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L&T’s CONSULTANT:
L&T-SARGENT & LUNDY LIMITED, BARODA
INDEX
SECTION-I
TECHNICAL SPECIFICATION
2X382 MW CCPP at Vemagiri
CONTENTS
1.0 INTENT OF SPECIFICATION...................................................................................................................6
9.0 DRAWINGS / DATA / DOCUMENTS TO BE SUBMITTED BY BIDDER ALONGWITH THE BID .34
1.2 It is not the intent to completely specify all details of design and construction
herein. Nevertheless, the equipment and installation shall conform to high standards
of engineering design and workmanship in all respects and shall be capable of
performing continuous operation in a manner acceptable to the Purchaser.
A 2X382 MW CCPP is being set up at Vemagiri, Andhra Pradesh. The CCPP will
have two (2) nos. Gas Turbine Generators, two (2) nos. Heat Recovery Steam
Generators and two (2) nos. Steam Turbine Generator as main equipments.
The Gas Turbine Generator (GTG) and Steam Turbine Generator (STG)
Transformers will be used for connecting the Gas Turbine and Steam turbine
Generators to the 400kV system.
The scope of work under this package will include design, engineering,
manufacturing, inspection and testing at manufacturer’s works, packing, supply on
FOR site basis, and supervision of erection, testing and commissioning at site of
GTG and STG Transformers as described hereunder. Items though not specifically
mentioned but are required to make the system complete will be treated as included
in the scope of Supplier unless otherwise specifically excluded. The total system
design and engineering will be sole responsibility of Supplier.
4.1.2 The scope of supply for each of the above transformers shall include but not limited
to the following:
b) Air release plug and 2 nos. Plugged pipe outlets for vacuum pulling to be
provided.
c) Pipe to soak pit with valve for quick oil drainage in case of fire to be provided.
2X382 MW CCPP at Vemagiri
d) Cable, trays, supports and conduits between the Supplier’s devices and marshalling
box / cooler control cabinet except those specifically excluded.
e) Structure for supporting conservator, radiator, control cabinet and any other
structure if required for supporting any parts of transformer.
f) First fill of oil (as per IS 335) till the level generally required in the conservator
including with 10% extra quantity in non-returnable sealed containers.
i) All relevant drawings, data, routine & type test reports, erection & commissioning
instructions and operation & maintenance manuals.
l) Bidder shall supply special tools, tackles & materials as required for erection,
commissioning & maintenance and shall include in the bid separately.
b) Packing, loading, for transportation and delivery of all the materials by rail/road
to site.
d) Submission of all necessary data sheets, drawings, documents, and QAP for
Purchaser’s approval. Submission of test certificates and carry out all testing /
inspection, inline with approved QAP. Vendor will also provide facilities for
Purchaser’s / Owner’s representatives to witness various tests inline with
approved QAP.
m) The bidder shall give an optional price for training of Owner's engineers at the
manufacturing works and plant site. Bidder to indicate in his bid, the duration of
training in man-days at each location and man-day rate considered. The same
shall however be finalised before award of contract.
e) Marshalling box (All Purchaser’s external power (3Phse 415V AC and 220V
DC), control & instrument cables)
4.4 EXCLUSIONS
f) 415 V, 3-phase, 3-wire, 50 Hz power supply and 220 V DC power supply (as
required). Bidder shall clearly indicate the auxiliary power supply requirements
(Number of supplies, voltage level, current ratings etc.) in his bid.
5.1 The equipment, systems and services furnished as per this specification will
conform to the codes and standards mentioned here which are furnished for
Supplier’s guidance.
5.2 In case of any conflict between this document and the Indian and Internationals
codes and standards, referred to herein, the stipulations of the more stringent
one will prevail.
5.3 Standards as applicable from the following list, or other internationally accepted
equivalent standards should be used in the design, manufacture and testing:
Oil IS : 335
Bushings IS : 2099
2X382 MW CCPP at Vemagiri
Tests IS : 2026
power grid. For this purpose the CCPP shall have its own 400 kV switchyard with a
1½-breaker arrangement.
6.2 The Generator Transformer shall be so sized as to be able to evacuate power from
the GTG / STG to which it is connected under all conditions of ambient
temperature. Gas Turbine curve showing Power output w.r.t ambient temperature is
attached with this specification. GTG Transformer rating should be higher than the
Gas Turbine output throughout the ambient temperature range.
6.3 Cooler control: Two (2) 100% capacity separately mounted radiator banks shall be
provided. Each bank shall be provided with adequate number of fans and pumps
and one oil pump and one fan spare. Each radiator bank shall be provided with
uni-directional bypass valve to permit oil to bypass the pump in the event of pump
failure. It shall be possible to completely isolate any one of the radiator banks for
maintenance, while the transformer is in service. Flexible expansion joints, one
each, on top and bottom pipe connections for each radiator shall be provided. Each
radiator bank shall have at least two (2) extra radiators to facilitate usage of the
same in case of leakage in the other radiators If radiators are arranged in groups,
each group of radiator shall have upper and lower shut-off valves with blanking at
either ends. The cooling fans for AF and cooling pumps for OF shall have provision
for local and remote operation. The controls shall also consist of an auto / manual
selection. Fan running indication from auxiliary contact of fan power contactor and
an oil flow indicator along with an electrical contact for alarm / interlock shall be
provided for the confirmation of the oil pump operating in a normal state.
Tap changer control: Generator transformers shall be equipped with On-Load tap
changer (OLTC) of range +7.5% to -15% in steps of 1.25% on the HV side and
suitable for bi-directional power flow. OLTC shall be operated from local OLTC
panel as well as from RTCC & remote. Tap position indication shall be provided in
local OLTC panel, RTCC and remote. Suitable interlocks shall be provided to
prevent inadvertent / mal operation of the tap changer.
7.1 GENERAL
a) The transformers shall be of the latest design, mineral oil immersed type.
Transformers shall be suitable for outdoor installation.
2X382 MW CCPP at Vemagiri
d) The type of cooling shall be Oil Natural Air Natural, Oil Natural Air Forced and
Oil Forced Air Forced, as specified, and the corresponding ratings of
transformer shall be as indicated in the specific requirements.
g) The transformer and all accessories including bushings, CTs, etc shall be
capable of withstanding the short circuit stresses due to terminal fault on one
winding with full voltage maintained on the other winding for minimum period
of one (1) seconds without damaging effect as well as any external short circuit
at bushing terminal.
h) The Transformers shall operate without injurious heating at the rated MVA
continuously at any voltage within + 10% of the rated voltage of the Tap.
i) The transformer shall be free from annoying hum or vibration. The design shall
be such as not to cause any undesirable interference with radio or
communication circuits.
j) The transformer and the associated accessories shall be suitable for bi-
directional flow of power. The transformer will be back-charged from the EHV
system to charge the unit auxiliary transformers.
2X382 MW CCPP at Vemagiri
k) Core clamping arrangement shall be equipped with core and coil lifting eyes.
Anti-earthquake clamping arrangement shall be provided.
m) Transformers shall be so designed that the average sound level will not exceed
the value 85dB at the distance of 1 meter from the equipment, as measured at
factory and site.
o) All hardware used in the transformer and accessories shall be zinc plated &
chrome passivated / stainless steel to suit the site environment.
a) The generator transformer shall be outdoor type, of welded mild steel plate
construction fabricated from good commercial grade low carbon steel of
adequate thickness and provided with gaskets steel cover plates. Base shall be
suitably reinforced to prevent any distortion during lifting. Base channels shall
be provided with skids and pulling eyes to facilitate handling. Bell type design
shall be adopted for transformer tank.
b) The tank of the transformer along with radiators, conservators, bushings and
other fittings shall withstand full vacuum of 760 mm of Hg while filling the oil
under vacuum and also an excess internal pressure of 0.35 kg/sq. cm.
c) All seams and those joints not required to be opened at site shall be welded and
wherever possible they shall be double welded in factory itself for absolute oil
tightness. After completion of tank and before painting, dye penetration test
shall be carried out on welded parts of jacking bosses, lifting lugs and all load
bearing members. Grinding shall clean all welds. Any tack welding deposits
shall be removed.
2X382 MW CCPP at Vemagiri
d) The tank covers shall be fitted with thermometer pockets (in locations expecting
maximum operating oil temperature) for bulbs of oil and winding temperature
indicators. The thermometer pockets shall be filled with a captive screwed top to
prevent ingress oil water. It shall be possible to remove these bulbs without
lowering the oil in tank.
e) Tank shields and two (2) inspection openings to be provided in transformer tank.
Tank shields shall be such that no magnetic field shall exist outside the tank.
They shall be of magnetically impermeable material. If required impermeable
shields shall be provided in the tank for positioning the core and coil assembly.
The inspection covers shall be suitably designed to prevent ingress of rainwater
and shall have suitable lifting arrangements. Bushings, turrets, inspection covers,
thermometer pockets etc. shall be designed to prevent ingress of water into, and
leakage of oil from the tank.
f) Tanks shall not resonate when excited at the natural frequency of the equipment.
g) The tank, radiator banks and marshalling box shall have at least two (2) distinct
stainless steel earth pads terminals, capable of carrying maximum system earth
fault current for a duration of one (1) sec, for connection to Purchaser’s earth
grid by 75 x 10 mm GI Flat.
i) Tank, tank cover and other associated components on the transformers shall have
electrical continuity for earthing.
j) All the bolted connections shall be fitted with weatherproof hot oil resistant
SRBP gasket / nitrile rubber gasket in between for complete oil tightness. If
gasket is compressible, metallic stops shall be provided for avoiding over
compression. Necessary bridging with copper strips shall be provided for the
electrical continuity across a gasket joint.
k) Suitable guides shall be provided for positioning the various parts including core
and coil during assembly or dismantling. Adequate space shall be provided
2X382 MW CCPP at Vemagiri
between the cores and windings and the bottom of the tank for collection of any
sediment
l) Each tank shall be equipped with the following valves with the standard flange
connection for external piping.
i) One drain and lower filter valve located on the low voltage side of the
transformer and so placed to completely drain the tank. The valve shall be
equipped with a small sampling cock.
ii) One filter valve located at the top of the tank on the high-voltage side. The
opening of this valve shall be baffled to prevent aeration of the oil.
iii) One filter valve, located diagonally opposite to (ii) slightly above the bottom
of the tank.
iv) Spring loaded pressure relief device, as required, to operate at a pressure
below the test pressure for the tank.
v) All valves excepting radiator valves shall be of gunmetal. Radiator valves
shall be of cast iron with stainless steel / gunmetal moving parts. All valves
shall be provided with stopper.
vi) Suitable pad locking arrangements should be provided for drain & bottom
sampling valves, to lock them in close / open position. All valves should be
provided with clear open/close position indications. Wherever rising spindle
type valves are provided the valves should be clockwise rotating for closing
operations.
7.3.1 CORE
a) Core shall be constructed of high grade, low loss, high permeable CRGO silicon
steel laminations. Maximum flux density in any part of the Core and Yoke at
rated MVA, voltage and frequency shall be such that under 10% continuous over
voltage condition it should not exceed 1.9 Wb/m2. Bidder shall submit the over
fluxing curve along with the offer.
2X382 MW CCPP at Vemagiri
d) The transformer shall be subjected to load rejection conditions and shall be able
to withstand 1.4 times the rated voltage for 5 seconds as per IS: 2026.
e) The framework and the core bolts shall be efficiently insulated from the core so
as to reduce the eddy-currents to a minimum.
f) The limbs and the yokes of the core shall have similar sections to minimise
heating and noise arising from transverse flux. The joints in the laminated
magnetic circuit shall be interleaved. Necessary cooling ducts shall be provided
for heat dissipation from the core so that the anticipated maximum hot spot
temperature in the core shall not be injurious to any material used in the core
assembly.
g) The frame, clamps and core-bolts shall be electrically insulated from the core.
Such insulation shall be capable of withstanding maximum temperature existing
in the core. For this purpose, Class-A or better insulation shall be used. Core
clamps shall be electrically connected to the tank.
k) The insulation of core to bolts and core to clamp plates shall be able to
withstand a voltage of 2 kV RMS for one (1) minute.
l) The completed core shall be provided with the lifting eyes and lugs to facilitate
its removal from the transformer tank and shall be adequately braced &
supported to prevent movement during transit or service. All steel sections used
for supporting the core shall be thoroughly sand blasted after cutting, drilling
and welding.
7.3.2 WINDINGS
c) All windings shall be fully insulated for the highest system voltage of 420 kV
systems. The 420 kV star connected windings shall have graded insulation
while 15.75 kV winding shall be uniformly insulated, as defined in IS: 2026.
The insulation shall be as specified in Vol III, Section II, Annexure-1. Coils
shall be so insulated that impulse and power frequency voltage stresses are
minimum. All neutral points shall be insulated to withstand applied voltage test
as defined in the relevant standard.
h) The end turns of the high voltage windings shall have reinforced insulation to
take care of the voltage surges likely to occur during any abnormal condition.
j) The windings shall be located in a manner, which shall ensure that they remain
electrostatically balanced and that their magnetic centres remain coincident
under all conditions of operation.
k) The windings shall be so designed that all coil assemblies of identical voltage
ratings shall be interchangeable, and field repairs to the windings can be made
readily, without special equipment. Insulating spacers and the barriers/bracing
shall support the coils and other insulation used in the assembly of the windings
shall be arranged to ensure a free circulation of the oil and to reduce hot spots in
the windings. Windings shall be suitably designed so as to conduct tan delta test
for winding/bushings at site or at factory.
2X382 MW CCPP at Vemagiri
l) All materials used in the insulation and assembly of the winding shall be
insoluble, non-catalytic, and chemically inactive in the hot transformer oil, and
shall not soften or otherwise be adversely affected under the operating
conditions.
m) All threaded connections shall be provided with locking facilities. All leads
from the winding to the terminal board and bushings shall be rigidly supported
to prevent injury from vibration. Guide tubes shall be used where practicable.
n) The winding shall be brought out through bushing and provided with suitable
terminal connectors.
q) The tolerance for the winding resistance measurement for different phases but at
same taps shall be limited to 1%.
r) The design of the magnetic circuit shall be such as to avoid static discharges due
to development of short circuit paths within itself or to the earthed clamping.
7.4 CONSERVATOR
b) The conservators shall be bolted into position so that it can be removed for
cleaning purposes.
c) The conservators shall be fitted with magnetic type oil level gauge (MOG) with
two independent low level electrically insulated potential free alarm contacts
wired up to the MOG’s terminal box, further wired up to the control cabinet
terminal strip. The oil level at 30C shall be marked on the gauge; however, the
range of the MOG shall be from minimum to maximum oil level. The dial size
shall be 150 mm. The conservator shall also have a prismatic oil level gauge.
Both the gauges shall be placed on the opposite sides of the conservator.
d) In the conservator, flexible oil resistant air cell nitrogen fill (rubber diaphragm)
breathing through silica gel breather shall be provided. The air cell shall be made up
of nitrile rubber reinforced with nylon rubber and with nylon cloth. As such air cell
used shall be suitable for operating continuously at the temperature rise limits. Air
cell of conservator should be able to withstand the vacuum during installation /
maintenance periods. Otherwise provision shall be kept to isolate the conservator
from the main tank when the later is under vacuum by providing a vacuum sealing
valve or other suitable means in the pipe connecting main tank with the conservator.
The connection of air cell to the top of the conservator shall be by air proof seal
preventing entrance of air into the conservator. The air cell material should not get
decomposed under the severe most operating conditions and should also not react
with oil / oil vapour. Necessary fittings (valves) with pressure gauge shall be
supplied for commissioning the air cell.
7.5.1 GENERAL
c) The cooler units shall be so arranged such that the transformer tank, bus-ducts /
cabling chamber, etc do not fall in the direct path of hot air coming out of the
2X382 MW CCPP at Vemagiri
unit coolers. Each cooler unit shall have its own cooling fan and pump, oil flow
indicator with shut-off valves, oil filtering valves at top and bottom, a drain
valve, air release plugs, etc. An oil flow indicator along with an electrical contact
for confirmation of each oil pump operating in a normal state will be included.
d) Cooler units shall be connected to the tank by machined steel flanged joints
provided with suitable quality gaskets for sealing purpose. The flanges shall be
welded to the both cooler units and the tank. At each cooler unit connection on
the tank an indicating shut off valve shall be provided which can be fastened in
either open or closed position. A separate oil tight blank flange shall be provided
for each tank connection for use when the cooler unit is detached. Each cooler
unit shall have a lifting eye, an oil drain at the bottom, and a vent at the top. The
vent and drain plugs of coolers should be provided with Teflon gaskets. Flexible
Expansion Joint, one each on top and bottom pipe connection for each radiator
bank shall be provided.
e) Radiators need to be properly and freely supported from the ground such that the
transformer can be taken out for maintenance without disturbing the radiators.
f) Each cooler unit shall be provided with the following:
auto changeover. The cooler control shall be suitable for both remote and local
indication.
b) Control equipment for pump and fan motors shall be mounted in a marshalling
box to be installed adjacent to the transformer and shall include the necessary
connections with automatic control and annunciation equipment with provision
for auto / manual control for each group of fans and oil pumps.
c) 240V, 1 ph, AC supply shall be derived by the Bidder from the 415V supplies
provided by the Purchaser to facilitate 240V AC supply to lights and heaters in
marshalling box.
d) The auto-changeover scheme shall be designed based on under-voltage relay
logic, to take care voltage dips on 415V supplies.
e) The main and starter control circuit for each fan and pumps feeder shall be
provided with fuses at both ends so that in case of fault on any contactor coil
only that particular fan shall be cut out and other fans can remain in service.
Each feeder shall also be provided with double pole switches to enable isolation
of the corresponding contactor in case replacement of the same is necessitated.
f) A single metal-enclosed main isolating switch, with HRC fuses, shall be
provided for the cooling plant contactor group.
g) The contactors, starters and relays provided in the marshalling box shall be of
reputed make. Bidder shall furnish the list of sub-vendors for purchaser’s
approval.
h) The switching in or out of the cooling equipment shall be controlled by winding
and oil temperature and there shall be provision for automatic switching in or
out at predetermined temperature levels which should be capable of adjustment
and setting at will.
i) A local mechanical indication scheme for all annunciations shall be provided in
the marshalling box with mechanical target relays/contactors.
j) Anodised aluminium plate showing details of all terminal nos. shall be provided
along with marshalling box.
7.6 BUSHINGS
a) All bushings shall conform to the requirements of IS:2099 - 1973 for the
respective application voltage. Bushings of identical ratings shall be
2X382 MW CCPP at Vemagiri
The LV bushings shall be cover mounted and have a flanged enclosure suitable for
connection to an isolated phase busduct. Ample space and access shall be provided
for the installation of the isolated phase bus duct. The busduct interface chamber will
be air filled and all current carrying parts in it will be properly insulated, supported
and braced. The low point of flanged enclosure will be provided with a screened
drain.
2X382 MW CCPP at Vemagiri
b) The OLTC’s tap changing gear shall comply with IEC: 60214, IS:8478 and CBIP
manual on transformer - 1987. The tap changer shall be mounted in a separate tank
or compartment in accessible position on the transformer tank. The operation of
the transformer at any of the taps shall not produce phase displacement. All the tap
changing switches shall be rated for full bi-directional power flow.
c) The OLTC gear shall have diverter resistance or reactance and current diverting
contacts. The contacts shall be accessible for inspection and their tips shall be
replaceable. OLTC oil chamber shall have oil filling, drain and sampling facility. It
shall be provided with oil level indicator and alarm contacts. On load oil filter
connection orifices, valves and silica gel breather shall be provided.
d) OLTC shall be provided with separate conservator and oil temperature indicator
with contacts and oil surge relay.
e) OLTC devise shall be such that the oil in the compartment containing making and
breaking contacts does not mix with oil in other compartment of OLTC or
transformer tank.
f) All contacts shall be silver plated and held in position under strong contact
pressure to ensure low contact drop and avoid pitting.
h) Mechanical Control
The cranking device for operation of the OLTC gear shall be removable and
located at a height not exceeding 1500mm above ground level for easy operation.
2X382 MW CCPP at Vemagiri
The mechanism shall be complete with normal accessories including at least the
following
i) Electrical Control
- Local-electrical operation
- Remote-electrical operation from RTCC/DCS
- Device to ensure a positive and full completion of tap change once it is
Initiated even if the control supply or any relay fails
- Protective devices to put the transformer out of service in case of abnormal
Tap changer performance and to initiate an alarm.
- Each operation of either the raise or lower control switch shall cause one tap
Movement only. The control switch shall be returned to the off position for
each successive operation.
- All electrical control switches and local operation gear shall be clearly
labelled to indicate the direction of the tap changing.
- Provision shall be made to cut out electrical control to prevent OLTC
operation during over-loaded operation of the drive mechanism motor.
A local tap changer cubicle shall be provided for housing motor drive mechanism
for on load tap changing at transformer. The tap changing cubicle shall be
fabricated with 2.5 mm CRCA sheet steel complete with all wiring, fuses, links,
cubicle illumination lamps, anti-condensation heater with thermostatic control
switch, gland plate, etc. The cubicle shall be suitable for outdoor installation. The
tap changer shall contain the following:
- MCB with magnetic and thermal overload devices for controlling incoming
supply to OLTC.
- Limiting devices
- Padlocking arrangement for hinged cabinet door
- Operation counter
- Cubicle lighting
- Oil Temp. Indicator
- Removable cable gland plate
k) The driving motor and electrical control of the motor drive mechanism shall be
designed to operate satisfactorily within the limits of 80% to 110% of the rated AC
voltage of 415V 10%, 3 phase, 50Hz 5%.
The RTCC shall be indoor simplex type, free standing, totally enclosed, floor
mounting type with rear access door. The panel shall be fabricated from structural
steel framework enclosed on all sides and top by CRCA sheet steel of minimum
2.5mm thickness. The panel shall be complete with all wiring fuses, links,
illumination lamps with door switch, anti-condensation heater with thermostatic
control switch, gland plate, etc.
m) Indicating lamp for Tap position maximum reached, Tap position minimum reached
and Tap changer stuck to be provided in local panel and also contacts for remote
indication to be provided.
OLTC devise shall be suitable for remote electrical parallel control with Master-Follower scheme.
2X382 MW CCPP at Vemagiri
n) Automatic and manual operation facility including hardware, AVR as required shall
be provided for the OLTC system.
a) A sheet steel, weather proof, vermin and dust proof marshalling box suitable for
out door application shall be furnished with each transformer to accommodate :
i) Temperature indicators.
ii) Transducers for WTI/OTI
iii) Terminal blocks for incoming and outgoing cables.
iv) Interposing Relays / Amplifiers for the Proximity switches
b) The sheet steel used shall be at least 2.5 mm thick. The box shall be free standing
floor-mounted type and having a sloping roof canopy. The degree of protection
shall be IP 55 for outdoor application
c) The temperature indicators shall be so mounted that the dials are not more than
1600 mm from ground level. The marshalling box door shall have a glazed
window of suitable size for convenience of temperature indicators reading.
d) The marshalling box shall contain all control circuits, auxiliary relays, terminal
boards, etc., as required to provide a single interface location
Equipment Signal
Generator Buchholz relay alarm
transformer control Buchholz relay trip
cabinet Winding temperature alarm
(Marshalling box) Winding temperature trip
Oil temperature alarm
Oil temperature trip
2X382 MW CCPP at Vemagiri
Equipment Signal
Oil level low alarm
Pressure relief device trip
4-20mA signal from WTI/OTI
Oil flow indicator for each cooler bank
Cooler bank failure
Cooler bank in service
AC control supply failure
DC control supply failure
f) Wiring from the current transformers and other control and alarm equipment
shall be carried out in conduits or alternatively in concealed trays and terminated
in the marshalling box.
g) All incoming cables shall enter the marshalling box from the bottom. The cable
glands shall be of brass and double compression type. A removable undrilled
gland plate shall be provided at the bottom of the box for accommodating glands
for Purchaser’s incoming and outgoing cables, which shall not be less than 450
mm from finished floor level. The gland plate shall be minimum 3.0 mm thick
and shall be made into detachable halves, for facilitating the termination of
incoming and outgoing cables separately. The gland plate and the associated
compartment shall be sealed in a suitable manner to prevent the ingress of
moisture, rodents, insect etc.
h) Terminal blocks shall be furnished in the marshalling box. All terminal blocks
shall be of disconnecting type. Terminal blocks for short circuiting the current
transformer shall be provided separate from the terminal blocks accommodating
the control and indicating circuits. The direct and alternating current terminals
shall be isolated from each other.
i) All tapping of CTs shall be brought to terminals in the marshalling box and 10%
spare links shall be provided. The terminals for the current transformer leads
shall be suitable for accommodating 6 sq.mm. cable leads while the terminals for
the control and other circuits shall be suitable for accommodation 2.5 sq.mm.
cable leads. Atleast 20% spare terminals for control wiring shall be provided.
j) CT terminal blocks shall be provided with test links and isolation facilities.
Neutral CT terminals shall be brought out to the terminal box for the connection.
Terminal blocks for 415 V power cables shall be suitably sized to terminate the
required size of cable.
2X382 MW CCPP at Vemagiri
k) Suitably rated switches shall be provided to enable the control supply to the
transformer to be cut off from the marshalling box.
l) Enough space shall be provided at the bottom of the operating marshalling box to
mount the Purchaser's control cables glands. The number and size of the cable
glands shall be intimated later. All terminal blocks for control shall be rated for
minimum 10 Amps.
m) Complete control cabling between the transformer and the marshalling box shall
be in the scope of the Bidder and it shall be supplied loose along with the
marshalling box.
n) All wiring in the housing shall be stranded copper and the insulation shall be
1100V grade PVC and shall be of reputed make. Size of wires shall be not less
than 4 sq.mm. for CT leads and not less than 2.5 sq mm for other connections.
CT circuit wiring shall be done using colour coded wires for better identification.
o) Not more than two (2) wires shall be connected to one terminal.
p) Wire and cable bunching saddles PVC channels shall be provided on all terminal
blocks on either side. The wire terminals shall be engraved or otherwise indelibly
marked ferrules and the wires shall be colour coded. All control wires shall have
cross ferruling at both ends for identification.
q) All devices and terminal blocks inside the marshalling box shall be clearly
identified by symbols corresponding to those used on applicable schematic or
wiring diagram. The terminal block shall be stud type. All terminal blocks should
have terminal nos. on either side of terminals.
r) All major equipment, devices, panels, and cubicles shall be provided with
stainless steel nameplates fastened with self-tapping screws. Nameplates shall be
provided on doors of cooler control cabinet, CT junction box and thermo
junction box. They shall be located so that a person standing on the ground can
read them without visual aids. Each current transformer shall be provided with a
diagrammatic type nameplate located near the CT terminal blocks. Self-adhesive
labels shall not be used.
s) Stud type fuse mounts shall be provided with an insulating cover as protection
against accidental contact with live terminals.
2X382 MW CCPP at Vemagiri
t) Drawing pouch with cooler control scheme drawings covered in the polythene
paper shall be provided inside marshalling box on the door.
v) The marshalling box shall be supplied with space heater, cubicle lighting
(Compact fluorescent lamp) and 240 V receptacle with ON-OFF switches and
associated fuses. It shall be located in such a way that the same shall not face
towards the transformer. Heaters shall be provided with suitable protective cover
to avoid accidental contact with the element (i.e. wire mesh enclosure with
asbestos sheet cover at the front).
w) Bidder shall furnish a list of the relays, control switches, timers, etc. indicating
the make, type, auxiliary supply requirements, contact rating etc. along with the
quotation.
a) Bidder shall furnish his standard Quality Assurance Plan along with the bids.
Inspection and testing shall be as per approved QAP. Transformer oil (both test
purpose as well as fresh oil) shall be as per relevant IS.
b) The bidder shall use his own transformer oil for testing purpose and the fresh oil
shall be supplied to site. In case of transformer are supplied oil filled than fresh
oil shall be filled in presence of Purchaser. The insulating oil shall conform to
the latest revision of IS-335.
c) The necessary topping up oil shall be supplied for the Transformer in non-
returnable container. 10% excess oil shall also be provided, in non-returnable
containers suitable for outdoor storing for one GTG Transformer.
i. Type tests
Following type tests and special tests (excluding short circuit test) as per IS
2026 shall be conducted on one transformer of each rating.
Temperature rise test.
2X382 MW CCPP at Vemagiri
Heat run test with dissolved gas analysis before and after.
The following routine tests as per IS : 2026 shall be conducted on each of the
transformer.
Dielectric tests.
Operation test after the tap changer is fully assembled on the transformer.
Auxiliary circuits insulation test – after the tap changer is assembled on the
transformer, a power frequency test shall be conducted on the auxiliary
circuits.
The following additional routine tests on each of the transformer shall be conducted.
No load loss and excitation current at 415V from LV side and at 90% and
110% rated voltage.
All Tests as mentioned above and any other tests as required by the relevant codes and
standards and as deemed necessary is to be conducted by the bidder.
Bidder shall furnish his proposed QAP along with his bid for Purchaser’s review.
iv) Foundation plan and mounting information with loading and transformer
anchoring details.
vii) Transformer cooling arrangement along with Control scheme for cooler
control unit.
xiii) Curve for Maximum Continuous Output vs. Ambient Temperature (13 oC to
50 oC)
xv) Performance curves for total losses vs. ambient temperature and MVA
loading at 0.85 pf.
In addition, the supplier shall supply comprehensive part list, spares & tools list,
supplemented by all drawings and catalogues of transformer and its fittings &
accessories.
The major components shall be delivered to site as a single piece and minor
components removed for shipping. Where this is not possible, individual modules
shall be delivered as to require only a minimum amount of site assembly. In the last
case the Bidder shall include with his proposal detail of how unit will be broken
down and estimates of the man-hours and equipment required at site. Project
information shall be legibly punched on the components.
Normally transformers will be delivered without oil, filled with inert gas and without
bushings and externally mounted accessories as applicable.
2X382 MW CCPP at Vemagiri
Care shall be taken during handling of insulation oil to prevent ingress of moisture or
foreign matter. In the testing, circulating, filtering or otherwise handling of oil, rubber
hoses shall not be used. Circulation and filtering of oil, heating of oil by regulated short
circuit current during drying runs and sampling and testing of oil shall be in accordance
with the Manufacturer’s instructions and Code of Practice as per IS 10028
(i) Packing
Bidder shall adequately prepare all the equipment for shipment. Where required by
the nature of the equipment, Bidder shall furnish and install necessary covers to
protect the equipment from rain, hail, wind, dust, etc. Equipment shall be adequately
sealed and protected during shipment to prevent corrosion, entrance of foreign
matter, and possible damage from rough handling during transit. Any articles or
materials that might otherwise be lost in shipping shall be boxed or wired in bundles.
Suitable weather protection (like PVC sheets) shall be provided to prevent wetting of
components during transportation and outdoor storage at site.
Each type of preservative used shall be identified as to quality, life expectancy and
type. Toxic and hazardous - type preservatives will not be allowed. Complete
information shall be submitted to the Purchaser (L&T)/Consultant covering step - by
- step procedures, including Indian governing laws for handling and removal of each
type of preservative. This information shall be submitted one (1) month prior to
delivery.
(iii) Marking
All loose components shall be identified with company material code, part no.,
weight and name for easy site identification. Bill of loading / shipping list shall be
provided prior to equipment dispatch. Each truck / separately despatched items shall
have a packing list giving details of the items supplied incloding number of
containers.
A comprehensive list of all items shipped shall also be submitted before despatch to
purchaser. A shipping list should be sent along with each consignment with the
despatch documents.
2X382 MW CCPP at Vemagiri
10.1 Transportation
b) The equipment shall be prepared for transportation after testing has been
completed. Lifting points shall be clearly marked and all openings shall be
tightly and effectively closed. Covers, screwed openings closed with steel
plugs, shall protect flanges and weld ends shall have plastic covers.
c) Before the equipment is shipped, the original shipping stops, bolts, ties, etc.,
shall be reinstalled in all devices.
d) Electrical and control panels shall be protected against corrosion, weather, and
mechanical damage during transit. Temporary structural bracing shall be
installed as required to allow for normal field handling, skidding, and hoisting.
e) In addition to the foregoing, the Supplier shall provide internal and external
protection from the effects of corrosion for all parts not otherwise coated or
painted. Where closure is incomplete, plastic material adequately supported,
protected, and sealed shall be used to fabricate an effective barrier.
f) Equipment that is liquid leak tested in the shop by the Supplier shall be
completely drained prior to shipment. When such drainage requires the removal
of plugs, drain valves, or other parts, supplier shall reinsert or reassemble these
parts prior to shipment. The supplier shall despatch the transformer nitrogen
filled with Automatic gas filling device & pressure monitoring device.
Necessary arrangement shall be ensured by the supplier to take care of pressure
drop of nitrogen during transit and storage till completion of oil filling during
erection. A gas pressure-testing valve with necessary pressure gauge and
adopter valve shall be provided.
g) The Bidder shall furnish all instructions for proper care and handling after
delivery, including outdoor storage procedures, before the equipment is shipped
to the job site.
2X382 MW CCPP at Vemagiri
SECTION-II
TECHNICAL DATASHEET
1. MVA Rating
a) With OFAF cooling 275 170
b) With ONAF cooling 220 136
(iii) HV Neutral Two (2) nos. tinned copper Two (2) nos. tinned
flats shall be provided upto copper flats shall be
the base of main tank provided up to the base
supported on pin of main tank supported
insulators. on pin insulators.
19. Type of Insulation of Cellulose Based /Class A Cellulose Based /Class A
winding
20. Tap changer
(i) Type On Load Tap Changer On Load Tap Changer
(ii) Voltage range +7.5% to -15% in steps of +7.5% to -15% in steps
1.25% of 1.25%
21. Category of voltage CFVV CFVV
variation
22. Guaranteed positive 12.5% 12.5%
sequence Impedance at 75
Deg C with 100% loading
a) principal tap
b) Maximum Tap By Bidder By Bidder
c) Minimum Tap By Bidder By Bidder
23. Zero Sequence Impedance By Bidder By Bidder
at 75 Deg C
24. X/R ratio of Generator By Bidder By Bidder
Transformer
25. Winding Resistance
43. HV bushing CT
52. Winding
SECTION-III