV terminations for connection to SF6 gas bus duct, bushing CTs, neutral and LV bushings, all necessary fittings, auxiliary equipment and accessories. Three (3) complete sets for transformer neutral interconnecting bus work, support insulators and neutral current transformers, one set for each transformer bank as per the single line diagram. Flanges on the 11kV side terminations of the transformers for three-phase Interconnections and for connections to the Isolated Phase Bus. Oil for first filling of the transformers, delivered in non-returnable containers. 9 sets of Online transformer oil gas analyzer.( one for each Transformer) One (1) set of mandatory spares. One (1) set of special devices and handling tools required for installation, testing and maintenance of the transformer. Factory testing of Generator Step-up transformers.
Any other item(s) not mentioned specifically but necessary for the satisfactory completion of scope of work defined above, as per accepted standard(s) / best international practices. 9.2 Rating and design requirements
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The particulars of the system in which the equipment shall be used are the following: 9.2.1 Sl No 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.1 2 2.1 2.2 2.3 2.4 2.5 2.6 3 3.1 3.2 3.3 3.4 4 System data Description 220 kV system Nominal operating voltage (kV) Maximum rated voltage (kV) System frequency (Hz) Frequency variation Number of phases System earthing 220 245 50 5% 3 Effectively grounded Rating
Minimum creepage distance external 25 based on rated voltage (mm/kV) BIL (kV peak) 1050 Power frequency withstand voltage (kV 460 rms) Short circuit current (kA for 1 sec.) 40 11 kV System Nominal operating voltage (kV) Maximum rated voltage (kV) System frequency (Hz) Number of phases Impulse withstand voltage (kV peak) 11 12 50 3 75
Power frequency withstand voltage for 1 35 minute (kV rms) Auxiliary Power Supply System AC voltage DC voltage AC supply voltage, variation DC supply voltage variation Elevation at the transformer location 415V,3 .,50Hz- 240 V , 1- , 50 Hz 220 V 10% +20%, -25% EL 2306.90
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9.2.2
Transformer Rating
The transformers shall be single phase, two winding, oil-immersed, forced oil and water cooled (ODWF) with conservator or external expansion tank, complete with accessories and spare parts, and suitable for underground operation. Sl No 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. Description Rating
Continuous rating at 650C temperature rise, water 43 MVA cooled on all taps Frequency ( Hz) 50 Rated Voltage HV ( kV ) Rated voltage LV ( kV ) H.V. winding connection of 3 single-phase units L.V. winding connection of 3 single-phase units Vector group: Polarity No of windings Lightning impulse withstand voltage, kVp (HV) Lightning impulse withstand voltage, kVp (LV) Power frequency withstand voltage, kV r.m.s ( HV) 220 / 3 11 Star connected and neutral solidly grounded Delta YNd11 Subtractive Two (2) 950 75 395 35 95 60C 12.5% per bank 55 C 1050 75 460 35 2 x 2.5 %
Power frequency withstand voltage, kV r.m.s (LV) Neutral end BIL (not less than) ( HV ) Maximum winding Temperature Impedence Maximum Oil Temperature HV Bushing - Lightning impulse withstand voltage, KVpeak LV Bushing - Lightning impulse withstand voltage, KVpeak HV Bushing Power frequency withstand voltage, kV r.m.s HV Bushing Power frequency withstand voltage, kV r.m.s Off load tap changer
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9.3
Design Considerations
Electrical equipment shall be designed and tested according to the latest relevant standards including amendments, or complementary standards mentioned in this document: ISO 9001 CSAC88-M90 CSAC50-1997 NEMA 107 ANSI/IEEE C57 ANSI/IEEEC57.12.90 IEEEC57.13 AWS D11 IEC 60044 IEC 60076-1,2,3,4,and 5 IEC 60060 IEC 60071 IEC 60137 IEC 60273 IEC 60296 IEC 60422 IEC 60529 IEC 60815 Quality Systems - Model for Quality Assurance in Development, Production, installation and servicing Power transformers and reactors. Insulating oil, electrical for transformers and switches. Method of measurement of radio influence voltage (RV) of high voltage apparatus Liquid immersed transformers. IEEE test code for liquid immersed distribution , power and regulating transformers IEEE standard requirement for instrument Transformers Structural welding code. Instrument Transformers Power Transformers High Voltage test techniques Insulation coordination Insulating bushing for alternating voltages above 1000V Characteristics of indoor and outdoor post insulators for transformers and switchgear Specification for unused mineral insulating oils for transformers and switchgear Supervision and maintenance guide for insulating mineral oils in electrical equipments Degree of protection provided by enclosures ( IP Code ) Guide for the selection of insulators in respect of polluted conditions Design,
9.4
Performance Guarantee
The GSU transformers along with all auxiliaries and accessories shall be capable of performing intended duties under specified conditions. The Contractor shall guarantee the reliability and performance of the individual equipment as well as of the complete system.
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9.4.1
Guaranteed losses
The no load loss in kilowatts at rated voltage and rated frequency, load losses and total loss in kilowatts at rated output, rated voltage and rated frequency shall be guaranteed. 9.4.2 Liquidated damages for shortfall in losses
For losses in excess to the guaranteed values of iron losses and copper losses, liquidated damages shall be applicable at rates given below: I. No load Loss per KW II. Auxiliary losses per KW III. Copper Loss per KW For the purpose of computations of liquidated damages, the tests figures of the no load, auxiliary losses and copper losses will be compared with the corresponding guaranteed figures. The liquidated damages shall be separately evaluated from: The excess of the test values of the no load loss and auxiliary loss in kW over the corresponding guaranteed values. Excess of the difference between the test values of the total loss and no load loss plus auxiliary loss in kW over the differences of the corresponding guaranteed values. No tolerance shall be permitted over the test values of the losses. For fraction of a kW, the liquidated damages shall be applied pro-rata. If the test values of the losses are less than the guaranteed values, no bonus will be given. The losses shall be computed for all the transformers. No-load tests shall be performed both before and after the impulse tests. If the variation is more than 15% between the test values the tested transformer will be rejected. Test figure of no-load loss after impulse tests shall be considered for purpose of liquidated damage provided variation remains within or equal to 15% of test figure measured before impulse tests. The Owner reserves the right to reject any transformer, if during tests at works; any individual loss (Iron Loss, Cu Loss and Auxiliary Loss) exceeds the guaranteed values by
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more than 15% individually. However, the total losses (Iron Loss, Cu Loss and Auxiliary Loss) should not exceed by more than 10% of the guaranteed values. 9.5 Construction
The generator step-up transformers shall include the equipment shown on the single line diagram, suitable for indoor (underground) installation in the transformer hall at EL 2306.90. All apparatus shall be designed to ensure satisfactory operation under such sudden variations in voltage as may be met with under working conditions in the system. The transformers shall be capable of withstanding, without injury, the mechanical and thermal stresses produced by external short-circuits on the terminal of any winding for duration of 2 seconds. It shall be assumed that rated voltage is maintained by the system. Transformers will be capable of operating at full load for 10 minutes after failure of the oil and/or water circulating pumps without the calculated winding hot-spot temperature exceeding 1500C. Similar ratio transformers shall operate satisfactorily in parallel with each other. The design of the transformers shall be done taking into consideration daily and seasonal cyclic energizing, loading and frequent starting of the units during peak hours. 9.5.1 Materials
All material used in the performance of this contract shall be new and of the best quality and of the class most suitable for working under the conditions specified. All material shall withstand the variations of temperature and atmospheric conditions arising under working conditions, without distortion or deterioration or the setting up of undue stresses in any part, and also without affecting the strength and suitability of the various parts for the work which they have to perform. All support structures to support the equipment required in the technical specification shall be of hot dipped galvanized steel. Support structures shall have all holes pre-drilled. 9.5.2 Core and Winding
The core shall be assembled with cold rolled grain oriented silicon steel, and treated with a layer of heat and oil resistant insulating varnish. The core supports shall be designed to counter the effects of marine and overland transport under poor conditions. The Supplier shall provide a description of construction details of the proposed core design. Winding shall be made of copper.
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9.5.3
Tank
Each transformer tank shall be capable of withstanding without leakage or distortion, an internal gas pressure specified in IEC, ANSI, IEEE, CSA or other standards as applicable The tank shall be made of high resistivity steel plates welded together. The cover design shall be bolted. The tank shall be designed to withstand full vacuum. The flanges of the tank and cover shall be fixed with sufficient number of bolts, equally spaced, to ensure a uniform pressure on the gaskets. The tank shall be complete in all respect with the following accessories: Oil drain valve; Top and bottom filter valves; Oil sample valve at the bottom of the tank; Valves on each side of Buchholz relay; Thermometer envelope; Wall ladder for access to Buchholz relay with suitable protection; Facilities for handling and installation (hoisting eyes, traction rings and rollers); Tank jacking pads; Valves for isolation of oil circulation; Valve identification plates. Locking arrangement on Drain valves. Arrangement for mounting of online transformer oil gas analyzer.
Gravity centre plates shall be fixed on each side of the tank for transportation and service and shall include an indication to this effect. All valves shall be provided with blank plate or plug and padlocking possibilities, in open or closed position, and shall have indicators which shall enable to see the open or closed position. It shall be possible to take oil samples even when the transformer is energized. Spring loaded pressure relief valves (PRV) with automatic reclosing shall be installed on the tank. The PRV shall have discharge vent of adequate size to discharge the excess pressure
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in a reasonable time. PRV shall have an indication flag and an alarm contact. The surface of the cover shall be of antiskid type. 9.5.4 Bushings and Terminations
The HV termination will be the oil to gas (SF6) type with a metal enclosure to accept the gas insulated bus duct. The HV, Neutral and LV bushings will be the oil to air porcelain type. The bushing shall have adequate current capacity to use the equipment to its maximum overload capacity. The neutral bushings shall have the same current capacity as the corresponding phase bushings. The bushings shall include current transformers. Bushings of identical current and voltage ratings must be interchangeable. The 220 kV terminations shall be capacitive type supplied with capacitive taps; bushings of lower voltages shall be porcelain solid-type. GIS adapter for Transformer shall be oil to SF6 Bushing The HV terminal of GSU shall be connected to the GIS through Gas Insulated Bus duct which shall be in the scope of GIS contractor. The Transformer and GIS manufacturer shall coordinate to finalise the type of termination in consultation with the Owner. This interface shall be designed in order to provide fast replacement of the transformer unit. Effective gas tight seals shall be provided between the duct enclosure and the oil to SF6 bushing. 9.5.5 Conservator Tank
The equipment shall have an appropriate expansion tank with vinyl air cushions bellows, allowing the oil expansion between the maximum and minimum values of oil temperature. The conservator tank shall include a rubber sack to avoid contamination of the oil by the humidity in the air. The expansion tanks oil capacity shall not be lower than 10% of the total oil volume of the equipment. An oil level indicator with an alarm contact for low level shall be installed in an accessible location.
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Openings of sufficient dimensions to allow access during inspection shall be provided. The plates used as covers for the inspection openings shall be bolted to the expansion tank and shall have handles to facilitate the installation and removal operations. The conservator tank shall have an air vent including silica gel and designed for 100% humidity. The silica gel shall include an incoming air oil-filter. This air vent shall be at a height of 1.6 m above the ground. The conservator tank shall be provided with oil level indicators and valves for oil filling, sampling drain and tank drainage. 9.5.6 Insulating Oil
Sufficient quantity of oil to fill the transformer tank to the proper operating level, with ten (10%) percent extra to allow for spillage, shall be supplied. The oil shall be pure and refined mineral oil, clean, clear and free from moisture and acid and completely free from solid particles. The oil shall be of high quality and suitable as an insulating and coolant medium for the transformers. No inhibitors shall be used in the oil. Oil shall be predominantly naptha-based. The oil shall be treated to withstand a dielectric test prior to filling the transformer. The Supplier shall provide his own equipment for the treatment of all oil provided and used for the initial filling of the transformers at Site. The oil shall be delivered in drums which should be of top quality and treated against corrosion and painted with oil and weatherresistant paint. 9.5.7 Online Transformer Oil Gas Analyzer
Each transformer shall be equipped with one set of Online Transformer Oil Gas Analyzer to detect concentration of combustible dissolved gasses in transformer oil. The Gas analyzer shall be capable of detecting presence of the following gasses in ppm, H2, CO,CH4,C2H6,C2H4 and C2H2. The change in production of each gas will help to determine the type of fault. The gas analyzer shall be connected to a processing computer with dedicated software , allowing real time analyzation and recording. The supply shall include all accessories,
interconnecting fibre-optic cables, data connectors, modems, calibration equipment and tools. The equipment sensitivity shall be as follows:
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Gases H2 CO CH4 C2H6 C2H4 C2H2
Sensitivity ppm 1 2 20 20 1 0.2
9.5.8
Cooling System
The transformer is designated ODWF, oil immersed forced oil water cooled. Each transformer shall be provided with: One (1) main and one (1) backup oil to water heat exchangers; One (1) main and one (1) backup motor driven oil pumps.
The capacity of each heat exchanger shall be such as to restrict temperature rise to allowable limits at rated load. The cooling tubes used shall be of stainless steel/cupro-nickel. Each heat exchanger and oil pump shall be mounted on the transformer. The transfer from the main heat exchanger or oil pump to the backup heat exchanger or oil pump shall be automatic. Required instrumentation for proper fault detection of the pumps, heat exchangers and related piping assembly (i.e. water and oil flow & pressure) shall be part of the scope. 9.5.9 Phase and Neutral Current Transformer
Each HV phase and neutral bushing shall be fitted with bushing type current transformers. The current transformers shall conform to IEC, ANSI, IEEE, CSA or other standards as applicable and shall be designed in line with the requirements, class accuracy and ratings as indicated on the Protection and metering single line diagram, drawing 167106-AL00-47DD0002.
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9.5.10 Lifting and Pulling Arrangement Suitable provision for lifting of the transformer and auxiliary equipment (hoisting eyes) shall be incorporated into the design. Tank jacking pads and suitable anchoring locations (traction rings) shall be provided so as to be able to attach the anchoring chain pulley blocks. Bidirectional rail rollers, hydraulic jacks and chain blocks of adequate capacity shall be supplied. Each tank shall be supplied with the necessary elements for moving and maintenance, including but not limited to the following: Steel base with flanged wheels to permit rolling of the assembled and oil filled transformer in any direction. It shall be possible to change direction of the wheels through 90 Deg when transformer is lifted on jacks to permit movement of the transformer in longitudinal and transverse directions. The track gauge shall be 1676 mm. Hooks for attaching hauling equipment Eyes or anchors for suspension Eyes for lifting the complete unit, eyes for lifting the tank cover and opening covers for maintenance, hooks on the yoke allowing withdrawal of the core and windings assembly from the tank. Each tank shall have at least four jacking steps exceeding the tub which shall enable the lifting or lowering of the complete unit, oil filled, using hydraulic or manual jacks. The lifting capacity of each base and jack shall be of at least 50% of the total weight of the unit. 9.5.11 Control Cabinet Control cabinets and Cubicles shall be waterproof and have a degree of protection against the ingress of foreign bodies. Terminal blocks for external wiring shall be rated at 600 V for operating voltages up to 150 V. Where the operating voltage is greater than 150 V they shall be rated at 1100 V. Current transformer circuits shall have disconnecting link type connectors to facilitate testing and protection against over voltages / open circuits. Each transformer shall be provided with a control cabinet attached to the tank. The control cabinet shall house all control equipment for oil pump and auxiliary controls. Control cabinet
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shall be placed on the service side of the apparatus to be freely accessible and easily visible to the operating personnel. Each equipment shall have its control cabinet made of 2.5 mm steel, with hinged doors containing: Tripolar moulded case thermo-magnetic circuit breaker, with a 14 kA rms symmetric short circuit capacity for 4 wire, 415 Vac system. Padlocking arrangement and a removable plate at the bottom to enable the conduit entry for fixing of cable glands for power and control cables. Thermostatically controlled anti-condensation heating element operating on 240V AC Lighting with door operated switch. A 240 V a.c. duplex receptacle protected by 15 A circuit breaker. Stranded copper wiring tin-plated with polymeric fluoride insulation. Terminal blocks and accessories. All external accessories shall be connected to the terminal blocks with armoured cables or cables in metallic conduits. Local/Remote selection switch and pump /motor controls. Manual and Automatic operation for OFWF cooling that shall be actuated by winding temperature and automatic transfer main and standby coolers upon loss of one of the coolers pumps. Indicating lamps for status indication of pumps (oil and water) (operation, failure, power supply failure, etc.) Overload protection of pump / motor The thermometers shall be located inside the control cabinet Facility for remote indication/annunciation as required.
The terminal blocks shall be arranged conveniently with respect to opening for cables and shall have a minimum of twenty (20%) percent spare terminals. Current transformer secondary windings shall be terminated on shorting-type terminal blocks. The wiring shall be of stranded copper not less than 2.5 mm2 (4 mm2 in case of current transformer circuits) with heat and flame resistant insulation being used for all wiring. All wire terminations shall be made with approved pressure type terminal lugs. All cables shall be
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clearly identified by means of non erasable, corrosion-resistant labels well secured around the cable termination just above the cable glands. Connections from the control cabinet to any external devices shall be made with armoured PVC jacketed cable. The control cabinet shall not be less than 1 m above the concrete base. The space below the control cabinet shall be kept free of obstructions which could interfere with the control and other conduit connections. The earth bus for individual earthing of circuits requiring earth points shall be provided in the control cabinet. The bus shall include one (1) bolted type connector for 10 sq mm stranded copper cable for each earthed circuit. 9.5.12 Protection Buchholz A Buchholz-type gas detector relay shall be provided. The relay shall have two floaters, two sets of electrically separate contacts for alarm on slow gas accumulation and for tripping on rapid pressure build-up. The relay shall be located in the main conservator pipe so that it collects gas generated and may be inspected. The relay shall be installed with all accessories, such as sampling valve, located at 1.6 m from the ground. The relay shall be self-reset type, resetting itself following cessation of oil flow on the draining off of accumulated gas. A copper tube shall extend from the gas accumulation element to a suitable valve located on the tank wall near the bottom to permit gas bleeding from ground level; a gas sampling device and a draining device, both approximately 1.5 m above finish grade or floor level, shall be provided. The relay shall be self-reset following cessation of oil flow or the draining off of accumulated gas. The relay shall also trip the transformer in the event of tank rupture. Magnetic Oil Level Gauge A dial type magnetic oil gauge readable from the ground shall be mounted on the end of the conservator tank. Normal, minimum, maximum oil levels shall be shown. The gauge shall provide two (2) sets of alarm contacts, one set of low-level contacts and the other set of contacts to close when the oil reaches a dangerously low level (not lower than 25 mm) above the outlet to the main tank. Oil Temperature Thermometer
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A dial-type oil thermometer equipped with two (2) separately adjustable sets of contacts for alarm purposes and with a scale readable from ground shall be provided. The temperaturesensitive element shall be installed in an oil-filled or close-fitting well, located to measure the hottest oil as nearly as practicable. Resistance thermometer and accessories for remote indication of oil temperature shall also be provided. Winding Temperature Thermometer Digital type winding temperature indicator shall be provided. The winding temperature indicator shall sense the temperature through the thermocouples or RTDs embedded in the winding and shall be responsive to the combination of oil temperature and winding current. The winding temperature indicator shall have at least two potential free electrical contacts for the following functions: Operate a remote alarm when the temperature reaches a preset value. Trip the transformer off the system when the temperature exceeds a higher preset value. The alarm and trip settings shall be adjustable. The current transformer connections for the winding temperature detector shall be terminated outside the main tank for testing purposes. The alarm and tripping contacts rating capacity shall be able to switch and withstand the current and voltage of the 220 V dc systems. Resistance thermometer and accessories for remote indication of winding temperature shall also be provided. Grounding Connections The core must be grounded with a bushing located in a manhole on the bolted cover. Access must be possible without lowering the oil level. Windings must not be grounded inside the tank. The neutral bushing must be installed on the cover. The neutral bushing will be grounded by a copper bus of sufficient section. This bus shall be installed down to the low part of the tank and be supported to the tank by insulators and terminated with a connector for installation of up to two 120 mm2 -240 mm2 bare copper conductors.
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The tank shall be provided with two (2) grounding terminals for connecting copper cable of 120 mm2 - 240 mm2 sizes. Each of those shall be located in the longitudinal face of the tank and at the opposite side. 9.6 Quality control and assurance
The Contractor shall submit the design calculation covering at least the following, for review / acceptance. Temperature rise, Size of cooling system, Ability to withstand short circuit, Design Review in respect of ability to withstand dynamic effect of short circuit for all GSU transformers, Design of oil soak pit with gravity based oil water separator arrangement.
Design review would consist of following steps: Review of design by comparison with a similar reference transformer, which has passed a short circuit of similar or higher magnitude successfully. The document to be provided by the manufacturer for the purpose of design review shall include, but not limited to, following items: Electromagnetic design data sheet as needed for calculation to demonstrate maximum axial thrust for worst fault conditions for each winding and minimum winding and support short circuit thrust for each winding,
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Drawings or sketches of the complete winding and insulation arrangement within the core window with indication of the types of the material,
Calculation of short circuit current values (both peak and symmetrical RMS values) affecting each single winding as a result of the service duty requirements specified and types of fault taken into consideration,
Calculation of the main short circuit forces (peak values occurring at the highest peak of the respective current) with reference to the fault cases and geometrical and relative positions of windings considered for the purpose of design,
Full information in simplified geometrical configuration is expected to be provided for windings, core and tank for the purpose of magnetic leakage field and electromagnetic force calculations.
Axial short circuit forces for core type and radial short circuit forces for shell type shall be dealt to the entire satisfaction of purchaser.
9.8
Spare Parts
Recommended spare parts shall be supplied in accordance to clause 2.36 Spare Parts and tools of General Technical Requirements. Specified spare parts to be supplied under this section are as follows: Sl no 1 2 3 4 Description HV bushings complete with gaskets HV Neutral bushings complete with gaskets LV bushings complete with gaskets Quantity 1 no 1 no 1 no
Complete set of gaskets for tank cover and fittings, valves etc. 1 no used for one transformer Oil-water coolers Oil circulation pump-motor set Flow indicators 1 no 1 no 1 no
5 6 7
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Sl no 8 9 10 11 12 13 14 15 9.9
Description Neutral bushing CTs of each type in use Temperature indicator ,RTD Buchholz relays Oil level indicator Pressure relief device Conservator Air Bag Pressure Gauge each type used Differential Pressure Gauge each type used Special tools
Quantity 1 no 2 nos 1 no 1 no 1 no 1 no 1 no 1 no
The Contractor shall supply all necessary tools and instruments etc. for installation, repair and maintenance in accordance to clause 2.36 of General Technical Requirements. The Contractor shall propose the list of special tools including their make and detailed specification as recommended by manufacturer(s), to be accepted by the Owner. The proposed list of special tools must include the following in addition to tools recommended by manufacturer(s): 9.10 Four (4), 50T hydraulic lifting jacks, Two (2), Nylon slings for lifting bushings, Nylon Slings for lifting bell of the transformer tank. Testing
The Contractor shall follow the Inspection and testing requirements in Quality assurance clause 2.31 Factory inspection and testing of General Technical Specifications and section 9 of document Quality assurance and testing specifications
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9.11
Delivery, Installation and Commissioning
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10. 10.1
220 KV GAS INSULATED SWITCHGEAR Scope of Work
Scope of work under this section covers the provision of labour, tools, plants, materials and performance of work necessary for the design, manufacture, quality assurance, quality control, shop assembly, shop testing, delivery at site, site storage and preservation, installation, commissioning, performance testing, acceptance testing, training of Owners personnel, handing over to Owner and guarantee for one year of 220 kV GIS System as per the specifications hereunder, complete with all auxiliaries, accessories, spare parts and warranting a trouble free safe operation of the installation. The scope of work shall be a comprehensive functional system covering all supply and services including but not be limited to following: (a). Two, 3 phase, SF6 gas-insulated metal enclosed 2000 A bus-bar enclosures running the length of the switchgear to interconnect each of the circuit breaker bay modules and bus bar end caps. (b). Two three pole inductive type bus voltage transformers complete with dis-connector switch and maintenance earthing switches, 2 sets of surge arresters, (one set on each bus) and gas monitoring Equipment, terminal boxes, control cubicle, interconnecting wiring, piping and grounding, support structures and platforms. Each bus shall have a maintenance earthing switch also for its maintenance. (c). One - 220 kV bus coupler circuit breaker bay module comprising of : One 2000 A, 3 phase, SF6 gas-insulated circuit breaker complete with operating mechanism. Six double core 1600 / 1A / 1A, Single phase current transformer. Two 3 phase, single pole, group operated disconnecting switches, complete with manual/motor driven operating mechanism. Two 3 phase, single pole, group operated maintenance earthing switches, complete with manual/motor driven operating mechanism. (d). Control cubicle of bay.
Three - 220 kV generator-transformer circuit breaker bay modules, each comprising of :
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One 2000 A, 3 phase SF6 gas-insulated circuit breaker, complete with operating mechanism.
Three 5 core, single phase current transformers (1600-800-400/1A). Two 3 phase, single-pole, group operated disconnecting switches, each complete with manual/motor driven operating mechanisms.
Two 3 phase, single-pole group operated maintenance earthing switches, each complete with manual/motor driven operating mechanisms.
Control cubicle of bay. Three single phase gas insulated terminal connections connecting Generator transformer (Oil/SF6) bushings with GIS through gas insulated bus ducts (2000 Amp rating).
(e).
Two - 220 kV transmission line feeder circuit breaker bay modules, each comprising of : One 2000 A, 3 phase, SF6 gas insulated circuit breaker complete with operating mechanisms. Three 6 core, single phase current transformers (1600-1A/1A). Three 3 phase, single pole group operated disconnecting switches, each complete with manual/motor driven operating mechanisms. Two 3 phase, single pole group operated maintenance earthing switch each complete with manual/motor operating mechanism. One 3 phase, singe pole high speed fault making earthing switch, complete with individual operated manual/motor driven operating mechanism. Control cubicle of bay.
Each bay module shall be complete with all necessary terminal boxes, SF6 gas filling, interconnecting power and control wiring, grounding connections, gas monitoring equipment and piping, support structures and platforms/scaffoldings etc. GIS equipment with intelligent type control system shall be provided. The scope of supply shall also include the following for completion of supplies a) First filling of SF6 gas for the Equipment supplied plus an additional quantity sufficient for conducting all tests on Equipment at site before placing it into successful
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operation. b) One SF6 gas processing unit alongwith adequate length of hoses for filling of SF6 gas with GIS cart in GIS cavity. c) d) Floor plates for the GIS floor for crossing of SF6 busduct. All support structure, support hangers for busduct (between transformer and GIS) foundation plates/bolts/rails, bolts and nuts necessary for completeness. e) All cables necessary for interconnection of GIS Equipment and special cables for interconnection of GIS to control room including optional fibre cables. g) All consumables necessary for complete installation , testing and commissioning and placing into successful operation. h) (ii) Epoxy coating in the entire G.I.S floor level EL.2317.90 m All necessary disconnect switches, earthing switches, potential transformers and current transformers. (j) (k) (l) (m) One (1) set of spare parts; One (1) set of special devices and handling tools; Factory Testing of GIS equipment. All necessary supporting structures.
Any other item(s) not mentioned specifically but necessary for the satisfactory completion of scope of work defined above, as per accepted standard(s) / best international practices. 10.2 Rating and Design requirements
10.2.1 220 kV Gas Insulated Switchgear Type Nominal voltage class, kV, rms Rated maximum voltage, kV, rms Rated frequency, Hz SF6, GIS indoor 220 245 50
Rated continuous current, A, rms ( for feeder, 2000 transformer bay and bus bar) Rated short circuits withstand current at rated max. voltage, kA (sym.) Rated lightning impulse withstand voltage kV peak
40 for 1 sec. 1050

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Rated power frequency withstand voltage, kV, rms Neutral earthing 10.2.2 Circuit Breakers
460 solidly grounded
The requirements of IEC 62 271-100 and 62 271-203 in respect of service operations making and breaking of fault current - shall apply to the specified circuit breakers. Number of poles Installation Temperature rise Rated short circuit making current, kA (peak) Rated short circuit withstands current at rated max. voltage, kA (sym.) Short circuit breaking current, kA First pole to clear factor 3 indoors as per IEC 62271-100 125 40 for 1 sec. 40 1.3
Total break time for any current up to the rated 40 msec (max) breaking current Closing time Rated operating duty cycle Auto reclosing (line breakers only) Small inductive current interrupting capacity Switching over-voltage Operating mechanism Number of trip coils Number of spare auxiliary contacts 100 msec(max) O-0.3 s - CO-3 min-CO Single and 3 phase 10A less than 2.0 pu spring charged or hydraulic 2 5 NO, 5 NC on each pole potential free contacts to be wired to terminal blocks in control cabinet. silver-plated copper
Main contact material
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10.2.3 Disconnect Switches Number of poles Installation Rated short circuit making current, kA (peak) Operating mechanism Number of spare auxiliary contacts 3 indoors 125 motor and manual 5 NO, 5 NC on each pole potential free contacts to be wired to terminal blocks in control cabinet. Tulip
Contact type 10.2.4 Earthing Switches Number of poles Installation Rated short circuit making current, kA (peak) Operating mechanism Number of spare auxiliary contacts
3 indoors 125 motor and manual 5 NO, 5 NC on each pole potential free contacts to be wired to terminal blocks in control cabinet. Tulip
Contact type 10.2.5 High speed Earthing switches Number of poles Rated short circuit making current, kA (peak) Closing time Operating mechanism Number of spare auxiliary contacts
3 125 Less than 0.065 sec. motor and manual 5 NO, 5 NC on each pole potential free contacts to be wired to terminal blocks in control cabinet. Tulip
Contact type 10.2.6 Current Transformers
All CTs shall conform to the applicable requirements of CSA, ANSI, IEEE and IEC standards. Generator/transformer bay module CTs
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Number of single phase CTs Number of cores per CT Ratio Accuracy Burden Transmission line bay module CTs Number of single phase CTs Number of cores per CT Multi-ratio Accuracy Burden Bus coupler bay module CTs Number of single phase CTs Number of cores per CT Ratio Accuracy Burden 10.2.7 Voltage Transformers
3 3 1600/1/1/1A 5P20, (M: Cl 0.2) Not less than 30 VA
2x3 2 1600:1/1A 5P20, (M: Cl 0.5) Not less than 30 VA
Voltage transformers shall be of the inductive type, constructed and tested in accordance the applicable requirements of CSA, ANSI, IEEE and IEC standards. Generator/transformer bay module and bus bars VTs Voltage ratio Number of single phase PTs Number of cores Accuracy class Burden Purpose 220 kV/3 : 110/3 3 2 Cl: 0.5 100 VA Synchronizing & metering
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Bus VTs Voltage ratio Number of single phase PTs Number of cores Accuracy class Burden Purpose Transmission Line bay module VTs Voltage ratio Number of single phase PTs Number of cores Accuracy class Burden Purpose 10.2.8 Surge Arresters The arresters shall comply with the applicable requirements of CSA, ANSI, IEEE and IEC standards. Rated voltage (kV) Standard nominal discharge current (kA peak) Impulse withstand voltage of equipment to be protected, (kV peak) 10.3 Design Considerations 192 10 1050 220/3 KV : 110/3 V 3 2 3P (Cl: 0.2) 100 VA Synchronizing & metering 220 /3 kV: 110/3 V 3 2 Cl: 0.5 100 VA Synchronizing & metering
10.3.1 Standards Electrical equipment shall be designed and tested according to the latest relevant standards including amendments, or complementary standards mentioned in this document, shall be applied, in particular to the following: IEC 60044-1 IEC 60044-2 IEC-60060 Instruments Transformers part 1 Current Transformers Instruments Transformers part 2 Voltage Transformers High voltage test techniques
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IEC 60099-4 IEC 60099-5 IEC 60137 IEC-60270 IEC-60376 IEC-60427 IEC-60480 IEC 60529 IEC 60694 IEC 60815 IEC 60859 IEC 60947 IEC-61233 IEC-61633`
Surge arresters Part 4: Non-linear resistor type arrester for a.c. systems Surge arresters Part 5: Selection and application recommendations Insulating bushing for alternating voltages above 1000 V Partial-discharge measurements Specification and acceptance of new sulphur hexafluoride Synthetic testing of HV a.c. circuit breakers Guide to checking of sulphur hexafluoride taken form electrical equipment Degrees of protection provided by enclosures (IP Code) Common clauses for high voltage switchgear and control gear standards Guide for the selection of insulators in respect of polluted conditions Cable connections for gas-insulated metal-enclosed switchgear for rated voltages of 72.5 kV and above. Low-voltage switchgear and control gear High-voltage alternating current circuit-breakers Inductive load switching High-voltage alternating current circuit-breakers Guide for short circuit and switching test procedures for metalenclosed and dead tank circuit-breakers Direct connection between power transformers and GIS High-voltage alternating-current circuit breakers High-voltage alternating-current disconnector and earthing switches High-voltage switchgear and control gear. Part 203: gasinsulated metal-enclosed switchgear for rated voltages above 52 kV (issue 2003) Code for pressure vessels Guide for safety in AC substation grounding.
IEC-61639 IEC-62 271-100 IEC-62 271-102 IEC-62 271-203
ASME Sec VIII div 1 IEEE-80
The maintenance free period for any of its external components, including the protective relays and instrument transformers, should be preferably not less than five years interval and for internal components including refilling of gas not less than ten years. The Supplier shall propose the recommended periods for the
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Contract drawings indicate the proposed general arrangement of GIS, layout of transformers and proposed termination arrangement of GIS for outgoing feeder circuits. The space available for GIS can be ascertained from these drawings. Intent of these drawings is to give information on Purchaser's requirement. Manufacturer is free to offer their standard horizontal or vertical configuration of GIS keeping the following factors in view:a) b) c) d) Space availability Removal of transformer for erection/repair without disturbing the SF6 busduct Minimum length of the 220 kV duct from transformer bushing to the switchgear Crane hook lift available (suitable alternative for better utilisation of head room can be considered), e) Operation and Maintenance requirements.
Not withstanding scope of requirement mentioned, if any Equipment, tools, or instruments that are considered essential for completion, shall be deemed to be included in the scope. Workmanship shall be of the highest quality and shall conform to the best modern practices for the manufacture of high technology machinery and electrical switchgear. The GIS assembly shall consist of completely separate pressurized sections designed to minimize the risk of damage to adjacent sections and protection of personnel in the event of a failure occurring within the Equipment. Rupture diaphragms of stainless steel/Nickel Alloy or any other proven material with suitable deflectors shall be provided to prevent uncontrolled bursting pressures developing within the enclosures. The switchgear shall be of modular design and shall have complete phase segregation. Each section shall be complete with high grade epoxy resin, gas-tight seal-off insulators. These insulators shall be designed to have high structural strength and electrical dielectric properties, and shall be shaped so as to provide uniform field distribution, and to minimize the effects of particle deposition either from migration of foreign particles within the enclosures or from the by-products of SF6 breakdown under arcing conditions.
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The enclosures shall be gas-tight which shall be achieved preferably through a double gasket system. The gasketing shall consist of O-rings made of synthetic rubber. All O-rings shall be easily replaceable at site. The enclosure and seals shall be designed to withstand the gas pressure encountered under normal and short circuit conditions. The material and thickness of the enclosures shall be in compliance with IEC - 517 and be such as to withstand an internal flashover without a burn through for a period long enough (500 ms) to enable the back up relay protection to clear the fault. Viewing windows shall be provided at the disconnecting and earthing switches to ensure that each switchgear component can be inspected during installation or maintenance. Each section shall have plug-in or easily removable connection pieces to allow for easy replacement of any component with the minimum of disturbance to the remainder of the Equipment. Materials used in the manufacture of the switchgear Equipment shall be of the type, composition and physical properties best suited to their particular purposes and in accordance with the latest engineering practices. Metal enclosures shall be fabricated from aluminium alloy. All joint surfaces shall be machined, and all castings shall be spotfaced for all bolt heads or nuts and washers. All screws, bolts, studs and nuts shall conform to metric system. All the conductors shall be fabricated of Aluminium of cross sectional area suitable to meet the normal and short circuit current rating requirements. The finish of the conductors shall be smooth so as to prevent any electrical discharge. The conductor ends shall be fitted with silver plated finger contacts or tulip contacts. The contacts shall allow the tubular conductors to expand or contract axially due to temperature variations without imposing any mechanical stress on supporting insulators. Each pressure filled enclosure shall be designed and fabricated to comply with the requirements of the applicable pressure vessel codes of the country of origin, and based on the design temperature and design pressures as defined in IEC 517. The English version of relevant pressure vessel code shall be supplied to the Purchaser. Manufacturer shall guarantee that the pressure loss within each individual gas-filled compartment will not be more than 1 percent per year. Each gas-filled compartment shall be
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equipped with static filters. These filters shall be capable of absorbing any water vapour which may penetrate into the enclosures. The switchgear line-up, when installed and operating under the ambient conditions shall perform satisfactorily and safely under all normal and fault condition. Even repeated operations upto the permissible servicing intervals, under full rated fault conditions, shall not lead to diminished performance or significantly shortened useful life of the switchgear. Arc faults caused by external reasons shall be positively confined to the originating compartment and shall not spread to other parts of the switchgear. Routine replacement of insulating gas shall not be required in intervals of less than ten years. Temperature rise of current carrying parts shall be limited to the values stipulated in IEC 694, under rated current and the climatic conditions. The temperature rise for accessible enclosure shall not exceed 30 K at an ambient air temperature not exceeding 40C. In the case of enclosures, which are accessible but need not be touched during normal operation, the temperature rise limit may be permitted upto 40 K. These temperature rises shall be applicable for site altitude of 2318 m. Bracing shall be provided for all mechanical components against the effects of short circuit currents. The design of the Equipment shall be such that the agreed permitted movement of foundations or thermal effects does not impair the assigned performance of the Equipment. Thermal rating for all current carrying parts shall be a minimum of 1 sec. at 220 kV for the rated symmetrical short-circuit current. If the max. short-circuit time is extended, the I. t value shall remain constant. The switchgear shall be of the free-standing, self-supporting dead-front design, with all highvoltage Equipment installed inside gas-insulated, metallic earthed enclosures, and suitably sub-divided into individual arc and gas-proof compartments, at least for: busbar section with associated busbar disconnector circuit breaker line disconnectors gas insulated busduct section between generator transformer and GIS.
Each phase / pole of GIS and SF6 busducts shall be housed in separate enclosures.
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Arrangement of the individual switchgear bays shall be such as to achieve optimum spacesaving, neat and logical arrangement, and adequate accessibility to all external components. It is required that the three phases of each switch bay be arranged side by side. Segregated phase blocks of Equipment in which one phase of each switch bay is mounted in a separate block are not acceptable. The arrangement of the Equipment offered must provide adequate access for operation, testing and maintenance. Each line up of switchgear shall be suitable, and prepared for future extension on either end without any drilling, cutting or welding on the existing Equipment. To add Equipment, it shall not be necessary to move or dislocate the existing switchgear bays. The switchgear shall be operated either from the front or from the side. For routine inspections and possible repairs, all elements shall be accessible without removing support structures. The removal of individual enclosure parts, or entire Equipment in any bay, shall be possible without disturbing the enclosure of neighboring bays. It shall be impossible to touch live parts of the switchgear unwillingly, i.e. without the use of tools or brute force, or to perform operations that lead to arcing faults. The primary design goal shall be the avoidance of all known reasons for internal arcing. Should it occur, nevertheless, the release of pressurized gas into the atmosphere must occur in such a controlled way that personnel standing at the operating position of the switchgear will not be hurt directly in the process. Further more, no part of the enclosure, or any loose parts, may fly off the switchgear in such an event, and no holes may burn through the enclosure until the nearest protective relay has tripped. All earthing connections must remain operational during and after an arc fault. All interlocks that prevent potentially dangerous mal-operations, shall be constructed such that they cannot be defeated easily, i.e. the operator must use tools or brute force to override them. The actual position of disconnector and grounding switches must be positively displayed by mechanical indicators visible from the operating position.
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Insulating gas The SF6 gas required for filling for maintenance shall be furnished with the switchgear, along with connecting hose and fittings. Characteristics SF6 gas to be filled in GIS shall in all respect conform to the following values (in accordance with IEC Publication no. 376): Impurity Air CF4 Moisture Hydrolyzable fluorides expressed as HF Gas System The gas pressure shall be based on the Suppliers design. The gas system shall be independently separated into logical groups to provide the largest practical gas reservoir for least leaks, but small enough to permit optimum installation, maintenance and leak detection procedures. The independent gas section shall be separated by gas-tight barriers capable of withstanding full pressure from either side with a vacuum on the opposite side. Counter measures against expansion, vibration and noise The GIS Equipment shall be furnished with specially designed compensators/bellows to preserve the mechanical strength of the Equipment at the connection portions to deal with the following problems: To absorb the expansion and contraction of outer enclosure and conductor due to temperature variations. Mismatch in various components of GIS To absorb the dimensional variations due to uneven settling of foundation To withstand seismic forces as mentioned. Max allowable concentration(by weight) 0.05% 0.05% 15 ppm 1.0 ppm
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Corona In general the contours of energized metal parts of the GIS and any other accessory shall be such as to eliminate areas or points of high electrostatic flux concentrations. Surfaces shall be smooth with no projection or irregularities which may cause corona. All components of the same rating and construction, which may need to be replaced, shall be interchangeable. Auxiliary switches which are installed on the frame of switching devices shall be suitably protected against accidental arcing from the main circuit. External effects of an arc shall be limited to the extent possible. Manufacturer shall give information on extent of damage and features which limit such damage. Design calculations or proof test report to demonstrate strength of enclosure at design pressure and design temperature shall be furnished. Wherever SF6 duct is crossing wall or floor suitable frame/plate shall be offered. The breaker enclosure shall have provision for easy withdrawal of the interrupter assemblies. The procedure may not involve the removal or dislocation of enclosure parts of neighbouring bay. The removed interrupter assembly must be easily and safely accessible for inspection and possible repairs. The enclosures of the same phase shall be electrically interconnected. At proper points they shall be connected to the other phases thus entailing a return current almost equal to the current circulating in the conductors. The enclosure shall be designed to practically eliminate the external electromagnetic field and thereby electrodynamic stresses even under short circuit conditions. Elbows, bends and T-Sections of interconnections shall include the insulator bearing the conductor at the change of direction to ensure that live parts remain perfectly centred and the electrical field is not increased at such points. Each gas compartment shall be fitted with separate non-return valve connectors for evacuating and filling the gas, checking gas pressure etc.
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The switchgear shall have provision for connection to the grounding risers. This provision shall consist of grounding pads of Copper or Aluminium. The Supplier shall furnish the details and drawings for ground mat requirement for GIS and busducts. Fire retardancy All components shall be fire retardant and shall be tested in accordance with IEC 695. Gas emissivity when the material is heated shall be minimal. PVC material shall not be used but fire retardant cables as per IEC 332-1 may be used. Control wire in a grouped environment shall not convey flame, continue to burn when tested as per IEC 695. The method of test and criteria for success or failure shall be in accordance with the above IEC. High voltage transients High voltage transients from switching operations and internal faults are coupled to the external sheath of the GIS. Since the effects of these transients on people are not known, operating personnel are required to avoid contact with the sheath during switching operations. Such a restriction is considered undesirable and the Supplier is requested to comment on devices and techniques which may reduce such hazard or new techniques to reduce transients to an acceptable safe level. Burn through prevention The Supplier shall explain the design features of their Equipment which prevent burn through when an internal arc occurs. Internal arcing test report for aluminium enclosures having similar configuration and wall thickness shall be furnished. The worst case of fault with an arc fixed adjacent to a spacer should be considered and discussed also. The effect of pressure rise and time to burn through should also be discussed for an internal arc. Service life SF6 Circuit breakers, disconnect switches and ground switches will be subjected to frequent, and occasionally repetitive, no load operations and switching off load, capacitive and inductive current within their ratings. In order to minimize maintenance and component replacement, the Supplier shall submit proof and further guarantee that all offered SF6 GIS Equipment has a minimum service life of 10,000 normal operations except for high speed
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fault making earth switch which has been tested upto 3000 normal operations. The maintenance free period for any of its external components shall not be less than 5 years intervals. Internal components including refilling of gas shall not be less than 10 years. The Supplier shall propose the recommended period for schedule maintenance. Conductors and live parts shall be supported by solid moulded epoxy-resin insulators. These insulators shall be designed to have high structural strength and dielectric properties and shall be shaped so as to provide long creepage distance, uniform field distribution and to minimize the effects of particle deposition either from migration of foreign particle within the enclosure or from the by-products of SF6 breakdown under arcing condition. Gas barrier and support insulators shall have the same basic design. Support Insulators shall have holes for gas communication on both sides. Gas tight barriers shall be clearly marked on the outside of the enclosure. Gas barrier insulators shall be provided so as to divide the GIS into separate compartments. They shall be suitably located in order to minimise disturbance in case of leakage or dismantling. They shall be designed to withstand 1.5 times full rated pressure on one side while vacuum is exerted on the other side. They shall also be designed to withstand any internal fault thereby keeping on internal arc inside the faulty compartment. Alarm circuit shall not respond to faults for momentary conditions. Following alarm circuits including those required elsewhere in the specification, shall be generally provided for indication of : In the gas-insulating system Loss of gas density Any other alarm necessary to indicate deterioration of the gas insulating system. In the Operating System Low operating pressure Loss of heater power Loss of operating power Loss of Control
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Pole discrepancy Any other alarm necessary to indicate faulty condition.
Provision for repeat of alarms on the Data Acquisition System of the Purchaser shall be made. To prove the capability of the Equipment to withstand the earthquake, the Supplier shall model the Equipment in such a manner that it will represent the Equipment completely installed and ready for service. The resulting system shall be dynamically analyzed using Model Analysis. The calculations and results shall be supplied to the Purchaser for his approval. A 5 -tonne capacity, electrically operated, overhead traveling crane with pendant type control in the GIS Cavity for installation, and future maintenance, of the GIS equipment shall be provided. 10.3.2 Performance Guarantee The GIS system along with all auxiliaries and accessories shall be capable of performing intended duties under specified conditions. The Contractor shall guarantee the reliability and performance of the individual equipment as well as of the complete system. Contractor shall state and guarantee the following: The maximum yearly gas loss in every monitored compartment, In the event of loss of gas exceeding 1.0 percent in any section measured in the first year after commissioning of GIS the manufacturer shall submit a procedure for the approval of Owner and based on agreed QA plan carry out necessary rectification or replacement to reduce the gas leakage shall be carried out by the manufacturer at no cost to Owner. Necessary outage however shall be provided by Owner, Number of mechanical and fault current operation of circuit breaker interrupter unit before it is opened for inspection and maintenance, Number of operation of operating mechanism before it is opened for inspection and maintenance.
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10.4
Construction
10.4.1 Enclosures The enclosure shall be gas tight, the seals shall be designed to withstand the gas pressure encountered under normal and short circuit conditions. The material and thickness of the enclosures shall be in compliance with IEC standards and be such to withstand an internal flashover without a burn through for a period of 0.1 seconds for currents up to 40 kA. 10.4.2 Insulating Gas and monitoring system GIS equipment shall be supplied with new SF6 gas only, as per IEC 60376. The independent gas system section shall be separated by gas tight barriers with bypass valves, where appropriate, capable of withstanding full pressure from either side with a vacuum on the opposite side. The gas density in each gas compartment shall be monitored continuously by density switches. It shall be directly secured on the enclosure, and shall have two threshold levels to continuously monitor the gas density. In addition to the continuously operating density switches, a pressure switch acting for the highest permitted gas pressure shall be provided for each separate gas compartment. The high-pressure switch shall give an alarm at the pressure corresponding to the highest ambient temperature, normal density during filling up, and bus current equal to the maximum rated value. A pressure gauge shall be installed for each separate gas compartment. Except for density and pressure switches, each gas filled compartment shall also be fitted with: One SF6 filling and draining valve with automatic shut off and quick coupling device; One safety diaphragm designed to prevent any bursting of the enclosure, should an internal fault of an abnormal pressure increase occur; One absorbent filter to retain moisture.
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Means shall be provided for routine testing and replacement of the gas density relay and any other associated accessories without draining the gas section or de-energizing the primary equipment. Each pressurised section shall be provided with a readily accessible rupture disc complete with flanges and outlet pipe directed away from normal location of personnel. The rupture pressure of the disc shall be coordinated with the vessel internal design pressure for normal conditions. 10.4.3 Bus Bars and Bus Ducts The SF6 three phase encapsulated bus bars and single phase encapsulated bus ducts shall be mounted in the horizontal/vertical configuration to suit the switchgear line up and transformer layout. The conductors shall be made of aluminium alloy or drawn electrolytic copper. Both, the conductors as well as the contacts for the conductor connections must be designed for the continuous rated current of the switchgear under the ambient conditions and shall not exceed the permissible temperature rise. 10.4.4 Circuit Breakers The circuit breakers shall be of single or double breaking chamber, SF6 puffer type interrupter units using SF6 gas for both insulation and arc-quenching. Line circuit breaker, shall have single-pole auto-re-closing capabilities. The operating/drive mechanism shall be trip-free, suitable for single-pole or three-pole tripping and shall have anti-pumping features. The breaker operating mechanism shall be of spring operating type or electro-hydraulic stored energy type. It shall be suitable for triple pole and where necessary for single pole automatic re-closure. Operating mechanisms shall be equipped with dc shunt coils for tripping and closing and suitable for local control and remote control. Power supply for all operating devices and control shall be 220 V dc.
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10.4.5 Disconnects and Earthing Switches All disconnect switches and earthing switches shall be equipped with local as well as remote controlled power-operated mechanism, an emergency manual operating device shall also be provided. The DC power supply to the mechanism shall be automatically disconnected and local/remote electrical operation shall be prevented when manual operating device is engaged. The requirements of IEC 62271-102 shall apply to the specified disconnect switches. 10.4.6 Surge Arresters The surge arresters shall be capable to ease the strain on transformer windings when being switched off and to protect the HV/MV equipment from lightning and switching surges. Furthermore, they shall be designed to prevent any oscillating over-voltages during normal and/or abnormal switching conditions. 10.4.7 GIS adapter for Transformer oil-SF6 Bushing Terminations The power transformers are to be connected to the switchgear via gas-insulated conductors; the supply of gas-insulated connection bus with the terminal for the conductor coming from the transformer shall form part of the GIS. The support of the conductor coming out of the transformer including the associated SF6-to-oil transformer bushing shall form part of the transformer contract. This interface shall be designed in order to provide fast replacement of the transformer unit. Effective gas tight seals shall be provided between the duct enclosure and the SF6-to-oil bushing. 10.4.8 Cable Terminations Suitable SF6 gas-filled cable sealing end boxes shall be provided, where required, for accommodating XLPE single-core copper cable terminations. The boxes shall be designed to accept the cable along with its termination cone from below. The scope shall also include necessary cable supports and cable grounding facilities. All cable connections shall generally comply with IEC 60859. 10.4.9 Current Transformers Current transformers shall be of the ring core design with grounded cores.
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The windings shall be located in accordance with the requirements of the single-line diagrams. CTs shall be located in a separate compartment. 10.4.10 Voltage Transformers
The voltage transformers shall be fully encapsulated. The gas compartment shall be segregated from the adjacent compartments. The rating and the features of the voltage transformers shall be in accordance with the Protection and Metering single line diagram. 10.4.11 Local Control Cabinet (LCC)
Each bay shall be provided with a dedicated Local Control Cabinet that shall be located in front of their respective GIS bays. The cabinet shall be of rigid construction, IP55 protection class with hinged doors provided with stops and a means of locking the door in the open position. The LCC shall contain local control switches and a mimic diagram for the operation and status indication of the circuit-breaker and all associated isolators and earth switches together with selector switches to prevent local, remote and supervisory controls being in operation simultaneously. The main functions of the Local Control Cabinet are: Mimic panel showing the bays single line diagram, with circuit breaker, disconnect switches and earthing switches, controls (close and open commands) and equipment status (open/close) by means of semaphore type indicator or turn-and-push control switch with discrepancy light. The mimic panel shall be located in the front of the LCC and behind a viewing window; Alarm monitoring system with a sufficient number of alarms to indicate specific types of troubles and their locations, equipped with a method for testing and resetting alarms; Switchgear interlocking between circuit-breakers, disconnect-switches and earthswitches; Master control selector Local-DACS shall determine either local electrical or remote control of all devices and prevent simultaneous operation from both points. Local electrical operation of devices shall be for maintenance purpose only;
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Metering of electrical parameters, analogue units or multifunction with three simultaneous-reading display (i.e. V, A, MW);
Marshalling box for CT and VT secondary circuits. Interface with DACS. Grounding
10.4.12
An effective grounding network within the switchgear location shall be established by providing a continuous copper ground bus extending over the entire length of switchgear enclosure. The bus shall be adequately sized to withstand the specified short-circuit current. Frames, cubicles, panels etc shall be grounded by copper strip bolted on one end to the equipment and the other end to the nearest earth riser. The temperature of the grounding conductors shall not exceed the temperatures specified in IEC 60517 during normal operation. 10.4.13 SF6 Gas Processing Unit
A portable SF6 gas processing unit suitable for evacuating, liquefying, evaporating, filling, drying and purifying SF6 gas during the initial installation, subsequent maintenance and future extension of the GIS shall be provided. The unit shall be suitable for handling, storage of gas for largest section and the two adjacent sections of GIS (reduced to atmospheric pressure) which may need evacuation during maintenance. The cart shall be equipped with rubber wheels and shall be easily manoeuvrable within the GIS hall. The unit shall be self contained (except for additional gas storage cylinders and external power supply at 415 Vac, 3-phase, 50 Hz) and fully equipped with an electric vacuum pump, gas compressor, gas drier, gas filter, refrigeration unit, evaporator, gas storage tank, full instrumentation for measuring vacuum, compressor temperature monitoring , tank pressure and temperature monitoring, valves , fittings and piping. 10.5 Quality control and assurance
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10.6.1 Design memorandum The Contractor shall submit all the drawings and documents in accordance with requirements stipulated in Section 2.12 Reference drawings and documents of General Technical Specification (GTS). 10.6.2 Drawings and documents The Contractor shall submit all the drawings and documents in accordance with requirements stipulated in Section 2.12 Reference drawings and documents of General Technical Specification (GTS). 10.6.3 Design calculation The Contractor shall submit the design calculation covering at least the following, for review / acceptance. Calculation of power requirement for operating mechanism of breakers, disconnector and earthing switches, Data/calculations in regard to the loads under severe short circuit conditions to be transferred to civil structures for designing of GIS hall accordingly. Insulation co-ordination studies to determine requirement of Surge Arresters and their performance and location. Calculations for load due to temperature variation and earthquake. Delivery, Installation and Commissioning
10.7
The supplier shall follow the requirements of Delivery, Installation and commissioning elaborated in section 2.34 Installation and Supervision of General Technical Requirements The supplier shall arrange personnel to oversee proper storage of equipment at site, their transhipment to powerhouse, installation and commissioning. 10.8 Spare Parts
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Sl no 1
Description
Quantity
SF6 gas for use during operation and maintenance 10% of total quantity in 40 kg in non-returnable cylinders cylinders Complete drive mechanism including motor for 1 no. disconnector switches and earthing switches Complete drive mechanism including motor for fast 1 no. acting earthing switches Trip coils for circuit breakers Closing coils for circuit breakers Complete set of rupture disc Pressure switch/gas pressure transmitter Pressure gauge Gas density relay Special tools 2 nos of each type 2 nos of each type 1 set 2 nos. 2 nos. 1 no.
4 5 6 7 8 9 10.9
The Contractor shall propose the list of special tools including their make and detailed specification as recommended by manufacturer(s), to be accepted by the Owner. The proposed list of special tools must include the following in addition to tools recommended by manufacturer(s): One (1), gas processing and filling unit, along with tools and spares to handle gas quantity in at least two largest gas sections, with provision to check SF6 moisture and acidity content, One (1), set of handling devices and tools for assembling and dismantling of bays / complete GIS modules, One (1) set of handling devices and tools for assembling and dismantling each type of operating mechanism of circuit breakers, disconnector and earthing switches. Testing instruments
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The Contractor shall propose the list of testing instruments including their make and detailed specification to be accepted by the Owner. Proposed list shall include following mandatory items: One (1) no. air / gas humidity tester, One (1) no. gas. purity detector for SO2,H2O,CF4,AIR etc., One (1) no. gas leakage tester, One (1) no. breaker timing measurement kit, One (1) set of equipment for pressure measurement and gas tightness testing.
10.10 Testing The Contractor shall follow the Inspection and testing requirements in Quality assurance clause 2.31 Factory inspection and testing of General Technical Specifications and also section 11 of document Quality Assurance and testing specification
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11. 11.1
220 KV XLPE CABLES Scope of Work
Scope of work under this section covers the provision of labour, tools, plants, materials and performance of work necessary for the design, manufacture, quality assurance, quality control, shop assembly, shop testing, delivery at site, site storage and preservation, installation, commissioning, performance testing, acceptance testing, training of Owners personnel, handing over to Owner and guarantee for one year of XLPE cables as per the specifications hereunder, each complete with all auxiliaries, accessories, spare parts and warranting a trouble free safe operation of the installation. The scope of work shall be a comprehensive functional system covering all supply and services including but not be limited to the following: a) Seven (7) single-phase lengths of 220 kV, copper conductor, XLPE cables complete with all components and auxiliary equipments necessary for connection between underground GIS terminations, through a cable access gallery to outdoor pothead terminations. This includes one spare cable; b) Six (6) cable terminations suitable for terminating cables at GIS, each complete with necessary fittings and accessories; c) Six (6) outdoor cable terminations suitable for termination of cables at overhead line potheads, each complete with necessary fittings and accessories; d) Six (6) suitably rated surge diverters for over voltage protection of the cable sheaths, complete with all mounting fixtures and connection hardware; e) Six (6) hot galvanized steel supports for the outdoor cable terminations, complete with all necessary hardware and accessories; f) One (1) set of sealing arrangement for sealing one (1) spare cable at both ends, complete with all necessary hardware and accessories; g) One (1) set of cable support system including cable trays / hangers, fixtures, hardware etc. for supporting all the cables along the entire length of cable; h) One (1) set of special devices and handling tools for cable sheath grounding, cable unwinding accessories, installation and maintenance of cables; i) One (1) set of spares.
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Any other item(s) not mentioned specifically but necessary for the satisfactory completion of scope of work defined above, as per accepted standard(s) / best international practices. 11.2 Rating and Design requirements
11.2.1 Rating DESCRIPTION Type Cable rated voltage (U) Highest voltage for equipment Frequency Voltage test - Voltage - Duration Impulse voltage test Continuous Current rating System Short Circuit Current for 1 sec, Momentary short-circuit current (peak) Maximum permissible continuous conductor temperature Maximum permissible conductor temperature, under shortcircuit current UNITS kV kV Hz kV minutes kV A kA kA C C DATA XLPE 220 245 50 5% 318 30 1050 1200 40 100 90 250
Design of Cable systems shall be such that a life expectancy of 35 years is achievable. Cable systems shall be so designed and constructed that it shall perform satisfactorily under all operating and service conditions including seismic conditions. The power loss in the system shall be kept to a minimum and induced voltages in the outer sheath shall not exceed 65 volts for reason of safety of operating personnel. The Supplier shall furnish design calculations for the guaranteed power losses and induced voltage in the sheath. Thermal rating of all current carrying parts shall be suitable for the rated symmetrical short circuit current for a duration of 2 seconds. If the maximum short circuit time be extended upto 3 seconds, the I2t value shall remain constant where I = Short circuit current and t = duration.
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The cable system shall withstand the mechanical forces due to short circuit and earth fault currents. Laying arrangement of cables shall be such as to achieve optimum space saving, neat and logical arrangement and adequate accessibility to each cable. In case of break down, it shall be possible that any cable shall be easily taken out without disturbing any other cables and suitable joint could be made after removing faulty section of cable length. The individual length of cables shall have no splice in the conductor. The cable sheath shall be preferably solidly bonded. All sealing end potheads shall be pressure type and shall conform to IEC 137 `Bushings and IEC 141-1 `Standard Test Procedures. The sealing end terminations at both ends shall have sleeve insulators for complete cable sheath ground isolation. Anti rodent treatment shall be provided to outer sheath. 11.2.2 Cable layout and routing General layout Generator Transformers will be installed in an underground cavity (parallel to machine hall cavity) at El. 2306.90m as shown in Drg. No.167106 AL00 47DD 0009 rev 00. The 220 kV gas-insulated switchgear comprising of six (6) bays shall be located on floor at El 2317.90m just above the transformers. The gas-insulated 220 kV feeder bays (2 nos.) shall be connected to outdoor potyard located at El 2441 m through single core XLPE Cable laid in Cable cum ventilation tunnel either on racks or on side walls or in trenches in floor. Proposed general layout plan and sections of transformer/GIS hall, interconnecting cable tunnel, potyard etc. are indicated in the drawings appended with these specifications. XLPE Cable system will comprise two (2) number of transmission circuits between GIS and outdoor potyard. Manufacturer shall indicate his preferred choice of installation of cables with a typical cross sectional arrangement.
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Cable laying arrangement The proposed arrangement of the cables is shown in Drg. No. 167106 AL00 47DD 0017 and 0018. Cables will be laid in trenches or laid on cable racks in cable tunnel and cable duct generally as per this drawing. The Supplier may examine the proposed arrangement and can suggest suitable alternatives based on his experience. The proposed arrangement should be such that there are no undue stresses on the cable sheath / cable core under any operating condition. The Supplier shall supply detailed drawings for the proposed arrangement which, in his view, offers the best techno-economic solution. Cable lengths Each length of XLPE Cable (7 nos.) shall be supplied without joint if possible . The Supplier must calculate the lengths to account for bending radius of cables, snaking margins, cutting allowance and any other allowances as per experience and provide for adequate length. Positive tolerance of maximum one percent (1%) is allowed on ordered length. The Supplier shall furnish the calculated lengths of each phase run of XLPE Cables in data sheets and furnish the supporting calculations alongwith the Contract. Cable length shall be subject to adjustment as per final approved drawings and lengths and cost of any plus/minus variation over ordered length shall be adjusted on basis of variation rate for each metre. Variation in cable length of + 10% and - 5% shall be considered and acceptance given with the Contracts. 11.2.3 Codes and Standards The equipment and works shall conform to the latest issue of the applicable standards and codes of the authorities and technical organisations including, but not limited to, those listed hereunder, and of any that may be listed or referred to elsewhere in the Technical Specifications. ASTM B8 ASTM B33 ICEA-P-45-482 IEC 60141-1 Standard specification for concentric-lay-stranded copper conductor, hard, medium-hard or soft. Standard specification for annealed soft and annealed copper wire for electrical purposes. "Short-circuit Performance of Metallic Shielding and Sheath of Insulated Cable". (ICEA: Insulated Cable Engineers Association) Test on oil filled, paper insulated, metal-sheathed cables and
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accessories for alternating voltages up to and including 400 kV IEC 60183 IEC 60228 IEC 60229 IEC 60230 IEC 60270 IEC 60287 IEC 60330 IEC 60331 IEC 60332 IEC 60502 IEC 60540 IEC 60060 IEC 60811-1 IEC 60811-1-1 IEC 60811-2-2 IEC 60859 IEC 62067 IEEE 48 - 1990 Guide to the selection of high-voltage cables Conductors of insulated cables Test on cable over-sheaths which have special protective functions and are applied by extrusion Impulse tests on cables and accessories Partial Discharge Measurements Calculation of the continuous current rating of cables (100% load factor). Methods of test for p.v.c. insulation and sheath of electric cables Fire-resisting characteristics of electric cables Flame-retardant characteristics of electric cables Power cables with extruded insulation and their accessories Partial discharge test of conductor to sheath High voltage test techniques Common test methods for insulating and sheathing materials of electric cables Thickness measurement Common test methods for insulating and sheathing materials for electrical cables Cable connections for gas insulated metal enclosed switchgear for rated voltages of 72.5 kV and above Power cables with extruded insulation and their accessories for rated voltage above 150 kV up to 500 kV test methods and requirements Test procedures and requirements for high-voltage alternating current cable terminations
Equipment meeting the requirement of any other authoritative standard that ensures a quality equal to or better than IEC shall also be acceptable. The Supplier shall enclose with the offer, copies of all the relevant IEC and other standards (in English), to which the equipment conforms. 11.2.4 Performance Guarantee The 220 kV XLPE cable along with all auxiliaries and accessories shall be capable of performing intended duties under specified conditions. The Contractor shall guarantee the reliability and performance of the individual equipment as well as of the complete system.
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11.3
Construction
The cable shall be composed of: Plain annealed compacted and stranded soft drawn copper conductor; Conductor shield; XLPE insulation; Semi conducting shield; Bedding of semi conducting tape; Metallic shield of copper; Metallic sheath of corrugated aluminium; Protective cover of PVC flame retardant.
Cable Description The conductor size shall be calculated on the basis of a continuous full load rated current under the climatic conditions and in accordance with the requirements of the applicable Standards. The conductor shall be round, compacted, shaped or circular stranded soft-drawn copper class 2 per IEC 60228. The conductor shield of cable, rated 220kV shall consist of an extruded black thermosetting semi-conducting material compatible with the conductor and the XLPE insulation. The insulation shall be super clean cross-linked polyethylene (XLPE), and smoothness and adhesiveness shall be assured for the interface between insulation and semi-conducting layers. The metallic sheath shall consist of a seamless tube of corrugated aluminium or extruded lead alloy. IEC Publication 60949 shall be used by the manufacturer to determine the
effective cross-sectional area of the metallic sheath and its short circuit current carrying capability. During normal operation, induced sheath currents shall not reduce the current carrying capacity of the cable circuit. The power cable shall be free of material and manufacturing defects that would prevent it from meeting the requirements of this Specification.
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Cable Layout Inside the tunnel cables will be laid on cable trays. Between the portion of the underground SF6 terminal and the entrance of the tunnel, cables will l be laid on cable supports. Cable Terminations The cable termination potheads shall be made in accordance with IEEE Standard No. 48 and tested according to the requirements for the 245 kV voltage class and a lightning impulse dry withstand voltage of 1050 kV peak, with both positive and negative polarity tests. The connecting stud of the cable terminations shall be equipped with suitable adaptors permitting the connection to the SF6 insulated cable termination of the GIS at one end of the cable and to the terminations of the overhead line outdoor potheads at the other end of the cable. Over-voltage limiters shall be installed on the floating end of cables where the sheath is grounded at one end only. The over-voltage limiters shall be designed such as to
adequately protect cable terminations, accessories and outer polyethylene insulation of the cable against the induced over-voltages in the sheath due to lightning or switching surges and allowing open circuit to operating voltages. Over-voltage limiters shall be installed in the panels in order to protect personnel and equipment. The panels shall be corrosion proof, waterproof and shall provide visual
inspection without opening it. The panels shall also permit easy replacement of over-voltage limiters. Indoor termination The Supplier shall offer suitable type of the termination arrangement with GIS as per his standard practice. It will include an arrangement for conducting various tests on cable to be performed at site independent of the GIS. The termination shall be so designed that no force is transferred to the GIS. The Supplier shall furnish, standard drawings showing details of indoor termination. Clearly indicating the interface details and limits of his supply in the drawing to be submitted by them. The Supplier shall supervise the erection of cable including cable terminations with the GIS. He will collect any required information from the GIS Supplier for getting the termination task
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completed with his cooperation. Scope of termination will be defined and agreed between GIS Supplier and 220 kV Cable Supplier to ensure completeness and scope defined in the Contract. The tests on the cable termination shall be carried out under the supervision of the cable Supplier as per IEC 859. Outdoor termination a) 220 kV Cables as above will be terminated at 220kV cable potheads in the outdoor
pothead yard. The cable Supplier shall supervise the termination of cable with the pothead. The mounting steel structure foundation and accessories for installation of cable pot head shall also be supplied by the cable Supplier. b) The outdoor terminal end housing shall be of porcelain of uniform quality and shall
have sufficient strength against electrical, mechanical and thermal stresses. Minimum creepage distance shall be 16 mm/kV. Bushing shall be corona free upto 1.10 Uo. Grounding switch The Supplier shall offer suitable grounding switch attached to the support structure of each outdoor cable pothead which will be used for grounding of the cable as per requirement. This grounding switch will have a disconnecting arm operating through a hand/motor operated box mechanism and will be used for maintenance purposes. The salient technical requirements are as under :Rated voltage Insulation level Basic impulse withstand voltage P.F. withstand voltage Material of Earthing Blade Details of Operating Mechanism Minimum Air Clearance 1050 kV 460 kV Aluminium tube Motor drive/Hand drive 3815mm 220kV
Alternatively the Supplier can offer suitable means for grounding for maintenance as per his standard practice. Detailed arrangement proposed shall be furnished. Supporting structures ,clamps , cleats etc.
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a)
All the supporting structures required for laying of cables (including cable clamps, cleats, anchors and hardware for fixing) from GIS termination end upto outdoor termination end shall be supplied by the Supplier.
b)
The Cable laying arrangement shown in the appended drawings is indicative only. The Supplier shall furnish the supporting arrangements, type of material and shall include the dimensioned drawings to illustrate the arrangement proposed by him in detail.
c)
Cable racks, trays and supports shall also be provided by Supplier, if applicable.
Earthing of cables a) Sheath of the each cable shall be earthed at both ends. One end of the cable shall be earthed through Cable Covering Protection Unit (CCPUs) for protection against high transient voltage appearing on the sheath because of lightning or switching surges. Suitable disconnecting link boxes shall be provided at both ends. b) The induced voltage under normal loading conditions shall be limited to 65V or a lower value as per recommendation of the Supplier. Necessary calculations for the same shall be supplied by Supplier. c) Suitable CCPUs comprising non-linear resistance which offer high resistance to normal sheath voltage and a lower resistance to transient sheath voltage shall be provided at the GIS end. The rating of CCPUs shall be selected with due regard to the induced voltages under specified short circuit current conditions. d) Metallic sheaths of the three cables of each transmission circuit at transformer end shall be connected together and earthed by bonding cable through link boxes. e) The outdoor terminal end side shall be connected to the earthing system through link boxes without using any Cable Covering Protective Unit (CCPU). f) Scope of Supply shall include all accessories required for total sheath isolation except at those places intentionally earthed. Suitable disconnecting links shall be provided to facilitate testing on insulation after commissioning. g) All the earthing material including link boxes, bonding cables required for earthing of cable system shall be supplied. Purchaser shall provide earth mat with risers in GIS
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hall, Cable tunnel and outdoor potyard. The cable system shall be earthed by connecting with the Purchasers earthing system. h) All the termination ends, supporting structures etc. shall be suitably grounded. The grounding connections shall be of sufficient mechanical strength to withstand electromagnetic forces as well as capable of carrying the anticipated fault currents. Precaution should be undertaken to prevent excessive currents from being induced into adjacent frames, structures or reinforcing steel and to avoid establishment of current loops. Bonding cable shall be used for earthing the metallic sheath of the cable and as a earth continuity wire equalising earth between link boxes. The construction and material shall comply with BS 6346 and the cross-section of conductor shall have enough size to withstand the specified short circuit rating of the cable system. The calculations regarding design of grounding system and detailed drawings shall be furnished by the Supplier. Link boxes a) Link boxes having disconnecting links shall be provided at both ends of cable sheath to facilitate periodical checks. The link boxes shall be suitably mounted on supporting structure or on the wall of duct or tunnel and provided for each phase individually. b) The switch blade in link box shall be made of copper. All pins and connections shall be weatherproof. All link contacts shall be of copper or silver-copper with special alloy tips. They shall be of self-adjusting type. The contacts shall be designed so that pressure may not change with the normal wear during operation. Temperature monitoring and fire detection system for the cables Supplier shall provide suitable temperature monitoring and fire detection system for cables. 11.4 Quality control and assurance
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11.5.1 Design memorandum The Contractor shall submit all the drawings and documents in accordance with requirements stipulated in Section 2.12 Reference drawings and documents of General Technical Specification (GTS). 11.5.2 Drawings and documents The Contractor shall submit all the drawings and documents in accordance with requirements stipulated in Section 2.12 Reference drawings and documents of General Technical Specification (GTS). 11.5.3 Design calculation The Contractor shall submit the design calculation covering at least the following, for review / acceptance. 11.6 Calculation of cross section of the cable. Delivery, Installation and Commissioning
The supplier shall follow the requirements of Delivery, Installation and commissioning elaborated in section 2.34 Transport and installation of General Technical Requirements. The supplier shall arrange personnel to oversee proper storage of equipment at site, their transhipment to powerhouse, installation and commissioning. 11.7 Spare Parts
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Sl. No 1
Description
Quantity
Cable sealing end arrangement for use at GIS terminal complete 1 set with gasket. Cable sealing end arrangement for use at Pot head yard terminal 1 set complete with gasket Link box, single phase Cable straight joint Special tools 1 set 1 set
3 4 11.8
The Contractor shall propose the list of special tools including their make and detailed specification as recommended by manufacturer(s), to be accepted by the Owner. 11.9 Testing
The Contractor shall follow the Inspection and testing requirements in Quality assurance clause 2.31 Factory inspection and testing of General Technical Specifications and section 10 of document Quality Assurance and testing specification.
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12. 12.1
CONTROL, MONITORING AND DATA ACQUISITION SYSTEM Scope of Work
Scope of work under this section covers the provision of labour, tools, plants, materials and performance of work necessary for the design, manufacture, quality assurance, quality control, shop assembly, shop testing, delivery at site, site storage and preservation, installation, commissioning, performance testing, acceptance testing, training of Owners personnel, handing over to Owner and guarantee for one year of control and monitoring system as per the specifications hereunder, complete with all auxiliaries, accessories, spare parts and warranting a trouble free safe operation of the installation. The scope of work shall be a comprehensive functional system complete in every respect including but not limited to the following: a) One (1) modern distributed control system (DCS) complete with two (2) SCADA servers/operator workstations, two (2) (redundant) dispatch communication
gateways, two(2) engineering work stations , Two (2) on-line data storage systems, four (4) laser colour printers and a complete redundant communication network system also called process LAN (Local Area Network) including the following: Three (3) unit controllers (dual redundant); One (1) substation controller (dual redundant) for monitoring and control of G.I.S switch gear; One (1) BFV controller (dual redundant) for control equipments in BFV chamber One (1) general and station auxiliary controller (dual redundant) for monitoring and control of common systems such as SSTs, SSBs, DC system, AC system, PLCC, UPS, Station compressed air system, HVAC & Fire protection system and other station auxiliaries; One (1) pothead yard controller (Dual redundant) sub control systems (0.415/11 kV etc.) at pothead yard, DG sets and other auxiliaries; One (1) intake gate controller (dual redundant) for control of Barrage switchgear system and data acquisition of gate data input from reservoir management sub control system (ARMAC);
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Three (3) sets of automatic synchronizing and a complete set of manual synchronizing equipment;
Three (3) complete sets of metering, one for each unit; One (1) complete internal station communication system including, a Radio system, a Telephone system and a Public Address system;
One (1) GPS Satellite Clock system; Redundant optical fibre line from Butterfly valve chamber to control room One Set of Control desk as per specifications One (1) Portable Laptop based engineering workstation for online/ offline programming of process controllers, development of mimics and other engineering applications. The engineering station will be equipped for online/offline debugging of logic.
One set of video wall consisting of an array of 2x4 screens along with workstation for video wall control. Each screen of 50.
One set of Network hubs/switches and data cables for networking of supervisory level equipment, printers, controllers, I/O racks and Profibus / Modbus network interfaced to the plant SCADA
One set of Hardware required for implementation of time synchronization scheme for the complete automation system via GPS clock. Time synchronization shall also be provided for protection systems for Units and Lines. All the hardware for the GPS clock, antenna, couplers, fibre etc to be included.
1 Lot of Remote I/O cabinets as per system requirements for data acquisition from GIS bays, cooling water system, etc.
1 set of Emergency push button station assembly for tripping of units and BFV from the control room.
One (1) complete set of instrumentation system for the balancing reservoir and the tailrace water level monitoring;
One (1) dual redundant uninterruptible power supply (UPS) system;
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One (1) complete set of redundant fibre optic communications system linking the powerhouse with the GIS, the Pothead yard structure, the balancing reservoir and the intake structure.
b) One set of spares; c) One set of special tools and instruments. Any other item(s) not mentioned specifically but necessary for the satisfactory completion of scope of work defined above, as per accepted standard(s) / best international practices. 12.2 Rating and Design requirements
12.2.1 Salient design features The intent of these specifications is to illustrate generally the basic requirements and features which the Purchaser would like the Supplier to incorporate while designing the SCADA system offered. The Supplier shall review these requirements and provisions and offer a suitable system based on experience from other power stations and offer best techno-economic solution. following: a) Redundancy shall be provided for the operator station, controllers, surge protected power supply (both at the CPU & I/O) and communication modules (both between the controller & the operator stations and between the I/O modules and the controllers). b) (c) (d) Redundancy shall be provided for the communication cables. Power supply used for interrogation with field devices shall be redundant For sequence interlocks and start/stop sequence of units, station and switchyard, a redundant PLC system will be used. Some of the critical interlocking signals may be dual signals derived from the same point of measurement. (e) Two independent transmitters, preferably connected to independent sets of tappings shall be provided for critical measurements. (f) The type of failure, which shall be taken in to account for ensuring operability of the plant shall include but not be limited to : Failure of sensor or transmitter
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The design features shall include but not be limited to the
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(g)
Failure of controller during automatic operation Failure of communication link between processors and central control /MMI. Loss of motive power to final control element Loss of control power. Failure of surge protection devices, connected in power supplies
Cabinets shall be designed for plug-in installation for control system modules in mounting racks. The system modules relating to a particular sub-system or system shall be grouped together when housed in the same assembly, to the extent possible.
(h)
Dedicated marshalling cabinets shall be provided for all termination of analog and digital inputs to the control system and all analogue and digital outputs from the system. These marshalling racks shall be installed at required locations to facilitate cabling. For signals going through the marshalling cabinets to the redundant controllers, the facility of surge protection is to be incorporated in the marshalling terminal blocks itself. The marshalling cabinets shall be in the scope of equipment Supplier.
(i)
A minimum of 20% spare terminals and a minimum space for 30% additional modules shall be provided in excess of the total requirement of control system design, for future expansion. The system shall have the flexibility to easily reconfigure any controller at any time without requiring additional hardware or system wiring changes and without disabling other devices from their normal operating mode. Modifications shall not require switching off power to other parts of the system. In case of redundant controller configuration, it shall be possible to remove/ replace on-line, the standby controller modules without switching off the power to the corresponding rack. Further, it shall be possible to completely isolate the stand by controller modules for maintenance while the main controller is in operation. The control system design shall ensure that any of the above actions does not cause any system disturbance or loss of any controller functions for main controller.
(j)
The SCADA shall include self-surveillance and monitoring facilities, diagnostic features, tools etc. so that a failure/ malfunction shall be diagnosed automatically down to the module level, giving automatically the details of the faulty module on the CRT and printer. To avoid the risk of common mode failures and to minimise the
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consequences of a fault within the system, all the hardware and the power supply modules shall be suitably distributed amongst the various control system cabinets so that no single fault leads to the non-availability of the complete system. (k) Over voltage protection shall be provided for power supply and other automation hardware. All protection signals shall be acting in hardwired mode, in addition to soft logic in controllers. (l) Wherever hot back-up or redundant equipment like controllers, processors, I/O have been provided, the same shall be powered through separate power supply feeders.The power supply feeder distribution for information system and control system shall be completely separate and independent of each other. (k) Timings Auto boot up facility for the SCADA shall be provided and the boot up time shall be within 2 minutes. Display response time shall be less than 2 Sec. Resolution of time of occurrence between SOE points shall be less than 1ms. Closed loop control task execution (Control response time) shall be done within 250 msec. Sequence control / Interlocks scan time shall be within 100 msec. All the real time clocks in the system shall be synchronised with each other and with the GPS clock. (l) The control system software shall have all the essential capabilities to perform advanced control algorithms as a minimum. It shall be user friendly, easily programmable and have excellent data acquisition, graphic display and logging capabilities. (m) The sequence of the events recording system shall preferably be an I/O system consisting of high resolution cards integrated into the existing system, with a capability to log occurrence of faults sequentially with a time resolution of 1 msec. All sub-systems of the system shall be able to operate satisfactorily upto 50 deg.C and 5% to 95% humidity. Galvanic / optical isolation along with current limiting circuit shall be provided for all field signals. Isolation shall also be provided between console and related
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sub-system connected to it if there is any possibility of high voltage from CRTs being transmitted to the sub-system. The system shall have the capability of detecting the open sensors/shorted sensors. Redundant communication link with Intake gate controller preferably one with optical fibre and another with PLCC. An interface / module complete in every aspect for remote control of the entire plant via PLCC from load dispatch centre. Necessary interfaces or devices shall be included in the scope. An interface / module complete in every aspect for remote monitoring and control of the entire plant from Purchasers head office through VSAT. Necessary interfaces or devices shall be included in the scope. (n) Ambient Conditions The system shall be designed for ambient temperature and relative humidity as below Ambient temperature (inside cubicle) during operation: during storage and transport +10 oC to +35 oC -20 oC to +55 oC
Permissible relative humidity (DIN 40046, class F) during operation 75% at max. 40 oC (yearly average) 95% at max. 40 oC (for < 30 days annually) 85% at 25 oC inside original packing between 40 and 55 %
during storage and transportation
For paper of printer and recorders 12.2.2 Distributed digital control system
The Distributed digital control system (DCS) shall provide data acquisition, monitoring, automatic control and supervisory control of the complete hydroelectric equipment of the powerhouse. Hydroelectric equipment includes hydraulic turbine-generator sets, main transformer, circuit breakers, transmission line terminal equipment, BFV, intake gates, and ancillary equipment. DCS shall have the following levels of control: The overall control hierarchy architecture shall consist of 4 control levels as described below: 1. Level 0, Field / Drive Level
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This level will broadly consist of local control stations, which will be installed for various systems viz: Governing system and spherical valve oil stations including its starter panel / MCC Cooling water pumps including its starter panel / MCC Dewatering pumps including its starter panel / MCC Spherical valve control system HP oil pumps HP compressors Generator Transformer marshalling and control panels Other auxillaries
This level shall permit manual control to facilitate testing, commissioning and maintenance. In this level the equipment can be directly controlled from a nearby location, either on the equipment itself or from its local cubicle. Under this control level only the safety protections will remain active to prevent the unit from damages. Giving the commands in the proper sequence shall be the operators responsibility. Systems where there is high density of signals to be exchanged with Level 1 controllers and high degree of complexity in operational logic, the system shall be designed with micro controllers which shall have capability to acquire process inputs and initiate control commands independently. This micro controller shall have hardwired / data interfaces with Level 1 controllers. This level shall also consist of the sensors, transmitters, control valves, motor starters, limit switches, solenoid valves, and other devices connected to the process equipment or installation. The control devices on this level shall be controlled by the level 1 system.
2.
Level-1
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The level 1 shall consist of local control units and shall cater to local mode operations of individual units. The process shall be controlled through local man machine interface (MMI) if the LOCAL position is selected. From the local MMI, the operator has access to information about the process in Level 0 and can control the unit operations in step by step or automatic mode. The controller sends the command to the equipment via output interfaces. The local control board of each system includes the power supply distribution, the interfacing with the process, main redundant controllers and MMI. All local control boards shall have non-volatile data storage facilities so as to store the plant process data for about a fortnight. Necessary interfaces and drives shall be provided. The process data of the sub-system under the local control board shall be updated continuously into these drives. These data storage devices shall be used for temporary storage of data when the plant control network is out of order. This data shall be automatically updated to the database of main data storage system in the central control room, when the plant control network is restored or repaired .
Man machine interface: The man machine interface shall have the features but not limited to the following: Display station with colour tactile screen or equivalent Graphics supervision software Withstand to machine hall environment Connect directly to redundant CPU mechanism Display mimic diagram views with control functions Maintain measurement indications including running hours Maintain alarms and status indications Perform archival of events Display visualization of subsystem status Execute commands
The unit controllers shall be part of the unit control board, which shall have the following sections: Unit controller
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Unit synchroniser Man machine interface (MMI) Automatic & manual control facilities Protections & energy logging.
The main unit controller also manages man machine interface, receiving control orders and displaying alarms, measurement and status indications, interface with the protection system, supervisory control station, governor, voltage regulator, local panels, automatic
synchroniser, electrical measuring and temperature monitoring devices. The station, switchyard and other controllers perform the above functions but dedicated to their respective subsystems. Control from the local control board shall be possible even though the upper level is out of order. The system shall be controlled by the higher level (level 2) if the remote position is selected. This selection shall be provided at the unit control board. Once the level 1 is selected, the orders from remote are inhibited. All interlocks and protections shall remain in service. 3 Level 2, Central Control Level
The level 2 shall consist of supervisory level equipment and shall be the normal operating level for the power plant. This level shall provide remote control and monitoring of operations for the whole power plant from the central control room, from any of the operator station in individual or joint mode. This level shall be used for remote start / stop of unit in auto / stepby-step mode. In individual mode, the operator shall introduce the set points and issue start up, shut down or load and MVAR change orders. In joint mode, the operator shall introduce global plant set point for the active and reactive power. This level is also used for data management, VDU display management, alarm / event reporting, trending, MIS and other functions. Dual redundant HDSR backup devices shall be provided at this level for archiving of historic plant data.
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The man machine interface shall consist of operator workstations equipped with features and essential functions necessary for manual, automatic and remote control of hydropower plant, switchyard and auxiliaries. Prerequisites for such a system would be: 4. Aesthetically designed graphic supervision and control mimics, Alarm and event listing with filtering, Trend curves with zoom and pan functions, Active trend windows on screen (embedded in mimics), Printing facility for alarm lists, event log, periodic logs, trends etc Historical data storage and retrieval, Daily and weekly reports, Remote control and Joint control of the units, auxiliaries, switchyard, balance of plant and other equipments. Logic execution debugging. Multi windowing. Level 3, Load Despatch Centre Level
The level 3 is the load despatch centre (LDC). In this level the LDC shall receive selected power plant data over PLCC and issue global active and reactive power set points to the power plant. The LDC shall also be capable of issuing Trip commands for the line breakers. Plant Interface The DCS system will interface, throughout the powerhouse, with the protection system, with all the local control systems and with the remote system at the intake and tailrace for exchange of alarms, status and controls. The SCADA server will communicate with all DCS Controllers for data acquisition and archiving and will interface with the Operators Work Station in Control Room for monitoring and control.
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The DCS will also interface with the GPS satellite clock system. 12.3 Design Considerations
12.3.1 Specific Codes and Standards The system and equipment shall be designed, built, tested and installed to the latest revisions of the following applicable standards. In the event of other standards being applicable they will be compared for specific requirement and specifically approved during detailed engineering for the purpose: Standard IEC 60255 IEC 60297 IEC 60326 IEC 60446 Description Electrical relays Dimension of mechanical structure of 19 inch series Printed Boards Basic and safety principles for man-machine interface, marking and identification, identification of conductors by colours or numerals Stabilized power supplies, DC output Interface system for programmable measuring instruments Electromagnetic compatibility for industrial measurement and control equipment Programmable controllers Digital data communications for measurement and control - Field bus for use in industrial control systems Information technology Ergonomic Design of Control centres Application guide for distributed monitoring for power stations digital control and process
IEC 60478 IEC 60625 IEC 61000
IEC 61131 IEC 61158
ISO/IEC 8802 ISO 11064 IEEE 1046
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Standard IEC 60870-5 IEC 60793 Part1 IEC 60793 Part2
Description Tele-control equipment and systems Optical Fibre- Measurement and test procedures Optical Fibre- Product specifications
Optical Fibre Cables used shall comply with the provisions of latest ITU-T Specifications and IEC standards. The communications and networks of the control system shall be implemented on open network standards conforming to IEC 60870-5 series standards. Any design feature or detail not specified herein shall be in accordance with the abovementioned standards, which shall supplement these specifications. All station services, unit auxiliaries, common services, unit control, switchyard control, electrical power distribution etc will be controlled and supervised from a centralised location in the control room. 12.3.2 Performance guarantee The computerized control and monitoring system along with all auxiliaries and accessories shall be capable of performing intended duties under specified conditions. It is the responsibility of the Contractor to supply the equipment as per guaranteed technical particulars and shall also guarantee the reliability and performance. The computerized control and monitoring system shall be fault tolerant with redundancies at all levels. The control system shall have fail safe features so that even in case of failure of all redundant controllers, the outputs shall be latched on to a safe value that ensure minimum plant safety features. The Contractor shall identify and submit to the Owner a detailed list of these fail safe outputs along with their safe values during detailed engineering. Real time, full duplex data transmission rate, of at least 1Gbps shall be provided. The availability of 1 Gbps data channel between two remote stations shall be greater than 99.99% and shall be guaranteed. The Overall control and monitoring system availability for top order events shall be at least be 99.98% and shall be guaranteed.
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The control system shall be guaranteed against interoperability with all the power house equipment and shall comply with IEC 60870-5 series. 12.4 Design
12.4.1 Architecture The architecture of the DCS system is indicated in drawing no.167106-AL00-47DD-0005. The proposed configuration of DCS for the substation and plant control system will be a network based distributed control system that will provide interconnection between: The Unit Controller, located on the generator floor, performing the control interface with the turbine-generator and its ancillary systems; The Substation Controller, located in the GIS hall and the pothead yard controller, located in the pothead yard outside, both performing the control interface with the 220 kV switchgear equipment. The pothead yard controller will also interface with the GPS clock system. The Auxiliary Controller, located in the electrical room, performing the control interface with the auxiliary equipment; The Intake Gate Controller, located at the intake housing, performing remote control and monitoring of the intake gate and the water level equipment of the intake; BFV controller located in BFV chamber for control of Butterfly valve The Operator Workstation(s), located in the Control Room, allowing the control and monitoring function of the DCS. The Communication Gateways providing data interface to the System Dispatch Centre via the grid operators communication system. At each location, The DCS system will be built around a high speed redundant LAN data communication system. 12.4.2 Functional Requirements The DCS system shall be able to perform the following tasks: Start-up the Unit, automatically or step-by-step, synchronize the unit and close its circuit breaker and adjust voltage/reactive power (kV or MVAR) and frequency/load (Hz or MW) from the Unit Control Board (UCB) or from the Control Room;
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Unload and shutdown the unit, automatically or step-by-step, from the Unit Control Board (UCB) or from the Control Room;
Emergency shutdown of the unit; Logic for Joint Control of the generator output; Logic transfer between the Unit Control Board (local control) to the Control Room (remote control);
Display on the Operators Work Station in the control room the following: Unit output and operating values; kWh and kVAh output of generator ,station service consumption, water level of the balancing reservoir, auxiliary system power flows, voltages, generator vibration levels, 220 kV circuit breaker status and other operational data as required; All alarms and events, with a time tag of +/- 10 milliseconds together with sequence of events logging of critical trip events at +/- 1 ms; The single line diagram of the 220kV, the 11kV and 415 V switching arrangement of each complete electrical system and equivalent displays for water flow/level, cooling system and lubrication systems; Surveillance of the external 11kV distribution and off site power feeds; The equipment status of the Substation, auxiliary station service ac and dc supply, status of all main circuit breakers, disconnect and earthing switches. The unit operations showing dynamic operating values including the MW/MVAR values on a x/y plot of the generator operating diagram; Logging of the events, alarms, measure and trend data in a historical data base with archiving to CD-ROM. Display on the unit control board HMI the following:
Unit output and operating values; Subset alarm display; Hydro/mechanical system critical data. Display on the substation and auxiliary control board HMI the following:
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Electrical system status and operating values; Subset alarm display;
12.4.3 Modes of operation Control Modes of Operation The DCS system shall be provided with the following modes of operation for the plant: Local Manual, Local Automatic, Step-by-step (or Semi-Automatic), Remote Automatic start / stop and Emergency stop. The Local operation will be performed from the local Unit Control Board (UCB) and the remote mode operation from the control room at the operators desk. The Local/Remote mode shall be selected from a selector switch located at the UCB. Local operation shall be possible only through permission from the operator. The Local manual and automatic mode shall be selected from a selector switch located at the UCB. Local Manual Mode A Local Manual Mode shall be provided for manual operation of the Unit from the local Unit Control Board (UCB). This will be primarily used for testing and maintenance purposes. Following the receipt of permissive signal from the Control Room, when UCB selector switch is selected to LOCAL-MANUAL this shall disable both the Control Room Operators Work Station and the UCB automatic control mode. Synchronizing and circuit breaker closure shall be possible either automatically from the UCB or manually from the control room. Local Automatic Mode A Local Automatic Mode (next to the Unit) shall be provided for automatic operations of the Unit from the UCB. The Local Automatic mode shall be selected when the UCB selector is in the LOCAL-AUTOMATIC position and this shall disable Remote Automatic Mode from the Control Room. The START, STOP signals from the local push buttons on the UCB shall result in the same operations as for Remote Automatic Mode. Step-by-Step Mode A Step by Step (Semi-Automatic) Mode shall be provided with the same functionality as the Automatic Mode but with a hold point between each step of the control sequence and a Step
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Initiation or Reverse Step Initiation (change from start to stop or vice versa) at each hold point. This mode should be available locally from the UCB and from the control room. Stepby-step selection will be done from the UCB HMI when the UCB selector is in the LOCALAUTOMATIC position and from the operators Workstations. Remote Automatic Mode Remote Automatic Mode shall be provided for automatic operation from the Control Room. Under this mode of operation once start command is issued by the operators work station the machine is automatically started, synchronised and loaded to a desired value. Similarly when shutdown command is issued the machine deloads and is brought to standstill status automatically following all the programmed logics. The transfer of control between the UCB and the Operators Work Station will be achieved by the Local/Remote selector switch on the UCB. Control access at the Operators Work Station will be by password controlled software at the Operators Work Station, using individual operator passwords. The passwords shall automatically end after 10 minutes of each operators scheduled shift. High levels of password which allow changes to display programs and scheme logic shall also be provided; these functions shall not be accessible to the operators. Emergency Shutdown Mode An Emergency Stop Mode shall be available from generator UCB , Operators Work Station and from emergency pushbuttons located on the Governor Panel. This function will issue a protection trip and will follow the normal Stop sequence but omitting step checking and will bring the machine to standstill as quickly as possible. This sequence will be the same provided for certain fast electrical or mechanical trips. The Emergency Stop sequence will take priority over any other sequence irrespective of the sequence stage. It should be noted that indication, alarm and metering signals will continue to be sent to the Powerhouse Operators Work Station and hence to the dispatch Centre irrespective of the control mode selected. Shutdown Mode The DCS control system shutdown modes shall be as follows: Normal Shutdown (Control)
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On normal shutdown following an operator command, the plant control equipment shall ramp down the generator output to nearly zero, trip the generator circuit breaker and stop the turbine unit. Closing of MIV is initiated after machine has come to standstill. Forced Shutdown (Protection)
For those protection trips where a potential problem exists that may be aggravated by tripping the breaker at full load, the protection systems will signal the DCS to ramp the generated power to zero, and issue MIV closing command with a time delay of 90-120 secs. ( Equivalent to the nozzle closing time) The protection logic will check that a low forward power condition exists and will then trip the generator breaker and stop the unit. Operation of the protection lockout relays will not permit a restart until the problem has been corrected. Emergency Shutdown The Emergency Stop push buttons and the generator protective devices (Relay 86) will operate the generator trip relays and, via hard wired direct connection, trip the generator breaker, trip the exciter, instructs the governor to stop the unit and close the inlet valve. The control system will monitor the shutdown and intervene, as necessary, to shutdown subsidiary systems. This logic will be functional for a control system failure should the operator need to initiate an emergency trip. It should be noted that a manual Intake Gate Emergency Close will only be initiated at the intake or in the Control Room. 12.4.4 Distributed Process Controllers General The distributed process controllers shall perform the actual process control and process interface. The process controllers shall monitor the status of designated inputs, direct the status of designated output functions and sequentially start up or shutdown the hydroelectric plant in accordance with the requirements of these specifications. The process data base shall be entirely distributed to the process controllers. Each process controller shall contain all the information and all the functions related to the specific section of the process. As an example, the unit controller shall contain the unit data base and perform all the control functions associated with the unit. Likewise, the substation controller
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shall contain the 220 kV substation data base and perform all the control functions associated with the substation. The various process controllers shall meet the following requirements: Central Processing Unit The process controllers shall have a central processing unit (CPU) based on a high performance 32 or 64 bit microprocessor. The system software shall be stored in read only memory (EPROM or Flash-PROM) modules. The application software shall be stored in read/write memory (RWM) with battery backup; the battery replacement schedules shall be defined. The application programs shall be executed cyclically in three priority levels. The cycle times shall normally be selectable between 10 ms and 2 second. Supervisory functions shall automatically monitor system operation. Supervisory functions shall include a real time watch dog, back-plane bus supervision, memory checking and power supply voltage supervision. Faults shall be indicated with LEDs on relevant board, with system error messages reported to all active Operator workstations. The process controller shall have a real time clock and calendar. When connected to the network, the system clock shall be automatically synchronized with other nodes of the network with an accuracy of 10 milliseconds or less. General Controller The general controller shall incorporate the two operator workstations and dual redundant DCS servers to provide overall control and monitoring for the Power Plant and associated equipments. The general controller shall provide overall station control, data acquisition, alarm and event annunciation, data logging, reporting, external communication and other functions required for the efficient management of the station. Gateway Server Redundant multi-protocol communication gateways shall be provided for interface with the remote dispatch centre via the external telecommunication circuits. The interface point is at the communication gateway terminals. The supplied hardware shall be complete with relevant switches / routers for extracting time stamped data from the data servers and passing it over to load despatch centre over OFC and/or PLCC equipment .
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The system shall have redundant data links to the redundant data servers and shall provide data in the grid specified protocol. As on this date the protocol specified for northern region is IEC 60870-5-101 interoperability profile. The details can be downloaded from website of Power Grid Corporation of India Ltd. (http://www.powergridindia.com/pgnew/02-0002039.aspx) under the link load despatch and communication information. However the Supplier shall be bound to supply system compliant with the prevalent system at the time of approval of final drawings. The details of data to be exchanged between LDC and power house shall be provided as per the requirement of Power grid and shall be considered in the scope. The despatch interface hardware shall also be equipped to extract certain specified data from the data servers for onward transmission through Purchasers VSAT equipment for display at the head office of the Purchaser. The relevant hardware at both the ends shall be included in the scope of the Supplier. Unit Controller The Unit Controller shall be a processor based, local monitoring and control system for the turbine-generator unit that shall provide automatic and step by step start/stop sequence for the unit. The unit controller will contain the unit data base and perform all control function associated with the unit locally and autonomously. The Unit Controller shall be provided with a local HMI (Human Machine Interface), such as a touch screen display, LCD display with panel mounted key pad or hardened keyboard with tray, mounted in the Unit Control Board from which it will be possible to control and monitor the unit independently of the Main Control System. Automatic synchronizing equipment is supplied on each Unit Control Board. Individual manual mode operation will be possible, with the control mode selected to manual mode, via the local direct wire controls on the respective equipment panels (Governor, Excitation, Cooling system etc.). Substation Controller The Substation Controller shall be a processor based, local monitoring and unit control system for monitoring and control of the 220 kV Gas Insulated Switchgear (GIS) equipment. It shall provide synchronizing logic for the line and unit circuit breakers. The Substation Controller shall contain the bus and line equipment data base and perform all control
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function associated with the synchronization of the line and unit circuit breakers via synchronizing relays located on the associated protection panels. The Substation Controller shall be provided with a local HMI, such as a touch screen display, LCD display with panel mounted key pad or hardened keyboard with tray, mounted in the Substation control board from which it will be possible to control and monitor all the 220 kV GIS equipment independently of the main control system. The 220 kV GIS equipment shall be provided with local control and interlocks for safe operation. Local indication and alarm display shall be provided in the individual GIS control cabinets of each bay and on the associated protection panels. The alarms shall be available through a LAN network. The Substation controller shall interface with the switchgear equipment via a network for transmission of alarms. Direct digital interface to the SF6 monitoring subsystem is preferred and suitable protocol conversion shall be provided. Pothead Yard Controller The Pothead yard controller shall be either a subsidiary controller of the substation controller or a separate mini-controller to collect data from the pothead yard such as the 220 kV line disconnects, CVT, back-up diesel and the 11 kV line. The pothead yard controller shall also interface with the transmission line PLCC or fibre optic communication systems. Auxiliary Controller The Auxiliary Controller shall be a processor based, local monitoring and control system for the common auxiliary equipment that will provide monitoring and control for the common auxiliary systems such as the 11 kV switchgear, 415 V AC, 220V station dc, Fire protection system, station compressed air system and Heating, Ventilation and Air conditioning system, etc. The Auxiliary Controller shall be provided with a local HMI, such as a touch screen display, LCD display with panel mounted key pad or hardened keyboard with tray, mounted in the station service control board from which it shall be possible to monitor all the common auxiliary systems independently of the Main Control System.
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Individual local manual mode operation shall be possible, with the control mode selected to manual mode, via the local direct wire controls on the respective equipment panels (415 V, dc system, 11kV switchgear, ventilation system etc.). Local indication and alarm display shall be provided in each respective equipment control cabinet. Intake Controller The intake gate shall only be opened and closed, by a local device at the intake. Remote controlled closing of the gate shall also be possible from the control system in the Control Room and from the protection system in case of failure of an emergency shutdown operation. The system shall be either a remote input/output device integrated with the control and monitoring system in the powerhouse over a suitable communication network or a separate controller with communication links to the DCS. The intake shall be interconnected to the DCS via a fibre optic communication system. The system selected shall be reliable and immune to electrical noise and compatible with the control and monitoring system at the powerhouse. 12.5 Construction
12.5.1 Metal Cabinet and enclosures The process controllers shall be of modular type with circuit boards mounted in 19-inch sub racks. The sub racks, power supplies, associated termination equipment, etc. shall be installed in cabinets. The cabinets shall be free standing, metal enclose type, with a minimum protection class of IP43 increasing to IP65 in areas where water leakage is possible. The cabinets shall be provided with facilities for top and bottom cable access. The front of each cabinet section shall be furnished with a hinged metal frame with a 19 inch wide opening for equipment mounting. A full length door shall be provided on the outside of the hinged frame. All Process connections wired directly to the cabinet shall be screw terminals located inside the cabinets. Remote I/O units shall be totally enclosed in junction box complete with brackets for DIN-rail mounting. All external connections shall be plug detachable screw terminals.
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12.5.2 Control Room The Operator Control Room is located in the Control Block. The Control Room shall be provided with a false floor. Operating desk for engineering stations and operator
workstations shall be located in the Control Room. Input/Output System All controllers shall be provided with sufficient I/O modules to cover the number and types of I/O modules required for each controller. Spare I/O shall also be provided for future use. The modules shall include analogue and digital inputs and outputs. These modules are used to capture all the control and monitoring system data of the hydroelectric plant. Analogue Inputs Analogue inputs shall be scanned with a cycle time selectable between 100 ms and 20 s. A process dead band shall be definable for each input. If the input value has not changed more than the dead band since the previous update, no updating or further processing shall take place. Each Analogue Input shall be capable of having four unique alarm limits, two low and two high, assigned to it. These limits shall be initially entered by the database programmer, but shall be changeable by the operator, on line, from the workstation. The limits shall be provided with hysteresis individually definable for each input channel. The Analogue Input (AI) module will convert analogue process signal to digital values, the AI shall include analogue to digital converter and programmable gain amplifier. The preferred input will be 4-20 mA. Analogue signal shall be scaled and converted to engineering units after being scanned and prior to being stored in the database. Digital Inputs The Digital Input (DI) modules will be from dry, electrically independent contact circuits located in the various project locations. DI module will convert contact states into digital values Each DI module will have a dedicated microprocessor to support the time tagging requirements. DI module will include filter to eliminate contact bounce and electromagnetic interference. The available voltage level will be 220 V dc for all external and GIS functions.
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The updating of digital inputs shall be event driven; meaning that only a change in state of an input shall result in updating of the database. In addition to the event driven updating a cyclic updating every fifth second shall be provided. All status changes shall be time tagged. The digital input modules shall be used to sense the pulsed outputs from the watt-hour meters. Analogue and Digital Output Analogue Output (AO) modules shall have a digital to analogue converter and the preferred output will be 4-20 mA. Digital Output (DO) modules shall be a relay type output contacts that will be powered at the field devices from the 220 V dc systems. All 220 V terminations shall provide IP20 protection level with access door open. Pulse counting modules In case the pulse capturing capabilities of the digital input modules are exceeded, pulse counting modules shall be used. The pulse counting modules shall interrogate and convert pulse inputs to digital values. Synchronization Automatic Synchronization Automatic synchronizing equipment shall be provided for each unit. The equipment shall be located in the UCB. The DCS shall provide logic for automatic connection of the synchronizer to the units control system when a unit is selected for start. The DCS shall initiate a start command to the synchronizer and the synchronizer shall match the units output voltage and frequency to that of the power system. When the voltage and frequency of the unit matches that of the power system, and the voltages are in phase, the automatic synchronizer shall close the generator breaker via a closing pulse initiated to predict the time when the vectors will be in phase. Interface for speed and voltage adjustment will be through hard wired connections between the synchronizing equipment and the excitation and governor panels Manual Synchronization
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Manual synchronizing equipment, with a synchronoscope, double voltmeter, double frequency meter and check synchronizing facilities shall be provided and installed in the Control Room as a back-up to the automatic synchronizing function provided for each generator and for the line and bus tie circuit breakers. Manual synchronizing will be through a synchronizing check relay. Speed and voltage adjustment will be from RAISE/LOWER hard wired push buttons on the synchronizing control panel located in the Control Room. The push buttons will be hard wired to the appropriate excitation and governor panels via the circuit selection logic. This selection logic shall be initiated by individual circuit selection push buttons and shall store this logic until reset. The logic will select the appropriate direct circuit breaker close circuits, governor and exciter raise/lower connections. The selection logic will also connect the appropriate incoming and running voltages to the voltmeters and frequency meters and the check synchronizing relay. This system will be interlocked so that only one circuit breaker and one generator shall be selectable at one time. The selection will be reset as soon as the controlled breaker has closed or after a fixed (settable) time if the controlled device has not been closed. The control panel shall be provided with a single pistol grip type circuit breaker control handle for manual closing and opening of the selected circuit breaker. The handle will be hardwired to the respective GIS breakers via the above circuit selection logic and the synchronizing check relay. 12.5.3 Control desk High quality control room furniture comprising of control desk, desks for printers, monitors, workstations etc shall be included in the scope with following features: The side frames of the control desk shall be 2.5 mm thick sheet steel. The desk shall have base channels which shall have provision for grouting flushed with the floor. The desk shall be of uniform height, pleasing appearance and the design shall be based on medical and anthropometric findings for the well being and effectiveness of control room personnel. The design shall be in compliance with DIN 33414 T1. The desk shall have front and back hang in doors. A dust, oil and moisture proof gasket shall be provided all around the doors.
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Rear of the desktop shall be lowered for installation of monitors (if required) All the surfaces shall be scratch and wipe proof. Colour shall be as approved by the Purchaser. The desk shall have electrical sockets, connection terminals and cable ducts for simple and safe connections of PCs, monitors, keyboards and other devices. The desk shall have cut outs in the front desktop for various built in devices like telephone, intercoms, emergency push button station as desired by the Purchaser. Design, material selection and workmanship shall be such as to result in a neat appearance outside and inside with no welds, rivets or bolt heads apparent from outside and with all exterior surfaces turned and smooth. There shall be no holes or slots left open. Ventilating louvers, if provided, shall have wire mesh screens. The edges and corners shall be slightly rounded for safe handling. All the sections shall be provided with a bottom plate with slots for bottom cable entry. The slots shall be covered with a removable cover plate. The bottom plate shall be supplied loose. The desk shall have adequate number of anti-vibration mounting blocks/strips. Industrial type fluorescent tube lights shall be provided for illumination of the interior of the control desk and shall be controlled through door limit switch. Desk cooling exhaust fans shall be provided to maintain temperature inside the control desk. A separate power distribution system comprising of suitably rated MCBs, stage I /stage II (Class B/C) type pluggable surge protection devices conforming to IEC-61643 guidelines and associated wiring shall be provided. Sufficient spare MCBs and sockets shall be provided. Earth busbar of copper shall be provided for panel body earthing as per the fault level. The shape of the desk shall be as approved by the Purchaser.
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12.5.4 Global Positioning System (GPS) Satellite A GPS satellite clock system including LAN and master clock board shall be provided to ensure a synchronization link between the control, metering and protection systems and the local official time. The GPS clock system shall include a master clock display for the Control Room and slave units for time display within the powerhouse. The receiver will be located in the Pothead yard housing with the antenna located to detect at least two satellite signals. A receiver location in the control room will be considered if a reliable antenna cable length can be achieved. 12.5.5 Intake Instrumentation Duplicate water level instruments shall be provided to measure the intake water level. The system shall be redundant and shall provide level indication to the station joint control system to optimize water usage for both continuous and peaking operating modes. The level will be monitored and logged by the DCS system through the LAN network and displayed on the Control Room Work Stations and will provide the reference data for the joint control water management system. 12.5.6 DCS Network (LAN) and Telecommunication Distribution A redundant communication network, also called the station LAN (Local Area Network) shall be provided for the communication between the control system, UCB, Auxiliary control system, substation control system, protection system, intake control system, the intake level measurement system. The network system shall be designed and supplied by DCS manufacturer according to the requirement of the DCS system. The use of either direct or multiplexed channels on the fibre optic cable to the intake and/or the balancing reservoir and pothead yard devices shall be studied at the detailed design phase and appropriate design briefs shall be provided to justify the final choice. 12.5.7 Fibre Optic Cable Fibre optic cables shall be supplied to interconnect the powerhouse, GIS Gallery, pothead yard and intake housing. All cables shall be protected in buried duct raceways or conduit. The ADSS cable shall be aerial and run below the 11 kV power line from pothead yard to the intake housing. The fibre optic contained into the cable shall be of a single mode type, G.652
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standard. The construction of the cable shall be of an all-dielectric loose tube type and shall count 24 fibres. 12.5.8 Main Distribution Frame At each main location (powerhouse, GIS gallery, pothead yard and the intake housing), a main distribution frame (MDF) shall be installed for the distribution of the telephony and public address speakers. The MDF shall permit an easy access to all channel interfaces of the PABX providing an efficient cabling management. 12.5.9 Optical Distribution Frame The Contractor shall supply optical distribution frames (ODF) sized to provide termination to the Ethernet switches and Routers and other optical interfaces as required and the incoming fibre optic cables. The panels shall be of a rack-mount type. All optical adapters provided within the ODF shall be of ST type. 12.5.10 Telecommunication Panel
One free standing telecommunication panel shall be provided in the powerhouse, one in the GIS gallery, one in the pothead yard and one in the intake housing. This panel shall house the optical distribution frames, the telephone and public address main distribution fames and the control system Ethernet switches and routers where suitable. This panel shall be a metallic free standing modular cabinets IP 50 (IEC 60297), or better, with proper ventilation to avoid overheating. Cabinet shall come with all wiring and terminal to allow connection between modules and terminal blocks for external cables. The terminal block shall be mounted on metallic rails. Exterior cables will enter from bottom plate of cabinet by means of cable glands. The cabinet will carry a nameplate indicating the specific equipment identification provided by the Owner as well as cables and link destination. Cabinet shall include hinged doors for convenient access to all modules and terminal blocks. 12.5.11 General The two (2) operator workstations in the Control Room shall be PC based high quality computers (industry grade) with display functions based on Windows NT, XP or 2000 or equivalent standard operating systems. They shall be provided complete with a keyboard,
Man Machine interface system
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mouse and two (2) Video Display Terminals (VDTs) for each workstation to facilitate the control and monitoring of the plant. The workstations shall be mounted on a suitable control desk. The operator shall be able to control and supervise the entire hydroelectric system from the operator workstations in the control room. The status of the process shall be presented on Video Display Terminals (VDTs) in the form of process displays, trends, reports, alarm and events lists. Messages, colour changes and flashing symbols shall be used to draw attention of the operator to any changes in the process and to abnormal operations. The operator workstation shall contain all the information that can be related to the system presentation and to local control operations, while the process database and the control functions shall be entirely distributed to the process controllers. The operator workstation shall access the process database via the redundant network systems. Each operator workstation shall be capable of supporting two Video Display Terminals (VDTs). The operator shall be able to view different displays simultaneously at the VDTs belonging to one operator workstation with single cursor movement across both screens. As an example the operator shall be able to display the powerhouse single -line diagram at one VDT and the start-stop sequence control display at another VDT. Both VDTs shall be controlled from one keyboard. Central Unit The operator workstation shall be based on manufacturers standards such as UNIX, X window, or standard software. Supervisory functions shall automatically monitor system operation. Supervisory functions shall include a real time watch dog, memory checking and power supply voltage supervision. All peripherals shall be monitored as part of their normal operation. Faults shall be indicated with system error messages reported in the operator workstation system list. The operator workstation shall have a real time clock and calendar. When connected in the network, the system clock shall be automatically synchronized with other nodes in the network and with the GPS clock system with accuracy better than +/-10 milliseconds. Power Supply
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The Supplier shall provided uninterruptible power supply source required for each operator workstation and its peripherals. The UPS system internal batteries shall be sized for four (4) hours standby duty. Peripheral Units Video Display Terminals (VDTs) The video display type shall be a 21 inch LCD type flat colour screen and provide a resolution of at least 1280 x 1024 pixels. Keyboards The operators keyboard shall be provided with standard alphanumeric keys as well as function keys, both fixed and user definable. The keyboard shall have at least 20 user definable keys for direct selection of process displays, and at least 10 dynamic function keys which can be individually defined for each display and dynamic point. A trackball for position of the cursor shall be connected to the keyboard. The operators keyboard shall provide the operator with the capability to control up to three VDTs. A separate keyboard shall be provided for the engineering Work Station for graphics display design. The display design keyboard shall have standard keys and function keys, and shall provide the operator with the capability to design static displays consisting of various graphics symbols. Printers Two (2) colour printers shall be provided to print selective plant data and screen displays as requested. One (1) dot matrix printer will be provided to print event logs on a line by line basis and one (1) grey scale laser printer will be provided to print out reports and other selected data. 12.5.12 General The operator workstation shall be capable of containing up to 240 user definable process displays. The operator shall be able to select a display for presentation via a menu, by using special keys for direct selection, and by using dynamic function keys. The dynamic function Process Displays
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keys shall be definable by the user to create his own display hierarchy, where each display is linked with up to ten other displays. Displays Control process displays shall be provided as an integral part of the control system function. These displays shall be interactive permitting the operator to initiate control actions and enter control data via the keyboard. The displays shall include, but not limited to, the single line diagram, the plant control display, the unit control display, the start/stop sequence display, the pre-conditions to starts display, the equipment status and the temperature and vibration measurement in the form of graphical displays. The graphical display will be used for the representation of the following: The turbine and governor operating diagram; The generator and exciter operating diagram; The transformer operating diagram; The 220 kV GIS; The ac auxiliary supply system; The dc auxiliary supply system; The controllers panel data (unit, Substation, auxiliary); The protection panels data (generators, transformers, bus and line); The intake water level; The intake gate status; The 415 V and 33 kV auxiliary system status; The cooling system; The drainage system; The emergency diesel generator; The DCS architecture showing DCS components and network status.
Display details
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All symbols will be based on IEC standards with the methods of showing position status to be approved. Colours shall not be used to indicate status, but will be used to discriminate between voltage level, oil, water and similar display details. Event and Alarms List Events and alarms shall be presented in chronologically ordered lists. The events list shall be circular, so that a new event overwrites the oldest one. The events shall be stored in a list in the operator workstation. The printout of an event shall occupy one line and include the date, time of day, signal description and signal status. The date shall be given as year, month and day and the time shall be given as hours, minutes and seconds and tens of milliseconds. Digital input status changes shall be time-tagged to the nearest ten milliseconds after the change is sensed at the process controller local input system. Since all the process controllers and operator workstations shall be connected to the GPS clock system used as an external time reference source, the time tag of all events listed shall be better than ten milliseconds. The process alarm list shall at least contain the most recent 500 alarms. Alarms shall be removed from the alarm list when they are acknowledged by the operator and when the alarm condition has disappeared. Alarms shall also be indicated on all displays as a latest unacknowledged alarm line, and as status indications with red colour in displays with dynamic data from the object concerned. Flashing unit the alarm is acknowledged, and then steady as long as the alarm condition persists. Alarms shall be acknowledged by placing the cursor on the alarm line and then pressing a dedicated key. Alarms shall be acknowledged also from the process alarms list page by page. The process alarms shall be such that the operator can organize the following: Assign alarms belonging to the units to one separate process section per unit; Configure an operator workstation to ignore alarms from one process section to allow for removal of alarms for a specific unit during maintenance.
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By means of simple commands, it shall always be possible for an operator to override the process section configuration, and view the total alarm or events list, or to view the list of any specific section. Colours Consistent use of colours is of prime importance to the operator. The colours that shall be used are suggested below: Task Response to the operators entry on the dialog line Indication of the selected equipment Event and alarm blocking and error message Alarms Normal status Colour White White Yellow Red Green
Audible Alarms When an equipment and/or function go to an alarm status, a buzzer in the Work Station must be activated. The alarm must be silenced by pressing a dedicated key on the keyboard. Trend Displays The operator shall be able to specify variables to be sampled and stored in logs in the process controllers. Both logging of analogue and digital values shall be supported. It shall be possible to log momentary values or mean, maximum or minimum values of a number of samples within the log interval. The trend data logging shall be carried out locally in the process controller. The logs intervals shall be selectable in steps between 10 second and one week. The values stored in the trend data logs shall be presented graphically in the form of curve in trend display. The operator workstation shall be capable of handling up to 10 different time scales for trend displays.
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Trend displays shall be configurable on line from the operator workstation. Control Tagging and lockout Each unit or electrical circuits control sequence shall be capable of being tagged and disable from the operator Work Station as part of an access and safety procedure. 12.5.13 General Automatic control programs and man-machine interface software shall be supplied in order to provide proper operation of the plant generating units and intake gate as described in this section. The plan generation shall be controlled by the DCS in response to set points entered by the operator at the control room in the powerhouse. A ramp function, having an adjustable ramp time, shall be applied to the set point changes to obtain a bump less adjustment to the desired value. A description of the functions requires by the DCS are listed in the following sections: Automatic Plant Control (Joint control) The following modes for automatic plant Joint Control shall be provided: A Automatic control of the units combined output: Water level control Active power control (MW) B Automatic control of the units combined reactive power output (MVar). Power Plant Applications
It shall be possible to assign some units to individual control and some to automatic plant Joint Control. When a unit or equipment is assigned to individual control, the DCS shall control the unit/equipment in response to individual set point value with the joint control monitoring the output. The control modes A and B shall be mutually independent, i.e. the station can operate in automatic plant MW-control and in reactive power control simultaneously or in the Mode A with the reactive control on individual voltage (excitation) output.
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Water level control This function shall control the water level in the intake in order to maintain the water level at a given set point. The function shall start and stop the unit according to water level set points and, provisionally, will start when level reaches 95% of maximum water level and stop when level reaches 10% of minimum water level, starting and stopping each unit in sequence. These levels shall be adjustable by the operator within a fixed range. The control shall have three modes of operation: Maximum flow continuous operations (Flow match) Peaking flow continuous operations (Flow match) Draw down mode to meet a programmed peak operating time
The details control logic function and draw down/flow prediction requirement will be provide during details design. In the event of a fault in the level transducer or its data transmission channel, the level control feature shall be switched off and a fault signal shall be issued. The system shall support redundant level transducers assessing the plausibility of the level signals and disconnecting the defective transducer from the control loop. Automatic water level control activation shall be enabled / disabled from the operator workstation in the control room. The level monitoring system shall issue alarms at the programmed sequence water level. The control logic shall have peaking flow match and monsoon flow settings. Plant MW Control This function shall adjust the plants total MW output to a given set point value. The regulator shall be of a PID character and shall calculate the desired total generation for those units on automatic plant control by subtracting the MW output of those units on individual control. The calculated load shall be divided between the units on automatic plant control, in accordance with the head dependent unit efficiency curves, to obtain optimum utilization of the water.
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The software shall automatically compensate for active power changes in individually controlled units. The software shall be designed to enable the setting of the plant speed droop between 0 to 10%. If the speed droop is set to 0, the plan MW-controller shall function as a pure power controller adjusting the plants MW output to the set point irrespective of the network frequency over a preset frequency band, outside this band a default droop setting will apply. Rough Zones Rough zones can exist at any point in a generators operating range. The software shall be configured to allow each unit to operate on either side of a rough zone. The unit shall be allowed to pass through the rough zone. The software shall allow the locations of the rough zone to be operator-entered. This rough zone operation limitation shall apply to units on automatic plant control by allowing differential individual power settings to avoid each units rough zones. Plant MVar control This function shall adjust the plants total MVar output to a given set point value. The regulator shall be of a PID character and shall calculate the desired total MVar for those units on automatic plant control by subtracting the MVar output of those units on individual control. The calculated MVar shall be divided between the units on automatic plant control, in accordance with power level and the operating diagram of the generator. The software shall automatically compensate for reactive power changes in individually controlled units. Start-stop initiation The software shall initiate the starting and stopping of the units in accordance with the required control scheme. The software shall provide the optimum number in operation in order to maintain the best possible efficiency of the plant. The criteria for automatic starting and stopping can be a change in the set point for either the plants load or the headwater level. A change in the water level outside the dead band (change of in-flow) is also a criteria for automatic start/stop initiation. Estimation of In-Flow
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Based on the rate of changes in the water level of intake, a mathematical model of the reservoir and the actual flow through the station, a calculation of the in-flow to the reservoir shall be made. The software shall recommend a continuous power level to hold the machine discharge steady to match the in flow in continuous mode and for the peak operating period in draw down mode. In operation theses modes will be self correcting if the in-flow changes or if the initial predictions are found to be in error. Unit Individual control functions Under individual Control, the units shall be controlled by individual set points: The following modes for individual unit control shall be provided A- Individual control on the units output: Power control Frequency control (governor droop mode) Needle limit position setting Flow control
B- Individual reactive power control: MVAR control Voltage Control (exciter mode)
All control modes will default to frequency and voltage control modes directly by the governor and exciter, respectively, if the system frequency or unit terminal voltage falls outside preset limits. Power control The software shall adjust the active power output to the set point value, as described in the Unit control Algorithm The set point value given in MW shall be checked before execution against applicable limits. If the set point is outside the limits, the controlling function shall not be activated and a fault signal shall be issued.
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Frequency control The software shall adjust the grid frequency output set point value transmit to the governor as entered onto the screen by the operator. The set point value given Hz shall be checked before execution against applicable limits. If the set point is outside the limits, the controlling function shall not be activated and a fault signal shall be issued. Nozzle setting The software shall adjust the Nozzle opening set point limit value given in % opening, the set point shall be checked before execution against applicable limits. If the set point is outside the limits, the setting function shall not be activated and a fault signal shall be issued. Flow control The software shall adjust the flow through the unit by adjusting the power output level to the set point value, as described in the Unit control Algorithm The set point value in % of flow shall be checked before execution against applicable limits. If the set point is outside the limits, the controlling function shall not be activated and a fault signal shall be issued. MVar control The software shall adjust the reactive power to the set point value. The set point value given in MVAR shall be checked before execution against applicable limits. If the set point is outside the limits, the controlling function shall not be activated and a fault signal shall be issued. Voltage control The software shall adjust the unit terminal voltage output set point value transmitted to the exciter as entered onto the screen by the operator. The set point value given kV shall be checked before execution against applicable limits. If the set point is outside the limits, the controlling function shall not be activated and a fault signal shall be issued. 12.5.14 Unit control algorithm
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By means of raise/lower pulse to the turbine governor, the unit control algorithm shall adjust the units MW-output to the governor which will set the nozzle opening to the desired value requested by the actual control mode. The pulse duration shall be proportional with the control error. The pulsing shall interrupt when the control error is within the dead band. From the programmers terminal, it shall be possible to set the pulses as a constant and independent of the previous pulse. As an alternative, it shall be possible to set the cycle time of the control algorithm as a constant, i.e. Pulse duration + pause interval = Constant. The duration of the pulse shall be limited in order to avoid excessive controlling actions and to be able to issue several shorter pulses during greater system errors. The control algorithm shall incorporate setting parameters for compensating for the characteristics of the governor. The process response shall be monitored during the control execution. In the event of a fault, a fault signal shall be issued and the control shall be interrupted. The control algorithm shall continuously monitor the controlled quantity to ensure that the control error does not exceed the operator entered dead band. The feedback signal to the control algorithm is the measured unit active power. Reactive power The control algorithm for reactive power shall be built in a similar manner as the active power algorithm. By means of raise/lower pulse to the voltage regulator, the unit control algorithm shall adjust the units MVAR output to the desired value requested by the actual control mode and be coordinated with the characteristics of the exciter in this mode. The feedback signal to the control algorithm is the measured unit reactive power. Alternative Control Mode If the governor and/or exciter provide adequate active and reactive control loops respectively, the DCS shall manage set point transmission and feedback check only. In this case, a 4-20 mA set point signal rather than raise/lower pulsing shall be provided.
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Start/Stop function The operator Plant shall be able to select a unit and initiate a start or stop sequence, and then monitor the sequence through completion of the operation. The operator shall be able to reset, cancel or abort any start or stop operation prior to its completion. Additionally, the unit start/stop function shall also accept directions from the start/stop initiation control mode to start or stop a unit under automatic plant control. 12.5.15 Engineering and Maintenance Programming tool
A separate engineering work station including a laser printer for more comprehensive programming functions and a maintenance programming tool shall be provided. Modification and maintenance task The engineering work station shall be provided with the necessary software tools and utilities to allow the powerhouse operators to perform the following maintenance tasks: Configuration and database management; Application program modification and maintenance (on-line and off-line); Testing and troubleshooting; Graphic documentation of application programs and database elements; Application program backup; Graphic display development and modification (on-line and off-line); Report development and modification.
The hardware tools shall include a field programming unit and a separate display design keyboard for connection to the operator Work Station for on-line development and modification of graphics displays. Maintenance Tool The maintenance tools shall be by software loaded in to a hardened industrial class lap-top type personnel computer (PC) and kept on a lockable docking station in the control system equipment area. It should be provide with the required access plugs and cables to access any digital devices associated to the control and protection systems. Programming language
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The application programs shall be written in a high level function block language with graphic representation. The language shall be specially developed for process control and shall easily be understood by persons familiar with the process. Each function element shall be represented as a building block with inputs and output. Application programming shall be performed by connecting inputs and outputs of a function block to other functions block or to process I/O. It shall be possible to print out graphic documentation of the applicable programs on the printer connected to the engineering workstation. The structure of the application programs shall be based on the functional structure of the hydropower plant. Each part of the power station shall be allocated its own program modules. It shall be possible to give different program modules in one process controller different cycle times and priorities. 12.6 Quality control and assurance
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12.7
Drawings, Documents and Design Calculations
12.7.1 Design memorandum The Contractor shall submit all the drawings and documents in accordance with requirements stipulated in Section 2.12 Reference drawings and documents of General Technical Specification (GTS). 12.7.2 Drawings and documents The Contractor shall submit all the drawings and documents in accordance with requirements stipulated in Section 2.12 Reference drawings and documents of General Technical Specification (GTS). 12.7.3 Design calculation The Contractor shall submit the design calculation, for review / acceptance. 12.8 Delivery, Installation and Commissioning
Requirements. The supplier shall arrange personnel to oversee proper storage of equipment at site, their transhipment to powerhouse, installation and commissioning. 12.9 S. No 1 Spare Parts Description Time Synchronizing connectors network cables Quantity with 1 no.
Power supply modules/unit and cards- type / 2 sets of each used type model used Network Interface Cards of type / model used Operator Workstation accessories complete with 2 sets of each used type all 1 no.
3 4
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S. No 5 6 7 8 9 10 11 12
Description Data storage drives of each type / model used Modem each type Repeaters of type / model used Recorder Sensors /transducers Indicating instruments Patch Cords Optic Fibre Optic Fibre Cable
Quantity 1 no. 1 no. 1 set of each type 1 no each type used 1 each type 1 each type 5% of Quantity used 10% of Quantity used
Recommended spare parts shall be supplied in accordance to clause 2.36 Spare Parts and tools of General Technical Requirements. Specified spare parts to be supplied under this section are as follows: 12.10 Special tools The Contractor shall propose the list of special tools including their make and detailed specification as recommended by manufacturer(s), to be accepted by the Owner. 12.11 Testing The Contractor shall follow the Inspection and testing requirements in Quality assurance clause 2.31 Factory inspection and testing of General Technical Specifications and also as per section 14 of document Quality Assurance and Testing Specification
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13. 13.1
PROTECTION SYSTEM Scope of Work
Scope of work under this section covers the provision of labour, tools, plants, materials and performance of work necessary for the design, manufacture, quality assurance, quality control, shop assembly, shop testing, delivery at site, site storage and preservation, installation, commissioning, performance testing, acceptance testing, training of Owners personnel, handing over to Owner and guarantee for one year of Protection system, as per the specifications hereunder, complete with all auxiliaries, accessories, spare parts and warranting a trouble free safe operation of the installation. The scope of work shall be a comprehensive functional system complete in every respect including but not be limited to following: 3 sets of Protection equipment for the generating unit and associated generator transformer(s) Each set comprising of: Generator protection as per specifications; Power transformer protection as per specifications; Excitation transformer protection as per specifications; Auxiliary transformer protection as per specifications; Generator 11kV connections protection as per specifications; 415 V unit transformer protection as per specifications; Step down transformer protection as per specifications; 220 kV bus protection as per specifications; Circuit breaker fail protection as per specifications; Accessories such as Trip circuit supervision relays for 220kV breakers and field breaker, high speed tripping relays with provision for remote reset, interlock relays, auxiliary relays, 4-20 mA dual output transducers, trip matrix relays, timers, switches, push buttons, indicating lamps, DC /DC converters, MCBs, cable glands, lugs, test
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terminals, space heaters, potential free contacts for signalling alarm, trip to SCADA, etc. required to complete the system. Common items to all three units Central monitoring and parametrization software and hardware Laptop with data loading cables & accessories alongwith software Relay testing kit (OMICRON or DOBBLE make, type CMC 156 or equivalent) along with a laptop, software and accessories. Spares for 5 years normal operation. Special tools for installation, testing and maintenance The 220 kV Line, 11 kV and 415V auxiliary systems protection monitoring, coordination and associated communications will be part of the DCS. Any other item(s) not mentioned specifically but necessary for the satisfactory completion of scope of work defined above, as per accepted standard(s) / best international practices. 13.2 Rating and functional requirements
13.2.1 General requirements The protection system (electrical and mechanical) will interface with the DCS system at a number of locations throughout the plant for the exchange of alarms, status and commands however, the system should be capable of autonomous operation and shall not depend on the DCS system for any of its functions except for the sequenced shutdown of certain noncritical ancillary systems. The IEC 61850 protocol shall be applicable for the communication link with the electrical protection and associated devices. 13.2.2 Design philosophy The protection system for the units, main step-up transformer and 220 kV GIS shall have two independent schemes: the main and the back-up protections. The various protection relays shall be grouped in these two categories, each of them connected to the separate cores of instrument transformers, to ensure duplication of fault initiation. The power supply circuit will also be segregated into two independent schemes with two separate supplies from the main
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dc power supply. The design of the system will be immune to malfunction if a dc system ground fault occurs on any termination external to the relay protection panel. The protection system shall be designed according to the protection single line diagram drawing No. 167106-AL00-47DD-0003 The protection system will have the following features: Dual main and back up systems which will operate independently and simultaneously; Each protection system will be provided with separate dc circuits and use of separate CT and PT windings; Separate metering windings will be provided for metering and DCS instrumentation; Breaker fail protection will directly detect the failure of a circuit breaker to trip on fault following a trip initiation from any protection tripping. A complete overall design will be provided for each protection system to include current and voltage transformers, measuring relays, auxiliary relays and all wiring necessary for the detection of a fault and the issuing of a trip signal to the main circuit breaker including the correct functioning of that circuit breaker. The Line, 415V and 11kV auxiliary system protections will be integrated with the protection and control system. 13.3 Design consideration
13.3.1 Specific Codes and Standards The system and equipment shall be designed, built, tested and installed to the latest revisions of the following applicable standards. In the event of other standards being applicable they will be compared for specific requirement and specifically approved during detailed engineering for the purpose: Standards IEC 60255 IEC 60870-5-103 Description Electrical relays Tele control equipment and systems
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Standards IEC 60044-2
Description Instrument Transformers - Part 2 : Inductive Transformers voltage
IEC 60044-1 IEC 60044-6
Instrument Transformers - Part 1 : Current Transformers Instrument transformers - Part 6 : Requirements for protective current transformers for transient performance
13.3.2 Performance guarantee The Protection system along with all auxiliaries and accessories shall be capable of performing intended duties under specified conditions. It is the responsibility of the Contractor to supply the equipment as per guaranteed technical particulars and shall also guarantee the reliability and performance. 13.4 Construction
13.4.1 Generator Protection The generator protection function will be provided by two complementary main multifunction relays providing both primary and back-up functions. The protection functions are as follows: Generator differential (87); Negative sequence over current (46); Loss of excitation (40); Directional power (32); Generator Stator Ground fault (64G) Over voltage (59) and under voltage (27); Over and under frequency (81); Fuse loss detection (60); Inverse time voltage controlled or restrained phase over current (51V) and or phase distance (21);
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Over excitation (24). Rotor earth fault relay (64F) Thermal Relay (49) Out of Step Relay (78)
The protection system will be provided with monitoring and instrumentation functions and also with the following user interfaces: Individual target LEDs for each protection system, with a common reset push button on the front panel; A keypad to enter settings, access data, and test outputs; An MMI display, used with the keypad for the above functions, and the display of event summary information and scrolled present AC values; Remote communication data port (for DCS); Local computer access data port; A time synchronization data port; Test and connections facilities for isolation, measurement, current and voltage injection testing; Blocking facilities for all trip and circuit breaker fail start outputs.
13.4.2 Power Transformer Protection The power transformer protection will include the following: Overall differential protection (87TG) and HV restricted ground fault (87TN); Phase and over current and ground fault protection (50/51) for HV side; Neutral over current protection (51N) for the high voltage neutral point; Over fluxing protection (24); Programmable inputs to received alarms and trip inputs, from devices such as the Buchholz relay, the winding temperature, the pressure relief device, the cooling system, etc., as per the transformer design; Lockout (86T) and self reset (94T) relays shall be provided for winding (internal) and external remote back up faults respectively.
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13.4.3 220 kV Bus Protection The 220 kV double bus will include the following: Phase by phase and zone by zone differential bus relay (87B1 and 87B2); Breaker fail (50/62) measurement and tripping logic; Phase and residual over current earth fault for the bus coupler (50/51, 50/51N). A circuit breaker failure protection shall be provided for each unit, line and the bus tie 220 kV breaker. This protection will detect any protective trip operation on the breaker and monitor the current through the breaker. If the adjustable preset time after operation of the trip relay is exceeded and current is still flowing in the breaker, a trip output will be given. Trip output contacts shall send a direct trip to the line and generator breaker and bus coupler breaker, selected to the bus on which the failed circuit beaker is connected, and direct transfer trip to the remote end of the associated line and to the associated generator, as appropriate and operate the bus lockout relays. The direct transfer trip (intertrip) will be self reset and not maintained from these lockout devices. Lockout (86T) and self reset (94T) relays shall be provided for bus and external remote back up faults respectively. Provision shall be made for the breaker fail logic to receive trips from 220 kV circuit breaker fail protection. Other Protections Generator 11 kV connections Protection An open delta voltage protection (64) shall be provided to detect earth faults on the 11 kV bus work and associated connections. This protection is provided as a back-up to the stator ground fault (59N) and will also protected the bus work from an earth fault in the case of a line feeding the auxiliary services with the associated generator is disconnected. Excitation System Protection A three phase over current relay (50/51) shall be provided for the excitation system protection. The excitation connection branch will be included in the overall differential (87T). However, if the excitation transformer size adversely affects the sensitivity of the differential zones, the branch could be excluded in the differential zone.
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The system shall be coordinated with the under/over voltage protection provided with the generator and with the excitation limits settings provided in the exciter logic. Auxiliary system Protection A three phase over current relay (50/51) shall be provided for the unit auxiliary transformer. An earth fault neutral over current relay (50/51N) will also be provided for each transformer 415V neutral. These relays and any internal fault detection devices will trip the associated generator and the 415 V unit circuit breakers. The winding temperature and the similar temperature detection devices provided with the unit auxiliary transformer, together with a stage 1 trip from the neutral over current relay, will trip only the 415 V breakers. The 415V auxiliary power system protection will be included in the low voltage switchgear equipment. The auxiliary power system will be provided with electrical protection and internal control logic which will communicate with the DCS for data, alarms and clock synchronization via a data link protocol. Tripping Logic A tripping logic shall be provided in a table form which will be developed during detailed engineering stage. The logic shall cover the split between lockout and non-lockout trips, urgent (fast electrical and slow (interlocked) electrical and mechanical trips and special (governor fail) trips. The line breaker fail logic shall be individual per phase where as for the generator and bus coupler combined phase and residual current monitoring could be used. The circuit breaker fail logic shall be designed to receive remote trip from the Line protection. Equipment Layout The generator protection, transformer protection, 220 kV bus and breaker fail protection equipment will be mounted in separate panels which will be located in the Control Room. The panels will be rack type cabinets with nominal 19 inch wide chassis in sub-panel assemblies as defined in ANSI C37.21-1995. The panels will be provided complete with all wiring, earthing bar, fuses, miniature circuit breakers, lamp test facility, and links and vermin proof joints. The panels will be equipped with internal lighting, operated by a door switch and
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space heater.
The panels will have a minimum protection class of IP43 or greater
depending on their location in the powerhouse cavern. The panels will be complete with all relays, indicating instruments. Control switches, indicating lamp, wiring etc., properly mounted and identified. 13.5 Quality control and assurance
Design memorandum The Contractor shall submit all the drawings and documents in accordance with requirements stipulated in Section 2.12 Reference drawings and documents of General Technical Specification (GTS). Drawings and documents The Contractor shall submit all the drawings and documents in accordance with requirements stipulated in Section 2.12 Reference drawings and documents of General Technical Specification (GTS). Design calculation The Contractor shall submit the design calculation, for review / acceptance of the following: 13.7 Complete protection scheme coordination, CT and PT application check, Setting for different relays, DC power requirements. Delivery, Installation and Commissioning
Requirements.
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The supplier shall arrange personnel to oversee proper storage of equipment at site, their transhipment to powerhouse, installation and commissioning. 13.8 Spare Parts
Specified Spare Parts Recommended spare parts shall be supplied in accordance to clause 2.36 Spare Parts and tools of General Technical Requirements. Specified spare parts to be supplied under this section are as follows: Sl. No 1 2 3 4 5 6 7 8 Description Protection relays Thermal overload relay Single phase metrosil Three phase metrosil Test block Tripping relay Trip circuit supervision Auxiliary relays Quantity 1 no of each type 1 no of each type 1 no of each type 1 no of each type 1 no of each type 1 no of each type 1 no of each type 1 no of each type
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13.9
Special tools
The Contractor shall propose the list of special tools and testing instrument including their make and detailed specification as recommended by manufacturer(s), to be accepted by the Owner. Proposed list shall include following mandatory items: Portable Universal relay testing kit Relays / card / module extraction tools, One (1) portable microprocessor based, universal relay testing equipment, A laptop with at least 512MB RAM, 60GB hard disk, CD-R/W drive, necessary software and latest features to facilitate testing, recording and analysis, Two (2) sets of test plug for all types of relays, Two (2) sets of extension cards for testing of printed circuit boards
13.10 Testing The Contractor shall follow the Inspection and testing requirements in Quality assurance clause 2.31 Factory inspection and testing of General Technical Specifications and section 15 of Document Quality Assurance and testing specifications.
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14. 14.1
COMMUNICATION SYSTEM Scope of Work
Scope of work under this section covers the provision of labour, tools, plants, materials and performance of work necessary for the design, manufacture, quality assurance, quality control, shop assembly, shop testing, delivery at site, site storage and preservation, installation, commissioning, performance testing, acceptance testing, training of Owners personnel, handing over to Owner and guarantee for one year of communication system as per the specifications hereunder, complete with all auxiliaries, accessories, spare parts and warranting a trouble free safe operation of the installation. The scope of work shall be a comprehensive functional system covering all supply and services including but not be limited to following: a) A Radio System including a Central base station in the pothead housing and an outstation in the colony housing; b) Telephone system including a Private Automatic Branch Exchange (PABX) in the powerhouse, telephone sets and distribution in the powerhouse, the GIS gallery, the pothead yard, the balancing reservoir tunnel, the intake and the colony housing. A minimum of 30 analogue, 10 digital, 5 outdoor and 5 IP telephone sets shall be provided; c) Public Address system including the power amplifier(s), pre-amplifier with radio, cassette and CD players, attendant console and all indoor and outdoor speakers and distribution in the powerhouse and GIS gallery. A minimum of 15 indoor and 3 outdoor speakers shall be provided; d) Power line carrier communication equipment Single channel PLCC terminal suitable for one speech Two(2) sets at P.H. end and one number for transmission of data (required digital/ analogue values on 220 kV Double Circuit lines) Single channel PLCC terminal suitable for speech + protection (direct and permissive tripping) on 220 kV Double Circuit lines, each terminal equipment with one number plug in type Protection Coupler,suitable for 4 commands. Four (4) sets at P.H. end
Single channel PLCC terminal suitable for one speech Two (2) sets, one set each at and one number for transmission of data (required P.H. and Barrage site. digital/ analogue values on 11 kV lines)
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Single channel PLCC terminal suitable for one speech Two (2) sets, one set each at channel (from P.H. to Colony on 11 kV line) P.H. end & Colony end e) Point to point VSAT communication system between barrage and power house for data and speech transmission. f) g) One set of spare parts; One set of special tools.
A communication system shall serve the following purpose Communication between powerhouse, the intake and the colony via radio link, EPBAX telephone system for communication in power house area and colony. Public address system for paging inside power house Power Line communication Carrier for transmission of speech and data transmission Point to point VSAT system for data and speech transmission between power house and Intake. 14.2.1 Radio System General This section covers the services and supplies necessary to implement a point to multipoint microwave communication link between the Powerhouse and the Colony. The project includes Central base station radio equipment with integrated multiplexers for the powerhouse and complete Outstation radio cabinet. One (1) Point to Multipoint digital radio system Central base station including antenna, transmitter/receiver and integrated multiplexer (MUX) for the powerhouse and one (1) Outstation radio cabinet with integrated MUX for the colony shall be provided for communication between the powerhouse, dam site and the colony. The equipment shall be grouped as follows:
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Central Base station located in powerhouse (pothead yard): Microwave digital radio with multiplexer Antenna Tower Outstation cabinet: Microwave digital radio with multiplexer Antenna Tower
14.2.2 Interface with other equipment In particular, the following interface shall be provided by the Supplier: E1 interface with the powerhouse PABX system (PABX and fibre optic cable supplied in another section of this document) including the required fibre optic to copper converters in the pothead yard and in the powerhouse telecommunication room. Two Change over interfaces and one E1 interface for the public telephone network connection. Two E&M trunk interfaces for connection with the PLCC systems (supplied by others) Hardwired I/O interfaces for alarms and status indications to the powerhouse control system via the local pothead yard controller. 14.2.3 Supervision and test facilities All equipment shall include adequate supervision and tests facilities to allow preventive and corrective maintenance. As a minimum, the following shall be supplied: Visual indication Internal power supply Input/output modules Power amplifiers Modulators/demodulators Transmitter/receiver
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Test points Power, voltage, current in and out of equipment All input/output signals of equipment interconnected with other equipment Internal signals such as: oscillating frequencies, carrier frequencies, intermediate and radio frequencies and their levels. 14.2.4 Protection and Security The equipment shall include short-circuit protective devices that will isolate the parts under fault and prevent any damage to related components such as interconnection cable. The equipment shall include short-circuit protective devices that will isolate the parts under fault and prevent any damage to related components such as interconnection cable. 14.3 Design considerations
14.3.1 Specific Codes and Standards The system and equipment shall be designed, built, tested and installed to the latest revisions of the following applicable standards. In the event of other standards being applicable they will be compared for specific requirement and specifically approved during detailed engineering for the purpose. Standards IEC 60065 Description Audio, video requirements and similar electronic apparatusSafety
IS 10426 IS 1881 IS 1882 IS 9302
Specification for public address amplifier Code of practice for indoor installation of public address system Code of practice for outdoor installation of public address system Characteristics and method of measurement for sound systems equipment Printed Boards Stabilized power supplies, DC output
IEC 60326 IEC 60478
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Standards IEC 60870-5 IS 5802
Description Tele-control equipment and systems Specification for flexible coaxial RF cable with characteristic impedence of 75
The radio equipment shall comply with International Telecommunication Union (ITU-R and ITU-T) latest recommendations and more specifically to the G and V ITU-T Series Recommendations. Moreover, the equipment shall conform to the Indian Laws (specifically from the Department of Communications). 14.3.2 Performance guarantee The communication system along with all auxiliaries and accessories shall be capable of performing intended duties under specified conditions. The Contractor shall guarantee the reliability and performance of the individual equipment as well as of the complete system. 14.4 Construction
14.4.1 Radio Equipment The radio equipment shall be housed in a modular free-standing panel for the central base station and in a wall cabinet for the outstation. Radio equipment includes microwave radio with 4-QAM or OQPSK modulation (or equivalent) and 2048 kbits/sec interface, order wire channel with voice communication for maintenance and remote supervisory control and alarm, 30 channels PCM multiplex for users voice and digital data with 2048 KBIT/sec. interface, antennas matching units, fuses, terminals wiring and accessories. The radio equipment shall include lamp indicators (LED) and dry contacts (for remote indication) for supervision of RF transmission power, level of receive signal, automatic frequency control operation, noise and carrier level Digital Multiplex The multiplex equipment (integrated or standalone) shall be modular and allow increasing the number of channels by plugging in the corresponding module. Coordination shall be made by the Buyer at the time of system study to confirm to the Supplier the nature and quantity of input/output user's interface that are required. DC supply
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The Outstation shall be supplied with the Power and Junction Pack (PJP) for 240 Vac supply and shall integrate a power conversion unit and a standby batteries for 10 hours backup operation. The base central station equipment located in the pothead yard shall be supplied from the 48V dc station service batteries. The supplier shall coordinate the battery sizing to ensure battery autonomy of 10 hours considering that power shall normally be restored to the pothead yard during that period. Antennas The antenna supply shall include all mounting material to tower, coaxial cable with all accessories (such as plugs, flanges, connectors, grounding, hoisting grips, etc.). The antenna shall be supplied with a special adjustable bracket that allows correct alignment during mounting. Station Tower The Supplier shall be liable for the installation of the tower at the various sites where the Supplier shall investigate, as part of his survey, the particular environmental conditions. The Supplier shall submit a structure design calculation report for approval by the Buyer before manufacturing of the tower takes place. Manufacturing shall be allowed only upon approval by the Buyer. The calculation report shall be complete and include details such as loading conditions, reaction on foundations, tilt and twist (deformation) at antenna attachment, loads and capacity of each element. If the Buyer considers that the report is incomplete, the Supplier shall make available to the Buyer all requested additional information. Design shall be based on the largest size of antennas that will be used. The tower shall be equipped with all accessories to conform to Indian laws (more specifically related to the Indian Department of Communications and Aviation Authority) such as security lighting (beacons) and painting. Also the tower shall come with all material necessary for installation of cables (such as brackets, hangers, bridge) and grounding material (such as grounding rods and cable, connectors...) The tower structure pieces shall be treated by immersion in a sodium dichromate and sulphuric acid solution. The concentration shall be sufficient for the pieces to resist, during 48 hours, the conditions of a saline atmosphere as specified in ASTM B201 standard. Grounding
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Provision shall be made for ground connection of the various equipment and tower to the substation grounding grid. The tower supply also includes the safety lighting equipment and painting in compliance with the Indian Aviation Agency (or relevant authority) regulation. The lighting equipment shall be of low energy consumption type to avoid imposing to the batteries of the station a large burden and a higher AH capacity. The tower shall normally be of self-support type. The Supplier may propose towers of other design. Field Installation It shall be the responsibility of supplier to install and commission the communication equipment in consultation with the owner. 14.4.2 Telephone System The power house shall be equipped with one (1) Private Automatic Branch Exchange (PABX) telephone system including interior telephones for the powerhouse and exterior telephones for the line terminal with extension and trunk interfaces for outside connections to the local satellite communication links interface with the local public telephone network, interface with the radio system/central station for communication with the colony, interface with the power line communication system (PLCC) for communication with the existing dispatch centre and interface with the public address system. The PABX shall provide internal communication within the powerhouse and the GIS gallery and external lines to the pothead yard and colony (via the central base station), the balancing reservoir and intake housing via IP telephones. An operator desk shall be provided in the Control Room to control external communications and to set priority telephone links for operational purposes. The telephone system shall consist of the following: Private exchange (PABX), public address system and multi-distributor frames outgoing distributor terminals, cabling accessories (such as junction box, cable and telephone jacks) for telephone sets, digital terminal and attendant console.
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Digital telephones, IP telephones and analogue telephones and fibre optic Ethernet switches for IP telephones Digital terminal for programming, maintenance and diagnostic.
Software for exchange operation, maintenance and diagnostic.
Private Automatic Branch Exchange (PABX) The PABX(s) shall be located in the telecommunication room along with other communication equipment. The PABX shall be of modular construction with provision for expansion. Printed circuit cards shall be supported by insulating guides, terminated on multi contact connectors and properly secured to the frame. Means shall be provided to extract cards easily for maintenance and installation. Interconnection between cards shall be made by use of multi conductor cables terminated by compatible connectors. All hardware components shall be treated against corrosion and fungus caused by humidity or moisture. It must be possible to enable or disable any shelf, plug-in unit, including common equipment where spares are provided, without affecting other parts of the system. It shall be possible to remove or insert any peripheral circuit pack without degrading service to any other part of the system. It must not be necessary to remove any components in order to access and / or test other components or connectors. The circuit packs shall be clearly labelled and visible from the front as to the functions of the card. Furthermore, it shall be possible to read serial numbers, if used, without removing the cards. Enclosure shall allow access to interior from the front or back by means of doors or removable panels. The PABX shall be fully digital and stored program controlled. It shall be equipped to
interface with analogue, digital, IP and ISDN subscriber lines and trunks, as defined by ITU standards. It shall be of modular design and housed in dust-proof cabinets. The equipment shall be designed in such a way that the heat dissipation should not require built-in forced cooling fans/ventilation. The Supplier shall take appropriate caution and undertake the necessary measures to preclude RFI/EMI to and from the other site telecommunications systems. Where IP telephony is specified, the required Ethernet fibre optic switches shall be provided with the PABX and at any point of distribution as required.
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The PABX shall be supplied to provide for the initial requirements as specified shall also be designed for future expansion (ultimate capacity) equivalent to at least 100 % of the installed capacity. The PABX shall be flexible and allow for easy growth of trunks and extensions over the initial installed quantities up to the ultimate capacity. The addition of common elements and memory should not be necessary to achieve the ultimate capacity. The configuration, hardware and software supplied shall be of latest technology that has a proven record of satisfactory service, defined as a minimum of 20 commercial systems with an in-service life exceeding 6 months. The PABX shall be capable of being programmed and reprogrammed as necessary to the required system numbering plan for the area, region, inter-region and national connections. Multi-conductors interconnection cables (5 meters length minimum) shall be fitted at one end to the PABX by means of a plug-in connector and at the other end to the wall-mounted Main Distribution Frame (MDF) terminals. All PABX circuits shall be terminated to the MDF. All external cables in the PABX enclosure shall enter through bottom plate. The PABX shall be supplied along with one attendant console and provision for operation with various attendant consoles including their cabling accessories to allow connection to the MDF. The PABX shall include an automatic transfer device which, upon power failure, will connect the trunks to designated extensions. Public central office trunk circuits shall be protected by a surge protecting device and line isolators. The PABX shall be provided with an interface
to allow connection to a digital terminal and a printer used for maintenance and programming. PABX Features The main features of PABX shall consist of: Feature Classes. The features to the extensions shall be software programmable. An extension user shall receive a number unobtainable tone in response to an attempt to gain access to a nonassigned feature;
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Conference Call Capability. The PABX shall have the Conference Capability allowing for conference calls up to four conferees. Conference capabilities shall be assignable to all extensions, subject to access restrictions. The PABX shall allow the attendant to be included as one conferee; PABX Recovery In the event of loss of power or other type of temporary failure, the PABX shall be capable of automatic recovery without any action from the operator. A dead system load and restart shall be accomplished within 15 minutes from initiation for the system at ultimate capacity; Call Forward. The call forward (dont answer) shall re-route a call to a secondary destination when a primary extension fails to answer the call within a pre-determined time. If the secondary extension is busy, the call shall continue ringing on the primary extension. If the primary extension is busy, an incoming call shall also be forwarded to the secondary destination (call forwarding when busy). Several primary extensions may share the same secondary
destination. Call forward (when absent) shall re-route a call to a secondary destination when a primary extension has dialled an absent code. Call forward (when busy) shall be rerouted if the called extension is busy. This feature shall be enabled or disabled by the user from his extension; Abbreviated dialling. Common pool abbreviated dialling enables entitled extension users or operators to dial short codes that are provided for dialling frequently used destinations. Group abbreviated dialling is similar to the common pool abbreviated dialling but with the restriction that it is only available to a specific group of extensions, the extensions included in a particular group shall be programmable in the PABX. Individual abbreviated Dialling enables designated extensions the ability to store personal set of external numbers for short code dialling; Add-On Conference. It shall be possible for the extension user to establish a three-party conference. The add-on conference can involve three extensions, two extensions and one trunk or one extension and two trunks. During the add-on conference, a tone shall be given to all parties;
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Call Pickup. It shall be possible for extensions within the same pickup group to answer calls ringing on other extensions (same group) by dialling a code from the initial dial tone condition. Call Transfer. All extensions' users have the facility to transfer a call (internal or external) to another party. Only after the new destination has answered the call can the calling extension effect the transfer by going on hook; Camp on Busy. It shall be possible to connect a call to a busy extension and place it in a waiting queue until the required destination becomes free; Call Waiting. When the operator or an extension camp into a busy extension, the called busy extension shall be informed that a call is waiting by receiving a short burst of call waiting tone. The called party shall be in the speech condition for this to be effective (an off hook extension who is dialling shall not receive the tone); Forced release of trunk by priority user It shall be possible for a priority call to always find a trunk free to establish a call. The existing connection shall receive an indication before termination; Night service When no operators are in service, it shall be possible to provide service to internal or external callers. The night service feature shall allow a specially nominated extension to provide this service. De-activation of night service shall be from the Attendant Console. All other system features necessary for the efficient handling of calls on the site and between the site and other PABX connections are to be provided whether specifically identified in this section or not.
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Where feature software packages contain features in addition to those specified as required all features contained in those software packages are to be installed and available for implementation at the Buyers option. Grounding The Supplier shall engineer and design the grounding connections for the PABX equipment cabinets and the various components of the distribution network in accordance with local and international recommendations, codes and standards. Power Supply The PABX shall be equipped with dual 240 Vac power supply that will be fed from the powerhouse redundant UPS system ensuring uninterruptible power supply. Where IP telephony is specified, the phone sets and associated Ethernet switches shall be supported by UPS at 240 VAC. Such UPS shall be supplied by the Supplier. Where a UPS (or batteries) are provided to support the DCS controllers, instrumentation or DCS LAN switches, the same backup source shall be used to supply the telephone Ethernet switches. Software The PABX software shall allow configuring the PABX to suit specific customer needs and includes as a minimum the features described in the technical data schedules. Main configuration software shall be placed on CD-ROM or other equivalent storage devices to allow reloading, following a power failure. Remaining software shall be stored in a nonvolatile type memory. The software shall be modular and allow for the following features: It shall be possible to perform the installation and the rearrangement of any telephone set in the system without affecting others on the same system. It must be possible to perform any feature changes (including removal of set data from software) at the set level at any time without disrupting service to that set or disconnecting calls in progress. It must be possible to perform software diagnosis on any part of the system without affecting service to any other part of the system.
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It shall be possible to program a variety of common groups of features for telephone sets through the use of programmable default values. preclude the capability of single feature entry. This ability should not
All software commands, outputs and diagnosis display should remain unchanged in format, meaning and information content throughout the life time of the system, regardless of later-generation development.
Telephone Sets All telephone sets shall have a designation suitable for identifying the set with the telephone number. Interior sets may have stencilled numbers placed in number holders. All exterior telephone sets and stations shall have engraved or painted plates provided to identify the telephone or station number with letters a minimum of 30 mm high. The plates shall be attachable to the set, enclosure or adjacent mounting location. All interior telephones shall have a label attached which provides room for the entry of up to 5 emergency numbers. Digital Phone Set The Supplier shall supply digital phone sets for offices at the powerhouse equipped with programmable keys and message waiting indication. It shall support all features provided by the PABX through system configuration and programming. Subscriber Phone Set The Supplier shall supply analogue subscriber phone sets at the powerhouse, the pothead yard and the colony equipped with limited features such as waiting key and automatic emergency dialling. It shall have a DTMF keypad. IP Phone Set The Supplier shall supply IP phone sets at the dam site equipped with limited features such as waiting key and automatic emergency dialling. It shall have a DTMF keypad. The IP Phone set shall be supplied with the necessary Fibre Optic Interface or Ethernet switch for proper interface with the fibre optic links up to the PABX. Outdoor Subscriber Phone Outdoor wall telephones shall be designed for operation in outside areas with the following features:
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Telephones shall be weatherproof and designed to operate in outside environmental conditions specified in previous section.
Telephones shall be constructed to resist corrosion, undamaged and performance unaffected by the external conditions, provide protection against rain, windblown dust, and splashing.
Telephones cases made from ferrous alloys other than stainless steel shall have a protective coating that shall resist rust and corrosion.
Telephones shall have an enclosure opening suitable for the termination of cable glands or alternatively provide a weather sealed cable tail suitable for terminating in a terminal box.
Telephones shall have a DTMF keypad. Handset cords shall be suitable for outdoor use. Handset coil cord extended length shall be 2000 mm nominal.
Attendant Console The attendant console shall be digital and equipped with all standard operating features. It shall be equipped for handset operation. All other attendant features necessary for the efficient handling of calls at the powerhouse and between the site and other PABXs connections (central station and outstation) are to be provided whether specifically identified in this section or not. Where attendant feature software packages contain features in addition to those specified as required all features contained in those software packages are to be installed and available for implementation at the Buyers option. Engineering Services The Supplier is responsible for the design and engineering activities leading to the proper supply of a Telephone Private Branch Exchange system that shall satisfy the functionality and operability criteria described in these Technical Specifications. The Supplier shall prepare and submit to the Owner for review the following details :analysis, calculation and equipment configuration, such as the powerhouse, the pothead yard and the colony telephone numbering plan and access procedures, necessary to ensure
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that the design meets the performance objectives of the private telephone network. The Supplier shall be available to participate to design review meetings at the Owners facilities. The engineering documents to be delivered by the Supplier shall include, in addition to the general documents, a detailed description of the private telephone network configuration to be implemented by the Supplier. The Supplier shall ensure full compatibility of proposed equipment with existing network facilities and with others proposed by the Supplier to allow full integration of the new facilities. As the power electrical grid coordination is dependent on the availability of operative phone network, the exchange shall allow node trunk to trunk transit and power station operator access without blocking. The Supplier is fully responsible and accountable for the proper operation of the equipment under the specific environmental conditions of the various sites such as temperature and humidity. Interfacing with other equipments The exchange shall be used for the operation of the new powerhouse and ancillary sites. It shall be linked with the existing or future PABX by 4 wires E/M trunks directly or through digital links, E1. There shall be analogue and digital phones subscribers in the powerhouse, the GIS gallery and the pothead yard (using the central base radio station), IP telephone subscribers at the balancing reservoir tunnel and the intake housing and remote analogue subscribers (using the microwave radio outstation) at the colony. The exchange shall also give access to the public network (CO lines) by means of HV line isolators (included in supply). 14.4.3 Public Address System A Public address system including power amplifier, master control microphone and loud speakers for fire/emergency warning in the powerhouse shall be provided. The system shall be linked to the PABX system of the powerhouse for remote calling of the operating personnel of the powerhouse from the telephone system. Equipment Requirements
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The amplifier units shall be at least a 100 W (RMS) amplifier unit and shall be mounted in the enclosed rack and installed in the communication equipment areas. ON/OFF power switches shall also be provided and shall be located remotely from the amplifier unit and controlled by the address system logic. The loudspeakers shall be of the following types and be suitable for the site conditions: Indoor ceiling type (office areas); Indoor horn type (maintenance areas); Outdoor weatherproof horn type.
A paging interface unit shall be provided to the interface between the PABX telephone exchange and the pre-amplifier unit. When a telephone page request is made, the interfacing unit shall turn on power to amplifier unit and send a pay attention tone to the calling extension and loudspeakers through amplifier unit for a certain period of time followed by a voice message from the initiator. Power Supply The Public address system shall be fed from one of the powerhouse redundant UPS system (supplied in another section of this document) ensuring uninterruptible power supply. 14.4.4 Power line carrier communication system.(PLCC) The power line carrier communication system (PLCC) shall be suitable for speech and data transmission and network protection. Power house shall be connected to the nearest pooling station and intake through PLCC. The voltage level of transmission lines between power house and Pooling station is 220KV whereas between intake and power house is 11KV. The power line carrier communication system shall comprise of a carrier current transceiver (CCT) interface with the electrical power line via a buffer which shall automatically provide a low output drive impedance while transmitting, and a high receiving impedance when receiving, all with solid state circuitry. The length of signal transmission by the CCT shall be monitored and automatically prevented from continuously loading the communication network in the event of a malfunction which may causes a signal transmission to exceed normal maximum transmission time. The power line carrier communication system for sending and receiving communication signals over an electrical power line shall comprise of the following:
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1. A carrier current transceiver (CCT), 2. A bi-directional coupling interface device disposed between CCT and the electrical power line, which includes a parallel resonant LC circuit tuned to the frequency of the power line carrier signals. The CCT shall have an input/output (I/O) port for receiving serial signals (RX Signals) from the electrical power line, and for applying serial signals (TX Signals) to the electrical power line, via coupling interface, 3. A time monitoring device to monitor and regulate the transmitted signals. The PLCC equipment shall be microprocessor based and shall be interfaced with power house DCS LAN for communication and data transfer and protection trip. PLCC shall have the following basic features: Type of modulation Type of transmission Carrier frequency range H.F. Oscillator I.F. Oscillator Stability of carrier frequency Amplitude modulation Single side band 40 500 kHz Crystal controlled Crystal controlled Within 5 ppm
Maximum H.F .Amplifier output with 40 W for suppressed carrier single / multiple tone keying ( Peak envelop power ) Nominal carrier frequency power ( Peak 20W for suppressed carrier envelop power) DC power input Characteristic impedance of RF cable Input level of telephone signalling channel Outputlevel channel of telephone 48 V DC 75 -20dB
signalling -20dB
Pulse distortion of telephone signalling <10% channel 14.4.5 Point to Point VSAT communication between Power house and Intake Introduction In order to maintain uninterrupted flow of data between barrage site and power house a two way point to point satellite communication link is envisaged which will enable power plant
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digital control system to access data from barrage control room and send command signals to barrage radial gates and other auxiliaries. Interface between Barrage Site and Power House. Data transfer The PLC of Hydro mechanical equipment shall perform the following functions: 1. Interface with satellite earth station at barrage site for sending and receiving signals. 2. Collect data from equipments of barrage site to be transmitted to power house via VSAT, PLCC and Optical fibre cable. 3. Collect and distribute the command signals received from power house via VSAT.
Signals to be transmitted from barrage site to power house Analog signals Intake water level Barrage water level LT supply voltage LT supply current LT supply KWH
Digital status signals Trash rack choked Intake water level low Alarm Intake water level very low Trip Barrage radial gate -1 , Open Barrage radial gate -1 , Close Barrage radial gate -2 , Open Barrage radial gate -2, Close Barrage radial gate -3 , Open
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Barrage radial gate -3 , Close Barrage radial gate -4 , Open Barrage radial gate -4 , Close Barrage radial gate -1 ,Heating ON Barrage radial gate -1 , Heating OFF Barrage radial gate -2 ,Heating ON Barrage radial gate -1 , Heating OFF DG -1 , OFF DG -1 , ON DG -2 , OFF DG -2 , ON DG -1 , Selection MAIN DG -1 , Selection Standby DG -2 , Selection MAIN DG -2 , Selection Standby DG selection AUTO DG Selection MANUAL DG , Selection Local DG selection Manual Battery Charger , OFF Battery Charger ON Control selection Local Control selection Remote Gate control Manual Gate Control Auto
Telephone
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Two telephone channels shall be available for communication from barrage site. At the power house end the telephone line will be interfaced with EPBAX system Command signals to be transmitted from power house. Control selection Local / Remote Control selection Auto / Manual Remote gate-1 Open Remote gate-1 Close Remote gate-2 Open Remote gate-2 Close Remote gate-3 Open Remote gate-3 Close Remote gate-4 Open Remote gate-4 Close DG set-1 Start DG set-1 Stop DG set-2 Start DG set-2 Stop
Control architecture 1. The transmission signals from barrage site to power house are placed into 4 groups Analog signals ( water level and electrical parameters) Digital status signals from various equipments. Alarm and trip signals (Intake water level low and too low) Telephone.
No command data is expected to be transmitted from barrage site to power house.
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The data transmission from power house to barrage site is placed into 2 groups. Command signals ( Gate open/close, DG ON / OFF) Telephone.
No status signal is expected to be transmitted from power house to barrage site. The data shall be transmitted through high speed point to point VSAT link working on C band or extended C band frequencies. Description of equipment and specification High speed point to point VSAT link The VSAT (Very Small Aperture Terminal) system shall consist of Earth station at barrage site complete with antenna, outdoor unit (ODU), interfacility link cable (IFL) and an indoor unit (IDU). Earth station at pothead yard location complete with antenna, outdoor unit (ODU), interfacility link cable (IFL) and an indoor unit (IDU). Satellite transponder in Geo synchronous orbit above the earth. Earth stations shall communicate via this satellite. Interface equipment complete with communication gateway protocol for packet addressing, routing, switching, virtual circuit and flow control etc. Network control centre shall be a high end server complete with operating software, Simple network Management Protocol traps for all the devices working on the IP and generate configurable reports for management purposes. The VSAT links between barrage site and pothead yard shall communicate directly with each other without involving any central hub. 1 Topology 2 way Mesh (Transmit and receive between two earth stations) 2 Frequency band C band / Extended C band
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3 4 5
Up-linking frequency Down -linking frequency Satellite capacity access protocol
5.925 GHz to 6.425 GHz/ 6.725 GHz to 7.025 GHz 3.70 GHz to 4.20 GHz / 4.5 GHz to 4.8 GHz Frequency Division Multiple Access (FDMA)
Satellite Network access protocol
Single Channel Per Carrier Demand Assignment Multiple Access (SCPC/DAMA).
Antenna sub system It shall consists of 1.8 to 2.4 meter, parabolic reflector, Sub Reflector, Low Noise Amplifiers and its integration modules like Cables, Wave Guides, Connectors, Dehydrators, Tracking Mechanisms etc. This system should have clear line of sight availability towards the satellite. The Antenna Control system shall be able to position the Antenna anywhere in vertical and horizontal plane thus taking care of Satellite drifts as well as change of Satellite. Antenna sub system shall communicate with Geo stationary satellite for unlinking and down linking data and voice signals. Out Door Unit (ODU) It shall be equipped with RF electronics and be mounted on the antenna itself. At the main focus of the antenna, a small feed-horn shall be placed to receive signals and to direct transmit signals. For transmitting path the RF electronics unit shall contain frequency converters and Solid State Power Amplifier for the conversion of Intermediate Frequency to Radio Frequency and its amplification in the transmit path. For the receiving path, it holds Low Noise Block and Low Noise Amplifier for blocking interference and amplifying the weak receive signals and a Down-Converter for conversion of RF to IF. Indoor Unit (IDU) It shall consist of modulators and demodulators (modems). Modulators convert information being transmitted into an IF signal, suitable for frequency up-conversion and transmission. Demodulators receive IF signals and convert them back into the information format suitable for the users. The number of modems required depends upon the configuration of the terminals. The indoor unit communicates with the end user equipment like standalone PCs,
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LANs, Telephones or an EPABX. The ODU is connected through a low loss coaxial cable to the IDU. The typical limit of this Inter Facility Link cable is about 300 feet. Network Monitoring Systems The Network monitoring system shall monitor and control the entire VSAT network, analyze the traffic flow, track the performance of the remote site connected and take corrective action in case of fault. It shall be high end Server working on proprietary software. The network shall be managed as well as configured using this system only. All history and configuration data shall be stored internally. The system shall also provide SNMP (Simple Network Management Protocols) traps for all the devices working on IP. These traps can be used by Open End dedicated Software which can generate many configurable reports for management purposes. The network management system shall easily integrate end-to-end monitoring and configuration control for all network subsystems. Interface equipment The VSAT Network shall be interfaced with the external data devices by using Router or Router Switch combinations barrage site Earth Station. At Remote Station, Ethernet LAN output shall be provided as standard interface. This can directly be connected to any device having Ethernet interface. Flexibility The VSAT system shall support network expansion to any other site. The VSAT networks shall offer enormous expansion capabilities to accommodate additional traffic loads. Power supply AC power supply Under normal condition 11 KV supply shall be available to Barrage site from Pot head yard. One 11KV / 415 V, 500KVA substation shall be located in the barrage area to feed 415 V supply to LT switch board for further distribution to other equipments. Two DG sets each rated for 500KVA shall be provided with automatic startup features as backup in case of failure of 11 KV supply from Pot head yard. The DG sets will work in main and standby mode and are not designed to run in parallel. The DG sets can also be started and stopped remotely from Power house through VSAT link.
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DC power supply One 220 V DC battery bank with charger and distribution board shall provide control supply for PLC of hydro mechanical equipment. UPS UPS will supply power to VSAT equipment during the interruption period encountered between 11 KV supply failure and starting of DG set. Earthing There shall be a separate Electronic earth grid for VSAT and HM PLC equipment. There shall be no connection between the earth mat of HM equipment and the electronic earth. Installation and maintenance The performance of VSAT equipment both at barrage site and pothead yard will be affected by ambient conditions. Hub Equipment generates a very high amount of heat. Continuous heat dissipation and maintaining normal temperature is an extremely important consideration for proper functioning of VSAT equipments.
14.5
Quality control and assurance
14.6.1 Design memorandum The Contractor shall submit all the drawings and documents in accordance with requirements stipulated in Section 2.12 Reference drawings and documents of General Technical Specification (GTS). 14.6.2 Drawings and documents The Contractor shall submit all the drawings and documents in accordance with requirements stipulated in Section 2.12 Reference drawings and documents of General Technical Specification (GTS).
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14.6.3 Design calculation The Contractor shall submit the design calculation, for review / acceptance including the following: 14.7 Calculation for echo sound generated in the powerhouse, Design calculation for selecting number of loudspeaker with power output. Delivery, Installation and Commissioning
Requirements. The supplier shall arrange personnel to oversee proper storage of equipment at site, their transhipment to powerhouse, installation and commissioning. The packaging and storage of electronic and electrical equipment shall be strictly in accordance with internationally accepted standards. Electronic equipment shall be packaged, shipped and stored in anti-static packing. All packages shall be stored indoor. Packages containing electronic equipment shall be stored in humidity controlled environment. 14.8 Spare Parts
Recommended spare parts shall be supplied in accordance to clause 2.36 Spare Parts and tools of General Technical Requirements. Specified spare parts to be supplied under this section are as follows: Sl. No 1 2 3 4 14.9 Description Quantity
Power supply modules/unit and cards- type / 1 set of each used type model used Loud speakers with wall mounting arrangements 1 no each type Telephone sets with wall/ column/ structure 1 no each type mounting arrangements Desk microphone Special tools 1 no each type
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The Contractor shall propose the list of special tools and testing instrument including their make and detailed specification as recommended by manufacturer(s), to be accepted by the Owner. The proposed list must include the following: Sl. No 1 2 3 4 14.10 Testing The Contractor shall follow the Inspection and testing requirements in Quality assurance clause 2.31 Factory inspection and testing of General Technical Specifications and also section 20 of Quality Assurance and Testing Specifications. Description Selective level Meter 75 ohm Return Loss Measuring Bridge Return Loss Measuring Attachment Digital Multimeter Quantity 1 no. 1 no. 1 no. 1 no.
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15. 15.1
AC STATION AUXILIARY SUPPLY SYSTEM Scope of Work
Scope of work under this section covers the provision of labour, tools, plants, materials and performance of work necessary for the design, manufacture, quality assurance, quality control, shop assembly, shop testing, delivery at site, site storage and preservation, installation, commissioning, performance testing, acceptance testing, training of Owners personnel, handing over to Owner and guarantee for one year of 415 V and11 kV switchgear and auxiliary transformers as per the specifications hereunder, each complete with all auxiliaries, accessories, spare parts and warranting a trouble free safe operation of the installation. The scope of work shall be a comprehensive functional system covering all supply and services including but not be limited to following: a) Two nos(2) 11kV / 0.415kV, 3 phase, 1250 KVA dry type Station Service Transformers (SST) for supplying power to the station auxiliary loads; b) Three nos (3) 11kV / 0.415kV, 3 phase, 1250 KVA dry type Unit Auxiliary Transformers (UAT) for supplying power to the unit auxiliary loads; c) One no (1) 11 kV /0.415 kV , 3 phase, 2000 kVA, ONAN outdoor type step down transformer for power requirement of power house d) One no (1) 11 kV /0.415 kV , 3 phase, 500 kVA, ONAN outdoor type step down transformer for power requirement at intake site. e) One no (1) 11 kV /0.415 kV , 3 phase, 500 kVA, ONAN outdoor type step down transformer for colony. f) One no (1) 11 kV /0.415 kV , 3 phase, 250 kVA, ONAN outdoor type step down transformer for power requirement at Valve house and Surge shaft area. g) One no (1) 11 kV /0.415 kV , 3 phase, 150 kVA, ONAN outdoor type step down transformer for pothead yard. Three (3) sets of non segregated phase bus duct system for interconnection between UAT, UAB, SST and SSB.
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h)
The transformers should be supplied complete with their enclosures and all necessary accessories such as bushings, winding temperature detectors, current transformers, instruments, fittings, marshalling kiosk etc.
i)
Three nos. (3) 415 V , 2500 Amps Unit Auxiliary Switch Boards (UAB) indoor type, self-supporting, totally enclosed and compartmentalized to house the bus bars and required equipment such as moulded case circuit breaker, instrument transformers and the necessary metering , protection and switching equipments;
j)
Two nos (2) 415 V , 2500 A Station Service Switch Board (SSB) indoor type, selfsupporting, totally enclosed and compartmentalized to house the bus bars and required equipment such as moulded case circuit breaker, instrument transformers and the necessary metering and protection equipments;
k)
One no. (1), 11 kV metal-clad switchgear of 400 A, 3-phase, 3-wire, vermin and dust proof, consisting of cells containing nine (09) draw-out type circuit-breakers. The switchgear shall be complete with instrument transformers and the necessary metering and protection equipments;
l)
One no. (1) 415 V , 1000 Amps Switch Boards for power distribution at Intake, The switch board will be indoor type, self-supporting, totally enclosed and
compartmentalized to house the buses and required equipment such as moulded case circuit breakers, instrument transformers and the necessary metering and protection equipments m) One no. (1) 415 V , 500 Amps Switch Boards for power distribution at surge shaft and valve house area. The switch board will be indoor type, self-supporting, totally enclosed and compartmentalized to house the buses and required equipment such as moulded case circuit breakers, instrument transformers and the necessary metering and protection equipments n) One no. (1) 415 V , 1000 Amps Switch Boards for power distribution at colony, The switch board will be indoor type, self-supporting, totally enclosed and
compartmentalized to house the buses and required equipment such as moulded case circuit breakers, instrument transformers and the necessary metering and protection equipments.
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o)
Six (6) nos Four pole structures at Potyard, colony, BFV and at intake along with isolator switch, earthing switch and with surge arrestor . PLCC interface equipment for colony and barrage to be provided.
p) q)
One set of spare parts; One set of special tools.
15.2.1 AC Supply System The ac auxiliary system is based on the following philosophy of operation: During normal running of the unit, each unit auxiliary board will receive power from their respective unit auxiliary transformers (UAT).The incoming circuit breaker feeding the unit auxiliary board (UAB) from the UAT can only be closed if and only if the generating unit is running stable at rated voltage and frequency, and the UAT is healthy and there is no bus voltage on the UAB. The UABs will feed the unit auxiliaries of their respective units. However, in case of failure of its supply, the power requirements of a particular UAB will be met from the station service board (SSB). SSBs are fed from 11 kV switchgear via SST 1 and SST 2 transformers. The11 kV switchgear is fed from two independent external supplies. The station service boards, in addition to feeding the station auxiliary loads, can also back-feed the UAB for black starting purposes, and also feed the adjacent SSB in case of its supply failure. In the event of failure of both Station Service Transformers (SST), the power requirements of the SSB will be assured by one of the UABs. In case of failure of power supply from both the external source, the supply of essential service loads will be assured from emergency diesel generator sets. In case of supply failure, transfer of loads from unit auxiliary supply to station service supply or vice-versa will be done with a minimum of power interruption. An interlocking scheme controlled by a programmable logic controller (PLC) and interfacing with the general
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auxiliaries control unit will be provided to achieve the required automatic changeover logic from unit supply to station supply and vice-versa for the UAB and SSB. The circuit breakers of both the external source and the DG set shall be suitably interlocked to prevent paralleling of supplies. The circuit breakers of any unit auxiliary board will not be able to close when there is either a bus voltage or no voltage on both sides of the breaker. In order to meet the ac requirements of essential loads, a single-phase uninterruptible power supply (UPS) will be installed. 15.2.2 11 kV Switchgear The 11 kV metal-clad switchgear will be located at the pothead yard control room. Under normal conditions its supply will be derived from two 11kV external sources. In case of failure of both the external sources the 11 KV switchgear will be powered by two 910KVA DG sets running in parallel. SSBs will be connected to 11kV switch board through XLPE cables. The 11kV Switchgear will have the following characteristics: Description Rated Voltage ( kV ) Rated frequency ( Hz ) Rated current ( A ) Lightning impulse withstand voltage ( kV peak) Power frequency withstand voltage 1 min ( kV rms) Rated short circuit withstand current ( KA rms sym) The single bus section shall consist of the following feeders: One (1) feeder of 100 A for 11 kV cable connections to SST-1 transformer; One (1) feeder of 100 A for 11 kV cable connections to SST-2 transformer; Two (2) feeders of 200 A for connecting 11kV external power source. One (1 ) feeder of 50 A for 11 kV connections to Intake; One (1 ) feeder of 50 A for 11 kV connections to Valve chamber ; One (1) feeder of 150 A for 11 kV connections to step down transformer of DG set. One (1) feeder of 150 A for 11 kV connections to colony.
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Rating 11 50 400 75 28 12.5
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One (1) feeder of 50A for 11kV connections to pothead yard
15.2.3 Auxiliary Distribution Transformers (UAT and SST) The installation being at an altitude of 2500 m, the standard voltage and current rating of the SST and UAT transformers will be derated accordingly. The transformers shall be designed, built, installed and tested to the latest revision of all relevant standards. The cubicles housing the transformers shall be ventilated by natural air. All transformers shall be epoxy resin insulated and indoor type. These transformers should have low noise and low noise level type with moisture- proof, tropicalised, flame resistant and self extinguishable insulation. The transformers shall be free from partial discharge up to 150% of the rated voltage. The transformers shall be able to withstand all forces caused by a worst short-circuit on the low voltage terminals without any damage. The transformer shall be equipped with necessary accessories such as temperature sensors of PTC- thermistor type. The transformer core shall be designed to maintain flux density well below saturation and shall be made from CRGO silicon steel laminations. The core shall be grounded to the enclosure with flexible grounding conductor. The Unit Auxiliary Transformers (UAT) will have the following characteristics. Description Type Rated Power ( KVA ) Number of phases Total no of transformers Minimum efficiency of transformer Type of cooling Winding material Class of insulation Connection of transformer HV side LV side Vector group
Rating Epoxy resin dry type 1250 3 3 98% AN Copper H Delta Star with neutral directly earthed. Dyn11
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Description Rated frequency ( Hz ) Rated HV side voltage ( kV ) Rated LV side voltage ( kV )
Rating 50 11 0.415
The Station Service Transformers (SST) will have the following characteristics Description Type Rated Power ( KVA ) Number of phases Total no of transformers Minimum efficiency of transformer Type of cooling Winding material Class of insulation Connection of transformer HV side LV side Vector group Rated frequency ( Hz ) Rated HV side voltage ( kV ) Rated LV side voltage ( kV ) 15.2.4 Power supply for Intake. One 11 kV / 415 V, 500 KVA transformer will be located at the head works for control supply, heating, illumination and other purposes. This transformer will be oil filled outdoor type equipped with all necessary sensors and monitoring devices as required for the safe working of the transformer. The above Transformers will have the following characteristics Description
Rating Epoxy resin dry type 1250 3 2 98% AN Copper H
Delta Star with neutral directly earthed. Dyn11 50 11 0.415
Rating
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Description Type Rated Power ( KVA ) Number of phases Total no of transformers No. of windings Minimum efficiency of transformer Type of cooling Winding material Class of insulation Connection of transformer HV side LV side Vector group Rated frequency ( Hz ) Rated HV side voltage ( kV ) Rated LV side voltage ( kV )
Rating Oil filled outdoor type 500 3 1 2 98% AN Copper H
15.2.5 Power supply for valve house and surge shaft One 11 kV / 415 V, 250 KVA transformer will be located at the Valve house for control supply, heating, illumination and other purposes. This transformer will be oil filled outdoor type equipped with all necessary sensors and monitoring devices as required for the safe working of the transformer. The above Transformer will have the following characteristics Description Type Rated Power ( KVA ) Number of phases Total no of transformers No. of windings Minimum efficiency of transformer
Rating Oil filled outdoor type 250 3 1 2 98%

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Description Type of cooling Winding material Class of insulation Connection of transformer HV side LV side Vector group Rated frequency ( Hz ) Rated HV side voltage ( kV ) Rated LV side voltage ( kV ) 15.2.6 Power supply for colony
Rating AN Copper H
One 11 kV / 415 V, 500 KVA transformer will be located at the colony substation for illumination and other purposes. This transformer will be oil filled outdoor type equipped with all necessary sensors and monitoring devices as required for the services they are intended for. The above Transformer will have the following characteristics Description Type Rated Power ( KVA ) Number of phases Total no of transformers No. of windings Minimum efficiency of transformer Type of cooling Winding material Class of insulation Connection of transformer HV side LV side
Rating Oil filled outdoor type 500 3 1 2 98% AN Copper H
Delta Star with neutral directly earthed.

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Description Vector group Rated frequency ( Hz ) Rated HV side voltage ( kV ) Rated LV side voltage ( kV ) 15.3 Design considerations
Rating Dyn11 50 11 0.415
15.3.1 Specific Codes and Standards Electrical equipment shall be designed and tested according to the latest relevant standards including amendments, or complementary standards mentioned in this document, shall be applied, in particular to the following: ISO 9001 Quality Systems Model for Quality Assurance in Design, development, Production, Installation and Servicing. Instrument Transformers Short-circuit currents in 3 -phase AC systems Short- circuit currents- calculation of effects Specifications for interconnecting bus-bars for AC voltage above 1 kV up to and including 36 kV. Method of measurement of radio influence voltage (RV) of high voltage apparatus IEEE standard requirement for instrument Transformers High Voltage test techniques Insulation coordination Insulating bushing for alternating voltages above 1000V Dry type Power Transformers Power transformers
IEC 60044 IEC 60909 IEC 60865 IEC 8084
NEMA 107
IEEE C57.13 IEC 60060 IEC 60071 IEC 60137 IEC 60726 IEC 60076
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IEC 60439 IEC 60364 IEC 60529 IEC 60439 IS 11171
Low voltage switch gear and control gear assemblies Electrical installation of buildings. Degree of protection provided by enclosures (IP Code) Low voltage switchgear and control assemblies. Specification for dry type power transformers
15.3.2 Performance guarantee The 415 V and 11 kV switchgear and auxiliary transformers along with all auxiliaries and accessories shall be capable of performing intended duties under specified conditions. The Contractor shall guarantee the reliability and performance of the individual equipment as well as of the complete system. 15.4 Construction
15.4.1 11 kV Switchgear The 11 kV metal-clad switchgear will be located at the pothead yard control room. It shall have three incoming feeders and 6 outgoing feeders. The incoming feeders shall be fed from 2 nos external 11 KV source and one from DG set. The outgoing feeders shall feed power to SST-1, SST-2, Intake, Valve chamber, pothead yard and colony. The incoming and
outgoing feeder connections shall be with XLPE cable. The 11KV switchgear panel shall have adequate provisions for terminating XLPE cables with stress cones. The complete 11 KV switchgear system shall be designed to be capable of withstanding without damage all stresses by maximum asymmetrical short circuit (peak) currents in the incoming and outgoing feeder bays . Feeder circuit breaker units shall be mounted on a carriage assembly, constructed so that the unit can be removed and replaced while the buses are energized. The carriage shall have self-engaging definite position stops for disconnected, test and connected positions. All necessary means shall be provided for easy removal and handling of the unit. 15.4.2 415 V Unit Auxiliary Switch Board (UAB) The ac powerhouse auxiliaries are fed from the following sources: 1. From the generating unit for the unit auxiliary services for that particular unit.
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2.
From external supply 11KV source through SST and Station service boards for starting of the units.
3.
From DG sets in case of failure of external 11KV source.
Unit auxiliary boards (UAB-1, UAB-2 and UAB-3 ) shall consist of: Vertical cells containing incoming feeders, outgoing feeders , draw-out circuit
breaker compartments, 415/240 V distribution board complete with control, protection and metering; Vertical cells forming a distribution feeder section, those cells consisting of compartments housing molded case circuit breakers. Each cubicle shall be divided into sections, or compartments, housing the incoming, interconnecting or out going feeder air circuit breaker units and moulded case circuit breaker units respectively. Each ACB and MCCB unit shall be mounted on a carriage assembly, constructed so that the unit can be removed and replaced while the buses are energized. The carriage shall have self-engaging definite position stops for disconnected, test and connected positions. All necessary means shall be provided for easy removal and handling of the unit. Each unit auxiliary services boards (UAB) will be supplied from its own 11 kV / 415 V, 3phase 1250 KVA, dry-type unit auxiliary transformer (UAT) The unit auxiliary transformers will be located on the generator floor of respective units. The primaries of the unit auxiliary transformers will be directly connected to their corresponding 11 kV isolated phase bus bars through bus duct T connections. The 415 V, 2500 Amp, unit auxiliary board of each generating unit will be located on the generator floor. The secondary of each unit auxiliary transformer will be connected via non segregated phase bus to their corresponding unit auxiliary boards. The unit auxiliary boards UAB-1, UAB-2 and UAB-3 will be connected respectively to station service boards SSB - 1 and SSB -2 by means of non segregated phase bus. The outgoing circuit breakers of the unit auxiliary boards will be electrically interlocked to prevent their inadvertent paralleling onto the station service boards.
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Each unit auxiliary board will be equipped with necessary controls and metering instruments, such as digital voltmeter, ammeter, CTs, PTs, 220 Vdc circuit breaker controls, indicating lamps for breaker position and power status. Each unit auxiliary board will be provided with protection relays and a programmable logic controller to achieve the required automatic changeover logic from unit supply to station supply and vice-versa. The PLCs will interface with the powerhouse auxiliary control unit, which in turn will interface with the Digital Distributed Control System (DCS). Unit Auxiliary Switch Board will have the following characteristics: Description Rated voltage Rated frequency Rated current Rated short circuit with stand current Rating 415 Volts 50 Hz 2500 Amps 50 kA rms
15.4.3 415 V Station Service Switch Board (SSB) The 415 V, 2500 A, Station Service Boards (SSB 1 and SSB 2) will be connected to the secondary of their corresponding station service transformers SST1 and SST2 via non segregated phase bus. Each station service board shall consist of: Vertical cells containing incoming feeders, outgoing feeders and one (1) bus-tie, draw-out type circuit breaker compartments, one (1) 415/240 V distribution board complete with control, protection and metering; Vertical cells forming a distribution feeder section, those cells consisting of compartments housing molded case circuit breakers. Each cubicle shall be divided into sections, or compartments, housing the incoming, interconnecting or out going feeder air circuit breaker units and moulded case circuit breaker units respectively. Station service boards and station service transformers will be located in the electrical room on the generator floor. Station service boards will be interconnected through a bus-tie circuit breaker. Station service boards will be equipped with necessary metering instruments, such
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as digital voltmeter and ammeter, CTs, PTs, 220 Vdc circuit breaker controls, and indicating lamps for breaker position and power status. Each station service board will be provided with protection relays and programmable logic controllers to achieve the required automatic changeover logic from station supply to unit supply and vice-versa. The station service board PLCs will interface with the powerhouse auxiliary control unit, which in turn will interface with the Digital Distributed Control System (DCS) Station Services Switch Board will have the following characteristics Description Rated voltage Rated frequency Rated current Rated short circuit with stand current Rating 415 Volts 50 Hz 2500 Amps 50kA rms
15.4.4 Non Segregated Phase Bus Duct Totally enclosed, low impedance, 3 phase, 415 Volts non segregated phase bus duct with internal grounding Aluminium (silver coated) bus way system will be used for connection between the following equipments: Unit auxiliary transformer -1 to Unit auxiliary board -1, Unit auxiliary transformer -2 to Unit auxiliary board -2 Unit auxiliary transformer -3 to Unit auxiliary board -3 Unit auxiliary board - 1 to Station service board -1 Unit auxiliary board - 2 to Station service board -2 Unit auxiliary board - 3 to Station service board -2 Station service transformer -1 to Station service board-1 Station service transformer -2 to Station service board-2
The housing shall be of extruded aluminium to provide maximum protection against corrosion. Bus bar shall be epoxy coated and suitably plated at all joints and contact surfaces. All hardware shall be plated to prevent corrosion.
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Tie bolts shall brace aluminium housing and bus bars to withstand forces generated due to short circuit currents without damage or permanent distortion. The joints shall be so designed as to allow removal of any length without disturbing adjacent lengths. Each bus bar shall be labelled or colour coded to maintain proper phasing. All housing width and depth dimensions shall be identical to straight lengths. The maximum hot spot temperature rise at any point in the bus way at continuous rated load shall not exceed 50 C above a maximum ambient temperature of 40 C in any position. One moulded case circuit breaker of 600A rating to be provided at a suitable location for disconnecting the Bus way system. The circuit breaker shall be manually as well as electrically operated with all standard interlocks, indications and safety features. The bus way system shall have a two hour fire stop barrier. The bus way system shall have the following ratings: Sl no 1 2 3 4 5 6 7 8 9 10 11 12 13 Description Rated voltage ( Volts ) Rated current ( A ) continuous Rated frequency ( Hz) Insulation type Class of insulation Short circuit withstand capability (kA RMS) 1 sec Length of bus way between UAT-1 and UAB-1 (mm approx) Length of bus way between UAT-2 and UAB-2 (mm approx) Length of bus way between UAT-3 and UAB-3 (mm approx) Length of bus way between SST-1 and SSB-1 (mm approx) Length of bus way between SST-2 and SSB-2 (mm approx) Length of bus way between SSB-1 and UAB-1 (mm approx) Length of bus way between SSB-2 and UAB-2 (mm approx) Length of bus way between SSB-2 and UAB-3 (mm approx) Rating 415 2500 50 Epoxy B 50 5900 mm 5900 mm 5900 mm 21500 mm 21500mm 51800mm 33800mm 15800mm
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15.4.5 Distribution board for intake. The 415 V switchgear shall be metal enclosed, free floor standing cubicle for indoor installation. The distribution board shall have two incoming feeder and multiple outgoing feeders for distribution to equipments installed in the Intake and barrage area. Under normal condition the power to intake distribution board will be fed from 11KV switch gear located in pothead yard. A 500KVA, 11KV/415 V step down transformer will be located at the Intake area for feeding this board. In case of failure of supply from power house, the requirement of supply will be met from DG sets. Hinged doors and removable covers shall be provided wherever necessary to allow access to all equipments. The frame of the cubicles shall be sufficiently sturdy and the metal sheeting of sufficient thickness to ensure safe transport, mounting and operation without deformation or bulging. Natural ventilation as required shall be provided. Provision for future expansion of cubicles shall be made in end cubicles. Continuous lifting angle or lifting hooks shall be provided to facilitate the installation of the cubicles. Each cubicle shall be divided into sections, or compartments, housing the incoming, interconnecting or out going feeder MCCB/ breaker units. Sufficient nos. of breakers / MCCB shall be provided to power each equipment individually. Ratings of breakers and MCCB shall be decided during detail engineering stage. 15.4.6 Distribution board for Valve house The 415 V switchgear shall be metal enclosed, free floor standing cubicle for indoor installation. The distribution board shall have one incoming feeder and multiple outgoing feeders for distribution to equipments installed in the valve house and surge shaft area. Under normal condition the power to valve house distribution board will be fed from 11KV switch gear located in pothead yard. A 250KVA, 11KV/415 V step down transformer will be located at the valve house area for feeding this board. Hinged doors and removable covers shall be provided wherever necessary to allow access to all equipments. The frame of the cubicles shall be sufficiently sturdy and the metal sheeting of sufficient thickness to ensure safe transport, mounting and operation without deformation or bulging.
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Natural ventilation as required shall be provided. Provision for future expansion of cubicles shall be made in end cubicles. Continuous lifting angle or lifting hooks shall be provided to facilitate the installation of the cubicles. Each cubicle shall be divided into sections, or compartments, housing the incoming, interconnecting or out going feeder MCCB/ breaker units. Sufficient nos. of breakers / MCCB shall be provided to power each equipment individually. Ratings of breakers and MCCB shall be decided during detail engineering stage. 15.4.7 Distribution board for Colony The 415 V switchgear shall be metal enclosed, free floor standing cubicle for indoor installation. The distribution board shall have one incoming feeder and multiple outgoing breakers for distribution to colony. The power to intake distribution board will be fed from 11KV switch gear located in pothead yard. A 500KVA, 11KV/415 V step down transformer will be located at the valve house area for feeding this board. Hinged doors and removable covers shall be provided wherever necessary to allow access to all equipments. The frame of the cubicles shall be sufficiently sturdy and the metal sheeting of sufficient thickness to ensure safe transport, mounting and operation without deformation or bulging. Natural ventilation as required shall be provided. Provision for future expansion of cubicles shall be made in end cubicles. Continuous lifting angle or lifting hooks shall be provided to facilitate the installation of the cubicles. Each cubicle shall be divided into sections, or compartments, housing the incoming, interconnecting or out going feeder MCCB/ breaker units. Sufficient nos. of breakers / MCCB shall be provided to power each equipment individually. Ratings of breakers and MCCB shall be decided during detail engineering stage. 15.5 Quality control and assurance
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15.6
15.6.1 Design memorandum The Contractor shall submit all the drawings and documents in accordance with requirements stipulated in Section 2.12 Reference drawings and documents of General Technical Specification (GTS). 15.6.2 Drawings and documents The Contractor shall submit all the drawings and documents in accordance with requirements stipulated in Section 2.12 Reference drawings and documents of General Technical Specification (GTS). 15.6.3 Design calculation The Contractor shall submit the design calculation, for review / acceptance including the following: 15.7 Fault level at each board taken in consideration for their design, Load calculation of transformers, Burden on CTs, Temperature rise calculation of transformers, Thermal ability to withstand short circuit. Bus bar rating calculations Delivery, Installation and Commissioning
Requirements. The supplier shall arrange personnel to oversee proper storage of equipment at site, their transhipment to powerhouse, installation and commissioning. The packaging and storage of electronic and electrical equipment shall be strictly in accordance with internationally accepted standards. 15.8 Spare Parts
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Recommended spare parts shall be supplied in accordance to clause 2.36 Spare Parts and tools of General Technical Requirements. Specified spare parts to be supplied under this section are as follows: Sl.no 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 15.9 Description Air circuit breakers MCCB Current transformer Supporting insulator Bushing Arcing chamber assemblies for circuit breaker Quantity 1 no each type used 1 no each type used 1 no each type used 2 no each type used 2 no each type used 2 no each type used
Main contacts for three poles, with spring, bolts, 1 set for each breaker nuts etc. for circuit breaker Primary isolating contacts Coils for tripping and closing Complete motor drives Winding temperature protection relay 1 set 1 no each type used 1 no each type used 1 no each type used
Overload and instantaneous trip mechanism for 1 no each type used circuit breakers Indication lamps Fuses Control and instrumentation switches Indicating instruments 11 kV, terminal bushing 415 V, terminal bushing 4 nos Under voltage relays Special tools 10% of the quantity used 10% of the quantity used 10% of the quantity used 1 no each type used 2 nos 2 nos 1 no.
The Contractor shall propose the list of special tools and testing instrument including their make and detailed specification as recommended by manufacturer(s), to be accepted by the Owner. One (1) hand lever or crank for manual closing of the electrically operated breakers shall be provided. 15.10 Testing The Contractor shall follow the Inspection and testing requirements in Quality assurance clause 2.31 Factory inspection and testing of General Technical
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Specifications and section 17 and 18 of document Quality assurance and testing specifications.
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16. 16.1
STATION DC SUPPLY SYSTEM Scope of Work
Scope of work under this section covers the provision of labour, tools, plants, materials and performance of work necessary for the design, manufacture, quality assurance, quality control, shop assembly, shop testing, delivery at site, site storage and preservation, installation, commissioning, performance testing, acceptance testing, training of Owners personnel, handing over to Owner and guarantee for one year of DC system as per the specifications hereunder, complete with all auxiliaries, accessories, spare parts and warranting a trouble free safe operation of the installation. The scope of work shall be a comprehensive functional system covering all supply and services including but not be limited to following: a) b) c) d) e) f) g) h) i) j) k) l) m) n) o) Two nos. (2) 220 Volts , 1600 AH lead acid / Ni-Cd battery banks for Power House One no. (1) 48 Volts, 200AH lead acid / Ni-Cd battery bank for Power House One no. (1) 48 Volts , 100 AH lead acid / Ni-Cd battery bank for Valve house One no.(1) 48 V, 150 AH lead acid / Ni-Cd battery bank for Intake Two nos. (2) Battery charger for 220 volts batteries for Power House One no. (1) Battery charger for 48 volts batteries for Power House One no. (1) Battery charger for 48 volts batteries for Valve house One no. (1) Battery charger for 48 volts batteries for Intake One no. (1) Dc distribution board for 220Vdc system for Power House One no. (1) DC distribution board for 48 Vdc system for Power House One no. (1) DC distribution board for 48 Vdc system for Valve house One no. (1) DC distribution board for 48 Vdc system for Intake UPS for control and monitoring system; One set of spare parts; One set of special tools.
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The equipment will be installed in the power house cavern situated at approximately 2000 m above sea level hence the nominal characteristics of the system should be de-rated due to high altitude. 16.2 Rating and design requirements
The power house DC system shall be supplied from the station service boards. The control and protection circuits, emergency lighting and inverters in the power house shall be supplied from the 220 Vdc systems. The 48 Vdc systems and its corresponding charger will be located inside the power house along with 220 V battery system. The UPS system will convert 220V station DC to 230 V, 50 Hz AC for powering the SCADA system in the event of AC failure. 16.2.1 Batteries Individual lead acid battery cell shall have removable top cover and a float to show the electrolyte level in the battery. Polarity of the battery terminal shall be engraved. Batteries shall be arranged in two levels. The cells should be easily accessible for periodic check (specific gravity of the acid, cell voltage, topping up etc.) can be performed with ease. 220 V dc Battery bank will have the following characteristics Description 220 volts battery bank Number of battery bank Number of cells in each battery bank Nominal cell voltage Cell voltage at equalizing charge Nominal end cell voltage Rating Lead acid type / Ni-Cd 2 ( Two) 110 2 Volts 2.33 Volts 1.85 V at 10 hour rate
Minimum Ampere hour capacity of each battery 1600 AH bank ( 8 hour discharge rate to 1.85 Vat 25C) 48 V DC battery bank will have the following characteristics Description 48 volts battery bank Number of battery bank
Rating Lead acid type 1 ( One)

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Description Number of cells in each battery bank Nominal cell voltage Cell voltage at equalizing charge Nominal end cell voltage Minimum Ampere hour capacity of each battery bank ( 8 hour discharge rate to 1.85 Vat 25C) 16.2.2 Battery chargers
Rating 24 2 Volts 2.33 Volts 1.85 at 10 hour rate 200 AH
The chargers shall be constant voltage type with current limiting devices. Each battery charger will have an input of 415 volts, 3 phases, 50 Hz. They will have the capacity to supply the total constant dc load, and float / equalize charge the 220 V lead acid batteries. Each charger will be equipped with standard metering and protection equipment, input circuit breaker, rectifier and controller. The charger will interface with the distributed control system only to indicate local alarms. The 48 V chargers shall have an input of 415 V, 3 phase, 50 Hz and shall have capacity to supply the total constant dc load, and float / equalize charge the 48 volts lead - acid battery. 220 V dc Battery chargers will have the following characteristics Rating 415 V 10% , 3 , 50 Hz 220 Volts adjustable 1% < 2 % RMS
Description AC Power supply Nominal DC output Voltage regulation ( From no load to full load) Ripple of out put voltage ( peak to peak )
48 V dc Battery charger will have the following characteristics: Rating 415 V 10% , 3 , 50 Hz 48 Volts adjustable 1% < 2 % RMS
Description AC Power supply Nominal DC output Voltage regulation ( From no load to full load) Ripple of out put voltage ( peak to peak)
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16.2.3 DC Distribution Board One split 220 V dc distribution board with two incoming circuit breakers shall be connected to the stationary batteries and chargers. A tie breaker shall connect the two split bus bars of the distribution board. Both incoming and bus-tie circuit breakers shall be electrically interlocked, thus each bus can be fed from their respective batteries and transfer of loads can be accomplished. The distribution board shall be complete with outgoing moulded case feeder circuit breakers, instruments, relays and other accessories. 16.2.4 Un interrupted Power Supply A UPS / Inverter will be used to supply the essential power to SCADA system. It shall convert 220 volts DC to 240 V AC, 1 phase, 50 Hz. UPS system will have the following characteristics: Description Rated capacity Nominal input voltage ( dc) Rated output voltage (ac ) Rated frequency of output Voltage regulation Wave form Rating 10 KVA( minimum) at cos 0.8 lag 220 V dc 10 % 1 , 240V 50 Hz 2% Sine wave with maximum 5 % THD at linear load Sine wave with maximum 7 % THD at non linear load Overload capacity for 1 sec Overload capacity for 1 min 2 times rated current 1.5 times rated current
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16.3
Design considerations
16.3.1 Specific Codes and Standards Electrical equipment shall be designed and tested according to the latest relevant standards including amendments, or complementary standards mentioned in this document, shall be applied, in particular to the following: ISO 9001 IEEE Std 485 IEC 60146 IEC 60439 Quality Systems Model for Quality Assurance in Design, development, Production, Installation and Servicing. IEEE recommended practice for sizing Lead Acid batteries for stationary applications Semiconductor converters Low voltage switchgear and control assemblies.
16.3.2 Performance Guarantee The DC system along with all auxiliaries and accessories shall be capable of performing intended duties under specified conditions. The Contractor shall guarantee the reliability and performance of the individual equipment as well as of the complete system. 16.4 Construction
The charger and distribution panels shall be free standing steel cabinets with degree of protection as per applicable standards. The panels shall be naturally cooled. The charger control system shall be micro processor based with the following features: Soft start Battery path limiting current Automatic Float Boost changeover Operation under reverse input phase sequence Dropper diode regulator in load path for specific application.
The following protections shall be provided Battery under voltage & over voltage. Battery over charged and over load
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16.5
Short circuit Bridge protection fast acting semiconductor fuses Surge suppressors AC&DC circuit protection Fuse fail Earth Fault Detection Quality control and assurance
The Contractor shall submit all the drawings and documents in accordance with requirements stipulated in Section 2.12 Reference drawings and documents of General Technical Specification (GTS). 16.6.1 Design memorandum The Contractor shall submit all the drawings and documents in accordance with requirements stipulated in Section 2.12 Reference drawings and documents of General Technical Specification (GTS). 16.6.2 Drawings and documents The Contractor shall submit all the drawings and documents in accordance with requirements stipulated in Section 2.12 Reference drawings and documents of General Technical Specification (GTS). 16.6.3 Design calculation The Contractor shall submit the design calculation, for review / acceptance including the following:
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Calculations of the DC power consumption during standstill of the generator units, during start, operation and shut-down of one generator unit, taking into consideration that the floating charge voltage of cell is maintained,
16.7
Calculations for capacity of the batteries, Calculations for ratings/ capacities of the battery chargers. Delivery, Installation and Commissioning
Recommended spare parts shall be supplied in accordance to clause 2.36 Spare Parts and tools of General Technical Requirements. Specified spare parts to be supplied under this section are as follows: Sl no 1 1.1 1.2 1.3 1.4 2 2.1 2.2 2.3 2.4 Description Batteries Battery cells Vent plugs/ caps/ connectors/ hardware Inter cell connectors Electrolyte Distribution boards Circuit breaker Indicating lamps Control switch and supervision relays Voltmeter 1 no of each type used 10% of each type used 1 no. 1 no.
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Quantity Four (4) nos. for 220 V system and Four (4) nos. for 48 V system Complete set for 5% Batteries of 220 V and 2% for 48 Volts Complete set for 5% Batteries of 220 V and 2% for 48 Volts 10% of the total quantity used
Volume 3B(PTS) Quantity 2 nos each type used 2 nos each type used 2 sets of each type used 2 sets of each type used. 20 % of each type used 2 nos of each type used 2 sets 4 sets of each type used 4 nos of each type used 2 nos
Sl no 3 3.1 3.2 3.3 3.4 3.5 4 4.1 4.2 4.3 4.4 4.5 16.9
Description Battery charger Ammeters and voltmeters Shunt resistor Diode / thyristor module Printed circuit cards Semi Conducting fuses UPS MCCB Thyristor Bridge Printed circuit cards Circuit breaker and auxiliary contact Cooling fan Special tools
The Contractor shall propose the list of special tools and testing instrument including their make and detailed specification as recommended by manufacturer(s), to be accepted by the Owner. The proposed list of special tools must include the following in addition to tools recommended by manufacturer(s): Two (2) nos. of lifting device for battery cells of each type, Six (6) nos. hydrometer, Two (2) cell testing voltmeter. One (1) set of acid resistant Hand gloves, Apron and Gum boots.
16.10 Inspection and Testing The Contractor shall follow the Inspection and testing requirements in Quality assurance clause 2.31 Factory inspection and testing of General Technical Specifications and section 13 of document Quality assurance and testing specification The equipment should have been subjected to the following type tests: Surge withstand capability test,
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Short circuit test on transformers for dynamic stability, Heat run test at 50.C ambient, Radio frequency interference test, Environment and soak test on PCBs, Vibration test of PCB racks / panels, Degree of protection tests upto IP5X & IPX2,
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17. 17.1
DIESEL GENERATING SET Scope of Work
Scope of work under this section covers the provision of labour, tools, plants, materials and performance of work necessary for the design, manufacture, quality assurance, quality control, shop assembly, shop testing, delivery at site, site storage and preservation, installation, commissioning, performance testing, acceptance testing, training of Owners personnel, handing over to Owner and guarantee for one year of DG sets as per the specifications hereunder, each complete with all auxiliaries, accessories, spare parts and warranting a trouble free safe operation of the installation. The scope of work shall be a comprehensive functional system covering all supply and services including but not be limited to following: a) Two (2) sets of 910 KVA, 0.85 pf, 415V, 3 - phase, 50 Hz, 1500 rpm, class F insulation category DG set for power house emergency supply requirement. b) Two (2) sets of 320 KVA, 0.85 pf, 415V, 3 - phase, 50 Hz, 1500 rpm, class F insulation category DG set for barrage site emergency supply requirements. c) One set of 250 KVA, 0.85 pf, 415V, 3 - phase, 50 Hz, 1500 rpm, class F insulation category DG set for Butterfly valve supply requirement. d) The diesel engine will be water cooled, turbo charged with an overload capacity of 10% for one hour in any 12 hours of continuous operation. Each diesel generator shall be equipped with following standard accessories:Exciter with automatic voltage regulator; Cooling system; Lubricating system; Fuel tanks and fuel system including fuel transferring pump, piping, valves, fuel level indication / alarm / trip etc.; Air intake system; Air exhaust system; Governing system; Starting system (automatic main failure starting system with panels);
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Set of batteries and battery charger; Auto and manual synchronizing panel; Stopping system; Instrument panel; Safety control trip; Automatic transfer system; Other accessories to complete the system; Coordination and provision of necessary contacts and / or ports for integration with plant SCADA system.
e) f)
One set of spares One set of special tools.
Any other item(s) not mentioned specifically but necessary for the satisfactory completion of scope of work defined above, as per accepted standard(s) / best international practices. 17.2 Rating and design requirements.
The installation being at an altitude of 2500 m, the standard voltage and current rating of the DG set will be derated accordingly. 17.2.1 Ratings DG set for Power house Type Rated Power ( KVA ) No. of units Rated generating voltage ( Volts AC ) Rated frequency ( Hz ) Power factor ( lagging ) No of Phases Speed of rotation ( rpm) Class of insulation Overload rating
Diesel, four stroke, sound proof 910 2 415V 50 0.85 3 1500 F In accordance with DIN 6270 (Internal
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Altitude of installation Cooling system Lubrication type Fuel supply System Electrical System Starting
Above 2500 meters Radiator type Forced feed Fuel supply pump As per IEC 60364 -3 Electrical installation of buildings- Assessment of general characteristics Electric starter, supplied by own batteries should be capable of proving sufficient current to carry out three successive start ups
DG set for Barrage site Type Rated Power ( KVA ) No. of units Rated generating voltage ( Volts AC ) Rated frequency ( Hz ) Power factor ( lagging ) No of Phases Speed of rotation ( rpm) Class of insulation Overload rating Altitude of installation Cooling system Lubrication type Fuel supply System Electrical System Starting Diesel, four stroke, sound proof 320 2 415V 50 0.85 3 1500 F In accordance with DIN 6270 (Internal Combustion Engines, Definition of output) Above 2500 meters Radiator type Forced feed Fuel supply pump As per IEC 60364 -3 Electrical installation of buildings- Assessment of general characteristics Electric starter, supplied by own batteries should be capable of proving sufficient current to carry out three successive start ups
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DG set for Butterfly valve chmaber Type Rated Power ( KVA ) No. of units Rated generating voltage ( Volts AC ) Rated frequency ( Hz ) Power factor ( lagging ) No of Phases Speed of rotation ( rpm) Class of insulation Overload rating Altitude of installation Cooling system Lubrication type Fuel supply System Electrical System Starting Diesel, four stroke, sound proof 250 1 415V 50 0.85 3 1500 F In accordance with DIN 6270 (Internal Combustion Engines, Definition of output) Above 2500 meters Radiator type Forced feed Fuel supply pump As per IEC 60364 -3 Electrical installation of buildings- Assessment of general characteristics Electric starter, supplied by own batteries should be capable of proving sufficient current to carry out three successive start ups
17.3
17.3.1 Specific Codes and Standards Electrical equipment shall be designed and tested according to the latest relevant standards including amendments, or complementary standards mentioned in this document, shall be applied, in particular to the following: ISO9001 Quality Systems- Model for Quality Assurance in Design, Development, Production , Installation and Servicing Instrument Transformers Short-circuit currents in 3 -phase AC systems
IEC 60044 IEC 60909
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IEC 60865 IEC 8084
Short- circuit currents- calculation of effects Specifications for interconnecting bus-bars for AC voltage above 1 kV up to and including 36 kV Method of measurement of radio influence voltage (RV) of high voltage apparatus High Voltage test techniques Insulation coordination Insulating bushing for alternating voltages above 1000V Rotating electrical machines Electrical installation Characteristics. of buildingsassessment of general
NEMA 107
IEC 60060 IEC 60071 IEC 60137 IEC 60034 IEC 60364-3
BS5514 IS 8183 Din 6270 IEC 69529 AWS D11
Reciprocating internal combustion engines Bonded Mineral wool Internal combustion engines definition of output Degree of protection provided by enclosures ( IP Code ) Structural welding code.
17.3.2 Performance Guarantee The DG sets along with all auxiliaries and accessories shall be capable of performing intended duties under specified conditions. The Contractor shall guarantee the reliability and performance of the individual equipment as well as of the complete system. 17.4 Construction
Diesel Generator The Generator shall be brush-less alternator, directly flanged to the engine, with closed damper cage and a reactive current compensator. The generator shall be capable of delivering continuously at full load, rated frequency and power factor and at any voltage
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between 105% and 95% of rated voltage without exceeding the maximum allowable temperature rise. It shall also be capable of operating continuously with 20% unbalance load. Suitable lifting lugs shall be provided on each diesel assembly. Governor Each DG set shall be provided with appropriate governor to maintain the speed within the value stipulated in appropriate codes. The governor shall have drooping characteristic to ensure proper load sharing. It should be possible to control the speed to facilitate the parallel operation and for this purpose speed raise / lower control switch shall be provided on the control panel. The governing system shall be complete with devices and shall be compatible with auto synchronizer for parallel operation. A mechanical over speed trip mechanism shall be provided to automatically shut off the fuel supply in case the engine speed reaches 110% of rated speed. The governor shall also be capable of feeding isolated load at required frequency. Excitation System Each DG set shall be provided with excitation system capable of meeting the full load and overload requirement of the alternator. The excitation system shall have over current limiters and field discharge arrangements. Automatic voltage regulator The DG set shall be provided with an automatic voltage regulator. The voltage regulator shall have regulation capability of 0.5% at all loads from no load to full load and power factor 0.85 lagging to unity. The AVR shall be panel mounted and a knob shall be provided to raise / lower voltage for synchronization and should be compatible with auto synchronizer for parallel operation. Automatic starting The diesel generators for Power house will be connected to the 11 kV switchgear located in the pothead yard through a 415V/11KV step up transformer and 11 kV XLPE cables. Automatic starting of the diesel generator shall be through a starting signal from the auxiliary control system after ensuring necessary interlocks in case of Mains power outage.
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Automatic Shut down The DG set shall shut down automatically under the following conditions: Low voltage Low frequency Over speed High water temperature Low radiator water level Low oil pressure High oil temperature Low fuel level Reverse power
Dehumidification arrangement The alternator and exciter shall be provided with suitable space heaters to prevent accumulation of moisture in the insulation system of the equipment. The space heater circuit will be interlocked so that space heaters switch ON only when the system is at stand still and switch OFF when the system starts to rotate. The heaters will be thermostatically controlled so as to maintain the temperature at least 15C above ambient. Instrument Panel Instrument panel shall contain the following instruments; Oil pressure gauge; Oil temperature gauge Water temperature gauge
Auxiliary equipment The following auxiliary equipment shall be included in the supply of the DG set. The generating set shall be housed inside a high quality acoustic enclosure of modular construction.
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A high quality insulating material in accordance with relevant IS 8183 or equivalent IEC code for maximum sound absorption.
The lubricating oil system shall be provided with suitable oil filters and oil coolers. The oil coolers shall be water cooled.
A high efficiency silencer along with associated piping etc Starting system complete with heavy duty lead acid batteries, battery charger, starter motor, controls, and connecting cables;
Fuel system consisting of a main fuel tank of adequate capacity (100 hours running of both DG sets) and individual fuel tanks for each DG set. The main tank shall be located at suitable location outside the DG room and the individual fuel tanks shall be located near respective set inside the DG room. Both tanks shall include all fittings, fuel fill points, contents indicators, breather, filters, all necessary valves, pipes and fittings.
An electric fuel pump to transfer from main tank to individual tanks. In addition, a hand operated fuel transfer pump shall also be provided scope of supply. The system shall be complete with fire trap valve and isolating valve, low level alarm device for main tank and individual tanks, over filling safety device etc.
Control, protection and alarm annunciation panel The DG set shall have a floor mounted control panel housing control switches, auxiliary relays, control and protection relays, Start / stop push buttons, terminal strips etc. The following equipments will be accommodated in the panel: Ammeter for battery charging current; Voltmeter for DC system; Voltmeter with selector switch for measuring phase voltage; Ammeter for each phase; Frequency meter; KW meter; KWH meter and Running hour meter; All necessary control and supervisory control equipment for automatic starting of the system;
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All protection relays necessary for the system.
A common audible alarm shall be incorporated in the control panel to operate in the event of a fault. Each alarm shall be identified by its own flag or light. The following alarms will be displayed: Breaker trip; Low fuel level; Over frequency; Over current; Low lubricating oil pressure; Generator over voltage; Generator under voltage; Generator under frequency; Generator winding temperature high.
Controls The DG set controls shall be able to operate system in the following modes: Off Manual \ Test Automatic
The above modes of operation can be selected through a 3 position selector switch mounted on the DG set local control panel. Off mode: Manual mode: In off mode the DG set shuts down immediately if running in any mode. The Off mode over rides all other commands. In manual mode of operation the DG set can be started by pushing the start button. Switching on of excitation system is done manually. Once switched ON the excitation system controls the generator voltage automatically. Loading of the DG set is done manually. The DG set can be switched off by pushing the stop button. In auto mode the systems starts / stops automatically after receiving command from station centralised control system.
Auto mode:
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The start command to DG set will be initiated by the AC system PLC controller. The synchronizing logic and loading commands will be part of the DG PLC control. 17.5 Quality control and assurance
17.6.1 Drawings and documents The Contractor shall submit all the drawings and documents in accordance with requirements stipulated in Section 2.12 Reference drawings and documents of General Technical Specification (GTS). 17.6.2 Design calculation The Contractor shall submit the design calculation for review / acceptance the following: Calculations for selecting the engine capacity based on the black start of the generating unit, 17.7 Automatic mode starting / stopping logics. Delivery, Installation and Commissioning
Requirements. The supplier shall arrange personnel to oversee proper storage of equipment at site, their transhipment to powerhouse, installation and commissioning. The packaging and storage of electronic and electrical equipment shall be strictly in accordance with internationally accepted standards.
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17.8
Spare Parts
17.8.1 Recommended spare Parts Recommended spare parts shall be supplied in accordance to clause 2.36 Spare Parts and tools of General Technical Requirements. 17.8.2 Specified spare parts Following specified spare parts shall be supplied: Sl no 1 2 3 4 5 6 7 8 9 10 11 12 17.9 Description Engine Lubrication Oil filter Fuel filter Nozzle Complete set of gaskets Complete set of belts Air filter element Generator Stop relay Pressure switch Temperature switch Controls Fuses of each type Indicating lamps Main electronic card Special Tools 4 sets 10% of each colour used 1 set 1 no 1 no. 1 no. 4 nos 4 nos 2 nos 2 sets 1 set 4 nos Quantity
The Contractor shall propose the list of special tools and testing instrument including their make and detailed specification as recommended by manufacturer(s), to be accepted by the Owner. The proposed list of special tools must include the following in addition to tools recommended by manufacturer(s): Sl no Description Quantity
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Sl no 1 2 3 4
Description Set of D spanners ( assorted sizes)
Quantity 2 sets
Box Spanner ( assorted sizes) set complete with 2 sets attachment etc. Screw driver set ( assorted sizes ) 2 sets Other general tools ( Pliers, nose pliers, Allen 2 sets keys etc)
17.10 Testing 17.10.1 Field tests
After installation of equipment and prior to operation of DG sets, following tests shall be performed; Meggar test of insulation between windings, between each winging and ground and between control circuit live parts and ground. Resistance measuring of each winding Phase sequence test Measurement of open circuit characteristics Measurement of short circuit characteristics Load test for two hours at rated capacity Starting time test Functional tests of all control circuits Functional tests of all safety devices Voltage regulation test Vibration test
The contractor shall propose to perform additional tests if felt necessary. The cost of performing such tests shall be born by the contractor. The contractor shall prepare written documents of all tests in a form approved by the owner and shall be submitted to the engineer of owner for review and approval.
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17.10.2
Shop Testing
Each DG set shall be loaded tested in the factory before despatch. All systems shall be thoroughly checked for correct operation. All faults, control functions and site load conditions shall be simulated and checked. Dielectric test of generator shall be performed according to IEC: 60034 1. All test sheets shall be provided to the owner for review and approval
The contractor shall submit a comprehensive maintenance and test schedule for the complete diesel generator set which will best serve the purpose of standby unit on long time basis.
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18. 18.1
ILLUMINATION SYSTEM Scope of Work
Scope of work under this section covers the provision of labour, tools, plants, materials and performance of work necessary for the design, manufacture, quality assurance, quality control, shop assembly, shop testing, delivery at site, site storage and preservation, installation, commissioning, performance testing, acceptance testing, training of Owners personnel, handing over to Owner and guarantee for one year of illumination system, as per the specifications hereunder, each complete with all auxiliaries, accessories, spare parts and warranting a trouble free safe operation of the installation. The scope of work shall be a comprehensive functional system covering all supply and services including but not be limited to following: a) Normal lighting system
Normal lighting system shall include indoor and outdoor lighting of complete power house including MAT, Cable cum ventilation tunnel, Adit to pressure shaft, complete barrage , pothead yard, Valve house, Adit to BFV chamber, , surge shaft, and adjoining areas, comprising following major components: Lighting cabinets / distribution boards; Lighting equipment, including the light fittings, lighting facia/panels, Warning/direction sign boards; Power sockets of 5 A; Control points, including: Push-buttons or switches; Dimmers, smart switches / sensors; Indicator lights on the main control panel indicating status of illumination circuits. Street light poles, masts for outdoor lighting. All cabling and wiring including conduits, racks, ducts, channels or any other media of cable runs and associated accessories / fixtures/ fasteners for normal Lighting system.
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b)
Emergency lighting system Emergency lighting system shall comprise of: Emergency lighting boards; Lighting equipment, including the light fittings; All cabling and wiring including conduits, racks, ducts, channels or any other media of cable runs and associated accessories / fixtures/ fasteners for emergency lighting system.
c)
Power supply network Maintenance power supply network shall comprise of: The power outlets circuits and individual sockets of single phase 5A /15A ; Fixed wall mounted sockets of single-phase 16 / 32A; Fixed wall mounted sockets of three-phase 63 A; All cabling and wiring including conduits, racks, ducts, channels or any other media of cable runs and associated accessories / fixtures/ fasteners for power supply network.
d)
Miscellaneous items
Illumination panels as per requirement complete with cubicles, bus-bar system, circuit breakers, instrument transformers, instruments cabling and wiring and complete with all other accessories; One (1) no. wheel mounted platforms with ladder for maintenance of overhead lighting system; Coordination and provision of necessary contacts and/or ports for integration with plant SCADA system. e) f) One set of spare parts; One set of special tools.
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18.2
The illumination system for powerhouse complex shall be supplied from the powerhouse illumination boards, which shall be connected to station service board (SSB). Lighting and service power supply network shall cover all areas of power house. Major areas are listed below: a) Area for Indoor lighting Power House block from 2293.25 m to EL 2306.90 m including service area and service bay; Control block from EL 2293.25 m to EL 2320.00 m; GIS-cum-transformer cavern including handling area; Cable-cum-ventilation tunnel; DG room, office, reception hall and facilities in pothead yard area; Conference room, record room, library, offices and facilities; (Complete control Block) GIB duct gallery; Bus duct gallery; Generator and Turbine pit; Staircases, lift wells, toilets, kitchens, pantry and other utility areas; Entrance gate and facilities; Main access tunnel to power house and transformer hall; Construction adit to GIS crown, Power house, Pressure shaft ; Approach adit to transformer cavern. Control cable gallery Butterfly valve chamber Main access Adit to Butterfly valve Surge shaft top cavern and
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b)
Barrage control room and DG room
Area for Outdoor lighting Main approach road to power house upto 500 m; Outdoor pothead yard areas and its approach road upto 500 m; Outlet area of tail race tunnel; Valve house approach road upto 300m Surge shaft approach road upto 300m Intake and surrounding areas. Power house colony Barrage colony
The entire lighting network of the power house shall be supplied from two different boards, each board supplying half of the power house lighting load. The installation being at an altitude of 2000 m, the standard voltage and current rating of the electrical items will be derated accordingly. Lighting will be designed to provide different illumination levels in various facilities of the power stations. The illumination system will comprise of the following: Indoor lighting system. Outdoor lighting system. Emergency lighting system.
In general, the type of lighting fixtures in different operating areas to be used will be as follows : High bay high pressure sodium or metal halide. Low bay metal halide or fluorescent. Electrical rooms fluorescent surface mounted and pendant. Control rooms, Office areas fluorescent as required. Maintenance shops fluorescent as required;
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Electrical room, Battery/Charger room fluorescent as required; Road lighting high pressure sodium; Parking areas high pressure sodium;
18.2.1 Illumination levels Lighting will be designed to provide the following illumination levels in various facilities of the plant, as indicated below. The illumination levels are in conformance with the values in the IES (Illuminating Engineering Society) lighting recommendations. Area Machine Hall El. 2292.50 Valve Floor Machine Hall El. 2298.10- (Turbine Floor) Machine Hall El. 2301.90 - (Generator Floor) Machine Hall El. 2306.90 - (Main Operating Floor) Machine Hall (Stairs, Passage etc.) Control Block (Stairs El. 2320 m to 2292.50 m) Control Block (Toilets) Control Block (Pantry) Control Block (Corridor at all area) Control Block - Canteen Control Block - Electrical Workshop Control Block - Mechanical Workshop Control Block - Compressor Room Control Block - 415 V Switchgear room Control Block - Store Control Block - Conference Room Control Block - Offices/Lobby Control Block - Battery Room Control Block - PLCC/Charger Room Control Block - Control Room Control Block cooling water floor Illumination Levels (Lux) 150 150 150 200 150 100 150 150 150 200 200 200 150 200 150 300 300 150 300 400 300
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Control Block - AC Room) Control Block - Ventilation Floor GIS Hall Transformer Hall Interconnecting Gallery PH / Tr. Hall Control Cable Gallery 11 kV Isolated Phase Bus-Duct Tunnels Cable cum Ventilation Tunnel Main Access Adit Construction Adit to PH/ G.I.S hall Surge shaft Adit Outdoor Potyard D.G. Room Butterfly Valve Chamber Butterfly Valve Adit Barrage Control Room Barrage D.G.Room Barrage Area Lighting Road , Yards, Parking Lighting 18.2.2 Emergency lighting level
150 100 175 200 100 100 100 50 40 40 40 300 150 150 40 300 150 20 20
In case of station supply failure, an emergency lighting system will be provided. The emergency lighting will be monitored by a controller and operated by the 220 Vdc systems. It will provide essential lighting in the Powerhouse, Transformer & GIS Hall, and access tunnels. 18.3 Design Considerations
18.3.1 Specific codes and Standards IEC 60598 IEC 60309 Luminaries Plugs, socket outlets and couplers for industrial requirements
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IS 6665 IS 10322 IS 3646 ISO 9001
Code of practice for industrial lighting Specification for Luminaries Code of practice for interior illumination Quality Systems Model for Quality Assurance in Design, Development, Production, Installation and Servicing.
18.3.2 Performance Guarantee The illumination system along with all auxiliaries and accessories shall be capable of performing intended duties under specified conditions. The Contractor shall guarantee the reliability and performance of the individual equipment as well as of the complete system. The Contractor shall guarantee the Lux levels in various areas as specified above. 18.4 Construction
Power supply network Control rooms, offices, facilities, utilities and all cabinets and cubicles shall be equipped with power outlet circuits. These circuits shall comprise of: Sockets for normal power supply, Sockets for normal (UPS) power supply.
Each office rooms shall have at least two power sockets and all other areas shall have at least one socket for every five meter. All rooms containing equipment requiring maintenance as well as all repair workshops shall be equipped with a maintenance power supply network to supply tools. This network shall comprise of: Fixed wall mounted sockets of single phase 16/32A, Fixed wall mounted sockets of three phase 63A, Portable socket cubicles supplied from a network of sockets distributed throughout the various areas. Leakage prone areas i.e. drainage gallery, Turbine pit, runner removal gallery etc shall be provided with fixed wall mounted sockets of single-phase 24V, 32A supply for inspection
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lamps. Supply distribution panels having step down transformer of suitable rating and required nos. of MCCBs shall be provided to feed the 24V power supply network. The three-phase power outlet sockets shall consist of triple pole neutral and protective earth. Number of power outlets shall be at least one for every fifteen meter in each area. Quantities, type and arrangement shall be decided according to the requirement and shall be approved by the Owner / Engineer. Necessary breakers/switches, protective and indicating devices shall be provided for each socket/cubicle. Distribution boards The boards shall be of wall-mounted/panel type and shall be suitably located. The boards shall be made of sheet steel not less than 3 mm thick and provided with front hinged cover for further enabling the board to be unscrewed for inspection of wiring in the board. Boards shall be waterproof and shall be provided with glands or adapters to receive a screwed conduit. Switchboards The switchboards shall be of heavy duty and modular type and shall be located 1.5 meters above the floors. All the switches shall be of piano type and shall have silver cadmium contacts. Multiple plug power sockets shall be capable of taking at least one 3-pin plug and one 2-pin plug simultaneously. Each type of power socket shall have elliptical spring loaded contacts. Cables The cables shall be of at least 1000 V grade, PVC insulated. All single core cables shall be of copper flexible conductor. Cables from distribution boards to switch boards and to light fixtures, single phase AC sockets shall be of copper flexible conductor. Minimum size of copper conductor for single core cable shall be 2.5 mm2. The insulating material of cable shall not deteriorate with age or due to the voltage stresses etc. Each cable coil shall be accompanied by the manufacturers test giving the results of the insulation test. The wiring shall be done in looping back system. No joints shall be made at intermediate points in the given length of the cables.
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Wiring It is proposed to carry out surface wiring for illumination circuits in equipment areas/floors. Concealed/recessed wiring shall be done in control room, offices, reception and any other area requiring aesthetic appeal. Conduits and/or wire ways shall be used for wiring between fixtures and control points. Separate conduits/wire ways shall be used for light, power and communication points. The cables shall be properly terminated by using lugs or other approved arrangement. Lighting accessories Each socket outlet for lighting and power shall be controlled by a switch, which shall be on the live side on the line. The socket outlets shall be of 3 pin type to provide earth connection to each outlet. The power socket outlets shall be 16A / 32A single-phase and 63A three-phase as per requirement to be approved by the Owner. Multi plugs of 16A, 32A and 63A shall be of metal clad type. Conduits Conduits shall be of heavy duty type, hot dip galvanised steel conforming to IS 9537 or fibre glass reinforced epoxy conduits which have compressive and impact strength that of galvanised conduits. In corrosive areas galvanised conduits shall have additional suitable epoxy coating. The conduits shall be supplied in lengths of 4 m to 6 m. The conduit jointing and junction shall be weatherproof and waterproof to prevent ingress of moisture. Additional precautions shall be taken in areas which are humid, corrosive and prone to dripping and/or spray of water like drainage gallery. All necessary bends in the system shall be done by bending of conduits or by inserting suitable solid or inspection type normal boards, elbows or similar fittings whichever is more suitable. Anchor fasteners shall be used for fixing of conduits, light fixtures etc. wherever required.
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Suitable inspection boxes shall be provided to permit inspection and to facilitate removal of wires if necessary. Earthing The continuous earth shall be run for all the 3 pin sockets. The neutral will be earthed at distribution transformer and the three phase four wires distribution system shall be connected to the station earthing system at two or more places. Maintenance ladders and platforms Wheel mounted platform with ladder for maintenance of overhead lighting system shall be of collapsible type of height suitable for maintenance of outdoor fixtures. 18.5 Quality control and assurance
18.6.1 Design memorandum The Contractor shall submit all the drawings and documents in accordance with requirements stipulated in Section 2.12 Reference drawings and documents of General Technical Specification (GTS). 18.6.2 Drawings and documents The Contractor shall submit all the drawings and documents in accordance with requirements stipulated in Section 2.12 Reference drawings and documents of General Technical Specification (GTS). These drawings and documents shall include at least the following: Outline, general arrangement and layout plan for illumination system, Cable and conduit routing diagram, Wiring and termination drawings,
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Type of luminaries, fittings, power sockets, switches etc., Drawings for distribution boards, control points etc., Lighting mast, lighting facia/panels details.
18.6.3 Design calculation The Contractor shall submit the design calculation for review / acceptance. Calculations for the illumination levels of the different areas with respect to installation plan, 18.7 Cable and conduit sizing. Delivery, Installation and Commissioning
Recommended spare parts shall be supplied in accordance to clause 2.36 Spare Parts and tools of General Technical Requirements. Specified spare parts to be supplied under this section are as follows: Sl no 1 2 3 4 5 Description Quantity
Multiple plug power sockets suitable for 5% of installed quantity 63A/32A / 16A /5 A Multi plug suitable for 63A/32A/16A /5A 5% of installed quantity High-pressure mercury vapour lamps 5 % of installed quantity complete with all accessories and fittings High pressure sodium vapour lamps 5 % of installed quantity complete with all accessories and fittings Fluorescent lamps complete with all 5 % of installed quantity
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Sl no 6 7
Description accessories and fittings
DC lamps complete with all accessories 5 % of installed quantity and fittings All type of switches, contactors, terminal 5 % of installed quantity blocks Special Tools
18.9
The Contractor shall propose the list of special tools and testing instrument including their make and detailed specification as recommended by manufacturer(s), to be accepted by the Owner. 18.10 Testing The Contractor shall follow the Inspection and testing requirements in Quality assurance clause 1.17 Factory inspection and testing of General Technical Specifications and also section 27 of document Quality Assurance and Testing Specifications.
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19. 19.1
CABLES AND CABLE TRAYS Scope of Work
Scope of work under this section covers the provision of labour, tools, plants, materials and performance of work necessary for the design, manufacture, quality assurance, quality control, shop assembly, shop testing, delivery at site, site storage and preservation, installation, commissioning, performance testing, acceptance testing, training of Owners personnel, handing over to Owner and guarantee for one year of cabling system as per the specifications hereunder, complete with all auxiliaries, accessories, spare parts and warranting a trouble free safe operation of the installation. The types of cables which will be used at the powerhouse for High voltage, medium voltage and low voltage application, control and protection application, instrumentation and communication application are classified as follows: a) 11 kV, 3-core, copper conductor, XLPE insulated power cables; b) 1100 V grade (Aluminium/copper) multi core power cables ; c) 1100V grade Multicore control and instrumentation cables; d) Fibre optic control / communication, coaxial cables ; e) Cable routing and support systems f) Cable trays, connectors, hardware etc.;
g) Flexible / adjustable cable support system including pre-fabricated Structures fixtures, strut channels, embedment, hardware etc.; h) Cable ducts, conduits, Channel, joints etc. i) j) One set of spare parts; One set of special tools.
19.2.1 11 kV Power Cables 11 kV power cables will be required to interconnect the following:
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Connection between DG step up transformer at pothead-yard to 11kV switchgear Connection between 11 kV switch gear to SST-1 & 2 , Pothead-yard transformer, 4 pole structure to 11 kV switchgear (Incoming supply), 11 kV switchgear to colony 4 pole structure near pot-yard;
Connection between 11 kV switchgear to Butterfly valve chamber Connection between 11 kV switchgear to Barrage
19.2.2 415 V / 230V Power Cables 415 V power cables will be required to connect the following equipments: Power connection to Battery charger, Three phase motors, Heaters, Compressors etc; Connection between UAB-1 and its auxiliaries; Connection between UAB-2 and its auxiliaries; Connection between UAB-3 and its auxiliaries; Incoming supply to Power house illumination. Power supply to all station auxiliaries Power supply to all unit auxiliaries 230V power supply to all unit / station auxiliaries as per requirement
19.2.3 220V DC / 48V DC Power Cables 220 V/ 48V DC power cables will be required to connect the following equipments: 220V DC board to all unit auxiliaries as per requirement 48V DC board to all station auxiliaries as per requirement Connection between UAB-1 and its auxiliaries; Connection between UAB-2 and its auxiliaries; Connection between UAB-3 and its auxiliaries; Incoming supply to Power house illumination. Power supply to all station auxiliaries
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Power supply to all unit auxiliaries
19.2.4 Control, Instrument and Communication Cables Control, instrumentation, coaxial and communication cables will include all cables required for installation of the complete instrumentation, control, protection and communication system in the power house complex including GIS-cum-transformer cavern, Butterfly chamber , Barrage and other area in the vicinity of power house such as fire tank etc. The main criteria governing the design of the power and control cables are as follows: The cables shall be flame retardant low smoke (FRLS) type, designed to withstand all mechanical, electrical and thermal stresses developed under steady-state and transient operating conditions. Control cables shall be of solid /stranded / plain / tinned / armoured / un armoured / shielded /unshielded type depending on their application and requirement. In order to minimize magnetic and electrostatic interference, instrumentation cables shall have twisted pair or triad conductors either individually shielded or having an overall shield. The cables should be suitable for laying on racks, trenches, conduits, trays, buried underground or in open. The following arrangement shall be followed for cable routing: Cables will be laid on perforated cable trays of required type and sizes for support. Cable trays will be supported on steel structures anchored on civil structures. Where several cables per phase are to be employed, a symmetrical phase configuration shall be used to avoid current unbalance between parallel legs of the same phase. Wherever necessary, conduits shall be provided for crossing walls or termination of cable on equipments like pressure gauge, limit switches or other instruments Power and control cables shall be run on different cable trays. Cable trays carrying control, protection and communication cables shall be adequately separated from power cable trays to avoid interference. Suitable sized cable glands shall be provided at terminating ends.
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Suitable indoor / outdoor terminations shall be provided for 11 kV XLPE cables. Low voltage power cables having a minimum cross-sectional area of 16 mm shall be made preferably of stranded aluminium conductors. The cables less than 16 mm will be made with stranded, tinned annealed soft copper.
Conductors for control and instrumentation cables will be of stranded annealed high conductivity copper.
Low voltage power, control and instrumentation cables will be insulated over their entire length with extruded polyvinyl chloride (PVC).
Single and multi core power cables shall be 1100 Volts grade, stranded aluminium conductor, HR PVC insulated , colour coded, laid up, inner sheathed with extruded PVC compound un armoured of sizes ranging from 4 sq mm to 400 sq mm. (Actual requirement will be determined during detail engineering)
19.3
19.3.1 Specific Codes and Standards Electrical equipment shall be designed and tested according to the latest relevant standards including amendments, or complementary standards mentioned in this document, shall be applied, in particular to the following: Standards IEC 61537 IEC 60331 IEC 60332 IS 1554 IS 7098 IS 1255 ISO 9001 IEC 60502-2 Description Cable tray systems and cable ladder systems for cable management Tests for electric cables under fire conditions Test on electric and optical fibre cables under fire conditions Specification for PVC insulated (heavy duty) Electric cables Specification for cross linked polyethylene insulated PVC sheathed cables Code of practice for installation and maintenance of power cables up to and including 33kV rating Quality Systems Model for Quality Assurance in Design, Development, Production, Installation and Servicing. Power cables with extruded insulation and their accessories for rated voltages from 1KV top to 30 kV Part2 : cables for rated voltage from 6KV to 30 kV Power cables with extruded insulation and their accessories for rated voltages from 1KV top to 30 kV Part 4 : test requirements on accessories for cables with rated voltage from 6KV to 30 kV
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IEC 60502-4
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19.3.2 Performance Guarantee The power and control cabling system along with all auxiliaries and accessories shall be capable of performing intended duties under specified conditions. The Contractor shall guarantee the reliability and performance of the individual equipment as well as of the complete system. 19.4 Construction
19.4.1 Control cables Multi core control cables of size 2.5 sq mm to 10 sq mm shall be of 1100 Volts grade, stranded copper conductor, HR PVC insulated, colour coded, laid up, PVC sheathed and unarmoured.( Actual requirement will be determined during detail engineering)
Multi core control cables of size 1.5 Sq mm shall be of 650 V grade, colour coded, annealed high conductivity, stranded copper conductor, insulated with HR-PVC, PVC sheathed and unarmoured ( Actual requirement will be determined during detail engineering)
Multi pair and multi triad control cables shall be 650 V grade, colour coded, annealed high conductivity, stranded copper conductor, insulated with HR-PVC, twisted individual and overall screened with aluminium / copper tape, PVC sheathed. ( Actual requirement will be determined during detail engineering)
Multi core control cables of size 4 sq mm to 10 sq mm shall be 650 V grade, stranded aluminium conductor, colour coded, annealed HR-PVC insulated, laid up, inner sheathed with extruded PVC compound.( Actual requirement will be determined during detail engineering)
19.4.2 Instrument cables Multi pair instrument cables of size 1.5 sq mm shall be of 650/1100 V grade, PVC insulated, unarmoured, pair screened with polyester and Mylar tape along with stranded tinned drain wire. Pairs, triads to be colour coded and numbered. (Actual requirement will be determined during detail engineering)
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19.4.3 11 kV XLPE cables 11 kV XLPE cable shall be of 3 cores, 35 Sq mm, armoured with plain annealed stranded compacted copper conductor. Cores identification shall be with coloured tapes of Red, Yellow and Blue. Each core is to be covered with a semi- conducting layer with a copper tape screen. 19.4.4 Cable accessories Termination kit The termination kits required for 11 kV XLPE cables terminations shall be heat shrinkable type. Any other latest type having proven performance in the field can also be accepted subject to approval of Owner The Contractor shall supply all hardware consumables such as plumbing metal, sealing compound, tapes and other materials required for the making of these terminal connections of various sizes of cables and should leave at least 5% of these items for future use by the Owner. Cable lugs The Contractor shall ensure that no bimetallic action takes place, between the conductor of the cable and the cable-connecting lug by filling the lugs with suitable compound. The lugs shall be of standard quality conforming to IEC / IS and of make approved by the Owner. Cable glands The cable glands shall be made of brass duly electro tinned in order to avoid corrosion and oxidation of the surface. Glands shall provide neat, tight, dust and vermin proof termination. Gland shall be provided with rubber ring to hold the cables firmly when check-nut is slightly tightened. Gland shall be complete with suitable washers etc. Compression type terminals for control wiring These terminals are required for copper conductor of control wiring. They shall be crimped to the conductor while other end will provide flat surface for better connections. The connectors shall be made of Copper electro tinned. Button tape (strap and stud)
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This consists of perforated cable strapping with holes conveniently spaced for assembly and moulded studs. The strapping shall be made of NYLON Grade 220 or other elastic material to give proper performance. The studs shall be made of 'NYLON'. Self adhesive marker Self-adhesive marker in the form of strips of any one character, which can be easily peeled from the backing cards and can be applied on the cable, shall be supplied. The strips shall be waterproof duly marked with special formulated ink with specific thermo-setting adhesive to withstand high temperature. Suitable plastic ring type ferrules marked with engraved indelible ink for control cables and sticker type ferrules for power cables shall be supplied. These shall be marked as per cable schedule such that each core of each cable can be identified easily. Cable Marker / Identifier tag Aluminium strip of adequate size for making tags for labels shall be supplied. Cable trays and support structure The cable trays including accessories like bends, elbows, tees, cross etc. shall be of perforated (long slots) type, for proper ventilation of the cables, made out of 14-gauge mild steel sheet. The trays shall have minimum 50 mm edge height. The cable trays shall be fully galvanized and the Owner reserves the right to test galvanizing as per approved standard in presence of its representative. Stainless steel cable trays shall be provided for humid premises and the area prone to water dripping and spray. Supports, screws and bolts for cable trays shall be made of the same materials as the cable trays they support. Tray support system shall be flexible/adjustable type having pre-fabricated sections and supports that can be assembled and bolted for quick and easy installation. Trays provided in tiers shall have minimum 300 mm spacing between tiers. Ladder type tray with double bends may be used wherever required.
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Fire proofing Cables passing through different fire zones shall be provided with fireproof barriers with the same fire rating as the penetrated walls or partitions. Cable junction boxes Junction box shall be constructed of sheet steel of thickness not less than two (2) mm. Ample wiring space shall be provided at the sides, and back of the enclosure for incoming and outgoing circuits. Removable plates with gaskets shall be fitted at the top and bottom of the box to provide the entry for conduit or cable. The door shall be provided with suitable gasket and fitted with a lock type handle. The door shall be hung on hinges having brass bodies and stainless steel pins. Each cable junction box shall be provided with terminals of adequate rating on the terminal strip of suitable thickness. Terminal blocks Terminal blocks shall be in accordance to clause 2.15.11, Terminal Blocks of General Technical Specification. Cable routing For the main cableways, a system of cable racks and trays as well as cable ducts and trenches shall be provided. The cables for emergency lighting, fire alarm systems, etc., shall be run on separate trays. The 11kV XLPE cables, power and control cables shall be run separately on racks/trays, in cable trenches/cable tunnels and on columns, walls, ceiling and pulled through pipes. The Contractor shall be responsible for carrying out proper dressing of the cables and supply non-magnetic/moulded fibre-glass cable fixing cleats, fasteners and clamps wherever necessary to hold the cables firmly to the trays. Contractor shall take proper care in handling of cables against external damages of any kind. Necessary rollers etc. shall be used while pulling and laying of the cables.
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Cables shall be properly clamped at regular intervals with the help of non-magnetic/moulded fibreglass strip clamps/PVC sleeved clamps, of suitable size. Contractor shall submit typical drawings along with tender giving proposed clamping arrangement and give distance of clamping at bends and in regular run of cables. Cable markers and cable binding Suitable cable markers of Aluminium with punch marks shall be provided and suitably tagged to the cable permanently so that cable could be easily identified. Cable binding/strapping All control cables after glanding shall be neatly routed and bonded with the help of cable straps and studs inside the panel. Complete routing in panel shall be such that it gives a neat appearance. For L.T. Power cables, suitable holding clamps shall be provided in the panel wherever required. The Contractor shall do the cable glanding suitable for each cable size at both ends of termination of each cable. 19.5 Quality control and assurance
19.6.1 Design memorandum The Contractor shall submit all the drawings and documents in accordance with requirements stipulated in Section 2.12 Reference drawings and documents of General Technical Specification (GTS). 19.6.2 Drawings and documents The Contractor shall submit all the drawings and documents in accordance with requirements stipulated in Section 2.12 Reference drawings and documents of General Technical Specification (GTS).
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These drawings and documents shall include at least the following: Outline, general arrangement and layout plan for illumination system, Cable and conduit routing diagram, Wiring and termination drawings, Type of luminaries, fittings, power sockets, switches etc., Drawings for distribution boards, control points etc., Lighting mast, lighting facia/panels details.
19.6.3 Design calculation The Contractor shall submit the design calculation for review / acceptance. Calculation for fault level and short circuit calculation for selecting the cable size, Cable schedule indicating size of cable, type of cable, no. of cores , cross section, origin, destination, length, no of cores spare and ferrule number. 19.7 Interconnection diagram indicating cables interconnecting various equipments. Cable routing diagram Delivery, Installation and Commissioning
Requirements. The supplier shall arrange personnel to oversee proper storage of equipment at site, their transhipment to powerhouse, installation and commissioning. 19.8 Spare Parts
Recommended spare parts shall be supplied in accordance to clause 2.36 Spare Parts and tools of General Technical Requirements. Specified spare parts to be supplied under this section are as follows: All spare parts and accessories shall be identical electrically and mechanically to corresponding parts in the equipment supplied and shall be suitably packed and clearly marked, ready for long term indoor storage.
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One set of spare cable and accessories for five years of normal plant operation: Description 11 kV cable LV power cable of each type Control cables of each type Communication cables of each type Instrument cables of each type Cable termination kit ( outdoor and indoor type) Lugs of each size Coaxial cables Cable glands of each size Junction boxes Terminal strips Cable trays of each size Cable support and hardware 11KV XLPE cable termination kit 19.9 Special Tools Quantity 200 meters 10% of installed quantity 10% of installed quantity 10% of installed quantity 10% of installed quantity 10% of installed quantity 10% of installed quantity 10% of installed quantity 10% of installed quantity 10% of installed quantity 10% of installed quantity 10% of installed quantity 10% of installed quantity 6 nos
The Contractor shall propose the list of special tools and testing instrument including their make and detailed specification as recommended by manufacturer(s), to be accepted by the Owner. One set of following devices and handling tools required for installation and maintenance of cables shall be supplied. Description Hydraulically operated crimping tool Hand operated crimping tool Wire stripper for all sizes of cables Heavy duty Wire cutter for all sizes of cables Quantity 1 set 2 sets 2 sets 2 sets
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19.10 Testing The Contractor shall follow the Inspection and testing requirements in Quality assurance clause 2.31 Factory inspection and testing of General Technical Specifications and also section 16 of document Quality Control and Testing specification
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20. 20.1
ELECTRICAL WORKSHOP Scope of Work
Scope of work under this section covers the provision of labour, tools, plants, materials and performance of work necessary for the design, manufacture, quality assurance, quality control, shop assembly, shop testing, delivery at site, site storage and preservation, installation, commissioning, performance testing, acceptance testing, training of Owners personnel, handing over to Owner and guarantee for one year of electrical workshop equipment as per the specifications hereunder, each complete with all auxiliaries, accessories, spare parts , instruction manual etc and warranting a trouble free safe operation of the installation. The scope of work shall be a comprehensive functional system complete in every respect including but not be limited to following: Sl no 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 1.13 1.14 Description Measuring Devices Insulation tester (Megger) Portable universal bridge Portable digital power measuring instrument Analog and Digital multimeter Phase sequence indicators Portable digital frequency meter Portable temperature measuring instrument Portable sound level measuring instrument Phase shifter Clamp-on volt-ammeters Portable multi channel vibration meter Portable earth resistance measuring devices Portable micro ohm-meter for measuring contact resistance of H.V. equipment DC earth fault locator Digital oscillographic fast recorder with at least 16 (2x8) Analogue channels i.e. i) 4 to 20 mA
10 Nos
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Sl no
Description ii) DC voltage 10 V to + 10V iii) DC voltage 0V to 24V iv) DC Voltage 0 to 500V v) DC Voltage 0 to 200mV : : : : 1 Nos 2 Nos 2 Nos 1 No.
No. of Digital Channels
6 Nos along with accessories
2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 3 3.1 3.2 3.3 3.4 4 4.1 4.2
Testing Devices Primary current injection set Electrical insulation dielectric strength test set; Transformer dc winding resistance measurement test kit; Automatic capacitance and tan kit; Single-phase automatic turns ratio tester; Thermal imaging camera; Frequency response analyser test kit; Instrument Testing and Calibrating Devices Pressure transmitters; Differential pressure transmitter; Sets of tools, screw driver, drills, wrenches and pliers; DC shunt for dc current measurement; General Tools and Devices Crimping machine; Stainless steel silica gel drying oven.
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20.2
Ratings and design requirements
The installation being at an altitude of 2000 m , the standard voltage and current rating of the electrical equipments will be derated accordingly. Calibration certificate for each testing instrument covering entire range should be supplied with the test kit at the time of supply. 20.2.1 DC insulation testers (Megger) Accuracy: 2%,
Range 100K to 100G at Steps of 500V, 1KV, 2.5 kV and 5 kV with locking and non-locking test buttons,
Battery
20.2.2 Portable Universal Bridge Accuracy class: 1 Built in capability for storing, printing and downloading test results Ranges Resistance: 100 m ...10 M Inductivity: 1...100 H Capacity: 10 pF...1 F tan : 0...1 in several steps
Frequency range: 15...1000 Hz
20.2.3 Portable digital power measuring instrument for single and three phase measurements One (1) double W meter, accuracy class 0.2 Three (3) ammeters, accuracy class 0.2 One (1) voltmeter, accuracy class 0.2 One (1) phase sequence indicator Power factor meter (Lead and Lag) Rated power ranges: 0 to 100 kW in several steps
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Rated current ranges: 0 to 100 A in several steps Rated voltage ranges: 0 to 500 V in several steps Frequency range: 15 to 200 Hz.
20.2.4 Digital Multimeter for AC and DC measurements Accuracy: DC: 1% AC: 1.5% Ohm: 1%. Ranges: Voltage: 60 mV...1000 V in several steps Current :1.5 mA...30 A in several steps Resistance: 0...50 k Ohm.
Continuity audible test Diode test, capacitance measurement, frequency measurement Hold display features Overload protection.
20.2.5 Analog Multimeter for AC and DC Accuracy DC: 1% AC: 1.5% Ohm: 1%.
Ranges Voltage : 60 mV 1000 V in several steps, Current : 1.5 mA30 A in several steps, Resistance: 050 k Ohm.
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20.2.6 Phase sequence indicator (Electro- mechanical type) Voltage 100 - 500 Volts Terminals marked with L1,L2,L3 Frequency range 25 to 60 Hz
20.2.7 Portable digital frequency meter Accuracy class Operating voltage Auxiliary supply Frequency Accuracy : : : : : 0.5 650 V AC 63.5 V / 110 V / 240 V AC 10% 40 to 400 Hz 0.5% of f.s.d 2 digits
20.2.8 Portable temperature measuring instrument (contact type) Accuracy Range : : 0.5% reading - 50C to + 210 C
20.2.9 Portable sound level measuring instrument Range Frequency range Phase shifter : : 25 to 140 db in four overlapping zone of 40 to 60 db range 20 Hz to 8 KHz
20.2.10
Output: Voltage 0-110 V AC, Phase angle 0-360 Reference Voltage range 0-250 V AC Reference Current range 0-10 A AC Phase angle measurement 0-360 Clamp-on volt-ammeters
20.2.11
Accuracy class: 1.5 Ranges: 1.2...60 A and 60...600 V in several steps For round conductors up to 30 mm diameter For flat conductors up to 30 x 45 mm.
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20.2.12
Portable multi-channel vibration meter
Frequency range up to 240 Hz Sufficient memory and computer connectivity Complete with all accessories including power supply, case etc Portable earth resistance measuring device
20.2.13
Accuracy class: 1 Digital indication Measuring ranges: 0... 20 in steps of .01 0... 200 in steps of 0.1 0 2000 in steps of 1.0
20.2.14
Micro ohm-meter
Portable type, suitable for measuring contact resistance of high voltage equipment 230 V AC power supply Measuring range: 0 - 1999 Accuracy: 1% Output current: 0 - 400 A DC All accessories. Primary injection test set
20.2.15
Power rating : 35 KVA Regulating transformer ( oil immersed) with indicating instruments and controls Main transformer ( oil immersed) complete with off load tap changing arrangement for 7000 Amps at 5 V , 3500 Amps at 10 V, 1000Amps at 70 Volts and 500 Amps at 70V
Input and output cables. Electrical insulation dielectric strength test set : 230 V AC , 50 Hz
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20.2.16 Input
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Output Features
: :
40 kV, 10 Amp Test voltage should be continuously adjustable
from zero to full output, with a zero-start interlock. A front-panel knob may adjust leakage current trip level. Pushbuttons should be provided to select one-second or continuous testing, to turn off the high voltage and to reset the instrument. All high-voltage connections are recessed to prevent accidental contact with high voltage. During testing, high voltage should automatically shut down within 50 ms of arcing or exceeding the preset trip level. Visual and audible alarms to alert the operator upon failure should be provided. Interlock to prevent the high voltage from being applied if the supply ground wire is open or if the hot and neutral wires are interchanged. A Tester Grounded lamp lights to confirm the instrument is connected to a properly grounded power source. 20.2.17 Transformer DC winding resistance test kit
The instrument is used for measuring DC winding resistance of the transformer/reactor where large inductance is present. The test kit shall be able to withstand inductive kicks from transformer winding. Variation in test current shall not result in loss of accuracy. The display or resistance should be through direct LED / LCD without requiring any balancing of decades to obtain stable readings. It should employ four-point method and no lead compensation shall be required for measurement. Built-in discharge circuit should be provided to discharge the specimen when test is completed when current lead accidentally disconnects or when instrument power supply is lost. Technical Parameter Test current 25 Amp Resolution 1 milliohm
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Range Accuracy
0 to 100 ohms 0.5% of full scale reading or better
Open circuit voltage min. 30 Volts, DC. Input supply of the kit shall be 230Volts AC, 50 Hz. Automatic capacitance and tan kit
20.2.18
The kit shall be capable of measuring capacitance and tan delta of each winding of the transformers in suitable mode so that capacitance of other windings does not affect the reading. The kit shall comply with the requirements laid down in internationally accepted standards. The kit shall be complete with measuring bridge, HV power supply unit of 10kV, standard capacitor etc. The effect of induced voltage on instrument during testing for getting null point should be fully compensated. The kit shall be capable of measuring excitation current of transformer winding at 10kV. Technical requirements Output Voltage Tan Delta Measurement range 0 to 10kV in continuously adjustable range 0 - 200% with an Accuracy of 1%, Resolution 1x10 Capacitance Measurement range 1.0pF to 50000 pf. with an Accuracy of Resolution 1pF. General requirements The instrument shall contain all standard accessories including testing lead of 15m with suitable Clamps / connectors and carrying case. Kit should be able to measure capacitance and tan delta/power factor automatically without interference suppression shall be automatic. The instrument should have been proven for repeatability of test results in charged switchyard conditions. The kit should be capable of operating and storing data at temperature from 10C to 50C and humidity up to 90%. balancing any decade and also 1%,
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Input supply of the kit shall be A.C 230 Volts 50 Hz, Variations 15% and 5% on voltage and frequency. 20.2.19 Single- phase automatic turns ratio tester
The equipment offered shall be used for measurement of turns ratio of various transformers and bushing current transformers automatically displaying the ratio without requiring any manual balancing of decades. Technical Requirement Operation Voltage 230 volts: 50Hz, single phase A.C Test Voltage : 230 volts AC Accuracy: 0.5 % of FSD
The kit shall be capable of operating at a temperature of 50C and at humidity up to 85%. It should have the facility to store 100 results and uploading to PC. 20.2.20 Thermal Imaging camera
Thermal Imaging camera shall be capable of measuring the hot spot temperature of power house equipments such as generator, generator step up transformers, bushings, HV cable, etc. The thermal imaging camera shall have the facility to measure the following temperatures: Absolute value of hot spot temperature Coloured thermal image of focused object Isotherm temperature.
Video recording for thermal images with facility to replay through display unit shall be provided. Software for retrieval of data to maintain database and preparation of reports shall be supplied along with the kit. The software supplied along with the kit shall have facility to display and generate reports in Graphical and Numerical formats and compare results obtained at different times. 20.2.21 Frequency response analyzer kit
The FRA test set consisting of various components like Network analyzer, auxiliary equipment, test leads, connectors and suitable software (to operate the hardware and store all tests data, to view data, compare data , storage and archival of data) shall be capable of
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doing frequency response analysis of inductor capacitor network of Transformers and Reactors by adopting swept frequency method, to assess mechanical condition (winding movements and mechanical distortion i.e. loss of mechanical integrity) of the transformers and reactors. Functional specifications of various components of FRA test set are as below: Network Analyzer (signal Generator and measuring device) Analyzer must be capable of measuring the amplitude change and phase shift over a frequency range of 10 Hz. to 10 MHz. in five (05) frequency bands, mentioned as below: 10 Hz. to 2 KHz. 50 Hz. to 20 KHz. 500 Hz. to 200 KHz 5 KHz. to 2 MHz. 25 KHz. to 10 MHz. Pressure transmitter : : : : : : 0 to 100 bar 4 to 20 mA proportional to applied pressure 0.15% 0.5% / 5% 9 to 30 V DC G female
20.2.22
Pressure measuring range Out put Accuracy Zero offset / span setting Supply voltage Pressure connection
Electrical connection DIN 43650 plug with free mating socket Differential pressure transmitter
20.2.23
With metallic measuring diaphragms and capillary diaphragm seals. Measuring range from -100mbar . +100mbar to - 40 + 40bar Overload ( on one side ) Ambient temperature maximum 160 bar
- 40 .+ 80 C
Accuracy 0.1 % of the set span + influence from diaphragm seal

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Supply voltage 10.5 to 45 Volts dc Output 4 to 20 mA with superimposed HART protocol Set of Tools
20.2.24
Normal screw driver set Star Screw driver set Allen key set Nut driver set Nose pliers Circlip Pliers Cutting pliers Wire stripper D spanner set Ring spanner set Hand drilling machine ( up to 10mm ) with drill bits of all sizes from 0.5mm to 10mm DC Shunts for DC current measurement.
20.2.25
Shunt should comply with the requirement of IS1248 / DIN43703 & DIN 43780. Rating Rating Accuracy : : : 150 Amps / 75 mV 1000 Amps / 75 mV 0.5%
Operating temperature - 10 C to 55 C Crimping tools
20.2.26
Hand operated crimping tools for lugs from 1.5sq mm to 6 sq mm Hydraulic crimping tool with moulds of all sizes up to 300 sq mm Stainless steel silica gel drying oven. single phase 240 V ac
20.2.27
Input voltage
Temperature control range 0 to 200 C

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20.3
Design consideration
20.3.1 Specific codes and standards Electrical equipment shall be designed and tested according to the latest relevant standards including amendments, or complementary standards mentioned in this document, shall be applied, in particular to the following: ISO 9001 Quality Systems Model for Quality Assurance in Design, development, Production, Installation and Servicing 20.3.2 Performance Guarantee The electrical workshop equipment along with all auxiliaries and accessories shall be capable of performing intended duties under specified conditions. The Contractor shall guarantee the reliability and performance of the individual equipment as well as of the complete system. 20.4 Quality control and assurance
20.5.1 Drawings and documents The Contractor shall submit all the drawings and documents in accordance with requirements stipulated in Section 2.12 Reference drawings and documents of General Technical Specification (GTS). submitted for approval. 20.6 Delivery, Installation and Commissioning Standard Instruction manual of all equipments shall be
The supplier shall follow the requirements of Delivery, Installation and commissioning elaborated in section 2.34 Installation and supervision of General Technical
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20.7
Spare Parts
Recommended spare parts shall be supplied in accordance to clause 2.36 Spare Parts and tools of General Technical Requirements. All spare parts and accessories shall be identical electrically and mechanically to corresponding parts in the equipment supplied and shall be suitably packed and clearly marked, ready for long term indoor storage. 20.8 Testing
The Contractor shall follow the Inspection and testing requirements in Quality assurance clause 2.31 Factory inspection and testing of General Technical Specifications and section 25 of document Quality Assurance and Testing Specification.
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21. 21.1
POT HEAD YARD EQUIPMENT Scope of Work
Scope of work under this section covers the provision of labour, tools, plants, materials and performance of work necessary for the design, manufacture, quality assurance, quality control, shop assembly, shop testing, delivery at site, site storage and preservation, installation, commissioning, performance testing, acceptance testing, training of Owners personnel, handing over to Owner and guarantee for one year of outdoor pot head yard equipment as per the specifications hereunder, complete with all auxiliaries, accessories, spare parts and warranting a trouble free safe operation of the installation. The scope of work shall be a comprehensive functional system covering all supply and services including but not limited to following: a) 220 kV potheads and supporting structures suitable for outdoor cable terminations for each of the seven (7) single-phase 220 kV XLPE cables; b) Six (6) nos. 220 kV, 20 KA lightning arrestors, station class, metal oxide type complete with discharge counter, leakage / grading current meter, insulator sub base and support structures; c) Four (4) nos. Single phase , 220/3 kV: 110/3 kV, 110/3 kV,110/3 kV capacitive voltage transformers with three secondary structures; d) Two (2) nos 3 phase, three pole, group operated earthing switches complete with manual and motor driven operating mechanism and support structure; e) Two (2) double gantry structure to support conductors for two (2) 220 kV outgoing transmission lines. f) Four (4) nos 1600Amps 0.5mH wave traps complete with supporting structures for two outgoing lines. g) One (1) lot of conductors, insulators, connectors and hardware as required to complete the installation; h) i) One (1) set of spares; One (1) set of special tools. windings, complete with support
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Any other item(s) not mentioned specifically but necessary for the satisfactory completion of scope of work defined above, as per accepted standard(s) / best international practices. 21.2 Ratings and design requirement
21.2.1 Rating The installation being at an altitude of 2500 m , the standard voltage and current rating of electrical items will be derated accordingly. Sl No 1 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 2 2.1 2.2 2.3 2.4 2.5 3 3.1 3.2 3.3 3.4 3.5 3.6 4 4.1 4.2 Description 220KV system Location Number of bays Rated voltage Maximum voltage Rated frequency Rated continuous current Rated lightning impulse withstand voltage Rated power frequency withstand voltage Rated short time frequency withstand voltage Lightning arrestors Type Rated arrestor voltage Maximum continuous operating voltage (MCOV) Rated nominal discharge current Rating Outdoor 2 220 kV 245kV 50 Hz 2000 Amps 1050 kV peak 460 kV rms 40 KA
Gapless metal Oxide 192 kV 152 kV rms 20 KA
Lightning arrester should conform to IEEE , IEC or other standards applicable Wave trap Inductance of mail coil 0.5 mH Rated continuous current 1600 Amps Rated short time current 40KA for 1 sec Rated bandwidth 100- 500 Khz Minimum resistive component of blocking 600 Ohms impedence Type of tuning Broadband Capacitive voltage transformers Number of cores of CVT 3 Voltage ratio (220 / 3 ) kV / (110 / 3) V /
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Sl No 4.3
Description Accuracy class
4.4 Burden 5 Earthing switch The earthing switches will be three poles, gang operated, motorized and manually operated with a hand wheel or crank. The earthing switches will be supplied with their supporting structures 21.3 Design consideration
Rating (110 / 3) V/ (110 / 3) V CL 0.5 for metering , 3P for protection 100 VA
21.3.1 Specific Codes and Standards Electrical equipment shall be designed and tested according to the latest relevant standards including amendments, or complementary standards mentioned in this document, shall be applied, in particular to the following: ISO 9001 IEC 60044 IEC 60909 IEC 60865 IEC 60694 IEC 60353 IEC 60186 IEC 60099-4 Quality Systems Model for Quality Assurance in Design, development, Production, Installation and Servicing. Instrument Transformers Short-circuit currents in 3 -phase AC systems Short- circuit currents- calculation of effects Common specification for high voltage switchgear and control gear standards. Line traps for AC power systems Voltage Transformers Metal - oxide surge arrestor without gaps for AC
21.3.2 Performance Guarantee The 220kV out door pot yard equipment along with all auxiliaries and accessories shall be capable of performing intended duties under specified conditions. The Contractor shall guarantee the reliability and performance of the individual equipment as well as of the complete system. 21.4 Construction
The transmission and power evacuation system of the GMR(Badrinath) project is designed to evacuate installed capacity of 345 MW through two outgoing overhead transmission lines designated as line-1 and line-2
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Lightning arresters Each outgoing line shall be provided with lighting arrestor to limit the switching surges to a safe value and provide adequate protection to the equipment against travelling waves entering the pothead yard. The lightning arresters shall be supplied with insulating bases, discharge counters and supporting steel structures. Capacitive Voltage Transformers (CVT) Capacitive Voltage Transformers for each of the two (2) outgoing lines, to provide protection and metering. The CVTs will be single-phase units consisting of coupling capacitive dividers, three secondary windings, and supporting steel structures. The capacitance voltage transformers shall conform to IEC-60186. The CVTs shall also be used to connect the carrier equipment to the high-voltage lines. Wave trap The wave trap can be pedestal mounted or hanging type. In case of pedestal mount, the scope of supply for wave traps shall include pedestals, supports structures and post insulators. The wave traps shall be broadband type designed to carry the full load current. The components of tuning device consisting of passive components and connected across the inductive main coil of the wave trap shall offer negligible impedance over the entire frequency range adopted by PLCC equipment. Layout and connection The high voltage equipment to be placed in the outdoor pothead yard will have their nominal characteristics derated due to the high altitude of 2500 m above sea level. They will be designed for a minimum 40 kA rms rated short-circuits current. The outdoor pothead yard and its surrounding area will have their respective grounding system. The earthing grid will be designed and constructed for the operating voltages and short-circuit capacities corresponding to short-circuit and earth-fault current levels. The station side of the outdoor pothead yard equipment will be interconnected with the underground GIS line feeders through 220 kV XLPE cables. The connecting stud of the cable terminations will be equipped with suitable adaptors allowing the connection to the terminations of the overhead line outdoor potheads to one end of the cable.
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Connections between the outdoor apparatus will be made by flexible aluminium conductor, Steel-reinforced (ACSR) and bolted terminal connectors. A network of vertical risers and runners from the grounding grid will connect all machinery, equipment, structures and other parts which are to be earthed. The dead end will be at the other side of the river i.e. around 200 to 250m far from potyard location. Gantry shall be designed keeping this provision. 21.5 Quality control and assurance
21.6.1 Design memorandum The Contractor shall submit all the drawings and documents in accordance with requirements stipulated in Section 2.12 Reference drawings and documents of General Technical Specification (GTS). 21.6.2 Drawings and documents The Contractor shall submit all the drawings and documents in accordance with requirements stipulated in Section 2.12 Reference drawings and documents of General Technical Specification (GTS). 21.6.3 Design calculation The Contractor shall submit the design calculation for review / acceptance. Covering at least the following: Calculations of the stresses for the gantry structure, Supporting structures, Validation of Calculations for burden of CVT, Validation of protection margins in SA characteristics along with calculation for deciding location, Validation of lightening protection,
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21.7
Short circuit forces when bundled conductor is used. Delivery Delivery, Installation and Commissioning
Requirements. The supplier shall arrange personnel to oversee proper storage of equipment at site, their transhipment to powerhouse, installation and commissioning. 21.8 Spare Parts
Recommended spare parts shall be supplied in accordance to clause 2.36 Spare Parts and tools of General Technical Requirements. All spare parts and accessories shall be identical electrically and mechanically to corresponding parts in the equipment supplied and shall be suitably packed and clearly marked, ready for long term indoor storage. Specified spare parts to be supplied under this section are as follows: Sl no 1 2 3 4 5 6 Description Capacitance 220 kV line voltage transformer Quantity for 1 no 1 no 10 no 100 m Three (3) nos. of each used type Three (3) nos. of each used type
Surge arrester for 220 kV line Disc Insulators Conductor of each type used Hardware fittings and fasteners Connectors on high voltage conductors
21.9
Special Tools
The Contractor shall propose the list of special tools and testing instrument including their make and detailed specification as recommended by manufacturer(s), to be accepted by the Owner.
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Following devices and handling tools required for installation and maintenance of cables shall be supplied. Two (2) nos. telescopic extension piece type earthing rod suitable for 220 kV. tested for making capacity, Two (2) nos. Aluminium channel ladders with wheels and platform suitable for two persons along with tools on first level of Bus Bar (8m / 5.5m). 21.10 Testing The Contractor shall follow the Inspection and testing requirements in Quality assurance clause 2.31 Factory inspection and testing of General Technical Specifications also section 12 and 25 of document Quality Assurance and Testing Specification.
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22. 22.1
GROUNDING SYSTEM Scope of Work
Scope of work under this section covers the provision of labour, tools, plants, materials and performance of work necessary for the design, manufacture, quality assurance, quality control, shop assembly, shop testing, delivery at site, site storage and preservation, installation, commissioning, performance testing, acceptance testing, training of Owners personnel, handing over to Owner and guarantee for one year of the complete Grounding system as per the specifications hereunder, each complete with all auxiliaries, accessories, spare parts and warranting a trouble free safe operation of the installation. The scope of work shall be a comprehensive functional system complete in every respect including but not be limited to following: 22.1.1 Underground earthing network The underground earthing network shall consist of underground earth mat in power house cavern, GIS-cum-transformer cavern, turbine discharge pit, Barrage, tailrace, pothead yard and other adjoining functional areas. It shall be composed of interconnected mesh of grounding conductors suitably spaced and buried in raft and grounding rods driven vertically in ground connected to mesh. The purpose of this underground earthing network is to lower the overall grid resistance to a value of 0.5 . a) Surface earthing network The surface earthing network shall consist of suitably spaced meshed grid embedded in GIS floor, Generator floor, All other floors of power house, Valve house and substation Intake gate Barrage site and substation Colony substation
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b)
Areas where earth fault current may flow.
Interconnection of all over-ground meshed grid embedded in various floors and connection with underground earthing network for reducing the touch and step potential to tolerable limits as well as serve as collectors for earthing flat from main equipment.
c)
Embedded grounding points connected to over-ground meshed grid at required locations for earthing of equipment,
d) e)
Connections of all steel structures and metal parts to embedded earthing network, An interconnected above ground / above floor main earthing network of galvanized iron flats at the powerhouse, generator floor, transformer area, GIS hall, cable-cumventilation tunnel, main access tunnel, approach adits, pot head yard and to other places wherever needed for earthing of machinery, equipment and other parts,
f)
Flexible copper braided connections for connection of ground points of equipment to grounding network,
d)
Clamps, sheaths, terminals and other miscellaneous items for making ground connections,
e) f)
One (1) set of spare parts, One (1) set of tools and instruments.
22.2.1 Rating Fault current level for Power House, Transformer, GIS hall (220 kV) and Pot head yard area may be taken as 40 kA for 1 second. The specified fault current value is for sizing of conductors for main grid and risers. The Contractor shall submit full detailed calculation for fault level and ground mat design for approval. 22.2.2 Design Requirements The earthing system shall provide: Adequate protection of personnel against dangerous voltages, currents and arcs,
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Low earthing impedance for the transformer neutrals and the generator neutrals and sufficiently low neutral conductor impedance,
The fault currents shall flow through the earthing system, Limiting the induced capacitively transformed voltages on electronic cables, circuits, panels and other equipment to low voltage, weak current.
The excavation/backfilling and concreting for laying of conductors and electrodes of the embedded grounding system shall be done by the civil Contractor and all other works measurement of soil resistivity at the locations, design, laying as per approved design will all be the suppliers scope. 22.3 Design Considerations
22.3.1 Specific Codes and Standards The system and equipment shall be designed, built, tested and installed to the latest revisions of the following applicable standards. In the event of other standards being applicable they will be compared for specific requirement and specifically approved during detailed engineering for the purpose:
Standard IEEE 80 -2000 IS 3043
Description Guide for safety in AC substation grounding Code of practice for earthing
22.3.2 Performance Guarantee The grounding system along with all auxiliaries and accessories shall be capable of performing intended duties under specified conditions. The Contractor shall guarantee the reliability and performance of the complete system to provide desired functions. 22.4 22.5 (Not in Use) Construction
The Contractor shall make the design and calculations of the whole grounding system of powerhouse complex, including transformer hall, GIS hall, pot yard area and discharge area of tailrace.
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The earthing system shall be such structured that breaking of a conductor at any point in the network shall not disconnect any part of the network from the earth. Following are the minimum requirement for design of the system: Irrespective of the material used in embedded system, the material for surface system shall be of galvanized steel, The earthing conductors shall be of minimum 32mm dia MS Rods. The risers shall be of GI with minimum size of 75X10mm, The mesh spacing of the ground mats shall not be greater than 5 m x 5 m. Earth conductor in ground shall be thermo welded to each other. Embedded earthing system. The embedded earthing system for the power house, transformer hall, GIS hall, pothead yard and the discharge area of the tailrace shall consist of an interconnected earthing grid formed by MS electrode, rods / flats and copper conductors of suitable size. The embedded earthing system of the powerhouse shall be connected to the penstock and to the earthing systems of the transformer hall, GIS hall, pothead yard and the discharge area of the tailrace. Risers from grid to various floors of power house shall be embedded in the columns/walls. At every floor an embedded grid of earth conductors shall be laid interconnecting all the risers for reducing the touch and step potential to tolerable limits. Prior and during the concreting stage, the Contractor shall provide / erect all material and shall co-ordinate all appropriate information in sufficient details to enable the civil contractor to ensure concreting only after connection of reinforcement bars and to form the adequate grid. The number and location of these interconnecting points shall be determined by the Contractor and put up for approval of the Employer. All connections of the embedded earthing conductors shall be thermo welded. The conductors buried in the soil or laid in cable trenches shall be MS flats/rods. Surface earthing system
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The earthing system shall consist of individual loops with connections to the different equipment to be earthed and with connections to the embedded earthing grid. At certain locations earthing measuring points shall be installed. Within the powerhouse and transformer hall, and other rooms or buildings containing electrical installations, at least one main protective earthing bus shall be provided, approximately 0.3 m above floor at the circumference of the building room. This bus consisting of bare steel flat of 75X12mm size shall be connected with the embedded earthing system. This protective earthing system shall be carried along with the cable trays to reach every electrical consumer in a convenient manner. Conductors and connections All main conductors from the grounding system shall have individual connections as per the required standards. The Contractor shall supply all the embedded conductor system, connection rods/flats etc and design suitable connection facilities for connection of individual conductors to the system. All the system materials and structures are to be connected in the embedded system at atleast two points. One of these should be to a main riser from embedded system. Schedule of connections The connections shall include but not be limited to the following: Connection to all cubicle ground bus, All transformer neutrals, All surge arresters, Generator neutrals, Generator frame, GIS duct, Pothead yard equipment and structures, All secondary circuits of instrument transformers, All metal equipment housings, and all other accessible metallic equipment and all steel structure parts,
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All cable screens, Other equipment and electrical installations as per requirement and relevant standard.
Connections to all equipment shall be of flexible type. In addition to the grounding through cable screens, all equipment such as cubicles, motors, etc. shall be connected directly to the grounding system using copper wire at two different points. In general, all iron parts such as supports, covers, railing, etc. shall be connected to the grounding system. Each conductor shall have its own separate connection point. Pressed on closed shoes shall be used for connections to bars. All pot yard towers shall be directly connected to ground mat by two separate ground conductors diagonally. 22.6 Drawings, Documents and Design Calculations
22.6.1 Design memorandum The Contractor shall submit all the drawings and documents in accordance with requirements stipulated in Section 2.12 Reference drawings and documents of General Technical Specification (GTS). 22.6.2 Drawings and documents The Contractor shall submit all the drawings and documents in accordance with requirements stipulated in Section 2.12 Reference Drawings and Documents of General Technical Specification (GTS). 22.6.3 Design calculation The Contractor shall submit the design calculation covering at least the following, for review / acceptance. Design calculations of the whole grounding system, The design shall be as per applicable rules and standards, "Guide for Safety in AC Substation Grounding" ANSI / IEEE Std 80-2000. 22.7 Delivery, Installation and Commissioning
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The supplier shall follow the requirements of Delivery, Installation and commissioning elaborated in section 2.34 Installation and Supervision of General Technical Requirements. The supplier shall arrange personnel to oversee proper installation of grounding system at site and commissioning. 22.8 Spare Parts
Recommended spare parts shall be supplied in accordance to clause 2.36 Spare Parts and tools of General Technical Requirements. 22.8.1 Special tools The Contractor shall propose the list of special tools and testing instrument including their make and detailed specification as recommended by manufacturer(s), to be accepted by the Owner. The proposed list of special tools must include the following in addition to tools recommended by manufacturer(s): 22.9 One (1) no. earth resistance testing kit Testing
The Contractor shall follow the Inspection and testing requirements in Quality assurance clause 2.31 Factory inspection and testing of General Technical Specifications.
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23. 23.1
ELECTRIC OVERHEAD TRAVELLING CRANES Scope of Work
Scope of work under this section covers the provision of labour, tools, plants, materials and performance of work necessary for the design, manufacture, quality assurance, quality control, shop assembly, shop testing, delivery at site, site storage and preservation, installation, commissioning, performance testing, acceptance testing, training of Owners personnel, handing over to owner and guarantee for one year of EOT cranes as per the specifications hereunder, each complete with all auxiliaries, accessories, spare parts and warranting a trouble free safe operation of the installation. The scope of work shall be a comprehensive functional system complete in every respect including but not be limited to following: 23.1.1 EOT Crane for Power House Two (2) 120/20 metric ton EOT crane with 10 T monorail crane for power house electric over head travelling crane of 20.5 m span complete with bridge, operators cabin, trolley, main hoist, auxiliary hoist, electrical controls, safety devices, fittings and connections and all necessary accessories to handle equipment, including wire ropes for main hoist and auxiliary hoist. Two (2) 10 - metric ton monorail supported beneath bridge girder of each power house EOT crane complete with electric control, hoist, brakes, safety devices, fittings and connections and all necessary accessories to handle equipment at extreme ends of power house, including wire rope for hoist. One (1) lifting beam of 240 metric ton capacity along with lifting stand for handling generator rotor and stator assemblies during tandem lifting using both the power house cranes. One set of main runway rails CR-100 with base plates, anchor bolts, rail clips, lock nuts, end stops, limit switches and striker plates. Main and auxiliary hoists will be mounted on the same trolley running on the bridge girders. The bridges will be of box girder structure. One set of bridge cross travel rails CR-100 with rail clips, lock nut, end stops, limit switches, strikers plates etc.
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One set of long travel insulated feed rail power supply system complete with metal enclosures, conductors, collector trolley, all fitting and connections etc. for total run length.
Load testing of cranes and lifting beam at site including load arrangement and all logistics,
Lubricating oil, grease and hydraulic brake fluid for first filling of all components with 100% reserve, in non-returnable drums, for both the cranes,
One (1) set of spare parts. One (1) set of tools and instruments. Any other item(s) not mentioned specifically but necessary for the satisfactory completion of scope of work
23.1.2 EOT crane for Penstock Valve house One (1) 50 / 10 metric ton electric over head travelling crane of 9.50 m span complete with bridge, floor pendant controller, trolley, main hoist, auxiliary hoist, electrical controls, safety devices, fittings and connections and all necessary accessories to handle equipment, including wire ropes for main hoist and auxiliary hoist. One set of main runway rails with base plates, anchor bolts, rail clips, lock nuts, end stops, limit switches and striker plates. Main and auxiliary hoists will be mounted on the same trolley running on the bridge girders. The bridges will be of box girder structure. One set of bridge cross travel rails with rail clips, lock nut, end stops, limit switches, strikers plates etc. One set of long travel insulated feed rail power supply system complete with metal enclosures, conductors, collector trolley, all fitting and connections etc. for total run length. Load testing of cranes at site including load arrangement and all logistics, Lubricating oil, grease and hydraulic brake fluid for first filling of all components with 100% reserve, in non-returnable drums, for both the cranes, One (1) set of spare parts.
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One (1) set of tools and instruments. Any other item(s) not mentioned specifically but necessary for the satisfactory completion of scope of work
23.1.3 EOT crane for GIS hall One (1) 5 metric ton electric over head travelling crane of 14.50 m span complete with bridge, floor pendant controller, trolley, hoist, electrical controls, safety devices, fittings and connectors and necessary accessories to handle the equipments. One set of main runway rails with base plates, anchor bolts, rail clips, lock nuts, end stops, limit switches and striker plates. Main hoists will be mounted on the same trolley running on the bridge girders. The bridges will be of box girder structure. One set of bridge cross travel rails with rail clips, lock nut, end stops, limit switches, strikers plates etc. One set of long travel insulated feed rail power supply system complete with metal enclosures, conductors, collector trolley, all fitting and connections etc. for total run length. Load testing of cranes at site including load arrangement and all logistics, Lubricating oil, grease and hydraulic brake fluid for first filling of all components with 100% reserve, in non-returnable drums, for both the cranes, One (1) set of spare parts. One (1) set of tools and instruments. Any other item(s) not mentioned specifically but necessary for the satisfactory completion of scope of work defined above, as per accepted standard(s) / best international practices. 23.2 Specific Parameters and layout conditions
23.2.1 EOT Cranes for Power House The power house EOT cranes shall be used for handling turbine, generator, inlet valve, associated apparatus and other equipment in an under ground power house. Both power house cranes shall be used in tandem to lift the rotor and stator assemblies of generator by
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using lifting beam. The power house cranes shall also be used to handle main transformers in service bay. The cranes shall be used for installation of the equipments as well as for routine maintenance after completion of power house. The two cranes shall be capable of operation in tandem. In coupled tandem operation, the power house cranes shall be used to lift a complete generator rotor mass including lifting devices. The crane shall be designed in such a way that cabins are located besides each other during tandem operation and controlled by any one of the cabins. The contractor shall supply necessary control and cables for this purpose. The Crane contractor shall co-ordinate with the contractor of generator for capacity, lifting arrangement and other provisions in the cranes with respect to installation and layout. Terminal clearance and hook approach of power house EOT crane shall be in accordance with the layout shown in the drawings. 23.2.2 EOT crane for Penstock Valve house The 50 T EOT crane shall be required for handling of Butterfly valve located in penstock valve house. The crane shall be used for installation of the above equipments as well as for routine maintenance after completion of valve house. 23.2.3 EOT crane for GIS hall The 5 T EOT crane shall be required for handling the equipment in transformer area at EL 2306.9 m and in GIS hall at EL 2317.90 m. The crane shall be used for installation of the above equipments as well as for routine maintenance after completion. 23.3 Rating and functional characteristics
The installation being at an altitude of 2300 m, the standard voltage and current rating of the Electrical components shall be derated accordingly. 23.3.1 Rating Sl no 1.0 1.1 Description Power house cranes Number of cranes 2 ( Two) Parameter
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Sl no 1.2 1.3 1.4 1.5 1.6 1.6.1 1.6.2 1.6.3 1.6.4 1.6.5 1.7 1.8 1.8.1 1.8.2 1.8.3 1.9
Description Main hoist lifting capacity Auxiliary hoist lifting capacity Monorail hoisting capacity Service / duty class of crane Normal Operating speed (Loaded) Main hoist Auxiliary hoist Monorail hoist Bridge travel ( long travel ) Trolley travel ( cross travel) Crane Span Total lift with load Main hook Auxiliary Hook Monorail Hook Minimum incremental movement (Not greater than the values given fellow) Main hoist Auxiliary Hoist Bridge Travel Trolley travel
Parameter 120 MT 20 MT 10 MT M5
1 m / min 5 m / min 5 m per min 20 - 25 m / min 10 12.5 m / min 20.50 m (Approximately)
25 m 30 m 30 m
1.9.1 1.9.2 1.9.3 1.9.4
0.1 m / min 0.5 m / min 2.0 m / min 1.0 m / min

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Sl no 1.9.5 1.10 1.11 1.12
Description Monorail hoist Rail length Elevation of runway rail bottom Elevation of main hook (in highest position)
Parameter 0.5 m / min 82.50 m ( approx ) EL 2316.50 m EL 2315.50 m
1.13
Maximum distance between bottom of 4000 mm crane rail and top point of crane Terminal Position of hooks of crane no. - 1 (Service bay end) Main / auxiliary hooks from centre of 2700/1400 mm crane rail on upstream side Main / auxiliary hooks from centre of 1900/3200 mm crane rail on downstream side The distance of main / auxiliary hooks 4000 mm from inner edge of wall in their terminal positions at both ends Note Crane no 2 (control block end) shall be mirror image of crane no. - 1
1.14
1.14.1
1.14.2
1.14.3
2.0 2.1 2.2 2.3 2.4 2.5 2.5.1 2.5.2
Penstock Valve House Crane Number of cranes Main hoist lifting capacity Auxiliary hoist lifting capacity Service class Normal Operating speed (Loaded) Main hoist Auxiliary hoist 1.0 m / min 5.0 m / min 1 ( One) 50 MT 10 MT M5
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Sl no 2.5.3 2.5.4 2.6 2.7 2.7.1 2.7.2 2.8
Description Bridge travel ( long travel ) Trolley travel ( cross travel) Crane Span Total lift with load Main hook Auxiliary Hook Minimum incremental movement (Not greater than the values given fellow) Main hoist Auxiliary Hoist Bridge Travel Trolley travel Rail length Elevation of runway rail bottom Elevation of main hook (in highest position)
Parameter 20 - 25 m / min 10 12.50 m / min 9.50 m
12 m 12 m
2.8.1 2.8.2 2.8.3 2.8.4 2.9 2.10 2.11
0.1 m / min 0.5 m / min 2.0 m / min 1.0 m / min 24.00 m ( approx ) EL 2875.67 m 2875.00 m
2.12
Maximum distance between bottom of 3000 mm crane rail and top point of crane Terminal Position of crane hook Main / auxiliary hooks from centre of 1975/900 mm crane rail on upstream side Main / auxiliary hooks from centre of 825/1900 mm crane rail on downstream side
2.13 2.13.1
2.13.2
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Sl no 2.13.3
Description
Parameter
The distance of main / auxiliary hooks 3000 mm from inner edge of wall in their terminal positions at both ends GIS crane Number of cranes Hoist lifting capacity Service class Normal Operating speed (Loaded) Hoist Bridge travel ( long travel ) Trolley travel ( cross travel) Crane Span Total Lift of hoist hook Rail length Elevation of runway rail top 5.0 / 0.5 m / min 15 m / min 10 m / min 14.50 m (approximately) 20.00 m 88.00 m ( approx ) EL 2326.40 m 1 ( One ) 5T M3
3.0 3.1 3.2 3.3 3.4 3.4.1 3.4.1 3.4.2 3.5 3.6 3.7 3.8 3.9
Maximum distance between bottom of 1700 mm crane rail and top point of crane Terminal Position of crane hook Hook from centre of crane rail on 1400 mm upstream side Hook from centre of crane rail on 650 mm downstream side The distance of hook from inner edge 2900 mm of wall in their terminal positions at both ends
3.10 3.10..1
3.10..2
3.10..2
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23.3.2 Clearance of Power House EOT Crane The clearance required for crane movement / maintenance from the centre line of rail up to the nearest obstruction on upstream and downstream of power house shall be limited to minimum 400 mm or as per IS:3177 in each crane. 23.3.3 Terminal Position of Power House EOT Crane Terminal position of main hook and the auxiliary hook from the centre of the rail on upstream and down stream shall be finalised by the crane contractor in consultation with the generator and turbine contractors. Similarly the distance of main hook and auxiliary hook from wall in their terminal position at service bay end and the other end near unit 3 shall be 3000 mm or less. Tentative position of main hook and auxiliary hook from the centre of the rail on upstream and down stream; and the distance of main hook and auxiliary hook from wall in their terminal position at service bay end and the other end near unit 3 shall be as indicated in crane clearance diagram. 23.4 Design and Construction
23.4.1 Specific Codes and Standards Unless otherwise stated hereafter, rating, characteristic, design, test and test procedures etc concerning to all the EOT cranes and monorail cranes shall comply with the provisions and requirements given relevant standards including amendments, or complementary standards mentioned in this document, shall be applied, in particular to the following: ISO 9001 Quality Systems Model for Quality Assurance in Design, development, Production, Installation and Servicing Code of Practice for electric overhead travelling crane and gantry cranes other than steel work cranes Design, Erection and testing (structural portion) of ceane and hoist code of practice
IS 3177
IS 807
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23.4.2 Functional Characteristics The EOT cranes shall be electrically driven, single trolley, double girder, and overhead travelling type. The cranes shall operate on runway rails. The bridge of the crane shall be carried on sufficient number of wheels, mounted on trucks designed to distribute the load equally on the truck beam and wheels. Wheel assembly should be designed to adjust themselves to the irregularities of the rails. The control system shall contain all the necessary controls for the operation of main and auxiliary hoist, long and cross travel. All crane controls shall be available inside the operator's cabin / pendant controller. Suitable Platforms and walkways shall be provided for access to equipments mounted on the bridge, trolley etc. Power shall be supplied from the feed rail power supply system mounted along the length of power house. The cabin shall be well illuminated with sufficient numbers of tube lights of adequate wattage. The Cranes for Penstock valve house and GIS hall shall be provided with detachable type pendent controller. Bridges Each crane shall consist of two bridge girder supported on end trucks. The girder end connections to trucks shall be rigid to prevent skew during operation of the crane. The crane bridge shall be box type welded construction with suitable stiffeners. The bridge girder shall be designed considering the following loads and transport limitation: Dead load Live loads Vertical impact load Braking load Dynamic load Temperature effect.
The crane bridge shall carry a set of runway rails for cross travel of main and auxiliary hoist.
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The bridge girder shall be designed to safely carry the full rated load without undue vertical or lateral deflection or vibration. The underside of each bridge shall be well illuminated using sufficient numbers of 230 Volts, 500 W lighting units with reflectors. Bridge travel mechanism (Long travel) The bridge travel mechanism shall comprise of electric motors for driving bridge wheels on each rail. The motors shall be located near each end of the bridge and connected to separate gear reduction unit. Long travel of the crane shall be affected in such a way that equal speed is ensured at each end truck drives. Mechanical, hydraulic and electrically operated braking mechanism shall be provided. Wheel stopper and buffer stopper shall be provided for stopping crane on reaching end of long travel. Each crane shall be provided with a feed rail power supply system. The feed rail system shall be of the metal enclosed, collector bus way type with internally supported conductors and collector trolley and shall have no live parts outside of the enclosure. The full current-carrying capacity of the system shall be maintained throughout. The feed rail system shall consist of an assembly of standardized, fully interchangeable units and shall include expansion sections at each building contractions joint, feed box, door track sections or other means of removing the collector trolley, coupling sets, dead-end caps track hangers and power take off collector trolleys as required for the complete system. Trolley The trolley shall be of welded construction of structural steel with adequate braces to withstand vertical, lateral and tensional strains without undue deflection. The trolley shall house Main and auxiliary hoisting mechanism and cross travel mechanism. Trolley travel mechanism (Cross travel) The trolley travel mechanism shall comprise of at least two numbers of electric motors and totally enclosed speed reduction gear unit, one for each end of the trolley to drive two trolley wheels to ensure equal speed. Electromechanical braking system shall be provided for stopping the trolley. Wheel stopper and buffer stopper shall be provided for stopping trolley on reaching end of cross travel.
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Trolley power conductors shall be of the festooned insulated wire type. Each motor on the trolley shall have separate conductors for the power and in no case shall a power conductor be used as a common conductor for more than one circuit. End trucks, wheel and axles The crane bridge shall be carried on the end trucks fitted with drive and idle wheels. Trucks shall be fabricated from high grade structural steel. Heavy gusset plates shall be attached to the bottom of the truck to insure rigidity and squareness. Each truck shall be fitted with double flanged rail wheels with roller bearings mounted on rotating axles, buffers etc. for easy maintenance. The size of journal shall be ample to carry the rated load at specified speed without excessive heating during continuous operation. The truck shall be designed to permit easy removal of wheels. The truck shall be equipped with rail sweeps, extending below the top of rail and projecting in front of the truck wheels, to push forward off the track, any object placed across the rail. Safety lugs shall be provided which shall extend below the top of rail on both sides to prevent the trucks from leaving rails. Wheel assembly shall be arranged such that replacement of a wheel can be achieved from the side without undue difficulties. The end trucks shall be designed to contact end stops and the contact faces shall be fitted with resilient bumpers or spring buffers. The end stoppers shall be provided and shall be designed such that they contact the face of the buffer fitted on the end truck and not the wheel. The stops shall be attached at each end of the runway rails. The design and construction of truck wheels shall be in accordance with IS: 3177. The bridge shall be carried on minimum 16 nos. of wheels for power house crane and 8 nos. of wheels for other two cranes. All wheels shall be double flanged with tapered treads, machined of ground to size. The high side of the taper shall be towards the centre of the span of adjacent to the inside bearing of the truck. The wheels shall be made from forged steel or rolled steel. The minimum hardness of the wheel rim should be maintained between 300 to 350 BHN with minimum depth of 10 mm. Hoisting mechanism The main and auxiliary hoist shall be trolley mounted and driven by suitable motors, gears and VVVF drives to achieve the required hoist speed. The trolley shall be provided with separate rope winding drums for main and auxiliary hoists. Each drum shall be designed to
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take full length of hoisting rope in one layer without layer winding. The end of the wire rope shall be anchored to the drum. The lifting capacity of wire ropes shall be 6 times the maximum lifting capacity of the hoist and shall confirming to the latest Indian standards. Lifting tackle and hook The lifting tackle shall consist of a lower block and hook, necessary sheaves, flexible steel wire rope etc. The lower block shall be a heavy steel housing to support the sheaves and hook. The load block shall be of enclosed designed. The hook and block shall be arranged to lift without twisting and sidewise pull of load. For power house and valve chamber cranes, the main hook shall be RAMSHOM type conforming to relevant Indian standard. All other crane shall be provided with Shank type point hooks. Hooks shall be swivel on antifriction thrust bearing and having adequate capacity to handle maximum load. The hooks shall be free to rotate 360 0 when supporting rated load. The hooks shall be fitted with safety latches designed to preclude inadvertent displacement of slings from the hook saddle. Hooks and lifting eyes shall be made of gorged annealed alloy or carbon steel. The hooks shall be designed such that the resultant load on the hook passes through the centreline of the shank. Prior machining all hooks shall be subjected to ultrasonic test and wet magnetic particle inspection of all surfaces of the forging. Runway rails The rails for power house shall extend to the full length of the power house including the service bay. The runway rails shall be properly secured on the crane beam with suitable sole plates, fixing clamps etc. Operator's cabin In power house cranes, the operator's cabin shall be located on the upstream side in one crane and downstream side in other crane so as to give the operator the maximum and best view for all operations and clear view as possible of the surroundings. The cabins have ample space for containing the control equipment and for performing all crane operations and maintenance provisions. An operators seat and an electric fan shall be provided. It shall be equipped with all controls required for safe operation of the EOT crane. The cabin shall
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be suspended from the crane outer girder and braced to prevent swinging during movement of the crane. A ladder shall be provided for access to the cabin. The cabin shall be air conditioned. Arrangement for keeping a CO2 cylinder of adequate capacity for fire extinguishers shall be provided in the Cabin. One electric bell, controlled by the operator, shall be provided at a proper location in the cabin for alarm purposes. For Penstock valve house crane and GIS crane, all required controls including the emergency push button shall be available on pendent control. Braking system Mechanical or Hydraulic operated foot brakes shall be provided for long travel, in addition to an automatic electro mechanical DC braking and electro hydraulic thrust brake for each motor of LT travel shall be provided. An automatic electro-mechanical DC braking system capable of bringing the motion of fully loaded trolley safely to rest shall be provided. In addition, a thrusters brake shall be provided for each motor of cross travel motion. All brakes provided on each bridge and trolley drive motor shall have a capacity not less than 150% of full load torque of the bridge or trolley drive motor. The monorail hoists holding brakes shall be rated for not less than 150% of the full load torque of the hoist motor. Both (main and auxiliary) hoisting mechanism shall be equipped with electro-mechanical and electro hydraulic braking system. The hoist brakes shall be fail safe and shall have adequate capacity to bring fully loaded crane to rest in shortest possible time and to arrest the motion and sustain any load up to and including test load at any position while hoisting and lowering. Each brake shall be capable of meeting the complete hoisting requirements independently. All brake shall have ample thermal capacity for the frequency of operation required by the application and shall be adjustable to compensate for the lining wear. The friction surfaces of brake drums, wheels and discs shall be free of defects that interfere with operation. All brake on travelling motion shall be selected for 1 hour intermittent duty and shall be equally effective in both directions of movement. All holding brakes on hoisting motions shall be designed for continuous duty. Magnets for all brakes shall be rated for continuous duty.
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Braking system shall be automatically set when controls are released or power is interrupted. 23.4.3 Electrical Apparatus and Control A two way supply control switch shall be installed in the service bay which shall be fed A.C. Supply from the board. Motors The cranes shall be equipped with motors of ample capacity for performing the duties specified without exceeding the rated full load torque and shall conform to latest version of relevant Indian standard. All motors shall be totally enclosed type and shall be strong and sturdy to withstand shock and vibrations transmitted to them. The class of protection shall be IP 55 and insulation class F with temperature rise limit to class B. All motor shall be suitable for frequent start-stop, frequent reversing, frequent acceleration and mechanical braking. Motor shall be so located that terminals are accessible for inspection and maintenance and for normal ventilation. All motors shall at least be of 60 minutes (40% CDF) rating with pull-out torque at least 2.5 times the rated load torque for permanent operation. Electrical equipment mounted on the bridge platform shall be enclosed type in sheet metal enclosure, with a provision for easy access to parts inside. The control panel shall be so spaced that efficient maintenance is possible and shall withstand the mechanical forces imposed by the crane under service condition. Controllers All hoist and travel motions of power house EOT crane shall be cabin operated. All hoist and travel motions of GIS hall EOT crane and valve chamber EOT crane shall be pendant controlled. All electrical equipment shall be suitably enclosed so that live parts shall not be exposed to accidental contact under normal operating condition. All master control switches, manually operated switches, circuit breakers, starters, contactors, limit switches and relays shall be clearly and permanently identified by attached nameplates.
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Pendant Controllers The GIS and valve chamber EOT cranes shall be independent travelling pendant controlled having its own electrification track and can move anywhere along the span of the crane without being tied to the hoist. Pendant switches shall be capable of withstanding rough handling and harsh environmental conditions without being damaged and the cover shall be affectively secured. Means shall be provided to prevent inadvertent operation from the floor while maintenance work is being carried out on the crane. Push buttons or switches shall be used in pendant control, which shall automatic return to the OFF position immediately after they are released. One lockable type bush button shall be provided to switch off control power when the crane is not in use and other means of switching off is not available. The weight of the pendant shall be supported independently of the electrical cables by means of chain of wire rope. Speed regulation Speed regulation shall be accomplished utilizing a VVVF drive control system for all crane motions. The hoist and travel motions shall be provided with step-less speed regulation from 5 to 100% of rated speed. The maximum acceleration produced by the control system shall be independent of the rate of change of control lever position. The speed in the lowering position shall not exceed 5% of synchronous hoist speed when lowering any load up to rated load. The speed in the first hoisting position when lifting any load up to 125% of rated hoist capacity shall not exceed 5% of synchronous hoist speed. Limit Switches Necessary limit switches shall be provided for all cranes including monorail hoist to prevent over winding, over traversing and over travelling. At least the flowing limit switches shall be provided for each crane: Hoist driven limit switches for the upper and lower hook position, A back-up over travel limit switch for the extreme upper position of each hoist. Lever operated limit switches for both end position of all travel motions.
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Hoist- driven limit switches shall be totally enclosed and shall be of the block operated type, where the trip action is caused by the lower sheave block. These limit switches shall be arranged and adjusted so that they trip only after the normal hoist driven switch position is over travelled. Back-up limit switches shall be of power type, which directly interrupt the power supply to the hoist motor. Each limit switch shall be positive and unidirectional in action and its contact shall be so designed that it shall not freeze. Contacts shall be enclosed and protected from dust, moisture and mechanical injury and shall be easily removable and replaceable. The switches shall be of quick-break type, capable of stopping the equipment quickly under all conditions of speed and loading. The limit switches after being tripped shall automatically get reset. The actuation of the limit switch shall trip the main incoming circuit breaker or contactor and shall operate an audiovisual warning to the operator. Cradles for load testing For load and overload testing at site a suitable cradle shall be supplied complete with hoisting attachments, slings etc. Lifting beam A lifting beam for lifting of stator and rotor with suitable arrangement shall be provided. The capacity of lifting beam shall be 240 MT. Safety devices Over speed protection Each handling device shall be equipped with an over speed detection device, to check the maximum speed under load. They shall be set at 110% of rated speed. Overload protection Each bridge or main crane shall be equipped with load cells to display the hoisted load value and also to stop lifting motion in case of overload Cable staggering protection Detection of circumferential cable stagger shall stop the hoisting motion. Brake wear protection
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Audible alarm shall be sounded if the brake tracks are worn out excessively Over travel protection Necessary limit switches shall be provided for all cranes including monorail hoists to prevent over winding, over traversing and over travelling. At least the following limit switches shall be provided for each crane: Hoist driven limit switches for the upper and lower hook position, A back-up over travel limit switch for the extreme upper position of each hoist, Lever-operated limit switches for both end positions of all travel motions.
Emergency Push button Emergency push button shall be provided in the cabin / pendant controller for emergency tripping. The push button shall be so arranged as to immediately put off the main supply and apply all the brakes simultaneously irrespective of controller position. Earthing The crane structure, motor frames and metal cases of all electrical equipment including metal conduit or, cable guards shall be effectively connected to earth complying Indian IS 3043. Walkways and ladders Ladders, platforms, walkways, hand hold, foot hold etc. necessary to give safe access to and movement in the cabin, bridge drive and trolley drive mechanism, and all other components of the crane needing inspection, maintenance, lubrication and repair shall be provided. Walkways shall be provided on both sides along the entire length of the bridge. All walkways and stair ways shall be of rigid construction, with hand railing and non-skid checker plate treads or grating, toe-boards not less than 100 mm high. Walkways shall be continuous and permanently secured. Walkways shall have a clear passageway. Bumpers Bumpers shall be attached to the bridge truck and the trolley. The bridge shall have four bumpers one at each corner arranged to meet the crane stops. Trolley shall have two bumpers on each side placed to meet the trolley stops. The bumpers shall be fastened to the
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trucks and the trolley and shall be capable of bringing the crane and the trolley to a gradual stop when travelling at rated speed in either direction. Holding Clamps As a safety against movement of crane off the rail during an earthquake, suitable provision to contain the movement of the crane shall be made. Clamps to keep the crane in a locked condition while not in operation and indication of locking in cabin / pendant shall be supplied and arranged. 23.5 Performance Guarantee
The electric overhead travelling (EOT) cranes (Power house, penstock valve house and GIS) along with all auxiliaries and accessories shall be capable of performing intended duties under specified conditions. The Contractor shall guarantee the reliability and performance of the individual equipment as well as of the complete system. The cranes shall be capable of raising, lowering, holding and transporting their rated lifting loads without any damage to or excessive deflection of any component. The cranes shall be able to control the following movements carrying rated lifting load: Main Hoist vertical movement Auxiliary Hoist vertical movement Bridge travel Trolley travel Monorail hoist 3.0 mm 3.0 mm 5.0 mm 1.5 mm 1.5 mm
The vertical deflection of crane girders caused by the rated load plus all dead load should not exceed 1/1000 of the crane span.
23.6
Minimum factor of safety for each crane shall be five (5) Minimum factor of safety for wire rope shall be six (6) Safety requirements
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In the design of Crane, all safety regulations as applicable with Factory Acts, Indian Electricity rules etc. as prevailing in the country and the site of installation shall be taken into consideration and provided for. In the event of extreme variation in supply voltage outside the expected limits defined in Clause 2.15.2 of General Technical Requirements, there shall be total load control and measures shall be taken to place the handled equipment in a secure position. Correct vertical motion functioning shall be guaranteed within the above mentioned ranges of expected frequency and supply voltage variation. In the event of a loss of electrical supply, load control shall be ensured. Collisions of trolleys and pieces of equipment with buffers shall not endanger load control. 23.7 Drawings, Documents and Design Calculations
23.7.1 Drawings and documents The Contractor shall submit all the drawings and documents in accordance with requirements stipulated in Section 2.12 Reference drawings and documents of General Technical Specification (GTS). This shall cover at least the following drawings; General assembly drawings of the crane General assembly drawings of crab / trolley General assembly drawings of individual mechanisms Drawings of bridge, end girder and their connection. Sub-assembly drawings of wheels, hook block and hoist drum. Wiring and control diagram of crane showing detailed rating of each motor, cable size etc. 23.7.2 Design calculation The Contractor shall submit the design calculation, covering at least the following, for review / acceptance; Calculation for ultimate tensile strength, yield point and factor of safety and other parameters for designing the EOT cranes,
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Calculation for allowable stresses / load etc. under various conditions including worst condition.
Calculations for selection of motor, reducers, brakes, couplings, runaway rails and cross travel rails etc.,
Calculation for design of bridge girder, end carriage, lifting beam, cradle, girder joint, Calculation for design and selection of wire rope, rope drum, sheaves and wheel size.
23.8
Shop and site tests
23.8.1 General The owner or his authorised representative shall have access to the manufactures works at all the time for the purpose of witnessing the manufacture, inspection of assembly, match marking etc. and testing of all the components, sub assemblies and assemblies of the crane. The owner engineer may reject any work found defective or unsatisfactory. The contractor shall furnish indicating the process of inspection for manufacture of component quality assurance plan. Customer hold points shall be clearly marked on the plan. 23.8.2 Shop Assembly and match marking The crane shall be completely assembled, operated and load tested in the shop and checked for adequacy of design and suitability for reliability, safe and proper operation. The parts of the crane shall be delivered assembled in as large units as practicable for field erection and handling. All site joints shall be fitted in shop and match marked suitably for ease in erection. All match marks shall be clearly visible and legible. 23.8.3 Tests at Works All material furnished shall be of tested quality and all works performed shall be subjected to rigid inspection as specified in relevant international or Indian standard. No item or material shall be despatched from suppliers works until despatch instructions are issued by the owner. The contractor shall submit the type test report in respect of all the major components as per requirement of the latest standard for inspection.
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Full load and 25% overload test shall be done at manufacturers works on hoisting and cross travel motions. Full load and 25% overload test with trolley up to 1.5 m on either side from centre of the bridge shall be done. Tests to verify specified speeds under load conditions and tests about deflection of bridge girder under safe working load at rest and with crab in centre position as per standard shall be done. Operation of brakes as per relevant standard shall also be done. Full load test to be done at manufacturers works on lifting beam. 23.8.4 Material Tests Material tests for important components of crane shall be carried out and test reports and certificates shall be submitted to the owner. 23.8.5 Field Test After installation at site, the contractor shall repeat all the tests conducted earlier at the works in accordance with this specification and shall also conduct all the tests as specified in IS: 3177: 1999. The contractor shall furnish a complete outline of the proposed methods and procedures to be used for conducting the tests for review well in advance. The contractor shall provide all necessary material and labour for performing all the tests at site. 23.8.6 Deflection Test The deflection test shall be carried out with test load i.e. rated load at rest and with crab in central position. The measurement shall not be taken on the first application of load. Datum line for measuring the deflection shall be obtained by placing the crab on the extreme end of the crane span with smaller hook approach.
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23.9
Installation and Commissioning
Requirements. The supplier shall arrange personnel to oversee proper storage of equipment at site, their transhipment to powerhouse, installation and commissioning including load test etc. All installation work shall be done by skilled workers in a workmanlike manner. The contractor is required to submit erection programme well in advance for proper coordination with other agencies. 23.10 Spare Parts and Special Tools All spare parts and accessories shall be identical electrically and mechanically to corresponding parts in the equipment supplied and shall be suitably packed and clearly marked, ready for long term indoor storage. 23.10.1 Recommended Spare Parts
Recommended spare parts shall be supplied in accordance to clause 2.36 Spare Parts and tools of General Technical Requirements. The contractor shall furnish the list of recommended spare parts. 23.10.2 Specified Spare Parts
Specified spare parts to be supplied for Power house, penstock valve house and GIS cranes under this section are as follows: Description Power House Crane Main hoist Brake lining for main hoist Brake solenoid coil complete Limit switches of each type Electric motor of each type Wire Rope Auxiliary Hoist
Quantity
1 set 1 set 1 set 1 set 1 length
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Description Brake lining for main hoist Brake solenoid coil complete Limit switches of each type Electric motor of each type Wire Rope Bridge drive Contacts for main runway collectors Contacts and springs for controller Brake lining for main hoist Brake solenoid coil complete Limit switches of each type Electric motor of each type Trolley drive Contacts for main runway collectors Brake lining for main hoist Brake solenoid coil complete Limit switches of each type Electric motor of each type Monorail Wire rope Brake lining for main hoist Brake solenoid coil complete Limit switches of each type Electric motor of each type Over load relay each type Push button each type Contacts of each type & size
Quantity 1 set 1 set 1 set 1 set 1 length
1 set 1 set 1 set 1 set 1 set 1 set
1 set 1 set 1 set 1 set 1 set
1 set 1 set 1 set 1 set 1 set 1 set 1 set
Coupling complete with coupling bolts, rubber, 1 set sleeve etc of each type Miscellaneous Spares Circuit breaker of each type 1 set
Spring, O-rings, oil seals, gasket, packing etc 2 sets of each type and size for complete crane Printed Circuit Board of each type
1 set
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Description Fuses of each type & size Indicating lamps each type Over load relays each type Coupling complete with bolts etc. Bearing for wheels, gear boxes & motor etc. Push button each type Thyristors and diodes of each type Control switches of each type Disconnecting switches of each type Terminal blocks of each type Resistors of each type Condenser of each type Fuse blocks of each type Plug connector of each type Plug module of each type Penstock Valve House Crane Main hoist Brake lining for main hoist Brake solenoid coil complete Limit switches of each type Electric motor of each type Wire Rope Auxiliary Hoist Brake lining for main hoist Brake solenoid coil complete Limit switches of each type Electric motor of each type Wire Rope Bridge drive Contacts for main runway collectors Contacts and springs for controller Brake lining for main hoist Brake solenoid coil complete
Quantity 2 sets 2 sets 1 set 1 set 1 set 1 set 1 set 1 set 1 set 1 set 1 set 1 set 1 set 1 set 1 set
1 set 1 set 1 set 1 set
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Description Limit switches of each type Electric motor of each type Trolley drive Contacts for main runway collectors Brake lining for main hoist Brake solenoid coil complete Limit switches of each type Electric motor of each type Miscellaneous Spares Circuit breaker of each type
Quantity 1 set 1 set
1 set
Spring, O-rings, oil seals, gasket, packing etc 2 sets of each type and size for complete crane Printed Circuit Board of each type Fuses of each type & size Indicating lamps each type Over load relays each type Coupling complete with bolts etc. Bearing for wheels, gear boxes & motor etc. Push button each type Thyristors and diodes of each type Control switches of each type Disconnecting switches of each type Terminal blocks of each type Resistors of each type Condenser of each type Fuse blocks of each type Plug connector of each type Plug module of each type GIS Hall Crane Main hoist Brake lining for main hoist Brake solenoid coil complete Limit switches of each type Electric motor of each type
1 set 2 sets 2 sets 1 set 1 set 1 set 1 set 1 set 1 set 1 set 1 set 1 set 1 set 1 set 1 set 1 set
1 set 1 set 1 set 1 set

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Description Wire Rope Bridge drive Contacts for main runway collectors Contacts and springs for controller Brake lining for main hoist Brake solenoid coil complete Limit switches of each type Electric motor of each type Trolley drive Contacts for main runway collectors Brake lining for main hoist Brake solenoid coil complete Limit switches of each type Electric motor of each type Miscellaneous Spares Circuit breaker of each type
Quantity 1 length
1 set 1 set 1 set 1 set 1 set 1 set
1 set
Spring, O-rings, oil seals, gasket, packing etc 2 sets of each type and size for complete crane Printed Circuit Board of each type Fuses of each type & size Indicating lamps each type Over load relays each type Coupling complete with bolts etc. Bearing for wheels, gear boxes & motor etc. Push button each type Thyristors and diodes of each type Control switches of each type Disconnecting switches of each type Terminal blocks of each type Resistors of each type Condenser of each type Fuse blocks of each type Plug connector of each type Plug module of each type
1 set 2 sets 2 sets 1 set 1 set 1 set 1 set 1 set 1 set 1 set 1 set 1 set 1 set 1 set 1 set 1 set
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23.11 Tools and testing Instruments 23.11.1 Recommended Tools and testing instruments
The Contractor shall propose the list of special tools and testing instrument including their make and detailed specification as recommended by manufacturer(s), to be accepted by the Owner. 23.11.2 Specified special devices and Tools
Following devices and handling tools required for installation and maintenance of EOT cranes shall be supplied. One (1) Torque wrench with required attachments Set of special tools Two (2) nos. 10 Tons hydraulic jacks Hand operated Greasing gun
23.12 Inspection and Testing The Contractor shall follow the Inspection and testing requirements in Quality assurance clause 2.31 Factory inspection and testing of General Technical Specifications
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24. 24.1
HEATING, VENTILATION AND AIR CONDITIONING SYSTEM (HVAC) Scope of Work
Scope of work under this section covers the provision of labour, tools, plants, materials and performance of work necessary for the design, manufacture, quality assurance, quality control, shop assembly, shop testing, delivery at site, site storage and preservation, installation, commissioning, performance testing, acceptance testing, training of Owners personnel, handing over to Owner and guarantee for one year of heating, ventilation and air conditioning system (HVAC), as per the specifications hereunder, each complete with all auxiliaries, accessories, spare parts and warranting a trouble free safe operation of the installation. The scope of work shall be a comprehensive functional system covering all supply and services including but not be limited to following: a) Air conditioning Units Two (2) air conditioning units, each 15 ton capacity (one main & one standby) for control room and office area, complete with interconnecting piping, controls, indicating instruments, necessary devices, safety devices, valves, thermostats, refrigerating pipes and duct heaters; Air conditioning ducts, elbows, fittings, supply diffusers, return air diffusers and regulating dampers for air conditioning system; Insulation for the complete ducting and lagging of pipe lines and fittings. 5 number hygrometers of 4 to 20 mA output to measure temperature and humidity and to interface with SCADA. b) Ventilation system Air handling Units Three (3) Air Handling Units (AHU 1, 2 & 3) each of capacity 7560 CMH, complete with back ward curved fan, motor, cooling coil and air filters, without ducting and will be located at operating floor EL 2306.90 m.
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One (1) Air Handling Unit (AHU 4) of capacity 7560 CMH, complete with back ward curved fan, motor, cooling coil and air filters, without ducting and will be located in erection bay EL 2306.90 m.
Three (3) Air Handling Units (AHU 5, 6 & 7) each of capacity 6120 CMH, complete with back ward curved fan, motor, cooling coil and air filters, without ducting and will be located at generator floor EL 2301.90 m
Three (3) Air Handling Units (AHU 8, 9 & 10) each of capacity 3600 CMH, complete with back ward curved fan, motor, heating coil and air filters, without ducting and will be located at turbine floor EL 2298.10 m
Three (3) Air Handling Units (AHU 11, 12 & 13) each of capacity 1500 CMH, complete with back ward curved fan, motor, heating coil and air filters, without ducting and will be located at MIV floor EL 2293.25 m.
Three (3) Air Handling Units (AHU 14, 15 & 16) each of capacity 9300 CMH, will be located in control block, one at each floor of EL 2293.25 m, 2298.10m and 2301.90 m. These AHU will have the provision of dual suction i.e. return air recirculation and fresh air mixing, back ward curved fan, motor and air filters. The return air suction shall be provided with motorised damper to close return air path to prevent smoke suction in case of fire.
One (1) Air Handling Unit (AHU 17) of capacity 9300 CMH will be located in control block at EL 2311.00 m. The AHU will have the provision of dual suction i.e. return air circulation and fresh air mixing, backward curved fan, motor, air filter, cooling coil and heating coil. The return air suction will be provided with motorised damper to close return air path to prevent smoke suction in case of fire.
Three (3) Air Handling Units (AHU 18, 19 & 20) each of capacity 7200 CMH, complete with back ward curved fan, motor, cooling coil and air filters, without ducting and will be located in GIS gallery at EL 2317.90 m.
Six (6) Air Handling Units (AHU 21 to 26) each of capacity 6120 CMH, complete with back ward curved fan, motor, cooling coil and air filters, without ducting and will be located in Transformer hall at EL 2306.90 m.
Three (3) Air Handling Units (AHU 27, 28 & 29) each of capacity 7200 CMH, complete with back ward curved fan, motor, cooling coil and air ducting, for bus duct gallery. The AHU shall be provided with two fans (one main & one standby).
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Fresh Air Blowers Two (2) back ward curved air supply fans (MAU 1, 2) each of capacity 70000 CMH (one main & one standby) for supply of fresh air from pot head yard to power house through cable tunnel. These blowers shall be located at the entrance of cable tunnel in pothead yard. 1 set of fresh air filters / air louvers of capacity 100000 CMH shall be provided in the Air intake room. One (1) back ward curved air fan with ducting of capacity 4000 CMH will be provided in ventilation room to pressurise the power house stair case. Air Make-up Units. Two (2) back ward curved booster fans (MAU 3, 4) each of capacity 20000 CMH (one main & one standby) complete with air filters for sucking fresh air from pothead area through cable tunnel for supply to power house. These blowers shall be located either in cable tunnel near GIS gallery or in GIS gallery. Two (2) back ward curved air supply fans (MAU 5, 6) each of capacity 50000 CMH (one main & one standby) complete with air filters, located in ventilation room for supply of fresh air to power house and control block. Two (2) supply back ward curved air supply fans (MAU 7, 8) each of capacity 5000 CMH (one main & one standby) with required ducting, air pre filters for supply of fresh air to Penstock valve chamber through entrance adit. These blowers shall be located in local niche in the entrance adit. Exhaust Fans Two (2) exhaust fans back ward curved type (EF 1 & 2), each of capacity 45000 CMH, for normal exhaust / smoke exhaust from machine hall & control block in case of a fire; Two (2) exhaust fans back ward curved type (EF 3 & 4), each of capacity 8000 CMH, for battery room, toilet, pantry and kitchen; Two (2) exhaust fans back ward curved type (EF 5 & 6), each of capacity 18000 CMH, for smoke exhaust from transformer hall; Two (2) tube type axial Exhaust fans / Roof extractors (EF 7 & 8) each of capacity 6000 CMH for exhaust of covered cable trench.
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Miscellaneous Items c) Air ducting, fittings, air filters, control dampers, grills and louvers. HVAC cooling water system Two (2) pump motor sets, each suitable for delivering 1500 LPM at 60 m head complete with starter, piping, fittings, valves, controls and associated instrumentation; Two (2) centrifugal sand separator complete with associated piping, fittings, valves, controls and instrumentation; Complete water distribution system including piping, fittings and valves; and associated instrumentation. d) Air duct distribution system for supply and return air of all HVAC systems, with necessary galvanized sheet metal ducts (for battery room exhaust air system special rust, acid and corrosion proof ducts), elbows, tees, supports, fixations, including all necessary grills, louvers, outside air louvers, adjusting duct dampers, motorised air dampers, heating and cooling insulations etc. e) A.C. System distribution system with insulation, piping, valves, strainers and fittings etc. f) Any additional AHUs, ventilation fans, pumps and other item / equipment felt necessary during detail engineering, g) One (1) microprocessor based / central computerised control station for HVAC system complete with all wiring, instrumentation and associated accessories. h) Local control panels for AHUs, Air Conditioning units, exhaust fans, fresh air supply fans and cooling water pumps etc. i) Necessary pressure, temperature, humidity, flow sensing devices / instruments and meters etc. j) k) One (1) set of spare parts; One (1) set of tools and instruments for erection, maintenance and repair.
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The numbers of equipments / units mentioned are tentative only. The actual requirement of number of equipments / units may need to be examined and reviewed and shall be got approved from the employer during detail engineering. 24.2 Specific Codes and Standards
Electrical equipment shall be designed and tested according to the latest relevant standards including amendments, or complementary standards mentioned in this document, shall be applied, in particular to the following: ISO 9001 Quality Systems Model for Quality Assurance in Design, Development, Production, Installation and Servicing. Code for practice for ventilation of surface hydel power stations. Code of practice for industrial ventilation. Ventilation for acceptable indoor air quality Handbook , data and guide book Safety code for air conditioning Specification for Centrifugal fans Specification for Electric Axial flow fans Air ducts - Specification Galvanized steel sheets (Plain & Corrugated)-Specification Specification for Wrought Aluminium and Aluminium alloy sheet and strip for General Engineering Purpose Thermal Insulation for Cold Storage - Code of Practice Methods of testing panel type air filters for air conditioning and ventilation purpose Sodium flame test for air filters (other than for air supply to I.C. Engines and Compressors).
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IS 4720
IS 3013 ANSI / ASHRAE standard 62 ASHRAE IS: 659 IS: 4894 IS: 3588 IS: 655 IS: 277 IS: 737
IS: 661 IS: 7613
BS: 3928
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IS: 3069
Glossary of terms, symbols and units relating to thermal insulation materials Specification for Expanded Polystyrene for thermal insulation purposes
IS: 4671
IS: 3768 IS: 900 IS: 325 IS: 3589 IS : 1545 IS : 1239 (Part I and II) IS : 1885 ( Part 17) IS : 3624 SMACNA NFPA AWS 24.3
Ventilation ducting vinyl coated, flexible & semi-rigid Specification Code of practice for installation and maintenance of Induction motors Three Phase Induction motors - Specification Steel pipes for Water and Sewage (168.3 to 2540 mm Outside Diameter) - Specification Solid Drawn Copper Alloy Tubes for Condensers and Heat Exchangers - Specification Steel Tubes, Tubular and Other Wrought Steel Fittings Specification Electrotechnical Vocabulary - Switch Gear and Control Gear. Specification for Pressure and Vacuum Gauges. Sheet Metal and Air-Conditioning Contractors National Association National Fire Protection Association American Welding Society
Rating and functional Characteristics
24.3.1 Rating of equipment The installation being at an altitude of 2300m, the standard voltage and current rating of the pump motors will be derated accordingly. Sl no 1.0 Equipment Capacity Location / purpose
Air Make-Up Units
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Sl no 1.1
Equipment
Capacity
Location / purpose
MAU 1 & 2
70000 CMH
Entrance of cable pothead yard.
tunnel
in
1.2
MAU 3 & 4
20000 CMH
In cable tunnel near GIS Hall or in GIS Hall Ventilation Room at EL 2320 m in Control Block Entrance Chamber Adit of BF Valve
1.3
MAU 5 & 6
50000 CMH
1.4
MAU 7 & 8
5000 CMH
1.5
Stair Case Blower
4000 CMH
Ventilation Room at EL 2320 m in Control Block
2.0 2.1 2.2 2.3 2.4 2.5 2.6
Air Handling Units Air handling unit -1, 2 & 3 Air handling unit - 4 Air handling unit 5, 6 & 7 Air handling unit 8, 9 & 10 Air handling unit 11, 12 & 13 Air handling unit 14 to 17 7560 CMH 7560 CMH 6120 CMH 3600 CMH 1500 CMH 9300 CMH Operating floor EL 2306.90 m Erection Bay EL 2306.90 m Generator floor EL 2301.90 m Turbine Floor EL 2298.10 m MIV Floor EL 2293.25 m One at each floor at EL. 2311.00, 2301.90 m, 2298.10 & 2293.25 in Control Block. GIS Gallery at EL 2317.90 m Transformer Hall at EL 2306.90 m For Bus Duct Gallery at EL 2306.90 m
2.7 2.8 2.9
Air handling unit 18, 19 & 20 Air handling unit 21 to 26 Air handling unit 27, 28 & 29
7200 CMH 6120 CMH 7200 CMH
3.0
Exhaust Fans
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Sl no 3.1
Equipment
Capacity
Location / purpose
Exhaust fans 1 & 2 (For normal / smoke exhaust from machine hall) Exhaust fans 3 & 4 (For exhaust from Toilet, Battery room and Pantry) Exhaust fans 5 & 6 (For smoke exhaust transformer hall) Exhaust fans 7 & 8 (For smoke exhaust covered cable trench) from
45000 CMH
tunnel
in
3.2
8000 CMH
tunnel
in
3.3
18000 CMH from
tunnel
in
3.4
6000 CMH
In pothead yard.
4.0 4.1
Cooling Water System HVAC cooling water pumps 1&2 Centrifugal separators type sand 1500 LPM at 60m head 1500 LPM Cooling water floor at EL 2293.25 m in Control Block Cooling water floor at EL 2293.25 m in Control Block
4.2
5.0 5.1
Air Conditioning Units Air Conditioning Unit 1 & 2 15 Ton Ventilation Room at EL 2320 m in Control Block
24.3.2 Functional characteristics Air conditioning and ventilation system Climatic Conditions The objective of the ventilation and air conditioning system is to provide and maintain workable temperature conditions in the Power house. Maximum and minimum ambient and water temperatures are as follows: Design parameter Outside air River water
Summer 34O C 10O C
Winter 5O C 1O C
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The air conditioning system shall provide conditioned air in the station control room and office area located in the power house. The system shall be designed to maintain a temperature of 241 C at a relative humidity of 50% 5% in all the areas air conditioned. During winter season when the temperature is below 24OC, heating requirement in the control room and offices shall be met with combination of duct heaters and base board heaters. The use of class I Ozone depleting chemicals including all Chloro-Fluoro Carbon, Halons or their mixtures are prohibited. Air conditioning duct shall be insulated and supply air diffusers shall have regulating damper and return air diffusers without damper. Standard Square type diffusers shall be considered. In Ventilation duct grills shall be with regulating damper to adjust flow of air. Anemometer shall be in the scope of supply to measure air velocity / discharge. The system shall draw fresh air from the station ventilation system. Ventilation system shall be provided to maintain workable temperature conditions within the power house cavern and within non-air conditioned areas. The normal air temperature in the power house shall be between 28 1 C at relative humidity not exceeding 65%. The cable tunnel shall be used as the main air supply duct for supplying outside air. The main access tunnel shall be used as the principal exhaust duct during normal ventilation. To provide better control and maintenance convenience, a central system is provided for supplying the make-up (outside) air. To minimize outside air requirements and to avoid cumbersome duct runs, the power house and transformer hall & GIS gallery ventilation will be done using local, water-cooled, recirculating-air-handling units. Battery and sanitary rooms shall be ventilated from the system but exhausted through separate duct work. Air duct distribution system for supply and return air of all HVAC shall be made of galvanized sheet metal. For battery room exhaust air system, special rust, acid and corrosion proof ducts shall be provided.
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The system shall also be provided with all the necessary control equipment for automatic unattended operation The HVAC cooling water system demand shall be met by two (2) pumps (one main and one stand-by) fed from cooling water sumps. The discharge of the pumps shall pass through centrifugal cyclone type separators suitable for continuous operation, complete with purge valves and controls for automatic purge. Water shall then be distributed to the different cooling coils after which it shall be discharged back to cooling water sumps. At each AHU pressure gauge, temperature indicator at inlet and out let shall be provided. During total plant shutdown, it is assumed that HVAC cooling water shall not be required. All equipment shall able to control from control room i.e. from Level 2. Air Changes per hour For all ventilation and air conditioned rooms, the air changes shall be as per relevant IEC / IS code to provide the desired heat relief and maintain a minimum level of fresh air in the power house and other areas. All ventilated and air conditioned area shall be designed to maintain a positive pressure within the power house. Noise Levels The noise level when measured at 1.5 m from source, caused by operation of the HVAC systems shall not exceed: 45 dB (A) in rooms as in the control rooms and offices and 60dB(A) in other areas. 70 dB (A) for all diffusers grills and 85 dB (A) for motors, fans, etc., Silencer, as required, shall be provided to guarantee the above sound levels.
Maximum Air Velocities The velocity in various ducts shall not exceed; 10 m/sec in main ducts 8 m/sec in branch ducts 2 m/sec in ducts in the occupied room zones
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The unit shall be provided with microprocessor based control system. It shall have control logic with the Clear Language Display, which shall have various functions that allow the operator to read unit information and adjust set points. 24.4 Performance Guarantee
The heating, ventilation and air conditioning system along with all auxiliaries and accessories shall be capable of performing intended duties under specified conditions. The Contractor shall guarantee the reliability and performance of the individual equipment as well as of the complete system. Fresh Air Intake Arrangements a) Steel M.S. bird screen: Suitable bird screen which prevent birds and direct exposure to dust from high winds to intake room shall be provided. The screen will have provision for 1200 x 2100 mm door. b) Filters for Blower Room Dry and washable panel type metallic air filters in deep crimped formation 50 mm thick of approximately 600 x 600 mm size panels (Module) designed screens complete with MS mounting frame (face velocity shall be about 110 m/min.) for installation in side the blower room in front of the main blowers capable of handling 70,000 m/hr of air. The filters shall be suitable for cleaning by compressed air from the reverse side. The filters shall be heat resistant up to 150C and preferably bacteria and odour free type. Each filter module shall have a flow capacity of 2700 m/hr with 4.5 to 5 mm WC pressure drop. Efficiency of the filters shall be 92 to 95% for particles of size up to 10 microns. 24.5 Design and Construction
24.5.1 Air Make up units It shall consist of a fan with following factory installed components as indicated below;
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Type
Filter section Regulating damper
Unit shall be sectionalised Double Skin construction, draw-thru type consisting of fan section, face and by pass damper section, filter section and drain pan. Casing Double skinned panels shall be 25 mm thick made of galvanised steel, pressure injected with foam insulation, Density 40 kg/m3 with K Factor not exceeding 0.92 Watt/C shall be fixed to 2.5 mm. thick Aluminium Alloy Twin Box section structural framework with stainless steel screws. Outer sheet of panels shall be made of galvanised pre-plasticised sheet of 1.0 mm thick, and inner sheet of 24 gauge plain G.I. Sheet. The entire framework shall be mounted on an Aluminium Alloy Channel base. Panels shall be sealed to framework by Heavy duty Ò Ring gaskets held captive in the framed extrusion. All panels shall be detachable or hinged. Hinges shall be made of Die cast Aluminium with stainless steel pivots, Handles shall be made of Hard Nylon and be operational from both inside and outside of the unit. Units supplied with various sections shall be suitable for on site assembly with continuous foam gasket. All fixing and Gaskets shall be concealed. Units shall have hinged, quick opening access door in Fan and filter section. Access doors shall be double skin type. Regulating dampers shall be provided at the outlet section of blower. Condensate drain pan shall be fabricated from 18 Gauge stainless steel sheet with all corners welded. It shall be isolated from bottom floor panel through 25 mm heavy duty `TF quality expanded polystyrene or urethane foam. 24.5.2 Air handling units General Description Units shall be central station air handler. It shall consist of a fan with following factory installed components as indicated below; Cooling coil section
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Heating coil section with electric coil Access and plenum section Filter section Mixing box section Grill box section Face and bypass damper sections for Multi-zone damper section Air mixer section Return fan section Exhaust section
All sections shall be flanged with gasket to allow easy assembly and disassembly. Type Unit shall be sectionalised Double Skin construction, draw-thru type consisting of fan section, coil section, face and by pass damper section, filter section and drain pan to meet requirements of the AHU. AHU without ducting have additional grill section box. Casing Double skinned panels shall be 25 mm thick made of galvanised steel, pressure injected with foam insulation, Density 40 kg/m3 with K Factor not exceeding 0.92 Watt/C shall be fixed to 2.5 mm. thick Aluminium Alloy Twin Box section structural framework with stainless steel screws. Outer sheet of panels shall be made of galvanised pre-plasticised sheet of 1.0 mm thick, and inner sheet of 24 gauge plain G.I. Sheet. The entire framework shall be mounted on an Aluminium Alloy Channel base. Panels shall be sealed to framework by Heavy duty Ò Ring gaskets held captive in the framed extrusion. All panels shall be detachable or hinged. Hinges shall be made of Die cast Aluminium with stainless steel pivots, Handles shall be made of Hard Nylon and be operational from both inside and outside of the unit. Units supplied with various sections shall be suitable for on site assembly with continuous foam gasket. All fixing and Gaskets shall be concealed.
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Units shall have hinged, quick opening access door in Fan and filter section. Access doors shall be double skin type. Gravity dampers at outlet section of blower. Condensate drain pan shall be fabricated from 18 Gauge stainless steel sheet with all corners welded. It shall be isolated from bottom floor panel through 25 mm heavy duty `TF quality expanded polystyrene or urethane foam. Mixing Box Mixing Box wherever specified shall also be double skin construction and complete with fresh and return Air Dampers in position. Grill Section Grill section box wherever specified shall also be double skin construction and complete with gravity / motorized dampers and with Aluminum extruded grills. Dampers i) Dampers shall be opposed blade type or equivalent. Blades shall be made of double skinned aerofoil Aluminium section with integral gasket and assembled within a rigid extruded aluminium alloy frame. All linkages and supporting spindles shall be made of Aluminium or Nylon, Turning in Teflon bushes, Manual dampers shall be provided with a Bakelite knob for locking damper blades in position. ii) Damper frames shall be sectionalised to minimise blade warping. Air leakage through dampers when in closed position shall not exceed 5 percent of maximum design air volume flow rate at maximum design air total pressure. Motor and Drive Fan Motor shall be energy efficient and shall be suitable for 415V 10% Volts, 50 Hz., three phase, supply, totally enclosed fan cooled with insulation class `F. Motors shall be specifically designed for quiet operation. Motor speed shall not exceed 1440 RPM. Drive to Fan shall be provided through belt-drive arrangement. Belts shall be of Oil-resistant type. Belt guard shall be provided over the drive.
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Motor shall be mounted inside the AHU casing on slide rails for easy adjustment of belt tension. Motor shall drive heavy duty V-Belt, Constant pitch drive selected at 110% of Motor Horsepower. Fan Fans shall be centrifugal, backward blades. Fan casing shall be made of galvanised steel sheet. Fan wheels shall be of galvanised steel. Fan wheels and pulleys shall be individually tested and precision balanced dynamically. Both fan and motor assemblies shall be mounted on a deep section aluminium alloy or galvanised steel base frame. Isolation shall be provided from the unit casing by combination of spring and Rubber Antivibration mounts. The rubber mount shall be flame retardant, water proof neoprene impregnated. Cooling Coils Chilled water coils shall have 12.5 to 15 mm. dia tubes, and 24 gauge thick sine wave Aluminium fins firmly bonded to copper tubes assembled in zinc coated steel frame. Face and surface areas shall be such as to ensure rated capacity from each unit. Air velocity across the coil shall not exceed 150 metres per minute, coils shall be pitched in unit casing for proper drainage. Each coil shall be factory-Tested at 21 kgs. per sq.cm. pressure. Tubes shall be hydraulically/mechanically expanded for minimum thermal contact resistance with Fins. Fin spacing shall be 4-5 Fins per cm. Coils shall be sealed in polythene bags and packed in crates properly. Coil with damaged Fins will not be accepted. Filters Each Air Handling Unit shall be provided with a factory assembled filter section containing reusable type vacuum cleaned and self-extinguishing media with anodised aluminum frame. The media shall be supported with HDP mesh on one side and aluminium mesh on other side. Filter banks shall be easily accessible and designed for easy withdrawal and renewal of filter cells. Filter framework shall be fully sealed and constructed from aluminium alloy. Filter bank face velocities shall not exceed 1.75 m/sec.
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At the design air volume flow rate, the initial (clean) resistance shall not exceed 50 p.a. Accessories Unit shall be complete with following accessories Double regulating valves in Return line, isolating ball/butterfly valves in supply line and drain piping. Thermowells for mounting of supply and return water thermometers. T-Connections with gauge cocks on supply and return lines for mounting of pressure gauges. Y-strainer. Automatic air vents with gate valve on the cooling coils. Dirt legs with drain cocks below supply and return header connections to AHU.
Noise level Fan and motor assemblies shall be complete with anti-vibration mountings. Noise data shall be provided and shall be based on tests in accordance with appropriate Indian Standard specifications. Full details of testing technique and procedure shall be given. Testing Each unit shall be tested for its design performance and test results shall be furnished as per standards and as called for. Controls Control system for Air Handling units shall comprise following : All AHUs and MAUs shall have a local control box with on-line starters and with provision for Local / Remote, Start / Stop, Auto / Manual, Main / Standby and other controls based on micro PLC or electromechanical Contactors i.e digital or conventional system. System will have facility for interfacing with DCS remote control.
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Controls shall be complete with all components, auxiliary relays, contactors, wiring etc. All control wiring in the AHU and termination into the control panel shall be carried out by the Contractor.
AHU/MAU Unit control shall be as follows : When Control circuit energised, fan is started. Dry bulb temperature shall be controlled by means of a return air thermostat to actuate 3 ways modulating motorised valve. Flap switch actuated by air pressure shall be provided with each air handling unit, Arrangement shall be made in the control circuit of AHU to shut-off the return air damper in case of fire signal from the fire alarm main control panel.
Painting Shop coats of paints that have become marred during transit or erection shall be cleared off with mineral spirit, wire brushed and spot primed over the affected area and then coated with paint to match the finish over adjoining shop painted surface. Specific Provisions for Blowers Rating of blowers/exhaust fans incorporated above shall be examined by the supplier for their duties etc. and confirm that no extra blowers/exhaust fans will be needed except those envisaged. All blower and equipments shall be carefully painted immediately after sand blasting with two coats of zinc chromate primer and two coats of approved shades of synthetic enamel paint to protect them from moisture present in the atmosphere and humid conditions of site. All the blower fans and motors are suitable for working under ambient conditions 0C to 30C. Smoke exhaust blowers will have a rating of minimum 250 C for one hour. Fans will be complete with standard TEFC Squirrel cage induction motors, V-belt drive with pulleys and belt guards, canvas connection, base frame and vibration isolator etc. A gravity type damper or equivalent shall be provided at the outlet of each fan.
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All the fans/equipments shall be provided with foundation bolts. Alternate type of blower according to classification as per manufacturers standard practice can be considered on its merits. The Contractor should furnish all fan data justifying their selection of the type of fan and its characteristics.
Estimated pressure loss in the system shall be given. The Contractor shall examine and ensure that fan characteristic shall be such that any over or under estimation of losses can be fully taken care by proper selection of the blower.
Motors Motors for blowers shall be TEFC, squirrel cage induction motors as per IS : 325 of Siemens/ NGEF / Crompton / ABB / Kirloskar make. Suitable on-line starters shall be provided for motors. Start / Delta starters to be provided in case it is necessary as an alternative. 24.5.3 Ducts The supply and return air ducts (with insulation on main ducts carrying cold air) supports, hangers and clamps etc. shall be included in scope of supply. Ducts will consist of GI sheet metal of thickness as per IS: 655 and as per Table given below
Duct size in mm upto 750 mm 751 to 1500 1501 to 2250 2251 & above
Thickness of GI sheets mm 0.63 mm 0.80 mm 1.00 mm 1.25 mm
Duct lengths shall be kept as per codes and/or as limited by physical considerations. These will be erected using standard pre fabricated galvanised supports, hangers, clamps and anchors etc. All support system shall be galvanised Hilti/Fischer or equivalent; anchors for support of ducts as required shall be fixed by the Contractor. All duct support accessories like supporting angles, channels, brackets, tie rods etc. shall be galvanised. Duct jointing shall generally be done by ROLAMAT 4D bolt system. Any other shall be approved by the purchaser.
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Duct shall conform to following: Sheets used for the ducting shall be galvanised iron of class VIII galvanisation as per IS: 277 and of nominal Zinc (Spelter) coating of 125 gm/m (Both sides inclusive). Long radius elbows and gradual changes in shape of ducts shall be employed as per IS: 655 and as per carrier handbook to maintain uniform velocities to ensure minimum turbulence, lower resistance and minimum noise. Friction drop in elbow will be approximately 2 mm WG. Flexible connection shall be provided between fan outlet and main duct to prevent noise of fan vibrations being transmitted directly to the sheet metal ducts. Ducts [inside false ceilings] carrying cold air shall be insulated with 50 mm thick glass wool insulation with aluminum foil. However, for all exterior areas, where duct is exposed, suitable insulation of aluminium sheet covering shall be provided. All ducts in battery room will be painted with acid resistant paint. Battery exhaust duct will also be painted from inside by acid resistant paint from battery room up to plenum for waste gases. Quantity for plenums will be payable at duct rates. Sheet metal work include ducting, grills, diffusers, F.A.I. louvers, volume control dampers, splitters, fire dampers and thermal insulation of all supply air A.C. ducts. Supply air ducts for all equipment shall be acoustically lined up to a distance of 6 m. from the fan. All ducts for ventilation and air conditioning system shall be galvanised sheet metal. The exhaust air ducts of battery room shall be corrosion, rust and acid resistant material. The sheet thickness shall not be less than the thickness indicated in the relevant IS or any applicable standard, the thickness depending on the length of the longer size of duct. All ducts shall be air tight with opening at suitable locations. If necessary, the rectangular elbows shall be equipped with aerodynamically formed guiding vanes. All take-off branches shall be equipped with an adjustable volume extractor, which assist in balancing by directing a regulated amount of air for supply outlets from the main duct. The ducts shall be supported by straps attached directly to the sides of the duct if the duct
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size is not more than 400 mm, but larger ducts shall be carried by structural angles, hangers in rods with adjustable nuts, anchored to the ceiling of walls by concrete fasteners bolts of anchors. Maximum allowable distance between duct supports shall not be more than 1500 mm. 24.5.4 Insulations The fresh air and cooled down supply air ducts shall be insulated to prevent condensation on the duct surfaces. The insulation material (thickness to be as per detail designed) shall be non-hygroscopic, rot-proof, preferably of mineral raw material such as rock wool. The insulation mats of plates shall be fastened on the duct and wrapped with aluminium foils. The insulation material shall also be sufficient to obtain the acoustical guarantee. The chilled and cooling water piping shall be properly insulated. The mentioned insulation shall be included in the supply. 24.5.5 Grills and Diffusers Aluminium extruded type air grills, diffusers with powder coated finish shall be provided as per standard. Main dampers shall be of parallel blade or opposed blade type or equivalent, using G.M. bushing for smooth movement. For Electrical control, damper motors shall be provided whenever required as per requirement. The Contractor shall offer good quality ducting grills, diffusers, louvers, volume control dampers, splitters, fire dampers, providing good acoustic, aesthetic and mechanical properties. The Contractor shall offer a suitable duct support arrangement comprising turnbuckle / extenders / suspenders, extension rods to adjust the length of the supports. The supply air grills shall be used for correct air distribution by horizontal and vertical adjustable bars of sidewall installations. The return air grill shall be suitable for adjustment from outside and shall be equipped with 45 degree horizontal fixed fins.
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The design has to fit the architectural false ceiling and lighting schemes and the grills be made of aluminium powder coated with high surface finish and the size have to correspond to the fixed noise criteria. Grills for the battery room shall be of acid corrosion and rust resistant material. 24.5.6 Outside air louvers Outside air louvers of each of fresh air and exhaust air system shall prevent the entrance of rain, insects, birds and trash into the ducts. They shall be stamped and pressed out of one piece of aluminium sheet of at least 2 mm thickness. The frames shall also be made of aluminium. 24.5.7 Louver dampers Double acting louvers shall be fabricated with a welded frame of rolled section. Bearing shall be of the oil retaining porous bronze type and shall be fixed into the frame. The louver dampers as well as the steel frame shall be hot-dip galvanised after fabrication. Louvers and dampers shall be equipped with related limit switches to be used in control and interlocking system. 24.5.8 Fire Dampers Specifications All fire and smoke dampers shall be of at least 90 minutes fire rating certified by CBRI Roorkee as per UL 555. Fire damper blades & outer frame shall be formed of 1.6 mm galvanized sheet steel. The damper blade shall be pivoted on both ends using chrome plated spindles in self lubricated bronze bushes. Stop seals will be provided on top and bottom of the damper housing made of 16 G galvanized steel sheet. For preventing smoke leakage, side seals will be provided. Damper shall be motorized type and open / close will be the command from PLC. The fire dampers shall be mounted in fire rated wall with a duct sleeve 600 mm long. The sleeve shall be factory fitted on fire damper. The joints at sleeve end shall be slip on type. Minimum thickness of GI sheet shall be 18 G.
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The damper shall be installed in accordance with the installation method recommended by the manufacturer and approved by the Employer. All wall mounted fire dampers shall have 485 mm long GSS sleeve. Duct mounted fusible link operated Fire Damper shall have 375 mm long GSS sleeve with flanged ends. Alternatively motorised dampers will be provided. Location of Fire Dampers i. ii. iii. Return air inlet of control AHUs Transformer Hall smoke duct PH / control block smoke duct.
24.5.9 Air filters Air filters shall be of the viscous impingements type, cleanable, aluminium wire mesh coated with viscous substance such as filter oil or grease. The frame structure of the panel cell shall be made of aluminium section. A properly positioned pressure gauge of inclined tube type shall give an indication of the degree of dust loading on the filters for establishing the periods between services. 24.5.10 Fans
Exhaust air fans shall be adjustable axial flow fans. Axial air fans shall be of the multi blade vane type. The vanes shall be adjustable individually at standstill. The hub of the impeller shall be directly coupled to the motor shaft and its diameter adapted to the motor frame. The impeller shall be statically and dynamically balanced. All bearing shall be pre-lubricated, self-aligning and selected for average life of a minimum of 40,000 hours of operation at maximum design rating. If, however, frequent lubricant is required this should be possible from the outside of the fan casing without disturbing the duct assembly. Bearing support shall be specially designed for trouble free bearing service. All fan shafts and wheels shall be designed to operate at their maximum rated speed, which is below the first critical speed.
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All motor bases shall be adjustable and v-belt drives selected for 120 percent of motor power. The steel casing of air fans shall be made of hot-dip galvanised steel of aluminium. Where the impeller is accessible in operation, guard shall be provided to prevent injuries to the maintenance personnel. All fans shall be with Anti- vibration mounting. 24.5.11 Piping System
The Supplier shall provide 2 nos. Vertical Turbine Pumps complete in all respects including motor starter panel, non-return valves, valves, cyclone sand separator and will deliver the water at valve floor unit cooling water sump as marked in the drawing. All Cooling Water Piping beyond this point to supply cooling water to the various AHUs, airconditioning units and air make up units in the Power House and Transformer Hall shall be provided by the Contractor. Necessary GI piping shall be provided for ; water supply for / from all cooling coils. Condense water discharge from cooling coils.
GI Pipes shall be as per IS 1239 heavy grade, flanges, bends, elbows, Tees and other fittings in accordance with IS 1239, Part II (PN rating minimum 10 kg / cm, Test Pressure 15 kg/cm) along with pre fabricated GI supports, hangers, pipe clamps, shut off valves, nonreturn valves, generally as per P&I Diagram for Cooling Water System. All pipes shall be galvanised and insulated. The cooling water piping offered shall be complete in all respects including gaskets, valves, flow control meters, pressure gauges, thermostats, insulations galvanised MS Nuts, Bolts, Washers, etc. Pump capacity selected is 1500 LPM at 60 m head. Contractor shall check and confirm adequacy of the same. 24.5.12 Air Conditioning Units
The Air conditioning package and split air conditioning units shall be of CARRIER` / ÀIRCON / Blue Star or other approved make as per detailed specifications, given below.
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Unit Base & Casing Base panel shall be constructed of fabricated steel structure of adequate size. Casing panels shall be of 1.25 mm thick welded construction removable type to provide easy access to equipment. Casing shall be complete with plenum, discharge outlets, grills, space for refrigeration equipments, fans, cooling coils and strip heaters etc.
Compressor Compressor shall be of multicylinder hermetic sealed type complete with motor, dynamically balanced with all accessories. Compressor assembly shall be installed on a spring mounted floating platform to provide quiet vibration less operation. Compressor shall be provided with overload protection switch. Condensers Condensers shall be water-cooled type with removable heads to enable cleaning of the tubes. Condensers shall be complete with water inlet and outlet connections with valves, and air vents, `Y strainer test cocks, thermometers and pressure gauges and any other standard accessories necessary with the equipment supplied. Cooling Coils Cooling coils shall be of the fin and tube type, aluminium fins, firmly bonded to copper tubes. Face and surface areas shall be such as to assure rated capacity and the air velocity across the coil shall not exceed 170 metres per minute. Pan Humidifier The pan humidifier shall be provided in sheet steel fabricated construction and shall comprise of immersion heater of 1 KW, humidistat and float valve. Electric Strip Heaters Each unit shall be provided with electric strip heaters in accordance with the requirements of the Schedule of Equipment. Minimum of specified steps of heaters shall be provided with two stage heating thermostats.
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Electric strip heaters shall be of the low temperature totally enclosed strip type fitted with radiation fins and suitable for operating at block heat. The surface temperature of the elements shall not exceed 400C when tested in still air at 21C. Sheath shall be completely sealed against entry of moisture. Heater bank shall be arranged to ensure an even temperature distribution across the air stream and shall be readily removable as a unit. Terminal ends of the heating element sheathings shall pass through casing of unit to a terminal box mounted on casing. Element sheet lings shall be fitted with screwed bushes where they pass through the casing and joints shall be sealed with gaskets and nuts on both sides. Alternatively, other approved means may be used to ensure that the joints are rendered airtight to prevent the entry of moist air from the duct into the terminal box. Equipment and complete wiring installation shall comply with statutory requirement of local electricity supply authority. Heater bank shall be totally protected by means of approved circuit breakers and be electrically interlocked with the fan motor so that the elements cannot be energised unless the fan motor contact has closed (Vane switches in the fan discharge or centrifugal switches on fan motor will not be accepted). Fan motor shall be suitably protected against overloads. Power supply for fan motor, heater elements and any necessary control circuits shall be taken through a common isolating switch if possible on the control panel to permit complete isolation of the plant. Sheet asbestos mill board 6 mm thick or other approved fire-proof lining shall be applied to the interior of the unit panels at the heaters and for a distance of one foot on each side of the heaters. A manually reset safety thermostat of approved type shall be installed additional to the above mentioned electrical interlock as a precaution against overheating in the duct. The thermostat shall be wired in series with the heater control circuit and mounted in an approved location within the duct in proximity to heaters.
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Fan Section Fan shall be backward type preferably with variable pitch pulleys. Filters Filters shall be cleanable, synthetic fibre filters Purair of Purolator make. Velocity through filters shall not exceed 107 m/sec. per minute and pressure drop through filters shall not exceed 5 mm of W.C. Insulation Fan Section of Unit shall be acoustically insulated with minimum 25 mm thick fibre glass covered with fibre glass tissue paper and perforated 24 G aluminium sheet. Coil Section shall be insulated to same specification as the Fan Section. Drain pan shall be thermally insulated with 25 mm thick in-form finished with two layers of cold setting bitumastic compound sealing all the joints. Fixing of coil section and drain pan shall be done in such a way to avoid direct metal contact with any other uninsulated metal part in order to avoid condensation. Drain piping within the unit shall be insulated with minimum 25 mm thick thermocole and finished with a suitable vapour barrier. All the surfaces to be insulated shall be throughly cleaned and provided with a thick coat of cold setting bitumastic compound before applying the insulating material The insulating material shall have a K factor of not more than 0.027 kcal/M.Hr. 0C at 100C mean temperature. Vibration eliminators All the moving parts in the unit shall be mounted in the steel frame work with the help of suitable vibration isolators in order to ensure quiet operation of the unit. Accessories Each unit shall be provided with the following accessories as part of the unit:
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a. b. c. d. e. f. g.
Crankcase heaters. High- Low pressure cut-outs. Safeguard against short cycling of the compressor. Compressor motor thermostat. Isolating butterfly valves for the condenser supply, and NRV at the return. Inlet and outlet pressure gauges and thermometers for condenser water circuit. Flow switch for condenser water piping and its inter locking with the compressor motor starter.
h. i.
Insulated drain piping within the package units room. Compressor and Fan motor starters with bi-metallic over load relays.
Controls and Instrumentation The MCC control System with provision for Local / Remote (DACS) control complete with on-line starters for all consumers, selection and other controls as for AHUs will be provided. Interlocks for self contained air-conditioning units shall be as follows: i) ii) Flow switch in condenser lines to prevent compressor starting without water flow. Condenser water pumps starters to be inter-locked with fan motor to prevent operation of compressor without the pumps running. iii) Strip Heater contactors to be inter-locked with fan motor to prevent switching ON of heaters without fan running. iv) Compressor starter to be inter-locked with fan motor to prevent switching ON of heaters without fan running v) Crank case heaters to be switched ON automatically when compressor stops.
Automatic temperature control for the units shall be as follows: i) Snap acting fixed differential variable range line voltage double throw thermostat with sensing element in return air suitable for summer cooling. ii) Double pole double throw changeover switch for summer/ winter operation.
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iii)
Relay /contactor to operate strip heaters for winter heating in two stages with Twostage heating thermostat for a group of units as shown on the drawings.
iv) Rotary switch with OFF-FAN - COOL - HEAT positions and indicating lights. One gyserstat shall be provided near strip heaters for each set of strip heaters which will be interlocked with the two stage strip heater contactors to put OFF the heaters in the case of excessive temperatures rise. Installation Package unit shall be mounted on vibration eliminators. The Contractor shall supply the required charge of refrigerant, lubricants and other consumables, for commissioning and testing the equipment. All the equipment shall be thoroughly tested and checked for leaks. The refrigerating system shall be maintained at a vacuum of less than 7.6 mm Hg absolute for four hours. At the end of this period the pumps shall be stopped and vacuum drop of 2.5 mm Hg absolute. The Contractor shall certify that the vacuum was maintained as specified above. All safety controls, low and high refrigerant pressure controls, starter overloads strips shall be suitably set and a record of all the settings shall be furnished to Engineer-in-charge. Testing Unit capacity in tons refrigeration, shall be computed from the temperature readings and water flow measurements. Computed results shall conform to the specified capacities and power consumption shall conform to the figures furnished with Contract drawings. All instruments, services needed for tests required for the computation of capacities and power consumption shall be furnished by the Contractor. Painting Units shall be factory painted in baked enamel. Painting of the units in factory shall be carried out in accordance with the standard practice after treating all metal parts with anti-corrosive treatment as may be specified by the relevant standards.
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The ducting shall conform to specifications given in clause Piping and Valves The pipe and pipe fittings shall be provided in GI construction of Class 'B'. The pot strainer shall be of cast iron construction with brass strainer. The valves shall be butterfly type made of cast iron. 24.5.13 Bolts, nuts and washers
All bolts, screws and nuts shall be of metric thread standards and have hexagonal heads. The material shall be of stainless steel. 24.5.14 Control and Electrical equipment
Control and monitoring The system shall be controlled and monitored at three (3) levels: Level -0- By respective local control cubicle for individual drive. Level - 1- Local control board for all equipment. Level -2-Control and monitoring (SCADA) system from control room for all equipment. Provisions shall be made in local control panel for interfacing with SCADA system. The HVAC system shall be designed to operate on fully automatic mode and manual mode. All necessary cabling between the control panels and the field HVAC components (as fans, sensors, pumps, valves, air dampers etc.) shall be included in the scope of supply. Each of the control systems shall be equipped with necessary control, interlocking and security devices. Any failure or breakdown in the control system shall be indicated by a signal on the respective control panel. Potential free contacts and terminals for remote indication of alarms shall be provided in the panel. All necessary protection i.e. single phasing, IDMT and instantaneous over current relays, under voltage relays etc. shall be provided. Pumps shall be provided with electric motors, anchor bolts and other mounting material. The pumps shall be with starting unit suitable for 415 V 10%, 50 Hz 5% with contacts for remote operation / indication.
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24.5.15
Automatic Control and Regulations
The HVAC system shall be equipped with a fully independent computerised and automatic control system for efficient operation. It should automatically stop the supply of fresh / recirculation air to the affected zone immediately in case of fire detection and initiate smoke extraction by using either motorised damper or any other alternate arrangement. All sensor and instruments (temperature, pressure, humidity etc.) limit switches etc. required for automatic regulation and monitoring of proper service of the system shall be included in the supply. 24.5.16 Manual Mode
Individual starting and stopping of equipment shall be by push buttons. 24.6 Quality control and Quality Assurance
The Contractor shall supply the equipment of best quality. The contractor shall maintain control and quality assurance during the manufacturing, installation, testing and commissioning of equipment as per approved quality assurance plan. 24.7 Drawings, Documents and Design Calculations
24.7.1 Drawings and documents The Contractor shall submit all the drawings and documents in accordance with requirements stipulated in Section 2.12 Reference drawings and documents of General Technical Specification (GTS). 24.7.2 Design calculation The Contractor shall submit the design calculation for review / acceptance. Covering at least the following: Sizing of ducts for air distribution, Calculation for selecting the AHU and other fans capacity, Cooling loads, air flow rate and temperature and humidity conditions at all locations/areas. The contractor shall also provide other calculations as required by the employer for approval of contractors design.
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24.8
Shop Testing
The HVAC system shall be type and routine tested as per relevant IEC / IS / Standards. The contractor is required to carry out all type tests on AC units and other equipment of one unit and routine tests on all units and submit the reports to employer. 24.9 Installation and Commissioning
Requirements. The supplier shall arrange personnel to oversee proper storage of equipment at site, their transhipment to powerhouse, installation and commissioning. 24.10 Field testing After installation the HVAC system shall be field tested for operation tests, visual inspection of complete installation, main air flow rate, performance of heaters, coolers, AC unit, electrical consumption of electrical components, room conditions in all rooms, control system, hydrostatical tests of whole piping system, air tightness, vibration and noise due to turbulence in duct assembly etc. The contractor shall furnish a complete outline of proposed method and procedures to be followed for field testing including a list of equipment and instruments to be used for owners review well in advance before the scheduled testing. The contractor shall prepare and furnish all test reports of the field tests of the equipment in a mutually agreed format. 24.11 Spare Parts 24.11.1 Recommended Spare Parts
Recommended spare parts shall be supplied in accordance to clause 2.31 Spare Parts and tools of General Technical Requirements.
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24.11.2
Specified Spare Parts
Specified spare parts to be supplied for HVAC system under this section are as follows: Sl no 1 2 3 4 5 6 Description Air Filter bank (All type & size) V- belts of each type and size Cooling water pump-motor set Air handling fan-motor set Ventilation fan motor Cooling coils of each type and size used Quantity 1 Set 1 Set 1 Set 1 Set 1 Set 1 Set
A set is defined as total number required for one set. All spare parts and accessories shall be identical electrically and mechanically to corresponding parts in the equipment supplied and shall be suitably packed and clearly marked, ready for long term indoor storage. 24.12 Tools and Instruments The contractor shall supply all necessary tools and instruments for installation, repair and maintenance of HVAC equipment. 24.12.1 Special tools
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25. 25.1
FIRE FIGHTING SYSTEM Scope of Work
Scope of work under this section covers the provision of labour, tools, plants, materials and performance of work necessary for the design, manufacture, quality assurance, quality control, shop assembly, shop testing, delivery at site, site storage and preservation, installation, commissioning, performance testing, acceptance testing, training of Owners personnel, handing over to Owner and guarantee for one year of fire fighting system, as per the specifications hereunder, complete with all auxiliaries, accessories, spare parts and warranting a trouble free safe operation of the installation. The scope of work shall be a comprehensive functional system covering all supply and services including but not be limited to following: 25.1.1 Fire Protection System Two (2) - water pumps each of suitable capacity and pressure rating complete with motor, starter/ local control panels, filters, piping, fittings, valves, controls, pressure gauges, pressure switches and flow switches for filling of overhead tank; Two (2) nos. - booster pumps of suitable type, capacity and pressure rating complete with motor, starter/ local control panels, instruments and accessories for supplying water at required pressure to hydrants located in pothead yard. Nine (9) - High velocity water sprinkle emulsifier system for fire protection of Generator transformer, complete with deluge valves, pilot valves, detectors, nozzles, control panel, spray piping, valves, fittings and associated accessories; Three (3) - High velocity water sprinkle emulsifier system for fire protection of Oil Pressure Unit of Governing system and MIV, complete with deluge valves, pilot valves, detectors, nozzles, control panel, spray piping, valves, fittings and associated accessories; Water supply connection up to generator barrel for fire protection system of Generator. Fire protection system for generator shall be designed and supplied by generator manufacturer; Portable fire extinguisher system for mechanical and electrical utility areas as per approved drawings and bill of material.
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Fire fighting system comprising hose cabinets with hydrant valves, hose pipes, quick coupling unions, isolating valves and fittings for power house complex, transformer / GIS caverns and Pothead yard.
Automatic fire detectors and manual pull stations as per approved drawings and bill of material.
Instruments; piping & pipe fittings; overflows & drain piping, valves and filling level switches etc. for overhead tanks;
Necessary piping for complete distribution system, fittings, valves and associated instrumentation;
Necessary cable and wiring for fire detection system including associated accessories.
Alarm panels and associated items Other items not specified but required to complete the system in all respects to make it functional.
25.2
Set if Spares Set of tools and tackles. Specific Codes and Standards
Electrical equipment shall be designed and tested according to the latest relevant standards including amendments, or complementary standards mentioned in this document, shall be applied, in particular to the following: NFPA 851 NFPA 72 NFPA10 NFPA13 NFPA 14 NFPA 15 Recommended practice for fire protection for hydroelectric generating plants National Fire Alarm Code Standard for portable fire extinguishers Standard for the installation of sprinkler systems Standard for the installation of stand-pipe, private hydrants, and hose systems Standard for water spray fixed systems for fire protection
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NFPA 20 NFPA 75 NFPA 1221 ISO 9001
Standard for the installation of stationary fire pumps for fire protection Standard for the protection of electronic computer/ data processing equipment Standard for the installation, maintenance, and use of emergency services communications systems Quality Systems Model for Quality Assurance in Design, Development, Production, Installation and Servicing
25.3
Rating and Functional Characteristics
The installation being at an altitude of 2300 m, the standard voltage and current rating of the pump motors will be derated accordingly. 25.3.1 Water Supply Water for fire protection system shall be supplied by gravity from an overhead tank located in pothead yard at suitable location. The location of tank shall be such that it should be able to supply fire-fighting water with adequate pressure to the entire power house complex except pothead yard. Booster pumps of sufficient capacity shall be provided to ensure adequate pressure for hydrants located in this are. 25.3.2 Fire pumps For filling the overhead tank, two pump- motor sets (one main and one standby) each of capacity 2400 LPM, shall be supplied. The design head for pumps shall be sufficient to fill the overhead fire tank. The capacity of pumps shall be adequate to fill the overhead tank in less than six (6) hours. However, capacity of each fire pump shall not be less than the flow requirements of a largest delude system or sprinkler or hydrant system at required pressure. The electric motors shall be with class F insulation, control panels, cables. The motor shall be suitably sized to drive the pump continuously over the specified characteristics without getting overloaded. The speed of pump - motor set shall not be more than 1450/1500 rpm The material of pump impeller and casing shall be stainless steel and cast iron respectively. The suction strainer shall be provided in the water pumping system. The element of filters shall be of stainless steel.
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The pump shall be automatically operated as per the requirement of water in overhead tank. Flow indicators with two potential free contacts for remote indication and alarm shall be provided for each pump. Shut-off valves and check valves shall be provided to allow disconnection and switching of each pump. Suitable alarm annunciation for non-functioning of the pumps shall also be provided in the control unit. Adequate arrangement shall be provided to prevent the pump from rotation in reverse direction. Water for filling the overhead tank shall be taken from bore well or from Khero Ganga / near by Nallah (if bore well is not possible in that area). 25.3.3 Booster pumps Two booster pump- motor sets (one main and one standby) each of capacity 2000 LPM shall be provided to ensure adequate pressure for hydrants located in pothead yard. The design head for pumps shall be sufficient to meet the pressure requirement of supply water to hydrants located in pothead yard. The system shall consist of electric motor, control panel, strainer/ filters, pressure indicators, flow indicator, pressure switches etc. The operation of the pumps shall be automatically according to the use of fire hydrants. 25.3.4 Headers and piping The fire header and piping shall be looped and of sufficient size to supply the flow requirements at any point in the loop considering the most direct path to be out of service. Water velocity in the pipes shall not exceed 2.5 m / s. Pipe size shall be designed to accommodate any future expansion / water demand. 25.3.5 Strainers Twin basket strainers or line filters of suitable capacity shall be provided with pumps. 25.3.6 Over head fire tank The capacity of overhead fire tank shall be sufficient to meet the flow requirement of largest deluge system or sprinkler and hydrant system combined whichever is higher at required pressure for two (2) hours.
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The overhead fire tank shall have suitable type of level switches in the control panel for automatic starting and stopping of the fire pumps and remote level indication. The tank shall be of reinforced concrete. The tank shall be suitably compartmentalised along with its level switches for inspection, cleaning or repair maintaining required capacity. The tank status shall be properly annunciated in the main control room. 25.3.7 Piping, valves and fittings All required pipes, flanges, fittings, supports, fasteners, valves and other related material necessary for completion of the system shall be supplied as a part of this contract. Pipes shall be of medium / heavy duty class and wall thickness and the material shall be as per approved standard of respective pipes. All water pipes shall be insulated against condensation wherever required with approved type insulation and be provided with vapour proof cover. 25.3.8 Fire detection devices Aspirating type smoke detection system Aspirator / air sampling type smoke detection system, based on laser-based technology, shall be provided with network of air-sampling pipe, drawing air continuously from the area under its coverage, by efficient aspirators. The detection chamber, located suitably, shall have series of internal filters removing dust and dirt from the sampled air. Care should be taken to protect the optical surfaces in the chamber from contamination and error free performance. The detectors, their associated control and cables shall be such designed so that no interference is created in proper operation of the generator. Suitable interfaces shall be provided for supervision of the real time data through plant SCADA. Provision for multiple alarm levels of at least three (3) levels with programmable relays shall be made. 25.3.9 Automatic fire detectors The detectors spacing and rating shall be in accordance with the applicable standards. The smoke detectors shall be designed with minimised effect of environmental conditions like air velocity, altitude, humidity and temperature, colour of smoke, electrical and mechanical influences like abnormal pressure or vibration and the influence of aerosols and any
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particulate matter. It shall be plug-in type with detector base containing terminals for making connections. Provision of visual indication of detectors alarm condition shall be visible from a distance of six (6) m and visually different from indications of other conditions. The openings of the smoke entry shall be at least thirty (30) mm below the ceiling level assumed to be smooth and flat. 25.3.10 Manual pull stations
The manual pull stations shall preferably be located at access ways within a distance of 1.5 m from the exit doorway opening at each exit on each floor and distance to the nearest pull station measured horizontally on the same floor shall not exceed 50 m. The coded manual pull station shall produce at least three (3) repetitions of the coded signal, with each repetition to consist of at least three impulses. The lever of the manual pull stations shall get locked after manual activation till it is reset. 25.3.11 Notification devices
If an alarm in a fire zone occurs, electric hooters / bells / horns / speakers, light or text displays providing audible, tactile, or visible outputs or any combination thereof shall be actuated. The number of these items shall be sufficient to alert the complete zone. These devices shall have separate screw terminal for each conductor and the sounders / audible appliances shall generate sound in the range of 500-1000Hz different from the equipments and other devices provided in the area and in the building. A minimum sound level of either 5dB (A) above any other noise likely to persist for a period longer than 30 seconds or 65dB (A), whichever is greater but not exceeding 120dB (A) shall be produced by the sounders at any point which can be occupied in the building. Audible notification appliances shall be so selected and placed that they are sufficiently intelligible with adequate audibility and clarity minimising any kinds of distortion in an electro acoustic system. Visual notification appliances shall conform to the applicable standards and shall be surface mounted.
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25.3.12
Fire suppression system
Hydrant systems and hose reels Fire hydrants and its components shall be designed and installed in conformity to relevant Code / standards. Hose reels with shut-off nozzle shall preferably be installed in recesses so that they do not form obstruction on a route of escape and shall be located in accessible positions at each floor level adjacent to exits in corridors on exit routes. The spacing of hydrants shall not be more than 20m from each other in alternate side. Hose reel brackets shall be firmly fixed to the wall so that the casual knocks or during stresses does not render it from being non-functional. The space requirement, location, maximum overall size, component case, water supply for hose reels, materials, appliances etc. shall be in accordance with relevant standards. The hose stations shall be so positioned that two streams can be directed to any location. Fire hose shall be provided at the following places: Operating floor EL 2306.90 m Generator Floor EL 2301.90 m Turbine Floor EL 2298.10 m 2 Nos. MIV Floor EL 2293.25 m Erection bay EL 2306.90 m 2 Nos. 1 No. 2 Nos. 2 Nos.
Control Block EL 2301.90 m 1 No Control Block EL 2306.90 m 1 No Control block EL 2311.00 m 1 No Control block EL 2316.00 m 1 No Control block EL 2320.00 m 1 No GIS Gallery EL 2317.90 m 2 Nos 2 Nos
Transformer Hall EL 2306.90 m Pothead Yard 3 Nos.
Water sprinkler and spray systems

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Each of high velocity water spray system (Deluge System) shall consist of a deluge valve, flow switch, distribution piping, nozzles, thermal/heat detectors and a deluge panel. The deluge panel shall provide a connection point from the deluge system to the powerhouse annunciation and detection system, as well as transferring the signal from heat detectors to electrically operated deluge valve. Each deluge system shall consist of an electrically monitored isolating valve; normal dry distribution piping, flow switch and bulb type air charged monitoring system which automatically gets activated at a rated temperature. The Contractor shall coordinate the system design with oil filled transformer manufacturer(s) to assure complete transformer protection system and to design the water requirement. Each sprinkler system shall consist of an electrically monitored isolating valve; normal wet distribution piping (except in deluge system), flow switch and glass type sprinklers which automatically gets activated at a rated temperature. All automatic sprinklers shall have temperature-sensitive sealing. The type, size and design of each sprinkler installation used in the system shall be appropriate to the hazards covered by the installation. All exposed metalwork in systems shall be efficiently earthed to prevent the metalwork becoming electrically charged. The temperature rating of a sprinkler shall be 30C greater than the highest expected ambient temperature of the location. Sprinklers shall be suitably coated with corrosionresistant material. The system design shall be in accordance with relevant standards. Sprinkler and spray system shall be used for the following equipments: Transformers Oil Pressure system
Portable fire extinguishers The type and number of portable fire extinguishers shall be determined on the basis of classification of fires anticipated in the area, the construction and occupancy of the individual property, ambient-temperature conditions etc.
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Necessary provision of hand appliances like fire buckets shall also be made. Fire buckets shall be of mild steel and shall conform to relevant standards. 25.3.13 Fire alarm and signaling system
Power supplies Fire alarm system shall be provided with at least two independent and reliable power supplies, one primary and one secondary (standby), each of which shall be of adequate capacity for the application and performance of the fire alarm system. It shall be ensured that the changeover from primary supply to secondary supply and viceversa shall be fully automatic without affecting the transmission of signal via the fire reporting system upon operation of the initiating devices. Fire alarm control panels The main and repeater fire alarm control panels shall provide automatic, supervised, multi zone detection and alarm system. Each fire alarm panel shall be of modular type, installed in a mounted steel cabinet with hinged door and cylindrical lock. The panels shall be clean, uncluttered and orderly assembled containing all necessary operating and supervising elements/ components, using a solid state technique. The start-up shall be automatic after restoration of power either primary or secondary. Signals and LEDs / LCDs together with visual annunciation shall be provided to indicate by zone any alarm, supervisory or trouble condition on the system as an integral part of the control panel with suitable identification. The operational features of the modules shall have at least the following: Supervising sprinkler water-flow, water level, power supply, trip circuit healthiness etc.; Supervision of fire detector open/short circuit condition, panel fault, panel door open etc.; Supervision of all smoke detectors, transmitters and alarm signals; Provision to switch of HVAC on detection of fire; Provision to monitor and recall elevator to the nearest landing in case of fire;
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Monitoring and control of fire sprinkler system, deluge valve and fire extinguisher system.
An alarm condition in the circuit which shall automatically annunciate in the mimic shall have at least the following functions: Transmission of signal to the plant SCADA system; Transmission of signal to the station security and surveillance system; Transmission of signal over the telephonic fire reporting system; Visual indication of the alarm device on the fire panel control panel display; Continuous operation and sounding of alarm notification appliances as per the applicable standards. Operation of smoke control system and de-activation of air handling units in alarmed area. Automatic discharge of the respective fire suppression system with maximum 15 seconds delay for deluge system and 30 seconds for wet pipe system. Signs and evacuation signals For deluge areas, the warning signs and releasing signs according to applicable codes may be installed. Fluorescent type exit and evacuation route signs shall be installed throughout the plant. Name plates and external indicators For an easy identification, each detector and manual pull station shall be equipped with a Name plate showing at least line number, detector identification number and fire zone number. Control and monitoring The system shall be controlled and monitored at three (3) levels: Level -0 - By respective local control cubicle for individual drive. Level -1 - From Local control board for common services. Level -2 Control and monitoring (SCADA) system from control room for common services.
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Provisions shall be made in local control panel for interfacing with SCADA system and for HVAC 25.4 Performance Guarantee
The fire fighting system along with all auxiliaries and accessories shall be capable of performing intended duties under specified conditions. The Contractor shall guarantee the reliability and performance of the individual equipment as well as of the complete system. 25.5 Quality control and Quality Assurance
The Contractor shall supply the equipment of best quality. The contractor shall maintain control and quality assurance during the manufacturing, installation, testing and commissioning of equipment as per approved quality assurance plan. 25.6 Drawings, Documents and Design Calculations
25.6.1 Drawings and documents The Contractor shall submit all the drawings and documents in accordance with requirements stipulated in Section 2.12 Reference drawings and documents of General Technical Specification (GTS). These drawings and documents shall include at least the following: Fire risk evaluation report, based on the plants specific considerations with respect to design, layout and anticipated operating requirements, containing a detailed list of recommendations, based on acceptable means and standards, for separation, control of hazards, control or elimination of ignition sources and suppression of fire.
Applicable codes, standards and other design criteria to which the system is required to comply,
Fire risk evaluation in tabulated form with details of type of fire suppression system, annunciator and their location, type of fire alarm system and types of initiating
devices, notification appliances etc. to be provided clearly demarcating the fire area boundaries, Complete list of fire safety control functions with complete sequence of operations detailing all inputs and outputs in the form of input/output matrix,
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A completion certificate stating compliance of the system with the applicable standards referred to with details of departure and recommendations, if any,
Complete set of operating instructions and as-installed drawings with proper identifications.
25.6.2 Design calculation The Contractor shall submit the design calculation for review / acceptance. Covering at least the following: Sizing of piping for distribution manifold and operating pressure, Selecting the pump capacity and working head for pumps, Size of the overhead tank, Deluge system for transformers and generators, Sprinkler system for mechanical and electrical utility areas, cable trays and offices, Numbers and type of automatic fire detectors and manual pull stations, types and quantities of notification appliances like bells, horns, speakers, flashlights etc. 25.7 Shop Testing
The pump, pipes, valves, deluge system, sprinkler system, automatic detectors ete to be supplied shall be routine tested as per relevant IEC / IS / NFPA at the works of contractor in the presence of the purchaser. The contractor is required to submit type test certificates and routine test reports of the equipments. 25.8 Installation and Commissioning
Requirements. The supplier shall arrange personnel to oversee proper storage of equipment at site, their transhipment to powerhouse, installation and commissioning. The power plant fire alarm system must be in any case, ready for operation prior to the commissioning of first generating unit, the control block fire alarm prior to the main control building finished date.
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25.9
Field Test
After installation, the fire fighting system with all its equipments and devices shall be field tested for performance / operational tests etc. as per general technical specifications. The tests at site shall include at least the following; Hydrostatic pressure tests of the whole piping system Pump output test Leakage test Test for meggar value of insulation as per relevant IEC. Test for sensitivity range of sensors / detectors.
The contractor shall prepare and handover to the employer details of test results in a report in a mutually agreed format. 25.10 Spare Parts 25.10.1 Recommended Spare Parts
Recommended spare parts shall be supplied in accordance to clause 2.31 Spare Parts and tools of General Technical Requirements. 25.10.2 Specified Spare Parts
All spare parts and accessories shall be identical electrically and mechanically to corresponding parts in the equipment supplied and shall be suitably packed and clearly marked, ready for long term indoor storage. Spare parts to be supplied under this section are as follows: Sl no 1 2 3 4 5 6 Description Filter element for pumps Aspiration type detector module Electronic plug-in cards for main and delude panels Indicating lamps Nozzles for HVW water spray system Deluge valves / sprinkler Valves Quantity 2 nos each type used 6 nos each type used 2 nos each type used 5 nos each type used 2 nos each type used 1 nos each type used
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7 8 9
Hydrant valve Portable fire extinguisher Manual pull stations
1 nos each type used 5% of total requirement but at least one no. of each type 5 nos.
25.11 Tools and Instruments The Contractor shall provide one set of all necessary special tools and maintenance equipment for repair and maintenance of fire fighting system as recommended by the manufacturer. A list of special tools and testing instrument including their make and detailed specification as recommended shall furnished by manufacturer for approval of Owner.
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26. 26.1
COOLING WATER SYSTEM Scope of Work
Scope of work under this section covers the provision of labour, tools, plants, materials and performance of work necessary for the design, manufacture, quality assurance, quality control, shop assembly, shop testing, delivery at site, site storage and preservation, installation, commissioning, performance testing, acceptance testing, training of Owners personnel, handing over to Owner and guarantee for one year of cooling water system, as per the specifications hereunder, complete with all auxiliaries, accessories, spare parts and warranting a trouble free safe operation of the installation. Six (6) number vertical turbine pumps of sufficient capacity (Three (3) main and three (3) standby) for cooling water system along with local control panel, instrumentation and associated accessories etc.; Six (6) nos. cyclone type sand separators of capacity 110% of pumps capacity (Three (3) main and three (3) standby) water system; Twelve (12) motor / solenoid operated valves (Four (4) for each unit) with associated control and accessories. Local starter panel with PLC interface for cooling water system with all wiring, instruments and associated accessories. Necessary valves, pipes, fittings, air scouring arrangement, flow meters, with associated accessories; for cooling
maintenance valves, regulating orifice, pressure and temperature transducers, dial indicators, level switches etc. for cooling water system. Cooling water Gauge panel Interconnection pipes, fittings, valves from tailrace pits to cooling water sumps as shown in the layout drawing 26.2 Items not specified but required to complete the system in all respects Set of spares Set of special tools and tackles for erection, repair and maintenance. Special Design and layout conditions
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For meeting cooling water requirement of all the units, two cooling water sumps (one main and one standby) shall be provided in control block. The storage capacity of each cooling water sump shall be sufficient to start one unit (equivalent to 30 minutes cooling water requirement). Both cooling water sumps and the tailrace of all the units shall be interconnected through suitable size of pipes and isolating valves. The cooling water system shall be an open loop type arrangement. The cooling water system shall consist of a common cooling water header, a return cooling water head and a transformer return cooling water header as shown in drawing no 167106-AL00-45DD-0004, Six vertical pumps (two for each unit) shall be provided. Each sump shall contain three pumps. Outlet of each pump will be connected to a common cooling water header through cyclone type of sand separator. Total six cyclone type sand separator (one for each unit) will be supplied. Cooling water for generator air coolers, generator and turbine bearing coolers and governor cooler will be taken from the common cooling water header and will be discharge to tailrace during normal running of unit. Immediately on tripping / closing of a unit, the cooling shall be discharge back to cooling water sump through a common cooling water return header. This arrangement will ensure the availability of minimum storage in cooling water sump in case of shut down of all the units. A provision shall also be made to supply cooling water to all bearings of turbine and generator from overhead tank in case of emergency shutdown of the unit (when there is no power supply for 5 minutes). This cooling water shall be taken from an over head tank provided for fire protection system and is located in pothead yard. A pressure reducing valve and a pressure safety device shall be provided in the pipe line if required. For generator step-up transformers, cooling water will be taken from the common cooling water header routed through a pressure reducer valves (if required) and will be discharge to tailrace during normal running of unit and in case of tripping / closing of the unit, the cooling shall be discharge back to the sump through a separate transformer return CW header to ensure the availability of minimum storage of water in the sump. Cooling water for HVAC shall also be taken from same sumps. Two separate vertical pumps (one main and one standby) of adequate capacity shall be provided along with two cyclone
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type sand separators, non return valves, isolation valves, instruments, pipes and fittings. The water shall be discharge back to cooling water sumps through common header. The cooling water system shall be complete with check valves, flow meters, maintenance valves, regulating orifices, pressure and temperature sensing devices etc as shown in control gear drawing. Adequate arrangement shall be made to discharge sedimentation from the cyclone sand separators to tailrace. 26.3 Basic Dimension and ratings
The cooling system shall be designed to meet the cooling requirements of the following equipments for each unit; Generator Stator air cooler Generator Upper and Thrust bearing cooling Generator Lower guide bearing cooling Generator step up transformer cooling Turbine guide bearing Governor oil system
The design capacity shall have a minimum safety margin of 15% over and above the requirement for maximum output from the machine. The design of cooling water system shall be such that temperature rise for generator air temperature, bearing oil temperature and main transformer winding / oil temperature shall not exceed the temperature rise specified in the respective sections / by their suppliers. 26.4 Specific Codes and Standards
The equipment shall be designed and tested according to the latest relevant standards including amendments, or complementary standards mentioned in this document, shall be applied, in particular to the following:
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ISO 9001
Quality Systems Model for Quality Assurance in Design, development, Production, Installation and Servicing.
ASME code VIII + IX
Pressure vessel code
26.5
Ratings and Functional characteristics
26.5.1 Rating The installation being at an altitude of 2300 m, the standard voltage and current rating of the cooling water motors will be derated accordingly. Cooling Water Sumps Storage Capacity 180 m3 of each sump
Pumps for unit cooling system Type of Pumps Discharge requirement Discharge Pressure Motor Type of motor Speed Input voltage Duty cycle Filters Type Flow switches Cyclone type capacity 6600 LPM * Electromagnetic type with two independently adjustable potential free contacts for low alarm and low flow trip Flow indicators Electromagnetic type with LCD display for local display and interface for plant SCADA system. * Cooling water quantity and cooling water pressure for turbine, generator, transformer and HVAC system shall be got confirmed from the respective manufacturers Induction 1450 rpm / 1500 rpm 415 V , 3 Phase , 50 Hz Continuous Vertical turbine type 6000 litres / min * 6.0 Kg/ Cm2 *
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26.6
Design and Construction
26.6.1 Pumps The cooling water pumps shall be vertical turbine type with direct coupling to motors. The motors shall be mounted at EL 2293.25 m. The design head and rating of pumps shall be such that one pump cater the cooling water requirement at desired pressure. 26.6.2 Cyclone type Sand Separators The sand separator shall be of centrifugal type. All its internal parts and components subjected to erosion shall be of stainless steel. All cyclone sand separators shall be provided with flanged connections for cooling water inlet and outlet as well as drain and vent connections. Required number of pressure gauges and other instruments shall be provided for each cyclone separator. 26.6.3 Pipes and fittings All pipes and fitting used in cooling water system shall be carbon steel. The pipes crossing floors shall be provided with cold insulation preferably tape type insulation. Remaining pipes shall be painted with epoxy paint. 26.6.4 Motors The motor shall be suitably sized to drive the pump continuously over the specified characteristics without getting overloaded. The motors shall be suitable for 415V 10%, 50Hz 5% with contacts for remote operation / indication. The speed of pumps-motor set shall not be more than 1450/1500 rpm. Electromagnetic type flow meters with two potential free contacts for alarm and start blocking shall be provided for each pump. Shut-off valves and check valves shall be provided to allow disconnection and switching of each pump without emptying pipes. Adequate arrangement shall be provided to prevent the pump from rotation in reverse direction.
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26.6.5 Control, protection and interface with SCADA The cooling water system and associated accessories / equipment shall also be controlled and monitored by the SCADA system. The pumps, motor operated valves shall be controlled and monitored at three levels: By respective local control cubicles, Local Control Board for common services, Control and monitoring (SCADA) system through Local Control Board for common services. Facility for selection of control either from Local Control Cubicle or Local Control Board or plant SCADA system shall be provided in the Local Equipment Panel or Local Control Board. The Contractor shall make provision of contacts and / or ports in local control cubicles for interfacing with SCADA system for control and monitoring. The Contractor shall provide and install all the sensors and operating devices necessary to fulfil the functional requirement of the specification for control system. All pumps shall be automatically controlled by plant SCADA based on the cooling water requirement. Main and standby pump change over shall be affected automatically after every pre set time. Following local controls shall be provided for each cooling water pump motor set, motor operated filters and motor operated valves: Remote / local selector switch, Start / stop push buttons, Automatic pump / filter change over from main to standby in case of electric or mechanical faults Running time control with change of sequence to equalise running time, Lamp test push buttons, Any other provision required.
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Provision of necessary contacts / ports for control, monitoring, supervision and annunciation functions shall be made for duplicating these functions in plant SCADA system. 26.6.6 Indication and alarm The Contractor shall supply suitable instruments and gauges for achieving desired control logic. Indicating instruments as required shall be installed on local control panel and indications may be replicated in Local Control Board/ control room for common services Following indications, but not limited to, shall be provided for each cooling water pump: Pump running, Pump stopped, Water no flow, Any other indication and alarm required.
26.6.7 Protection The motor for each pumping and filter units shall be provided with at least the following devices: 26.7 Over load protection, Under voltage protection, Single phasing protection, Performance Guarantee
The cooling water system along with all auxiliaries and accessories shall be capable of performing intended duties under specified conditions. The Contractor shall guarantee the reliability and performance of the individual equipment as well as of the complete system. 26.8 Drawings, Documents and Design Calculations
26.8.1 Drawings and documents The Contractor shall submit all the drawings, design calculation and documents in accordance with requirements stipulated in Section 2.12 Reference drawings and documents of General Technical Specification (GTS).
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26.8.2 Design calculation The Contractor shall submit the design calculation for review / acceptance covering at least the following: Cooling water requirement of generator, turbine and transformer Sizing of piping for cooling water header and return water header Calculation for selecting the pump capacity and working head for the pump. Size of the cooling water sumps. Basis of size / capacity selection of cyclone sand separator.
The Contractor shall also provide other calculations as required by the Employer for acceptance of the Contractors design. 26.9 Shop Tests
The pumps, pipes and valves shall be routine tested as per relevant IEC / IS at suppliers works. The contractor is required to submit type test reports and routine tests schedule and reports of the equipments. 26.10 Installation and Commissioning The supplier shall follow the requirements of Delivery, Installation and commissioning elaborated in section 2.34 Installation and supervision of General Technical
Requirements. The supplier shall arrange personnel to oversee proper storage of equipment at site, their transhipment to powerhouse, installation and commissioning. 26.11 Field testing After installation of all equipment the complete system shall be leakage tested as per field test in general technical specifications as per IEC / IS. The contractor shall furnish a complete outline of proposed method and procedures to be followed for field testing including a list of equipment and instruments to be used for owners review well in advance before the scheduled testing. The contractor shall furnish a complete report of the field tests of the equipment.
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Following site tests shall be included Pressure test of all field installed piping at 1.5 times of the design pressure. Leakage test of all field piping. Opening and closing of all valves. Operation of all controls including mechanical locking devices. Other tests as deemed necessary by the engineer.
26.12 Quality control and Quality Assurance The Contractor shall supply the equipment of best quality. The contractor shall maintain control and quality assurance during the manufacturing, installation, testing and commissioning of equipment as per approved quality assurance plan. 26.13 Spare Parts 26.13.1 Recommended Spare Parts
All spare parts and accessories shall be identical electrically and mechanically to corresponding parts in the equipment supplied and shall be suitably packed and clearly marked, ready for long term indoor storage. The following specified spares shall be supplied Sl no I 1 2 3 Description Vertical Pump motor set for cooling water system Complete pump with motor Shaft sleeve Impeller (stainless steal) 1 no 1 No. 1 No Quantity
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Sl no 4 5 II 1 2 3 4 5 6 III 1 IV 1 2 3 26.14
Description Motor bearings Pump bearings / bushes Vertical Pump motor set for HVAC system Complete pump with motor Shaft sleeve Impeller (stainless steal) Motor bearings Pump bearings / bushes Complete pump with motor valves Motor operated valve of each type Instruments All pressure gauges and pressure switches Transducers and flow meters Temperature sensors
Quantity 1 set 1 set
1 no 1 No. 1 No 1 set 1 set 1 set
1 set
1 no each type 1 no each type 1 no each type
Tools and Instruments
The Contractor shall provide one set of all necessary special tools and maintenance equipment for repair and maintenance of cooling water system as recommended by the manufacturer. A list of special tools and testing instrument including their make and detailed specification as recommended shall furnished by manufacturer for approval of Owner.
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Two electrically operated monorail hoist of suitable capacity shall be provided in cooling water area for handling water pumps during erection and maintenance. Two chain pulley blocks of adequate capacity will also be included in scope for handling cooling water equipments.
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27. 27.1
LOW PRESSURE COMPRESSED AIR SYSTEM Scope of Work
Scope of work under this section covers the provision of labour, tools, plants, materials and performance of work necessary for the design, manufacture, quality assurance, quality control, shop assembly, shop testing, delivery at site, site storage , preservation, installation, commissioning, performance testing, acceptance testing, training of Owners personnel, handing over to Owner and guarantee for one year of low pressure compressed air systems, as per the specifications hereunder, each complete with all auxiliaries, accessories, spare parts and warranting a trouble free safe operation of the installation. Two nos. (2) Low pressure air compressors with free air discharge of 123 cfm and working pressure of 8.6 Kg/cm; One no. (1) air receiver assembly with capacity of 1000 Litres and working pressure of 8.6 Kg/cm, with hermetically sealed manhole for Generator brakes; One no. (1) air receiver assembly with capacity of 2000 Litres and working pressure of 8.6 Kg/cm, with hermetically sealed manhole for station service; Two nos. (2) Air dryers complete with associated accessories; Pipes, isolating valves, pressure switches, pressure gauges, safety valve, etc. for generator brake system, station service and for cooling water sumps; Two sets (2) of service air hoses of 20 m length with necessary connections etc. as per approved drawings and bill of material 27.2 Necessary relays and starter panel for operation of motors of the compressor; Suction silencer and cleanable air filter; Other items not specified but required to complete the system in all respect; One set of spare parts; One set of special tools. Specific Codes and Standards
Electrical equipment shall be designed and tested according to the latest relevant standards including amendments, or complementary standards mentioned in this document, shall be
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applied, in particular to the following: ISO 9001 Quality Systems Model for Quality Assurance in Design, development, Production, Installation and Servicing. Guide for selection, installation and maintenance of air compressor plants with operating pressure up to 10 bars. Specification for air receivers for compressed air installation Code for selection and testing of rotary screw air compressor ( oil flooded ) Technical supply condition for air screw compressor (oil flooded) for general purpose and industrial application. Rules for air quality Pressure vessel code
IS 6206
IS 7398 IS11780 IS 12258
ISO 8573-1 ASME Section VIII 27.3
27.3.1 Rating The installation being at an altitude of 2300 m, the standard voltage and current rating of the compressor motors will be derated accordingly. Compressor Type of compressor Free air discharge Working pressure No. of stages Cooling system Drive Noise Level
Rotary screw type / suitable type 123 CFM 8.6 Kg / cm Single stage Air cooled Belt driven 66 dB(a)
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Motor Type of motor Rating of motor Speed Input voltage Duty cycle Receiver for generator brakes Capacity Working pressure 1000 litres 8.6 Kg / cm Induction 30 kW (tentative) 1450 rpm 415 6% V , 3 Phase , 50 3% Hz Continuous
Receiver for station service and for cooling water sump pits Capacity Working pressure Air Dryer Type Capacity Nominal working pressure Noise Level 27.3.2 Functional Characteristics Station compressed air system will be equipped with two (2) low pressure air compressors; and two (2) air receiver assemblies, one for supply of air to generator brakes and other for feeding air for station services, HVAC / unit centrifugal separator flushing system, cooling water sump pits etc. Regenerative type with dew point temp. 3O C 123 CFM 8.6 Kg / cm 66 dB(A) 2000 litres 8.6 Kg / cm
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The system will have a nominal pressure of 8.60 kg / cm2 and will be sized to meet the service air requirements for: Generator braking system; Operation of pneumatic tools during maintenance; Service air for cleaning and miscellaneous use; Purging operation of HVAC / unit cooling water pumps centrifugal separators Cooling water sump pits for silt / water mixing etc.
Compressors will come complete with motor, starter, base plate, air dryer, suction silencer, cleanable air filter, pressure gauges, check valves, un-loader valves, isolating valves and complete control system. Main low pressure air header will be laid on each floor of the power house and control block. Suitable number of air tapping points with snap on coupling will be provided on upstream and downstream sides in front of each unit and at other places for use of service air for cleaning. Suitable number of taps will also be provided in the erection bay, transformer cavern and out door switchyard area. Station service air connections at various floors in power house and control block shall be provided as per drawing no. 167106-AL00-45DD-0003. Compressor LP Compressors will be rotary screw / centrifugal type, heavy duty and electric motor driven for indoor use. Both compressors shall be identical, each of flow capacity as prescribed above. The compressors shall be complete with air filter, oil filter, after cooler, instrumentation, moisture trap and other associated accessories. Drive motors The motors of the compressors shall be continuous duty equipped with DOL starters. The insulation of motor winding shall be class F type with temperature rise limited to class B. The motors shall be suitable to operate at 415 V + 10%, 50 Hz + 5%.
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Air receivers The air receivers shall be of welded construction and designed for working pressure of 8.6 Kg / cm. The are receivers shall be constructed in accordance with the requirement of Indian code or International code for pressure vessels Each air receiver shall have one hermetically sealed man / inspection hole to visual inspection. A condensate drainage system shall be provided. The capacity of air receiver for generator brake shall be 1000 litres and where as the capacity of air receiver for station service shall be 2000 litres. Each air receiver shall be equipped with pressure gauge, pressure switches, preset safety relief valve, drain valve, isolating valve etc. A bleed-off valve should be provided between the isolating valve and the check valve to permit convenient testing of check valve tightness The tank shall be painted on the inside and on the outside as per approved painting system. Thickness of inside painting shall be such that these do not flake off during operation. Prior to shipping, all threaded openings shall be closed with standard pipe plugs. Flanged openings shall be protected with blind flanges with gaskets bolted in position The safety relief valve shall be set to open on 110 % of the working pressure of the tank. An automatic condensate drainage system shall be provided on the discharge separator to automatically drain condensate. It shall provide automatic drain of the system. Air Dryer The compressed air system shall be equipped with two regenerative type of air dryers to dry the humid air. The heating element and fans shall be suitable for 240 V + 10%, 50 Hz + 5% ac supply. Valves and piping All required pipes, valves, flanges, fitting supports, fasteners and related material shall be supplied as a part of contract. All piping shall be of black seamless steal heavy duty class. Minimum pipe wall thickness shall be as per relevant standard for heavy duty of pipes. The contractor shall coordinate with the turbine generator and inlet valve manufacturer to decide layout of piping system. Complete supply and installation of all the pipe lines and various type valves for making the system complete in all respect shall be in the scope of
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contractor. Interconnection between two air receiver with isolation and non return valves shall be provided. Control and monitoring The system shall be controlled and monitored at three (3) levels: By respective local control cubicle for individual drive. Local control board for common services. Control and monitoring (SCADA) system from control room for common services.
Provisions shall be made in local control panel for interfacing with SCADA system. 27.4 Performance Guarantee
The low pressure (LP) compressed air system along with all auxiliaries and accessories shall be capable of performing intended duties under specified conditions. The Contractor shall guarantee the reliability and performance of the individual equipment as well as of the complete system. 27.5 Quality Control and Assurance
The contractor shall supply the equipment for low pressure air system of best quality. The contractor shall maintained quality control during manufacturing of equipments as per the approved quality assurance plans. 27.6 Drawings, Documents and Design Calculations
27.6.1 Drawings and documents The Contractor shall submit all the drawings and documents in accordance with requirements stipulated in Section 2.12 Reference drawings and documents of General Technical Specification (GTS). 27.6.2 Design calculation The Contractor shall submit the design calculation for review / acceptance covering at least the following: Calculation for selecting the compressor capacity and motor rating,
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27.7
Size and thickness selection of air receivers for compressed air systems. Sizing of piping including distribution header. Shop Tests
The motors, air compressors, air receivers, valves and pipes etc. shall be routine tested as per relevant IEC / IS codes and international code for pressure vessels. The contractor shall submit routine test certificate of the equipments. All air receivers, piping etc. shall be pressure tested in works as per relevant code / standard. 27.8 Installation and Commissioning
Requirements. The supplier shall arrange personnel to oversee proper storage of equipment at site, their transhipment to powerhouse, installation and commissioning. 27.9 Field Tests
After installation, the compressed air system shall be field tested for operational tests as per the intended requirements and leakage tested as per general technical specifications. The contractor shall furnish a complete outline of proposed method and procedures to be followed for field testing including a list of equipment and instruments to be used for owners review well in advance before the scheduled testing. The contractor shall furnish a complete report of the field tests of the equipment. Following site tests shall be included Pressure test of all field installed piping at 1.5 times of the design pressure. Leakage test of all field piping. Pressure tested at air receivers and interconnecting piping at 1.5 times of design pressure.
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Operation of all controls including interlocking devices. Other tests as deemed necessary by the engineer.
27.10 Spare Parts 27.10.1 Recommended Spare Parts
All spare parts and accessories shall be identical electrically and mechanically to corresponding parts in the equipment supplied and shall be suitably packed and clearly marked, ready for long term indoor storage. The following specified spares shall be supplied Sl no 1 2 3 4 5 27.11 Description Air dryer assembly Safety valve Pressure gauge, switch and transducer Oil filter and moisture trap Auto condensate drain Quantity 1 no 2 no 1 no each 1 no each 1 set
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28. 28.1
OIL HANDLING SYSTEM Scope of Work
Scope of work under this section covers the provision of labour, tools, plants, materials and performance of work necessary for the design, manufacture, quality assurance, quality control, shop assembly, shop testing, delivery at site, site storage and preservation, installation, commissioning, performance testing, acceptance testing, training of Owners personnel, handing over to Owner and guarantee for one year of oil handling system as per the specifications hereunder, complete with all auxiliaries, accessories, spare parts and warranting a trouble free safe operation of the installation. The scope of work shall be a comprehensive functional system covering all supply and services including but not be limited to following: Two mobile centrifuge type hydraulic and lubricating oil purifying unit of adequate capacity (not less than 20 LPM) suitable for centrifuging largest single oil volume of equipment of one unit in less than 8 hours complete with all associated accessories, oil pump, oil heater, thermostatic control, discharge pump, control panel, instrumentation, piping, fittings, oil hose, vacuum hoses, hose coupling and other accessories; Two mobile transformer oil purifying unit of capacity 100 LPM or high complete with transformer evacuation system, oil heater, thermostatic control, filtering
compartment, vacuum pump, dehydrating compartment, discharge pump, control panel, instrumentation, piping and fittings, oil hose, vacuum hoses, hose coupling and other accessories to complete the system. One trolley mounted oil transfer pump of capacity 50 LPM, electrically driven with oil hoses, hose coupling and other accessories. One air dryers of suitable capacity for generator transformers. Two trolley mounted transformer oil tanks of capacity 25000 litres each or 120% of oil requirement of one generator step up transformer unit. One set of spare. One set of tools and instruments.
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28.2
Electrical equipment shall be designed and tested according to the latest relevant standards including amendments, or complementary standards mentioned in this document, shall be applied, in particular to the following: ISO 9001 Quality Systems Model for Quality Assurance in Design, development, Production, Installation and Servicing. Insulating oil conditioning plants- specification Standard Specification for pressure vessel plates, carbon steel for moderate and lower temperature service Code for unfired pressure vessels
IS 6034 ASTM A516
ASME Section VIII 28.3
The installation being at an altitude of 2300m, the standard voltage and current rating of the pump motors will be derated accordingly. 28.3.1 Rating Insulating oil handling system The purifier shall be capable of processing the oil on single pass basis at rated flow to the following specification: Moisture content Gas content Dielectric strength Filtration Power factor Tan Delta at 90 C : : : : : Less than 5 PPM; Less than 0.1% by volume; 70 kV across 2.5 mm gap; Less than 1 micron; 0.002.
Transformer evacuation system Capacity to have an ultimate blank-off of 10-4 Torr or less; Evacuation to the level of 0.1 Torr or less when connected to main transformer tank.
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Lubricating oil handling system The purifier shall be capable of processing the lubricating oil on not more than two (2) passes basis at rated flow to the following specification: Free water Moisture content Filtration : : : 100% reduction; Less than 50 PPM ; Less than 1 micron.
28.3.2 Functional Characteristics Insulating oil handling system Suitable arrangement / provision shall be made in the system/ system components such that the plant can be docked near each of the transformer units for the intended purpose. The seller shall ensure adequate coordination while designing the system to ensure compatibility of inlet outlet ports between the transformers and oil handling equipment. The oil hoses and vacuum hoses for each plant shall be of sufficient length and size to filter the oil of any transformer unit. Lubrication oil handling system The oil hoses shall be of sufficient length and size to connect lubrication oil purifying plant to various equipment / components / systems. Suitable piping, fittings, fixtures etc. shall be coordinated with the Turbine, Governor and Generator manufacturers / sub-contractors for suitable arrangement. Oil Purifiers The systems shall have its own control panel with suitable pressure gauges, push-buttons for starting and stopping with a flow-meter, a volume-meter with manual zero reset etc., other controls and monitoring with necessary protection. The insulation of motors shall be of Class-F with IP 55 protection class. Insulating oil purifiers The insulating oil purifiers shall be of filtration and vacuum de-hydration type. Unit shall consist of coarse filter, oil transfer pump, thermostatically controlled ceramic heaters, filtration section, deoxidizing column, vacuum pumps, discharge pump, two stage degassing system, transformer evacuation system, thermometers, pressure / vacuum gauges, flow
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meter, valves, piping, control panels with on-line process monitoring facilities and other accessories necessary for satisfactory operation of purifiers. The insulating oil purifiers shall be suitable for indoor and outdoor duties. The seller shall select the operating temperature and size of the oil heater to heat the oil from normal room temperature to the design operating temperature. The heaters used shall be ceramic type sealed heaters. Vacuum gauges to monitor vacuum shall be provided at various stages in the transformer evacuation system and in the external pipe beyond the isolation valve for external system. Lubricating oil purifiers The purifying unit shall be a complete self-contained and enclosed unit with motor-driven pumps or pump of suitable rating, centrifuging chamber and other appurtenances to make the system complete and functional. The lubricating oil may contain free and dissolved moisture of the order of 1000 to 2000 PPM initially which needs to be reduced in the range of 50 PPM, Besides moisture, the oil may contain suspended impurities such as cotton waste, welding slag and spatters, metallic chips, small sand particles, iron fillings, pebbles, dust and pipe scales. The offered equipment shall not be damaged by the flow of oil containing these impurities. The oil may also contain grease and kerosene, which shall also be required to be removed. The purifier shall reduce the free and dissolved moisture in the lubricating oil to acceptable level for reuse. Oil Tanks The oil tanks shall be cylindrical, of welded steel construction and shall be designed and fabricated from steel plate conforming to ASTM A516 Grade 60 in accordance with part UW of the ASTM code for unfired pressure vessels, section VIII, for design. The tanks shall be mounted horizontally on wheels and equipped with inspection / man holes, gauge glasses, overflow, vent line and drain etc. The tanks shall be provided with suitable saddles so that it can be rested on ground when removed from trolley. Each tank vent shall be fitted with dehydrators to prevent the entry of moisture into the tanks. The thickness of the tank plate shall be sufficient for temperature variation effect and pressure due to oil. However, the thickness shall not be less than 8 mm for shell and 10 mm for dish ends. The oil tanks shall be vacuum tested and for leakage as well.
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Oil Transfer Pump The oil transfer pump shall be of vacuum tight positive displacement gear type with horizontal driving shaft directly connected to its electric motor through a flexible coupling and complete with check valve, shut off valve, safety relief valve, high temperature shutdown etc. Each pump shall be tyre mounted and shall b e equipped with pressure gauge, pressure relief valve to protect the pump against excessive pressure in case of throttling in discharge pipe line. Pipes, Fittings and hoses All pipes shall be seam less steel pipes. Fitting shall be forged of compression type steel fitting with cutting ring seal. Plug type valves with oil resistant seats shall be used throughout the system. Hoses shall be steel-armoured, oil resistant and of suitable length. The hoses shall be provided with leakage-proof, quick-connecting coupling. The hoses shall be able to withstand the required pressure and temperature of oil during filtration process. Air Dryers The air dryers shall be of regenerative type to fill the dry air in transformer when required. Each air dryer shall be provided with at least 150 m cable. 28.4 Performance Guarantee
The oil handling system along with all auxiliaries and accessories shall be capable of performing intended duties under specified conditions. The Contractor shall guarantee the reliability and performance of the individual equipment as well as of the complete system. 28.5 Drawings, Documents and Design Calculations
28.5.1 Drawings and documents The Contractor shall submit all the drawings and documents in accordance with requirements stipulated in Section 2.12 Reference drawings and documents of General Technical Specification (GTS). These drawings and documents shall include at least the following: Schematic drawings of the oil handling plant with all piping systems, control systems and instrumentation with reference of the relevant Indian/international standards
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followed for the design and construction of the plant and its components/material,
General arrangement plan, section of main and sub-assemblies with detailed dimensions of the parts and the size of each and every part of the equipment to be supplied under this specification,
Complete list of accessories and auxiliaries with their make and accompanied with catalogue/pamphlets/literature/write-ups,
Complete list of instruments offered with their make and accompanied with catalogue/pamphlets/literature/write-ups.
28.5.2 Design calculation The Contractor shall submit the design calculation for review / acceptance. Covering at least the following: Calculation for selecting the pumping capacity of the pumps including vacuum pumps, oil tank and plant capacity, Size of De-gassing chamber, Methods/ principal adopted for determination of oil characteristics, Capacity of the heater for both lubricating oil and insulating oil handling system, Total power requirement individually for the insulating oil and lubricating oil purifying system and of oil transfer pumps, The Contractor shall also provide other calculations as required by the Employer for his approval of the Contractors design. 28.6 Shop Tests
The pumps, pipe and valves and complete purification plants shall be routine tested as per relevant IEC / IS at the suppliers works / contractors shop. The contractor shall submit the required type test certificates and routine test reports of the equipment for approval before despatch of equipment.
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28.7
Installation and Commissioning
The contractor shall follow the requirements of Delivery, Installation and commissioning elaborated in section 2.34 Installation and Supervision of General Technical
Requirements. The seller shall arrange personnel to oversee proper storage of equipment at site, their transhipment to powerhouse, installation and commissioning. 28.8 Field testing
After installation, the filtration plant shall be field tested operational tests as per intended requirements. The contractor shall furnish a complete outline of proposed method and procedures to be followed for field testing including a list of equipment and instruments to be used for owners review well in advance before the scheduled testing. The contractor shall furnish a complete report of the field tests of the equipment. 28.9 Quality control and Quality Assurance
The Contractor shall supply the equipment of best quality. The contractor shall maintain control and quality assurance during the manufacturing, installation, testing and commissioning of equipment as per approved quality assurance plan. 28.10 Spare Parts 28.10.1 Recommended Spare Parts
All spare parts and accessories shall be identical electrically and mechanically to corresponding parts in the equipment supplied and shall be suitably packed and clearly marked, ready for long term indoor storage. The following specified spares shall be supplied
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Sl no 1 2 3 4 5
Description Complete set of seals and gaskets for the system Complete set of filters for the system Complete set of valves for the system Connecting hose with couplings of each type and size Oil Pump of all type
Quantity 2 sets 2 sets 2 sets 1 set 1 set of each used type
28.11
The Contractor shall provide one set of all necessary tools and instruments etc. for installation, repair and maintenance as recommended by the manufacturer. 28.12 Special Tools The Contractor shall provide one set of all necessary special tools and maintenance equipment for repair and maintenance as recommended by the manufacturer. A list of special tools and testing instrument including their make and detailed specification as recommended shall furnished by manufacturer for approval of Owner.
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29. 29.1
MECHANICAL WORKSHOP Scope of Work
Scope of work under this section covers the provision of labour, tools, plants, materials and performance of work necessary for the design, manufacture, quality assurance, quality control, shop assembly, shop testing, delivery at site, site storage and preservation, installation, commissioning, performance testing, acceptance testing, training of Owners personnel, handing over to owner and guarantee for two years of mechanical workshop equipment, as per the specifications hereunder, each complete with all auxiliaries, accessories, spare parts and warranting a trouble free safe operation of the installation. The scope of work shall be a comprehensive functional system covering all supply and services including but not be limited to following: a) One (1) universal milling machine (for horizontal and vertical milling) with attachments, clamping device, arbors, vice, swivel base, tools and tackles. b) One (1) hollow spindle centre lathe with travelling and fixed steadies, taper turning attachment, 3 and 4 jaw chucks, dead and live centres, change wheels for metric threads, tools, tackles and accessories. c) d) One (1) shaper machine with vices, tools, tackles and accessories, One (1) universal radial drilling machine complete with vices, chucks, tilting table, tapping attachments, tools, tackles and accessories. e) One (1) power hacksaw with adjustable angle vices, automatic cutout and coolant system. f) One (1) double-ended pedestal mounted grinding machine with tools and accessories. g) h) i) j) k) l) Two (2) electrical hand drilling machines with tools and accessories. Two (2) electrical hand grinders with grinder wheels Two (2) Electrical Angle grinders - AG7 Two (2) Flexible shaft grinders FF2 Two (2) Electrical hand horizontal sanders Two (2) sets of TIG welding machines complete with all accessories.
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m)
Two (2) mobile welding generators complete with welding leads, welding holders, welding helmets, goggles and gloves.
n)
Two (2) mobile rectifier type welding machines complete with welding leads, welding holders, helmets, goggles and gloves.
o) p) q) r) s) 29.2
One (1) electrical electrode Oven Four (4) Oxy-Acetylene welding and cutting set. One (1) Pipe bending machine One (1) mobile air compressor unit for workshop and maintenance. One set of hand tools and measuring instruments. Specific Codes and Standards
All equipments shall be designed and tested according to the latest relevant standards including amendments, or complementary standards mentioned in this document, shall be applied, in particular to the following:
ISO 9001
Quality Systems Model for Quality Assurance in Design, development, Production, Installation and Servicing.
29.3
Rating and Descriptive Data
A mechanical workshop is proposed for powerhouse to meet regular operational and maintenance (O&M) requirements. The mechanical workshop will be equipped with turning, drilling and milling machines, as well as general tools and equipment. The mechanical workshop equipment will be designed and constructed to suit the required needs of the powerhouse. The mechanical workshop will be located in control block at EL 2298.10 m. The installation being at an altitude of 2300m, the standard voltage and current rating of the electrical equipments will be derated accordingly. 29.3.1 Universal milling machine for horizontal and vertical milling Universal milling machine conforming to relevant standard with following specifications shall be supplied;
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1 2 2.1 2.2 2.3 3 3.1 3.2 4 4.1 4.2 5 6 7 8
Table size Work table travel Long travel Cross travel Vertical Feeding speed Long and cross Vertical Rapid Long and cross Vertical Number of T slot and width Maximum rotation angle of table Level spindle speed Mill head spindle speed
> 300 mm x 1500 mm
> 700 mm > 230 mm > 380 mm
20 mm to 700 mm / min 6 mm to 240mm / min
2100 mm / min 700 mm / min 3 x 18 mm 45 70 to 1500 rpm in 12 steps 70 to 1500 rpm
Universal milling machine shall be complete will all accessories including arbors, vices, rotary table tools and tackles etc. 29.3.2 Hollow spindle centre lathe machine Lathe machine conforming to relevant standard with following specifications shall be supplied; 1 2 3 4 5 6 7 8 9 Swing over bed Swing over carriage Swing over gap Maximum length of work piece Width of bed Spindle speed Maximum travel of cross slide Maximum travel of top slide Travel of tail stock quill > 500 mm > 300 mm > 800 mm 1000mm > 350 mm 30 to 1700 rpm in 16 steps 355 mm 150 mm 150 mm
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Lathe machine shall be complete with travelling and fixed steadies, taper turning attachment, 3 and 4 jaw chucks, dead and live centres, tool holders, change wheels for metric threads, tools, tackles and accessories etc. 29.3.3 Shaping machine Shaper machine conforming to relevant standard with following specifications shall be supplied; 1 2 3 4 5 Length of stroke ( max ) Horizontal travel of table Ram vertical travel Maximum distance - table and ram Working surface of table top 620 mm 700 mm 350 mm 425 mm 525 x 360 mm
Shaper machine shall be complete will vices, tools and tackles and all accessories etc. 29.3.4 Radial drilling machine Radial drilling machine conforming to relevant standard with following specifications shall be supplied; 1 2 3 4 Drilling capacity in steel Drilling capacity in cast iron Maximum spindle stroke Minimum / maximum drilling radius 60 mm 75 mm 400 mm 550 / 2350 mm
Radial drilling machine shall be complete with vices, chucks, tilting table, tapping attachment, cooling device, tools and tackles; and accessories etc. Two (2) sets of HSS twist drills of best quality covering the whole range of 2 30 mm sizes. 29.3.5 Electrical hand Drilling Machine It shall be suitable for operation at 230 V, 1 phase, 50 Hz with following particulars; of Rated power 450 watt or more, double insulated Overload protection
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Drilling capacity of maximum 16 mm diameter in mild steel Two (2) speeds and electronic speed control
Hand drilling machine shall be supplied with following accessories and tools; Two (2) sets of HSS drills of best quality covering the whole drilling range One (1) spare drill jar socket One (1) spare key for drill jar socket
29.3.6 Double Ended Pedestal Mounted Grinding machine It shall consist of Grinding disc of maximum diameter of 300 mm Drill grinding device 10 zircon grinding discs Four (4) rotary wire bushes Eyes protection devices / shield etc.
29.3.7 Power hack saw The power saw shall be suitable for operation at 415 V, 3 phase, 50 Hz AC with following particulars; 1 1.1 1,2 2 3 Cutting capacity Round section Square section Number of strokes per min Blade size 300mm 250 x 250 mm 80 - 100 - 125 525 x 45 x 2.25.mm
Power hack saw shall be supplied with following accessories and tools; One (1) electrically driven coolant tank with chip separator, pump with motor and coolant piping and nozzle. Fifty (50) power blades One (1) adjustable bar rest One (1) V shape vice jaws to cut materials in bundles
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29.3.8 Electrical Hand Grinders Electrical hand grinder shall be suitable for 100 230 mm grinding wheels. It shall be suitable for operation at 230 V, 1 phase, 50 Hz. It shall be supplied with twenty four (24) grinding wheels of different sizes. 29.3.9 Electrical Angle Grinders Electrical angle grinders (hand) AG7 shall be suitable for 100 230 mm grinding wheels. It shall be suitable for operation at 230 V, 1 phase, 50 Hz. It shall be supplied with twenty four (24) Zircon wheels. 29.3.10 Flexible Shaft Grinders
Flexible shaft grinders FF2 shall be suitable for burr cutters and wheels up to 6.3 mm and shall be supplied along with all accessories and set of HSS burr cutter (14) and wheels. 29.3.11 Electrical hand Horizontal Sanders
Electrical hand Horizontal Sanders shall be suitable for finishing and polishing along with 100 No. each of sandy discs of at least three grades. 29.3.12 TIG Welding Machine
TIG Welding Machine shall have rectifier units as defined in clause Rectifier Type Welding Machine with TIG welding nozzle and accessories. 29.3.13 Welding Generator and accessories
Welding machine suitable for operation on 415 V, 3 phase 50 Hz AC. Welding generator conforming to relevant standard with following specifications; 1 2 3 4 5 6 Current range Type of cooling Type of insulation Rated open circuit voltage Welding cable Earthing cable 40 to 400 amps Natural air cooled H Max. 80 V (rms) 20 meters 20 meters
The welding machine shall be suitable for M.S. and S.S. welding with low hydrogen and basic coated type of electrodes. Welding machines shall be provided with the following accessories / items
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Two (2) Welding goggles Two (2) sets hand gloves One (1) head shield Rectifier type Welding machine and accessories
29.3.14
Thyristorised Welding machine with smoke eater suitable for operation on 415 V, 3 phase 50 Hz AC. Welding generator conforming to relevant standard with following specifications; 1 2 3 4 5 6 Rated Current range Type of cooling Type of insulation Rated open circuit voltage Welding cable Earthing cable 60 to 400 amps Natural air cooled H Max. 80 V (rms) 20 meters 20 meters
The welding machine shall be suitable for M.S. and S.S. welding with low hydrogen and basic coated type of electrodes. It can also be used for gouging by carbon electrode also. Welding machine shall be provided with the following accessories / items Two (2) Welding goggles Two (2) sets hand gloves One (1) head shield Electrical electrode Oven
29.3.15
The welding electrode oven shall be of standard size and type and suitable for operation at 415 V, 3 phase, 50 Hz. It shall be used to pre - heat and store welding electrodes before use. The oven shall be capable of maintaining pre-set temperature automatically and a knob shall be provided to adjust / set the temperature of the oven. 29.3.16 Oxy Acetylene welding and cutting equipment
Each set of Oxy Acetylene welding and cutting equipment shall consist of following; One (1) welding blow pipe with two (2) sets of five (5) welding type of nozzles of different sizes. One (1) cutting attachment with two (2) sets of four (4) cutting type of nozzles of different sizes.
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Fifteen (15) m long of oxygen hose Fifteen (15) m long of acetylene hose One (1) set of hose ferrules Two (2) pairs of goggles Two (2) pairs of gloves One (1) two wheel borrow for carrying standard size of oxygen and acetylene cylinders
29.3.17
Pipe Bending Machine
Pipe bending machine shall be hydraulic and hand operated type for bending of mild steel pipes of dimensions to 3 complete in all respect. 29.3.18 Mobile Air Compressor Unit for workshop and maintenance
Mono Block piston type with air receiver, pressure switches and motor protection for fully automatic operation complete with electric cable and pressure pipe hose and coupling. The unit shall be with following specifications 29.4 Inlet Volume Nominal working pressure Maximum discharge pressure Power supply Performance Criteria Guarantee : 20 30 Nm3 per hour : 6 bar at continuous operation : 10 bar : 3 phase, 415/240 V, 50 Hz.
The mechanical workshop equipment along with all auxiliaries and accessories shall be capable of performing intended duties under specified conditions. The Contractor shall guarantee the reliability and performance of the individual equipment as well as of the complete system.
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29.5
29.5.1 Drawings and documents The Contractor shall submit all the drawings and documents in accordance with requirements stipulated in Section 2.12 Reference drawings and documents of General Technical Specification (GTS). 29.5.2 Design calculation The Contractor shall submit the design calculation for review / acceptance. Covering at least the following: 29.6 Forces on foundation. Power requirement Shop Tests
The equipment shall be routine tested as per relevant IEC / IS at the suppliers works / contractors shop. The contractor shall submit the required type test certificates and routine test reports of the equipment for approval before despatch of equipment. 29.7 Quality control and Quality Assurance
The Contractor shall supply the equipment of best quality. The contractor shall maintain control and quality assurance during the manufacturing, installation, testing and commissioning of equipment as per approved quality assurance plan. 29.8 Installation and Commissioning
The contractor shall follow the requirements of Delivery, Installation and commissioning elaborated in section 2.34 Installation and Supervision of General Technical
Requirements. The contractor shall arrange personnel to oversee proper storage of equipment at site, their transhipment to powerhouse, installation and commissioning.
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29.9
Field testing
After installation, the equipment shall be field tested to demonstrate the operational capability as per intended requirements shall furnish a complete report of the field tests of the equipment to the owners engineer. 29.10 Spare Parts 29.10.1 Recommended Spare Parts
All spare parts and accessories shall be identical electrically and mechanically to corresponding parts in the equipment supplied and shall be suitably packed and clearly marked, ready for long term indoor storage. The following specified spares shall be supplied Sl no 1 2 3 Description Electronic cards of each type Indicating lamps of each type Fuses of each type Quantity 1 no. 2 sets 5 sets
29.11 Tools and Instruments The Contractor shall provide two (2) sets of all special and standard tools, covering whole range, necessary to perform all the required relevant mechanical work properly for maintenance of the complete equipment in the power house. A list of special tools and testing instrument including their make and detailed specification as recommended shall furnished by manufacturer for approval of Owner.
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30. 30.1
ELEVATOR Scope of Work
Scope of work under this section covers the provision of labour, tools, plants, materials and performance of work necessary for the design, manufacture, quality assurance, quality control, shop assembly, shop testing, delivery at site, site storage and preservation, installation, commissioning, performance testing, acceptance testing, training of Owners personnel, handing over to Owner and guarantee for one year of elevators, as per the specifications hereunder, each complete with all auxiliaries, accessories, spare parts and warranting a trouble free safe operation of the installation. The scope of work shall be a comprehensive functional system covering all supply and services including but not be limited to following: Power House Elevator a) One (1) 10 passenger elevator for power house complete with control and accessories (elevator # 1); b) One (1) 8 Passenger elevator for cable shaft complete with control and accessories (elevator # 2); c) One (1) - Embedded parts, scaffolding, fire service switch, sound-reducing systems, safety devices, pit ladder, indicators, facia and alarms etc.; d) e) f) One (1) One (1) Set of spares; Set of special devices for installation and maintenance.
Any other item not specified above but necessary to complete the assembly, erection and reliable operation of elevator.
30.2
Electrical equipment shall be designed and tested according to the latest relevant standards including amendments, or complementary standards mentioned in this document, shall be applied, in particular to the following:
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ISO 9001
Quality Systems Model for Quality Assurance in Design, development, Production, Installation and Servicing. Electric traction lifts
IS 14665 30.3
30.3.1 Rating The power house elevator (elevator # 1) shall serve all the floors. The capacity of the elevator shall be 10 passengers (680 kgs) and suitable for carrying tools and tackles. The assured levelling accuracy shall be within + / - 5 mm. landing door opening width and height shall not be less than 0.7 m and 2.0 m respectively. The construction of elevator shall be such that all motions shall take place smoothly and positively with no slippages, jerks and vibrations. The elevator shall be provided with all safety devices, alarms, fire service switch etc. There shall be provision in the elevator for auto landing to nearest floor in case of power failure. The elevator shall have best and modern design with interior of aesthetically pleasing appearance and having adequate illumination and shall suit to the industrial requirement. The interiors and exteriors shall be approved during detailed engineering. All the exposed steel items in the elevators shall be painted with anti corrosive epoxy paint to withstand the corrosive atmosphere and the hoist and governor ropes shall be galvanised. The elevators shall be suitable for power supply 415 10%, 3 phase, 50 5% Hz and alternating current. The control elevators shall be A.C. Variable voltage variable frequency. The control shall be provided with single phase and phase reversal protection. The installation being at an altitude of 2300 m, the standard voltage and current rating of the Electrical components shall be derated accordingly. Sl no 1 2 Description Type Capacity Power house Elevator # 1 Passenger 10 passengers ( 680 Kgs)
Cable Shaft Elevator # 2 Passenger 6 passengers ( 544 Kgs)

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Sl no 3 4 5 6 7 8 9 10 11 12
Description Well dimension Car size Speed (meters / sec) Number of landings
Power house Elevator # 1
Cable Shaft Elevator # 2
1900 mm x 2100 1900 mm x 1700 mm mm 1300 mm x 1350 1100 mm x 1000 mm mm 1 6 1 2* EL 2434.00 m ------------EL 2325.00 m
Office area / conference room EL 2316.00 m landing level (top most landing) Control room landing level EL 2311.00 m
Erection bay / Operating floor EL 2306.90 m landing level Generator floor landing level Turbine floor landing level EL 2301.90 m EL 2298.10 m
MIV Floor landing Level (Bottom EL 2293.25 m most landing)
* Any additional landing between top most & bottom most landing, if recommended by manufacturer for service purpose, can be provided. 30.3.2 Functional Characteristics Car frame Every Elevator car shall be carried in a complete frame of steel, which shall be sufficiently rigid to withstand the operation of the safety gear without permanent deformation to the car frame. Car enclosure The car enclosure for elevators shall be constructed from interlocking panels of stainless steel. The car enclosures shall be modern aesthetically pleasing appearance with stainless steel panels, extruded aluminium handrail on rear panel, diffused fluorescent lighting, pressure fan with grille and wooden flooring lined with PVC.
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Car roof A solid roof, capable of supporting two persons that is 2 x 68 kg, shall be provided. A threepin plug socket with switch for a hand lamp shall be fitted on roof of the elevator car for use by persons working thereon. Car doors Car doors shall be constructed from at least 1.519 mm thick (16 gauge) stainless steel sheet in plain finish. Clear opening about 800 mm wide x 2000 mm high for power house elevator and 700 mm x 2000mm for cable shaft elevator shall be provided. Each door shall be reinforced to receive required operating mechanism and hardware. Seams, screws or binding strips shall not be visible from within the car. The car doors shall be operated quietly and smoothly by an electric door operator mounted on top of car. An electrical lock on the car door shall be provided to prevent elevator movement away from the landing unless the door is in the closed position. When door is in full-open position, door shall be unable to initiate closing if a person comes within the detection zone. The detection zone moves with the door, so that if a person or object enters the zone after the door has begun to close, the door shall stop, and then reverse to reopen. The door shall re-close after a brief time. After a stop is made, the door shall remain open for a time to permit passenger transfer, after which they shall close automatically. The door operation shall be automatic with VVVF door operator. Landing doors Landing doors shall be of sheet steel and shall be installed in hoist way fixed on steel angles. The openings for the landing doors shall not be wider than that of the width of elevator car. An electromechanical lock on the landing doors shall be provided to prevent elevator movement away from the landing unless the doors are in the closed position. Platform It shall be of framed construction of steel. Car floor shall be of a flat non-slippery surface or chequered surface.
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Car operating panel At least the following facilities shall be included in the car operating panel of each elevator: Red push button / switch for emergency stopping; An Alarm button; An overload indicator; Digital floor and direction indicators; Digital temperature indicator; Facility for transfer from normal passenger control to car preference feature by a key operated switch in the car; DOOR OPEN button; DOOR CLOSE button; Car fan and light switches; Battery operated Alarm bell; Emergency light; Communication (speaker phone, grille, and push-to-call button)
All buttons, indicators shall be in stainless steel face plates. Locking devices for landing doors It shall not be possible to open the landing door from the landing side until the elevator car is within that particular landing zone. Provision shall be made for opening of the door in case of emergency by means of a special key. There shall be electric lock for preventing the elevator movement away from landing unless all the landing doors are closed except when the car is coming to a stop at a landing within the levelling zone. There shall be protective device to prevent the doors from closing should a person or object touch the door while it is closing.
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Emergency exit Car top for the elevators shall be manufactured with a hinged emergency exit panel held in place with non-removable fastening devices at each corner, and manually operable from top of the car and key-operable from inside. Exit shall be equipped with sensor that will prevent operation of car when exit door is open and make the alarm bell to ring. Communications A telephone system in stainless steel cabinet shall be provided for the elevator. A vandalresistant speaker type intercom with push-button to activate shall be installed in the car behind a stainless steel perforated grille and connected to a programmable auto-dialler located in operating floor and control room. Auto-dialler shall be provided with a solid-state charger unit which will automatically provide emergency power and an immediate transfer in the event of failure of normal power supply. The push-button located in the car shall be identified as Emergency phone (push to activate). The telephone communications shall not be terminated until one of the communicating parties hangs up the receiver or manually disconnects the communication link. In addition to above provision shall be there to install a telephone connected to power house EPBAX exchange. Audible signals Audible signal at each floor landing and in the car shall sound coincident with the digital indicators. The audible signal shall be not less than 20db with a frequency not higher than 1500Hz. Car lighting, ventilation, fan and other utilities Elevator car shall be fitted with a luminous ceiling light which shall be left burning during the whole time the elevator is available for use. Lighting shall also be provided at the top and bottom of the elevator wells for safety of maintenance when stepping on to elevator car top or into elevator pits. Provisions shall be made for adequate ventilation, a fan, a battery operated emergency light and a battery operated emergency alarm inside the elevator. To permit switching off the power supply to the elevator without switching off the fan and light, a separate circuit with
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control in machine room shall be provided for fan and light. Ventilation openings shall be provided in the enclosure walls as per requirement. Landing fixtures At each landing, hall push buttons as per requirement shall be provided. A digital hall position indicator with direction indication shall be installed at every landing. All hall push buttons shall illuminate after pushing until elevator reaches the landing. Push buttons and indicators should be flushed with wall. A fire service switch for the elevator shall be located at every landing. 30.4 Performance Guarantee
The elevators along with all auxiliaries and accessories shall be capable of performing intended duties under specified conditions. The Contractor shall guarantee the reliability and performance of the individual equipment as well as of the complete system. Guaranteed performance shall consist of the following characteristic quantities 30.5 Capacity, Speed, Levelling accuracy. Drawings, Documents and Design Calculations
30.5.1 Drawings and documents The Contractor shall submit all the drawings and documents in accordance with requirements stipulated in Section 2.12 Reference drawings and documents of General Technical Specification (GTS). 30.5.2 Design calculation The Contractor shall submit the design calculation for review / acceptance. Covering at least the following: Detail dimension of wells, Calculation for selecting the rope, motor size and speed of the elevators.
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30.6
Shop Testing
The motor, rope of lift and control panel of lift shall be routine tested as per relevant IEC / IS at the suppliers works / contractors shop. The contractor shall submit type test certificate for motor and rope and routine test reports of the equipment. 30.7 Installation and Commissioning
Requirements. The supplier shall arrange personnel to oversee proper storage of equipment at site, their transhipment to powerhouse, installation and commissioning. 30.8 Field Tests
After installation, the elevator shall be site tested to demonstrate the operational capability as per intended requirements. The elevator shall pass at least the following tests when carried out at site and before it is put into normal service. The necessary test weight and instruments shall be provided by the contractor. Test to determine that the insulation resistant between power and control lines and earth is not less than o.5 M when measured with a DC voltage of 500 V should be carried out with the conductors so connected together as to ensure that all parts of every circuit are simultaneously. Test to determine that the motor, brake, control equipment and door locking devices and limit switches function correctly. Brake to be tested to check whether it can sustain a car at rest with contract load plus 25% of contract load. Test to determine that the lift car raise and lower rated load. Test to determine that the lift car at least achieves the contract speed. Test to determine that the safety gear stops the lift car with rated load. Over speed test shall be made with ropes attached and all electrical apparatus operative except the over speed switch on the governor.
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The contractor shall furnish a complete report of the field tests of the equipment for approval / reference. 30.9 Quality control and Quality Assurance
The Contractor shall supply the equipment of best quality. The contractor shall maintain control and quality assurance during the manufacturing, installation, testing and commissioning of equipment as per approved quality assurance plan. 30.10 Spare Parts 30.10.1 Recommended Spare Parts
All spare parts and accessories shall be identical electrically and mechanically to corresponding parts in the equipment supplied and shall be suitably packed and clearly marked, ready for long term indoor storage. The following specified spares shall be supplied Sl no 1 2 3 4 5 6 Description Motors of each type and size Brake lining Brake motor Fixed Brake disc Guide rollers for car door Guide rollers for landing door Elevator # 1 1 no. each 4 sets 1 no. 1 no. 1 set 1 set Elevator # 2 1 no. each 4 sets 1 no. 1 n. 1 set 1 set
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30.10.3
The Contractor shall propose the list of special tools and testing instrument including their make and detailed specification as recommended by manufacturer(s), to be accepted by the Owner. 30.11 Inspection and Testing The Contractor shall follow the Inspection and testing requirements in Quality assurance clause 2.31 Factory inspection and testing of General Technical Specifications
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31. 31.1
DEWATERING CUM SILT EJECTION SYSTEM Scope of Work
Scope of work under this section covers the provision of labour, tools, plants, materials and performance of work necessary for the design, manufacture, quality assurance, quality control, shop assembly, shop testing, delivery at site, site storage and preservation, installation, commissioning, performance testing, acceptance testing, training of Employers personnel, handing over to GMR and guarantee for two years of dewatering cum silt ejection system, as per the specifications hereunder, complete with all auxiliaries, accessories, spare parts and warranting a trouble free safe operation of the installation. The scope of work shall be a comprehensive functional system covering all supply and services including but not be limited to following: 31.1.1 Submersible pumps and associated accessories i) Two (2) Submersible pumps with starter panel, submersible cables and associated accessories complete with non-return valves and isolating valves. ii) iii) iv) A set of level switches to start and stop pumps One (1) set of silt disposal pipe with fittings and isolating valves. Two sets of piping with valves and fitting for supply of compressed air in cooling water sumps to facilitate effective silt removal. v) vi) vii) One (1) set of spare parts. One (1) set of tools. Any other item(s) not mentioned specifically but necessary for the satisfactory completion of scope of work defined above, as per accepted standard(s) / best international practices. 31.2 Specific Codes and Standards
Electrical equipment shall be designed and tested according to the latest relevant standards including amendments, or complementary standards mentioned in this document, shall be applied, in particular to the following:
Volume 3B(PTS)
Standard IS 4721
Description Code of Practice for Drainage and Dewatering of Surface / Underground Hydroelectric Power Station
31.3
Special Design and Layout conditions
Two dewatering cum silt ejecting pumps (one in each cooling water sump) will be provided to dewater unit tailrace channel and to remove the silt from cooling water sumps. During dewatering of a tailrace channel, any one cooling water sump will be isolated from other two units, whereas the tailrace channel to be dewatered will be isolated from the other cooling water sump. Dewatering pump located in former sump shall be used to dewater the tailrace by discharging the water either directly to tailrace of unit one or to the other sump. The capacity of pump shall be designed to dewater tailrace and sump in a reasonable time. These dewatering pumps shall also be used to remove the silt from cooling water sumps. The cooling water sumps will be cleaned one by one without disturbing the power generation. Silt will be pumped out and discharged into tailrace of unit -1 through silt disposal pipe. During silt cleaning process compressed air shall be released in the cooling water sump to facilitate silt removal in effective manner. 31.4 Rating and Functional Characteristics
31.4.1 Rating Pumps The dewatering pumps shall be of submersible type with motors of continuous duty. Both pumps shall be of same capacity and interchangeable. The capacity of the pumps shall be as mentioned below. The contractor shall do necessary calculation for selecting the rating (i.e. pump discharge and design head) of pumps. In case of lesser discharge requirement, below mentioned pump discharge capacity shall be provided. The pumps shall be suitable for continuous operation and capable of handling mixture of water and silt.
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Volume 3B(PTS) Discharge capacity 2700 L / minute Design Head 15 m
Description Pumps
Nos. of Pumps 2
The pump impeller and casing shall be of stainless steel and cast steel respectively. The material for shaft and fasteners shall be stainless steel. The pump impeller shall be properly balanced along with other rotating parts on proper balancing equipment to prevent vibration. Pumps shall be provided complete with continuous duty electric motors with class F insulation, starter for auto operation, power cable, discharge piping and hardware, anchor bolts and other mounting materials. The pumps shall be suitable for 415 V 10%, 50 Hz 5% with contacts for remote operation / indication. For maintenance and handling, the pumps shall be provided with auto-setter coupling, lifting lug, guide support, guide rail and chain and the material shall be stainless steel. Valves, Piping and Floor drains All required pipes, valves, flanges, fittings, supports, fasteners, and related material shall be supplied as part of this contract. All embedded and exposed piping shall be of heavy-duty class. Minimum pipe wall thickness shall be as per relevant standard for heavy duty pipes. The piping shall be in accordance with General Technical Specification (GTS). The contractor shall do necessary coordination and shall make detailed layout drawings for routing of the pipes etc. and submit the same for approval of the Owner during detailed engineering. Check valves shall be provided in pump discharge lines. The velocity in the pipe shall not exceed 2.0 m/s and 2.5 m/s at suction and delivery side respectively. All required pipes, valves, flanges, fittings, supports, fasteners, and related material shall be supplied as part of this contract. Valve body of all type of valves shall be preferably of cast steel except smaller valves (50 mm and lower).
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Insulation for piping All exposed pipes, wherever required, shall be insulated against condensation with approved type insulation / lagging with vapour proof cover. The cover shall be painted in accordance with approved colour code. 31.4.2 Functional characteristics Tailrace channel dewatering system The dewatering water pumps provided in cooling water sumps will be used to dewater tailrace channels. The outlet water from pumps shall be discharged into the tailrace of unit 1, in the other cooling water sump. These pumps will also be used to remove silt from the cooling water sumps. The outlet of pumps shall be discharged into tailrace of unit -1. Control and monitoring The contractor shall provide and install all the operating devices to fulfill the functional requirement of this specification for control system. Facility for selection of control either from Local Control Cubicle or Local Control Board or plant SCADA system shall be provided in the Local Equipment Panel or Local Control Board. The Contractor shall make provision of contacts and/or ports in local control cubicles for interfacing with SCADA system for control and monitoring. The Contractor shall provide and install all the sensors and operating devices necessary to fulfill the functional requirement of the specification for control system. All pumps shall be automatically controlled based on the sump level sensed by adequate instrumentation. Following local controls, but not limited to, shall be provided for each dewatering pumps: Manual/Automatic switch for manual/automatic operation of each pump, Remote/ local selector switch for each pump, Start/stop push buttons for each pump, Emergency stop push button switch
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Automatic start and stop of pumps on the basis on level in the sump, Lamp test push buttons.
Indication and Alarms The Contractor shall supply suitable instruments and gauges for achieving desired control logic. Indicating instruments as required shall be installed on local control panel and indications may be replicated in Local Control Board/ control room for common services. Following indications and alarms, but not limited to, shall be provided for each drainage and dewatering water pump: Pump running / stop / trip for each pump, No flow for each pump, High and Low water level indication and alarms, Other indications, as required.
Protection The motor for each pumping unit shall be provided with at least the following devices: 31.5 Over load protection, Under voltage protection, Single phasing protection. Performance Guarantee
The dewatering cum silt ejection system along with all auxiliaries and accessories shall be capable of performing intended duties under specified conditions. The Contractor shall guarantee the reliability and performance of the individual equipment as well as of the complete system. 31.6 Quality control and Quality Assurance
The Contractor shall supply the equipment of best quality. The contractor shall maintain control and quality assurance during the manufacturing, installation, testing and commissioning of equipment as per approved quality assurance plan.
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31.7
31.7.1 Drawings and documents The Contractor shall submit all the drawings and documents in accordance with requirements stipulated in Section 2.12 Reference drawings and documents of General Technical Specification (GTS). 31.7.2 Design calculation The Contractor shall submit the design calculation for review / acceptance covering at least the following: Calculation for selection of pump capacity, working head and motor rating for dewatering pumps, 31.8 Sizing of piping Any other calculation required during detailed engineering. Shop Tests
The pumps, pipe and valves shall be routine tested as per relevant IEC / IS at the suppliers works / contractors shop. The contractor shall submit the required type test certificates and routine test reports of the equipment for approval before despatch of equipment. 31.9 Installation and Commissioning
Requirements. The supplier shall arrange personnel to oversee proper storage of equipment at site, their transhipment to powerhouse, installation and commissioning. 31.10 Field testing After installation of all equipment the complete system shall be leakage tested as per field test in general technical specifications as per IEC / IS.
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The contractor shall furnish a complete outline of proposed method and procedures to be followed for field testing including a list of equipment and instruments to be used for owners review well in advance before the scheduled testing. The contractor shall furnish a complete report of the field tests of the equipment. After installation and prior putting the equipment in operation at least following site tests shall be carried out; The complete system along with pumps shall be hydrostatically tested for leakage at requisite pressure. The system shall be maintaining the requisite pressure for 24 hours without showing any sign of pressure loss and leakage. If the system is tested in sections, it applies for each section. Pump output test Opening and closing of all valves. Other tests as deemed necessary by the engineer.
31.11 Spare Parts 31.11.1 Recommended Spare Parts
All spare parts and accessories shall be identical electrically and mechanically to corresponding parts in the equipment supplied and shall be suitably packed and clearly marked, ready for long term indoor storage. The following specified spares shall be supplied Sl no 1 2 Description Complete submersible pump-motor set Complete shaft seal of each type Quantity 1 no. 2 no. each
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Sl no 3 4 5 6 7 8 9 10
Description Complete set of rubber rings and gasket Submersible cable full length Level switches Pressure gauges Valve of each type Pump Impeller Pump shaft Stator
Quantity 2 set 1 set 2 nos 1 no each 1 No of each 1 no. 1 no 1 no
31.12 Tools and Instruments The Contractor shall provide one set of all necessary special tools and maintenance equipment for repair and maintenance of cooling water system as recommended by the manufacturer. A list of special tools and testing instrument including their make and detailed specification as recommended shall furnished by manufacturer for approval of Owner.
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ANNEXURES
Annexure-I
ANNEXURE - II
REPORT ON SILT CONTENT IN WATER AT ALAKNANDA H.E. PROJECT (300 MW)
Recently observed silt data at Alaknanda Project Sediment in ppm 249 485 481 657 1323 1407 1313 1462 1285 324 240 24 23 21 18 10 9 8 6 6 7 8 13 13 11 10 10 11 12 29 48 69 151 187 186 434
Month JUNE I II III I II III I II III I II III I II III I II III I II III I II III I II III I II III I II III I II III
Period 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 10 days days days days days days days days days days days days days days days days days days days days days days days days days days days days days days days days days days days days
JULY
AUSUST
SEPTEMBER
OCTOBER
NOVEMBER
DECEMBER
JANUARY
FEBRUARY
MARCH
APRIL
MAY

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GMR (BADRINATH) HYDRO POWER GENERATION PVT. LTD.

Alaknanda Hydroelectric Project (300 MW) (UTTARAKHAND, INDIA)

(Particular Technical Specifications)

PARTICULAR TECHNICAL SPECIFICATIONS

Alaknanda Hydroelectric Project (300 MW) Particular Technical Specification

GBHPL/LOT-5: Electro-mechanical works

Alaknanda Hydroelectric Project (300 MW) Particular Technical Specification

GBHPL/LOT-5: Electro-mechanical works

Alaknanda Hydroelectric Project (300 MW) Particular Technical Specification

Alaknanda Hydroelectric Project (300 MW) Particular Technical Specification

Alaknanda Hydroelectric Project (300 MW) Particular Technical Specification

GBHPL/LOT-5: Electro-mechanical works

Alaknanda Hydroelectric Project (300 MW) Particular Technical Specification

GBHPL/LOT-5: Electro-mechanical works

Alaknanda Hydroelectric Project (300 MW) Particular Technical Specification

Alaknanda Hydroelectric Project (300 MW) Particular Technical Specification

GBHPL/LOT-5: Electro-mechanical works

Alaknanda Hydroelectric Project (300 MW) Particular Technical Specification

31.5 31.6 31.7 31.8 31.9 31.10 31.11 31.12

GBHPL/LOT-5: Electro-mechanical works

Alaknanda Hydroelectric Project (300 MW) Particular Technical Specification

GBHPL/LOT-5: Electro-mechanical works

Alaknanda Hydroelectric Project (300 MW) Particular Technical Specification

TURBINE AND ACCESSORIES Scope of Work

Alaknanda Hydroelectric Project (300 MW) Particular Technical Specification

Alaknanda Hydroelectric Project (300 MW) Particular Technical Specification

GBHPL/LOT-5: Electro-mechanical works

Alaknanda Hydroelectric Project (300 MW) Particular Technical Specification

Standards IEC 60308 IEC 60545

ISO 7919 part-5

CCH 70 3 2.2 2.2.1

Turbine Rating and Design Requirements Turbine Rating

GBHPL/LOT-5: Electro-mechanical works

Alaknanda Hydroelectric Project (300 MW) Particular Technical Specification

Operating Net Head Range

Normal Internal design pressure:

GBHPL/LOT-5: Electro-mechanical works

Alaknanda Hydroelectric Project (300 MW) Particular Technical Specification

GBHPL/LOT-5: Electro-mechanical works

Alaknanda Hydroelectric Project (300 MW) Particular Technical Specification

Alaknanda Hydroelectric Project (300 MW) Particular Technical Specification

GBHPL/LOT-5: Electro-mechanical works

Alaknanda Hydroelectric Project (300 MW) Particular Technical Specification

Runner removal arrangement

Alaknanda Hydroelectric Project (300 MW) Particular Technical Specification

GBHPL/LOT-5: Electro-mechanical works

Alaknanda Hydroelectric Project (300 MW) Particular Technical Specification

GBHPL/LOT-5: Electro-mechanical works

Alaknanda Hydroelectric Project (300 MW) Particular Technical Specification

Alaknanda Hydroelectric Project (300 MW) Particular Technical Specification

Volume 3B(PTS) where,

= 0.1 x 115 + 0.6 x 100 + 0.2 x 75 + 0.1 x 50 = Weighted average efficiency

Alaknanda Hydroelectric Project (300 MW) Particular Technical Specification

Alaknanda Hydroelectric Project (300 MW) Particular Technical Specification

GBHPL/LOT-5: Electro-mechanical works

Alaknanda Hydroelectric Project (300 MW) Particular Technical Specification

GBHPL/LOT-5: Electro-mechanical works

Alaknanda Hydroelectric Project (300 MW) Particular Technical Specification

<= <= <= <=

0.2% 0.2% 0.2% 0.2%

Alaknanda Hydroelectric Project (300 MW) Particular Technical Specification

Alaknanda Hydroelectric Project (300 MW) Particular Technical Specification

Alaknanda Hydroelectric Project (300 MW) Particular Technical Specification