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Malaxmi Thermal Power Project 1040 MW


1.01.01 The Design, Manufacture, erection, testing, and performance of items

and services
Provided under this specification shall comply with the latest edition
including all applicable official amendments and revisions as on the date of
award of the following standards. In case of conflict between this
specification and code ( IS code, standards, etc.) referred herein, the
former shall prevail.


2.1.0 The bus duct will serve as an inter connection between generator, and its
associated generator transformer bank and its unit transformer.

2.2.0 The bus duct will be installed partially indoors and partially outdoors in a
hot, humid and tropical atmosphere. However, cubicles for neutral
grounding, voltage transformers and surge protection equipment will be
installed indoors.

2.3.0 The portion of the bus duct at the generator end will be subject to
vibrations, bus duct enclosure shall not be bolted with generator. A silt of
10-20mm shall be kept between enclosure and generator flange. Suitable
covering shall be provided on the silt to allow escape of hydrogen and
avoid dust entry inside the common chamber.

2.4.0 Supplier/contactor shall furnish the following calculations for main delta and
tap off run bus duct.

(a) Temperature rise rated current considering effect of solar radiation.

(1) Conductor size.

(2) Guaranteed KW losses in conductor & enclosure

(3) Supporting span.

(4) Dynamic and static forces transferred to TG foundation.

2.05.0 Generator Transformers and Unit Transformers shall be handled on the

rail track from Main Plant side/switchyard side. The contactor shall design
the bus duct and supporting structure in such a way so as to permit the
transformers removal, after opening the terminations, but without
dismantling bus duct run or supporting structure.


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Section 5.1
Malaxmi Thermal Power Project 1040 MW


3.01.01 The bus duct shall be isolated phase, continuous (bonded enclosure),
natural; air cooled, positive pressure type.

3.01.02 The layout of the bus duct shall be generally in accordance with tender

3.1.3 The details shown, however, are only typical, Supplier/ contactor may propose
changes to suit the particular design. Number of flexible, bolted and welded
joints shall be provided as per requirement.

3.02.00 Temperature Rise

3.2.1 For continuous operation at rated current under the specified site conditions,
the temperature rise shall not exceed the limits as defined under technical
parameters. The supplier/Contactor has to ensure high standards of design.
The purchaser shall approve the process and workmanship of silver plating.

3.03.00 Enclosure

3.3.1 Each phase shall be of enclosed in a weather proof, dust tight, non-magnetic
metal (Aluminium alloy) enclosure. The enclosure shall be designed for
welded connection.

3.3.2 The enclosure shall be of minimum flux type to permit not more than (5)
percent of total, magnetic flux, outside enclosure.

3.3.3 The enclosure cross-section, connecting n members between enclosure

section, flexible and rigid joints between phase enclosures hall be adequate
to allow the flow of longitudinal current corresponding to the rated
continuous current of the bus without over-heating. Metallic bellows along
with necessary flexible links (to ensure required cross-section) shall be
provided in bus duct run. Rubber bellows shall be provided on equipment

3.3.4 Phase enclosures shorting links rated for continuous current shall be provided
at bus duct termination on generator, GT, UT, tap-off and excitation
transformer (if applicable).

3.3.5 The enclosures shall be insulated at the connections to various equipment as

listed above so that the longitudinal current will Flow through or be
transmitted to any connecting equipment, The insulation shall be non-
deteriorating and shall be clearly indicated on the contactor’s drawings. The
insulation test voltage shall be 10kV AC.

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Section 5.1
Malaxmi Thermal Power Project 1040 MW

3.3.6 The contactor should ensure that no load is transferred on electrical

equipments transformers, generator terminals, etc. by the bus ducts.

3.3.7 Inspection, opening/split covers shall be provided to allow easy access for
installation, inspection, replacement, or repairs of the insulators,
disconnects, bus connections, terminations and current transformers.
Inspection covers/ split covers should be connected electrically to the main
duct by flexible braids for proper earthing. The inspection/split covers shall
have reliable sealing arrangements with neoprene, rubber/synthetic rubber
bonded cork gaskets in grooves to ensure air tightness.

3.3.8 Wall frame and support plates shall be provided where the bus duct
penetrates the building wall. It should be ensured that no loads are
imposed on building wall/ structure.

3.3.9 Filtered drain tapping with dual stop cocks shall be provided for drainage of
condensate at the lowest point and at such other locations where
accumulation of condensate can be expected. In particular a drain valve
shall be provided at the lowest point of transformer end termination. The
contactor shall be required to add drainage points if required during
installation. Contactor has to take care of proper draining arrangement
even though bus duct is pressurized.


3.4.1 The bus conductor shall be of high conductivity, painted aluminium alloy as
per IS: 5082 supported on insulators.

3.4.2 The bus conductor shall be designed for welded connections except at
equipment terminations, bolted disconnect links, and bolted flexible. The
purchaser should furnish detailed welding procedure adopted by the
manufacturer along with the affer and approver.

3.4.3 Flexible connections shall be provided between bus connections to allow

for expansion and contraction of the conductor. Flexible connections
hardware shall be non-magnetic and shall have high corrosion resistance.


3.5.1 Bus support insulators shall be interchangeable. High creep and high
strength, fine glazed porcelain manufactured by wet process, or high
strength cast resin insulators.

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Section 5.1
Malaxmi Thermal Power Project 1040 MW

3.5.2 Insulator shall be mounted in such a way so as to permit at easy removal

or replacement without disassembly of the bus.

3.5.3 The conductor shall be fastened on the insulator through fixed and sliding
joints so as to allow conductor expansion or contraction without straining
the insulator. Positive contact shall be made between end caps of the
supporting insulators. And the conductors.

3.5.4 Additional support insulators shall be provided at bend, at tap-offs for

withstanding all possible forces.


3.6.1 All matching flanges, seal off bushings, gaskets, fittings, hardware and
supports required for termination of the bus duct at Generator,
Transformers and other equipment shall be furnished under the scope of
this specification. Bus duct lengths for payment purposes shall be
measured from the matching flanges.

3.6.2 Flexible connections both for conductor and enclosure shall be furnished:

(a) At all equipment termination to take care for misalignment up to 25mm

(1”) in all directions.

(1.)Between bus duct supported from building steel and that

supported by turbine foundation to prevent transmission

3.6.3 The equipment terminal connections shall be readily accessible and shall
provide sufficient air gap for safe isolation of requirement during electrical

3.6.4 If the material of bus conductor and that of the bus conductor and that of
the equipment terminal is different, then suitable for the contactor shall
provide bi-metallic connectors shall be provide by the contactor.

3.6.5 Seal off bushings shall be provided at the generator end of the bus duct,
tap off to PT cubicles and N.G. cubicle and Static Excitation Transformer
cubicle (in case it is provided).


3.7.1 The electricity continuous bus enclosure shall be used as the grounding
bus. all parts of the bus enclosure, supporting structure and equipment
frames shall bee grounded to purchaser’s earthing mat by the contactor.

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Section 5.1
Malaxmi Thermal Power Project 1040 MW

3.7.2 Duplicate bolted type Ground pads shall be provided to accommodate

50X6mm galvanized steel flats wherever IPB terminates.

3.7.3 As an alternative to the above arrangement other standard and proven

furnish sufficient details and justifications.


3.08.01 All supporting structure required for hanging and/or supporting the
complete bus duct shall be furnished. These include all members,
indoor/outdoor posts, bolts, shims, base plates, hangers, brackets, bracings
and hardware.

3.8.2 All bus ducts shall be adequately supported and braced to successfully
withstand normal operation, vibrations, thermal expansion, short circuit
forces and al specified design loads. The support structure shall also be
designed to take care of Purchaser’s cable tray load of 200 Kg/meter (if
required). Supporting calculations shall be furnished to establish

3.8.3 Supports shall be designed to provide tolerance of 12mm (1/2”) in the

horizontal and vertical directions.

3.8.4 All steel members shall be hot dipped galvanized after fabrication. All
hardware shall be of high strength steel with weather resistant finish.

3.8.5 Concentrate foundation, building, building steel inserts/plates in concentrate

will be provided by the purchaser as required by the contactor.

3.8.6 Arrangement of support steel work shall be such as to prevent heating of

structures caused by circulating currents.

3.8.7 Hinges of all inspection covers shall be strapped across with earth connections.


3.9.1 Air pressurization of entire bus duct installation shall be provided to keep
pressure inside the bus duct 10 to 15mm water column above atmospheric
pressure by clean dry air. The supplier/contactor shall guarantee and
demonstrate at site the air leakage rate of not more than 5% of total
enclosure volume per hour after installation.

3.9.2 The supplier/ contactor shall offer a compete arrangement for

pressurization of bus duct with purchaser’s compressed instrument air

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Section 5.1
Malaxmi Thermal Power Project 1040 MW

supply which shall be at 5.0 to 7.0 Kg/sq. cm. Supplier/ contactor shall
include equipment for pressure reduction, drying, bus duct internal
pressure indication, dust filters control, safety valves and alarms for failure
of pressurization and excessive leakage. Air-drying plants shall have
2X100% redundancy.

3.9.3 To prevent ingress of foreign matter into the bus duct enclosure during
plant shut down or maintenance, aluminium end caps shall be provided for
the following locations:

(a) Generator transformer end, and

(b) Unit transformer end

3.9.4 One feeder of required capacity shall be made available at each control
panel which shall house starters and control systems for blowers, heaters,
solenoid valves etc.

3.9.5 The complete details of air drying plant shall be furnished.

3.9.6 The supplier/contactor shall furnish the following details clearly:

(a) Parameters of clean air

(b) Requirement of air in m3/hr.at NTP

(c) Scheme/method to calculate the leakage rate.


3.10.01 The current transformer shall be epoxy cast-resin, single-core ring type,
mounted within the bus duct enclosure and suitable for operation at an
ambient temperature existing within the bus duct enclosure which may be
in the range of 90 deg. C to 100 deg. C. Mounting arrangement of CT shall
be so designed so as to avoid equalizing connections between live
conductor and CT inner surface.

3.10.2 CT secondary leads shall be brought out through non-magnetic metallic

conduits to a marshalling box (MB) with the degree of protection IP-55 (IS:
13947 Pt.1). The MB shall be provided with removable aluminium gland
plant. The facility for shorting and grounding shall be provided at the
terminal blocks. In addition to above the marshalling box having
termination of line side CT’s, the transducers as listed at annexure-B to this
chapter shall be provided. Accordingly, the interconnection from VT panels
to this marshalling Box housing transducers shall be located near PT & SP

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Section 5.1
Malaxmi Thermal Power Project 1040 MW

3.10.3 Transducers for all electrical parameters like current, voltage, VAR, watt,
frequency, power factor phase angle difference, etc. shall be provided by
the supplier/contactor. The transducers shall provide 4-20A dual output.
The terminal blocks in transducer panels shall be provided suitable for
signals form CT/PT. Proper segregation shall be done to ensure isolation
between incoming high-level signals and low level output signal of

The supplier/contactor shall be hookup Purchaser’s 220 V DC supply to this

transducer panel with automatic changeover scheme. Suitable
annunciation to DDC MIS (for power supply failure) shall be provided.
Further, each transducer shall be fed through independently fused power
supply feeder.

All transducers shall be of tested quality as per IEC 668 (For impulse test
etc.) and SWC test as per ANSI C-37.90.1-1989 or equivalent.

Each transducer shall be provided to decouple 4-20 mA outputs, one for

driving electrical meters and the other for wiring to DDCMIS. The accuracy
of transducer shall be +/- 0.2 scale or better.


3.11.1 The V.T.and S.P. cubicles for each phases shall be metal clad, dust, and
vermin proof, free standing, dead front assemblies housing VTs, surge
capacitor, lighting arrestor, VT, L.V. side fuses etc.

3.11.2 Each VT and SP cubicle shall have seal off busing at the terminations of tap-
off bus duct to cubicle.

3.11.3 Lightning arrestor shall be gapless type station class, hermetically sealed,
connected between line and ground, specifically suitable for generator
protection as per technical parameters given elsewhere in the specifications.

3.11.4 A discharge counter shall provide for lightning arrestor. The discharge
counter register shall be visible without having to open the compartment

3.11.5 Mineral oil filled /Askarel (PCBS) filled surge capacitor shall not be

3.11.6 The voltage transformer shall be epoxy cast-resin type, suitable for nominal
voltage operation, connected from line to ground, and as per technical
parameters given elsewhere in the specification.

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Section 5.1
Malaxmi Thermal Power Project 1040 MW

3.11.7 The voltage transformer along with secondary fuses shall be mounted on
draw out type carriage. Suitable guide slots and stops shall be provided to
ensure easy withdrawal and positioning.

3.11.8 The fixed and draw out contacts of voltage transformer primary shall be
tinned or silver-plated.

3.11.9 In the disconnected position, the voltage transformer primary and secondary
circuits shall be automatically disconnected. The draw out frame shall be
grounded at all times. A reliable automatically operated shutter mechanism
shall be provided for isolating and shrouding the bus bar live parts when the
VT is in drawn out position.

3.11.10 The secondary leads from the voltage transformers shall be extended to two
separate fuses for dual accuracy PT and terminal cabinet flush mounted in
the compartment.

3.11.11 VT and CT secondary neutral or common lead shall be earthed at one place
only at the terminal blocks, provided in the instrument transformer
marshalling boxes. The facility for connecting purchasers earthing grid, shall
be provided by the contactor through suitable connectors in the marshalling
box, with isolating links for testing of instrument transformers.


3.12.1 The transformer and resistor shall be located in separate

cubicles/compartment adjacent to each other. The cubicles shall have
hinged access doors capable of being pad locked.

3.12.2 The transformer cubicle shall be made of angle frame steel construction with
formed sheet sides. The resistor cubicle shall be made of angle frame steel
construction with hot dip galvanized screen sides. Alternatively, it can be
painted with heat resistant paint assembled, wired, connected to the neutral
and ground.

3.12.3 The neutral grounding transformer shall be cast epoxy resin type natural air
cooled single phase connected between generator neutral and ground

3.12.4 The loading resistor shall be formed of non-aging, corrosion, resistant

punched stainless steel grid element provided with necessary insulation and
designed for indoor service for a temperature rise not exceeding 300 deg. C

3.12.5 All alarm protection and indication leads shall be wired up to the terminal
blocks that shall be mounted in a IP:52 enclosure suitable for flush mounting
and having a fully hinged cover with lock.

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Section 5.1
Malaxmi Thermal Power Project 1040 MW


3.13.1 All cubicles shall be fabricated from cold rolled sheet steel for minimum 2mm
thick suitably reinforced top ensure structural rigidly. The degree of protection for all
indoor cubicle shall be IP: 52 except for neutral grounding enclosure which shall be
minimum IP: 52


3.14.1 Each cubicle shall be equipped with space heater with thermostat, internal
illumination lamp, 240 V AC, 5A receptacle. Ground bus suitable for receiving two (2)
numbers of 50x6mm galvanized steel flats shall be provided on each cubicle.

3.15.0 WIRING

3.15.01 All wiring shall be done with insulated stranded copper conductors of
not n less than 2.5 Sq. mm cross-section with suitable lugs on both

3.15.02 The wiring inside the bus duct enclosure (i.e. for CT etc.) shall be
suitable for operating in the ambient temperature existing inside the
bus duct.

3.15.3 Not more than two wires shall be connected to a terminal. Spare
terminals equal in number to 20% of active terminals shall be
furnished and these shall be uniformly distributed through out the
cubicle CT terminal blocks shall be of stud type and suitable for round
type lugs with a facility for isolation, shorting and grounding. It shall
be Elmex type CATD or equivalent.


3.16.1 Name plates shall be furnished for each equipment, disconnect link, voltage
transformer compartment, lightning arrestor compartment and fuse block,
current transformer TB, Air pressurization cubicles etc.

3.16.2 Material for Name Plate shall be plastic/lamicoid 3mm thick using white
letters on black background.

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Section 5.1
Malaxmi Thermal Power Project 1040 MW

3.17.0 FINISH

3.17.1 Except for supporting steel structures, which shall be galvanized, all
equipment including bus duct enclosure shall be finished with an under
coats of high quality primer followed by two coats of synthetic enamel paint
which shall have a thickness not less than 50 microns.

The interior surface of bus duct enclosure shall be as per manufacturers

standard. The shade of exterior surface shall be shade no.692 for indoor bus
duct and equipment. the shade of interior surfaces of cubicles shall be
glossy white.

3.17.2 Pre-treatment consisting of degreasing, derusting etc.shall be done on all

fabricated parts before painting of cubicles, cabinets, marshalling boxes and
galvanization of steel structures.


4.1.1 The contactor shall carry out type tests as listed in the “LIST OF TESTS TO BE
CONDUCTED” on the equipment mentioned therein. The supplier /contactor
shall indicate the charges for each of these type tests separately in the
relevant schedule of BPS.

4.1.2 The type tests shall be carried out in the presence of the purchaser’s
representative for which minimum 150days notice shall be given to the
contactor. The contactor shall obtain the purchaser’s approval for the type
test procedure before conducting the type test. The type test procedure shall
clearly specify the test set up, instruments to be used, procedure,
acceptance norms, recording of different parameters, interval of recording,
precautions to be taken etc.

4.1.3 Irrespective of the requirement of conducting the type tests under this
contract, the Contactor shall submit the reports of the type tests listed in the
“LIST OF TESTS TO BE CONDUCTED” and carried out within five years. These
reports should be for the tests conducted on the equipment similar to those
proposed to be supplied under this contract and the test(s) should have been
witnessed by a client. The purchaser reserves the right to waive conducting
of any or all of the specified type tests under this contract, in which case the
type test charges shall not be payable for this type tests waived by the

4.1.4 Further the contactor shall only submit the reports of the type tests as listed in
carried out within last five years. These reports should be for the tests
conducted on the equipment similar to those proposed to be supplied under
the contract and the test(s) should have been either conducted at an

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Section 5.1
Malaxmi Thermal Power Project 1040 MW

independent laboratory or should have been witnessed by a client. In case

the contactor is not able to submit report of the type test(s) conducted
within last five years, or in case the type test report(s are not found to be
meeting the specification requirements, the Contactor shall conduct all such
tests under free of cost to the purchaser and submit the reports for approval.

4.1.5 All acceptance and routine tests as per the specification and relevant
standards shall be carried out. Charges for these shall be deemed to be
included in the equipment price.


The following type tests shall be conducted on each rating of bus ducts.

(a) Heat run test (the set up shall include 3 phase straight run, 90 deg. Bend,
set of flexible connection of each type, metallic bellow or enclosure, CT’s
mounted in position, (as applicable), bolted link, and necessary inspection
covers. Milivolt drop across bolted flexible joint shall be measured.

(b) Short circuit withstand test (set up same as for heat run).

(c) Impulse withstand test (set up shall include typical X-section with flexible
connections. CT’s in position, seal off bushing, inspection cover and

(d) One minute high voltage power frequency withstand test (set up as for
short circuit test).

(e) Test for radio interference (as per NEMA 107-Method of measurement of
radio influence voltage of High Voltage Apparatus). The set up shall
include inspection one flexible connection and “L” of substantial length.
The maximum RIV shall not exceed 100microvolts at 1000kHz.

(f) Air leakage rate and water tightness test(set up shall include inspection
cover, flanged joint and bellow )


Type tests reports shall be submitted for following type tests on auxiliary

(a) Panels, cubicles and marshalling boxes shall be type tested for the degree
of protection provided by enclosure as specified below:

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Section 5.1
Malaxmi Thermal Power Project 1040 MW

(1.) For 5X-it shall not be possible to insert a thin sheet of paper under
gaskets and through enclosure joints.

(2.) For 4X-It shall not be possible to insert a one mm diameter steel
wire into enclosure from any direction without force.

(3.) For 3X-It shall not be possible top insert a twelve (12) mm dia.
Steel wire into the enclosure from any direction without any force.

(4.) Test for second digit shall be in line with IS: 13947 pt.1

(b) For the equipment and materials such a current transformers, voltage
transformers, lightning arrestors, grounding transformers, loading
resistors, bushings and surge capacitors for which type tests are not
specified in this section, successful type tests certificate shall be
submitted to the purchaser.


5.01.01 Pre-commissioning/ Commissioning

(a) 10% radiography and 100% DP test on all site welded joints of bus bar
and enclosure.

(b) Milli volt Drop test

(c) Ratio and polarity tests on current and voltage transformers

(d) Insulation measurement of equipment and all wiring.

(e) Functional test on pressurization (Tightness test as per ANSI 37.20)

(f) One minute high potential power frequency withstand test at full test

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Section 5.1
Malaxmi Thermal Power Project 1040 MW

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Section 5.1
Malaxmi Thermal Power Project 1040 MW



S.No Measuring Parameter Dual Output Remarks

. (Range) Transducer
1.) Generator Voltage 0 -110 V ac/4 Three (3 Nos.
(0 -30 kV) -20mA RY,YB & BR
2.) Generator Active 0-110 V ac/4-20mA
Power (0 -350 MW) 0-5 A ac
3.) Generator reactive 0-110 V ac/4-20mA
Power (120 lead – 0 0-5 A ac
- 210 lag)
4.) Generator Frequency 0-110 V ac/ 4-
(45-55Hz) 20mA
5.) Generator Power 0-110 V ac/4-20mA
factor (0.5 lead - 1 - 0-5 A ac
0.5 lag)
6.) Generator Ammeter 0-5A ac/4-20mA
R-Phase (0 -10KA)
7.) Generator Ammeter 0-5A ac/4-20mA
Y-Phase (0 -10KA)
8.) Generator Ammeter 0-5A ac/4-20mA
B-Phase (0 -10KA)

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Section 5.1