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TENDER SPECIFICATION

BHEL: PSSR: SCT: 1466 FOR Pre-bid tie up on back to back basis for Civil, Structural & Balance of Plant for 1x 700 MW Combined Cycle Power Plant of Andhra Pradesh Power Development Company Limited at Nedunoor, Karimnagar Dist, AP TECHNOCOMMERCIAL BIDVOLUME-G –TECHNICAL REQUIREMENTS FOR GENERAL ELECTRICAL

BHARAT HEAVY ELECTRICALS LIMITED
(A Government of India Undertaking) Power Sector – Southern Region 690, Anna Salai, Nandanam, Chennai – 600 035.

BHARAT HEAVY ELECTRICALS LIMITED (A Government of India Undertaking) Power Sector, Southern Region 690, Anna Salai, Nandanam, Chennai – 35

Tender Specification No. BHEL: PSSR: SCT: 1466 For

Pre-bid tie up on back to back basis for Civil, Structural & Balance of Plant for 1x700 MW Combined Cycle Power Plant of Andhra Pradesh Power Development Company Limited (APPDCL) at Nedunoor, Karimnagar Dist, AP One set of Tender documents consisting of Volume - A to Volume- L (details as below)
BOOK SLNO_________________ Issued to M/s

Refer NIT for Last date of submission Please note this tender document is not transferable For and on behalf of BHARAT HEAVY ELECTRICALS LIMITED

ADDL GENERAL MANAGER / CONTRACTS Place: Chennai -35

Tender Specification BHEL PSSR SCT 1466 comprise of Volume-A to Volume -L as below: Sl no of Volumes BHEL Vol -A NIT Project information, schedules, QA, Other requirements Scope TP, Exclusions Proposed scope split of Electrical between BHEL & EPC contractor Scope split BHEL & EPC contractor dt 29-06-2011 Scope of lifting equipments SCC- BHEL Consolidated GCC- BHEL-PEM APPDCL Volume -1,SECTION A1 TO A4 Geo tech investigations Tech requirements for General Civil works Additional civil drgs Scope of Cooling tower Tech requirements for General Electrical works Technical spec for Mechanical packages- Bought out packages NOT APPLICABLE Amendments & clarifications Schedules Price schedule Description No. of pages (including Remarks drawings)

BHEL Vol -B

BHEL Vol -C BHEL Vol -D BHEL Vol -E BHEL Vol -F BHEL Vol -G BHEL Vol -H BHEL Vol -I BHEL Vol -J BHEL Vol -K BHEL Vol -L

TECHNICAL REQUIREMENTS FOR GENERAL ELECTRICAL
VOLUME -G

Bharat Heavy Electricals Limited

1X700 MW CCPP AT NEDUNOOR, KARIMNAGAR ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.

TECHNICAL REQUIREMENTS FOR GENERAL ELECTRICAL WORKS

DOCUMENT NO. PE-TS-I59-888-E001 REV 0

BHARAT HEAVY ELECTRICALS LIMITED
POWER SECTOR, PROJECT ENGINEERING MANAGEMENT NOIDA 201301

Doc. No. PE-TS-I59-888-E001 700MW KARIMNAGAR CCPP TECHNICAL SPECIFICATION FOR GENERAL ELECTRICAL WORKS Rev. : Page : 0 of

CONTENTS
SL. NO. 1. 2. 3. 4. 5. 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11 5.12 6. 7. 8. 9. 10. 11. DESCRIPTION INTENT OF SPECIFICATION SCOPE OF WORKS DOCUMENTS TO BE SUBMITTED BY BIDDER WITH EPC BID DOCUMENTS TO BE SUBMITTED BY EPC PARTNER AFTER THE AWARD OF CONTRACT ELECTRICAL TECHNICAL SPECIFICATION: GENERAL REQUIREMENT LT BUS DUCTS 400V SWITCHGEAR & MCC NEUTRAL EARTHING EQUIPMENT DC SYSTEM CABLING SYSTEM LIGHTING SYSTEM EARTHING & LIGHTNING PROTECTION SYSTEM PUBLIC ADDRESS SYSTEM ELECTRICAL LAB EQUIPMENT INSULATING MATS CATHODIC PROTECTION CUSTOMER DRGS.-ANNEXURE-II BHEL ELECTRICAL SINGLE LINE DIAGRAM- PE-DG-I59-565-E001 QUALITY ASSURANCE, INSPECTION & TESTING BHEL CLARIFICATIONS (ENCLOSED AS ANNEXURE-B) SCHEDULE OF TECHNICAL DEVIATION SPARES 15 16 16 3 13 18 16 7 15 7 1 2 5 1 77 2 1 3 PAGES 1 1 1 2

IT IS CONFIRMED THAT OUR TECHNICAL OFFER COMPLIES WITH THE SPECIFICATION IN TOTO.

--------------------------------------------------------------------BIDDER’S STAMP & SIGNATURE

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Doc. No. PE-TS-I59-888-E001 700MW KARIMNAGAR CCPP TECHNICAL SPECIFICATION FOR GENERAL ELECTRICAL WORKS Rev. : Page : 0 of

1. INTENT OF SPECIFICATION

1.1 The owner Andhra Pradesh Power Development Company Ltd has invited bids for the EPC package of 1X700 MW CCPP at Nedunoor Karimnagar Dist. BHARAT HEAVY ELECTRICALS LIMITED (BHEL) intends to bid for this project and invites quotations for design and execution of the work for electrical systems of the project mentioned in relevant clauses. 1.2 At the outset the bidder must understand that this offer is to be submitted on back to back basis which means that the bidder assumes total and unconditional responsibility for all electrical works as per owner’s requirements and subject to owner/ owner’s consultant’ approval. 1.3 Timely submission of drawings & documents / obtaining approval of drawings / documents from owner / owner’s consultant shall be the responsibility of the bidder. 1.4 It is specifically emphasized that the bidder quoting for Electrical Works package shall be comprehensively responsible for complete scope of work stated or unstated including preparation of design and drawings, obtaining necessary approvals, materials, execution as per codes, best engineering practices and to the satisfaction of the owner.

IT IS CONFIRMED THAT OUR TECHNICAL OFFER COMPLIES WITH THE SPECIFICATION IN TOTO.

--------------------------------------------------------------------BIDDER’S STAMP & SIGNATURE

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Doc. No. PE-TS-I59-888-E001 700MW KARIMNAGAR CCPP TECHNICAL SPECIFICATION FOR GENERAL ELECTRICAL WORKS Rev. : Page : 0 of

2. SCOPE OF WORKS 2.1 It shall be Contractor’s responsibility to provide all the equipment / systems / services and interfacing between various systems for the completeness of the 700 MW Combined Cycle Power Plant (CCPP). The following configuration shall be considered. 2 GTs + 2 HRSGs + 1 STG in Multishaft configuration. The requirements described here are for 700 MW CCPP. All equipment in the plant shall operate without any limitation upto the full load of Gas Turbine offered. This shall be applicable to all regimes of GT operation including the temperature range, frequency range, voltage range, with evaporative cooler etc. However for the purpose of the PG test, the evaporative cooler shall be switched off. The Plant electrical systems for proposed combined cycle power plant shall essentially comprise but not be limited to the following: 1. HT power cables, LT Power cables, LT Control cables & instrumentation cables 2. Cabling & installation equipment(cable trays & accessories, cable tray support, trefoil clamps, termination kits, jointing kits cable glands & lugs etc). 3. Earthing & lightning protection(including above & below grade grounding material) 4. Station lighting system. 5. Neutral grounding resistors for Unit auxiliary transformers. 6. 220V DC battery, battery chargers, DC switchboards and their accessories. 7. 400V AC switchgear, LV power distribution boards and accessories. 8. Public address system equipment. 9. Electrical laboratory equipment 10. Insulating mats 11. Cathodic protection 12. Drawing & Document submission for all packages : System design, Design Calculations, Design Memorandums, Layout drgs., Electrical load list, cable schedules, cable interconnections, Data sheets, OGA, Quality plans, test certificate etc. Detailed scope of work shall be as per scope chart enclosed as Annexure-A.

2.2

2.3

Any deviation to technical specification is to be clearly mentioned in “schedule of technical deviation” & undeclared technical deviation is not acceptable at any stage of project.

IT IS CONFIRMED THAT OUR TECHNICAL OFFER COMPLIES WITH THE SPECIFICATION IN TOTO.

--------------------------------------------------------------------BIDDER’S STAMP & SIGNATURE

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Doc. : Page : 0 of 3. DOCUMENTS TO BE SUBMITTED BY BIDDER WITH EPC BID: BIDDER TO SUBMIT SIGNED & STAMPED COPY OF FOLLOWING SHEETS: i) CONTENTS ii) INTENT OF SPECIFICATION iii) SCOPE OF WORKS( ALONG WITH SCOPE CHART IN ANNEXURE-A & TABLE-1) 4 . PE-TS-I59-888-E001 700MW KARIMNAGAR CCPP TECHNICAL SPECIFICATION FOR GENERAL ELECTRICAL WORKS Rev. No.

7M & 10.H.5M EL) LAYOUT OF DC BATTERY ROOM CABLING LAYOUT BELOW MAIN SWITCHGEAR ROOM CABLING LAYOUT BELOW DC BATTERY ROOM CABLING TRAY LAYOUT AT 9. CABLE VAULTBC BAY CABLE TRAY LAYOUT IN TG HALL IN BELOW 8.0M FLOOR IN BFP BUILDING (SHEET 2 OF 3) CABLE TRAY LAYOUT AT EL 14.500M FLOOR IN BFP BUILDING (SHEET 3 OF 3) CABLE TRENCH LAYOUT IN GAS TURBINE BUILDING ELECTRICAL EQUIPMENT LAYOUT OF BFP BUILDING CABLE TRENCH LAYOUT IN STEAM TURBINE BUILDING INTERPLANT CABLING LAYOUT (2 SHEETS) CABLE TRAY LAYOUT IN AIR WASHER ROOM – STG BUILDING CABLE TRAY LAYOUT IN AIR WASHER ROOM .H.4.STG BUILDING OUTSIDE A ROW CABLE TRAY LAYOUT ON STORM WATER PUMP HOUSE CABLE TRAY LAYOUT ON PORTABLE WATER PUMP HOUSE CABLE TRAY LAYOUT IN AC PLANT ROOM (FACILITY BUILDING) CABLE TRAY LAYOUT IN A.No.U ROOM (FACILITY BUILDING) CABLE TRAY LAYOUT IN A. DEPT_CODE SI_NO SYSTEM BHEL_DRG_NO DRAWING TITLE DESIGN PHILOSOPHY FOR ELECTRICAL EQUIPMENT LAYOUT LAYOUT OF TRANSFORMER YARD LAYOUT OF ELECTRICAL EQUIPMENT IN CW PUMP HOUSE LAYOUT OF ELECTRICAL EQUIPMENT IN RW PUMP HOUSE LAYOUT OF MAIN SWITCHGEAR ROOM EQUIPMENT LAYOUT IN STATIC EXCITATION ROOM(GTG) EQUIPMENT LAYOUT IN STATIC EXCITATION ROOM (STG) (AB BAY 13.5M EL.U ROOM (STG BUILDING) ELECTRICAL EQUIPMENT AND CABLE TRAY LAYOUT IN ETP MCC ROOM ELECTRICAL EQUIPMENT AND CABLE TRAY LAYOUT IN WATER TREATMENT MCC ROOM CABLE TRAY LAYOUT IN CW PUMP HOUSE 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT ELE LAYOUT PE-DC-I59-100-E999 PE-DG-I59-100-E001 PE-DG-I59-100-E003 PE-DG-I59-100-E004 PE-DG-I59-100-E006 PE-DG-I59-100-E007 PE-DG-I59-100-E008 PE-DG-I59-100-E009 PE-DG-I59-100-E013 PE-DG-I59-100-E016 PE-DG-I59-100-E020 PE-DG-I59-100-E021 PE-DG-I59-100-E022 PE-DG-I59-100-E038 PE-DG-I59-100-E050 PE-DG-I59-100-E051 PE-DG-I59-100-E060 SH 1 OF 3 PE-DG-I59-100-E060 SH 2 OF 3 PE-DG-I59-100-E060 SH 3 OF 3 PE-DG-I59-100-E063 PE-DG-I59-100-E065 PE-DG-I59-100-E067 PE-DG-I59-100-E071 PE-DG-I59-100-E072 PE-DG-I59-100-E073 PE-DG-I59-100-E074 PE-DG-I59-100-E075 PE-DG-I59-100-E076 PE-DG-I59-100-E077 PE-DG-I59-100-E078 PE-DG-I59-100-E079 PE-DG-I59-100-E080 PE-DG-I59-100-E081 5 .5M EL CABLE TRAY LAYOUT ON HRSG PLATFORMS IPB LAYOUT-GT IPB LAYOUT-STEAM TURBINE GENERATOR 0.5M EL CABLE TRAY LAYOUT IN TG HALL IN ABOVE 8. MASTER LIST OF DRAWINGS/ DOCUMENTS TO BE SUBMITTED BY EPC PARTNER AFTER AWARD OF CONTRACT (INDICATIVE) S.0M CABLE TRAY LAYOUT AT EL 0 0M FLOOR IN BFP BUILDING (SHEET 1 OF 3) CABLE TRAY LAYOUT AT EL 6.

(I. DEPT_CODE SI_NO SYSTEM BHEL_DRG_NO DRAWING TITLE 34 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE ELE 100 506 506 507 507 507 507 507 507 507 507 507 507 507 508 509 509 509 509 509 509 509 557 558 561 565 565 565 ELE LAYOUT LV SWGR LV SWGR CABLES & CABLING CABLES & CABLING CABLES & CABLING CABLES & CABLING CABLES & CABLING CABLES & CABLING CABLES & CABLING CABLES & CABLING CABLES & CABLING CABLES & CABLING CABLES & CABLING DC SYSTEM LIGHTNING PROTECTION LIGHTNING PROTECTION LIGHTNING PROTECTION LIGHTNING PROTECTION LIGHTNING PROTECTION LIGHTNING PROTECTION LIGHTNING PROTECTION PUBLIC ADDRESS SYSTEM LIGHTING & LOW VOLTAGE SERVICES EMERGENCY DG ELECTRICAL SYSTEM DESIGN ELECTRICAL SYSTEM DESIGN ELECTRICAL SYSTEM DESIGN PE-DG-I59-100-E082 PE-DC-I59-506-E004 PE-DG-I59-506-E003 PE-DC-I59-507-E001 PE-DC-I59-507-E002 PE-DC-I59-507-E004 PE-DC-I59-507-E005 PE-DG-I59-507-E005 PE-DG-I59-507-E006 PE-DG-I59-507-E007 PE-DG-I59-507-EXXX PE-DG-I59-507-EXXX PE-DG-I59-507-EXXX PE-DG-I59-507-EXXX PE-DC-I59-508-E001 PE-DC-I59-509-E001 PE-DC-I59-509-E002 PE-DG-I59-509-E003 PE-DG-I59-509-E004 PE-DG-I59-509-E005 PE-DG-I59-509-E007 PE-DG-I59-509-E008 PE-DC-I59-557-E001 PE-DC-I59-558-E001 PE-DC-I59-561-E001 PE-DC-I59-565-E004 PE-DC-I59-565-E002 PE-DG-I59-565-E001 CABLE TRAY LAYOUT IN RAW WATER PUMP HOUSE ELECTRICAL LOAD DATA (BOARD WISE) CONTROL LOGIC FOR 415V SWGR DESIGN CALCULATIONS FOR HT CABLES SELECTION & SIZING DESIGN CALCULATIONS FOR LV CABLES SELECTION & SIZING CABLING PHILOSOPHY CABLE NUMBERING SCHEME TYPICAL DETAILS OF CABLE TRAYS AND ACCESSORIES TYPICAL INSTALLATION DETAILS FOR CABLE TRAY SUPPORT SYSTEM TYPICAL DETAILS FOR CABLE TRAY SUPPORT SYSTEM LAYOUT FOR ALL AREAS CABLE TRAY LAYOUT FOR ALL AREAS CABLE SCHEDULES FOR ALL AREAS CABLE INTERCONNECTION FOR ALL CABLE SCHEDULES DESIGN MEMORANDUM FOR 220V DC SYSTEM DESIGN MEMORANDUM FOR EARTHING SYSTEM DESIGN MEMORANDUM FOR LIGHTNING PROTECTION SYSTEM TYPICAL BELOW GROUND EARTHING DETAILS TYPICAL ABOVE GROUND EARTHING DETAILS BELOW GRADE GROUNDING SYSTEM LAYOUT FOR MAIN POWER PLANT AREA BELOW GRADE EARTHING LAYOUT FOR OFFSITE PLANTS LIGHTNING PROTECTION FOR OFFSITE PLANTS DESIGN MEMORANDUM FOR PUBLIC ADDRESS SYSTEM DESIGN MEMORANDUM FOR LIGHTING & LV POWER SERVICES DESIGN CALCULATION FOR EMERGENCY SUPPLY DG SIZING RELAY SETTINGS CHART FOR LV/HV MOTORS DESIGN CALCULATION FOR GENERATOR AND MV SYSTEM ELECTRICAL SINGLE LINE DIAGRAM FOR AUXILIARY POWER DISTRIBUTION DRG.) FOR ALL ELECTRICAL PACKAGES 65 ELE 565 ELECTRICAL SYSTEM PE-DG-I59-XXX-EXXX 6 ./DOC.4.No. MASTER LIST OF DRAWINGS/ DOCUMENTS TO BE SUBMITTED BY EPC PARTNER AFTER AWARD OF CONTRACT (INDICATIVE) S.E. DATA SHEET/ OGA/ SCHEME/ TEST CERTIFICATES/ QUALITY PLANS ETC.

KARIMNAGAR DIST. OF SHEETS 15 39 06 09 03 16 08 D3. EPC SPECIFICATION -ELECTRICAL SYSTEMS VOLUME-III – CONTENTS ELECTRICAL SYSTEM SECTION NO. TITLE NO.8 D3.NO.SPEC. REV.3 D3.14 D3.19 TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 R0 49 09 15 05 16 03 13 07 18 16 07 15 05 ISSUE R0 TCE FORM NO. GENERATOR. TITLE VOLUME III SECTION: CONTENT SHEET SHEET 1 OF 2 700 MW CCPP AT NEDUNOOR.0 D3.1 D3.11 D3.5 D3.9 D3.12 D3.16 D3.17 D3. TRANSFORMER AND UAT PROTECTIONS 400 kV SWITCHYARD GENERATOR CONTROL PANEL 6.6 TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01 R0 R0 R0 R0 R0 R0 R0 GENERAL REQUIREMENT GENERATOR AND ACCESSORIES GENERATOR CIRCUIT BREAKER GENERATOR TRANSFORMERS UNIT AUXILIARY TRANSFORMERS BUS DUCTS GENERATOR.13 D3.18 D3.7 D3.5960A-H-500001 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. 329 R5 7 .NO. TCE.15 D3.10 D3.6 kV SWITCHGEAR SERVICE TRANSFORMERS 400V SWITCHGEAR & MCC NEUTRAL EARTHING EQUIPMENT DC SYSTEM UNINTERRUPTIBLE POWER SUPPLY SYSTEM CABLING SYSTEM LIGHTING SYSTEM EARTHING & LIGHTNING PROTECTION SYSTEM COMMUNICATION SYSTEM FIRE DETECTION AND ALARM SYSTEM D3.4 D3. SPECIFICATION NO.2 D3.

0 TCE.5960A-EL-2007 TCE.0 3.NO.5960A-EL-2005 TCE.SPEC.5960A-EL-2004 TCE.23 D3. TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01 TCE-5960A-H-500-01 R0 R0 R0 R0 R0 R0 MOTORS ELEVATORS ELECTRICAL LABORATORY EQUIPMENT MISCELLANEOUS ELECTRICAL EQUIPMENT CONSTRUCTION POWER SUPPLY TRANSDUCERS 10 08 07 03 04 02 DRAWING NO. OF SHEETS 01 01 01 01 01 01 01 01 1.5960A-EL-2003 TCE.5960A-EL-2001 TCE. TITLE VOLUME III SECTION: CONTENT SHEET SHEET 2 OF 2 700 MW CCPP AT NEDUNOOR.25 BID DRAWING SL NO.0 8.5960A-EL-2008 P0 P0 P0 P0 P0 P0 P0 P0 KEY ONE LINE DIAGRAM MAIN ONE LINE DIAGRAM (SH. EPC SPECIFICATION -ELECTRICAL SYSTEMS D3.0 6.21 D3.5960A-EL-2006 TCE.5960A-EL-2003 TCE.5960A-H-500001 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.20 D3. TCE. 329 R5 8 .0 4.0 2.22 D3. TITLE NO. REV.0 5. KARIMNAGAR DIST.0 7. 1 OF 2) MAIN ONE LINE DIAGRAM (SH.NO. 2 OF 2) SWITCHYARD SCADA ARCHIETCTURE DIAGRAM PARALLEL REDUNDANT UPS WITH STATIC BYPASS TO REGULATED SUPPLY FLOAT CUM BOOST CHARGER WITH 2x100% BATTERY 400kV SWITCHYARD PLAN 400kV SWITCHYARD SECTIONS ISSUE R0 TCE FORM NO.24 D3.

Control supply voltage for all the switchgear for the GTG. The step up voltage of the project shall be 400 kV as applicable. material and systems shall.5960A-H-500-001 1. accessories and services for the entire station/plant in his scope as well as those specifically required by the Owner.0 General Requirements (a) For the purpose of design of equipment / systems.5. in general. ELECTRICAL SYSTEMS GENERAL REQUIREMENTS SPEC. conform to the latest edition of relevant National and International Codes & Standards. The equipment/material/systems conforming to other equivalent national and international standards shall also be considered provided the same ensures equal or better features compared to standards listed in accompanying specification. to be carried out as a part of this contract.6 kV systems and 50 kA rms for 400 V system. for equipment in air-conditioned areas. especially the Indian Statutory Regulations. To cater the 400kV switchyard PLCC load. if 2x100% air conditioning system is provided. The nominal voltage of main DC system shall be 220V and 24V DC system for I& C application.1 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. TCE. All the equipment.0 SHEET 1 OF 17 1X 700 MW CCPP AT NEDUNOOR. The equipment shall operate in a highly polluted and highly corrosive environment. All equipments shall be suitable for rated frequency of 50 Hz with a variation of +3% to -5% and 10% combined variation of voltage and frequency unless specifically brought out in the specification. TITLE SECTION: D3. The accompanying specifications also indicate the applicable codes and standards. 329 R5 9 (b) (c) (d) (e) (f) (g) . Fault level shall be limited to 44 kA rms for 6. separate 48V DC system shall be provided. However the area where the DC control supply is required shall be finalized during the detailed engineering. Contractor shall provide fully compatible electrical system. HRSG. equipments. However. Cooling tower & STG shall be 220 V DC & 110 V AC. KARIMNAGAR DIST. design ambient temperature shall be 350C. Any other voltage required shall be derived from 220V DC or 230V AC UPS distribution board for catering to the control & instrumentation loads. an ambient temperature of 500C and relative humidity of 95% shall be considered. However the three phase symmetrical short circuit fault current value shall be based on load flow and fault studies. ISSUE R0 TCE FORM NO. NO.

5960A-EL-SK-2006 ISSUE R0 TCE FORM NO.5960A-EL-SK-2003 (Sh.6 kV & 400 V) under various grid and loading conditions are always within permissible limits and equipment are not subjected to unacceptable voltages during operation and starting of motors. TITLE SECTION: D3. All control and protection panels. MCCs.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.5960A-EL-SK-2003 (Sh. shall be by the Contractor. TCE.5960A-EL-SK-2001 : TCE. impedances and tolerances thereon. 1 of 2) : TCE. ELECTRICAL SYSTEMS GENERAL REQUIREMENTS SPEC. The electrical scheme for the project shall be as per the enclosed drawings: Key one line diagram Main one line diagram Main one line diagram Switchyard SCADA Architecture diagram UPS scheme Float cum boost charger with 2 x 100% battery : TCE.5960A-EL-SK-2004 (i) (j) (k) (l) : TCE.5960A-H-500-001 (h) The Contractor shall furnish calculations of maximum loading and fault levels under the most onerous conditions for the various equipment/systems to prove adequacy of their parameters. DC and AC distribution board and battery charger panels shall be painted by powder coating process. 329 R5 10 .5960A-EL-SK-2005 : TCE. External surfaces of all equipments shall be painted with Epoxy paint. taps.6 kV switchgear. In case any equipment or system is found to be inadequate. 6. NO. The vector groups of the transformers shall be so selected that all the buses of particular voltage level have same vector through out the plant. The responsibility of coordination with electrical agencies and obtaining all necessary clearances from all the statutory authorities. shall be so optimized so that the auxiliary system voltages (6. KARIMNAGAR DIST. 400 V switchgear. 1 of 2) : TCE. Transformer voltage ratios. Paint shade shall be opaline green (external) & semi-glossy white (internal).0 SHEET 2 OF 17 1X 700 MW CCPP AT NEDUNOOR. it shall be changed / modified without any additional liability to the Owner.

2 Generator Circuit Breaker (GCB) The continuous current rating of the GCB shall be arrived at considering the maximum output of the generator and at specified minimum voltage. cylindrical rotor. NO.3 Generator Transformers 1.0 SHEET 3 OF 17 1X 700 MW CCPP AT NEDUNOOR. 1.2 The Gas Turbine Generator and Steam turbine Generator shall be of hydrogen & water cooled. Static Frequency Converter (SFC) for starting of one gas turbine generator at a time. horizontal.3.1 The continuous rating of the generator transformers shall be such that the declared maximum continuous output of the respective turbine unit at any ambient temperature between 00C and 500C can be delivered at the rated ISSUE R0 TCE FORM NO. The GCB shall be of SF6. The voltage class of the Generator circuit breaker shall be same as that of the generator. 1. metal enclosed. The Stator winding shall be DM water cooled.3 The Contractor shall offer 2 nos. The Gas turbine generators /steam turbine generators and their excitation systems shall have a capability at least matching the declared maximum continuous output of the associated gas turbine /steam turbine at the outside ambient air temperature ranging from 00C to 500C. It shall be ensured that either of SFC can be used for cranking any of the Gas turbines without any limitation on successive starts of all gas turbines and restarts thereon.1 Generator and its auxiliaries 1.1. outdoor and freestanding type. The Stator core & Rotor winding shall be hydrogen cooled. no part of the generator shall attain a temperature in excess of the temperature limit specified in IEC 60034.1.1. KARIMNAGAR DIST. 1.1 The generator shall be three phase.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. ELECTRICAL SYSTEMS GENERAL REQUIREMENTS SPEC.85 lagging and 0. TCE. The contractor shall ensure that when the generator is working at this capability.5960A-EL-SK-2008 1.5960A-EL-SK-2007 400kV Switchyard sections : TCE. two pole.5960A-H-500-001 400kV Switchyard plan : TCE. TITLE SECTION: D3. 329 R5 11 . at all power factor between 0.95 leading. The Insulation class of the machine shall be Class-F but its temperature rise shall be limited to Class-B. Wye connected machine with phase and neutral terminals brought out for connection to isolated phase bus duct. 1.

three phase. UAT shall be a * MVA.V. ELECTRICAL SYSTEMS GENERAL REQUIREMENTS SPEC. Bus duct shall be sized based on the transformer rating at minimum tap.5 Bus duct 1.0 SHEET 4 OF 17 1X 700 MW CCPP AT NEDUNOOR.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.5. Critical equipments/systems shall be provided with double protection. with On Load Tap Changer with +10% to -10% of in steps of 1.7 400 kV Switchyard (a) A 400 kV switchyard shall be provided for evacuation of power generated in the plant through four (4) nos. 1. Further a margin of 5% on the rating shall be provided considering the maximum Generator output. ONAN / ONAF / OFAF cooled transformer. 1. two winding.9kV. UAT shall be suitable for medium resistance earthing with earth fault current limited to 300A. 400kV transmission lines.6 Protection Fully graded protection system with requisite speed.2 The GT shall be with voltage ratio of generator voltage / 420kV.25% on the HV side. 1. ONAN/ONAF cooled transformer with * % impedance with OLTC +10% in steps of 1.5. 1. KARIMNAGAR DIST. TITLE SECTION: D3. / L. 50 Hz. The 400 kV switchyard shall have one and half breaker switching scheme.1 The continuous current rating of the generator bus duct shall be arrived at considering the maximum output of the generator and at specified minimum voltage. Contractor shall recommend the relay settings to be adopted along with back-up calculations. 1. */6. TCE. NO. 50 Hz.5960A-H-500-001 power factors and allowable generator voltage variations without exceeding the permissible temperature rise limits set by the applicable Indian Codes and Standards for these equipment. two winding. 329 R5 12 . sensitivity and selectivity shall be provided for the entire plant. Unit auxiliary transformer shall be capable of supplying auxiliary power requirement of complete station system. Further a 10 % margin on rating shall be provided after considering final load requirement. 1. The Bidder shall furnish the rating of the equipments.3.4 Unit Auxiliary Transformer 2 Nos.2 The M.25% on HV side (*By Bidder).V. ISSUE R0 TCE FORM NO.

Approach road all around the switchyard shall also be provided for maintenance and patrolling.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. for each dia. Earth mat The earth mat shall be extended 2 m beyond fence for the switchyard. The coolers shall preferably be arranged on side. All tension insulator strings shall have double tension string arrangement. other than LA. The Conductor tensions shall be 2 Tonnes per conductor. PLCC Panels. (c) (d) The EMVT/CVT and LA shall be connected to earth pit through pipe electrodes. Approach road shall be provided. Air conditioned outdoor kiosks will be suitably located in switchyard. The earth mat shall be designed for short time rating of 1 second rating and shall be considered for calculation of step & touch potential. The connections from LA to transformer shall be through shortest electrical distance. etc. (e) (f) (g) (h) (i) (j) (k) ISSUE R0 TCE FORM NO. Fault Disturbance Recorders.5960A-H-500-001 (b) The layout of the switchyard shall be such that adequate space for maintenance of prime equipment like circuit breakers and current transformers is available. TCE. housing various Intelligent Electronic Devices (IEDs) such as Bay Control Units (BCUs). 329 R5 13 . ELECTRICAL SYSTEMS GENERAL REQUIREMENTS SPEC. NO.0 SHEET 5 OF 17 1X 700 MW CCPP AT NEDUNOOR. Protection Panels. For the Earthing system design System fault current to be considered is 50 kA. The receptacles of 63 A ratings shall be provided on the gantries at suitable location for connection to welding sets/other emergency equipments. KARIMNAGAR DIST. TITLE SECTION: D3. The earth mat of 400kV switchyard shall be inter connected with main plant. The aluminium tubular busbar conductors wherever if used shall have maximum one joint per span.

energy capability etc. Additional arresters. Contractor shall carry out detailed calculations to evolve the required parameters. of surge arrestors such that an adequate protective margin exits between the peak impulse voltage occurring due to other connected sub stations.7 are indicative and shall be finalised after insulation coordination studies. shall be provided by the Contractor. The Contractor shall provide surge arrestors and other devices as required to protect all the equipments from fundamental frequency. The Contractor shall furnish the system studies like load flow.0 SHEET 6 OF 17 1X 700 MW CCPP AT NEDUNOOR.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. The requirements regarding RIV and corona extinction voltage shall include terminal fittings.5960A-H-500-001 (l) Corona rings & corona bells shall be used wherever required and same shall be of non-magnetic material. harmonics. locations. TCE. Contractor shall submit the relay co-ordination. The switchyard shall be provided with suitable phase markers and danger plates. Insulation Co-ordination (m) (n) (o) (p) The Contractor shall be fully responsible for complete insulation coordination of switchyard. (r) 400 kV System ISSUE R0 TCE FORM NO. In addition to the above. All equipments shall be suitable for hot line washing. ELECTRICAL SYSTEMS GENERAL REQUIREMENTS SPEC. The quantity of surge arresters shown in the drawings are minimum required. NO. TITLE SECTION: D3. dynamic & transient conditions. The connectors for termination of conductor on equipment shall be either of rigid or expansion type suitable for aluminium tube or Moose ACSR conductor. if required based on the insulation coordination study. 329 R5 14 . short circuit and transient stability studies of the complete system including the transmission lines during detail engineering stage for Owner’s approval. and lightning impulse over voltages under steady state. switching surges. motor starting studies for the complete plant for Owner’s approval. Bidder to note that surge arrester parameters given at D3. ferro-resonance. KARIMNAGAR DIST.

ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. 329 R5 15 . SF6 Spring / Spring charge mechanism (u) (v) Type of circuit breaker Operating mechanism Circuit breaker (w) (x) Type of isolator Instrument transformer Horizontal centre break/Pantograph Outdoor. TITLE SECTION: D3. KARIMNAGAR DIST.5960A-H-500-001 (i) (ii) (iii) Max voltage Rated frequency Rated short time current withstand capacity Rated one minute power frequency withstand voltage Rated lightning impulse withstand voltage Clearance Phase to phase Phase to earth Sectional clearance Ground clearance 420 kV 50 Hz 50 kA rms for one (1) second iv) 630 kV rms v) 1425 kVp vi) 4200 mm 3400 mm 6500 mm 8000 mm (s) (t) System neutral earthing Auxiliary contacts Effectively earthed The contacts shall have continuous rating of 10A and breaking capacity of 2A with circuit time constant of minimum 20 ms at 220 V DC. Oil filled hermetically sealed with SS bellow. ELECTRICAL SYSTEMS GENERAL REQUIREMENTS SPEC. ISSUE R0 TCE FORM NO.0 SHEET 7 OF 17 1X 700 MW CCPP AT NEDUNOOR. TCE. NO.

synchronizing and sequential event logging for each generator and its subsystem shall be provided on the DCS. 329 R5 16 . annunciation. The fault level for the switchgear. The control. earth switch. 1. SCADA shall have communication with plant DCS for providing measurement.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. shall be arrived at. monitoring. etc. isolators. TITLE SECTION: D3.6 kV switchgear and its accessories shall conform to all latest editions of national and international standards.10 Service transformer Adequate number of 6. monitoring.6 kV and service transformers. ELECTRICAL SYSTEMS GENERAL REQUIREMENTS SPEC. bus bars.55 times this value. (b) (c) (d) e) 1. KARIMNAGAR DIST.0 SHEET 8 OF 17 1X 700 MW CCPP AT NEDUNOOR.V.6 kV / 420V epoxy cast resin dry type service transformers shall be provided to meet the demand on 400V systems. with the criteria that each 400 V switchgear / MCC / DB shall be fed by 2x100% transformers / feeders. Control. auxiliary power system. PLCC panels for lines shall be located in the outdoor kiosk panels.. NO. Protection.C current.9 6. on the basis of short circuit current contribution from UAT plus short circuit contribution by the motors running on the bus. and these shall be rated to carry the maximum load expected to be imposed with 10% margin at all ambient. Each of the ISSUE R0 TCE FORM NO. A margin of 5% over higher of the above S. covered under the scope of this package shall be provided through the DCS system. shall be applied and rounded off to the next higher standard ratings and this value shall be adopted for the breakers and switchgears.V.8 Control philosophy of electrical system (a) Control of L. measurement. adequately rated switchgears shall be provided. monitoring. circuit breakers. annunciation and metering of complete 400 kV switchyard under Bidder's scope shall be through SCADA. For feeding the plant auxiliaries rated for 6. indication. The momentary current ratings shall be 2. and M.6kV Switchgear The 6. annunciation etc of 400kV switchyard.5960A-H-500-001 (y) Creepage distance for insulators 31mm/kV 1. TCE.

The neutral of service transformers shall be independently connected to the earth. No. The switchgears shown in Key One Line Diagram drg. The neutral of GTs are independently connected to earth.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. Dry type AN cooled with off-circuit taps of ±5% in steps of 2. Any additional switchgear / MCCs as required shall also be provided. 1. 50 Hz. 400V system shall be a solidly earthed system.5%. three phase.12 Neutral Earthing Equipment (a) 400 kV system is solidly earthed.6 kV systems shall be medium resistance earthed. (b) (c) (d) (e) (f) 1. 6600 / 420 Volts. TCE. limiting the earth fault current to about 510 A. The service transformers shall be two winding. 329 R5 17 . TCE. TITLE SECTION: D3. NO. 220 V DC system & UPS system shall be kept ungrounded.5960A-H-500-001 switchgear / MCC / DB shall be sectionalised. 1. The neutral earthing equipment shall be rated to carry this current for at least 30 seconds considering the generator terminal voltage under maximum field forcing conditions. Diesel generator shall be of solidly earthed system.5960A-EL-SK-2001 is tentative.11 400 V Switchgear The 400 V switchgear and its accessories shall conform to all latest editions of national and international standards. KARIMNAGAR DIST. Generator neutral shall be high resistance earthed. The earth fault current shall be limited to 300A. The neutral of the unit auxiliary transformers shall be independently connected to the earth through a suitable resistance designed for 30secs.0 SHEET 9 OF 17 1X 700 MW CCPP AT NEDUNOOR. The neutral shall be connected to a suitably rated neutral earthing transformer with secondary loading resistor. For feeding the 400V / 230V AC loads of the plant. 6.e.13 DC System ISSUE R0 TCE FORM NO. 400V switchgear / motor control centres (MCCs) and AC distribution boards (ACDBs) shall be provided. ELECTRICAL SYSTEMS GENERAL REQUIREMENTS SPEC. when the bus coupler is open. Highest efficiency operating point shall be designed near to the normal loading of the transformer i.

48V. DC 2 x 100% battery bank with associated float cum boostcharger. (b) (c) (d) (e) (f) (g) (h) (i) 1.5960A-H-500-001 (a) DC power supply with high discharge Lead acid plante type battery cells forming bank shall be the source of the power supply for control. The GTG unit DC system with 100% capacity shall be sized to cater complete unit loads for atleast 10 hrs. 329 R5 18 . DC 2 x 100% battery banks with associated float cum boostchargers and 1 No. interlock. DC 2 x 100% battery banks with associated float cum boostchargers and 1 No. The boost charger unit shall be rated such that the battery can be fully charged from fully discharged condition within 8 hours. Sizing criteria shall include design margin of 10%. The switchyard DC system shall be sized to cater loads for at least 10 hrs. ELECTRICAL SYSTEMS GENERAL REQUIREMENTS SPEC. 25% margin on ageing and ambient temperature compensation as per IS.0 SHEET 10 OF 17 1X 700 MW CCPP AT NEDUNOOR. NO. DC switchboard shall be provided for station DC system. DC switchboard having 2 Incomers & one bus coupler shall be provided for 400kV system (switchyard) auxiliaries. 24V. The station DC system shall be sized to cater STG. 1 No. DC switchboard shall be provided for each gas turbine generator (GTG) unit. annunciation of the complete plant including I&C system during the running of the plant as well as for a safe shutdown at the time of the total power supply failure.14 Uninterruptible Power Supply (UPS) ISSUE R0 TCE FORM NO. 220V. Each battery charger shall be capable of float charging the two batteries while supplying the normal DC loads. DC switchboard having 2 Incomers & one bus coupler shall be provided for I& C . TITLE SECTION: D3. 220V. DC switchboard having 2 Incomers & one bus coupler shall be provided for 400kV switchyard PLCC application. DCS system. 220V.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. TCE. KARIMNAGAR DIST. protection. HRSG and station loads for at least 10 hrs. DC 2 x 100% battery banks with associated float cum boostchargers and 1 No. DC 2 x 100% battery banks with associated float cum boostchargers and 1 No.

Voltage grade of cables shall be of earthed grade when used in solidly earthed systems. IS:2309 & IEEE : 80 and IEEE : 665. 1. etc. TITLE SECTION: D3. 1. local rules etc. boundary. grouping and soil resistivity.0 SHEET 11 OF 17 1X 700 MW CCPP AT NEDUNOOR. for maximum fault current of 50kA for 1. Cables shall be selected to limit maximum voltage drop at equipment terminals during normal operation and starting conditions well within permissible values. TCE. SWAS etc. The minimum rate of corrosion of steel for selection of earthing conductor shall be 0. The layout design shall meet all the statutory requirement.18 Motors (a) Wherever the basis for motor ratings are not specified in the corresponding mechanical specification sections. The lighting layout shall be designed to provide uniform illumination with minimum glare. 1. ELECTRICAL SYSTEMS GENERAL REQUIREMENTS SPEC.5960A-H-500-001 Parallel redundant UPS shall be with duplicate charger.12mm per year. maximum continuous motor ratings shall be at least 10% above the maximum load demand of the driven equipment under entire operating range including voltage and frequency variations.0 sec. ISSUE R0 TCE FORM NO. KARIMNAGAR DIST. outdoor areas.15 Cabling System Cables shall be derated for the site ambient and ground temperatures. Contractor shall furnish detailed cable selection/sizing criteria for Owner’s approval.17 Earthing System The earthing system shall be designed for a life expectancy of at least forty (40) years. The UPS shall be sized considering full load plus spare loops plus 20% margin. and unearthed grade when used in non-effectively earthed systems. 329 R5 19 . switchyard and other areas or buildings covered in the specification shall be provided in accordance with IS:3043. roads.16 Lighting System Lighting system shall be provided for the entire plant covering all the buildings. NO.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. Grounding and lightning protection for the entire power plant. inverter & battery system and standby supply to cater the UPS loads of complete plant Instrumentation and control system loads such as HMI. The lighting system design shall comply with the acceptable norms and the best engineering practices. yards. 1.

1. motors shall be ±10%.V. (c) 1. TCE. non-segregated phase bus duct (NSPBT) assemblies shall be preferred for incoming connection from transformers to the switchboard.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.6 kV incomers and ties from transformers to switchgear shall be through 6. steam turbines. station service and switchyard loads. MCCs and DBs shall have positive foolproof interlocking to ensure that different supplies and transformers are never operated in parallel and fault level does not exceed the switchgear capability. motors shall be suitable for 6.0 SHEET 12 OF 17 1X 700 MW CCPP AT NEDUNOOR. 50 Hz and LV motors shall be suitable for 400 V. The voltage for M.6kV and 400V switchgear. which shall run with the available plant load under such condition. 1.20 Islanding Scheme The plant shall be designed to operate in islanding mode of operation by tripping all the lines and generators except for one pre-selected unit.6kV and motors rated upto 175 kW shall be 400 V. The motors rated 175 kW and above shall be 6.6 kV. TITLE SECTION: D3. Manual live changeover and slow changeover shall also be arranged for all 6.6 kV system shall incorporate a microprocessor based numerical fast auto change over scheme which will restore supplies to the 6.6 kV buses & 400V buses. 329 R5 20 (b) (c) . 3 phase.21 Auxiliary System (a) 6. ISSUE R0 TCE FORM NO.6 kV segregated phase bus duct (SPBD) only.6kV unit board from other unit board. and L. Automatic changeover to the reserve supply source shall be arranged for 400V critical switchgear/MCC sections as necessary to prevent the loss of a unit or to ensure the equipment safety. 3 Phase. NO. contribution from emergency DG set shall be considered while designing the fault level. The 6.19 Emergency Diesel Generator Set Each Emergency Diesel Generating set shall be sized at an ambient temperature of 500C for all essential auxiliaries and emergency loads of all gas turbines. For 400V system. on loss of supplies from unit transformer. ELECTRICAL SYSTEMS GENERAL REQUIREMENTS SPEC.V. KARIMNAGAR DIST. 6. If adequately rated cables shall be provided then Owner’s permission shall be obtained.V. For 400V switchgear.5960A-H-500-001 (b) All M. 50 Hz power supply.

ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.
TITLE

SECTION: D3.0 SHEET 13 OF 17

1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST.

ELECTRICAL SYSTEMS GENERAL REQUIREMENTS

SPEC. NO. TCE.5960A-H-500-001

(d)

During Grid black-out condition, it shall be ensured that only the essential auxiliaries of all units are fed from emergency Diesel generator & non- essential loads are automatically tripped. DC scheme shall provide at least two feeds through diode sharing to critical consumers e.g. all protection panels / control desks, circuit breakers, GCB, 6.6 kV / 400 V unit and emergency switchgear panels, generator excitation system, generator oil seal system, etc. The details shall be subject to Owner’s approval. For generator protection and protection panels for all 400 kV switchyard feeders, duplicated DC feeders shall be provided, one from each battery system.

(e)

1.22

The insulation level for the transformer windings and bushings shall be as follows: Winding Highest System Voltage Rated Power Freq. withstand voltage (kVrms) 20 28 38 95 630 Rated lightning impulse withstand voltage (kVp) 60 75 95 250 1300 Bushing Rated Power freq. withstand voltage (kVrms) 20 28 38 95 630 Rated lighting impulse withstand voltage (kVp) 60 75 95 250 1425

7.2 kV 12 kV 17.5 kV 34.5 kV 420 kV

Note: for 400kV system switching impulse of 1050 kVp shall be considered.

1.23

Degree of protection Degree of protection for various enclosures as per IS: 13947 shall be as follows:

ISSUE R0 TCE FORM NO. 329 R5
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SECTION: D3.0 SHEET 14 OF 17

1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST.

ELECTRICAL SYSTEMS GENERAL REQUIREMENTS

SPEC. NO. TCE.5960A-H-500-001

(a)

6.6 kV switchgear i) ii) iii) VT/relay compartments Other compartments Switchgear in air-conditioned areas (all compartments) - IP 52 - IP 42 - IP 32

(b)

400V switchgear / MCC / DBs / Fuse Boards i) Compartments and busbar chambers upto 1600A Compartments and busbar chambers above 1600A All compartments in case switchgear in air-conditioned areas Switchgear located out door - IP 52

ii)

- IP 42

iii)

- IP 32

iv) (c)

- IP 54

Busduct enclosure / GCB i) ii) iii) Indoor portion including VT & SP cubicle - IP 52 Outdoor portion GCB - IP 65 - IP 65

(d)

Motors i) ii) Indoor motors Outdoor motors - IP 54 - IP 55

(e)

Control and relay panel i) ii) In air-conditioned areas In other areas - IP 32 - IP 52

(f)

Transformers
ISSUE R0 TCE FORM NO. 329 R5
22

ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.
TITLE

SECTION: D3.0 SHEET 15 OF 17

1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST.

ELECTRICAL SYSTEMS GENERAL REQUIREMENTS

SPEC. NO. TCE.5960A-H-500-001

i) ii) iii) iv) v) (g)

Indoor Transformers Cable box - indoor area Cable box - outdoor area Indoor kiosks and marshalling boxes Outdoor kiosks and marshalling boxes

- IP 31 - IP 52 - IP 55 - IP 52 - IP 55

Push button stations and any other kiosk / box / panel / enclosure i) ii) Indoor Outdoor - IP 54 - IP 55 - IP 55 - IP 55 - IP 22 - IP 33

(h) (i) (j) (k) 1.24

Junction boxes for cables/wires Outdoor lighting fixtures Gen. Neutral grounding resistor 6.6 kV Neutral grounding resistor

FAULT LEVEL Equipment through fault withstand capabilities under worst operating conditions duly taking into account tolerances on transformer, generator & maximum fault levels of source etc. shall be as follows : i) ii) All other transformers Generator busduct main run, GCB, (higher of generator or EHV system fault contribution) Tap off run busduct (sum of generator and EHV system fault contribution) 6.6 kV Busduct Switchgears - 2 seconds - 1 second

iii)

- 1 second

iv) v)

- 1 second - 1 second
ISSUE R0 TCE FORM NO. 329 R5
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SECTION: D3.0 SHEET 16 OF 17

1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST.

ELECTRICAL SYSTEMS GENERAL REQUIREMENTS

SPEC. NO. TCE.5960A-H-500-001

vi)

Cables to the feeders protected by breakers

Main protection fault clearing time with 0.16 seconds minimum

vii)

Cables of all other feeders

As per fuse operating time - 2 seconds for the adopted ground fault current - 1 second

viii)

6.6 kV cable screen

ix) 1.25

EHV systems

Type Test All equipment / systems to be supplied shall conform to type tests as per relevant standards / relevant chapters of this specification and shall be of proven type.

1.26 Communication System For effective communication in the plant, public address system, private automatic branch exchange system (EPABX), radio paging system, walkietalkie and P&T telephone system with the features described below will be provided: a) Public Address System This system will have paging and party channels comprising handset stations with amplifiers, transmitters, receivers, and loud speakers. This system will facilitate paging, communication and also private conversation as in conventional telephone. b) EPABX System This system will have adequate number of push button type handset stations, central automatic telephone exchange, etc. The handsets in the control room would be provided with priority service facility to enable them to have immediate access to any handset even if it is already engaged.
ISSUE R0 TCE FORM NO. 329 R5
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1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST.

ELECTRICAL SYSTEMS GENERAL REQUIREMENTS

SPEC. NO. TCE.5960A-H-500-001

c) Landline Telephones, Broadband connectivity Necessary number of ISDN / PSTN landlines would be provided at strategic locations within the plant boundary. Broadband connectivity would be provided at strategic locations for online access of data from remote station.

d) Wireless System (Walkie-Talkie System) Walkie-Talkie system will be provided for mobile communications. These systems will be of particular use during commissioning stage as well as subsequently during maintenance. e) GPRS/CDMA mobile system of any reputed service provider can be provided for wireless system. The mobile system coverage in the power plant area should be 100%. f) Interface between the EPABX, PA and Wireless systems shall be provided to enable communication between these systems.

ISSUE R0 TCE FORM NO. 329 R5
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ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.

SECTION:

D3.1

SHEET 1 OF 42

1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES

SPEC. NO. TCE.5960A-H-500-001

1.0

GENERATOR & ACCESSORIES The generator and its accessories such as the cooling system excitation system, automatic voltage regulator, static start up systems for gas turbine generator etc. shall generally comply with the requirements specified in the national and international standards indicated as per Data sheet A 3.1 and shall additionally comply with the specific requirements of Data sheet A 3.1 and as indicated below:

1.1 1.1.1

Generator The MW out put of generator of the Gas turbine generator unit and Steam turbine generator unit shall be sufficient to evacuate the normal and peak power output of gas turbine power over the complete range of site ambient conditions specified in Section-B and at rated casing (Hydrogen) pressure and temperature. The Maximum Continuous Rating (MCR) of the generator shall correspond to the maximum MVA, MW and minimum associated over-excited power factor that it is guaranteed to deliver continuously (without exceeding its specified temperatures or temperature rises at rated casing (hydrogen) pressure and temperature. The generator shall be three phase, horizontal, two pole, cylindrical rotor, Wye connected machine with phase and neutral terminals brought out for connection to isolated phase bus duct. The generators shall conform to IEC60034-1, IEC60034-3 or other equivalent international standards. The generator shall be capable of satisfactory continuous operation at rated MVA and power factor at any voltage from 95% to 105% of rated voltage and within a frequency range of 47.5 to 51.5 Hz (and a combined frequency and voltage variation of 5%) even if frequency and voltage variations occur simultaneously, without exceeding safe temperature rises, but not necessarily in accordance with the standards established for operation at rated voltage and frequency. The generators shall be provided with Class-F insulation with temperature rise limited to that of Class-B at full load and at rated voltage & frequency. However, for abnormal operating conditions of voltage and frequency, the temperature rise shall in no case exceed that of Class-F when the machine is operating continuously at full load and at rated power factor at any working voltage and any frequency in the range stipulated above.

1.1.2

1.1.3

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SECTION:

D3.1

SHEET 2 OF 42

1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES

SPEC. NO. TCE.5960A-H-500-001

1.1.4

The generator unit shall be capable of withstanding 3 phase short circuit at the generator terminals when operating at rated MVA and power factor, 5% over voltage and with rated excitation for 3 seconds. The line charging capability of the generator shall not be less than 30% of its rated MVA at zero power factor. The generator shall be non-effectively earthed through a singlephase distribution transformer provided with secondary loading resistor. The sizing of the transformer and the value of the resistance shall be such as to restrict the maximum earth fault current to 1.5 times the capacitive current at normal working voltage. The generator shall be capable of operating alone or in parallel with other generators and / or utility grid. The core of the generator shall be designed such that it permit the flow of earth fault current of at least 15 amperes for one (1) second without any core damage. The generator phase and neutral side terminals shall be brought out through seal off bushings. The bearings shall be lubricated by oil from the turbine lube oil system. Non-hygroscopic insulation shall be provided to prevent any damage due to the circulation of shaft current to the bearing surfaces and the lubricating oil. At least one of the bearings shall be suitably insulated with arrangements for checking the insulation resistance while the machine is in operation. On-line shaft leakage current monitoring system shall be provided to detect any leakage current through the shaft. Abnormal leakage current shall trigger an alarm in the control room. The generator and its components shall be designed to avoid resonance over the entire range of operating frequency or their multiples. The noise (sound) power level emitted by the generator as measured one (1) metre from the surface of the generator and at 1.5 metre height above floor level shall be limited to 85 dB(A).
ISSUE
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1.1.5

1.1.6

1.1.7

1.1.8

1.1.9

1.1.10

1.1.11

1.1.12

1.1.13

27

TCE FORM NO. 329 R5

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SECTION:

D3.1

SHEET 3 OF 42

1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES

SPEC. NO. TCE.5960A-H-500-001

1.1.14

The generator unit shall be capable of withstanding the electrical, mechanical and thermal stresses developed during fast auto reclosing of high voltage line, transmission line switching, grid faults, out of step operation, out of phase synchronisation, etc. The vibration severity when measured on generator and main exciter bearings shall not exceed 2.8mm / sec. When tested on open circuit and at rated speed and voltage, the telephone influence factor of the turbine generator shall not exceed 1.5 %. The generator winding shall withstand test voltage of 4 U + 5 (where U is the rated voltage in kV). Lightning arrestors of suitable rating shall be provided for the surge protection of generator winding. In addition to the above if surge capacitors are recommended, the same shall be included in the offer. All components of the generator requiring inspection and maintenance shall be designed for easy access and replacement. Resistance / thermocouple type temperature detectors shall be provided where the highest temperatures are expected. The approximate number and location of temperature detectors shall be as follows: (a) Twelve (12) duplex RTDs (Four per phase) distributed equally around the periphery of the stator winding and also between three phases shall be provided. The geometry of the detectors shall be such that hot spots anywhere in the stator winding can be detected. (b) Twelve (12) duplex RTDs for stator core out of which six shall be located in the end zones where maximum temperatures are expected. (c) Two (2) duplex RTDs for each hydrogen cooler section at inlet and outlet (if applicable). (d) Two (2) thermostats per hydrogen cooler section for gas inlet and outlet (if applicable). (e) Two (2) duplex RTDs for hydrogen cooler water inlet and outlet (if applicable).
ISSUE
R0

1.1.15

1.1.16

1.1.17

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28

TCE FORM NO. 329 R5

excitation. KARIMNAGAR DIST.25 29 TCE FORM NO.1. (j) Additional RTDs / Thermocouples / Thermostats if required or if required at additional locations shall be provided as found necessary. Terminal box shall be at an easily accessible position so as to enable maintenance / testing of the devices when the machine is under operation.20 All RTDs shall be of platinum duplex four wire type and shall have a resistance of 100 Ohms at zero degree centigrade and calibrated as per DIN standards.21 1. (g) Two (2) duplex RTDs for cold air temperature and two (2) duplex RTDs each for air temperature in the exciter air passage and rectifier wheel along with thermostats for cold and hot air. not exceeding those given in IEC 60034-1. (i) Rotor winding temperature measurement is also to be done through 2 Nos. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC. indication / annunciation and necessary main control system interfacings with DCS. 329 R5 .ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. All the above temperature measurement devices shall be hooked to DCS. SECTION: D3. etc. One (1) generator condition monitoring system shall be supplied along with all piping and accessories to continuously sample the generator hydrogen for detection of thermally produced particulates / aerosols which indicates overheating. shall be provided with respective local control panels with required control.5960A-H-500-001 (f) Two (2) duplex thermocouples per bearing.24 1.22 1.1..1. TCE. NO.1. Termination of RTD leads shall be at terminal box after grouping of signals.1 SHEET 4 OF 42 1X 700 MW CCPP AT NEDUNOOR. Termination box of the temperature measuring devices shall be of IP-55. (h) Set of duplex RTDs and thermostats for shaft seal system (if applicable). hydrogen gas handling system. Generator auxiliary system like cooling. or temperature rises.1. Insulation and Temperature Limits ISSUE R0 1. Generator rating shall be on the basis of continuous operation with guaranteed temperature.1.23 1. 1. of duplex RTDs located at the locations where the temperature is likely to be maximum.

TCE. The housing shall have suitable provision for handling. 1. 329 R5 . 1. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC. 1. starting from stability temperature at rated load.5960A-H-500-001 The generator stator and rotor windings inclusive of main and neutral leads.1. KARIMNAGAR DIST. 1. Manholes with sealing arrangement shall be 1.26 Short Circuit Withstand Capability during Unbalanced Faults The generator shall be capable of withstanding.1 Stator Housing The stator housing shall be of totally enclosed gas tight construction. Suitable numbers of trunions shall be provided for handling the stator by means of crane. shall be provided with Class F insulation but temperature rise shall be limited to class B.2.27 Overload Capability With balanced current.3 ISSUE R0 30 TCE FORM NO. SECTION: D3. lifting and / or jacking the stator.1. having sufficient mechanical strength and rigidity to withstand internal gas pressure. NO. 100 percent vacuum and vibrations and also internal hydrogen explosion without any damage or permanent deformation.2 1. where I2 is per unit negative sequence current and t is the duration of fault in seconds. any short circuit at its terminals provided the integrated product of I22t does not exceed the value stipulated in IEC60034-1.28 Capacity with one Gas Cooler Out of Service Hydrogen coolers would be built into the stator frame of the generator and would be sized to ensure at least 80% of the rated output continuously with 10% of tubes in each coolers are plugged and one of the hydrogen cooler is out of service then also the temperatures rises shall be limited to class B.1 SHEET 5 OF 42 1X 700 MW CCPP AT NEDUNOOR.2.2 1.2. the short time thermal capability of the generator armature shall permit operation at 150% of the rated armature current for at least 30 seconds.1.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. The maximum permissible temperatures of different parts of the generator shall be as specified in IEC-60034. The Bidder to clearly bring out in the proposal the features provided in the generator body construction to enable generator stator to be lifted/dragged in case of nonavailability of suitable crane. without injury.

etc. NO.2. All leads. The core assembly shall have adequate ventilation ducts for cooling by hydrogen.3 1. ISSUE R0 1. TCE. The instrumentation terminal box shall have IP55 protection class and shall be located at an easily accessible position so as to enable maintenance / testing of the devices when the machine is under operation. end winding area. The core assembly and mounting arrangement shall be such that the transmission of the forced vibration of the core to the housing and foundation is effectively restricted. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC.1 1.1 SHEET 6 OF 42 1X 700 MW CCPP AT NEDUNOOR.3.2. internals such as back of the core. A drawing indicating the location of the temperature detectors and the terminal box shall be enclosed with the proposal.5960A-H-500-001 provided at suitable locations to facilitate inspection of terminals. KARIMNAGAR DIST.5 1. Stray current insulation shall be provided so that all paths of stray current will be broken at two places in series at one end of the generator with provision made for determining the insulation resistance at each place of insulation with the unit in operation.6 1.3.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. 329 R5 .2 31 TCE FORM NO. including power. The frame shall be stress relieved and then subjected to an extended hydraulic test at a pressure not less than 1. Location may be preferably on the TG Deck. Press plates and fastening elements shall be made of non-magnetic material and shall be with proper locking arrangement. Stator Core The stator core shall be fabricated out of high permeability best quality cold rolled silicon steel so that losses are minimum.5 times the maximum design pressure.2.7 1. control and instrumentation shall be suitably supported to contain vibrations and shall be brought out of the generator housing to terminal boxes through gas tight seals.2.4 End plates of the generator frame shall be suitably shielded from stray flux. The end packets shall be adequately strengthened to minimise the magnetic vibration due to end leakage flux. The dimensions of the generator stator body to be within the maximum permissible rail transportation dimensions within the country taking into account the special wagons available / being made available for transporting such heavy over sized consignment. SECTION: D3. 1.

4. 100 and 200 Hz.4. KARIMNAGAR DIST. frame and mounting shall be designed to avoid resonance at 50. Terminal Connection All phase and neutral terminals shall be brought out from the top of the generator (non-drive end) and located in a non-magnetic steel terminal box. In order to reduce the corona in the slot and where the stator bar leaves the stator core. short chorded.4.1 ISSUE R0 32 TCE FORM NO. Stator Winding The stator winding shall consist of three phase. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC. a surface treatment corona grading system shall be applied which shall be carried into the end turn area. The stator core. The winding and all connections inclusive of phase and neutral leads shall be insulated for full voltage to ground. 329 R5 .5 1. Phase terminal bushing shall be spaced to 1. Provision shall also be made available to connect the same to DCS.4.5. Firm seating of the stator bar in the slot shall be ensured by proper wedging and fillers. The end turns shall be suitably braced and supported to withstand forces during normal operation and sudden short circuit at generator terminals when the machine is operating at rated MVA.4.1 SHEET 7 OF 42 1X 700 MW CCPP AT NEDUNOOR.3 The stator core mounting arrangement shall be such that radial and tangential magnetic vibrations of the stator core due to electromagnetic loading transferred to stator frame are minimised.4 1. double layer. Bidder shall wire up all the pickups to a junction box outside the generator casing. Ripple springs shall be provided below the slot wedges to compensate for any future shrinkage and ensure permanent firm seating of the bars in the slot during operation.5 1. symmetrically located around the periphery with connection to Turbine Supervisory system. SECTION: D3. bar type lap winding having two parallel paths. At least six (6) numbers of vibration pickups at each end of over hang portion of the winding shall be provided.3 1. The strands making up the stator bar shall be Roebel transposed to minimise eddy current losses.4 1. power factor and permissible maximum over voltage. The stator windings shall be designed for connection in single /double star with three (3) phase and three (3) / six (6) neutral terminals brought out. TCE.3.4.6 1.5960A-H-500-001 1. NO.2 1.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.1 1.

Adequate margin shall be provided between critical speed and the running speed to ensure smooth running. Facilities shall be provided for inserting at least two radial and one axial probe into the rotor shaft for carrying out ultrasonic and residual stress measurements during the life of the rotor. KARIMNAGAR DIST. 329 R5 . Rotor winding shall be secured in the slots by suitable slot wedges and fillers. Winding insulation shall correspond to Class-F (i.5.2 33 TCE FORM NO.3 1.6.2 1.7.6.7 1. TCE. epoxy glass based material) with temperature limited to Class -B. Rotor Winding Rotor winding shall be made of hard drawn silver bearing solid copper conductors. The retaining rings shall be machined from high strength. The overhung portion of rotor winding shall be held in position against centrifugal force by retaining rings when the rotor is running at upto 20% above its normal speed.e.7.5960A-H-500-001 permit connection to isolated phase bus duct to provide complete phase isolation directly upto the generator housing. shrunk on rotor body and prevented from axial movement by snap rings / locknuts. 1. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC.1 1. ISSUE R0 1.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. The terminal bushing shall be cooled by suitable arrangement with cooling medium/system envisaged for the generator.1 1.2 The bushing shall be preferably of porcelain type or of epoxy based material with non-hygroscopic property. The retaining rings shall be floating type. Adequate spacing shall be provided between phase and neutral bushings to permit connection of the neutral enclosure.6 1. the rotor shall be dynamically balanced and subject to 20% over speed for 2 minutes.6. Silver coated copper terminal connectors suitable for connection to the busduct through flexibles shall be provided for which the operating conductor temperature shall not exceed 105OC. NO. SECTION: D3. Rotor The generator rotor shall be machined from a single alloy steel forging to ensure required mechanical strength and magnetic properties. nonmagnetic alloy steel forging with the material specification X8CrMnNi1818 resistant to stress corrosion. After assembly. The forging shall be subjected to elaborate ultrasonic and mechanical tests to ensure freedom from any internal defect.1 SHEET 8 OF 42 1X 700 MW CCPP AT NEDUNOOR.

seal oil pressure in the annular gap between the rotating shaft and seal ring shall be maintained at a higher level than the 1. The rotor shall be suitable for operation without requiring preheating of the rotor or rotor winding or pre-warming of the rotor forging.7. Each bearing shall be provided with a well for thermometer in the return line and a sight glass with illumination to observe bearing oil flow.9 1. Shaft Seals Labyrinth shaft seals shall be provided.4 1. Redundant vibration pick-ups and transducers for bearing shall be provided. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC.1 ISSUE R0 34 TCE FORM NO. The vibration sensors shall be installed on X and Y dimensions. RTDs for measurement of metal temperature and bearing drain oil temperature shall be provided.2 1. Build-up of shaft voltage beyond permissible limits as well as a short in the bearing insulation shall trigger an alarm.8 1.9. All the intermediate support pieces of the bearing shall have complete interchange ability with those of similar type and size of TG bearing. Oil buffers shall be provided to prevent leakage of oil and oil vapours along the shaft.3 Suitable damper winding shall be provided on the rotor to permit increased asymmetrical electrical loading.1 SHEET 9 OF 42 1X 700 MW CCPP AT NEDUNOOR. 329 R5 .5960A-H-500-001 1.8. The bearings shall be of horizontally split construction and forced lubricated from turbine oil system. This shall be achieved by having two layers of insulation with a metallic plate in between.8. The bearing shells shall be lined with tin based babbitt metal.8. preferably of double flow ring type shall be fitted to the end-shields to prevent hydrogen leakage from generator housing.4 1. Non-hygroscopic insulation shall be provided between bearing and frame to prevent any damage due to circulation of shaft currents to the bearing surfaces and the lubricating oil. Shaft seals. To ensure effective sealing. SECTION: D3. Arrangement shall be provided to measure the insulation of the generator bearing with the machine in operation.7. Bearing The generator shall be provided with self-aligning type sleeve bearings either mounted on separate pedestals or on the end shields.3 1.8. NO.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.1 1. Provision shall be made for hydraulic jacking of the shaft during start up and turning gear operation. KARIMNAGAR DIST. TCE.

Carbon brushes for the measurement of the rotor winding temperature is also to be provided on the oil free surface similar to the carbon brush used for shaft voltage measurement 1. Brush holders shall be of constant pressure type.1. 329 R5 . The excitation system offered shall be of proven design and shall have a satisfactory field service record on machines of similar size and construction incorporating the type of excitation.12.12 1. 1. 1. The excitation system shall have matching characteristics suitable for satisfactory parallel operation with other generators in the plant.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. TCE.2 The hydrogen side seal oil housing shall be provided with oil baffle rings to prevent intrusion of seal oil into the generator along the rotor shaft. KARIMNAGAR DIST. Suitable insulation shall be provided to prevent passage of current through pressure device.5960A-H-500-001 gas pressure in the generator casing.2 ISSUE R0 35 TCE FORM NO.11 Brushes The rotor winding insulation and shaft voltage shall be monitored through a brush.10 1. The system shall be a brushless excitation system. The fans shall be shrunk on to their seats on the rotor shaft and locked against tangential or axial movement. The face of the sealing ring shall be lined with babbitt metal.1. Shaft grounding brushes shall be provided at the turbine end bearing pedestal.1 Excitation System Type A complete generator excitation and voltage regulating system shall be provided with the generator. Arrangement shall be made to measure the insulation of the shaft seals while the machine is in operation.12. which can be adjusted as per requirement.12.1 SHEET 10 OF 42 1X 700 MW CCPP AT NEDUNOOR. NO. SECTION: D3. 1.9. Fans Hydrogen shall be circulated in the generator in closed circuit by the axial fans located on rotor shaft. suitably mounted and sliding on an oil free surface. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC. It should be possible to increase the brush pressure while generator is working.1 1. Shaft seals and oil piping shall be suitably insulated to prevent circulation of shaft current.

5 meet the performance 1. 329 R5 .5 1.3 The various change over relays and other equipment.4 1.6 36 TCE FORM NO.12.2.1. The excitation system shall also be capable of supplying higher current to meet the short time duty mentioned above.2.1. SECTION: D3. the system shall be capable of restoring the voltage within 2% of the nominal preset value within negligible time.5 sec.12.12. The reference voltage set point shall be adjustable over a range of 70% of no load to 110% of the nominal rated voltage at MCR. The necessary inputs and interface equipment shall be provided with Generator Excitation and Automatic Voltage Regulator for hooking up with Turbine Automatic Run up system and Electro Hydraulic Governing System.1 1.12.2. KARIMNAGAR DIST. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC.1. The system shall have high initial response to improve steady state and dynamic stability of the generator.2 1.4 1.2 1.12.2.12. Each shall be equipped for auto operation with the facility for selecting either channel in Auto or Manual mode. ISSUE R0 1. power converters and controls. When the generator is subjected to a sudden loss of rated output at rated power factor. Performance Requirements The excitation system shall have two (2) 100% channels including independent AVR’s.5 % of the preset value over the entire load range of the machine.12.12.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. The system shall function without hunting and shall be capable of preventing any abnormal change or oscillation in the generator voltage. NO. The excitation system shall be rated to continuously carry current at least 20% above the rated generator field current at MCR output. TCE. The excitation system shall be capable of maintaining generator voltage within + 0.12.3 1.12.5960A-H-500-001 1.1 SHEET 11 OF 42 1X 700 MW CCPP AT NEDUNOOR. The excitation system shall also requirement specified hereinafter. which are not controlled by the control supply required by AVR shall be such that the loss of their control supply does not lead to the excitation system outage.2.2. The excitation system response time shall be less than 0.

12.5 percent of the setting value without hunting.3.1 1. Automatic Voltage Regulator Continuous acting.3 37 TCE FORM NO. In excitation system monitoring facilities with self-diagnostic features to indicate faulty cards and abnormalities shall be available. i.2.2 1.12.3. failure in the follow-up circuit.12.e. All rectifying elements shall have over voltage and short circuit protection. continuously acting. The nominal exciter response ratio shall not be less than 2.13 1. TCE. high speed. the field of the main exciter shall be transferred to the supply derived from the auxiliary 400V station supply. 329 R5 . ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC.12 1.3 1.2. NO.12. The automatic voltage regulating equipment shall control the generator voltage under steady state load conditions and over the whole of the operating range of the exciter within ± 0.2.12. The system shall be capable of supplying the field-forcing requirement for at least 10 seconds even for close-in faults on high voltage outgoing lines or bolted faults at generator terminals. This changeover shall be such that it does not result into the tripping of the generator. so as to limit the voltages across the rotor winding to a safe value. adjustable type ISSUE R0 1.11 1. KARIMNAGAR DIST.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.9 1.12. a) Maximum Excitation Limiter.5% with a 1sec time delay.5960A-H-500-001 1. In case of failure of the PMG.2.3. digital type and shall be complete with the following limiters.1 SHEET 12 OF 42 1X 700 MW CCPP AT NEDUNOOR.2. compensators etc. The excitation system shall have proper field suppression arrangement.2.12. The automatic voltage regulator shall be capable of working over the whole load and voltage range of the generator. An alarm shall be generated if the difference in the set point of the Auto-1 & Auto-2 is more than a ±0.12.7 The ceiling voltage shall not be less than 150% of the machine excitation voltage at MCR condition.8 1. The voltage regulator shall be automatic. high response. SECTION: D3.2. non dead-band type microprocessor based digital automatic voltage regulators with accessories mounted in a suitable panel shall be provided for the generator.12.10 1.12.12.

accept-reset-test push buttons.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. NO. KARIMNAGAR DIST.) f) Minimum Excitation Limiter g) Adaptive Power System Stabiliser (PSS shall be suitable for damping the various modes of electro-mechanical oscillations at all frequencies in the range of 0 to 3 Hz under varying generator loading and power system network configurations.) e) Load Angle Limiter (This shall enable to keep the angle between the direct axis of the machine and network vector within the set reference value as determined by stability.) h) Rotor Current Limiter (The regulator shall act with time delay. Automatic supervision and Blocking/Switch off facility along with indications.) i) Ramp generation circuit to enable gradual rise of reference signal applied to the comparator circuit to avoid sudden voltage build up shall be provided. The time delay in overexcited range shall enable a temporary overloading of the machine) c) Reactive Drop Compensator (Suitable feedback proportional to transformer drop shall be provided for compensation and the range of compensation shall be 0-15%) d) Over Fluxing (volts / hertz) Limiter (To limit the ratio of generator voltage and frequency at all operating conditions to such a value that the maximum generator transformer core flux density does not exceed the value specified. SECTION: D3. so that the regulation dynamics are not impaired in case of a fault. shall also be provided. sequence logic. 1. etc.12. 329 R5 . indicating lamps.3. by adjusting the excitation. TCE. control ISSUE R0 38 TCE FORM NO. PSS shall automatically adapt itself to varying operating conditions with features to compute optimum stabilising signal along with suitable scheme for identifying external reactance of the generator. j) The channel reference control shall be either solid state control or microprocessor control. Local AVR panel shall be complete with necessary facia windows. Facility for remote manual switch off-on along with indication shall be incorporated. power supplies. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC.5960A-H-500-001 b) Maximum Stator Current Limiter (The stator current limiter shall act immediately in under-excited range.1 SHEET 13 OF 42 1X 700 MW CCPP AT NEDUNOOR.4 All the above conditions of limiter operations shall be annunciated in local panel as well as in DCS.

ISSUE R0 39 TCE FORM NO. SECTION: D3. Automatic change over shall be possible from ‘Auto’ to ‘Manual’ in case of: 1. etc.3 1.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. the range of regulation shall be 70% of no-load to 110% full load excitation. a suitable arrangement shall be provided to follow up changes in ‘Auto’ mode along with follow up indication in Unit Control Panel.1 auxiliary relays and Auto / Manual Channels Two fully equipped independent automatic regulators with one acting as Master and the other as Slave shall be provided. Generator protection circuit operation i.12. 1. 329 R5 . 3. TCE.12. the Slave control.4. 5. 7. In auto mode.12. Either channel shall be capable of being selected as manual also.4. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC. 6. 2. In manual mode the range of regulation shall be 0 to 110% of nominal rated voltage.4 1.4. after field forcing and over excitation condition with a time delay Loss of terminal voltage feedback by way of any of the VT fuse blowing up Faulty over excitation condition Loss of automatic channel reference signal Power supply failure in the automatic channel Manual intervention Any other condition as considered necessary by the Bidder 1. On failure of the Master control.5960A-H-500-001 switches.1 SHEET 14 OF 42 1X 700 MW CCPP AT NEDUNOOR. programmable logic controllers. shall take over automatically. Automatic change over from Auto-1 to Auto-2 channel or vice versa shall be possible in case of trouble in the running channel. Either channel shall be capable of being the main or stand-by. local/remote switches. e. KARIMNAGAR DIST.2 1.12.4. An alarm and visual indication shall be provided to indicate change over from Auto channel-1 to Auto channel-2 or from ‘Auto’ to ‘Manual’.12. which follows the Master control. NO. 4.4 In order to avoid a sudden change in generator voltage when voltage regulation is transferred from ‘Main’ to ‘Standby’ or from ‘Auto’ to ‘Manual’.

A center zero balance indicator to indicate the channel difference signal Generator field current indicator Rotor winding temperature recorder Auto Channel-1 to Auto Channel-2 & Auto/Manual changeover indications Generator field breaker/exciter field breaker control & instrumentation PSS control and instrumentation Auto and manual channel control of excitation level Speed set point control 1. A negative sequence component filter to permit response only to the positive sequence component of the regulated voltage shall be provided. Further.7 1.1 Brushless Excitation System The complete equipment shall be mounted on a bed plate and enclosed by suitable enclosure. Inter-connecting cables between different components of the system ISSUE R0 1.5960A-H-500-001 1. 6. 3.4. At least. The system shall consist of : 1. 3. the following instruments and control devices suitably clubbed on a plate/console shall be supplied for being mounted on unit control panel.5 The maximum change in generator voltage when AVR is transferred from Auto to Manual under all conditions of excitation shall be less than 0. SECTION: D3. TCE.12. 4. 2. 5. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC.6 1. it shall be possible to exchange information with DCS through suitable protocol.5 1. 4. KARIMNAGAR DIST.12. 7. 2.6 Pilot Exciter 40 TCE FORM NO. 329 R5 .12. NO.12.5%. 5.12. Rectifier Unit for PMG Brushless Main Exciter Rotating Rectifier Unit Regulator Cubicle Complete instrumentation and protection system.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.12.5.4.1 SHEET 15 OF 42 1X 700 MW CCPP AT NEDUNOOR. 8. 7. Permanent Magnet Generator (PMG) type Pilot Exciter.4. 1. 6.

ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC. Rectifier Unit for PMG Fully controlled three phase. The rotor shall be magnetized and stabilised by the Manufacturer to give stable magnetisation characteristic during operation. Suitable lamp indication shall also be provided to indicate the defective ‘thyristor’. KARIMNAGAR DIST. 329 R5 . self ventilated.12.5960A-H-500-001 1. NO.8.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.7 1.1 The pilot exciter shall be revolving field. The armature conductor in the overhang portion shall be adequately held to withstand the electro-dynamic forces during field forcing condition. SECTION: D3.8 1. They shall be suitable to ensure trouble free service of the cells under all fault conditions.12.1 SHEET 16 OF 42 1X 700 MW CCPP AT NEDUNOOR.12. salient pole. The stator winding shall be of class ‘F’ insulation or better but its temperature rise shall be limited to Class-B. The thyristors shall be selectively protected against short circuits by ultra high speed fuses.12. star connected. full wave bridge type thyristor converter facilitating fast and high ceiling performance shall be provided. The armature shall be stationary 3 phases feeding current to the static rectifier assembly and excitation control equipment. The exciter shall be totally enclosed.2 1.12.3 1.9 41 TCE FORM NO. The converter shall have redundant thyristors for satisfactory operation even in the event of failure of any of the thyristors.7.12. Rotating Rectifier Assembly ISSUE R0 1. permanent magnet high frequency type. TCE. The stator and rotor winding insulation shall be of class ‘F’ with the temperature rise limited to class B limits of IEC 60034.2 1. Brushless Main Exciter The rotating armature shall be 3-phase.12. The armature core shall be made from silicon sheet lamination to reduce eddy losses and shall be suitably varnished on both sides. frame supported on the generator foundation having journal bearings.8.8. Rotor end winding retaining ring shall be made up of stress corrosion resistant material.6. Integrally mounted air fan shall be provided for the cooling of the exciter.12. suitable for operation at 500C ambient temperature.6.12. The machine shall be fitted with fans for self-ventilation.1 1. feeding current to the rotating diodes mounted on the exciter shaft.1 1.

the generator and exciter can be tested individually. The rectifier assembly made of silicon diodes shall be arranged as two distinct rings with opposite polarity diodes on respective rings. but not be limited to the following: i) Suitable duplex RTDs for measuring hot and cold air temperature of exciter with necessary provisions for protection tripping/interlocks.5960A-H-500-001 1. 5. sheet metal enclosed with swing doors and ventilating louvers with wire gauge shall be furnished for the excitation and voltage regulating equipment. The diodes shall be connected in a conventional threearm full wave rectifier bridge.12. KARIMNAGAR DIST. SECTION: D3. Rectifier assembly shall have one complete bridge as redundant. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC.9.1 SHEET 17 OF 42 1X 700 MW CCPP AT NEDUNOOR. 4.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. 1. 3. The axial copper connector shall be designed such that it shall be possible to disconnect this connector at the point where the exciter shaft couples to the generator so that. Natural ventilation shall be provided for the cooling of excitation cubicles. Each diode shall be provided with a fuse together with visual indication in the event of diode failure. The output from the rectifier shall be fed to the generator field through the bore of the rotor shaft and necessary plug in type of shaft connection. Rectifier assembly shall have same requirements as regards the component features and rating as detailed out for the thyristor assembly. 1. ISSUE R0 42 TCE FORM NO.12.1 The rotating rectifier assembly shall have the following essential features : 1. NO. Diodes shall be cooled by forced air circulation by means of fans mounted on the main exciter. if necessary. 329 R5 . 2. TCE. Alternatively a single three phase rectifier bridge having at least one redundant parallel rectifier branch in each of the six arms of the bridge may also be considered.12.11 Instrumentation The instrumentation for excitation system shall generally include.10 Regulator Cubicle Self-supporting.

The major system components are H2 and CO2 gas manifolds. carbon-dioxide scavenging system and compressed air supply system. 1. air is first displaced by CO2. vi) For all alarms in the system. For removing CO2. inter-connecting pipings.5960A-H-500-001 ii) Instruments and devices for the measurement of rotor winding temperature. v) A pair of auxiliary slip rings shall be provided to give access to the rotor circuit allowing an earth fault detector circuit to be connected.13 1. The system shall be provided with transmitters for the above indicators.1. For filling. gauges.1 Hydrogen Cooling System System Requirements The hydrogen gas cooling system comprises a hydrogen circuit for cooling the stator core. contacts shall be taken from the temperature switches.13. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC. iv) Suitable arrangement for exciter field suppression.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. SECTION: D3. provided at suitable points. The design has to be such as to ensure safe filling / emptying by preventing formation of explosive H2 – air mixture. valves. thermometers.1. CO2 heating system. iii) Stroboscope or suitable alternative device for detection of faulty rotating diode element.1 SHEET 18 OF 42 1X 700 MW CCPP AT NEDUNOOR. ISSUE R0 1. maintain it under pressure.13. lead terminal bushings and rotor windings. etc.3 43 TCE FORM NO. While emptying H2 is first displaced by CO2 before admission of air in the machine in order to obviate possibility of any explosion. 329 R5 . NO. Annunciation and electrical instruments shall be located in a separate electric panel common with seal oil system outside the hazardous area.2 1. The system is required to fill the generator with hydrogen. H2 gas coolers. TCE. monitor and control gas purity and to empty the hydrogen from generator.1. hydrogen pressure regulator. H2 drying equipment. control & monitoring panel.1 1. pressure transmitters and other instrumentations. KARIMNAGAR DIST. stator winding. which in turn is replaced by H2.13. instrument quality air supply shall be used. Also the system shall permit emptying of the generator casing with help of CO2 purging. fittings.13.

if any.13. TCE. Corrosion resistant tubes with integral fins shall be provided and arranged in the stator casing so as to avoid the direct fall of water during leakage. H2 gas is cooled by water/gas heat exchangers located in the generator housing. Water pressure in the coolers shall be maintained below the operating hydrogen pressure in the generator casing. Intermediate valves shall allow replacement of individual cylinders during operation.7 1.1. The system shall be complete with necessary pressure. temperature and flow gauges as well as thermostats as required.5 1. Gauge pressure on the gas side irrespective of a lower normal operating casing pressure.13. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC.1.13.1.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.5960A-H-500-001 1. The hydrogen coolers shall be provided with 10% excess tubes.6 1. ISSUE R0 44 TCE FORM NO. KARIMNAGAR DIST. 1.13.1.1.8 1. 2x100% capacity H2 dryers with in-situ reactivation facility shall be provided to maintain the H2 inside the machine dry with 0O C dew point at operating pressure. The generator drying arrangement complete with all electrical/mechanical drives/equipment.1. Cooler shall be designed for at least 10 Kg/sq.9 1.13. The coolers shall be of sectionalised design such that with one cooler section out of service & 10% of the tubes in other sections are plugged. the unit can deliver at least 80% of the rated load continuously without exceeding the permissible temperature limits of class B. Hydrogen shall be circulated in the generator in closed circuit by fan fitted on the rotor shaft. The distributor shall be capable of connecting H2 cylinders to meet at least one shutdown & one start up of all the units & 30 days of normal operating requirement.13.4 Hydrogen supply of 97-99% purity shall be obtained from H2 cylinders on rack through H2 distributor.1 SHEET 19 OF 42 1X 700 MW CCPP AT NEDUNOOR.1.10 A certain quantity of H2 circulating in the generator shall be bypassed through gas drier for removing the moisture and maintaining the gas in dry condition. NO. It shall be possible to clean/plug the cooler tubes of a section with the machine under operation.13. The high pressure H2 gas from the distribution header shall be provided with 2x100% pressure reducing valves. accessories and controls to enable drying out operation of the generator with hot air circulation shall be provided. SECTION: D3. on the winding insulation. This shall be further reduced to generator pressure requirements by means of 2x100% pressure reducing circuit. 329 R5 . cm.

1.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. 1.13.13.2 Instrumentation ISSUE R0 45 TCE FORM NO. For controlling the time/regime of reactivation. A suitable hot air blowing system complete with blower. NO. heater and thermostatic control etc. The three way valves used along with the drier for interconnecting the hydrogen and airline (as applicable) shall preferably have mechanical interlocking such that closing of the hydrogen side port is positively ensured before opening of the air side port.15 Seamless steel tubes shall be used for valve piping.13. 329 R5 . The arrangement of CO2 distributor shall correspond to that of H2 distributor. 1. 1. timers etc. with a local control panel shall be provided. The CO2 shall leave the cylinder in liquid state and shall be evaporated and expanded in a vaporiser. Arrangement for purging out entrapped air from the drier after regeneration shall also be provided. Glass indicator shall be provided to indicate humidity.12 The design of the drier shall be such that it is possible to reactivate the drying medium in-situ after isolation from the generator casing and connecting it to atmosphere.13. thermostats.13 On line dew point monitoring system shall be provided across the inlet and outlet lines to the drying system along with alarm/annunciation in case of high moisture content in the generator casing hydrogen.1. TCE. Thermostat controlled electrical heating system shall be provided for CO2 system so that the freezing of CO2 pipe is prevented. wherever possible.13. suitable thermometers. piping valves and accessories along with required control equipment shall be provided.1.1. A manually operated vent valve shall be provided for discharging casing hydrogen to atmosphere (outside the TG hall) in case of emergency. as applicable.1. 1. Safety relief valves shall be furnished at hydrogen manifold both on low and high pressure sides of the gas system. SECTION: D3. shall be provided to prevent condensation during long shut down. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC. Valves shall be glandless diaphragm type.5960A-H-500-001 The arrangement shall be such that one drier can be taken out of service for reactivation without affecting the system performance in any way.1 SHEET 20 OF 42 1X 700 MW CCPP AT NEDUNOOR.14 The cylinders of CO2 shall ensure complete emptying of the cylinders as well as to avoid evaporation of liquid CO2 to gas in cylinder itself.1. 1. The valves in gas system shall be of special design to minimise gas leakage. KARIMNAGAR DIST.11 To run the gas system for short time during shut down of generator (at standstill) for which gas circulation arrangement through drier with blower.13.

b) % of Hydrogen in CO2 leaving the casing when Hydrogen is being admitted or expelled. air pressure in the air supply manifold and dew point level indicator for casing H2 across drier inlet and outlet lines.1 SHEET 21 OF 42 1X 700 MW CCPP AT NEDUNOOR. etc. H2 gas purity.2 1.13. fan differential pressure.1 To ensure efficient and reliable operation of the generator gas system adequate instrumentation shall be provided.1 Annunciation The following annunciation shall be provided on the local electric panel and DCS. The local control and annunciation panel shall be complete with switches.3 1. 329 R5 . SECTION: D3.13. accept-reset-test push buttons. NO. The local H2 panels shall include indicators for H2 gas cylinder pressure. indicators. power supply. pressure and liquid level detector switches for alarm and interlock. TCE. gas manifold. c) % of air in CO2 leaving the casing when CO2 is being admitted or expelled. KARIMNAGAR DIST. H2 gas manifold pressure.13. facia annunciation.2. Pressure gauges for gas cylinders.5960A-H-500-001 1. The analyser shall measure the gas purity under the following three conditions: a) Normal % of purity of Hydrogen in air in the generator casing. H2 pressure and purity shall be monitored in DCS. CO2 pressure in the manifold. The Contractor shall provide instrument for on line monitoring of moisture content in hydrogen inside generator casing. Portable gas analyser as detailed above shall be provided for supervision of the gas purging operation.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. Gas Analyser shall be of thermal conductivity type and shall continuously analyse the gas discharged from the casing during purging and shall also analyse samples of the casing hydrogen during normal operation.13. This shall include the following as a minimum: Dial type thermometers for CO2 vaporiser. generator casing pressure. hooter. lamps. generator casings. Necessary sensors/transmitters for remote indication and recording in DCS. and gas drier. CO2 pressure inside generator.2. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC. ISSUE R0 46 TCE FORM NO. Required number of temperature.3. Purity range shall include a low purity alarm. H2 gas temperature (for hot and cold H2 inside casing). 1. gas flow meter.

1 SHEET 22 OF 42 1X 700 MW CCPP AT NEDUNOOR.5960A-H-500-001 H2 Pressure in Generator Casing H2 Pressure in Cylinders H2 Pressure in Manifold Purity of H2 in Generator Casing : : : : High / Low Low Low Low High Low / High High High High Failure Temp of Cold/Hot Gas in the Generator : Pressure of Cooling Water of H2 : Coolers Dew Point Level in H2 Gas across the : drier inlet & outlet lines H2 Leakage into Cooling Water Liquid Level in Generator Casing Power / Control Supply 1.13. TCE.4 1.2 1. The cylinders to be supplied under this specification shall conform to IS:8198. H2 and CO2 Cylinders The number of H2 and CO2 cylinders shall be equal to total requirement for one start up and one shut down of a unit plus those required to be connected on manifolds of all units plus total requirements for seven days consumption of all units. shall be connected to DCS system.13.13. The Contractor shall also furnish the necessary test certificates and filling certificates.4.3 47 TCE FORM NO.0 litres. Each gas cylinder shall be complete with cap and valve as per IS:3224.3.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. ISSUE R0 1. Each cylinder shall be hydro tested at pressure of 250 kg/cm² (min. SECTION: D3. 329 R5 . ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC. Getting necessary approval from chief controller of explosives is in the scope of the Contractor. All instruments shall be mounted on a gas control cubicle to be located near the machine. KARIMNAGAR DIST. The Contractor shall supply H2 and CO2 gas till completion of trial operation.13. NO.2 : : : Independent signals. analog and digital.4.4.). Volumetric (water) capacity of each cylinder shall be 45.13.1 1.

5 1. filters.1. The pressure regulator or the regulating valve used for the purpose shall be adjustable type.1. TCE. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC. Piping and valve arrangement shall be such that any cooler/filter can be taken out for cleaning and maintenance without affecting the operation of the system. A shaft seal oil system shall be provided to prevent the leakage of hydrogen from the generator casing. The oil pressure in the coolers shall be greater than water pressure under all operating conditions.1.4 1. SECTION: D3.6 1.1. gauges. Seal oil system shall have connection to turbine oil system ISSUE R0 1.14.14 1.5960A-H-500-001 1.1.14.7 48 TCE FORM NO.1 SHEET 23 OF 42 1X 700 MW CCPP AT NEDUNOOR. The seal oil system shall be so designed that it is possible to run the machine at no load in air medium at a slightly positive air pressure without any modification in the system. pressure regulators.1. 329 R5 . thermometers and other instruments.1. regulating and control valves.14. Seal oil coolers shall be designed to have 15% excess tube surface area over and above designed tube surface area required for the rated load conditions while maintaining the design pressure drop on cooling water side. KARIMNAGAR DIST.3 1. oil tanks.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. NO. de-gassification tanks. A diaphragm operated regulating valve in the seal oil supply line shall control the seal oil pressure by a constant amount.1 Generator Shaft Seal Oil System System Requirements A complete seal oil supply and control system including AC and DC motor operated pump sets.14. interconnecting piping including hangers and supports. valves and control/annunciation panel complete with all interlocking relays shall be provided.1 1.14. These coolers shall be shell and tube type suitable for using DM water of condensate quality. coolers.14.14. The differential pressure shall be kept constant once set at the time of commissioning. The seal oil.2 1. Seamless steel piping shall be used in the system. The seal oil shall be cooled in two (2) 100% capacity water cooled heat exchangers along with necessary 3 way valves for isolating or bringing one cooler in service. at all hydrogen pressures and all regimes of generator operation. 2x100% capacity filters shall be provided.14. when maintained at a pressure suitably in excess of the hydrogen gas pressure in the generator casing shall provide an effective gas seal and shall lubricate and cool the seals when the generator is running.

2x100% capacity motor driven AC pumps shall be provided of which one pump shall always be in operation.14.14. On of the seal oil pumps shall be fed from the emergency DG bus. 2 x 100% Blowers for venting out Hydrogen gas liberated from oil shall be provided suitably mounted at places where such gas accumulation is likely to occur. the standby pump shall automatically take over the supply. unit may be tripped and seal oil supply for such coasting down period shall be from a suitable arrangement from lubrication oil system or a damper tank.10 The seals shall be designed so that minimum oil enters the hydrogen side of the machine and the oil drained from this part of the machine passes to a suitable hydrogen detraining tank.8 For the seal oil system.1. The seal oil system shall thus be selfcontained. NO. Upon failure of the normal service pump due to a mechanical or electrical fault.1 SHEET 24 OF 42 1X 700 MW CCPP AT NEDUNOOR. the seal oil supply shall be taken over by the emergency DC seal oil pump without any interruption.1. 1.5960A-H-500-001 for make up and also excess return and also shall serve as 100% back up. KARIMNAGAR DIST. SECTION: D3. 1.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. The auto starting of standby seal oil pumps shall be interlocked with seal oil pressure. Also H2 diffusion loss through seal oil shall be minimum to maintain H2 purity level inside generator at a high level.1. which may arise due to non availability of both AC & DC pumps. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC.9 1. During short time emergency. 329 R5 . The hydrogen dilution blower shall have the following features: HYDROGEN DILUTION BLOWER Type Capacity Air intake filter type Suction pressure Discharge pressure m3/hr Bar Bar Centrifugal/Twin lobes By bidder Simplex / Duplex type Atmospheric pressure By bidder ISSUE R0 49 TCE FORM NO. TCE. Upon the failure of both AC driven pumps.14.

ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.14. 1.1 SHEET 25 OF 42 1X 700 MW CCPP AT NEDUNOOR. KARIMNAGAR DIST. 400V. SECTION: D3.14. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC.1.5 meter distance Base Plate Prime mover details Silencer Noise level Pressure drop across the lobes Performance test dB(A) mmWc By Bidder Shall be conducted as per standard 1. 50 Hz & 3φ Shall be provided (If applicable) 85 @ 1. IS:2062 Gr.5960A-H-500-001 Mounting type - Skid mounted MATERIAL OF CONSTRUCTION Impeller/Lobes Shaft Casing AISI Type SS 316 AISI Type SS 410 (Duplex SS) AISI Type SS 316/ AISI Type SS 304/ 2% Nickel Cast Iron. 329 R5 . 1.B with epoxy coated.13 The oil which is used for the hydrogen sealing shall be same as the lubricating oil for the turbine & generator bearing & governing system. NO.14.1.14.1. TCE. 1.12 A water detector with sight glass and drain valves shall be mounted adjacent to the gas manifolds at the end of a pipe connected to the bottom of the generator casing.11 Necessary hydraulic sealing arrangement shall be provided in H2 side oil discharge line to prevent circulation of gas due to any possible difference of heads developed by fans mounted at the end of the generator.2 Instrumentation ISSUE R0 50 TCE FORM NO.

Seal Oil Tank Level Seal Oil Temperature Pressure of Seal Oil Pressure of Thrust Oil Seal Oil Pressure H2 : High / Low / Very Low : High : Low : Low 1.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. KARIMNAGAR DIST.3 1. at inlet and outlet of pressure regulators and filters. iii) Seal oil tank level indicator and flow meters for flow through seals. SECTION: D3. NO. hydrogen-casing pressure.2. seal oil temperature at the seals and status indications for seal oil pumps.14. 1.14. The remote instrumentation at Unit Control Room shall include seal oil temperature recording and seal oil / H2 differential pressure recording in DCS.1 Differential : High / Low : Low ISSUE R0 Oil Level in Damper Tank (if applicable) 51 TCE FORM NO.14. seal oil inlet to hydrogen and airside seals. pressure and level gauges for alarms and interlocks.3 1.1 SHEET 26 OF 42 1X 700 MW CCPP AT NEDUNOOR.5960A-H-500-001 1.14.2. seal oil flow. 329 R5 . iv) Required numbers of temperature.2 Local seal oil control panels shall be provided with indicators for pump discharge pressure.3. seal oil pressure at the seals (for both hydrogen and air side streams).1 To ensure efficient and reliable operation of the seal oil system adequate instrumentation shall be provided. Annunciation The following annunciations shall be provided on the local electric panel and in DCS system.14. at outlet of coolers. across each strainer and H2 seal oil differential pressure and at oil supply header. Necessary sensors / transmitters for remote indication and recording in DCS. hydrogen / seal oil differential pressure. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC. thrust oil pressure.2. TCE. This will include the following as a minimum: i) ii) Dial type thermometers for inlet and outlet temperature of the seal oil and cooling water to each cooler. Pressure gauges at inlet and outlet of pumps.

14. The Bidder shall indicate and provide devices to detect.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.2 One (1) number primary water tank shall be provided and mounted on the stator frame on anti-vibration pads and covered by the generator cladding. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC. monitor and release the ISSUE R0 52 TCE FORM NO. The system shall generally include but not be limited to the following: 1.1.15 1. separate alarm contacts shall be provided. The empty space in primary water tank may be filled with Nitrogen to minimise water evaporation. Stator Water Cooling System System Requirements 1. SECTION: D3.15.1 Generator stator winding shall be cooled by water.3. Water cooling shall be with a closed loop cooling system.5960A-H-500-001 Oil Level in Damper Tank – : Very Low Emergency (if applicable) Oil Level in Hydraulic Seal Oil Level in Hydraulic Seal Seal Oil Filter Seal Oil Pump Standby Seal Oil Pump DC Seal Oil Pump : High : Low : Choked : Failure : Running : Running AC Seal Oil Motor Power : Failure Supply DC Seal Oil Motor Power : Failure Supply Power / Control Supply Seal Oil Pressure Cooler : Failure Water : High / Low Water : High / Low Seal Oil Cooler Temperature. analog and digital shall be made available for connection to DCS system. trap. Independent signals.15.1 1. NO. For this purpose.15. TCE. 1. KARIMNAGAR DIST.2 All annunciations shall be duplicated in the Unit Control Room.1. 329 R5 .1 SHEET 27 OF 42 1X 700 MW CCPP AT NEDUNOOR.

Standby pump shall cut in automatically in case the working pump fails or the pressure of circulating water drops below a certain preset value. The exchanger shall be designed to have 10% excess tube surface area over and above the designed surface area required for the rated load condition while maintaining the design pressure drop on cooling water side.15.1.5960A-H-500-001 hydrogen that leaks into the stator water cooling system. 1. KARIMNAGAR DIST. The permanent magnet bars shall be protected by sleeves of stainless steel.3 The make-up water for primary water system shall be tapped off from condensate extraction pump discharge header (before and after the condensate polisher) and from DM water make-up line to the condenser. The system shall be so designed that the pressure of primary DM water inside the cooler is always greater than that of secondary DM water (condensate quality).5 Two (2) 100% capacity fine wire mesh filters with magnet bars of unlimited life shall be provided for removal of all magnetic particles. The water-to-water heat exchanger shall be designed to accept secondary DM water (condensate quality). The system shall be designed such that the MBD could be taken out of service for refilling without untoward effect on the system which could necessitate load reduction/rejection. NO.1. The level in the tank shall be maintained by means of suitable valves in the make up line.15. 1.8 Alkaliser unit shall be provided alongwith stator water required for ensuring a corrosion free operation system. 1.15.15.15. 1.6 Two (2) 100% capacity AC motor driven cooling water circulating pumps shall be provided. 1. It shall be possible to clean easily the ferromagnetic particles adhering to the magnet bars during capital maintenance. TCE. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC.2 Control System ISSUE R0 53 TCE FORM NO.15. The Bidder shall indicate in the proposal the capacity of MBD necessary to maintain the quality water at the desired level for time duration of six months or more.1.4 Two (2) 100% capacity water to water heat exchangers shall be provided. 329 R5 . 1.15.1. 1.1.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.1.1 SHEET 28 OF 42 1X 700 MW CCPP AT NEDUNOOR. The MBD shall remain continuously in service in order to retain high purity of stator cooling water with its associated electrical resistivity. SECTION: D3. to a safe place outside the building through suitable safety valves.7 One (1) mixed bed demineraliser (MBD) of adequate capacity shall be provided to maintain the required quality of water.

Indicators for primary water temperature at the inlet and outlet of stator winding. 4. 2. 3. Vapour filled temperature detectors shall also be provided to give signals for high temperatures.2.15. 1. Set of dial type thermometers for cooling water at the inlet and outlet of the cooler.3. Set of conductivity meters in the main water circuit and after the demineraliser. SECTION: D3. transmitters. Indicator for stator winding differential pressure.1 The following instruments shall be provided on the local panel : 1. Set of resistance temperature detectors/indicators for primary water before and after the generator winding. 3.3 Instrumentation 1. level switches for high and low level alarms and other accessories for primary water tank. TCE. 329 R5 . 6.) to monitor the low distillate condition and flow transmitters/meters for primary water to stator winding and main bushing.1 The following minimum instrumentation shall be provided : 1. make up water etc.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. Sets of pressure gauges at the inlet and outlet of stator water filters.15. Indicator for primary water pressure at the inlet of stator winding 1. 5. Water gauge.15.5960A-H-500-001 1. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC. Indicators for primary water conductivity at the inlet of winding and after the demineraliser.1 SHEET 29 OF 42 1X 700 MW CCPP AT NEDUNOOR.15. 4. differential pressure gauge across stator winding and pressure transmitters as required. KARIMNAGAR DIST. 5. bushing and cooler. NO. 2. Indicator for primary water flow in the stator winding.4 Annunciations The following minimum annunciations along with duplicate contacts for use in DCS shall be provided: ISSUE R0 54 TCE FORM NO. Set of flow switches (at least two nos. differential pressure switches for the filters.

10. 3. TCE. of primary cooling water at outlet of stator wdg. of primary cooling water at inlet of stator wdg.high. Differential pressure across stator winding . and shall be possible to exchange information with DCS through suitable protocols. 16. 329 R5 . Pressure of primary cooling water at the inlet of winding low. Water level in the primary water tank . 7. if the manufacturer recommends continuous monitoring of dissolved oxygen content in the stator water. to prevent copper corrosion. 12. Reserve control supply for stator water cooling .15. Flow of primary cooling water to the stator winding . Water level in the primary water tank . 11. 9. On-line oxygen monitoring system shall be provided. 13.high.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. 4.low.high. high. ISSUE R0 1. 14. Conductivity of primary cooling water at the winding outlet . 2.low. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC. NO. 15.5960A-H-500-001 1. 6.6 55 TCE FORM NO. header water flows. pressure etc.high Temp. SECTION: D3. Flow of primary cooling water to the stator winding . Any other critical parameter to be annunciated A “summary annunciation” for the above shall be provided on the unit control panel 1.failed. Differential pressure across the primary water strainer high.high Primary stator bar water temperature . Leakage of hydrogen into primary water . 8. KARIMNAGAR DIST. high. 5.tripped on overload. Temp.5 On line stator water temperature monitoring system for individual stator winding bars shall be complete with all software and hardware required to detect any abnormalities in the temperature at any given generator operating point and shall be sensitive to generator loads.1 SHEET 30 OF 42 1X 700 MW CCPP AT NEDUNOOR.15. Conductivity of primary cooling water at the winding inlet high. Stator water cooling pumps .very low.

1 SHEET 31 OF 42 1X 700 MW CCPP AT NEDUNOOR. generator temperatures and vibration parameters.2 1.17.16. 329 R5 . The panels for DC Motor starters shall house stainless steel starting resistors.17. etc.17.17. Measurement / Alarms in Control Room Each alarm shall be individually available on the DCS HMI whereas set of alarms can be grouped into a group alarm on the window of Local Control Panel. (b) Automatic Voltage Regulator (c) Hydrogen Cooling System (d) Seal Oil System (e) Stator Water Cooling System. clearly displayed on DCS.3 1. lube oil.1 1. process/flow diagrams such as seal oil. tag numbers. Stator coolant flow recorder shall be monitored in DCS. 1. They shall also have limiting values for alarm/trips.1 1. NO.5960A-H-500-001 1. All inputs including logics for recommended control and instrumentation system required to integrate with artificial intelligence based software’s pertaining to generator and its auxiliary system shall be furnished.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.16 1. floor-mounted type. SECTION: D3. The turbine generator control VDU in the central control room shall have graphical display of various generator subsystems. All the required relays / contacts / devices shall be provided to achieve the same.16. hydrogen.8 1.5960A-EL-SK-2002 shall be made available in DCS and also in Local Control Panel. TCE. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC. The continuous measurement of the rotor winding temperature while the machine is running shall be provided in DCS.4 ISSUE R0 56 TCE FORM NO. In addition operator help features for control of these systems and historical and reference data shall also be made available for efficient operator guidance of these systems. All the measurements shown in the protection and metering one line diagram TCE. The panels shall be of the self-supporting. generator stator and rotor parameters along with display of generator capability curves and operating points.15.2 1. KARIMNAGAR DIST.15.7 Liquid leakage detector shall be provided at all the low level points inside the generator casing including end shields along with provisions of indication and alarm during leakage of liquid in generator.17 1. Cubicle and Motor Starters Cubicles shall be furnished as required for (a) Excitation System. etc. (f) DC Motor Starters.

synchronising are indicated in I&C System Section No.18.18 1. TCE. Additional thyristors in converter / inverter units to take care of thyristor failure. 1. Permanently connected Independent sensing unit for each generator shall be provided.4 1.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. CTs. The voltage to frequency ratio of the start-up system output shall be maintained constant throughout the start-up and shall not lead to overfluxing condition of generator transformer and neutral grounding transformer. Both these signals shall be suitably supervised and annunciated.4. SECTION: D3. and cut off the start-up system in the event of operation of these protections.3 1. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC. 329 R5 . Over fluxing shall be limited to 110%. Static start-up system for gas turbine unit complete in all respects shall be offered. D2. However evaluation unit for all generators shall be common.6 1. measurement.18. It shall also be suitably connected to DCS.2 1.18. KARIMNAGAR DIST.5 On line partial discharge measurement system. etc.18.1 Gas Turbine Generator Unit Start-Up System 2 nos.18. Also.5 1. The current transformers (CTs) in the busduct and voltage transformers (VTs) shall not temporarily or permanently saturate even after successive starts through the start-up system. VTs. Minimum electrical system requirements in respect of control.19 Tests ISSUE R0 57 TCE FORM NO. 1.. NO. Latest software shall be provided to interpret the PD result. the Contractor shall provide suitable blocking and de-blocking signals from the start-up system. To this extent the Contractor shall provide suitable protections on the start-up system output to protect the generator.5960A-H-500-001 1.17. annunciation.1 SHEET 32 OF 42 1X 700 MW CCPP AT NEDUNOOR. The Contractor shall note that all the protection shall be set for normal operation of the plant and the settings will not be altered during start-up. In case any of the protections are to be blocked during start-up operation due to likelihood of mal-operation. redundancy for critical items and self monitoring features. the protections shall not mal-operate during gas turbine starting.18. monitoring.

NO. AC High Voltage Test on Stator and Rotor Winding Measurement of Rotor Winding Impedance at standstill and at various speeds upto 3000rpm. Measurement of bearing leakage current / shaft voltage. also the measurement of the capacitance between the complete winding and the body. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC.1 Tests on Generator The following Routine Tests shall be carried out at works on each generator: i) Measurement of insulation resistance of the following before and after high voltage test: a) Stator Winding Insulation b) Rotor Winding Insulation c) ii) iii) iv) Embedded Resistance Temperature Detectors d) Bearing Pedestal Insulation Polarisation Index for Stator Winding Insulation. SECTION: D3. Overspeed Test Mechanical Run and measurement of Vibrations ISSUE R0 xiii) xiv) xv) 58 TCE FORM NO. Measurement of phase to neutral and phase to phase capacitance of all the three phases of the stator and the rotor and calculation of the equivalent generator capacitance as viewed from the generator terminals. short circuit characteristics and calculation of short circuit ratio. Measurement of the DC resistance of the following: a) Stator Winding b) Rotor Winding c) v) vi) vii) viii) ix) x) xi) xii) Embedded Resistance Temperature Detectors Determination of generator open circuit characteristics.19. 80% and 60% load. TCE.19. Tan-delta measurement of Stator Winding Insulation. Measurement of Core Losses Measurement of Mechanical Losses Determination of generator efficiency by the separation of losses at 100%.1 1.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.1 SHEET 33 OF 42 1X 700 MW CCPP AT NEDUNOOR. 329 R5 .1. KARIMNAGAR DIST.5960A-H-500-001 1. Stator Phase Sequence checking.

Open circuit and short circuit tests. 1. Line charging capacity Short Circuit tests on the generator end and the generator transformer HV end to check the stability and operation of the generator and the overall (i.) ISSUE R0 59 TCE FORM NO. Any other test considered necessary by the bidder shall also be carried out : i) Measurement of insulation resistance of the stator and the rotor windings to the frame and between phases. SECTION: D3. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC.1. KARIMNAGAR DIST. Measurement of the insulation resistance of bearings Capacitance measurement and dissipation factor between the winding and body. Hydrogen leakage test Vibration test Overspeed test Hydraulic tests on coolers Bearing and shaft current test ii) iii) iv) v) vi) vii) viii) ix) x) xi) xii) xiii) xiv) 1. Performance capability of the machine.1 SHEET 34 OF 42 1X 700 MW CCPP AT NEDUNOOR. The tests shall be carried out keeping all conditions/parameters as close as possible to site conditions with all the built in instrumentation (like RTD etc. These tests will be carried out jointly with the commissioning engineers of other vendors whose equipment are under test. TCE. NO. generator transformer and unit auxiliary transformers) differential protections and negative phase sequence protection.5960A-H-500-001 xvi) Retardation test to establish GD2 xvii) Hydrogen leakage test xviii) Partial discharge tests on stator windings. and measurement of polarisation index.e. Measurement of the DC resistance of all windings and embedded temperature detectors. Measurement of temperature rise at the rated load.2 The field tests to be conducted on each generator at the site shall include but not be limited to those listed below.3 One generator of each type and rating shall be assembled at works and shall be tested to verify/ensure design and workmanship in accordance with IEC-60034/VDE-0539/IEEE-43. generator.1. after drying out the machine.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. 329 R5 .19.19.

with hammer test.19. Determination of negative sequence and zero sequence impedance.2. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC. c) Sudden short circuit conditions.1 SHEET 35 OF 42 1X 700 MW CCPP AT NEDUNOOR.2 Tests on Exciter and AVR ii) iii) iv) v) 1. The test results of above shall prove that the values are within the normal operating limits for long satisfactory performance and that there are no components or parts.1 The following Routine Tests shall be carried out at works on each exciter and AVR: a) Pilot Exciter (PMG) i) ii) Measurement of output voltage at rated speed Checking of phase sequence and measurement of frequency ISSUE R0 60 TCE FORM NO. 1. Determination of Telephone Influence Factor and Total Harmonic Distortion of the voltage waveform.5960A-H-500-001 suitably wired and the readings recorded. NO. 329 R5 . The tests to be carried out under the contract shall include the following : i) Instantaneous short circuit test shall be carried out to determine transient and sub-transient reactance parameters and to ensure stability of winding during sudden short circuit condition. Recording of bearing and seal oil running conditions and environmental conditions (like temperature etc. Short circuit heat run test at rated pressure and cooling parameters with one cooler out of circuit at two third of rated stator current.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. KARIMNAGAR DIST. Vibration measurement on all planes on stator overhang winding at minimum six (6) locations on each end and at other critical locations for the following conditions : a) Open circuit operation. During various tests bearing. TCE. b) Short circuit operation. shaft overhang vibrations shall also be measured with and without excitation.19. d) Stand still condition. SECTION: D3. which have natural frequency of resonance near operating frequencies or 100Hz.) shall also be done.

2 The field tests to be conducted on each AVR at the site shall include but not be limited to those listed below.3 The following type tests on Brushless excitation system of one machine of each rating shall be conducted. SECTION: D3. TCE. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC.5960A-H-500-001 iii) Measurement of load characteristics iv) Measurement of insulation resistance and high voltage test on stator winding v) b) Measurement of DC resistance of stator winding Main Exciter (Brushless Exciter) i) ii) Measurement of open circuit characteristics Load magnetisation characteristics iii) Measurement of insulation resistance and high voltage test on armature and field winding iv) Measurement of DC resistance of armature and field winding c) Voltage Regulator i) ii) Response ratio test Insulation resistance and high voltage test iii) Performance test at reduced supply voltage iv) Auto –1 / Auto –2 channel follow up test v) Auto – Manual channel follow up test vi) Thyristor load test (light load test at rated voltage and full current test) vii) Functional tests 1.19.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.19.2. Any other test considered necessary by the bidder shall also be carried out : i) ii) iii) iv) v) vi) vii) viii) Accuracy test Sensitivity test Performance tests on all limiters Impulse input response test Auto –1 / Auto –2 channel follow up test Auto – Manual channel follow up test Range of voltage adjustment for both auto and manual channels Functional tests 1. ISSUE R0 61 TCE FORM NO.2. 329 R5 . KARIMNAGAR DIST.1 SHEET 36 OF 42 1X 700 MW CCPP AT NEDUNOOR. NO.

PMG : Temperature rise test at peak rating of excitation system shall be demonstrated. ii) Input and output surge withstand capability test. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC. Converter Assembly (of the exciter field) : i) Temperature rise test at peak rating of excitation system and ceiling duty condition shall also be demonstrated. NO. TCE. KARIMNAGAR DIST. Field Breaker : Type tests on exciter field breaker shall be conducted as per IEEE/ANSI C 37-18.5960A-H-500-001 a) Main Exciter : Temperature rise test at peak rating of excitation system and ceiling duty condition shall also be demonstrated. iii) Soak test for electronic modules.3 The following test to be conducted on startup system a) SFC panels i) Temperature rise test ii) Surge withstand capability test iii) Noise level test b) SFC Transformer The following type tests shall be conducted on one transformer i) Tank Pressure test ii) Tank vacuum Test iii) Short circuit test on one transformer to be selected by Owner. iv) Noise level v) Measurement of harmonics of no load current ISSUE R0 62 TCE FORM NO. b) c) d) e) Voltage Regulator : i) Soak test on electronic equipment ii) Surge withstand capability test on electronic equipment 1.1 SHEET 37 OF 42 1X 700 MW CCPP AT NEDUNOOR. SECTION: D3. 329 R5 .ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.19.

TCE. 1.5 ISSUE R0 63 TCE FORM NO. All Type and Routine test certificates shall be furnished to the Owner for review and approval.1 SHEET 38 OF 42 1X 700 MW CCPP AT NEDUNOOR. SECTION: D3.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.19. 329 R5 .4 All components of the excitation system shall be tested in accordance with the relevant standards and type and routine test certificates shall be furnished. ELECTRICAL SYSTEMS GENERATOR AND ACCESSORIES SPEC. KARIMNAGAR DIST.5960A-H-500-001 vi) PRD operation test vii) Degree of protection test on marshalling box viii) Zero sequence Impedance ( not applicable for Deltadelta transformer) ix) Temperature rise test x) Lightning impulse test on one limb xi) DGA test on oil before and after temperature rise test 1. NO.19.

6 1. rise limited to that of class B) CLIENT : APPDCL PROJECT : 700MW CCCP AT NEDUNOOR.1 39 OF 42 SPEC. KARIMNAGAR DIST. 330 R3 64 REV. of phases Continuous operation under unbalanced load Stator winding connections Speed Type of cooling (a) Stator Winding (b) Rotor Winding and Stator Core Water Hydrogen rpm Hz Ref clause 1.1.1 1. BY CKD.9 1.5 Generator and Excitation System Rated Output Rated terminal voltage Rated frequency (a) Rated power factor (b) Power factor variation No.11 No. TCE. DATA SHEET – A3.5 As per IEC-60034-1 1.95(lead) 3 As per IEC: 60034-1 1.1 By Bidder 50 0. BY DATE TATA CONSULTING ENGINEERS LTD . DESCRIPTION UNITS VALUES / REQUIREMENTS 1. NO. of line terminals to be brought out No. NO.10 Star 3000 1.8 1.13 Rated short circuit ratio at MCR not less than Operation under unsymmetrical fault Class of insulation of generator stator and rotor windings R0 MAR’ 10 PPD. DATE REV.BY RKD HA JOB NO. Three (3) Six (6)-(In case of split brought out phase winding and having more than one conductor per phase or else three (3) ) 1.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.7 1.5960A-H-500-001 SL.85 (lagging) 0.2 1. 5960A 0.3 1.85 (lag) to 0.15 Class F (temp.14 1. TCE FORM NO.12 1. NO.4 1. of neutral terminals to be Nos.1 SECTION: SHEET D3.

NO. TCE FORM NO.16 Degree of protection for generator enclosure Excitation system response ratio Excitation system response time sec.20 Minimum 2.19 1.23 1.1 40 OF 42 SPEC. BY CKD.17 1.5960A-H-500-001 SL.1 SECTION: SHEET D3. Solid state.1 REV. BY DATE TATA CONSULTING ENGINEERS LTD .0 <0. monitoring devices for generator excitation system Minimum excitation limiter R0 MAR’ 10 PPD. As per IEC 60034 shall meet the requirements as per respective gas turbine and steam turbine sections (Bidder shall indicate) 1. compensators. Terminal voltage % Manual channel shall follow auto channel within Telephone harmonic factor % 1.27. 330 R3 65 REV. DATE Required CLIENT : APPDCL PROJECT : 700MW CCCP AT NEDUNOOR.5 Field forcing capability during bolted fault on generator terminals % Type of voltage regulator Minimum 150 Two auto and one manual channel.18 1. IP-54 1. NO.21 1. 5960A 1. TCE. NO. (Bidder shall indicate).22 % shall not exceed 1.24 Space heaters for generator 1. KARIMNAGAR DIST.25 Maximum amplitude of vibrations (peak to peak) 1.26 Noise level from the surface of equipment 1.5 Accuracy of Gen.5 <0.27 Limiters.5 <+0. continuously adjustable Required (to be switched on automatically when turbine is shut down) As per VDE 2063 and shall meet requirements as per respective gas turbine and steam turbine sections.BY RKD HA JOB NO. DESCRIPTION UNITS VALUES / REQUIREMENTS 1.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. DATA SHEET – A3.

27.27.27.8 1. TCE FORM NO.2 1.27. DESCRIPTION UNITS VALUES / REQUIREMENTS 1.5960A-H-500-001 SL. BY CKD.31 REV.BY RKD HA JOB NO.12 Required Required 1.5 1.10 1.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.3 1.11 Maximum excitation limiter Maximum rotor current limiter Under/over excitation limiter Maximum stator current limiter Cross current compensator Overfluxing (V/Hz) limiter Load angle limiter Transformer drop compensation Power system stabiliser Two stage Field suppression facility Two stage Field earth fault monitor Automatic power factor controller Motorised manual control for remote parallel operation Manual control range of AVR Required Required Required Required Required Required Required Required (adjustable between 0% & 15%) Required Required 1. 330 R3 66 REV.27. BY DATE TATA CONSULTING ENGINEERS LTD .27. NO.27.27.9 1.28 Number of RTDs/Thermo-couples required for generator Efficiency at 100% load at rated power factor Maximum Inlet Temperature of Cooling Water available for Hydrogen / Air coolers Type of cooling water available R0 MAR’ 10 PPD. NO.27. TCE.1.1 41 OF 42 SPEC. NO.15 1.27.14 Required 70% of no load to 110% full load of voltage range Ref.30 C 1.13 1.27. 5960A 0 1.20 1.27.7 1.1 SECTION: SHEET D3. KARIMNAGAR DIST.4 1. clause 1. DATA SHEET – A3.29 As per IS-4899 350 C 1.6 1.27.27. DATE DM water CLIENT : APPDCL PROJECT : 700MW CCCP AT NEDUNOOR.

32.3 IS-7132 1. 330 R3 REV.32. TCE.6 IS-4691 and IEC-60034-5 IS-6362 and IEC-60034-6 1.8 1. BY CKD.32.3 IS-4889 1. NO.32.4 IS-12075 IS-7306 and IEC-60034-4/4A 1.7 1.32.1 42 OF 42 SPEC. DESCRIPTION UNITS VALUES / REQUIREMENTS for Hydrogen coolers / Air coolers / water coolers (ordinary water / sea water) 1.9 IEC-60034-8 IS-6098 and IEC-60034-9 REV. DATE R0 MAR’ 10 PPD.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. NO.5 1.32.32. BY DATE 67 TATA CONSULTING ENGINEERS LTD .1 SECTION: SHEET D3. 5960A CLIENT : APPDCL PROJECT : 700MW CCCP AT NEDUNOOR. NO.32 1.BY RKD HA JOB NO.32.2 1.5960A-H-500-001 SL. DATA SHEET – A3. TCE FORM NO.32. KARIMNAGAR DIST.rating & performance Guide for testing synchronous machines Method of determination of efficiency of rotating electrical machines Measurement and evaluation of vibration of rotating electrical machines Methods for determining synchronous machine quantities from tests Degree of protection provided by enclosures for rotating electrical machines Methods for cooling rotating machinery Terminal markings and direction of rotation of rotating machines Method of measurement of airborne noise emitted by rotating electrical machines IS-4722 and IEC-60034-1.1 Codes and Standards Specification for rotating electrical machines .

The Generator Circuit Breaker (GCB) is installed indoor / outdoor and connected to Generator busduct (Isolated Phase) on both sides. supervisory and control equipment.6 2. surge arrestors and protective capacitors in three single phase enclosures. current and voltage transformers. The short time and momentary current rating of the Generator circuit breaker shall be decided as follows: (a) Short time current rating for 1 second: (i) Higher of the short circuit current contribution from generator or the short circuit current contribution from 400 kV system through generator transformer (400 kV system fault level 50 kA) Plus (+) ISSUE R0 68 2.1 GENERATOR CIRCUIT BREAKER Generator circuit breaker shall be provided in single phase enclosures..5960A-EL-SK-2003. as shown in attached Main one line diagram TCE. Design calculations of support structure shall be furnished for Owner's approval. The Generator circuit breaker shall be integrated with seriesdisconnector. SECTION: D3. ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.2 SHEET 1 OF 8 1X 700 MW CCPP AT NEDUNOOR.4 2.2 2.0 2. ELECTRICAL SYSTEMS GENERATOR CIRCUIT BREAKER SPEC NO TCE.7 2.8 TCE FORM NO. grounding switches.5960A-H-500-001 2.5 2. The voltage class of the Generator circuit breaker shall be same as that of the generator. Suitable provisions shall be made for connection with Isolated Phase Busduct (IPB) through flexible connection. Support structure shall be designed to withstand the dynamic as well as static load of the GCB. The continuous current rating of the Generator circuit breaker shall be arrived at considering the maximum output of the generator and at specified minimum voltage.3 2. 329 R5 . The GCB movement during short circuit shall be restricted so as to limit the stresses on GCB support insulators within their capabilities. all fully assembled on a common frame with operating mechanisms. KARIMNAGAR DIST.

A manually fitted grounding link for the above short circuiting connection. e) Protective capacitors fitted to both sides of the unit and to all three phases. 329 R5 .25μF surge capacitor on either side of circuit breaker as shown in the Main SLD. SECTION: D3. one per phase on transformer side. h) Supporting structures and suitable platform. 2. two per phase on generator side.5960A-EL-SK-2003.10 The system shall be extended by all of the following items: a) b) c) A switched (motor operated) short circuiting connection between the power circuit breaker and the series disconnector for maintenance and protection checking.55 times the short time current rating arrived as above. 2. indoor / outdoor and free standing type. An isolator for the SFC connections The accuracies of the CTs & PTs shall be as per the enclosed Main one line diagram TCE. d) Voltage transformers with two secondary windings.. a) Circuit breaker with disconnector for series isolation on Generator Transformer side.5960A-H-500-001 (ii) (b) Contribution of 6. It shall be provided with three pole gang operation ISSUE R0 69 TCE FORM NO. metal enclosed.9 The basic switchgear module shall include the following minimum equipment but shall not be limited to the same. The CTs and VTs shall not temporarily or permanently saturate even after successive starts through the start up system.6 kV auxiliary system through unit auxiliary transformers. KARIMNAGAR DIST. ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. Momentary current rating: 2. f) Surge arrestor with surge counter on generator transformer side g) 0. the protections shall not mal-operate during gas turbine starting.2 SHEET 2 OF 8 1X 700 MW CCPP AT NEDUNOOR. ELECTRICAL SYSTEMS GENERATOR CIRCUIT BREAKER SPEC NO TCE. 2. Also.11 The GCB shall be of SF6. c) Generator side current transformers with upto two cores per phase towards GT side. b) Grounding switches fitted both sides of unit and to all three phases.

2. The Main One Line diagram enclosed indicates the relays and meters to be connected to the current transformers and voltage transformers. ELECTRICAL SYSTEMS GENERATOR CIRCUIT BREAKER SPEC NO TCE. when routine testing the protective relaying. knee point voltage. Grounding switches shall be provided on both sides of the switchgear unit.2 SHEET 3 OF 8 1X 700 MW CCPP AT NEDUNOOR. ISSUE R0 70 2. If all the poles do not close simultaneously the breaker shall trip on pole discrepancy. SF6 gas monitor for each phase shall be provided..16 2. The short circuiting disconnector and its connections shall be designed to expedite the testing and adjustment of the power plant protection system. The VA burden. as well as. 329 R5 . both during initial commissioning. Necessary interlocks are to be arranged to prevent breaker operation on fall of SF6 gas density.5960A-H-500-001 and anti-pumping feature.13 2. KARIMNAGAR DIST. the fixed contact being on the circuit breaker side of the unit. The Generator circuit breaker shall use SF6 gas both as its arc-extinguishing medium as well as for internal insulation. ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. The connections and the switches shall be rated for full fault current. The ground connections shall be made via the switchgear enclosure to the housings of the isolated phase busbars and then to their grounding connection. secondary resistance and the exciting currents of CTs and VA burden of the VTs shall suit the connected metering/protective equipment. All the three poles shall operate simultaneously. Semaphore position indicators shall be provided for local indication of the position of the circuit breaker.18 TCE FORM NO. Closure of the disconnector shall establish a three phase short circuit on to the generator connections but without ground to save time. Insulators shall be of high strength.17 2.12 The GCB enclosure shall be non-magnetic aluminium alloy. minimum flux. fine glazed porcelain or epoxy resin type.15 2. SECTION: D3. It shall be designed with separate contact systems for the current breaking and current carrying functions.14 2. A series disconnector shall be fitted on the outgoing side of the circuit breaker and within the same enclosure. and isolated phase type with degree of protection IP-65 and canopy shall be provided if installed outdoor. The disconnector shall be of a tubular telescopic unit with the moving contact tube connected on the transformer side.

ISSUE R0 71 TCE FORM NO. Duplicate shunt opening release coils suitable for operation with voltage upto 60% of rated voltage of coils along with status monitoring shall be provided. The minimum number of auxiliary potential free contacts required to be wired up to the terminal strip for PURCHASER’s use after BIDDER’s use in all Control and Protection circuits shall be : 12 NC + 12 NO for Circuit Breaker 8 NC + 8 NO for Disconnector 8 NC + * NO for each Earthing Switch Contact wear monitoring shall also be offered along with the GCB. the stored energy shall be suitable for two close open operations. The bidder shall clearly bring out the details in respect to this offer.21 2.25 2. The breaker shall have 2 x 100% hydraulic pumps. 2. Local control panel shall include a Local/Remote selector switch. In case of hydraulic mechanism.20 2. Capacity of each high pressure receivers shall have stored energy for 2 close-open operations. Capacity of local air receivers shall meet one close-open operation. status indication.24 2. In case of pneumatic operating mechanism compressed air plant shall be provided with 2x100% compressors.5960A-H-500-001 2.2 SHEET 4 OF 8 1X 700 MW CCPP AT NEDUNOOR. ELECTRICAL SYSTEMS GENERATOR CIRCUIT BREAKER SPEC NO TCE. 329 R5 . KARIMNAGAR DIST.19 Locking bars or effective mechanical arrangement shall be provided to lock main and auxiliary contact in the open position to prevent inadvertent closing either in main breaker or on disconnecting switch.23 2..22 2. Driers shall also have same capacity. The operating mechanisum shall be spring operated both for closing and tripping operations. ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. alarm and annunciation of the breaker and all auxiliary equipments shall also be located in local control panel. SECTION: D3. The spring charging motor shall be suitable for 220V DC and shall be fed from respective Unit DCDB.26 Local control panel shall be provided near GCB to facilitate Local ON/OFF Control. If the offered breaker is pneumatic operated then. on loss of compressed air supply breaker shall get locked in its current state. The stored energy in the spring shall be sufficient to permit at least two close-open operations. The spring charging motor shall be capable of charging the spring within 30 secs.

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ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.

SECTION: D3.2

SHEET

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2.27

The GCB shall be suitable for synchronizing duty and capable of withstanding out of phase voltage across open contacts. The breaker shall also be capable of switching on to a fault and out of phase switching.
Main contacts shall have ample area and contact pressure for carrying the

2.28

rated current and the short time rated current of the breaker without excessive temperature rise which may cause pitting or welding. Contacts shall be easily replaceable and shall have a minimum of movable parts and adjustments to accomplish these results. Main contacts shall be the first to open and the last to close so that there will be little contact burning and wear. 2.29 Arcing contacts, if provided, shall be the first to close and the last to open and shall be easily accessible for inspection and replacement. Tips of arcing and main contacts shall be silver faced or have tungsten alloy tipping. The operating mechanism and associated accessories shall be enclosed in weather proof mechanism cabinet of hot dip galvanised sheet construction, thickness of which shall not be less than 2 mm. Hinged doors giving access to the mechanism at the front and sides shall be provided. Suitable gaskets shall be provided to make the mechanism housing water-proof and dust-proof. The housing latch shall accommodate padlock requiring a 12 mm diameter hole. Padlock and duplicate keys shall be included in the BIDDER's scope of supply. Working parts of the mechanism shall be of corrosion resisting material. Bearings which require grease shall be equipped with pressure type grease fittings. Bearing pin, bolts, nuts and other parts shall be adequately pinned or locked to prevent loosening or changing of adjustment with repeated operation of the breaker. Provision shall be made for connecting travel recorder to perform speed test of breakers at site. Motor operated mechanism shall be provided for Disconnectors & Earth switches with suitable Electrical & Mechanical interlocks. Normal operating mechanism shall also be provided for emergency purpose. The operating mechanism offered for GCB shall be in service for a minimum of 2 years in any of the power plant with trouble free operation.
ISSUE R0
72

2.30

2.31

2.32 2.33

2.34

TCE FORM NO. 329 R5

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ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.

SECTION: D3.2

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SPEC NO TCE.5960A-H-500-001

2.35

SF6 density monitoring, alarm on low density and close & Trip blocking on very low density shall be provided. Tests All acceptable & routine tests as per IEC-60056 and IEEE Std C37.013a-2007 standards shall be conducted on all the equipment/components of each of the generator circuit breaker. a) Power frequency voltage withstand dry tests on the main circuit. b) Voltage withstand tests on control and auxiliary circuits c) Measurement of the resistance of the main circuit. d) Mechanical operating tests. e) Design and visual checks.

3.0 3.1

3.2

Following type tests shall be conducted on each type & rating of the equipment. a) Rated dielectric strength tests (i) (ii) Rated low frequency withstand voltage dry test. Rated full wave impulse withstand voltage test.

b) Short circuit rating and transient recovery voltage tests (i) Test for rated symmetrical short circuit current interrupting capability, duty cycle and rated transient recovery voltage parameters. Test for rated closing, latching and short time current carrying capability. Test for rated Generator source asymmetrical short circuit interrupting capability.

(ii) (iii) d) e)

Load current switching test Out of phase switching current tests
ISSUE R0
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f) g)

Rated excitation current switching tests. Type tests and oscillographic test records for closing and tripping timings for generator circuit breaker of the rating offered.

3.3

Test reports for the following type tests shall be submitted for each type & rating of equipment: a) b) c) Rated continuous current carrying tests Mechanical endurance life tests. Noise level tests.

ISSUE R0
74

TCE FORM NO. 329 R5

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ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS GENERATOR CIRCUIT BREAKER

SECTION: D3.2 SHEET 8 OF 8
SPEC NO TCE.5960A-H-500-001

Technical Parameters GCB shall comply with the technical particulars given below and the Contractor shall furnish the details wherever indicated as ‘*’. Sl. No. (a) Make (b) Description Unit * IEEE(ANSI) std C37.013a2007 , IEC60056 (1987), IEC 60694 (1980) & IEC 60298 (1990), IEC-60529, IEC60129, BS-5169 & BS-5500 Bidder to indicate 50 Bidder to indicate Bidder to indicate Bidder to indicate Bidder to indicate IP 54 IP 65 CO-30 min-CO Opaline Green(external) , Semi Glossy white (internal) Technical Particulars

Applicable Standards

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

Voltage rating Frequency Rated current Rated short circuit breaking current Rated short time withstand current for 1 sec. Rated short circuit making current Degree of protection • Control cubicles and drives • Enclosure Duty Panel paint shade

kV Hz A kA kA kAp

(j) (k)

ISSUE R0
75

TCE FORM NO. 329 R5

ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.

SECTION:

D3.3

1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS GENERATOR TRANSFORMERS

SHEET 1 OF 11 SPEC. NO. TCE.5960A-H-500-001

3.0

GENERATOR TRANSFORMERs (GTs) The generator transformer (GT) and its accessories shall conform to the latest editions of national and international standards indicated in Data sheet – A 3.3. Also, the GT and its accessories shall comply with the requirements indicated in Data Sheet – A 3.3 and specific requirements indicated below.

3.1

The MVA rating of the Generator Transformers (GTs) shall be sufficient to evacuate power generated by the respective gas turbine generators and steam turbine generators. The GT shall be so sized as to be able to evacuate power from the GTG / STG to which it is connected without exceeding the average winding temperature of 870C and hot spot temperature of 980C over the entire range of site ambient temperature as specified in Section - B of this specification. The GT shall be with voltage ratio of generator voltage / 420kV, two winding, 3 phase, 50 Hz, ONAN/ONAF/OFAF cooled transformer, with On Load Tap Changer with +10% to –10% in steps of 1.25% on the HV side. Three (3) of 50% 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 atleast 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. Control scheme shall be suitable for both manual and automatic operation of each group of fans and oil pumps. Electrical Performance The transformers shall operate without injurious heating at the rated MVA at any voltage within ±10% of the rated voltage of that particular tap.

3.2

3.3 3.3.1

ISSUE R0
76

TCE FORM NO. 329 R5

ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.

SECTION:

D3.3

1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS GENERATOR TRANSFORMERS

SHEET 2 OF 11 SPEC. NO. TCE.5960A-H-500-001

3.3.2

The transformer shall be designed to deliver rated MVA continuously even at the lowest tap without exceeding specified temperature rise. The transformer shall be capable of remaining in operation without injurious heating at full load atleast 10 minutes when complete forced cooling equipment has failed. The dynamic ability to withstand short circuit shall be demonstrated by the Contractor by calculations. Generator transformers shall be suitable for back charging. It shall also be capable of being charged from HV side through circuit breakers without pre-insertion resistors and kept charged continuously with no load on the LV side without any adverse impact on the transformer life. Generator transformers shall be suitable for bi-directional power flow. Bidder shall furnish the guaranteed loss values of Transformer.

3.3.3

3.3.4

3.3.5 3.3.6

3.3.7

3.3.8

3.4 3.4.1 3.4.2

Constructional Features Bell type design shall be adopted for transformer tank. The magnetic circuit shall be constructed from high grade cold rolled non-ageing grain oriented silicon steel laminations. The flux density shall not exceed 1.7 Wb/m2 at rated voltage and Current density shall not exceed 3 A/mm2. For generator transformers the insulation of core to bolt and core to clamp plates shall be able to withstand a voltage of 10 kV rms for 1 minute. The windings shall be made of electrolyte grade copper. Tank shall be made of good commercial grade low carbon steel and shall be of welded construction. The tank of the transformer along with radiators, conservators, bushings and other fittings shall withstand full vacuum of 760 mm
ISSUE R0
77

3.4.3

3.4.4 3.4.5

3.4.6

TCE FORM NO. 329 R5

ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.

SECTION:

D3.3

1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS GENERATOR TRANSFORMERS

SHEET 3 OF 11 SPEC. NO. TCE.5960A-H-500-001

of Hg while filling the oil under vacuum and also an excess internal pressure of 0.35 kg/cm2. 3.4.7 Tank shields shall be such that no magnetic fields shall exist outside the tank. They shall be of magnetically permeable material. If required, impermeable shields shall be provided at the coil ends. Tank shield shall not resonate when excited at the natural frequency of the equipment. Contractor shall conform use of tank shields in the additional information scheme. Bushing shall be of porcelain. No arcing horn to be provided. For 52 kV and above, bushing shall be oil filled porcelain condensor & non-oil communicating type with following fittings: i) ii) iii) 3.4.9 Oil level gauge Oil filling plug and drain valve if not hermetically sealed Tap for capacitance and Tan delta test

3.4.8

Bushing below 52 kV shall be soild porcelain/condensor/oil communicating type. Bushing CT’s shall be of adequate rating for protection as required, WTI etc., These CT’s shall be mounted in the turret of bushing. Busduct termination shall be suitable for high air temperature inside the bus duct and shall be provided with draining arrangement as lowest point for leaked oil / water. Fire protection system shall be provided for the GTs as per the requirement specified under relevant fire and safety codes/standards, TAC guidelines and as specified under section D1.11 of this specification Fittings and Accessories Transformers shall be provided with all accessories like, but not limited to inspection manholes / handholes, lifting lugs, jacking pads, bi-directional flanged wheels, haulage lugs, skids, earth pads, neutral earthing downcomers (2 nos.) supported on pin insulators, terminal marking, rating and diagram plates, marshalling boxes, conservators (breatherless) (flexible oil resistant air bag), valves for various purposes including draining, filtering, filling,
ISSUE R0
78

3.4.10

3.4.11

3.4.12

3.4.13

TCE FORM NO. 329 R5

ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.

SECTION:

D3.3

1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS GENERATOR TRANSFORMERS

SHEET 4 OF 11 SPEC. NO. TCE.5960A-H-500-001

double float buchholz relay, oil and winding temperature indicators with high and very high contacts, magnetic (150 mm dia) and prismatic oil level gauges, anti-earthquake clamping arrangement, tank mounted radiators with accessories, and pressure relief valve (Min. 02Nos. & the adequacy of the number of PRDs and their location shall be established for any location of the fault inside the tank). 4-20mA signal for remote WTI & OTI. It shall be a repeater of local WTI & OTI. 3.4.14 On-line Gas Extractor Analyser shall be provided for each Generator transformer. It shall be hooked up to the plant DCS.
A device for measuring the hot spot temperature of the winding shall be provided.

3.4.15 3.4.16

For Top oil temperature measurement & Winding temperature
measurement RTDs / transducers shall be provided for remote indication in SCADA.

3.4.17 3.4.18 3.4.19 3.4.20

A flexible oil resistant air bag shall be provided in the conservator to prevent the air from coming into contact with the oil. Suitable shock recorders to record maximum shock forces during shipment/ transport shall be provided. A set of hydraulic jacks suitable for the transformers under supply.

Transformer oil shall be supplied in non-returnable oil drums ( with 10% extra oil). 3 Nos., 20 KLitres capacity Transformer oil tank and 1 No. 6 KLitres Transformer oil filter machine of reputed make approved by Owner shall be supplied. Impact recorder shall be provided to monitor the impact during transport on returnable basis. Transformer shall be transported with tank filled with pure inert gas at pressure of 2 – 2.5PSI. The temperature and pressure at the time of gas filling shall be marked. Necessary accessories including filled replenishment N2 shall be maintained at site also till the transformer is filled with oil. Two auxiliary power supplies, 400 V, 3 phase, 3 wire shall be drawn from two separate boards for the cooler control cabinet and OLTC cubicle. Cooler control equipments shall be divided in to
ISSUE R0
79

3.4.21

3.4.22

3.5

TCE FORM NO. 329 R5

7 3. Devices shall be incorporated to prevent tap change when the through current is in excess of the safe current that the tap changer can handle.6 Each cooling fan and pump motor shall be provided with isolating switch.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. loads shall be automatically transferred to other. Indications are to be provided at cooler control cabinet and at OLTC cubicle along with remote annunciation in DCS for failure of normal source and for transfer to standby source. It shall permit operation of generator at full load and at rated terminal voltage & p. starter.1 3. 329 R5 . over the entire range of variation of grid voltage: (a) Complete its operation once commenced. independent of power supply.f. ELECTRICAL SYSTEMS GENERATOR TRANSFORMERS SHEET 5 OF 11 SPEC. 3. 3. In case of one power supply failure. with remote annunciation in DCS. On Load Tap Changer (OLTC) The OLTC gear shall be designed to complete successfully tap changes at 150% of rated current. TCE. SECTION: D3. Be equipped with separate conservator for OLTC oil temperature and oil surge relay with contacts. single phase preventer and short circuit protection. All cooling equipment trouble shall be indicated in local control panel with repeat alarm in main control room. each having one power supply incomer with bus section between two halves. The OLTC gear shall withstand through fault current without injury. Block reverse tap change command during the forward tap change in progress. Cut off of power supply when manual handle is inserted. Separate on/off switch for each incoming power supply with MCCB shall be provided.5960A-H-500-001 two halves. Status of each cooler fan/pump shall be available in DCS. NO. The tap range shall be decided based on the voltage profile of the grid and following shall be complied with / provided. 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.7. KARIMNAGAR DIST.3 1X 700 MW CCPP AT NEDUNOOR.2 (b) (c) (d) (e) ISSUE R0 80 TCE FORM NO. and also for failure to transfer. relays etc.7. thermal overload.

(g) (h) (i) (j) 3. 329 R5 . Be equipped with Digital type tap position indicator with inbuilt transducer for repeating the tap position in DCS. SECTION: D3.1 Tests Following type tests and special tests as per IS 2026 (revision as applicable on date of submitting of offer) shall be conducted on one transformer : ISSUE R0 81 TCE FORM NO. relays as required. NO. Be equipped with automatic and manual operation facility including hardware. All wiring for remote connection for OLTC control / indication / annunciation from OLTC cabinet shall be terminated in Marshalling box by providing separate terminal block. The degree of protection shall be IP 55. TCE. A sheet steel.5960A-H-500-001 (f) Remote and local electrical operation & tap position indication. KARIMNAGAR DIST.3 1X 700 MW CCPP AT NEDUNOOR. ELECTRICAL SYSTEMS GENERATOR TRANSFORMERS SHEET 6 OF 11 SPEC. dust and vermin proof marshalling box shall be provided for each transformer and shall be provided with thermostatically controlled space heaters. Be provided with necessary initiating contacts for annunciation of any abnormal condition in DCS and grouped alarm in control desk.8 3.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.8.

ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. Partial discharge test. Measurement of tan delta and capacitance of each winding and bushing. (i) 3. ELECTRICAL SYSTEMS GENERATOR TRANSFORMERS SHEET 7 OF 11 SPEC. Radio influence voltage. Determination of cooler losses.8. ISSUE R0 82 (h) TCE FORM NO. Dissolved gas analysis of the oil. 100% and 110% rated voltage Calibration of temperature indicators and relays Impulse test on GTs shall include chopped wave test Sweep Frequency Response Test at factory and at site Magnetic balance test. (a) (b) (c) (d) (e) (f) (g) Impedance voltage shall be measured at principal and at all the taps No load loss and exciting current shall be measured at rated frequency at 90%. SECTION: D3. NO. (b) Vacuum withstand and deflection measurement on tank and radiators. Short circuit impedance of each limb with single phase voltage from each HV & LV sides. (c) (d) (e) (f) (g) Pressure test on tank with deflection measurement. Pressure test on PRD. All routine tests as per IS : 2026 shall be conducted on each of the transformer. TCE. (h) Oil leakage test – 12 hours (this test to be conducted after heat run test). KARIMNAGAR DIST. The following additional routine tests on each of the transformer shall be conducted. before and after the temperature rise test.5960A-H-500-001 (a) Temperature rise test. 329 R5 .2 Auxiliary power measurement.3 1X 700 MW CCPP AT NEDUNOOR.

2 3.3 1X 700 MW CCPP AT NEDUNOOR. Core isolation test Noise level measurement ACSD & ALD as per standards Minimum electrical system requirements in respect of control. NO. liquidated damages based on the charges indicated in Data Sheet A3. annunciation.3 For the purpose of evaluation of Bids.3 3.1 Evaluation of Bids Bids will be evaluated based on the formula furnished in Data SheetA3.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.11. synchronising are indicated in I&C system Section No. monitoring.11. SECTION: D3. The following calculation shall be furnished for Owner’s approval: a) OLTC recovery voltage calculations in case of buck and boost type of OLTC (wherever applicable) Transfer surge calculations Short circuit withstand calculations 3. TCE.4.5960A-H-500-001 (i) (j) (k) (l) 3.9 Measurement of zero sequence impedance. the quoted load losses and iron losses shall be included to take into consideration tolerance as permitted by applicable standards. D2.12 ISSUE R0 83 TCE FORM NO. ELECTRICAL SYSTEMS GENERATOR TRANSFORMERS SHEET 8 OF 11 SPEC. the VENDOR shall pay to the PURCHASER. Liquidated Damages for Non-Performance Should the losses as measured on the transformer after manufacture be found to be in excess of the guaranteed losses including tolerance.11 3. KARIMNAGAR DIST.10 b) c) 3. measurement. 329 R5 . if any.

5960A CLIENT : APPDCL PROJECT : 700MW CCPP AT NEDUNOOR.1 1.8 1.2.5960A-H-500-001 SL.2 1.3 1.1.1 DESCRIPTION Generator Transformers Type MVA Rating UNITS VALUES / REQUIREMENTS Outdoor.2 1.8.4 Winding connections HV LV Vector Star Delta Ynd1 1.7 0 C 55 1. Two winding.1 1. DATA SHEET – A3.1 1. DATE REV.5 Impulse (1.8.2.8. 330 R3 84 .0 1. 1.6 LV 0 * / * C 50 Maximum temperature rise of oil at 110% of full load for 24 hrs. BY CKD.3 1.3 Cooling method ONAN ONAF OFAF Overfluxing capability 60% 80% 100% 110% for continuous 125% for 1 minute 140% for 5 seconds 1.25% CFVV JOB NO. Maximum temperature rise of winding at 110% of full load for 24 hrs.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.3 SHEET 9 OF 11 SPEC NO: TCE. TCE FORM NO. NO. KARIMNAGAR DIST. 3 phase MVA 315MVA for GTG (tentative). NO. 340MVA for STG (tentative) 1.8.4 REV.2 / 50 microsecond) / power frequency withstand voltage windings HV 1425 kVp / 630 kV (rms) 1.3 GENERATOR TRANSFORMER SECTION: D3.2. Tapping particulars Type Tap range Tapping step Category of voltage variation R0 JUNE’ 10 PPD.BY DATE RKD HA 1. BY OLTC + 10% to – 10% 1.2 1.

80.2 1.000 B = 2.3 GENERATOR TRANSFORMER SECTION: D3.1 1. . BY Applicable codes and standards Power transformer Fittings and accessories Loading of oil immersed transformers Oil Bushings Degree of protections R0 JUNE’ 10 PPD. NO.000 / kW B = Rs.000 C = 2. 330 R3 85 IS : 2026/IS:6600/IEC:60076 IS : 3639 IS : 6600 IS : 335 / IEC:60296 IS : 2099 / IEC:60185 IS : 2147 RKD HA JOB NO.13.32000 / kW 1./ 3400 mm / --. KARIMNAGAR DIST.5 1.000 / kW C = Rs.9./ .32000 1.3 1.1 Paint shade Noise level Loss evaluation formula Formula for evaluation of Bids Evaluated price + (A x guaranteed no-load loss in KW) + (B x guaranteed load loss in KW) + (C x guaranteed cooler loss in kW) A = Rs.9. BY CKD.1 1.13.12 1.11 1.13. NO.3 SHEET 10 OF 11 SPEC NO: TCE. 1. 3.9.13. DATA SHEET – A3.3 1.4 1.13.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.13 1.13.4 DESCRIPTION Tapping power Bushing particulars Voltage class HV / LV / HV (n) Standard applicable Creepage distance Clearance in air (a) (b) Phase-phase-HV/LV/HV(n) Phase-earth-HV/LV/HV(n) UNITS Full VALUES / REQUIREMENTS 420 kV / --.9 1.2 1.9.mm Opaline Green Not to exceed values specified in NEMA TR1 1.2 Rates of liquidated damages for exceeding the guaranteed losses No load loss Load loss Load loss Rs/kW Rs/kW Rs/kW A = 3. DATE REV.60.BY DATE TCE FORM NO.80.5960A-H-500-001 SL. 5960A CLIENT : APPDCL PROJECT : 700MW CCPP AT NEDUNOOR. 2.12.12./ 36 kV IS : 2099 25 mm / kV 4200 mm / -. 2.6 REV.8.60.5 1.10 1.

DATA SHEET – A3.9 1. BY R0 JUNE’ 10 PPD.13. 1.3 GENERATOR TRANSFORMER SECTION: D3. 5960A CLIENT : APPDCL PROJECT : 700MW CCPP AT NEDUNOOR. 330 R3 86 .3 SHEET 11 OF 11 SPEC NO: TCE.8 1.5960A-H-500-001 SL.13.13.13. BY CKD. TCE FORM NO.10 Tests DESCRIPTION UNITS VALUES / REQUIREMENTS IS : 2026 IS : 2026 IS : 3637 Tolerance on guaranteed particulars Buchholz relay Electrical insulation classified by stability thermal IS : 1271 REV.BY DATE RKD HA JOB NO.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. KARIMNAGAR DIST. DATE REV. NO. NO.7 1.

25% on HV side (*By Bidder). ELECTRICAL SYSTEMS UNIT AUXILIARY TRANSFORMERS SPEC.4. three phase. the UAT and its accessories shall comply with the requirements indicated in Data Sheet–A3.4.0 UNIT AUXILIARY TRANSFORMER (UAT) The Unit Auxiliary Transformer (UAT) and its accessories shall conform to the latest editions of national and international standards indicated in Data sheet .1. All tests specified in Section D-3.1. ONAN/ONAF cooled transformer with *% impedance with OLTC ±10% in steps of 1.3 4. the same can be separately mounted.1 4. The tank cover for the UAT can be of conventional type.A 3. Additional margin of 10% shall be kept over & above all the loads due to variation in the loads i.2 4.e.4 and specific requirements indicated below: 4. 329 R5 .3 shall be conducted on UAT.4. two winding.2 4. Also.3.4. 110% of the complete station load.1 MVA rating UAT Each UAT shall be able to supply (100%) auxiliary running load of 700 MW power plant.1 UAT shall be a * MVA. Specific Requirements The unit auxiliary transformers shall comply with the specific requirements indicated in Section D-3. TCE-5960A-H-500-001 4.4 SHEET 1 OF 3 1X 700 MW CCPP AT NEDUNOOR. SECTION: D3. The Contractor shall provide the design calculations for arriving at the capacity of UAT during detail engineering stage.NO.9kV. 50 Hz.20 4. KARIMNAGAR DIST. */6. 6.6kV system shall be suitable for medium resistance earthing with earth fault current limited to 300A.4. It shall be able to start the largest motor at 80% base load.4 4.1. Each radiator bank shall have at-least two extra radiators for use in case of leakage in any other radiator. The UAT shall be provided with 2 x 50% detachable built on radiator banks and if it is not possible to have built on radiator banks.3 TCE FORM NO.3 except for the following variations.ANDHRA PRADESH POWER DEVELPOPMENT COMPANY LTD.1 4. ISSUE R0 87 4.6 kV and 400 V switchgear & the voltage dip at motor terminals not exceeding the limits specified in Section D 3. Impedance The impedance of the transformers at taps corresponding to nominal transformation ratio (primary taps) shall be selected keeping in view the short circuit level of the 6.

ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.
DATA SHEET – A 3.4 UNIT AUXILIARY TRANSFORMER SL. NO. 1.0 2.0 Type No load voltage - HV - LV 2.1 3.0 Rating on ONAF Cooling method (a) (b) 4.0 ONAN ONAF % % 80% 100% kV kV MVA DESCRIPTION UNITS

SECTION : D 3.4 SHEET 2 OF 3
SPEC NO.

.

TCE-5960A-H-500-001

VALUES / REQUIREMENTS UAT Outdoor, two winding * 6.9 28 ( tentative)

Overfluxing capability

110% continuous, 125% for 1 minute, 140% for 5 seconds

5.0

Winding connections HV LV Vector group Delta Star Dynll

6.0

Impulse (1.2 / 50 microsecond) / power frequency withstand voltage windings HV LV HV (n)
0

*/* 60 kVP / 20 kV (rms) --C C 50 55

7.0 8.0 9.0

Maximum temperature rise of oil Maximum temperature rise of winding Tapping particulars (a) (b) (c) (d) (e) Tap Tapping range Tapping step Category of voltage variation Tapping power

0

ON LOAD CIRCUIT TAP CHANGER % % ±10% 1.25 -

10.0

Bushing particulars (a) Voltage class HV / LV / HV (n) / tertiary R0 PPD. BY RKD JUNE’ 10 CKD.BY HA DATE TCE FORM NO. 330 R3
88

* / 7.2 kV / JOB NO. 5960A CLIENT : APPDCL PROJECT : 700MW CCCP AT NEDUNOOR, KARIMNAGAR DIST.

REV. NO. DATE REV. BY

ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.
DATA SHEET – A 3.4 UNIT AUXILIARY TRANSFORMER SL. NO. DESCRIPTION UNITS

SECTION : D 3.4 SHEET 3 OF 3
SPEC NO.

.

TCE-5960A-H-500-001

VALUES / REQUIREMENTS

(b) (c)

Standard applicable Creepage distance

IS-2099 31 mm / kV based on line to line highest system voltage

(d)

Clearance in air (i) (ii) Phase-Phase-HV / LV Phase-Earth-HV/LV/HV(n) * / 127 * / 127/Opaline Green Not to exceed values specified in NEMA TR-1

11.0 12.0 13.0 13.1

Paint shade Noise level Loss evaluation formula Formula for evaluation of Bids

Evaluated price + (A x guaranteed no-load loss in KW) + (B x guaranteed load loss in KW) + (C x guaranteed cooler loss in kW) A = Rs. 3,80,000 / kW B = Rs. 2,60,000 / kW C = Rs. 2,32000 / kW

13.2

Rates of liquidated damages for exceeding the guaranteed losses No load loss Load loss Load loss

Rs/kW Rs/kW Rs/kW

A = 3,80,000 B = 2,60,000 C = 2,32000

Note: - (*) By Bidder

REV. NO. DATE REV. BY

R0 JUNE’ 10

PPD. BY CKD.BY DATE

RKD HA

JOB NO. 5960A

CLIENT : APPDCL PROJECT : 700MW CCCP AT NEDUNOOR, KARIMNAGAR DIST. TCE FORM NO. 330 R3

89

ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.

SECTION:

D3.5

1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS - BUS DUCTS

SHEET 1 OF 15 SPEC. NO. TCE.5960A-H-500-001

A)

ISOLATED PHASE BUS DUCTS (IPBD) The Isolated phase bus duct (IPBD) and its accessories shall conform to the latest editions of national and international standards indicated in Data sheet – A 3.5 IPBD. Also, the IPBD and its accessories shall comply with the requirements indicated in Data Sheet–A 3.5 and specific requirements indicated below:

5.1

Isolated phase bus duct forming the main current carrying leads shall be used in following circuits: Generator phase side terminals to respective GCB, GCB to Generator transformer LV terminals for GTG and generator phase side terminals to generator transformer LV terminals in the case of STG. Tap-off bus duct for Unit Auxiliary Transformers in the case of GTG. Tap-off bus ducts for VT and SP cubicle, static excitation transformer (if applicable) Bus duct to generator neutral side terminals to neutral grounding equipment panel, which shall house a neutral earthing transformer and neutral earthing resistor. The CTs etc., to be located in the Isolated phase bus duct shall be as per the enclosed Main one line diagram – Drg. No. TCE.5960A-EL-SK-2003. Current transformers as required shall be located in the above bus duct. If the generator transformer is three numbers single phase units, then the delta formation of the LV Windings shall be carried out with Isolated Bus Duct. The voltage class of the bus duct shall be as follows: Generator voltage (a) Upto 12 kV (b) More than 12 kV upto 21 kV Bus duct voltage class 12 kV 24 kV

5.1.1

5.1.2 5.1.3

5.1.4

5.1.5

5.1.6

5.1.7

5.2

Sizing and Design

ISSUE R0
90

TCE FORM NO. 329 R5

ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.

SECTION:

D3.5

1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS - BUS DUCTS

SHEET 2 OF 15 SPEC. NO. TCE.5960A-H-500-001

5.2.1

Sizing of the bus duct shall be arrived based on the continuous and short time rating of the respective circuit. The continuous current rating of the main (generator) bus duct shall be arrived at considering the maximum output of the generator and at specified minimum voltage. Short time current rating of the main busduct shall be for 1 second and shall be decided as follows:. (a) Higher of the short circuit current contribution from generator OR the short circuit current contribution from 400 kV system through generator transformer (400 kV system fault level 50 kA) Plus (+) Contribution of 6.6kV auxiliary power supply system through UAT. (b) Momentary current rating shall be 2.55 times the short time current rating arrived as above.

5.2.2

5.2.3

5.2.4

The short time and momentary current rating of all tap-off bus ducts (to VT and SP cubicle) shall be as follows: (a) Short time current rating for 1 second: (i) Short circuit current contribution from generator Plus (+) (ii) Short circuit current contribution from 400 kV system

NOTE: Negative tolerance allowed in the standards shall be considered for generator and generator transformer impedance for calculation of short time ratings in clauses 5.2.3 and 5.2.4 above. 5.2.5 The bus duct shall be designed to withstand the internal or external forces resulting from the following: (a) (b) Normal operating conditions Momentary short circuit currents
ISSUE R0
91

TCE FORM NO. 329 R5

ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.

SECTION:

D3.5

1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS - BUS DUCTS

SHEET 3 OF 15 SPEC. NO. TCE.5960A-H-500-001

(c)

Rigorous / adverse weather conditions as detailed in project information section B Seismic forces as detailed in project information section B.

(d)

5.2.7

The degree of protection shall meet the requirements of water and air tightness test specified in IS-8084 and the degree of protection shall be IP-55 or better. The outside of the busduct shall be painted with 631 of IS-5. Specific Requirements The bus enclosure shall be of continuous bonded type. The material of bus conductor & enclosure for main run shall be Al alloy grade 19501 (H2) of IS-5082. The material of bus conductor for tap-off shall be Al alloy grade 63401 WP (range 2) & for enclosure material shall be Al alloy grade 19501 (H2). Inspection covers for periodic inspection of the insulators shall be provided. There shall be no joints or fixing bolts on top of the enclosure through which water can seep. The outdoor portion of the bus duct shall take into account heating effect due to solar radiation and shall be provided with a continuous rain hood of non-magnetic material suitably supported from the bus duct support structure. The bus conductor shall be given a coat of matt black paint to facilitate heat dissipation. However, the sizing of the bus conductor shall consider the conductor as bare. The process of silver plating shall be approved by the owner. Each phase shall be enclosed in weatherproof, dust tight, non-magnetic metal enclosure. The enclosure shall be designed for welded connections. The enclosure shall be of minimum flux type to permit not more than five (5) percent of total, magnetic flux outside enclosure. The enclosure shall be insulated at the connections to various equipment so that the longitudinal current will not flow through or be transmitted to any connecting equipment. The insulation shall be nondeteriorating and shall be clearly indicated on the Contractor’s drawings.
ISSUE R0
92

5.3 5.3.1

5.3.2

5.3.3

5.3.4

5.3.5 5.3.6

5.3.7

TCE FORM NO. 329 R5

ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.

SECTION:

D3.5

1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS - BUS DUCTS

SHEET 4 OF 15 SPEC. NO. TCE.5960A-H-500-001

5.3.8

The Contractor should ensure that no load is transferred on electrical equipments transformers, generator terminals etc. by the busducts. The bus conductor shall be designed for welded connections except at equipment terminations, bolted disconnect links, and bolted flexible. Detailed welding procedure adopted by the manufacturer should be furnished along with the offer and approved by the Owner. Flexible connections shall be provided between bus sections to allow for expansion and contraction of the conductor. Flexible connections shall also be provided at all equipment terminations. The bus support insulators shall be mounted on resilient pads. The bus support insulator shall be interchangeable, high strength & fine glazed porcelain manufactured by wet process or high strength epoxy resin cast. The voltage rating shall depend upon generation voltage. The spacing of the bus support insulators shall be considered by giving due factor of safety to withstand the forces due to the momentary short circuit assigned for the bus duct. Wall frame assembly and seal-off bushings shall be provided where the bus duct passes from indoor to outdoor area to prevent condensation due to air temperature variation between indoor and outdoor portion. Wall frame assembly shall be fabricated out of aluminium angles and sheets. It shall be ensured that no load of the bus duct is imparted on the walls. The bus duct supports shall be fabricated from standard steel sections. The support structures shall be hot dip galvanised. Thermostatically controlled space heaters shall be provided along the length of the bus duct. Duplex RTD shall be provided for measurement of ambient air inside the bus duct. The same shall be hooked upto the DCS. The equipment terminal connections shall be readily accessible and shall provide sufficient air gap for safe isolation of requirement during electrical testing.

5.3.9

5.3.10

5.3.11 5.3.12

5.3.13

5.3.14

5.3.15

5.3.16

5.3.17 5.3.18

ISSUE R0
93

TCE FORM NO. 329 R5

ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.

SECTION:

D3.5

1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS - BUS DUCTS

SHEET 5 OF 15 SPEC. NO. TCE.5960A-H-500-001

5.3.19

If the material of bus conductor and that of the equipment terminal is different, then suitable bi-metallic connectors shall be provided by the Contractor. The electrically continuous bus enclosure shall be used as the grounding bus. All parts of the bus enclosure, supporting structure and equipment frames shall be grounded to earthing mat. Neoprene Rubber bellows shall be provided at the termination point of the bus duct at various equipment. Rubber bellows shall also be provided in the run of the bus duct after gas turbine generator foundation block to avoid transfer of vibrations of GTG pedestal. In case of rubber bellows at intermediate locations flexible braids copper connection, shall be provided across the bellows to establish continuity of bus duct from end to end. Provision shall be made in bus duct at an approved location for installation of shorting bar having rated current carrying capacity same as that of main bus duct for carrying out generator stator dryout. A set of shorting bar along with requisite hardware shall be supplied for this purpose. A set of shorting bars along with requisite hardware shall be supplied for this purpose. Disconnecting links with rating same as that of the main bus conductor shall be provided in the run of the bus duct as required to facilitate disconnection of the bus conductor during testing. The IPBD shall be of natural air cooled type. Silica gel filters shall be provided both in indoor and outdoor portions of the bus duct for absorption of moisture. Seal off bushings (a) Seal-off bushings shall be provided at the entry of tap-off bus duct to the VT and SP cubicle, static start-up, unit auxiliary transformers, neutral grounding cubicle, etc. One set of seal-off bushings shall be provided in the bus duct after the generator bushings to prevent hydrogen leakage into the bus duct. Arrangement shall be provided to vent the trapped hydrogen in the portion between generator bushings and these seal off bushings (applicable for hydrogen cooled generators).

5.3.20

5.3.21

5.3.22

5.3.23 5.3.24

5.3.25

(b)

5.3.26

Two numbers earthing terminals with bi-metallic connectors shall be brought out at termination points of the bus duct, main and cross
ISSUE R0
94

TCE FORM NO. 329 R5

ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.

SECTION:

D3.5

1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS - BUS DUCTS

SHEET 6 OF 15 SPEC. NO. TCE.5960A-H-500-001

supporting structures, terminal boxes, adapter boxes, unit auxiliary transformer, VT and SP cubicle, etc., and for further connection to earthing grid. 5.3.27 5.4 5.4.1
5.5

All steel supporting structures and hardware shall be hot dip galvanised after fabrication. Pressurisation System Not used. Current Transformer The current transformers 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 range of 900C to 1000C. Mounting arrangement of CT shall be so designed so as to avoid equalizing connections between live conductor and CT inner surface. CT secondary leads shall be brought out through non-magnetic metallic conduits to a marshalling box (MB) with degree of protection IP-55 (IS:13947 Pt.1). The MB shall be provided with removable aluminium gland plate. The facility for shorting and grounding shall be provided at the terminal blocks. All CTs shall be tested for partial discharge. The partial discharge at 10 percent over voltage of the highest system voltage shall not exceed 50 pico coulombs. Arrangement shall be made to maintain potential of inner surface of busduct CTs at the same value as the conductor to prevent partial discharge. Protection CTs shall be rated for 5A secondary current and shall be of Class PS & Class 5P20. Metering CTs shall be rated for 5A secondary current and shall be of 0.2S accuracy class with instrument security factor less than 5. Voltage Transformer and Surge protection Cubicles 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, lightning arrester, V.T. L.V. side fuses etc. Lightning arrester shall be Gapless type station class, hermetically sealed, connected between line and ground, specifically suitable for
ISSUE R0
95

5.5.1

5.5.2

5.5.3

5.5.4

5.6 5.6.1

5.6.2

TCE FORM NO. 329 R5

6. with isolating links for testing of instrument transformers. The discharge counter register & leakage current measurement meter with suitable environmental protection covering. provided in the instrument transformer marshalling boxes. The voltage transformer shall be epoxy cast-resin type..6. Suitable guide slots and stops shall be provided to ensure easy withdrawal and positioning.5 1X 700 MW CCPP AT NEDUNOOR. N.3 A discharge counter along with the ampere meter shall be provided for each lightning arrester. to accommodate all VT leads.6. From phase cabinets the VT secondary leads shall be brought to marshalling box having sufficient number of terminals with 20% spare.5 5. The secondary side of voltage transformer shall be provided with MCB. Facility of making star points and undrilled gland plate for cable connections shall be provided in the marshalling box. NO. The facility for connecting with earthing grid. VT and CT secondary neutral or common lead shall be earthed at one place only at the terminal blocks.8 5. Cubicle Construction (V. connected from line to ground. ELECTRICAL SYSTEMS .6 5.BUS DUCTS SHEET 7 OF 15 SPEC.G.1 TCE FORM NO.4 5. TCE.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.6. the voltage transformer primary and secondary circuits shall be automatically disconnected. suitable for nominal voltage operation. KARIMNAGAR DIST. The degree of ISSUE R0 96 5.) All cubicle shall be fabricated from cold rolled sheet steel for minimum 2mm thick suitably reinforced to ensure structural rigidly.7 5.7 5. Mineral oil filled/Askarel (PCBS) filled surge capacitor shall not be acceptable.P. 5. 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. The fixed and draw out contacts of voltage transformer primary shall be tinned or silver plated.5960A-H-500-001 generator protection as per technical parameters given elsewhere in the specifications. 329 R5 .9 5. In the disconnected position. & S.6.6. The draw out frame shall be grounded at all times. SECTION: D3. shall be visible without having to open the compartment door. Cubicle etc.6.7. shall be provided by the Contractor through suitable connectors in the marshalling box. and as per Technical Parameters given in the specifications.T.

shorting and grounding. etc. Material for nameplate shall be embossed on SS plate & letters filled with indelible black ink. 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.5960A-H-500-001 protection for all indoor cubicle shall be IP:52 except for neutral grounding resistor enclosure which shall be minimum IP:23.1 5. internal illumination lamp. Name plate Name plates shall be furnished for each equipment.7. Hot Air Blowing Equipment Suitable facility shall be provided to blow hot air into the bus duct to evacuate moisture inside the bus duct during initial start-up and also after subsequent shutdowns for maintenance on the bus ducts.5 1X 700 MW CCPP AT NEDUNOOR.7. The wiring inside the bus duct enclosure (i.9. voltage transformer compartment. lightning arrester compartment and fuse block. ELECTRICAL SYSTEMS .2 5.3 5.8.2 5.8.5 mm² cross-section with suitable lugs on both sides. TCE. NO.9 5.1 ISSUE R0 97 TCE FORM NO. for CT etc.10.2 5.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.8.1 5. disconnect link. 230 V AC. Wiring All wiring shall be done with insulated stranded copper conductor of not less than 2. 329 R5 .10 5.3 Space heater.9.BUS DUCTS SHEET 8 OF 15 SPEC. current transformer TB. 5A receptacle. 5. KARIMNAGAR DIST. Not more than two wires shall be connected to a terminal. It shall be Elmex type CATD or equivalent.e.) shall be suitable for operating in the ambient temperature existing inside the bus duct. Each cubicle shall be equipped with space heater with thermostat. Illumination and Grounding.8 5. SECTION: D3. 5. Ground bus suitable for receiving two (2) numbers of 50x6mm galvanised steel flats shall be provided on each cubicle.

7 5.5 1X 700 MW CCPP AT NEDUNOOR.10. The mobile trolley shall be common for the specified number of bus duct units. capable of blowing hot air simultaneously in the indoor and outdoor portions of the bus duct.8 5. Suitable provision shall be made to isolate this system after the drying operation is complete.6 5. The system shall be suitable for operation at low voltage 3 phase AC supply indicated under project information.10. shall be provided with the necessary control. valves.10.5 5. The hot air blowing system shall be complete with motor blower unit.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. control.3 5. dampers.10. necessary ducting. Hot air shall be distributed by properly sized ducts and dampers to the indoor and outdoor portions of the bus duct. The system shall be sized to completely dry the entire bus duct installation within two hours. b) Impulse withstand test ISSUE R0 98 TCE FORM NO. A local control cabinet mounted on the trolley.10.11 5.10. TCE. flexible connections and current transformers.11. ELECTRICAL SYSTEMS . SECTION: D3. heaters. all mounted on a mobile trolley. 329 R5 .BUS DUCTS SHEET 9 OF 15 SPEC. piping. The bus duct assembly tested shall include bolted connections. combination starter. KARIMNAGAR DIST.2 The hot air blowing system shall be open loop type.4 5. NO. The tap off air ducting from IPB to mobile trolley delivery flange is included in Bidder’s scope of supply.1 Type Tests a) One minute power frequency withstand voltage test. instrumentation and monitoring system. indication and monitoring devices. thermostats. 5. The bus duct of each unit shall be provided with suitably supported inlet ducting with blanking plates. Tests & Test Reports The following type and routine tests shall be conducted on representative section of the bus duct assembly.10. Hot air shall be let out through suitably directed outlets provided at the indoor and outdoor portions of the bus duct and at each equipment suitably. washable filters.5960A-H-500-001 5. Ambient air will be drawn in through inlet dampers and dry air filters and then forced through thermostat controlled heaters.

5960A-H-500-001 c) Temperature rise test of black matt painted conductors & enclosures d) Short time current test e) Dynamic current withstand test f) Water-tightness test g) Air tightness test h) Milli-volt drop test 5. Temperature rise at rated current considering effect of solar radiation.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. a) b) c) d) Conductor size Guaranteed kW losses in conductor & enclosure Supporting span Dynamic and static forces transferred to TG foundation. TCE.12.12 Bidder shall furnish the following calculations for main run and tap off run busduct.2 Routine Tests a) One minute power frequency withstand voltage test b) IR measurement 5. SECTION: D3. ELECTRICAL SYSTEMS . 5. 329 R5 .BUS DUCTS SHEET 10 OF 15 SPEC. NO.5 1X 700 MW CCPP AT NEDUNOOR. KARIMNAGAR DIST.1 ISSUE R0 99 TCE FORM NO.11.

The enclosure shall be rectangular and shall be made of aluminium alloy sheets for SPBD and for NSPBD the same shall be of mild steel. The continuous rating of the bus duct from UAT to 6.6 kV switchgear.3 5.13 5. The short time and momentary current ratings of the bus ducts shall be same as that of associated 400V switchgear. 5.15.14.14.15.15.1 5.13.2 5. SECTION: D3.14.13. TCE. The short time and momentary current ratings of the bus ducts shall be same as that of associated 6.3 ISSUE R0 100 TCE FORM NO. The busbars in the bus-duct shall be sleeved with FRLS heat shrinkable.2 5.5960A-H-500-001 B) 5.6 kV switchgear.5.3 5.15 5. Non-Segregated Phase Bus Ducts [NSPBD] 1.14.2 kV class segregated phase bus duct and accessories shall be provided for connection of the two winding unit auxiliary transformer to 6. NSPBD shall also be considered for connections between other switchgear / MCCs to suit the layout. NO.14 5. Specific Requirements The bus conductor shall be of Aluminium alloy grade 63401 WP (range 2) as per IS: 5082. KARIMNAGAR DIST. the phase segregation shall be of either aluminium or non-hygroscopic insulating material like fibreglass. In case of segregated phase busduct. The continuous rating of the bus duct shall be same as the rated current of respective switchgear bus.BUS DUCTS SHEET 11 OF 15 SPEC. ELECTRICAL SYSTEMS . 329 R5 .4 5.2 5.2 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.1 HV & LV Bus ducts Segregated Phase Bus Ducts [SPBD] 7. colour coded XLPE sleeves.5 1X 700 MW CCPP AT NEDUNOOR.1 5.13.6 kV switchgear bus.1 kV class non-segregated phase bus duct and accessories shall be provided for connection between all service transformers and their respective 400V switchgear.6 kV Switchgear shall be same as the rated current of 6.

15. Inspection covers for periodic inspection of the insulators shall be provided.15.5 5. SECTION: D3.10 5.15. The bus duct supports shall be fabricated from standard steel sections.6 5. ELECTRICAL SYSTEMS .BUS DUCTS SHEET 12 OF 15 SPEC. Thermostatically controlled space heaters shall be provided along the run of bus duct. 329 R5 . 5. TCE. There shall be no joints or fixing bolts on top of the enclosure through which water can seep.15.15.1 kV class for non-segregated phase bus ducts and shall be mounted on resilient pads. The joints along the conductors shall be of highest quality and the temperature rise test shall be conducted including the joints.15.4 Flexible expansion joints shall be provided for the conductor and enclosure along the run of the bus duct length to take care of expansion.12 5.15. Wall frame assembly and seal off bushings shall be provided where the bus duct passes through walls (indoor to indoor).15.5960A-H-500-001 5.13 5. KARIMNAGAR DIST.15.15 ISSUE R0 101 TCE FORM NO. The support structures shall be hot dip galvanised. The bus support insulators shall be of 7. The adjacent sections of the bus conductor shall be welded or bolted.7 5. The outdoor portion of the bus duct shall be provided with a continuous rain hood of non-magnetic material suitably supported from the bus duct support structure.2 kV class (as required) for segregated phase bus ducts and 1.9 5. The spacing of the bus support insulators shall be considered by giving due factor of safety to withstand the forces due to the momentary short circuit current assigned for the bus duct. Wall frame assemblies with seal off bushing shall be provided where bus ducts pass through walls (outdoor to indoor).8 5. The bus conductors shall be given a coat of matt black paint to facilitate heat dissipation. The material of insulator shall be epoxy resin cast. These shall be fabricated out of aluminium angles and sheets.15.11 5. Also flexible joints shall be provided at the termination points.15. However the sizing of the bus conductor shall consider the conductor as bare.5 1X 700 MW CCPP AT NEDUNOOR.15.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. NO.14 5.

17.5 1X 700 MW CCPP AT NEDUNOOR. NO. joints etc. Description Requirement for Segregated Phase Bus duct Natural air 40oC 30oC Non-segregated Phase Bus duct Natural air 40oC 20oC 5.3 TCE FORM NO. following type tests shall be conducted (a) (b) (c) (d) (e) air tightness test water tightness test Temperature rise test Short circuit current withstand Impulse withstand test For NSPBD.18. Technical Requirements Segregated/non-segregated phase bus ducts shall comply with the particulars indicated in the following table. KARIMNAGAR DIST. ISSUE R0 102 5.18 5.1 Data to be furnished with the Bid Technical particulars for the segregated/non-segregated phase bus ducts as per Table below. SECTION: D3. TCE.17 On all the pieces of SPBD & NSPBD applicable routine tests shall be conducted.BUS DUCTS SHEET 13 OF 15 SPEC. on one typical section of SPBD containing bends. Experience list of the make of bus duct proposed..15. type test certificates shall be furnished. 5.18. test certificates shall be furnished for bought out items.15. No.16 At the factory. air tightness test and water tightness tests shall be conducted at site on fully assembled bus duct.18.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. Sl.1 (a) Type of cooling (b) Maximum temperature rise of conductor over 50oC ambient (c) Maximum temperature rise of enclosure over 50oC ambient 5.2 5. 329 R5 . HV voltage test.18 5.16 5. ELECTRICAL SYSTEMS .5960A-H-500-001 5. Also. Typical calculation for arriving at the size of the conductor and the insulator spacing.15.

14.13.19 (e) One second short circuit kA rms withstand rating (as per clauses 5.No.13.4 Type test report (short circuit.5960A-H-500-001 5.2) Amps (f) ISSUE R0 103 TCE FORM NO. ELECTRICAL SYSTEMS . (a) (b) (c) (d) Description Designation (from & to) Manufacturer Applicable standard Momentary short circuit withstand current (as per clauses 5.BUS DUCTS SHEET 14 OF 15 SPEC.3 & 5.14.2 & 5. 329 R5 .) Sl. TCE.5 1X 700 MW CCPP AT NEDUNOOR. Technical Particulars (To be separately furnished for each rating of segregated and nonsegregated phase bus ducts.18. SECTION: D3. temperature rise test) for similar bus duct manufactured by the proposed manufacturer. impulse withstand. KARIMNAGAR DIST.3) Continuous current rating at 50oC design ambient air temperature (as per clauses 5. NO.3) kA peak Unit Technical Particulars 5.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.13.

0 6. BY CKD. DATE REV. NO.0 Type of bus duct Type of cooling Maximum temperature rise of over an ambient temperature of 500C Conductor (Hot spot) Enclosure (Cold spot) Applicable codes and standards Bus conductor material Porcelain bushing Porcelain post insulators Hot dip galvanising Interconnecting busbars Creepage distance for insulators and bushing Voltage of : (i) Acc. DATA SHEET – A 3.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.5960A-H-500-001 VALUES / REQUIREMENTS Isolated Phase Bus Duct 1. NO. and neutral grounding transformer Duty rating (i) NGT (ii) NGR 30 Secs.2 Cont.0 3.5960A-EL-SK2003 1.Continuous Natural air cooled 3.4 4. 5960A CLIENT : APPDCL PROJECT : 700 MW CCPP AT NEDUNOOR. KARIMNAGAR DIST.9 for 30 seconds.0 REV. Cast epoxy resin IS :5082 IS : 2099 IS : 2544 IS : 2629 IS : 8084 25 mm/kV of rated voltage 0 Isolated Phase Bus Duct .5 SL. NO. class (ii) Rated voltage factor 7. 30 Secs.2 4. TCE.1 3. 330 R3 104 .1 4. BY R0 JUNE’ 10 PPD. Refer Main Line Dia TCE. 1.2 4..0 Type of insulation for current trf. DESCRIPTION UNITS SECTION: SHEET D3. TCE FORM NO.5 5.BY DATE RKD HA JOB NO.0 2.0 C C 55 30 0 8.5 15 OF 15 SPEC.0 4.3 4.

Dead machine protection shall receive their DC power supply from station DCDB as appropriate. TCE. ELECTRICAL SYSTEMS – GENERATOR. timers. transducers etc.. auxiliary relays. its subsystems. generator transformer and unit auxiliary transformer. these two groups will derive DC supply from two separate feeders. Similarly.. SECTION: D3. supervision of trip relays. CT and PT supervision and supervision of both trip circuits shall be provided.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. 329 R5 105 .1 GENERATOR PROTECTION Complete protection system consisting of protective relays. However.5960A-H-500-001 6. Hence. This panel will be located in the Main control room. etc.6 SHEET 1 OF 8 1X 700 MW CCPP AT NEDUNOOR. Class. supervision of protective relays.2 6. Class – A trip shall be classified into GCB & field breaker trips (Class-A1) and GT HV breaker Trip (Class-A2).2 6. Both groups of protection shall be divided into these three modes of tripping. The breaker failure relays connected with 400 kV generator transformer bay and relays connected with 400 kV bus bar protection shall be housed in separate relay panels which will form part of 400 kV switchyard protection system. 6. The generator protection system relays shall be classified into three categories viz. physically and electrically separated into two separate and independent systems. One group shall be receiving all AC and DC signals from one set of devices and the other from another set of devices. 6. Generator Protection All the protective relays. to protect the complete generator.1 Protection Philosophy The protection philosophy of every equipment shall be divided into two 100% groups namely two main protection groups. shall be provided to protect the generator..4. Class-B shall trip GCB or GT breaker on reverse power through Class A1 or A2. Complete protection of the respective equipment shall be fully available even if either of the group is not available. KARIMNAGAR DIST. auxiliary relays. the relays in each group shall be tripping the circuit breaker through both trip coils I & II.3 ISSUE R0 TCE FORM NO. both groups shall be mechanically. GENERATOR TRANSFORMER AND UAT PROTECTIONS SPEC. Monitoring devices such as supervision of DC supplies. NO.C shall trip GT HV circuit breaker.3.3 6.3. its subsystems shall be housed in generator relay panel (GRP).0 6. timers.

Loss of excitation relays shall be with two independent outputs for conditions with and without under voltage. Pole slipping relay protection (78G). NO. Numerical relays shall have adequate output contacts for tripping. TCE. GENERATOR TRANSFORMER AND UAT PROTECTIONS SPEC.6 kV switchgear. contact multiplication relays shall be provided if necessary. (g) Negative phase sequence protection (46 G). dead machine protection and pole slipping protection. Both the list and the drawing shall be considered Complementary to each other and all the protections indicated shall be provided. Generator stator 95% back-up earth fault protection (64 G3). Two identical numerical relays shall be provided for generator protection. A dedicated operator station shall be provided in the Main control room for setting the numerical relays of Generator protection and 6. Contractor shall include any additional protections deemed necessary by him for the equipment offered even if not indicated in the list and the drawings. (h) Back-up impedance protection (21G). GT and UAT.. 329 R5 106 . It shall have a definite time stage for alarm and inverse stage for trip.4. ELECTRICAL SYSTEMS – GENERATOR. Main One Line Diagram drg. interlocking etc. Numerical relays shall be provided for main protection of Generator. They should likewise have adequate number of opto couplers for external trip inputs. No. Generator stator 95% earth fault protection (64G2). etc.5960A-H-500-001 6.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.5960A-EL-SK-2003 indicates various protections envisaged.4 The protections envisaged in GRP are listed below. ISSUE R0 TCE FORM NO. In addition they shall have an output of 4-20 mA for remote indication of negative phase sequence current. SECTION: D3. Loss of excitation protection (40 G).6 SHEET 2 OF 8 1X 700 MW CCPP AT NEDUNOOR. However.TCE. static relays have to be provided for PT supervision. KARIMNAGAR DIST. annunciation. (a) (b) (c) (d) (e) (f) Generator differential protection (87G) Generator stator 100% earth fault protection (64 G1).. Also.

5960A-H-500-001 (i) Stator over-load alarm relay (50 GS).ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. ELECTRICAL SYSTEMS – GENERATOR. Local breaker back up protection (50 LBB) with it’s own trip relay. GENERATOR TRANSFORMER AND UAT PROTECTIONS SPEC. SECTION: D3. TCE. NO. 60G23) Reverse power/ Low forward power protection (32 G/37G). 60G13 / 60 G21. Generator field over voltage protection (can be a part of excitation system) Over fluxing protection (99G) with inverse time characteristics.6 SHEET 3 OF 8 1X 700 MW CCPP AT NEDUNOOR. 4 stage with independent time and frequency adjustment. (k) (l) (m) Over voltage protection (59 G). (j) Generator VT fuse failure protection (60 G11. Over voltage protection shall have an instantaneous stage and a definite time stage with independent voltage settings. 60 G12. KARIMNAGAR DIST. (q) (r) (s) (t) (u) ISSUE R0 TCE FORM NO. Islanding protection schemes to isolate power plant from grid for disturbances in the grid. (n) (o) (p) Under voltage protection (27G) Dead machine relay (61 B). 329 R5 107 . 60 G22. Rotor earth fault (64F) 2 stage Inter turn fault protection through differential current measurement in case generator has six terminals brought out on neutral side Or Through residual voltage (Vo) with neutral biasing in case three terminals are brought on the neutral side. Under frequency protection (81 G). It shall be provided with timer to detect actual over load.

Generator transformer restricted earth fault protection (64 GT) Generator transformer back-up earth fault protection (51 NGT). generator transformer overall differential protection (87GTU) for STG and generator. 329 R5 108 . GENERATOR TRANSFORMER AND UAT PROTECTIONS SPEC. UAT overall differential protection for GTG (87 G/GT/UAT).5960A-H-500-001 (v) Generator.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.6 SHEET 4 OF 8 1X 700 MW CCPP AT NEDUNOOR. SECTION: D3. KARIMNAGAR DIST. generator transformer. NO. TCE. Tripping relays for protection devices of Generator Transformer (GT) and 63X / 49X for multiplying the contacts of protection. ELECTRICAL SYSTEMS – GENERATOR. (aa) For trip function (63X1/49X1) • • • • • • GT buchholz II stage (63TX) GT OLTC buchholz II stage (63 OLTC TX) GT winding temperature very high (49 WTX) GT oil temperature very high (49 OTX) GT pressure relief device operated (63 PTX) GT fire protection trip (63 FRTX) (w) (x) (y) (bb) For annunciation function (63x2/49x2) • • • • • • • • GT Buchholz I stage (63AX) GT OLTC buchholz I stage (63 OLTC AX) GT winding temperature high (49 WAX) GT oil temperature high (490AX) GT oil level low (OLAX) GT cooler supply failure GT cooler trouble GT OLTC trouble ISSUE R0 TCE FORM NO.

ISSUE R0 TCE FORM NO. GENERATOR TRANSFORMER AND UAT PROTECTIONS SPEC. data acquisition. transformer cooler circuit interlocks. UAT differential protection (87 UAT). UAT restricted earth fault protection (64 UAT). SECTION: D3. etc. ELECTRICAL SYSTEMS – GENERATOR. Contacts from each category of tripping relay for annunciation. 329 R5 109 . 400 kV circuit breakers tripping / close permissive. 6. NO..ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. Open delta VT for Pre-synchronising Earth fault (59NGT) 400 kV generator breaker trip coil supervision relays (98G1 to G4). TCE. winding temperature (49 WT) and oil temperature (49 OT) protections Auxiliary relays for protection devices of UAT 63 x 1/49 x 1 and 63 x 2 / 49 x 2 for multiplying their contacts. 10% spare contacts (both N/O and N/C). UAT instantaneous earth fault relay (51N UAT) High speed trip relays (86 G1 to GX): Adequate number of high speed trip relays for each category tripping and separately for each group shall be provided for the protection of the unit. Contacts for control.5960A-H-500-001 (z) (aa) (bb) UAT IDMT overcurrent protection on HV and LV sides (51) UAT Instantaneous over current protection on HV side (50) UAT – Buchholz (63).6 kV auxiliary supply breakers trip / close permissive. The quantity of the trip relays shall also consider the requirement due to the following: (i) Contact requirements from these relays to various systems covered under the scope of this contract.. LBB protection.6 SHEET 5 OF 8 1X 700 MW CCPP AT NEDUNOOR. protection and interlock in system viz. KARIMNAGAR DIST. and sequential event recorder and fault disturbance recorder. (cc) (dd) (ee) (ff) (gg) (ii) (iii) (iv) (hh) (ii) (jj) Supervision relays for tripping relays (98 GL1 to GLX).

3 The relay panels shall be provided with supervisory system facilities to indicate the location of the failed component when pre-engineered ISSUE R0 TCE FORM NO. The NC contact of the relays shall be delayed on drop off by approximately 100 to 200 m sec.2 6. The relay shall be provided with flag indicators wherever required.. GENERATOR TRANSFORMER AND UAT PROTECTIONS SPEC. All LEDs shall be 22. independent. for annunciation in Operator station/Generator control panel. timers in adequate number to make the protection & the scheme complete.5960A-H-500-001 (kk) Auxiliary relays. 329 R5 110 . White colour supervision lamps of clustered LED type shall be provided on GRP to indicate availability of DC supply.8 6.8.8. In addition to the relays/protections mentioned in this specification. In the Independent position Group-1 & 2 protection system will be fed by source 1 & 2 respectively and the common services from any one of the sources. TCE. KARIMNAGAR DIST. (ll) 6. Trip Matrix required for implementing class A/B/C tripping schemes shall be provided by the Contractor and shall be indicated in block interlock diagrams to be submitted. NO.8. ELECTRICAL SYSTEMS – GENERATOR.1 6.6 The characteristics and relay setting ranges shall be decided by the Contractor and shall be such as to provide complete protection for the generator under normal and all abnormal operating conditions. SECTION: D3.7 6. relays required for the discrepancy switch scheme in Generator control panel. Two Nos. 6. source-1 & source-2. These supplies shall be taken through a selector switch with the positions. Specific Requirements The protection system shall comprise pre-engineered modular or discrete self-contained systems comprising preferably of static relays.6 SHEET 6 OF 8 1X 700 MW CCPP AT NEDUNOOR. viz. DC auxiliary supply shall be supervised by supply supervising relays. DC supplies shall be arranged for the GRP. any additional protections/relays considered necessary by the Contractor for his system shall be included and offered by the Contractor. The parameters of the same shall be selected to suit the application and the same is subject to approval of Owner.5 mm size self coloured. Auxiliary VTs and Auxiliary CTs required for the protection systems.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. In case of failure of any one source (say source 1) switch shall be changed over to the other source (source 2) and complete DC supply requirement of GRP will be fed from the other source.

Contact multiplication relays for generator circuit breaker and associated isolators shall be provided for this purpose. transformer. Minimum electrical system requirements in respect of control.4. annunciation.6 SHEET 7 OF 8 1X 700 MW CCPP AT NEDUNOOR.8. 6.4 Either hand reset mechanically operated operation indicator or LED with reset push button shall be provided for protective relays.5 6. KARIMNAGAR DIST.12 111 . They shall be arranged to operate only when tripping current passes through output circuit of the relay. line and motor protection relays. shall be individually indicated in Operator station and also individually or appropriately grouped available in the annunciation windows in generator control desk / panel. abnormal conditions through the protection relays. NO. Control room alarms/indications/SER points Each of the alarms. (Further the lockout relay operation and certain grouped alarms shall be available in the SCADA/400kV-switchyard control system. Self checking facility ‘In-Built’ in the relay panel shall be provided with watch dog contact for remote annunciation and DCS. D2. This is in addition to self monitoring and watch dog facilities that will be built into these protective relays. measurement.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. One laptop of high configuration shall be provided with necessary software & hardware (with multiple licences) for setting the parameters & evaluation of numerical relays.1 6. synchronising are indicated in I&C system section No. timers by secondary injection. 329 R5 6. SECTION: D3. ISSUE R0 TCE FORM NO. annunciation windows.8.5960A-H-500-001 protection system is offered.9 6. trip conditions. In addition to the contacts required as per schemes.11 6. Testing Unit Two Nos. monitoring. alarms in Operator Station.10 6. The protection scheme shall include all the necessary contacts to achieve the schemes required. TCE. Contractor shall wire out to the terminal block atleast all NO & NC spare contacts of each of the relays. ELECTRICAL SYSTEMS – GENERATOR. GENERATOR TRANSFORMER AND UAT PROTECTIONS SPEC. sequence event recorder and for switchyard control panel annunciation wherever required. Selected alarm/trip conditions finalised during the detailed engineering stage shall be used for SER system. Operator station/SER shall have a time resolution of 1 (one) ms.11. of test kits shall be offered to test all of generator.

ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.. 329 R5 112 .13 Fault disturbance recorder Microprocessor based fault disturbance recorder shall be provided for each generator to record the graphic form of instantaneous values of voltage and current in all three phases and neutral. ISSUE R0 TCE FORM NO. KARIMNAGAR DIST. Facility of fast scan as well as slow scan feature to be provided to record transient as well as dynamic performance of the system. GENERATOR TRANSFORMER AND UAT PROTECTIONS SPEC. NO. open and close positions of relay contacts and breaker during disturbance etc. SECTION: D3. TCE. 6.14 Tests Tests shall be as mentioned in Section D3. ELECTRICAL SYSTEMS – GENERATOR.6 SHEET 8 OF 8 1X 700 MW CCPP AT NEDUNOOR.5960A-H-500-001 6.7 for Switchyard Relay Panels.

1 7.4.5 7.5960A-H-500-001 7.6 TCE FORM NO.1 400 kV SWITCHYARD A 400 kV switchyard shall be provided for evacuation of power generated in the plant through four (4) nos. The 400 kV switchyard shall consists of various bays for different configuration as follows: Description Generator Transformer 400 kV Line Bus Reactor Future bay (Spare) Total No. 329 R5 . ELECTRICAL SYSTEMS .0 7. The necessary line bay equipment.4.2 7. TCE. The Main One Line Diagram sketch no.4 7.3 7. monitoring.3 7. ISSUE R0 113 7. 420 kV circuit breakers 420 kV isolators 420 kV current transformers (CTs) 420 kV capacitor voltage transformer (CVTs) and electromagnetic voltage transformers (EMVTs).7 1X 700 MW CCPP AT NEDUNOOR.2 7.4.5960A-EL-SK2003 shows the switchyard scheme and arrangement of major equipment in the switchyard. KARIMNAGAR DIST. controls.4. 360 kV lightning arresters (LA’s) Wave traps & Coupling capacitors.400 kV SWITCHYARD SHEET 1 OF 51 SPEC. NO. SECTION: D3. 400 kV transmission lines. The switchyard shall include the equipment indicated below but not limited to the following.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. The 400 kV switchyard shall have one and a half breaker switching scheme. protection and SCADA system shall be provided by the Contractor.4. of Bays 3 4 2 1 10 7.4.4 The switchyard equipment shall be supplied and installed with all accessories to make the switchyard complete in all respects. generator transformer bay equipment with associated equipment. TCE.

13 7.7 1X 700 MW CCPP AT NEDUNOOR. PC. detection & protection system for switchyard.4.4. PLCC/OLTE panels. SECTION: D3.4.3 IEC 61850 (universal): Substation automation protocol ISSUE R0 114 TCE FORM NO.4.4.16 7. HMI.4. fault disturbance recorders.7 7. RTU (Remote Transmission Unit) for transfer of data to SLDC (State Load Dispatch Centre) and RLDC (Remote Load Dispatch Centre).5. communication and interfacing panels as required. 329 R5 . 7.9 Power line carrier communication (PLCC) system for 4 lines. Bus bars. earthing.14 7.12 7. Printer and evaluation software. KARIMNAGAR DIST.4. Outdoor kiosks housing BCUs.10 7. TCE. Air conditioning and ventilation system for control building and outdoor kiosks. Bus Reactor Design Criteria The switchyard shall be generally designed based on the following codes and standards. trenches and complete civil works including switchyard floors with RCC blocks.8 7.4.11 7. Stand alone disturbance recorders with associated network cabling.4. clamps and connectors.4. ABT (Availability Based Tariff) meters including necessary software & hardware for monitoring on dedicated PCs with suitable networking. 7. SCADA (Supervisory Control and Data Acquisition) system for entire switchyard with bay control units for each bay including event logging. etc.17. NO. Fire alarm. insulators. switchyard fences.18 7. protection panels.15 7. Switchyard structures.1 (b) (c) CBIP Technical Manual on layout of substation report No.5960A-H-500-001 7.5 7. Protection panels for all bays/equipment.400 kV SWITCHYARD SHEET 2 OF 51 SPEC.4. ELECTRICAL SYSTEMS . (a) IS 10118 – 1982 : Code of practice for selection installation and maintenance of switchgear and control gear – part-3 (Installation).ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.4.

The switchyard shall be designed for a fault level of 50 kA for 1 sec.400 kV SWITCHYARD SHEET 3 OF 51 SPEC.7 7.5. Bus reactor. The busbars shall be of standard ACSR or tubular aluminium / copper according to standard metricised iron pipe size (IPS) of suitable size. SECTION: D3.2 A creepage distance of 31 mm/kV on 400 kV shall be provided for circuit breakers. The associated metal part shall be permanently secured to the insulator. TCE. string insulators and 420 kV transformer bushings. suitability under short circuit conditions. The size and spacing of strung bus.8 7. CVTs. Insulators (a) Design of insulator shall avoid stresses due to expansion and contraction in any part of the insulator leading to deterioration. LA’s. ISSUE R0 115 7.7 1X 700 MW CCPP AT NEDUNOOR.3 p. NO.03 mm per annum. Bay buses shall be rated according to the circuit rating. minimum size of the shield wire shall not be less than 70mm2. and dynamic rating of 130 kA. if galvanised steel wires are used. KARIMNAGAR DIST.5 7.4 7.3 7. 329 R5 .5.u. The 400 kV system shall be designed to withstand the power frequency over voltage to 1. The conductor size of tubular bus and stranded conductors shall be based on the maximum load current. Allowance shall be given in the final size to account for corrosion of the shield wire during service at rate of 0. bus post insulators.5. The switchyard main buses shall be designed for continuous rating.9 (b) TCE FORM NO. EMVTs.5.5. ELECTRICAL SYSTEMS .ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. isolators.6 7.5. corona / voltage gradient and effect of solar radiation. air tight and shall be designed to withstand all shocks and stresses to which they may be subjected to during operation and maintenance. CTs.u and surge over voltage to 2. Calculation shall be submitted for Owner’s approval. All ferrous parts shall be hot dip galvanized. tubular bus and clamps connections shall be checked to limit the voltage gradient to 17 kV/cm to reduce corona effect. The size of shield wire shall be based on the lightning impulse current expected and the time duration for which it is likely to flow.5.5. However.5960A-H-500-001 7. The final temperature of the conductor when carrying full load current shall not exceed 850C with a maximum ambient temperature of 500C.5 p.

ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.11 ISSUE R0 116 TCE FORM NO. burns and other similar defects. Insulator hardware shall be corona free upto a falling power frequency visible discharge test voltage of 1. for the end shield wires. NO.1 times the maximum system voltage. TCE. 31 mm / kV. insulation level.e.. The criteria for deciding phase to phase clearance in case of strung conductors shall take into account that the conductor swing of one of the conductors (say R phase) with maximum wind velocity and the adjacent conductor (say Y phase) with 80% of maximum wind velocity at maximum sag conditions.7 1X 700 MW CCPP AT NEDUNOOR. (d) (e) (f) (g) (h) (i) 7. The zone of coverage for the shield wire shall be considered as 60 deg. There shall be no electric discharge between conductor and insulators. Electro-mechanical strength shall be selected with factor of safety of 2. free from laminations. and shall be thoroughly vitrified. Composite insulators can be of grey in colour.5960A-H-500-001 (c) The design shall ensure uniform compressive pressure on the joints.10 The lightning protection of switchyard shall be provided by lightning masts and shield wires. cavities and other flaws or imperfections. insulation level mechanical strength and pollution level requirements.5. i. when operating at normal voltage. Creepage chosen shall be suitable for high pollution. 329 R5 . tough and impervious to moisture. 7. pollution level and electro-mechanical strength. SECTION: D3. KARIMNAGAR DIST. All insulators shall be of homogeneous glazed porcelain or composite type with silicon shed profile.5. Tension and suspension insulator strings shall be anti-fog type selected based on the voltage. between the two shield wires and 45 deg.400 kV SWITCHYARD SHEET 4 OF 51 SPEC. free from blisters. which would cause corrosion or injury to any of the material. Porcelain glazing shall be uniform brown in colour. Bus post insulators shall be solid / post insulator anti-fog type and shall be selected based on the system voltage. ELECTRICAL SYSTEMS .5.

depending on the actual dimensions of the equipment keeping in view the design criteria / requirements and without sacrificing any maintenance space / conveniences. All structural steel and steel components in the switchyard equipment shall be of hop dip galvanised.6. the point of anchoring on TG building shall be such that the vertical angle of deviations is limited to 300C from horizontal plane.7 1X 700 MW CCPP AT NEDUNOOR. KARIMNAGAR DIST.1 7. current transformers and power transformers and flexible jumper connectors for connecting lightning arresters and voltage transformers. fixed type of terminal connectors for isolator terminals.2 7.13 The switchyard shall be designed for the seismic coefficient and wind pressure as indicated in Section-B. (a) Sum of all permanent normal loads (wind load on tubular bus + wind load on stack + dead weight of the tubes) x 2.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. NO.14 7. (b) Combination of all normal loads plus either maximum short circuit or earthquake load whichever is higher x 1 (factor of safety). The Contractor shall consider suitable bay width.5 (factor of safety).6.6 7..5 TCE FORM NO.5960A-H-500-001 7.5. phase spacing. The Contractor shall note that the sequence of bays shall be so arranged that the maximum horizontal angle of deviation of the incoming power and shielding conductors from Generator transformers do not exceed 300C.6. Switchyard Layout Requirements The Contractor shall adopt bolted type connectors for tubular bus conductors. ELECTRICAL SYSTEMS .5.5. 7.4 7. ISSUE R0 117 7. TCE.12 For the layout proposed by the Contractor the adequacy of the cantilever strength specified shall be checked considering the following factors of safety. clearances.6.400 kV SWITCHYARD SHEET 5 OF 51 SPEC. In the transformer yard. flexible type of terminal connector for circuit breakers.3 7. The tap off conductor shall be routed through a bus post insulator located near the transformer. etc. Similarly.6. the power conductor termination shall not be tapped off directly to the Generator transformer from the strung bus between the TG building and switchyard. SECTION: D3. 329 R5 . The switchyard shall be provided with access ways near the current transformers and circuit breakers.

civil works. marshalling box / junction box shall be with IP 55 degree of protection. The circuit breaker and its accessories viz. Each SF6 circuit breaker pole shall be provided with its own self-contained gas system.7. 329 R5 .5960A-H-500-001 7.6. The fence provided around switchyard shall be of 2500 mm minimum height and at a minimum distance such that section clearance is available from any live part.7 7.7.0.6.7 7.1 (b) (c) (d) ISSUE R0 118 TCE FORM NO. The SF6 circuit breakers shall be single pressure type and utilise puffer cylinder for interrupting currents. Earth mat of suitable size with closely spaced earth conductor shall be provided below the operating handle of individual switchyard equipment As per the allowed step & touch potential values in IS.7 1X 700 MW CCPP AT NEDUNOOR.400 kV SWITCHYARD SHEET 6 OF 51 SPEC.8 7. NO. SECTION: D3. 7.1 7.10 7. Lockable gates for personnel entry and equipment shall be provided at convenient locations. TCE. The fence shall be suitably earthed as per relevant Indian standards. The switchyard shall be enclosed in fence or wall around for safety and to prohibit unauthorised persons from entering.6 The cable trenches for the equipment shall be run as close to their foundations as possible even preferably touching. Tie beams between foundations of breakers of different phases are recommended as during closing / opening operation additional load in the form of vibrations may be transferred to the foundations. Design criteria for civil works and structures shall be as specified in Section-D4. the gap between open contacts shall be suitable to withstand at least rated voltage at zero gauge pressure of gas. KARIMNAGAR DIST. The breaker shall be so designed that upon loss of pressure. Switchyard Equipment Circuit Breaker (a) The 420 kV circuit breakers shall be of SF6 outdoor type.6.6.6. The circuit breakers shall comprise three identical single phase units with operating mechanism suitable for single pole operation.9 7.1. ELECTRICAL SYSTEMS .ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.

Duty cycle for the breakers shall be O-0. The trip coils shall have sufficient continuous rating to cater to the trip coil supervision relay current. The operating mechanism shall also have pressure switches for low alarms. It shall be anti-pumping type and trip-free.400 kV SWITCHYARD SHEET 7 OF 51 SPEC. ELECTRICAL SYSTEMS . Manually operated emergency trip push button or any other device.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. high alarm.7 1X 700 MW CCPP AT NEDUNOOR.2 Operating mechanism (i) Circuit breakers shall be operated by spring / spring charged mechanism. SF6 breakers shall be provided with temperature compensated SF6 density switches for individual poles with separate lockout. NO. Circuit breakers shall be suitable for rapid auto re-closing duty. alarm and blocking contacts. lock out switches for close.7. conveniently located for mechanical tripping of all the three phases simultaneously shall be provided. 329 R5 . 7. TCE. trip. KARIMNAGAR DIST.C. (ii) ISSUE R0 119 TCE FORM NO. open and reclose operation. (f) (g) (h) (i) (j) (k) (l) (m) The middle breakers and the outgoing line breakers shall be provided with PIR. All the circuit breakers in the switchyard shall be of identical make and type with interchangeable components to maximum possible.5960A-H-500-001 (e) Design of circuit breaker shall be such that contacts shall not close automatically upon loss of gas / air pressure.1. Two trip coils shall be provided for greater reliability. One O-C-O operation shall be possible with failure of AC supply. circuits for two trip coils shall be separate and each of them shall be monitored separately. Temperature compensated SF6 Density monitor to be provided for each phase at such a level so as to enable viewing and reading.3sec-CO–3min-CO under all normal and fault conditions. SECTION: D3. D.

ELECTRICAL SYSTEMS . AC motor. Contractor shall supply spare SF6 gas equal to 20% of the total requirement for the station.5 7. (iv) A closing release shall operate correctly at all values of voltage between 80% and 110% of the rated voltage.7.4 7. 2 nos. 3 phase.400 kV SWITCHYARD SHEET 8 OF 51 SPEC.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.1.1. (b) Isolators & Earth switch shall be suitable for operation on 400V. 329 R5 .3 One set of SF6 gas filling. of gas leak detector shall be included in the scope of supply. NO. A shunt trip shall operate correctly under all operating conditions of the circuit breaker upto the rated breaking capacity of the circuit breaker and at all value of supply voltage between 50% and 110% of rated voltage. (v) Mechanical interlocks shall be provided in the operating mechanism to prevent discharging of closing springs when the breaker is already in the closed position. Earth switches shall be motor ISSUE R0 120 7. KARIMNAGAR DIST.2 TCE FORM NO. it shall also be possible to operate them manually in the event of failure of power supply or outage of the drive motor with proper interlock provision for isolation of motor in case of manual operation. Isolators & Earth Switch (a) Isolators shall be horizontal centre break type suitable for horizontal upright type of mounting.1.7 1X 700 MW CCPP AT NEDUNOOR. Type test certificates for all tests carried out on identical circuit breaker as per IEC-62271-100 shall be furnished. However.7.5960A-H-500-001 (iii) Separate pole discrepancy circuit with proper relay and other accessories shall be provided.7. Provision shall be made to prevent a closing operation to be carried out with the springs partially charged.7. The equipment shall be trolley mounted. All routine tests on the circuit breakers shall be carried out as per IEC62271-100. Disagreement circuit shall be provided which shall detect pole position discrepancy. Detectors shall be of reputed make and have Visual as well as Audible sound facility when leakage is detected. All circuit breakers controlling the lines shall be provided with either closing resistors or proven controlled switching devices to reduce over voltages and in-rush currents. SECTION: D3. gas regulator with manometer and necessary coupling for filling gas in the breaker shall be provided. evacuation and refilling equipment consisting of trolley mounted compressed SF6 cylinder. TCE. 7.

phase coupling rods. NO.5960A-H-500-001 operated with proper interlock so that it shall not operate in case respective isolator is ON and other requisite conditions are not met. Similarly they shall open after isolator opens and breaks the primary current. SECTION: D3.e. 329 R5 . TCE.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. Interlocking scheme shall be so designed as to ensure absolute safety maximum flexibility and proper switching of CT and PT circuits. Tripping of drive. (c) Isolators shall be electrically interlocked with the circuit breakers in accordance with the switchyard safety interlocking scheme. The Disconnecting switches and earth switches shall be independent pole and gang operated. bolts. Manual operating handles shall be galvanised steel. KARIMNAGAR DIST. Electrical remote. operating mechanism boxes. loss of AC drive supply and DC control supply shall be wired for giving alarm. Electrical local and Manual local. Flexible copper earth connectors shall be provided for connecting operating handles of isolators and earthing switches to the earthing system.400 kV SWITCHYARD SHEET 9 OF 51 SPEC. All castings except current carrying parts shall be made of malleable cast iron or cast steel. ISSUE R0 121 TCE FORM NO. brazed to the channel base.7 1X 700 MW CCPP AT NEDUNOOR. The interlocks shall be effective for all modes of operation i. (d) The design of the auxiliary switches for the isolators shall be such that signalling of the closed position shall not take place unless the contact system has reached such a position that the rated current and the rated short time current can be carried safely. ELECTRICAL SYSTEMS . Bolt type interlock and any special accessories required on the isolator side for satisfactory operation of scheme shall be included. signalling of the open position shall not take place unless the contact system has reached a position of at least 80 percent of the clearance distance of the isolating distance. (e) Base channels and other structural steel members such as operating pipes. (f) The isolator and earthing switch shall be provided with high current carrying contacts on the hinge and jaw ends and all contact surfaces shall be of silver faced copper. shall be hot dip galvanised or metallised. The poles of the isolators shall be mechanically ganged. (g) Each pole of the isolator shall be provided with two earthing pads of non-corrodible material at opposite ends. etc. pins. Contacts used for CT switching shall make before the isolator closed and starts carrying current.

The operating mechanism box shall have enclosures conforming to IP 55. SECTION: D3. the power operation shall be made inoperative. 329 R5 . TCE. Pad-locking facility shall be provided for the manual operating handle. (m) Operating Mechanism and Controls (i) The manual operating handles shall be mounted on the base of supporting structure. The flexible copper connections between rotating shaft of earth switch and frame shall have a cross section suitable to withstand the short time current. auxiliary switches etc. control valve solenoids. (i) Isolator and earthing switch shall be mechanically interlocked such that it will not be possible to close the earthing switch when the isolator is closed and vice-versa.7 1X 700 MW CCPP AT NEDUNOOR. NO. The arrangement shall be such that when manual operating handles is in the engaged position. KARIMNAGAR DIST. (ii) ISSUE R0 122 TCE FORM NO. Isolator shall be provided with electrical interlocking feature in all modes of operation.400 kV SWITCHYARD SHEET 10 OF 51 SPEC. ELECTRICAL SYSTEMS . It shall be possible to release the latch by energising the interlock coil when certain pre-set conditions of interlocking scheme are fulfilled. motor starters.5960A-H-500-001 (h) Earthing switch shall be provided with some isolators as indicated in main one line diagram. (l) Isolator shall be provided with mechanical interlocking feature in addition to electrical interlocking feature described above. Arrangement shall be provided to permit manual operation of power isolators.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. A weather-proof galvanised sheet steel cabinet with gasket hinged door and padlocking facility shall be provided to house the driving mechanism. This shall be in the form of bolt interlock comprising an interlock coil of latch in type to lock the isolator driving shaft and hence prevent isolator operation in the latch-in condition. Two independent earthing pads each with flexible copper braids (tinned or suitably treated against corrosion) and suitable connectors for the specified size of earth conductor lead shall be provided at the hinge end of the switch. (j) (k) Electrical interlocking arrangements shall be fail-safe type.

ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.7. future additions. One assembled isolator shall be subjected to 1000 operations for checking mechanical endurance. their operating devices and auxiliary equipment.5960A-H-500-001 (n) All routine tests as per IEC 60129 shall be carried out. The CTs and EMVTs shall be either oil filled hermetically sealed or SF6 gas filled single phase type.7 1X 700 MW CCPP AT NEDUNOOR.2S for tariff metering for each line. lead burden etc. The VA burden of the tariff metering CTs shall be subject to the approval of grid authorities.400 kV SWITCHYARD SHEET 11 OF 51 SPEC. Separate CT cores for Main-1 and Main-2 Carrier aided Distance Protection (21) for each line. (b) (c) (d) (e) (f) (g) ISSUE R0 123 TCE FORM NO. capacitor voltage transformers (CVTs) and Electromagnetic Voltage Transformers (EMVTs) (a) Electromagnetic VTs shall be provided for tariff metering (if required by grid) and CVTs for other metering and protection. Type test certificates for all tests carried out on identical isolators as per IEC60129 shall be furnished. Metering cores of CTs and EMVTs/CVTs shall be with accuracy class 0. 7. gas density monitors with remote alarm facility shall be provided. NO. KARIMNAGAR DIST. TCE. The rated burden for the metering and protection cores shall be decided considering all the loads/relays connected. 329 R5 .2S and 0. Tariff metering CT & PT should comply with the requirements of CEA regulations on installation and operation of energy meters & respective grid authorities which will be intimated to successful bidder during detailed engineering. SECTION: D3. Tariff metering EMVT terminals shall be housed in separately sealable terminal boxes. A separate 2 winding EMVT (for Main and Check Meters) of accuracy class 0. ELECTRICAL SYSTEMS .2 respectively. (o) All tests shall be made on completely assembled isolators.2S for tariff metering for each line. The CVTs shall be oil filled single phase type.3 Current transformers (CTs). A separate 2 core CT (for Main and Check Meters) of accuracy class 0. In case of SF6 filled CTs and EMVTs. earthing switches.

for the purpose of supervision on remote panel. ELECTRICAL SYSTEMS . (i) (j) (k) (l) (m) (n) (o) (p) (q) ISSUE R0 124 TCE FORM NO. Insulator shall be one piece without any metallic flange joint. The cores shall produce undistorted secondary current under transient conditions at all ratios with specified parameters. The CVT secondary shall include necessary MCBs with auxiliary contacts for alarm for protecting the secondary winding. SECTION: D3. line terminals of the CVTs shall be brought out through second set of MCBs. Facility shall be provided for short circuiting and grounding the CT secondary at the terminal box. The tank/base and all exposed ferrous parts shall be hot dip galvanised conforming to applicable standards. All the taps of each core shall be wired to Marshalling Box to facilitate ratio changing. The magnetising current at Vk/2 shall be as minimum as possible (say 15 mA). The core lamination shall be of cold rolled grain oriented silicon steel or other equivalent alloys. Tariff metering core terminals (for connecting main and check meters) shall be housed in a separate sealable terminal box. TCE. CT/CVT/EMVT assembly shall be suitably braced to withstand stresses induced due to seismic disturbances. NO. 329 R5 . KARIMNAGAR DIST.5960A-H-500-001 (h) The knee point voltage for PS class cores shall be decided considering the total connected burden with adequate margin. Expansion chamber at top shall be provided with oil sight glass. Further. Shall have provision for taking oil samples from bottom of CT without exposure to atmosphere to carry out dissolved gas analysis periodically.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.7 1X 700 MW CCPP AT NEDUNOOR. Shall have a rated extended primary current of 120% of rated primary current.400 kV SWITCHYARD SHEET 12 OF 51 SPEC. Secondary terminals of CTs shall be brought out in a weather proof power coated terminal box. The box shall have a degree of protection IP-55. All the terminal boxes shall be powder coated with IP-55 degree of protection.

Each CT/CVT/EMVT shall be supplied with suitable G.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. and EMVTs shall be earthed only at protection panels by means of a disconnecting link. 329 R5 . CVTs and EMVTs shall be formed in marshalling box of the respective equipment. TCE. Polarity marks shall indelibly be marked on each instrument transformer and at the secondary terminals at the associated terminal block. Neutral of all cores of CTs. of disconnector type of test terminal boards suitable for terminating 2 nos. NO. The MBs shall be fitted with adequate no. of 2. tappings will have to be provided on the secondary windings.5 sq mm multi-strand copper wires. for which purpose. The neutral of CTs. Oil filled insulator/bushings shall be hermetically sealed to prevent ingress of moisture. At least 20% spare terminals shall be provided. One MB for each set of 3 CTs/CVTs/EMVTs shall be provided. The MB shall be fixed to the supporting structure of CT/CVT/ EMVT. It shall be possible to select the ratio on any core independent of the setting in the other cores. A cushion of nitrogen gas shall be provided to allow for expansion. (s) (t) (u) (v) (w) (x) (y) (z) (w) Tests & Test Reports All routine tests on the 400 kV voltage and current transformers shall be carried out as per relevant standards. SECTION: D3.I supporting structure.400 kV SWITCHYARD SHEET 13 OF 51 SPEC. All CTs/EMVTs shall be provided with stainless steel bellows. ELECTRICAL SYSTEMS .7 1X 700 MW CCPP AT NEDUNOOR. CVTs. The instrument transformers shall be provided with filling and drain plugs.5960A-H-500-001 (r) Each CT shall be equipped with an over voltage protective device to limit the voltage developed across the secondary terminals to a safe value not exceeding 3 kV under open circuit condition. KARIMNAGAR DIST. Cables with sufficient number of cores are run from these marshalling boxes to protection panels. Type test certificates for all tests carried out on identical voltage and current ISSUE R0 125 TCE FORM NO.

4 BUS REACTORS a) 400 kV. NO. KARIMNAGAR DIST. However. ELECTRICAL SYSTEMS . Bus reactors shall be designed for 110% continuous over-fluxing withstand capability. 50 MVAR Three Phase Oil Filled Bus Reactors are considered in the switchyard. However. The impedance of reactor shall have a constant value upto about 1. Special measures shall be taken by providing non-magnetic shielding to combat the effects of stray/leakage flux. the exact requirement for these Bus reactors will be confirmed during detailed engineering based on the system study to be carried out by the bidder. ISSUE R0 126 b) c) d) e) f) g) h) i) j) k) TCE FORM NO. Windings shall be of copper unless specifically approved by the PURCHASER. The magnetic circuit of reactor shall be so designed that the audio sound level shall be minimum. Further the impedance shall be accurately balanced between the three-phase system. the bidder shall consider these Bus reactors in their offer. TCE.5960A-H-500-001 transformers shall be furnished. The reactors shall be either gapped core type or coreless type.400 kV SWITCHYARD SHEET 14 OF 51 SPEC.5 times rated highest system voltage. SECTION: D3.7 1X 700 MW CCPP AT NEDUNOOR. Bus reactors shall operate continuously at the highest system voltage without exceeding the guaranteed temperature rise. The losses of the reactor shall be limited to the values to permit ONAN type of cooling.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. 7. Tank shall be made from good commercial grade low carbon steel and shall be of welded construction. The total harmonic content in the phase current of a star connected reactor and zero sequence components appearing in the neutral shall be below 3% of the crest value of rated current. at present. The conductors shall be transposed at sufficient intervals in order to minimise eddy currents and equalise the distribution of currents and temperatures along the windings.7. 329 R5 . If test reports are not in line with the requirement of IS/IEC then the Contractor shall carry out type test at no additional cost to the Owner.

ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.5960A-H-500-001 l) Tank shall be provided with a pressure release device which shall operate at a pressure below the test pressure for the tank and radiators. The pull through lead shall be fitted with a gas bubble deflector. Valves shall be of forged carbon steel upto 50 mm size and of gun-metal or of cast iron bodies with gun-metal fittings for sizes above 50 mm.It shall be possible to remove turret mounted Bushing CT's from the reactor tank. Condenser type bushings shall be equipped The angle of inclination to vertical shall not exceed 30 deg. without removing the cover.5960A-EL-SK-2002. 329 R5 . An equaliser pipe connecting the pressure relief device to the conservator shall be supplied. ELECTRICAL SYSTEMS .7. which shall be connected to the connector housed in the helmet of the bushings. The under-carriage of the reactor shall be provided with detachable steel flanged wheels. Current transformers shall be provided and the bushing shall be so arranged that it can be removed without disturbing the current transformers and secondary terminals. KARIMNAGAR DIST.7 1X 700 MW CCPP AT NEDUNOOR. m) n) o) p) (d) q) The Bushing CT’s for protection shall be provided as per the enclosed Main One Line Diagram TCE. SECTION: D3. Stress rings and lower and shields. (a) (b) (c) Provision for power factor testing without disconnecting main leads. There shall be no oil leakage when the valves are in closed position. They shall be of full-way type with screwed ends and shall be opened by turning counter clockwise when facing the hand wheel. Bushings shall be of the oil-filled condenser type with a central tube and draw-in conductor. which shall be connected to route any gas collection through the Buchholz relay. The device shall be rain-proof after blowing and shall be provided with a device visible from ground to indicate operation. NO. Bushing turrets shall be provided with vent pipes. Lightning Arrester 7.400 kV SWITCHYARD SHEET 15 OF 51 SPEC. Separately mounted radiator banks shall have bolted flanged connections and pipe extensions to permit withdrawal of reactor tank without disturbing the radiators.5 ISSUE R0 127 TCE FORM NO. TCE.

Shall be robust with excellent mechanical and electrical properties. 20 kA nominal discharge current.5960A-EL-SK-2003. circuit breakers. disconnecting switches. ELECTRICAL SYSTEMS .7 1X 700 MW CCPP AT NEDUNOOR. (iv) Each lightning arrestor shall be complete with insulating base for mounting on structure. Shall be suitable for circuit breaker duty cycle in the given system. (v) Shall be capable of discharging over-voltages occurring due to switching of unloaded transformers and long lines. SECTION: D3. 329 R5 . (ii) (iii) The reference current shall be high enough to eliminate the influence of grading and stray capacitance on the measured reference voltage. gap less lightning arrester shall be provided as per the Main one line diagram No. with insulation levels specified in this specification. TCE. (i) (ii) Shall be hermetically sealed single phase unit. (iv) Shall be fully stabilized thermally to give a life expectancy of one hundred (100) years under site conditions and take care of effect of direct solar radiation. class – IV pressure relief class-A. metal oxide. Operational requirements (i) (b) Shall protect power transformers.400 kV SWITCHYARD SHEET 16 OF 51 SPEC. TCE. ISSUE R0 128 TCE FORM NO.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. KARIMNAGAR DIST. The Contractor shall carry out the insulation coordination studies for deciding the exact location and voltage levels of the LA’s. Values and calculations shall be furnished with offer. (iii) Shall be capable of withstanding meteorological and short circuit forces under site conditions. instrument transformers etc. (c) Specific Requirements Arrester shall be suitable for installation in effectively earthed system.5960A-H-500-001 (a) 360 kV. NO.

SECTION: D3. It shall be suitable for outdoor pedestal mounting and mechanically strong to withstand the stresses due to wind pressure. (b) (c) (d) (e) ISSUE R0 129 TCE FORM NO.6 kV. (xi) Suitably sized bypass copper shunts shall be provided for bypassing the discharge counter for removal / maintenance of the counter. 7. (ix) Surge monitor shall be provided for each arrester and the same shall be mounted at a suitable height to facilitate easy reading of the counter mechanism and leakage current detectors.6 Line Traps (a) Line trap shall be of pedestal mounted. Line trap shall prevent undue loss of carrier signal for all conditions. wound coil.5960A-H-500-001 (v) LAs shall be provided with grading and/or corona rings as required. (viii) The end fittings shall be non-magnetic and of corrosion proof material. (vii) Porcelain shall be so coordinated that external flashover will not occur due to application of any impulse or switching surge voltage upto maximum design value for LA. ELECTRICAL SYSTEMS . It shall be mounted on a tripod structure formed by three solid core bus post insulators. broad band tuned. Insulation level of the same shall not be less than 3.7 1X 700 MW CCPP AT NEDUNOOR. KARIMNAGAR DIST. 329 R5 .400 kV SWITCHYARD SHEET 17 OF 51 SPEC. TCE. NO. (vi) LA’s shall not fail due to porcelain contamination.7. terminal and lightning arrester earth terminal.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. (x) Insulated copper conductor of adequate size and length shall be used for connecting discharge counter. It shall have negligible impedance at power frequency. which shall be relatively high over the frequency band appropriate to carrier transmission.

Shall be Galvanized mild steel for connecting to shield wire. In case the terminals are of copper. ELECTRICAL SYSTEMS . (g) (h) (i) (j) 7. the same clamps/ connectors shall be used with 2mm thick bimetallic liner. ISSUE R0 130 (b) (c) (d) (e) (f) (g) TCE FORM NO. TCE. It shall be provided with protective device and tuning device. Even though the line traps shall be installed in two phases. nuts and plain washers shall be hot dip galvanized mild steel for sizes M12 and above. Shall be designed and arranged such that neither significant alternation in its protective function nor physical damage shall result from either temperature rise or the magnetic field of the main coil at continuous rated current or rated short time current. NO. Shall have same current rating as that of the connected equipment with temperature rise limited to 350C over 500C. For sizes below M12. surface blisters.7 1X 700 MW CCPP AT NEDUNOOR.400 kV SWITCHYARD SHEET 18 OF 51 SPEC. they shall be electro-galvanized mild steel.7. The spring washers shall be electro-galvanized mild steel. Suitable surge arresters shall be provided. KARIMNAGAR DIST. the foundation shall be constructed in all the three phases to facilitate the change of location of line trap between the phases. 329 R5 . All castings shall be free from blow holes. Bolts. Suitable corona rings shall be provided to meet corona and radio interference performance as specified for 400kV equipment if required.5960A-H-500-001 (f) Line trap shall consist of a main coil designed to carry continuously the rated current without exceeding the limit of temperature rise limits. cracks and cavities. All sharp edges and corners shall be rounded off to meet specified corona and radio interference requirements. It shall be equipped with bird barriers and shall be spray painted as per IS.7 Clamps and Connectors (a) Shall be Aluminium alloy casting conforming to designation A6 of IS:617 for connecting to equipment terminals and conductors of aluminium. SECTION: D3.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.

Shall be manufactured to have minimum contact resistance.400 kV SWITCHYARD SHEET 19 OF 51 SPEC. In one span. TCE. SCADA servers and associated equipment. DC battery. C.7. However. Design shall take care of fixing and removing during installation and maintenance. NO. housing various IEDs such as Bay Control Units (BCUs). (b) (c) 7.8 7. braids or laminated strips shall be made up of copper/ aluminium. SCADA Operator Station. Fault Disturbance Recorders.1 Switchyard Control and Relay Panel Bidder shall offer air conditioned outdoor kiosks suitably located in switchyard. battery chargers. Shall generally meet the requirement of clamps and connectors specified above. ISSUE R0 131 TCE FORM NO. SECTION: D3.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. etc. PLCC/OLTE Panels.7.7 1X 700 MW CCPP AT NEDUNOOR.5960A-H-500-001 (h) (i) (j) All current carrying parts shall be at least 10 mm thick. RTU for SLDC/RLDC. Tension string assembly at one end shall be supplied with suitable turn buckle.9 Spacers (a) Shall be non-magnetic material except nuts and bolts. Suitable sag compensating spring shall be supplied in case the design calculations show excessive variation of the sag over the temperature range of 0 to 80 deg. 329 R5 . (k) 7. KARIMNAGAR DIST. Protection Panels. which can be of malleable cast iron. Current rating and size of terminal/conductor for which connector is suitable shall be embossed/punched on each component. Shall also generally meet the requirements of clamps and connectors as specified above. Flexible connectors. (b) (c) (d) 7. which shall be of hot dip galvanized mild steel. ELECTRICAL SYSTEMS .8 Insulator String Hardware (a) Shall be of bolted type and forged steel except for insulator cap.8.

The scheme as approved by Owner shall be provided. required for the scheme are deemed to be included in the Contractor scope.2 The control and interlocking scheme suitable for one and a half breaker switching scheme shall be provided.400 kV SWITCHYARD SHEET 20 OF 51 SPEC. Different routes shall be adopted for OFC. shall be provided for housing busbar protection panels at suitable location in switchyard. 400 V ACDBs. All the necessary relays. ELECTRICAL SYSTEMS .8. switches.8. The auto re-closing scheme shall be available in one of the numerical line protection relays but shall get independently actuated by the operation of both the protective relays. KARIMNAGAR DIST. auxiliary relays shall be provided. if required. the kiosk shall have necessary space for accommodating the future bay IEDs. etc. etc. trip relays.as a part of BCU (c) 7. Line bays shall be provided with single phase and three phase auto reclosing feature.7 1X 700 MW CCPP AT NEDUNOOR. UPS system. Provisions shall be made to accord higher reclosing priority to main breakers. One kiosk shall be considered per diameter (comprising of two circuits in one and half breaker scheme) of 400kV switchyard. from switchyard equipment shall be connected to respective IEDs located in kiosks. SECTION: D3. timers. 329 R5 . Technical requirements of outdoor kiosks are detailed elsewhere in the specification. hardware. All the auxiliary relays. One additional kiosk. The layout of equipment/panels shall be subject to Purchaser’s approval.. Rapid reclosing & delayed reclosing features shall be 7. TCE. control cables. In case of incomplete diameter. etc. Contractor shall furnish block interlock diagrams for the switchyard for Owner’s approval. or to issue reclosing command to both breakers simultaneously.5960A-H-500-001 DCDB. NO. shall be located in the switchyard control building for overall optimization in respect of cabling and control room building size. PT. The switchyard protection shall consist of: (a) One complete set of relay panels for 400 kV equipment switchyard (b) System fault locaters – as a part of Main-1 numerical relay (BCU) Stand alone Disturbance recorders .3 ISSUE R0 132 TCE FORM NO. All CT. The kiosk shall be provided with fire alarm system with at least two detectors and shall be wired to fire alarm panel as described elsewhere in the specification.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. Two optical fibre cables (OFC) shall be laid to connect BCUs to SCADA for data exchange.

8.400 kV SWITCHYARD SHEET 21 OF 51 SPEC. Synchronising facility shall be provided for all lines in DCS. Synchronizing function shall be through BCU for GTG units and a separate synchronizing equipment along with check synchronizing facility to be provided for STG units.8. In check synchronising position. isolators and earth switches.4 I & C requirements. KARIMNAGAR DIST. Monitoring-Indication. In manual mode.5 7.8.5960A-H-500-001 provided. contact multiplying relays shall be used.9 7. NO.8.5960A-EL-SK-2003 and Section D2. ELECTRICAL SYSTEMS . protection.4 Live line–dead bus closing and dead line-live bus closing facilities shall be provided using dedicated relays for this purpose.8.11 7.8 7.8. closure is possible only if either the line or the bus is dead.4 All relay panels shall be located in outdoor kiosk and these kiosks shall be located in switchyard.8.8. It shall be possible to control (including synchronising) all the 400 kV switchyard breakers and isolators from SCADA . It shall not be possible to close in manual mode if both line and bus are live. Indicating lamps for fulfilment of the permissive condition shall be provided.12 7. SECTION: D3. Measurement required in DCS shall be as given in Section D2.8. All conditions requiring blocking auto reclosure shall be considered.13 TCE FORM NO.8. the synchronising criteria shall be fulfilled as indicated by the closing permissive provided by check synchronising relay. In the event of shortage of contacts in main circuit breakers.6 7.7 1X 700 MW CCPP AT NEDUNOOR. annunciation. At least 2NO + 2NC spare contacts shall be wired to terminal block after fully utilising for control.. latching type with electrical reset and shall be mounted in switchyard relay panels. All main protections shall be of numerical type. 7. Relay setting calculations shall be furnished by the Contractor to the Owner for his approval. etc. Control and indication shall be provided for each of the breaker and isolator. The same shall be two coil.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. 329 R5 . TCE. The measurement requirements for each of the bays shall be as per the Main one line drawing TCE.10 7. The functional requirements and characteristics of the relays specified are the ISSUE R0 133 7. abnormal conditions.7 7.

It shall also be possible to configure the SCADA BCUs remotely from the SCADA Engineering Station.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. All the auxiliary relays.5960A-H-500-001 minimum required.16 7. hardware. The relay settings.15 7.17 7. static relays have to be provided for breaker protection. PT supervision.8. (a) The protections envisaged for each 400 kV switchyard bay are listed below and also in Main one line diagram Drg. required for the scheme are deemed to be included in the Contractor’s scope. No.6 for Generator protection shall be followed for switchyard protection as well. The numerical protection relays shall be able to be configured locally. etc. Relay setting calculations shall be furnished by the Contractor to the Purchaser and the grid authorities for their approvals. 7.8. Numerical relays shall be provided for main and secondary protection of lines. The configuration/specification of the laptop shall be the latest as available in the market as on date of supply. TCE. 329 R5 . data transfer and parameterization. ELECTRICAL SYSTEMS . etc. The communication between the numerical relays and SCADA system shall be through serial link with fibre optic cable connection.8.7 1X 700 MW CCPP AT NEDUNOOR. This laptop shall be common for SCADA BCU (Bay Control Unit) parameterization and protective relay parameterization. For this. The responsibility of establishing the equivalence or superiority of relays offered vis-a-vis the stipulation of the specification rests with the Contractor.8. Contractor shall furnish block interlock diagrams for the switchyard for Purchaser’s approval.9 ISSUE R0 134 TCE FORM NO. The communication protocol between the numerical relays and SCADA system shall be IEC-61850.14 The Contractor shall provide licensed copy of software on CD for relay setting software and calculations for future use of the Purchaser. Protection Philosophy The protection philosophy indicated in section D3. Buses. The scheme as approved by Purchaser shall be provided. NO. switches. timers. SECTION: D3.400 kV SWITCHYARD SHEET 22 OF 51 SPEC. Contractor shall provide a laptop and the necessary software for relay settings. The interlocking scheme shall be hard wired and shall be suitable for one and a half breaker switching scheme. parameterisation and the retrieval of data from the relay and relay operations shall be possible from SCADA operator station in addition to the laptop. KARIMNAGAR DIST. However. 7.

27S) ISSUE R0 135 TCE FORM NO. 21-1 & 21-2 line protection relays shall have all the basic protection like SITF. NO.5960A-H-500-001 TCE. It shall be read in conjunction with the following and all protection indicated shall be provided. physically and electrically separated into two separate and independent systems. PSB etc. TCE. (b) Line Bay Relay panel (Each Line Bay) (i) Main-1.3-zone carrier aided distance protection (21-1) with in-built back-up directional over current and earth fault protection (67/67N). Both main-1 & main-2 protections shall be (ii) mechanically.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.400 kV SWITCHYARD SHEET 23 OF 51 SPEC. 329 R5 .5960A-EL-SK-2003.3-zone carrier aided distance protection (21-2) with in-built back-up directional over current and earth fault protection (67/67N). dead bus/live line closing and safe grid re-establishment (271. ELECTRICAL SYSTEMS . 27-2. Main-2. KARIMNAGAR DIST. SECTION: D3. Both main-1 and main-2 protections shall work on different principles/algorithms. (vii) (viii) (ix) Under voltage relays for live line/dead bus. (iii) Identical distance relays shall be supplied loose for four (4) 400kV lines (iv) Fuse fail relay (FFR) for each secondary of CVT / EMVT (v) Two stage over voltage relay (instantaneous & time delayed) (vi) Stub protection (50STB) as part of main-1 & main-2 protections for 400 kV lines to protect the stub portion of line bays during line outages Distance to fault locator (DFL) Fault disturbance recorder (FDR) with 8 analog and 16 digital channels.7 1X 700 MW CCPP AT NEDUNOOR.

TCE. NO. Common Items/protections to be included in all relay panels (i) Local breaker back up protection with its own trip relay (50 LBB for each breaker). (d) Over head line differential protection (between GT HV bushing & switchyard gantry) (87OH) shall be part of switchyard relay panel (SRP). Auxiliary relays and timers in adequate numbers to make the protection scheme and discrepancy switch scheme complete. 329 R5 .7 1X 700 MW CCPP AT NEDUNOOR.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. ELECTRICAL SYSTEMS . Supervision relays for tripping relay (98 LT1 to LTX) to supervise the coil of each trip relay. KARIMNAGAR DIST. Each trip relay shall be supervised and contacts shall be made available for annunciation/SCADA.5960A-H-500-001 (x) Auto reclosing scheme relays with single phase & three phases reclosing. LBB in-out switch shall also be provided. (c) Busbar Protection Relay Panel Numerical type. suitable (e) (ii) (iii) (iv) (v) (vi) f) Reactor Protection Over Current Protection (50 and 51) Neutral Over Current Protection (51N) High Impedance type Differential Protection (87R) ISSUE R0 136 TCE FORM NO. CT supervision and In-Out switch. Auxiliary CTs and auxiliary VTs with characteristics and accuracy as required. Each breaker shall be provided with its own trip relay.400 kV SWITCHYARD SHEET 24 OF 51 SPEC. SECTION: D3. It shall have check and discriminating zones. Pre and Post close Trip circuit supervision relay for each trip circuit (98L) High speed trip relays (86L). distributed busbar protection scheme based on”low impedance” principle for selected bus arrangement shall be provided. dead line charging and live line reclosing.

9. Any additional protection considered necessary by the Contractor shall also be provided by him.5 7.3 7. The numerical protective relays shall be based on internationally accepted Open Protocol IEC-61850.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. Contact multiplication relays for 400kV circuit breakers and associated isolators shall be provided for this purpose. required for tripping/interlock schemes shall be provided by the Contractor. All numerical relays and SCADA clock shall be time synchronised with the GPS master clock. TCE. The protection schemes shall include all the necessary contacts for interlocks.1 The functional requirements and characteristics of the relays specified are the minimum required.9. All protective relays and meters shall be provided with test terminal blocks for secondary injection testing of protection relays and meters. For each category. Contractor shall wire out to the terminal block at least one NO & one NC spare contacts of each of the relays. NO. Numerical relays shall have self diagnostics and watch dog feature for remote annunciation in SCADA.9. separate discrete numerical/microprocessor/static relays shall be provided. In addition to the contacts required as per the schemes. ELECTRICAL SYSTEMS . Push buttons for testing and resetting the LEDs shall also be provided. The contact rating of contactors provided in SCADA Panels shall be suitable for making/breaking of control circuit currents of the respective devices being controlled. alarms in SCADA.9.400 kV SWITCHYARD SHEET 25 OF 51 SPEC.7 1X 700 MW CCPP AT NEDUNOOR. All hardware. auxiliary relays.9. KARIMNAGAR DIST. All SCADA alarms shall be categorized into different categories (typically 5). timers etc.4 7. All digital inputs shall have a time resolution of 1 (one) ms. 329 R5 .2 7. a different tone shall be sounded on the hooter and the alarm shall be represented in a different colour on the screen. The responsibility of establishing the equivalence or superiority of relays offered vis-a-vis the stipulation of the specification rests with the Contractor. If any of the protections are not covered in the main numerical relay.6 7. Supervisory Control and Data Acquisition (SCADA) System ISSUE R0 137 7.5960A-H-500-001 7.9. Protective relays shall have adequate number of site configurable LEDs and output relays.10 TCE FORM NO. SECTION: D3. The protective relays shall be of integrated numerical type with serial interface for communication with SCADA system. sequence event recorder wherever required.

5960A-H-500-001 7. mimic diagram. The controller shall be configured with redundant CPU. The SCADA system shall be based on a de-centralised concept with bay oriented distributed intelligence devices. The switchyard equipment shall be remote controlled from Central Control Room (CCR) of the Power Plant through the SCADA HMI in order to enable the Switchyard Control Room being totally un-attended. Scalability and Open Architecture. The OS and ES display/monitors shall be dual headed. remote control functions. Engineering Station shall be provided in the Switchyard control room to make the SCADA configuration changes and system settings. indication. TCE.4 7. One (1) no.10.7 1X 700 MW CCPP AT NEDUNOOR. etc. All the SCADA switches and servers shall be located in switchyard control room. ELECTRICAL SYSTEMS . SCADA system shall be fail safe design.5960A-EL-SK-2004. The offered SCADA system shall be based on internationally accepted Open Protocol IEC 61850. 24 inches size. One (1) no.. KARIMNAGAR DIST. shall be provided for the switchyard. 329 R5 .10. synchronising. for safety and availability reasons.1 SCADA system comprising of various controls.10. The Controller shall also be configured with double redundant power supply units.10. NO. TCE.7 TCE FORM NO.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. LCD type and the make shall be finalised during detailed engineering so as to match with those ISSUE R0 138 7. sequence of events recording. The redundant CPU shall be configured to operate as hot standby.400 kV SWITCHYARD SHEET 26 OF 51 SPEC.10. The Engineering Station(ES) located in Switchyard control room shall also be configured as Operator Station to act as standby in case of failure of the Operator Station in Switchyard control room. metering.2 7. annunciation.3 7. The Contractor shall furnish documents to establish and prove that the system is highly reliable with very high MTBF (Mean Time between Failures). The communication between the numerical relays and SCADA system shall be with fibre optic cable. The SCADA system shall be generally in line with the details shown in SCADA System Configuration Drawing. All SCADA servers & Front End Processor servers (if any) shall be rack mounted.10. The offered SCADA system shall be of latest state of art design with capability to interface with bay control units (separate for each bay).10.5 7. SECTION: D3. Operator Station(OS) for SCADA (for control and monitoring of complete 400 kV switchyard equipment) shall be located in Central Control Room (CCR) of power plant and one (1) no. in Switchyard Control Room.6 7.

necessary printers as shown in SCADA Configuration Drawing shall also be provided for SCADA system.dead bus or dead line – dead bus with no synchro-check function c) Synchronising between live line and live bus with synchrocheck function. It shall not be possible to control the switchyard equipments from both the locations simultaneously. viz. synchroscope and the sync. Display of voltages and frequencies of incoming and running supplies. fast. Synchronising facility shall be provided for all lines in SCADA. a) selection of the breaker to be closed. TCE.400 kV SWITCHYARD SHEET 27 OF 51 SPEC. Control room furniture for mounting the operator station along with 3 nos. All printers shall be equipped with USB port and enough USB cables (minimum 5m length) to enable the printers to be placed in a convenient location. In the CCR. In dead bus/line mode. a) Setting voltage.5960A-H-500-001 provided for Main Plant DCS. NO. But provision shall be made available in the SCADA to control the switchyard equipments from Centre control room (CCR) also.10. b) mode of closing operation i.8 The control location for the switchyard equipments shall be Switchyard control room by default. permissive signal shall be simulated in the SCADA operator station. live line .live bus. The correct voltage for synchronizing and energizing is derived from the auxiliary switches of the circuit breakers and the isolators and shall be selected automatically by the bay control and protection IEDs. KARIMNAGAR DIST. ELECTRICAL SYSTEMS . All features shall be available viz. Information exchange shall be provided from SCADA to plant DCS through suitable.10. reliable and redundant serial communication interface.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. In check synchronising position. The required selection shall be provided in the operator station of Switchyard control room.9 7. phase angle. and frequency difference b) Energizing for dead line . the synchronising criteria shall be fulfilled as indicated by the closing permissive provided by check synchronising relays in-built in BCUs (separate sync check relays are not envisaged).7 1X 700 MW CCPP AT NEDUNOOR. It shall be possible to configure the printers to print on demand/online or at specified intervals. The synchronising of the line shall be possible through both main breaker and the middle breaker. The console on which the operator station is mounted shall be properly ventilated (forced cooled if required). The closing operation of line breaker shall involve the following steps. chairs shall be provided in the switchyard control room. 329 R5 . 7.10 TCE FORM NO. The synchronism and energizing check functions shall be bay oriented and distributed to the bay control units and/or protection devices.10. closure is possible only if either the line or the bus is dead. whether both the line and the bus are ISSUE R0 139 7.e. SECTION: D3.

The control of middle breaker from SCADA shall be suitably interlocked such that its closure is not possible when it is used as generator synchronising breaker. of analog and digital IO (input/output) points shall be dicided during detailed engineering. NO. SER function.13 7. It shall be possible to control the middle breaker from both DCS (through auto/manual synchronisation) and SCADA with the help of a selection available in the SCADA software. protection. It shall be possible to control and monitor (including synchronising) all the 400kV switchyard breakers & isolators from SCADA except main ISSUE R0 140 7. for the indication of electrical parameters related to switchyard bays as required.400 kV SWITCHYARD SHEET 28 OF 51 SPEC.10. ELECTRICAL SYSTEMS . In live-bus/live-line case. The exact no. annunciation. 7. For monitoring of all other bay wise electrical quantities. Transducers shall be provided. The selection shall have two positions i. Transducers shall be used only for monitoring of non electrical quantities such as Bus reactor oil and winding temperature and for electrical quantities such as battery charger voltage. If “SCADA” is selected. If either the line or the bus is dead. At least 2NO + 2NC spare contacts shall be wired to terminal block after fully utilising for control. The same shall be two coil. wherever necessary. the logic develops using the contacts of bus voltage and line voltage relays which generates permissive for closing of the breaker. interlocks. battery charger current. contact multiplying relays shall be used. c) issuing the closing command after obtaining the synchro permissive or live-bus/dead-line or liveline/dead-bus permissive as the case may be. earth switches shall be brought to the protection panels for indications. If “DCS” is selected.10. IEDs such as BCUs shall be used. All the auxiliary contacts of main equipment such as circuit breakers. SECTION: D3.7 1X 700 MW CCPP AT NEDUNOOR.14 TCE FORM NO. “SCADA” and “DCS”. all the required signals including PT signals for synchronising shall be transferred to SCADA system. synchronisation between the two voltages is checked by the check synchronisation relay which generates permissive only if the synchronisation criterion is met. etc.12 7.11 The generator transformer main breaker will be controlled from main plant DCS. latching type with electrical reset and shall be mounted in switchyard protection panels. all the required signals shall be transferred to DCS/GRP (Generator Relay Panel). etc.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. 400 kV bus voltages. KARIMNAGAR DIST. 329 R5 .e.5960A-H-500-001 live or only one of them is dead as sensed by voltage relays connected to the respective CVTs.10. isolators.10. TCE. In case of shortage of auxiliary contacts. This permissive shall be displayed on the SCADA HMI.

329 R5 . voltage selection. Earth switches shall be operated only from local but is monitored in SCADA. trip circuit faulty. abnormal conditions of breakers. KARIMNAGAR DIST. voltage selection. shall be available in SCADA.15 Monitoring – SCADA a) Indication – status of all breakers. Busbar protection. VT circuit unhealthy of each VT. SECTION: D3. Trip circuit unhealthy of each equipment. DC supply fail. DC & UPS system alarms. Trip relay unhealthy of each equipment. etc. pole discrepancy relay operation.5960A-H-500-001 circuit breakers of generators. ELECTRICAL SYSTEMS . TCE. etc.10. isolators and earth switches of all 400 kV bays. protection unhealthy of each equipment. shall be available in SCADA. The alarm states are not exhaustive. opening and closing commands. synchronising switch positions. The selection of control of middle breaker of generator bay from DCS/SCADA shall be displayed both in DCS and SCADA.16 TCE FORM NO. LBB operation of each breaker. SF6 pressure Low. NO. Main circuit breakers of generators are controlled from Central Control Room through Plant DCS and monitored both in DCS and SCADA. Auto re closing selection.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. wrong selection of PT supply. selection of control from SCADA/DCS. The Contractor shall include all alarm states deemed necessary for the safe operation of the system. trip relay faulty. synchronising selection. change of positions of switches such as Local/Remote selection. selection of control from SCADA/DCS. LBB operated. DC supply failure of each protection / control scheme as appropriate. direct trip send and receive.10. auto reclosing selection. local/remote selector switch positions. c) Event register with time stamping – Opening or closing of all breakers. isolators and earth switches. Isolators and earth switches pertaining to generator transformer bay shall be monitored both in DCS and SCADA.400 kV SWITCHYARD SHEET 29 OF 51 SPEC. this list shall include all events and operation of switchyard equipment that are considered essential for analysis of faults. As stated at b) above. Abnormal conditions to be considered for alarm inputs are 400 kV system operation of each line protection. VT fuse fail relay operation.7 1X 700 MW CCPP AT NEDUNOOR. auto re-closing operation. 7. successful /unsuccessful auto reclosure. operation of all protection and trip relays. etc. Mimic ISSUE R0 141 b) 7.

ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. NO. The colours of different voltage levels shall be as per relevant IS applicable for mimic on panels. It shall be possible to store historical data for a minimum of two years.18 Event logging and trending facilities shall be provided in SCADA system.10. ELECTRICAL SYSTEMS . Winding & Oil temperature TVM V(All phases) A(All phases) MW MVAR MWH MVARH TVM V(bus 1&2) F(bus 1&2) (b) 400 kV line bays (c) 400 kV Bus PT 7. 7. 7.400 kV SWITCHYARD SHEET 30 OF 51 SPEC.10.5960A-H-500-001 A mimic diagram depicting the entire electrical system being controlled from the system with different colours for different voltage levels shall be provided in SCADA operator stations.19 The Contractor shall make provision for terminating 4-20 mA analog signals and potential free digital signals for the following data on a terminal block in a suitable interface panel located in switchyard control building for transmission to SLDC (State Load Despatch Centre) and RLDC (Regional Load Despatch Centre) through RTU (Remote ISSUE R0 142 TCE FORM NO. It shall be possible to trend different parameters on the same trend. 329 R5 . SECTION: D3. TCE. SCADA system shall have provision for expansion and shall be capable of communicating with other systems through open protocol.10.7 1X 700 MW CCPP AT NEDUNOOR.17 Measurement The measurement requirements for each of the bays shall be as per the Main one line drawing TCE.5960A-EL-SK-2003 and as given below: Feeder Description (a) GT bays DCS Operator Station V (All phases) A (All phases) MW MVAR Tap position. KARIMNAGAR DIST.

Generator transformer bays. The BCU shall provide direct connection to the switchyard equipment for control (with or without interposing relays) and shall perform control and monitoring functions. The BCUs shall be installed in the respective protection panels of each circuit breaker in the switchyard relay room (Outdoor Kiosk).11 Bay Control Unit (BCU) a) The BCU shall be an intelligent unit and shall be state of the art technology. dead-line/live-bus and live-line/livebus breaker closing. The communication link between BCU and SCADA shall be redundant. Numerical protection relays shall also be connected to the SCADA bus for retrieval of data.400 kV SWITCHYARD SHEET 31 OF 51 SPEC. The actual data to be transmitted to SLDC/RLDC shall be finalised during detailed engineering and the following is the minimum data to be transmitted through RTU.7 1X 700 MW CCPP AT NEDUNOOR. NO. Protection relays shall be separate and shall not be part of BCU.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. The specification of RTU provided for this purpose by the Contractor shall be subject to approval by the SLDC/RLDC authorities. BCU shall have adequate number of ports for communication and interface with switchyard control system for bay control and monitoring. Tap positions of GTs & UATs • 7. 329 R5 . • • • • MW and MVAR of all lines MW and MVAR of HV side of all generator transformers Voltage and frequency of 400 kV buses ON/OFF positions of all breakers and isolators of all line bays. Bus PT bays. SECTION: D3. The BCUs shall be independent of each other and functioning shall not be affected by any fault occurring in any of the other BCUs. ELECTRICAL SYSTEMS . b) c) ISSUE R0 143 TCE FORM NO.5960A-H-500-001 Transmission Unit). Direct hard wiring shall be employed for critical tripping. including live-line/dead-bus. It shall perform control functions in accordance with control commands from SCADA and shall also do monitoring of the respective bays. The energy meters(EM) shall not be connected to the RTU’s. KARIMNAGAR DIST. The degree of protection of the panel shall be IP-52. The BCU shall comply with relevant IEC/BIS standards. The control voltage for the BCU shall be 220V DC. TCE.

The analog and digital signals pertaining to a circuit shall be taken through the BCU provided for that circuit. instrument transformers. NO. The lap top computer provided for the switchyard shall be loaded with this software. isolators and earth switches (The interlocks for earth switches shall be hard wired) iii) Recording The event recording function shall be provided and processed in the BCU and the record stored in SCADA. KARIMNAGAR DIST. Each BCU shall contain an event recorder capable of storing at least 200 time tagged events.7 1X 700 MW CCPP AT NEDUNOOR. The BCU shall have at least the following features: i) Monitoring The following monitoring functions shall be provided as a minimum : • Status monitoring and failure monitoring (in SCADA HMI) of bay equipment like breaker. ISSUE R0 144 TCE FORM NO. 329 R5 . The configuration shall be carried out from local or from laptop computer but operation shall be from SCADA operator station. TCE.5960A-H-500-001 d) Atleast one bay control unit (BCU) shall be provided for each breaker. isolators. SECTION: D3. ELECTRICAL SYSTEMS .ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. pole discrepancies) and data stored in SCADA server Energy metering values e) f) • • • ii) Control The following control functions shall be provided as a minimum: • • Control of circuit breakers and isolators Interlocking for isolators and circuit breakers. One no.400 kV SWITCHYARD SHEET 32 OF 51 SPEC. breaker auto-reclose. Configuration of BCUs shall also be possible from remote through engineering work station. protection relays and ancillary equipment metering (measured-value acquisition) Signal and command indications Switching statistics in BCU (breaker ON/OFF. earth switches. licensed software for configuration and parameterization of SCADA shall be delivered on CD along with BCUs.

Failure of IEDs connected to the SCADA System such as BCUs. TCE. The paint shade of the panels shall be Opaline Green(external) and semi glossy white(Internal). (CT & PT marshalling boxes shall be provided with respective CTs & PTs. 329 R5 . Numerical Relays and Tariff Meters shall be indicated in the SCADA HMI vi) vii) Operating Mode Selection • Operation mode selection (local or remote) shall be provided in BCU. phosphating and oven drying. ELECTRICAL SYSTEMS . The phosphate coating shall be sealed by the application of two coats of ready mixed. Position of switching elements (Feeder control diagram) shall be shown on the graphic display. 7. free standing type. The pretreatment of the sheet steel shall involve degreasing rust/scale removal.7 1X 700 MW CCPP AT NEDUNOOR. (a) Terminal box: Providing intermediate termination of all auxiliary contacts of breaker. SECTION: D3. NO. Bay marshalling box shall be provided with two subsections namely: Terminal box and auxiliary supply distribution box. isolator and earthing switches (whether used or not) and preparing interlocking.5960A-H-500-001 iv) Human Machine Interface (HMI) Following local human machine interface inbuilt in BCU shall be provided as a minimum : • The local HMI is a monitoring and maintenance tool for bay control unit and data communication unit during commissioning and/or maintenance.) ISSUE R0 145 TCE FORM NO. • v) Time Synchronizing Feature • BCU shall be time synchronized with GPS based Master Clock of the Facility Self diagnostic and Supervision Features • BCU shall have self diagnostic and supervision features. power coated bay marshalling boxes shall be provided in switchyard. stoving type zinc chromate primer followed by two coats of synthetic enamel paint by powder coating process. KARIMNAGAR DIST.12 Bay Marshalling Box(s) Adequate number of outdoor mounted.400 kV SWITCHYARD SHEET 33 OF 51 SPEC.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.

Contacts for remote alarm for supply fail shall be provided. Remote independent alarm for failure of all AC and DC outgoing feeders shall be provided by supply supervision relays having delayed dropout NC contact. isolators/ earthing switches local marshalling box/equipment marshalling box and heating and lighting supply to various bay marshalling boxes. control supply of all isolators and earthing switches. indications. TCE.400 kV SWITCHYARD SHEET 34 OF 51 SPEC.7 1X 700 MW CCPP AT NEDUNOOR. AC and DC distribution and all other schemes shall be prepared in such a way that cables shall be laid in radial pattern. All auxiliary contacts and interlocked scheme contacts shall be wired to respective panels in the control room. Cables with sufficient ISSUE R0 146 TCE FORM NO. Single phase 230V heating and lighting supply shall be provided in a loopin / loopout mode at bay marshalling box. shall be provided in each auxiliary supply bay marshalling box. NO. The marshalling boxes shall be provided with doors on both sides with key lockable handle for each door. All auxiliary contacts of the CBs. interlocking. Neutral of all cores of CTs. ELECTRICAL SYSTEMS . After the manual selector switch. All hardwired interlocking shall be wired in the above box. Similarly provision for terminating 2 Nos. controls. KARIMNAGAR DIST. isolators and earthing switches shall be terminated in terminal box section of bay marshalling boxes. The key shall be removable only in door locked position. MCB controlled AC distribution shall be provided in such a way that individual and radial feeder supplies to driving mechanism/motor of every equipment is arranged. Either of them shall be used after distributing it via suitably rated HRC fuses to feed. metering. SECTION: D3. 3 wire AC 50 Hz power supply called supply I & II. The AC distribution scheme shall be wired to manually select any one of the supplies by manually operated selector switch.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.5960A-H-500-001 (b) Auxiliary supply distribution box from where both AC auxiliary supply. heating/lighting supplies and DC auxiliary control supply shall be distributed to various motors of all CBs. 329 R5 . The scheme for all protections. Provision for terminating two number of 3 phase. The heating and lighting supply shall be sub-distributed in radial way to provide heating and lighting supplies for all HV equipment marshalling boxes and each bay marshalling box. DC supplies and selection feature to select any one of the two supplies as supply-I and other as supply II shall be provided. CVTs and EMVTs shall be formed in marshalling box of the respective equipment. Loop formulation of cables shall be completely avoided.

Fault-Recording and Event Recording Systems The DC distribution scheme in various panels shall be prepared based on following DC distribution philosophy for various functions. Annunciation. The selector switch and fuses. In case of failure of any one source (say source-1). Bus bar protection scheme and indications shall be provided with two (2) nos. CVTs. etc. The NC contact of the relays shall be delayed on drop off by approximately 100 to 200msec for annunciation in SCADA. independent. In the independent position main-1 & main-2 protection systems will be fed by source-1 & source-2 respectively and the common services from any one of the sources. DC supplies shall be arranged from two sections of switchyard DCDB to each of the protection panels. The neutral of CTs. The selector switch and the fuses shall be mounted inside the panel. (a) Protective Functions Two nos. These supplies shall be taken through a selector switch with three positions. Loss of supply shall be wired for annunciation at SCADA indication and annunciation supplies shall be separately fused. (c) Control Functions Control circuit of each breaker circuit will be provided with 2 independent 220V DC control supplies. 7. DC auxiliary supply shall be supervised by supply supervising relays.5960A-H-500-001 number of cores are run from these marshalling boxes to control and relay panels as appropriate. source-1 & source-2. 329 R5 .7 1X 700 MW CCPP AT NEDUNOOR.400 kV SWITCHYARD SHEET 35 OF 51 SPEC. protection. Indication. TCE. viz. the switch shall be changed over to the other source (source-2) and complete DC supply requirement of protection panels will be fed from the other source. of 220V DC supplier through three (3) position selector switch fused and supervised by supply supervision relays having time delayed drop off type NC contact. NO. KARIMNAGAR DIST. (b) Similarly. shall also be mounted internally inside the panel.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. Each of the above ISSUE R0 147 TCE FORM NO. These DC supplies shall be separated from DC supplies in the control panel by provision of interposing relays (IPRS) in protection relay panels. ELECTRICAL SYSTEMS .13 DC Distribution Philosophy for Controls. EMVTs shall be earthed only at control/relay panel by means of a disconnecting link. SECTION: D3.

5960A-H-500-001 feeders shall be fed from separate section of DC board.400 kV SWITCHYARD SHEET 36 OF 51 SPEC. TCE. independent and source II shall be used to select any one as closing/synchronizing and trip coil I supplies and other as trip coil II and auxiliary supply for contact multiplication/follower relay supplies. 7. The Contractor shall tap annunciation supply through fuses and after supervision relays use it for all annunciation in respective panels. and 2.7 1X 700 MW CCPP AT NEDUNOOR. etc.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. d) The RTU’s and the PLCC located in the Switchyard control room for SLDC/RLDC shall be provided with 48V dual DC supply. ISSUE R0 148 TCE FORM NO. In turn the failure of AC annunciation supply shall be annunciated in normal DC operated annunciate. Manually operated 8 pole. SECTION: D3.6 for generator protection shall apply for switchyard protection system also in addition to the following: (a) The panels shall have a degree of protection not less than IP52 and shall be fabricated with 3 mm thick cold rolled sheet steel for front and rear equipment bearing surfaces and bottom gland plates. One separate 220V DC annunciation supply for upto half number of the control panel shall be provided. failure of annunciation supply shall also be combined and annunciated on 230V AC operated annunciation system. 3 position selector switch for positions called source I. The panels shall be provided with anti vibration pads. KARIMNAGAR DIST. Each incoming supply before select switch and outgoing supply after selector switch shall be separately fused and supervised by supply supervision relay having time delayed type “NC” contact. NO. Loss of supply shall be wired for annunciation at SCADA.5 mm for sides and top. Remaining half shall be supplied by separate but similar 220V DC supply. The paint shade of panels shall be of shade opaline green (External) and semi-glosy white (Internal). The doors and removable covers shall be gasketed. ELECTRICAL SYSTEMS . The supervision relay shall have time delayed drop off type NC contact for annunciation. D3. It shall all be provided with additional contacts for event recording and remote annunciation. The DC supplies shall be isolated from DC supplies in relay panels as specified in a) above.14 Specific Requirements The specific requirements listed in Sec. 329 R5 .

push buttons and indicating lamps shall be not less than 750 mm and centre lines of relays. The phosphate coating shall be sealed by the application of two coats of ready mixed. recorders shall be suitably MCBs or designed to limit short circuit currents. They shall be mounted either internally or on the respective relay panel. TCE. All the internal wiring shall be carried out with 1100V grade stranded copper conductor wires with PVC insulation. 329 R5 . phosphating and oven drying. The paint shade of panels shall be of shade opaline green (External) and semi-glosy white (Internal). stud type terminals with terminal marking.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.0 m and 1.5960A-H-500-001 (b) The pre-treatment of the sheet steel shall involve degreasing rust / scale removal. Means for detection of blown or open circuited fuses shall be provided.5 mm2 / lead and other circuits it shall be 1. Control switches / push buttons / selectors and relay resetting knobs shall be located at a height between 1. meters and recorders shall not be less than 450 mm from the bottom of the panel. The insulation between any two terminals and terminal to framework shall withstand 2 kV rms for one minute. SECTION: D3. No auxiliary relay shall be mounted on front of the control panel.400 kV SWITCHYARD SHEET 37 OF 51 SPEC. NO. ELECTRICAL SYSTEMS .5 mm2 / lead. CT secondary leads shall also be provided with short circulating and earthing facility. All wiring meant for power supply to transducers. The centre line of switches. KARIMNAGAR DIST. stud type. At least 20% spare terminals shall be provided. Terminal blocks for SCADA control commands shall be of disconnecting type. Terminal blocks for CT & VT secondary leads shall be disconnecting.7 1X 700 MW CCPP AT NEDUNOOR. 10 amps rated. For CT / PT circuits the wire size shall be 2. All relays and measuring instruments shall be flush mounted type & the equipment on the front of panel shall be flush mounted. stoving type zinc chromate primer followed by two coats of synthetic enamel paint by powder coating process.2 m from the bottom of the panel. Terminal blocks shall be 650V grade. Terminal blocks for SCADA digital inputs shall be with knife type isolation. ISSUE R0 149 (c) (d) (e) (f) (g) TCE FORM NO. A clearance of 250 mm shall be maintained between terminal blocks and gland plate and 150 mm between two rows of terminal blocks.

the colour of PBs shall be different for various functions. 329 R5 . Each of the control & relay panels shall be provided with thermostat-controlled space heaters. SECTION: D3. distributing. the speed of operation of MCB shall be less than 5 milli seconds. Where high-speed protections are involved. Separate copper earthing flat shall be provided in the panel for cable screens of static equipment. Push buttons shall be suitably shrouded to prevent inadvertent operation. instruments and other panel-mounted equipments shall be connected to the earth bus by 2. All PBs shall have 2 NO + 2 NC contacts.400 kV SWITCHYARD SHEET 38 OF 51 SPEC. lighting and space heater circuits.C. NO. they shall have adequate auxiliary contacts for blocking trip circuits of voltage dependent protection and annunciation.7 1X 700 MW CCPP AT NEDUNOOR. ISSUE R0 150 (i) (j) (k) (l) (m) (n) (o) TCE FORM NO. All indicating lamps shall be of self-coloured clustered LED type of size 22. All the metallic cases of relays. ELECTRICAL SYSTEMS .5mm.5960A-H-500-001 (h) Provision shall be made to mount Tariff meters supplied by grid in the switchyard itself in the grid tie lines as per requirement of grid authorities. If miniature circuit breakers (MCBs) are used in VT secondary circuits. signalling. and A. CT and PT secondary neutral or common lead shall be earthed at one point only at the terminal block and such earthing shall be made through links. All PT circuits shall be provided with HRC fuses having special holders such that they cannot be interchanged with other types of fuse holders and other fuse holders cannot be inserted into them.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. KARIMNAGAR DIST. 3 pin receptacle. All the panels shall be equipped with a continuous earth bus with connectors and clamps between panels for interpanel connection of the earth bus. supplies for various control. TCE. All the push buttons shall be momentary contact type. isolating and short circuit protection by use of MCBs/MCCBs of D. CFL type cubicle illuminating lamps and a 5A. Each control & relay panel shall be provided with necessary arrangement for receiving.C. Colour of the lamps shall be different for different purposes.5 mm2 copper wires.

alarms and indications. Certified copies of all type and routine test certificate shall be submitted for the Owner’s approval before dispatching the control / relay panel. 329 R5 .5960A-H-500-001 (p) Tests (i) relay panels shall be subject to the following tests : • • • • • Mechanical operation test High voltage test (2000V for 1 minute) Megger test Verification of wiring as per approved drawings Electrical control. Printer and evaluation software shall be provided for the 400 kV Switchyard. HMI.15. It shall have 8 analog and 16 digital channels. 7. Provision shall be made to synchronise the electronic clock of each disturbance recorder with external master clock which GPS based. The FDRs shall be modular and shall be suitable for expansion. a number of disturbance recorders in the particular location shall ISSUE R0 151 TCE FORM NO.15 7. NO. Interlock and sequential operation tests (ii) Type tests and routine tests Type tests and routine tests shall be carried out on all associated components / equipment as per relevant standards and test certificates shall be furnished. relays. ELECTRICAL SYSTEMS . The equipment shall be complete with disturbance recorder. control / display unit.7 1X 700 MW CCPP AT NEDUNOOR.1 Fault Disturbance Recorder Stand alone Fault Disturbance Recorder with associated cabling. junction box and accessories like auxiliary CTs and shunts. PC. The HMI and PC loaded with evaluation software shall be located in Switchyard Control Room/Central Control Room.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. SECTION: D3. Also. (III) • • Acceptance Tests The equipment shall be demonstrated for proper operation. TCE.400 kV SWITCHYARD SHEET 39 OF 51 SPEC. KARIMNAGAR DIST. including operation of meters.

The accuracy of analog channel recording shall be less than +3% for current channels and +1% for voltage channels. 329 R5 . Recording shall be self started or triggered by dI / dt.16 Synchronising Scheme The closing schemes of the CB shall be prepared and wired in such a way that only one CB is selected at a time for synchronising.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. if any. breaker contacts.2kHz to 10kHz. lock out relay contacts. It shall be possible to bypass synchronising relay only through a bypass switch ISSUE R0 152 TCE FORM NO.2 Specific Requirements of the Equipment (a) The microprocessor based fault recorder shall be designed to continuously monitor analogue. TCE. 7. The data acquisition unit of the fault recorder shall be provided with self-test diagnostic feature. (b) (ii) (iii) (iv) 7. KARIMNAGAR DIST. Digital channels: Protective relay contacts. NO.15.400 kV SWITCHYARD SHEET 40 OF 51 SPEC.5960A-H-500-001 be capable of being synchronised with any one of the recorders as master.7 1X 700 MW CCPP AT NEDUNOOR. The sampling rate of the wave shall be between 1.5 or 1 sec. ELECTRICAL SYSTEMS . Auxiliary CTs while catering for the required VA burdens shall not saturate under maximum fault current conditions. The number of channels / recorders offered shall cover the following: (i) Analog channels: (a) Currents in 3 phases and neutral (b) Voltages of 3 phases and their vector sum wherever VTs are provided. The fault recorder and all its peripherals shall be designed for operation on 220V DC. The total number of channels offered shall be such that 20% spare channels are available. or change of state of any of the digital input signals. dV / dt. Auxiliary multi ratio PTs shall be provided to facilitate tap selection in voltage signal recording. which annunciates and alters the operator to rectify the defect or fault. Recorders shall be provided with pre-history recording feature with pre-history recording time not less than 0. digital signals and contacts of all protective / lockout relays. SECTION: D3.

1 Sequence of events recording System (SER) The SER system shall be a part of SCADA system. pole discrepancy relay operation. it shall be noted that key operated auto / off / manual selector synchronising switch provides command from control panel. synchronising check relay permissive output contact and synchronising check relay indicating lamp contacts shall all be switched to respective circuit after synchronising selection scheme for any equipment is switched on. The technical details of each isolating transformer shall be 30 VA.g.17 7. bright lamps. The closing shall be possible only in manual position of synchro selection switch. 7. Isolating transformer shall be provided in each incoming AC and running AC potential circuit of the synchronising scheme. After synchronising selection is switched on. auto re-closing selection. shall be available in SCADA. direct trip send and receive.7 1X 700 MW CCPP AT NEDUNOOR. change of positions of switches such as Local/Remote selection. synchronising selection. TCE. all synchronising indicators (e. etc.17. VT fuse fail relay operation. SECTION: D3. live line / dead bus. Live line-dead bus and dead line / live bus closing facility shall be provided using dedicated relays on CVT. the CB can be closed only after the operation of synchronising check relay. NO. DC power supply. 329 R5 . ELECTRICAL SYSTEMS .ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. opening and closing commands. double frequency meter. the CB shall not be closed on operation of the check relay. DC supply fail. etc. The synchronising and guard relay scheme shall be designed in such a way that when closing impulse is given. KARIMNAGAR DIST. Live-line / dead bus and dead-line / live-bus relays shall be one set per CB. While preparing the scheme.5960A-H-500-001 and under voltage relays to sense dead-line / live-bus and live-line / dead-bus conditions. LBB operated. SER shall be designed with 1 ms resolution for digital input events with time stamping from each phase of all breakers. operation of all protection and trip relays. selection of control from SCADA/DCS.. voltage selection.5 All AC circuits. dead line / live bus and guard relay outputs shall all be started and permissive conditions be generated for closing the respective circuit breaker. isolators and earth switches. SF6 pressure Low. Critical interlocks and ISSUE R0 153 TCE FORM NO.) synchronising check relay.400 kV SWITCHYARD SHEET 41 OF 51 SPEC. synchroscope. 110 / 110V with accuracy class of 0. If closing impulse is initiated before synchronising check relay operates. trip circuit faulty. trip relay faulty. double voltmeter.

Test & Test Reports The Contractor shall conduct all the routine. The test certificates shall be furnished for Owner’s approval.19. synchronising are indicated in I&C system section D2. Separate core for main & check tariff metering with 0.17.19 7. PLCC System PLCC system shall be provided for four nos. It shall be possible to synchronise the clock with an external master clock.2S shall be provided with suitable communication port for interfacing the same with SCADA system.7 1X 700 MW CCPP AT NEDUNOOR.1 Control. ISSUE R0 154 7. Further occurrences shall be printed chronologically.2S accuracy class shall be provided for all the lines.20. The clock shall have resolution of 1 ms and first up feature.400 kV SWITCHYARD SHEET 42 OF 51 SPEC. This list is only indicative and not exhaustive. Indication. KARIMNAGAR DIST. annunciation. Energy meters must be provided with a pair of suitably rated potential free contacts to generate signal for annunciation and SCADA. In SCADA system separate work station shall be provided for accessing the Energy Meter readings. however exact requirement of APTRANSCO grid authorities shall be intimated to successful bidder. 329 R5 . dedicated channel shall be provided for speech/data necessary hardware & software & accessories shall be included.21.5960A-H-500-001 those SER points which are not covered by numerical relays shall be hard wired to SCADA. 7.1 TCE FORM NO. The chronological printout facility shall be provided for any of the first 100 occurrences. TCE. ABT Metering System ABT compliant energy meters for main & check with accuracy class of 0.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.2 7. 1 no.1 7. if voltage supply to the meters are interrupted. 100% redundancy shall be provided in hardware for protection signalling. type and acceptance tests as per the relevant standards and as specified in this specification in the presence of the Owner. of 400kV outgoing lines. ELECTRICAL SYSTEMS . NO. SECTION: D3.20 7.21 7.18 The event recorder shall be suitable for operation on 220V DC supply. Alarm and SER Points Minimum electrical requirements in respect of control. monitoring measurement. Provision shall be made to amount Tariff meters supplied by grid in the switchyard itself in the grid tie lines as per requirement of grid authorities. 7.4.

329 R5 . However if due to any reason Owner requires the same to be conducted again. lighting arresters insulators strings. current transformers. TCE. Disturbance recorder shall comply with the test requirements as per IEC-60255-5&6. such tests will normally be waived. conducting the tests are included in the scope. control & relay panels and other components of all the main equipment type tests are already conducted on identical equipment to the one offered and found to be acceptable. in case of circuit breaker. isolators. voltage transformers.7 1X 700 MW CCPP AT NEDUNOOR. bus post insulators. ELECTRICAL SYSTEMS . NO.400 kV SWITCHYARD SHEET 43 OF 51 SPEC. In case of hardware such as clamps the temperature rise test material composition test and mechanical test shall be conducted on one sample of each type even if test reports are already available. KARIMNAGAR DIST.5960A-H-500-001 If. SECTION: D3.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. ISSUE R0 155 TCE FORM NO.

8 C 50 31 mm / kV based on highest system voltage mm 1. NO.7 44 OF 51 SL.1 1. . KARIMNAGAR DIST.1 2. single pole * O-0.4 400 kV SWITCHYARD Nominal voltage Highest System voltage Short circuit breaking current Making current kV kV kA kA (peak) kV (Peak) 400 kV 420 kV 50 kA for 1 sec.9 Clearances i) Phase to phase ii) Phase to earth iii) Sectional clearance iv) Ground clearance mm mm mm mm 4200 3400 6500 8000 2. DESCRIPTION UNITS VALUES / REQUIREMENTS 1.6 One minute power frequency withstand voltage Reference ambient temperature Creepage distance kV (rms) 630 o 1.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. DATE REV. 330 R3 156 SF6 Nos.0 1. DATA SHEET – A3. BY 400 KV CIRCUIT BREAKERS Type Execution of poles Rated current Operating duty R0 JUNE’ 10 PPD.. A 3 nos. NO.7 SECTION: SHEET D3.BY DATE TCE FORM NO. BY CKD.3 2.4 REV.5 Impulse withstand voltage 1425 1.3 sec-CO-3 min-CO RKD HA JOB NO.7 1.2 1.3 1. 5960A CLIENT : APPDCL PROJECT : 700 MW CCPP AT NEDUNOOR.0 2.2 2. 130 1.

6 2.2 REV.14 2. KARIMNAGAR DIST. NO. Two (2) 4200 mm 15 NO + 15 NC (minimum) Not required Required kgs 600 Required. of auxiliary contacts SF6 Gas filling plant Gas evacuation and filling unit Cantilever strength Out of phase switching 400 kV ISOLATORS Type Reference standard R0 JUNE’ 10 PPD.19 3.9 2. 5960A break / CLIENT : APPDCL PROJECT : 700 MW CCPP AT NEDUNOOR.8 2. DATA SHEET – A3. 2.15 2.7 Auto Reclosing First pole clear factor Breaker opening time Breaker closing time Line charging breaking current Small inductive current breaking Type of operating mechanism Operating mechanism to be suitable for (a) Control voltage (b) Spring Charging - Required 1.16 2.11 2.18 2. BY CKD. DESCRIPTION UNITS VALUES / REQUIREMENTS 2. DATE REV.7 SECTION: SHEET D3. m. 330 R3 157 .13 2. NO.10 2. A * * * From 0. of trip coils per pole Phase to phase spacing No.5A to 10A Spring / Spring charged 1 Phase operation 2.sec.0 3.sec.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.3 m.5 2.17 2. BY No.12 220V DC 220V DC Nos.BY DATE RKD HA Horizontal centre Pantograph type IS 9921 JOB NO.7 45 OF 51 SL. TCE FORM NO.1 3.

9 3.7 3.2 Impulse withstand voltage (a) (b) Between poles and earth Across isolating distance kVp kVp 1050 1200 Cu Yes 3.10. BY CKD.7 SECTION: SHEET D3.7 46 OF 51 3.8.4.6 Material of main contact Whether contacts are to be silver faced Insulators Codes and Standards Operating mechanism (motor/ manual) Main blade Earth blade Insulation Data Minimum cantilever strength Miscellaneous Auxiliary supply (a) Electrical PPD.8 IS 2544 3. TCE FORM NO.4. BY R0 JUNE’ 10 .BY DATE RKD HA JOB NO.1 3.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. NO. DATA SHEET – A3.10 3. 330 R3 158 REV. CLIENT : APPDCL PROJECT : 700 MW CCPP AT NEDUNOOR.8.9.3 3.2 3.1 Motor & Manual Motor & Manual kg 600 220V DC for control and interlock.1 3. DATE REV.7.3 SL. Rated current DESCRIPTION UNITS A * VALUES / REQUIREMENTS Insulation Test values One minute P.F wet withstand voltage (a) (b) Between poles and earth Across isolating distance kV(rms) 1425 kV(rms) 1425 3.1 3.5 3.1 3. 5960A 3. NO. KARIMNAGAR DIST.

DATA SHEET – A3. 3 phase for motor drive For both Electrical and manual operation.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.8 4. of cores Primary current ratio 4.2 3.1 Type of interlock Codes and Standards Insulators Isolators 400 kV CURRENT TRANSFORMER Type IS : 2544 IS : 9921 Outdoor. TCE FORM NO.7 SECTION: SHEET D3. rise of winding above ambient of 50°C Cantilever strength of CT at the terminal Applicable Standards Current transformers Insulating oil Bushings Large hollow porcelains R0 JUNE’ 10 PPD.5 4. 5960A CLIENT : APPDCL PROJECT : 700 MW CCPP AT NEDUNOOR.4 4. 330 R3 159 .11 3.7 Secondary current Class of insulation Maximum temp.8.2 4. BY CKD.6 4. KARIMNAGAR DIST. TCE.11.BY DATE RKD HA C 500 C 600 kg 4.7 47 OF 51 SL. DESCRIPTION UNITS 400V AC.11. SF6/oil filled hermetically sealed with SS bellow Refer Main one line diagram Drg. NO.2 4. 5960A-EL-SK-2003 A 1 Oil immersed Class A 0 4. DATE REV.3 4.0 4.1 3. NO.8. No.8.2 4. Bolt interlock electrically operated VALUES / REQUIREMENTS 3. BY IS 2705 IS 335 IS 2099 IS 5621 JOB NO.10.4 REV.8.1 4.3 No.

oil filled/ SF6 gas filled. 5960A CLIENT : APPDCL PROJECT : 700 MW CCPP AT NEDUNOOR. DATE REV.Hz 40 – 500 5.1 SL.5 5. TCE.BY DATE RKD HA JOB NO.10 5.0 5.8. KARIMNAGAR DIST. rise of winding above ambient of 50°C Cantilever strength of CVT at the terminal Rated voltage factor Oil immersed Class A 50°C 5.8 1. BY R0 JUNE’ 10 PPD. 5960A-EL-SK-2003 5. BY CKD.5 for 30 seconds Contractor to furnish depending upon frequency selected for PLCC + 10% to – 5% k. No.4 Refer Main one line diagram Drg.7 600 kg 5. 330 R3 160 .6 5. NO.12 Tolerance High frequency range High frequency capacitance For entire carrier frequency range Within 80% to 150% of rated capacitance REV. DATA SHEET – A3. hermetically sealed CVT: Oil filled only Solidly earthed 5.9 Rated capacitance 5. TCE FORM NO.3 System neutral earthing No.5 4. of primary / secondary windings Primary / secondary winding voltage 5. Insulators DESCRIPTION UNITS IS 2544 VALUES / REQUIREMENTS Hot dip galvanising IS 2633 and IS 2629 400 kV CAPACITOR VOLTAGE TRANSFORMERS / EMVT Type EMVT: Outdoor.7 48 OF 51 4.8.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.6 Class of insulation Maximum temp.2 continuous and 1.2 5.11 5. NO.7 SECTION: SHEET D3.

19. 330 R3 161 . DATA SHEET – A3.19.2 6.2 5.3 5.4 REV. 5960A 600 CLIENT : APPDCL PROJECT : 700 MW CCPP AT NEDUNOOR.1 6. BY CKD. NO. KARIMNAGAR DIST.15.05 Cn Pf. Where Cn is rated capacitance mho 50 - 5. Class .BY DATE RKD HA kV 320 IS 3156 IS 335 IS 2099 IS 5621 IS 2544 IS 2633 and IS 2629 Solidly earthed Metal Oxide Gapless 20 kA.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.13 Stray capacitance and conductance of low voltage terminal Stray capacitance of low voltage terminal over entire carrier frequency range Stray conductance of the low voltage terminal over entire carrier frequency range 300 + 0.0 6. DATE REV.4 5.15 5.6 6. BY Corona extinction voltage Applicable Standards Voltage transformers Insulating oil Bushings Large hollow porcelains Insulators Hot dip galvanising 360 KV LIGHTNING ARRESTORS System Earthing Type of arrester Discharge class Minimum cantilever strength of arrestor assembly R0 JUNE’ 10 PPD.IV kg JOB NO.15.14 5. TCE FORM NO.15.5 5.3 6.15. - Equivalent series resistance over the entire carrier frequency range DESCRIPTION UNITS Less than 40 ohm VALUES / REQUIREMENTS 5.7 SECTION: SHEET D3.7 49 OF 51 SL. NO.1 5.

3 Puncture voltage 7.7 50 OF 51 SL.2 IS .4. DATA SHEET – A3. IS : 398 IS : 282 IS : 4826 BS : 159 IS : 5082 JOB NO.5. CLAMPS & CONNECTORS Applicable Standards AAC.5.2544 IS – 5621 7. TCE FORM NO. NO.3070 and IEC . BY CKD. KARIMNAGAR DIST.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.BY DATE RKD HA .0 Applicable standard Post insulators Suspension insulators Insulator fittings BUS CONDUCTORS. 1.3 times corresponding flash over voltage. BY R0 JUNE’ 10 PPD.1 7.4.60099 6.0 7.4 7.3 7. DATE REV.1 REV.1 Codes and Standards Lightning arrester for alternating current systems Insulators Large Hollow Porcelain insulators INSULATOR Type Cantilever strength kg Solid core / post type / string 600 kg minimum for bus post insulator.5 6.7 SECTION: SHEET D3. NO. 5960A CLIENT : APPDCL PROJECT : 700 MW CCPP AT NEDUNOOR.2 6.5.1 7. 330 R3 162 IS 2544 IS 731 IS 2486 IS 5561 8.3 8. ACSR conductors Copper conductors Galvanisation of steel wires Copper tubes Aluminium / Aluminium Alloys Bars.2 7.4. DESCRIPTION UNITS VALUES / REQUIREMENTS 6. IS .

5960A CLIENT : APPDCL PROJECT : 700 MW CCPP AT NEDUNOOR.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. BY CKD. NO.7 51 OF 51 SL.BY DATE RKD HA JOB NO.7 SECTION: SHEET D3. Sections for Electrical Purposes Fittings for Aluminium and steel cored aluminium conductors for overhead lines Electric power connectors Hot dip galvanised process DESCRIPTION UNITS VALUES / REQUIREMENTS IS : 2121 IS:5561 IS : 2629 & 2633 9.8 9.0 9.7 9. BY R0 JUNE’ 10 PPD. IEC:60353 REV. IEC :60353 IS : 8793. NO.1 9.12 9. 330 R3 163 . TCE FORM NO.10 9. Rods. DATA SHEET – A3.9 9.13 LINE TRAPS Installation Type of earthing Line trap arrester discharge current Band width Tuning device required Maximum tapping loss Type of tuning Winding material Line traps Methods of test for line traps dB kA kHz Outdoor Effectively earthed 20 40-500 Required 2.11 9. Tubes. KARIMNAGAR DIST. DATE REV.6 Wide band Copper IS : 8792.3 9.6 9.

ELECTRICAL SYSTEMS – GENERATOR CONTROL PANEL SPEC. synchroscope.6 kV & 400V auxiliary power supply system shall be provided. of synchronising panel/trolley shall be provided through which the synchronising of all the GCB & breakers in 400kV switchyard can be synchronised (GCB in the case of GTGs and 400 kV GT breakers in the case of STGs) by plugging the control cable into a socket provided on each Control panel of the respective breaker.2. synchronising and sequential event logging for each generator and its subsystem shall be provided on the Operator stations (plant DCS through HMI). Auto synchroniser relay for generator (25A): The Auto synchronising facility shall be made available to auto synchronise the above breakers through DCS. synchronising lamp.. NO. The raise/lower commands for the same also be done through the trolley itself. TCE.2 8. shall be provided in the hardwired GCP as follows: (a) One No. the mimic of the generator. This synchronising trolley shall have all the necessary equipments & meters for carrying out the manual synchronisation.8 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. 329 R5 .2 8.5960A-EL-SK-2003. data logging. ISSUE R0 164 8. double frequency meter. SHEET 1 OF 10 1X 700 MW CCPP AT NEDUNOOR.2. its subsystems and 6.3 (b) TCE FORM NO.1 8. TCE. operation and annunciation on GCP and monitoring. monitoring. Auto synchronisers shall connect the generators to the 400 kV grid either through generator circuit breaker or 400kV generator transformer breakers automatically after synchronising the two systems.2. etc.1 GENERATOR CONTROL The control. bringing upto rated voltage and speed. initiation of synchronising. KARIMNAGAR DIST. The equipment shall be supplied to control both the voltage and frequency of turbine generator set to match with those of the grid. Synchronising equipment consisting of Auto synchroniser. alarm. The minimum requirements of the measurements are indicated in the Main One Line Diagram drg no.0 8.5960A-H-500-001 8.SECTION: D3. double voltmeter. In the GCP. Generator and Auxiliary Power Supply System Control & Monitoring Provision in the plant control system shall be made for the starting. essential controls and annunciation shall also be available from the Generator control panel (GCP). recording and sequential event recording for generator and its excitation system from the Operator stations (plant DCS through HMI). measurement. check synchronising relay. Synchronising. annunciation.

NO. ISSUE R0 165 8. indicating lamps as needed for the control of the systems envisaged. The GCP shall be provided with all the synchronising switches. When the “Manual” mode is selected. breaker control switches. 400 kV generator transformer breakers along with grouped alarms of generator and generator transformer shall be made available for indication/annunciation in 400kV system SCADA switchyard Control Room as well as main control room. breaker selector switch. synchronising shall be done from the stand-alone synchronising panel which houses the required synchronising gear (consisting of dv & df meters with associated transducers. etc. Synchronising. ELECTRICAL SYSTEMS – GENERATOR CONTROL PANEL SPEC. check synchronising relay.8 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.6 8. However. essential controls.3. SHEET 2 OF 10 1X 700 MW CCPP AT NEDUNOOR. synchronising of complete electrical system supplied under this contract shall be possible from plant DCS system. KARIMNAGAR DIST. monitoring. measurement. This shall be read in conjunction requirements with requirements indicated in I&C Section D2. Further.4 8. In case of failure of any OS. the status of generator circuit breakers.6 8. The interlocks for the auxiliary power supply system shall be hardwired interlocks. synchronising lamp.3 8. The push buttons shall be suitably protected to prevent inadvertent operation.2.5960A-H-500-001 8.1 TCE FORM NO. synchroscope.4 Manual synchronising facility common to all the units shall be provided for manual synchronisation of the generators. When the “Remote” mode is selected. metering and annunciation shall also be available from the Respective control panels for the lines. 329 R5 . the 400kV system SCADA shall be interfaced with the plant DCS through serial link for monitoring of 400 kV system from DCS.5 8. selector switches. Remote/Manual selection shall be provided in DCS. Hard wired emergency trip push buttons for tripping of generator circuit breakers of GTGs shall be mounted on the operator console. synchronising shall be initiated from DCS through auto synchroniser.). The 400kV system controls shall be implemented in an independent SCADA system.2. it shall be possible to carry out the necessary operation from one of the healthy OS. push buttons.2. CONTROL AND MONITORING IN DCS Control. The synchronising panel shall be located in the control equipment room. annunciation.SECTION: D3.2.5 8. etc.2.2.4. guard relay. TCE.

2 DCS System Minimum functional requirement of plant DCS system in respect of electrical system shall be as below: 8. Control of generator excitation and governor system shall be possible from plant DCS including mode selection and set point control for various parameters viz.1 CONTROLS (i) Control of all the Incomers. Remote position.F. KARIMNAGAR DIST. ELECTRICAL SYSTEMS – GENERATOR CONTROL PANEL SPEC.8 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. NO. service position. All the necessary controls required for synchronising the DG set & stopping of DG set after resumption of Normal power shall be included in the DCS. DG breaker closing shall be possible from DCS. MW. MVAR & P. DCDB & UPS DB. (ii) (iii) (iv) (v) (vi) 8. issuing raise / lower command to OLTC from plant DCS system. Abnormal conditions to be considered for alarm inputs to DCS are: ISSUE R0 166 (b) TCE FORM NO. Synchronising gear shall be housed in the respective switchboards. other breakers (ON. It shall also have the facility to carryout the live changeovers at all the switchboards at 6.3. shall be carried out from the DCS. TCE. Local / remote and auto / manual selection will be done at DG set control panel. voltage raise/lower. bus ties of all the electrical switchboards except outgoing feeders from the main Lighting Distribution Board. SHEET 3 OF 10 1X 700 MW CCPP AT NEDUNOOR. breaker health. speed raise/lower. Selector switch for the operation of equipment shall be at respective control panel.5960A-H-500-001 8. controls. service.2 Monitoring (a) Indication-Status of GCB.3.2.6kV & 400V. DG start. test) position of Local/Remote selector switches. Initiation of auto synchroniser.3. permissive for interlock set shall be considered as input to the DCS system. OFF. All transformers with OLTC shall have provision for control viz. Selector switch for the operation of equipment shall be at respective control panel.2.SECTION: D3. 329 R5 . spring charged indication etc.

protection unhealthy of each equipment. Successful/Unsuccessful changeover of 400V supplies. motor protection. group faults in case of DC boards. (ii) LV System (400V) Breaker auto trip. VT circuit unhealthy of each VT. 329 R5 .6kV and 400kV breaker) Operation of each of Generator protection. (iii) Generator. LBB operation of each breaker. (vi) Battery charger Group trouble alarm for chargers with details as available from equipment.8 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.6 kV supplies. Trip circuit unhealthy of each equipment. DC under voltage. Tap position of GT & UATs shall also be monitored from DCS. VT fuse failure.SECTION: D3. SHEET 4 OF 10 1X 700 MW CCPP AT NEDUNOOR. trip relay failure. (iv) DC System DC earth fault. 6.5960A-H-500-001 (i) HV System (Generator CB. GT and UAT condition shall be monitored from DCS. signals generated in Transformer MB about abnormal operating conditions of Transformer. unit auxiliary transformers and service transformers. ELECTRICAL SYSTEMS – GENERATOR CONTROL PANEL SPEC. DC supply failure. and normal operating parameters of the DC system etc. individual protective relay operation. KARIMNAGAR DIST. Monitoring of winding & oil temperature of all the transformers & of all temperatures & pressure parameters related to Generator. DC supply failure of each protection/control scheme as appropriate. bus under voltage. TCE. (v) UPS System All normal & abnormal conditions of UPS system with details. Trip relay unhealthy of each equipment. NO. Unit Auxiliary & Service Transformers All alarm and trip conditions of generator transformers. Successful/Unsuccessful changeover of 6. Trip circuit unhealthy. ISSUE R0 167 TCE FORM NO.

SHEET 5 OF 10 1X 700 MW CCPP AT NEDUNOOR. generator & auxiliary consumption shall be taken from the ABT compliant energy meters through communication.8 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. KARIMNAGAR DIST. (x) (xi) (xii) (c) Single line diagram showing Voltage. abnormal conditions in excitation system and generator. 8. SLD shall also show the Generator phase currents. field current and 400kV bus voltages & frequency. More than one frame can be used if all the details cannot be represented on a single frame.SECTION: D3. 329 R5 . (ix) Alarm for the running hours of 30KW & above motors shall be generated after achieving predefined set points. All the energy parameters of the lines. TCE.3. NO. breaker and isolator positions shall be available on DCS/SCADA. MW and MVAR flows. alarm and trip conditions. frequency.2. (viii) DG Set DG operating parameters.3 Measurement Feeder Description (a) 400 kV line bays DCS MW MVAR A V MWH MVARH Pf MVA Control Panel ISSUE R0 168 TCE FORM NO. Temperatures of all the >= 100KW motors. Energy parameters on HV side of GTs & UATs shall also be monitored. ELECTRICAL SYSTEMS – GENERATOR CONTROL PANEL SPEC.5960A-H-500-001 (vii) Excitation System and generator Each of protection relay alarm and trip conditions. Monitoring of the complete electrical system during the normal operation.

8 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. Tie feeders & Outgoing feeders of 6.V (All phases) .MW -MVAR -Frequency -pf -MWH - MVAR MVARH* Frequency MW trending MVAR trending pf MWH * (d) 400 kV Bus V(Bus –1& 2) Frequency(Bus –1& 2) * By pulse output from TVM /Meters (e) Unit Auxiliary A(All phases) Transformer (HV side) MW MVAR MWh Tap position winding & oil temperature (f) Incomer. Buscoupler & outgoing feeders of 400V switchgear -A (All phases) -MW MWh - A-All phases for I/C & Ties.6kV switchgear and Incomer. ELECTRICAL SYSTEMS – GENERATOR CONTROL PANEL SPEC. TCE.A (All phases) . One phase for others MW MVAR MWH ISSUE R0 169 TCE FORM NO. KARIMNAGAR DIST.SECTION: D3. 329 R5 .5960A-H-500-001 (b) 400 kV GT bays A(All phases) MW MVAR MWh Tap position winding & oil temperature V(All phases) A(All phases) MW -A (All phases) -MW MWh - (c) Generator . NO. SHEET 6 OF 10 1X 700 MW CCPP AT NEDUNOOR.

4 Event logging shall be provided for all manual operations and relay operations as detailed below: (a) Status of each breaker of all equipment being controlled.3. KARIMNAGAR DIST. The metering data for the 400kV bays shall be through the ABT compliant energy meter provided except the tariff meters. These power meters shall have the local display also. A V & Hz for UPS V (All phases) F (j) Generator stator winding and bearing Temperature - NOTE : DCS Input current and voltage shall be considered for all three (3) phases.3. 329 R5 . TCE. ELECTRICAL SYSTEMS – GENERATOR CONTROL PANEL SPEC.5960A-H-500-001 (g) 6. . SHEET 7 OF 10 1X 700 MW CCPP AT NEDUNOOR. NO. electrical parameters & Energy reading shall also be measured through numerical protection relay provided at the DG set. Running hours.SECTION: D3.8 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. isolators and earth switches.6kV & 400V Buses (h) Emergency DG set (i) DC and UPS System All energy metering shall be through the power meters provided on the incomers & tie feeders on the DCS. 8. ISSUE R0 170 TCE FORM NO. Running hours of the motors decided during the detailed engineering shall be calculated or taken from the numerical relays.

alarm relay operation. The change from normal mode to disturbance mode shall be through threshold/gradient settings provided in the system for analog quantities and external binary signals obtained from selected protective relays. 329 R5 . double frequency meter. etc.2. (b) 6.2. distance relay output contacts. NO.6 kV Incomer & tie circuit breakers shall have facility for fast and slow auto changeover/manual synchronising and dead bus closing. 400V switch board / MCC incomer and bus coupler breakers shall have facility for dead bus auto change over / manual live transfer.) Event logger shall be a part of the DCS with first up feature.6 (c) ISSUE R0 171 TCE FORM NO.5/1. It shall have a time resolution of 1 ms. all transformer.3. 3-poles of line circuit breaker.0 sec. Event logging for each phase shall be provided wherever applicable (eg. TCE.. UPS. Generator. SHEET 8 OF 10 1X 700 MW CCPP AT NEDUNOOR.5 Trending of parameters during disturbance shall be with a resolution of 0. Selector switch positions. are to be included.5960A-H-500-001 (b) (c) (d) Close and open commands. trip relay. Capturing of momentary values of all these parameters shall also be possible triggered either by a protective relay or by a manual keyboard command. battery charger.SECTION: D3. ELECTRICAL SYSTEMS – GENERATOR CONTROL PANEL SPEC. KARIMNAGAR DIST. generator protections. Synchronising (a) Generator (Manual and through Auto synchroniser) Synchronising facility shall be provided for the generator through auto synchroniser in auto mode and with the help of double voltmeter. all electrical switchboards etc. (e) (f) 8. 8. Each protective relay. and at 15 minutes during normal operation.3.8 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. Trip contacts of the complete electrical installation/equipments in the station viz. fuse fail alarm. synchroscope and check synchronising relay permissive condition in the manual mode.

1 8. ISSUE R0 172 8. synchroniser with lockable only in ' off ' position. The coupling relays shall be rated for 0.5 8.5 8.6 8. KARIMNAGAR DIST.3.4. shall be provided for each of the following: (1) Generators (2) Breakers associated with Emergency DG synchronising 8. Interposing Relays The interposing relays required for the switchgear / equipment being supplied under this contract shall be located in separate IPR panels located in the control room.3.5960A-H-500-001 (d) One (1) set of synchronising equipment consisting of double voltmeter. Interposing relays used for 400 kV circuit breaker closing shall be adequately rated for the making current. synchroscope. The control / selector switches & meters shall be of miniaturised version.3..4. UAT & generator metering shall be provided.2S for lines. The time critical controls and interlocks shall be hardwired system only.4 8. All the transducers shall be self-powered. check synchronising relay. Check & main Meters – ABT compliant Tri-vector energy meters of Accuracy class 0.3 TCE FORM NO. The transducers shall comply with the requirements specified for transducers in Electrical section D3.2 8.SECTION: D3. 329 R5 .25. any additional requirement arising during detailed engineering shall be provided by the Bidder without any additional cost to the Owner. synchronising lamps. double frequency meter. the Bidder shall provide all necessary controls indications.1 8.5.5. etc.3.5 Amp breaking at 220V DC and 6 Amp make and continuous current at 220 V DC. ELECTRICAL SYSTEMS – GENERATOR CONTROL PANEL SPEC. Transducers The Contractor shall provide all the transducers for electrical system either in respective switchgear / control panels.3 The functional requirement indicated above are minimum.4 8. SHEET 9 OF 10 1X 700 MW CCPP AT NEDUNOOR.5. TCE. NO.2 8.8 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. Also. interlocks & devices required for the system offered by him.

329 R5 . SHEET 10 OF 10 1X 700 MW CCPP AT NEDUNOOR.8 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.SECTION: D3.5960A-H-500-001 8.7 for Switchyard relay and control panels. TCE.6 Tests Tests for control desk shall be as indicated in Section D3. ISSUE R0 173 TCE FORM NO. KARIMNAGAR DIST. NO. ELECTRICAL SYSTEMS – GENERATOR CONTROL PANEL SPEC.

2. TCE.2.5960A-H-500-001 9. ii) In Phase Transfer The breaker power contacts shall close when the decaying and drifting bus voltage synchronizes with the incoming source voltage within acceptable voltage and frequency parameters. The FBTS should have following transfer modes: i) Fast Transfer 9. adequately rated switchgears shall be provided.0 6. Manual & Automatic Transfer of Loads The station switchgear shall be provided with manual live changeover scheme for planned changeover of supply from one incomer to another and vice versa.1 9.41 (1982) criterion.Ts. NO. The closure of the unit supply breaker shall be supervised by a synchrocheck relay permanently connected to and energised by the secondary voltages of the unit bus P.2.9 1X 700 MW CCPP AT NEDUNOOR. The Bus transfer system ISSUE R0 174 TCE FORM NO. ELECTRICAL SYSTEMS . Also. the switchgear and its accessories shall comply with the requirements indicated in Data Sheet – A 3.3 The bus voltage and incoming source voltage should be monitored on a continuous basis for magnitude and phase angle to ensure that transfer operation is carried out under conditions conducive to fast bus transfer as per high speed sync-check supervision and ANSI C50. an automatic “slow” transfer shall be initiated.6 kV and service transformers.2 9. If fast auto change over fails for whatever reason.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.6 kV SWITCHGEAR The 6. The fast changeover scheme shall be such that the running motors are not tripped or there is only allowable inrush current due to motor reacceleration. SECTION: D3. 329 R5 .2 9.9 and specific requirements indicated below.6. 9. KARIMNAGAR DIST.6 kV switchgear and its accessories shall conform to all latest editions of national and international standards indicated in Data Sheet – A 3. Automatic fast changeover scheme for changeover of supply from one source to another in the event of supply failure from upstream end shall be provided. The high-speed transfer shall be completed in not more than 40 ms.6 kV SWITCHGEAR SHEET 1 OF 15 SPEC. Changeover shall be blocked if incomer has tripped due to bus fault.1 For feeding the plant auxiliaries rated for 6.9.

Asymmetrical S.4. transformer feeder on each bus (colony supply) for Owner’s use shall be provided.3 TCE FORM NO. on the basis of short circuit current contribution from UAT plus short circuit contribution by the motors running on the bus. KARIMNAGAR DIST. shall be arrived at.5960A-H-500-001 shall continuously process the bus voltage and the drifting phase angle dynamics to determine in real-time the exact moment of sending a command to the breaker-closing coil to achieve the above.2 9.3 9. TCE.2. 9. A margin of 5% over higher of the above S. NO. Additionally One (1) no. ELECTRICAL SYSTEMS .4. The momentary current ratings shall be 2. Spare Feeders One motor and one transformer type spare feeder of highest rating shall be provided on both sections of Bus-A & Bus-B of 6. the new source breaker is closed before opening the old source breaker. iv) Momentary Paralleling Transfer This is a “Make before Break” transfer for a very short duration of the order of few cycles where. bus bars. circuit breakers.4..9 1X 700 MW CCPP AT NEDUNOOR. ISSUE R0 175 9.6kV switchgear.55 times this value. 329 R5 .C current breaking capacity of the breaker shall consider the higher time constant for decay of current in the vicinity of power generating stations and the breaker offered shall be suitable for this duty.4 9. earth switch. The auxiliary drives are selectively tripped simultaneously to limit the transformer inrush current.C current.6.4 The bus transfer scheme shall be totally microprocessor based numerical system with in-phase transfer facility and communication facility to DCS.1 Short Circuit Current Ratings The fault level for the switchgear. etc. under supervision of the bus voltage and incoming source voltage for magnitude and phase angle.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.6 kV SWITCHGEAR SHEET 2 OF 15 SPEC. thus calculated shall be applied and rounded off to the next higher standard ratings and this value shall be adopted for the breakers and switchgears. isolators. Normally not recommended for unplanned transfers and auto/protective transfers from the system safety considerations 9. iii) Slow Transfer The breaker power contacts shall close when the falling bus voltage shall reach an acceptable safe value. SECTION: D3.

All live parts shall be provided with isolating barriers between phases to avoid exposure to live parts. (b) circuit breakers.5.9 1X 700 MW CCPP AT NEDUNOOR.. shall be provided in the ISSUE R0 176 TCE FORM NO. A fixed type checkered net shall be provided between cable termination and door to avoid accidental contact to live termination. Constructional Measurements The switchboard shall be indoor. 9.1 9. The continuous current rating of the feeders shall be based on the name plate current rating of the connected equipment with 20% margin rounded off as indicated in 9.4 Calculations for arriving at the time constant at this plant shall be furnished to justify breaker selection in accordance with IEC-62271-100 and contractor shall furnish calculation during detailed engineering stage to establish the adequacy of support insulators and busbar sizes for the declared continuous and short time current rating.5. vertical droppers and connectors to the fixed end of isolating contacts.2 Required number of high speed trip relays.1 9. Switchgear shall be suitable for extension on both sides. (c) phase bus bars. metal clad having separate metal enclosed compartments for (a) control. The switchgear assembly shall be rodent and vermin proof. timers. Continuous Current Ratings The continuous current rating of the 6. Switchgear shall be suitable for extension on both sides.5960A-H-500-001 9. NO. 329 R5 . Door enclosing the cable termination shall be with hinge.6 kV unit switchgear buses.5 9. All circuit breaker compartments shall be provided with separate door so that circuit breaker front cover shall not be used as front door. supervision relays. ELECTRICAL SYSTEMS . TCE.1. SECTION: D3.6 kV SWITCHGEAR SHEET 3 OF 15 SPEC.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.2 9.6. (d) instrument transformers and (e) power cable terminations and adjacent cubicles (panels) shall have sheets on either side to ensure complete isolation.4. KARIMNAGAR DIST. contact multiplication relays.6.5. The bottom of each panel shall be covered by sheet steel and necessary glands plates. etc. This arrangement is required to take Thermographic measurement using Infrared thermometer. incomer breaker shall be the rated LV winding current of UAT's respectively with 20% margin rounded off to the next higher standard rating.6.6 9. metering and relaying devices. Conductor shall be of high conductivity aluminium alloy for the horizontal busbars. auxiliary relays.

Suitable mechanical interlocks shall be provided to prevent the closing of earth switch on live circuit. Withdrawal of circuit breaker shall not be possible unless it is in open position and operation of circuit breaker shall not be possible unless it is fully in service position. or is fully in test position and drawn out position. NO. service and isolated positions.6.5mm² for all circuit and 2. ISSUE R0 177 9. 10 amps rated complete with insulated barriers. Automatic safety shutters shall cover live parts when the breaker is withdrawn and all other standard safety features shall be provided. 650 volts grade.3 The circuit breaker shall be drawout type and it shall have test. Not more than 2 wires shall be connected at a one terminal. The circuit and bus bar earthing facility with earthing trucks shall be provided for each type of breaker. KARIMNAGAR DIST.6.6.7 9.6.9 9. Terminal blocks shall be of stud type.8 9. SECTION: D3. At least 5NO+5NC spare contacts shall be wired to the terminal block after fully utilising for protection.6. In test position the circuit breaker shall be capable of being tested for operation without energising power circuits.6. All spare contacts and terminals of cubicle mounted equipment and devices shall be wired to terminal blocks with 20% spare terminals.5 mm² for CT circuits. Adequate space shall be available for termination using heat shrinkable type cable termination in cable compartment and for mounting of zero sequence current transformers (core balance current transformers). etc. Switchgear shall be supplied completely wired and inter panel wiring between cubicles of same switchgear shall be provided. ELECTRICAL SYSTEMS .5960A-H-500-001 panels to meet the system requirements and to meet the system operation philosophy indicated in the specification elsewhere.6 9.All non-current carrying metal work of the switchgear shall be effectively bonded to the earth bus. The current transformers shall be mounted in the fixed portion of the switchgear.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. 9.11 TCE FORM NO.6.9 1X 700 MW CCPP AT NEDUNOOR.10 9.6.6.5 9. 329 R5 . The sizes of wire in the panel shall be stranded copper conductor. TCE. Terminal blocks for CTs and VTs shall be provided with test links and isolating faciliting and CT terminals with short circuiting and earthing facility. Hinged doors shall be earthed through flexible earthing braid for each type of breaker. Earth bus of size 50x6 mm Cu shall be provided at the bottom and shall extend throughout the length of the switchboard . interlocking. annunciation.6.6 kV SWITCHGEAR SHEET 4 OF 15 SPEC.4 9. 1.

In the event of shortage of contacts in circuit breakers. lead burdens. 50 Hz. auxiliary. Provision shall be made for receiving.13 9.5 mm) shall be provided and the same shall be on AC supply. Space heaters of adequate capacity shall be provided. space heating. changes during engineering stage and adequate margin at the time of handing over the plant: (a) The CTs shall withstand momentary and short time current ratings of the associated switchgear. contacts shall be gold flashed with 20 micron thick plating.6.12 All relays protective. Push buttons provided shall be shrouded. instrument selector switches shall be of maintained stay put type.17 9.9 1X 700 MW CCPP AT NEDUNOOR. Timers shall be of electromagnetic or electronic type only.. Externally operated hand reset indicators shall be provided on all relays and timers. 3 pin receptacle with switch located in a convenient position. In such cases separate protection CT core with higher ratio shall be selected to avoid saturation at high fault currents. NO.6. distribution. DC supply supervision lamps (self coloured clustered LED type of size 22. The same shall be two coil. TCE.6. isolating and fusing of auxiliary DC and AC supplies for controls.6. In case of smaller rated CTs (say 200 Amp and less) at the expected fault level the CT saturation may result in the non operation of the instantaneous short circuit protection. latching type with electrical reset. 329 R5 . Two numbers DC feeders shall be provided for 6. ISSUE R0 178 9. Each switchgear panel shall be provided with 230 Volts. CTs and VTs shall be of the cast resin type and completely encapsulated. 1 phase. trip relays.5960A-H-500-001 9. Breaker control switches shall be 3 position spring return to neutral. SECTION: D3. KARIMNAGAR DIST.16 9. The ratings of instrument transformers shall be decided by Bidder based on connected load.6. shall be distributed between different phases to keep the loading on all the phases uniform. Atleast 1NO + 1NC spare contacts of all relays / timers shall be wired to terminal block.18 (b) TCE FORM NO.6 kV SWITCHGEAR SHEET 5 OF 15 SPEC. All relays shall be of self reset type unless otherwise specified.6.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. Necessary test plugs shall be supplied loose and is included in the scope of supply.6kV switchgear with selector switch for selecting any one supply. Breaker control switches shall be pistol grip black and selector switches shall be oval or knob. ELECTRICAL SYSTEMS .14 9.15 9. black. and timers shall be in draw out cases with built in test facilities.6.6. 5 amps. etc. Single phase loads for motor space heating etc. contact multiplying relays shall be used.

KW. All breakers of identical ratings shall be interchangeable. for motor tripping and remote annunciation on supply failure. Bidder shall supply and mount transducers as per Main One Line diagram and philosophy of control defined elsewhere in the specification. 4-20mA outputs for parameters available in numerical relays shall be used. Primary fuse replacement shall be possible with VT in isolated position only. separate transducers shall be provided.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.26 ISSUE R0 179 TCE FORM NO. running hours etc) required in DCS. VTs shall be provided with HRC fuses on both primary and secondary sides under voltage relays. Contractor shall furnish calculation during detailed engineering stage to establish the adequacy of support insulator and busbar sizes for the declared continuous & short time current ratings.6.f. 329 R5 .6.e.2kV grade shall be provided at front and rear of switchgear. NO. Those terminals required to be connected to earth shall be earthed by an isolating link without a fuse. SECTION: D3.5%. Adequate space shall be available for the termination of the heat shrinkable cable termination & mounting of the CT & CBCT.6. etc. suitable mechanical/ electromechanical interlocks to ensure that earth switch is not closed/truck is not inserted with the bus live or cable side energised.23 9. KARIMNAGAR DIST. Switchgear panel shall be suitable for bottom cable entry and provided with removable gland plates. in the individual switchgear panels. For the analog parameters (i. Rubber mats suitable for 7.6 kV SWITCHGEAR SHEET 6 OF 15 SPEC.20 9.9 1X 700 MW CCPP AT NEDUNOOR. Wherever not available.25 9. Cable lugs for all power.6. timers. control and instrumentation cables connections shall be supplied.22 9. A. TCE.6. 9.21 9.6. The cable glands shall be of double compression type brass glands. ELECTRICAL SYSTEMS . The transducers shall have 4–20 mA dual output and accuracy class shall be less than 0.6. drawout type and housed in a separate sheet metal enclosure. Fuses on primary side shall have rupturing capacity equal to the switchgear rating.6.5960A-H-500-001 (c ) Service transformers and motor feeders shall be provided with 50/1 A core balance CTs for connecting earth fault relays.19 VTs shall be single phase.6. p. 9.24 9. The lugs shall be tinned copper/Aluminium depending on cable conductor and of solderless crimping type. Those terminals required to be connected to earth shall be earthed by an isolating link without a fuse.

6.6. 'White' supervision lamp for lockout relays. NO. Blue' for breaker in 'Service' position.5 times the peak line to neutral voltage of the system. CTs etc.6.29 9.27 Current ratings of all switchgears. 329 R5 . SECTION: D3.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. The connection between the start up transformer and 6.Close' spring return to neutral position. ELECTRICAL SYSTEMS . 9.Neutral . KARIMNAGAR DIST. Bidder shall furnish temporary overvoltage capability curve and pressure relief device shall be provided for relieving internal pressure and preventing violent shattering of the housing following prolonged passage of follow current or internal flashover of arrestor.6kV switchgear shall preferably be by means of segregated phase bus ducts. circuit breakers.6. They shall be mounted within the switchgear cubicle between line and earth preferably in cable compartment and shall be suitable for indoor duty.Remote' switchgear control stay put type. Use of two breakers in parallel to meet the required rating shall not be acceptable. shall be sufficient for carrying the connected load currents without exceeding the permissible temperature limits or reduction in service life.28 Cubicle Components Each circuit breaker cubicle shall be provided with the following minimum standard accessories: (a) One control switch `Trip .6 kV SWITCHGEAR SHEET 7 OF 15 SPEC. TCE. Surge arrestors shall be provided for motor and transformer feeders and shall be as per manufacturer’s recommended type and generally in accordance with IEC 99-1.5960A-H-500-001 9. ‘Red' for breaker ON indication at the back of the switchgear at cable box door (b) (c) ISSUE R0 180 TCE FORM NO. ‘Amber' for breaker in 'Test' position.9 1X 700 MW CCPP AT NEDUNOOR.28 9. One two position control selector switch `Local .6. `Green' for breaker `OFF' indication. Surge arrestors shall be suitable for non effectively earthed system and the maximum switching overvoltage shall not be more than 2. Indicating lamps (i) (ii) (iii) (iv) (v) (v) (vi) (vii) `Red' for breaker `ON' indication and trip coil supervision. ‘Amber’ for breaker auto trip indication 'White' for breaker closing spring 'Charged'.

Tripping from local shall be possible only when local/remote selector switch is in local position. Location of relays in the switchgear shall be at convenient height. All relays except for LBB. Castle key interlocks shall be provided to prevent opening of cable compartment door when breaker is closed and busbar compartment when any of the incomers to bus are closed. 329 R5 . SECTION: D3. such that it can be surfed by standing at ground. if the same is not available in the numerical relay. Closing coils shall operate satisfactorily in the control voltage range of 85-110% and tripping coil shall operate satisfactorily in the control voltage range of 70-110%. ELECTRICAL SYSTEMS . NO. All indicating lamps shall be on DC. KARIMNAGAR DIST.6 kV SWITCHGEAR SHEET 8 OF 15 SPEC.7 Metering & Protection Adequate protection / metering shall be provided for the switchgear panels.. heater with thermostat and plug point.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. Tripping from remote shall be possible only when either breaker in service position or selector switch being in remote position One electrical antipumping relay. One double pole control supply switch and set of fuses.9 1X 700 MW CCPP AT NEDUNOOR.6.5mm. Cubicle lamp. (e) (f) (g) (h) (i) (j) (k) (l) (m) 9. TCE. Mechanical close push button provided shall be accessible only after opening of the front door. PT fuse failure shall be numerical with RS232/RS485 port. The push button shall be shrouded type. (d) Mechanical trip push button to trip the breaker when control supply is lost. Closing from local shall be possible only in test position whereas closing from remote shall be possible in either service or test position. Suitable labels/Name plates for feeders and cubicle mounted components. Mechanical indication for spring charged/discharged status. Relay setting ISSUE R0 181 TCE FORM NO. Separate meters shall be provided for each of the feeders mentioned below. One breaker operation counter.5960A-H-500-001 The indicating lamps shall be self coloured clustered LED type of size 22.They shall be bright and visible from any angle.

watt meter (or) Multifunction meter with all the metering parameters 1 no. A combination of electromechanical & numerical communicable type relays for main protections is not acceptable. MW transducer ISSUE R0 182 TCE FORM NO. which shall provide the annunciation to the DCS. MW transducer 1 no. current transducer (Y-Phase) 1 no.5960A-H-500-001 software for setting all the numerical relays in 6.6 kV switchgear and generator protection panels shall be loaded in a dedicated operator station in the main control room. kWh meter 1 no. On failure of any of the numerical relay a contact shall be generated. and shall be suitable for efficient and reliable operation of the protective schemes.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. MVAR transducer Local breaker backup protection Fuse failure relay 9. All numerical relays shall be time synchronized with the GPS master clock. The minimum protections / metering shall be provided required for various typical feeders shall include. TCE. The Bidder shall include in his bid a list of installations where the relays offered are in trouble free operation for last two years. ELECTRICAL SYSTEMS . SECTION: D3.6.9 1X 700 MW CCPP AT NEDUNOOR. 329 R5 . KARIMNAGAR DIST. but not be limited to the following: 9.1 Incomers Protections Composite numerical feeder protection relay Under voltage relay Metering Ammeter and voltmeter with selector switch Wattmeter (or) Multifunction meter with all the metering parameters Current transducer for each phase 1 no.6 kV SWITCHGEAR SHEET 9 OF 15 SPEC.7. except for auxiliary relays shall have – remote/local reset facility. NO.2 Tie breakers Protections Composite numerical feeder protection relay Local breaker backup protection Metering Ammeter and voltmeter with selector switch 1 no.7. All the protective relays.

KARIMNAGAR DIST. ELECTRICAL SYSTEMS .5960A-H-500-001 9.7.6.7.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. 9.6 kV SWITCHGEAR SHEET 10 OF 15 SPEC. Wattmeter (or) Multifunction meter with all the metering parameters 1 no. watt meter (or) Multifunction meter with all the metering parameters 1 no. with selector transducers–3 9. 329 R5 . kWh meter selector 1 no. TCE. current transducer (Y Phase) * For motor feeders separate ammeters shall be provided. kWh meter selector 1 no. SECTION: D3.5 Service Transformer Feeders Protections Composite numerical transformer protection relay Local Breaker backup protection Winding temperature and Buchholtz protection Metering Ammeter with switch 1 no.3 Bus PT Feeders Protections Under voltage protection Fuse failure protection Metering Voltmeter switch Voltage Nos.9 1X 700 MW CCPP AT NEDUNOOR.4 Motor feeders Protections Composite motor protection relay (99) Differential protection for motor feeders (rated 1000kW or above) Local Breaker backup protection Time delayed under voltage trip Metering Ammeter* with switch 1 no. current transducer 9.9 TCE FORM NO. Means shall be provided to prevent access to the live part to avoid accidents during service as well as maintenance period. Bidder shall bring out the safety means provided to achieve above. A detailed instruction plate suitable for wall mounting shall be provided for each switchgear/MCC room describing various safe operating procedure/safety precautions for safe operation and maintenance of the switchgear. Tests ISSUE R0 183 9.8 The switchgears shall be designed to offer adequate level of safety to operating/ maintenance personnel. power factor meter 1 no. NO.7.

NO. measurements.5960A-H-500-001 All relevant routine tests and acceptance test shall be conducted as per applicable standards and typical type test certificates of identical switchgear shall be furnished. monitoring. 329 R5 .6. ELECTRICAL SYSTEMS . SECTION: D3.6 kV SWITCHGEAR SHEET 11 OF 15 SPEC. annunciation. 9. D2.4. ISSUE R0 184 TCE FORM NO.10 Minimum electrical system requirements in respect of control. TCE.9 1X 700 MW CCPP AT NEDUNOOR. and synchronization are indicated in I & C system section no.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. KARIMNAGAR DIST.

DATA SHEET – A 3.10 1.5960A-H-500-001 SL.0. doors and covers Thickness of gland plate for 1 core cable Degree of protection mm mm mm Cold rolled Hot rolled - 2 2. Removable bus bar joints with shrouds of 7. ph.5 REV.1 Bus bar support insulator Bus bar joints / connection Bus bar rating Short circuit current rating and duration Momentary withstand current Switchboard Constructional Details Thickness of sheet steel enclosures. Non-magnetic material VT/relay compartments – IP52 Other compartments – IP42 Air conditioned area – IP32 Interior: Semi glossy white Exterior: Opaline Green Galvanised steel – 50 x 6 mm Copper 2.9 1.1 1.ANDHRA PRADESH POWER DEVELPOMENT COMPANY LTD. 100kA 1. ambient temperature Material of bus bars Material of bus bar insulation V kV(rms) kV(peak) 0 V.9 12 OF 15 SPEC.2 2.5 Switchboard cubicles and Bus bar ratings Nominal system voltage.7 1.BY DATE RKD HA JOB NO.2 / 50 microsecond impulse withstand voltage Maximum temperature of bus bars. DATE REV. DESCRIPTION 6. TCE. droppers.13 2.0 2.2kV insulation 7. connectors and contacts at continuous current rating under site ref. phases and frequency System neutral earthing Maximum system voltage One minute power frequency withstand voltage 1.6 kV SWITCHGEAR UNITS VALUES / REQUIREMENTS 1. NO.3 3.12 1.4 Colour finished shade (Enamel / epoxy) 2.8 Tin coated Copper Heat shrinkable PVC sleeve.11 1.3 1.0 1.4 1. 330 R3 185 . BY Material of earthing bus R0 JUNE’ 10 PPD. NO.2 kV Silver faced By Bidder RMS Peak 44 kA* for 1 sec. NO.6 C As per IEC-60694 . table 3 1. Hz 6600 / 3 / 50 Non-effectively earthed 7200 20 60 1.2 1. BY CKD.9 SECTION: SHEET D3. 5960A CLIENT : APPDCL PROJECT : 700MW CCPP AT NEDUNOOR. KARIMNAGAR DIST. TCE FORM NO.5 2.

0 3. To be provided rms kA(peak) 44 kA* for 1 sec. NO. DATA SHEET – A 3. No.9 3.7 3.5 3.5 5.0 REV.9 SECTION: SHEET D3. BY CKD. ph. TCE. TCE FORM NO. 2.10 Anti pumping feature Short circuit current rating and duration Momentary withstand current Auxiliary control voltage: (a) For closing / tripping coil / spring charging motor For space heaters and lighting and plug point V. 5960A V.0 4. Ratio 50/ 1 (As per consumer rating) CLIENT : APPDCL PROJECT : 700MW CCPP AT NEDUNOOR. Current transformer details Type System voltage and frequency Class of insulation Short circuit withstand current and duration Core balance CT for all outgoing feeders Voltage transformer details R0 JUNE’ 10 PPD. NO. 100 3. DATE REV. NO.ANDHRA PRADESH POWER DEVELPOMENT COMPANY LTD.2 / 3 / 50 3.2 4.2 Breaker details Circuit breaker type Voltage.1 3. BY Cast resin bar primary 6600 / 50 Class ‘B’ or better 44 kA* for 1 sec. of phases and frequency kV.6 Rated operating duty Total opening time Total closing time Trip free operating mechanism type O-3 min-CO-3 min-CO 3 cycles 5 cycles Motor charged spring. KARIMNAGAR DIST.4 4. Hz Vacuum 7.9 13 OF 15 SPEC.1 4. Manual trip and close facility to be provided.3 4.8 3. 330 R3 186 .5960A-H-500-001 SL.6 DESCRIPTION Clearance in air of live parts UNITS mm mm VALUES / REQUIREMENTS Phase to Phase – 120 Phase to Earth – 120 3.3 3.4 3. Phase 230 V.11 Pressure switch with two potential free contacts for monitoring SF6 gas. 1 phase 3. Hz NA 4. DC 220 (b) V.BY DATE RKD HA JOB NO.

NO.7 Class of insulation One minute power frequency withstand voltage 1.2 / 50 micro second impulse withstand voltage Meters Accuracy class 6. BY CKD.9 14 OF 15 SPEC.0 8.BY DATE RKD HA JOB NO. 5960A IEC : 62271-100 IS : 3427 IS : 2705 IS : 3156 IS : 5578 IS : 11353 IS : 2544 IS : 2147 IS : 3231 CLIENT : APPDCL PROJECT : 700MW CCPP AT NEDUNOOR. TCE FORM NO.2 for energy meters on the switchgear incomers) 1.0 8.1 0. NO.8 REV. BY .6 8. main connection and auxiliary wiring Bus bar support insulators Degree of protection Electrical relays for power system protection R0 JUNE’ 10 PPD.2 continuous 1.0 6.0 for others Digital V. 110/3 for open delta 5.ANDHRA PRADESH POWER DEVELPOMENT COMPANY LTD.7 8. DATA SHEET – A 3.1 8. DC 220 6. NO.5 5.1 Type DESCRIPTION UNITS VALUES / REQUIREMENTS Cast resin 5.4 8. TCE.2 8.5S for energy meters (0.3 8.4 Rated voltage factor 5.3 Method of connection - Star / Open 1.9 for 30 seconds Class ‘B’ or better kV(rms) kV(peak) 20 60 5.2 7.5960A-H-500-001 SL. KARIMNAGAR DIST.6 5.2 Rated voltage - Primary Secondary Primary Secondary V V 6600 / 110 / Star 3 3 / 110 / 3 . 5.5 Type of meters Spring charging motor supply voltage Codes and Standards Circuit breakers Metal enclosed switchgear Current transformers Potential transformers Arrangement for switchgear bus bars. DATE REV. 330 R3 187 8.9 SECTION: SHEET D3.

NO.14 8.15 DESCRIPTION Electrical indicating instruments High voltage fuses AC electricity meters Aluminium bus bars Code of practice for phosphating iron and steel (Off-load) isolators HRC fuses UNITS VALUES / REQUIREMENTS IS : 1248 IS : 5792 IS : 722 IS : 5082 IS : 6005 IS : 6005 IS : 1818 REV.12 8. DATA SHEET – A 3. TCE.BY DATE RKD HA JOB NO. NO. 330 R3 188 . KARIMNAGAR DIST. BY CKD. DATE REV.9 15 OF 15 SPEC. NO. 5960A CLIENT : APPDCL PROJECT : 700MW CCPP AT NEDUNOOR.9 SECTION: SHEET D3. BY R0 JUNE’ 10 PPD.ANDHRA PRADESH POWER DEVELPOMENT COMPANY LTD.9 8.11 8. 8. TCE FORM NO.10 8.5960A-H-500-001 SL.13 8.

ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.4. sump pumps.2 11. The service transformers shall be two winding. KARIMNAGAR DIST.2 for intermittent loads like cranes.10 and specific requirements indicated below. TCE. shall be considered.8 for continuously running loads and 0. three phase. Each of the above boards shall be sectionalised. An appropriate load factor with a minimum of 0.3. the service transformer shall comply with the requirements indicated in Data sheet A3.1 The number and rating of service transformers shall be decided based on the geographical location of loads without sacrificing the unit and common load concept..1. 11.0 SERVICE TRANSFORMER The service transformer shall conform to the latest editions of national and international standards indicated in Data Sheet A . 50 Hz. plug points.4 Specific Requirements All service transformers shall be cast resin dry type (indoor). Adequate number of service transformers shall be provided as required to meet the demand on 400V system based on the criteria that each 400 V switchgear / PCC / MCC / Distribution board shall be fed by 2 x 100% transformer / feeders. ISSUE R0 TCE FORM NO. Impedance The impedance of the transformers shall be selected such that the fault level on the switchgear do not exceed its short circuit capability including the motor contributions and also voltage dip while starting any auxiliary does not exceed the limit acceptable for the equipment concerned but in no case shall exceed 15%. An additional margin of 20% over the rating thus established shall be provided for load variations during the detail engineering stage. SECTION: D3. 6600 / 420 Volts.1 11.3 MVA Rating Each transformer shall be rated to feed of the entire load on the respective switchgear considering the outage of another transformer. with off-circuit taps of + 5% in steps of 2.5%. 11. 329 R5 189 .SERVICE TRANSFORMERS SPEC. ELECTRICAL SYSTEMS .5960A-H-500001 10. NO.4. Degree of protection of enclosure shall be atleast IP32. valve actuators etc. 10. 10.10 SHEET 1 OF 4 1X 700 MW CCPP AT NEDUNOOR. Also.1 Dry Type Transformers The cast resin transformers shall be housed in naturally ventilated floor mounted cubicle with louvers backed by fine brass wire mesh.10 Service Transformers.

10 SHEET 2 OF 4 1X 700 MW CCPP AT NEDUNOOR.4.5 Tests and test reports All routine tests shall be conducted as per relevant IS standards.7 11.6 11. KARIMNAGAR DIST.SERVICE TRANSFORMERS SPEC. Type test certificates carried out on similar transformer shall be submitted for review. ELECTRICAL SYSTEMS .1. ISSUE R0 TCE FORM NO.1.5960A-H-500001 11.4 11. NO. with temperature high alarm and very high trip contacts. SECTION: D3.5% per step and a range of + 5% shall be provided. Off-circuit tap changers with lockable operating handle. The dry type transformers shall be provided with core and winding temperature detectors.3 11.4. and with a variation of 2. The insulation class for cast resin transformers shall be class-F.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. TCE.4.1. The core and windings shall be provided with embedded temperature detectors for remote indication in DCS.4.5 11. The HV connections shall be through cables.1.1.2 The transformer cubicle shall be located right next to respective 400V switchgear and LV side shall be connected through cables or bus duct.4. 329 R5 190 .4. mechanical tap position indicator. Noise level shall not exceed the values specified in NEMA TR-1. 11.1.

0 Cooling method Overfluxing capability Winding connections HV LV Vector group Impulse (1. kV(rms) kV(rms) 0 Delta Star Dyn11 6.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LIMITED DATA SHEET – A3.1 10.2 8. KARIMNAGAR DIST.0 Tapping particulars Type Tap range Tapping step Category of voltage variation Tapping power Bushing particulars Voltage class – HV / LV Noise level kV 7.2/1. DATE REV. TCE FORM NO. NO.4 8.BY DATE RKD HA JOB NO.0 5.0 REV. load voltage HV LV Volts Volts Cast resin dry type . 5960A .0 2.3 6.0 4.0 LV Maximum temperature rise of winding a) Dry type transformer -/3 Class-F (155 oC) C 8. 3-ph.10 3 OF 4 SPEC. DESCRIPTION Service Transformers UNITS VALUES / REQUIREMENTS 1.5 9.0 5. BY CKD. NO.10 SECTION: SHEET D3. TCE.1 5.5 CFVV Full 11. BY Paint shade R0 JUNE’ 10 PPD.0 Type No.0 8. NO. two winding 6600 420 AN 110% continuous 3.1 Not to exceed values specified in NEMA TR1 Shade 631 of IS-5/RAL 7032/eqt.1 60 / 20 6.5960A-H-500-001 SL.2 / 50 micro second) / Power frequency withstand voltage windings HV kVp.0 9.2 5.2 7.1 8.3 8. CLIENT : APPDCL PROJECT : 700MW CCCP AT NEDUNOOR. 330 R3 191 Off-load % % +5 2.

NO.2 12.10 SECTION: SHEET D3. NO.5960A-H-500-001 SL.7 12. NO. KARIMNAGAR DIST.BY DATE RKD HA JOB NO.3 12.5 12.6 12. 12.0 12.10 4 OF 4 SPEC. 5960A CLIENT : APPDCL PROJECT : 700MW CCCP AT NEDUNOOR.8 DESCRIPTION Codes and Standards Service transformer Fittings and accessories Bushings Degree of protection Tests Tolerance on guaranteed particulars Buchholz relay Electrical insulation classified by thermal stability UNITS VALUES / REQUIREMENTS IS : 11171 IS : 3639 IS : 2099 IS : 2147 IS : 2026/ IS: 11171 IS : 2026 IS : 3637 IS : 1271 REV. 330 R3 192 . TCE FORM NO.1 12.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LIMITED DATA SHEET – A3.4 12. BY R0 JUNE’ 10 PPD. BY CKD. TCE. DATE REV.

3 11. No.20% of each type and each rating with minimum of one no.3. Power Sources for 400V Switchgear The switchboard shall derive power from the designated auxiliary transformers as shown in the Key One Line Diagrams TCE. 1 phase space heating .11 400 V Switchgear / MCC. on each bus section.5960A-EL-SK-2001 are tentative.1 no. ELECTRICAL SYSTEMS - SHEET 1 OF 17 SPEC. SECTION: D3.4 11. Also. feeder.2 11. Any additional quantity required for any increase/changes during detailed engineering stage also shall be duly considered). The switchgear shown in Key One Line Diagram drg.1 no.3. the 400 V switchgear / MCC and its accessories shall comply with the requirements indicated in Data Sheet – A 3. NO.3 11. All 400 V switchgear. Switchboard 230V. The switchgear / MCC shall be provided with suitable numbers and type of outgoing feeders as required. Any additional switchgear / MCCs as required shall also be provided. MCCs & ACDBs shall be procured from the same source in order to ensure interchangeability of components.11 1X 700 MW CCPP AT NEDUNOOR.2 11.1 no. TCE. 329 R5 11. 400V switchgear / motor control centres (MCCs) and AC distribution boards (ACDBs) shall be provided. 11.3.3.5960A-ELSK-2001.3 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. on each bus ISSUE R0 TCE FORM NO.3. KARIMNAGAR DIST.1 Feeder Details The switchgear / MCC shall be provided with two incomers and a bus coupler (100% each). 230V.5960A-H-500-001 400V SWITCHGEAR & MCC 11.1 For feeding the 400V/230V/110V AC loads of the plant. TCE. Spare feeders . Bus VT module .5.0 400V SWITCHGEAR & MCC The 400V switchgear and its accessories shall conform to the latest editions of national and international standards indicated in Data sheet A 3.6 193 . 1 phase motor space heating supply module . on each bus.3.5 11. reliability and flexibility of operation and with unit and common loads demarcation. The Bidder shall provide additional switchboards as required without sacrificing the standby philosophy.11 and specific requirements indicated below: 11. (Above quantity is the minimum requirement at the time of handing over the plant.

400 kV isolator motorised operating mechanism. All drawout contacts. NO.4.2 11.52 degree of protection.3. including for auxiliary and control wiring shall be of self-aligning type. 329 R5 194 . dust and vermin proof construction with IP . Enclosed vertical busbars serving all modules in vertical section. One feeder for maximum of 3 Nos. 11. 11.4.3.4 11. panel and base frame. Proper gasketing shall be provided all around the perimeter of adjacent panels. SECTION: D3.4. Individual feeder modules in multitier arrangement. the incomers shall be suitable for NSPBD.5960A-H-500-001 400V SWITCHGEAR & MCC 11. 3 phase plug points.11 1X 700 MW CCPP AT NEDUNOOR. one feeder shall be provided except for the following cases: (a) (b) One feeder for maximum of 2 Nos.3.9 Alarm module for common alarm for out going feeder fault . ELECTRICAL SYSTEMS - SHEET 2 OF 17 SPEC. easily extensible on both sides having switchboard designation indicating labels.3 ISSUE R0 TCE FORM NO. Switchgear/MCC shall be divided into distinct vertical sections of: (a) (b) (c) Completely enclosed busbar compartment running horizontally. floor mounted modular type of uniform height not more than 2450 mm. In this type of construction it shall be possible to drawout the chassis without having to unscrew or unbolt any connections to the equipment mounted on the withdrawable chassis.1 Control transformer on each bus section: 01Nos Construction Switchgear/MCCs shall be metal enclosed. TCE.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. For each auxiliary or load.10 11.1 no. The power and control drawout type connections shall be of sliding type. Switchgear / MCCs shall be single or double front as execution needed. Any of the system/equipment which requires power supply. 400V.7 11. indoor. Switchgear shall be designed for the bottom entry of cables however. The circuit breaker and feeder modules in switchboard and MCCs shall be of fully drawout construction.8 11. KARIMNAGAR DIST. removable covers and doors.3.

The auxiliary relays and timer may be provided in fixed cases.4.10 11. drawout construction for easy replacement and testing facility.11 1X 700 MW CCPP AT NEDUNOOR. adequately supported to withstand stresses developed due to short circuits. Cable alley shall be provided with suitable hinged doors. All types of relays and timer shall be flush mounted with connections from inside. and shall have transparent & dust tight cover. Material used for sleeving shall be capable of withstanding maximum temperatures specified in technical requirements table. Stop Push buttons shall be of latch type with mushroom knobs.7 11.4.11 11.9 11. Rear of single front switchboard shall be provided with removable panels. KARIMNAGAR DIST. SECTION: D3. 329 R5 11.5960A-H-500-001 400V SWITCHGEAR & MCC (d) Vertical cable alley covering entire height and minimum 250mm wide.4. Switchgear/MCC shall be designed such that all component equipment and busbars operate satisfactorily without exceeding their respective maximum permissible temperature limits of 105oC. aluminium alloy of E91 grade. The switchgears / MCC shall be designed to offer adequate level of safety to operating / maintenance personnel. Busbar joints shall be shrouded with moulded epoxy removable shrouds. Busbars shall be sleeved.4 Each vertical section shall be equipped with space heater and thermostat.4.4. All doors shall be with concealed type hinges and captive screws. if required. NO. TCE. Supports shall be of glass reinforced phynolic material or cast resin. For cable connection to circuit breaker. and with proper clearances.4. a separately enclosed cable compartment shall also be acceptable. Switchgear/MCC busbars shall be of uniform cross section throughout the length and made of high conductivity.4. A horizontal separate enclosure for all auxiliary power and control bus.8 11. removable from front. The busbar rating of the 400V switchgear / MCC shall be rated for LV (400V) side current of auxiliary transformer plus 20% margin rounded off to the next standard rating.4. (e) (f) 11.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.4. Means shall be provided to ISSUE R0 TCE FORM NO.6 11.5 11. ELECTRICAL SYSTEMS - SHEET 3 OF 17 SPEC.12 195 .

Breakers shall have inherent fault making and breaking capacities. test and Isolate positions.6. They shall have shunt trip coils.4. Additionally one such trolley shall be kept at each switchgear room. Rubber mats shall be provided in front & back of each panel. Control Supply Individual two (2) nos.1 The breaker / feeder modules shall have service. The auxiliary bus bars for control supply shall be segregated from main bus bars.11 1X 700 MW CCPP AT NEDUNOOR. Rating transformers each transformer shall be adequate to cater both the bus sections.5960A-H-500-001 400V SWITCHGEAR & MCC prevent access to the live part to avoid accidents during service as well as maintenance period. 11. All air circuit breakers (ACBs) shall be of short circuit performance category P2 as per IS 2516 parts I & II. NO.13 All switchgears. local starters and push buttons shall have prominent engraved identification plates.6 Specific Requirements Switchgear / MCC shall comply with specification requirements indicated below: 11. Bidder shall bring out the safety means provided to achieve above.5 11. 329 R5 196 .6. 1-ph.3 ISSUE R0 TCE FORM NO. Control circuits shall operate at suitable voltage of 220V DC. KARIMNAGAR DIST. MCCs.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. sizes and rating can be withdrawn on trolley and lowered for maintenance purpose. it shall be 220V DC. Control supply for the SFU operated motor feeders shall be 110V AC and for all ACB feeders. 11. ELECTRICAL SYSTEMS - SHEET 4 OF 17 SPEC. Suitable trolley arrangement shall be provided for breaker modules. (100%) 400/110V. DBs. A detailed instruction plate suitable for wall mounting shall be provided for each switchgear / MCC room describing various safe operating procedure / safety precautions for safe operation and maintenance of switchgear / MCC. 11. All breakers shall have built in interlocks for equipment and personnel safety. panels. The control supplies shall be monitored. modules. TCE. A changeover switch shall be provided for selection.6. SECTION: D3. transformers shall be provided in each main plant switchgear for deriving control supply. Two trolleys in the main switchgear room shall be provided so that breaker module of all types.2 11.

ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. 20% spare terminals shall be provided for each module. contactors and other power devices shall consider a margin of about 20% over the nameplate current rating of the respective load. 2 nos. future additions of cables.6.5960A-H-500-001 400V SWITCHGEAR & MCC 11.6. TCE.4 Paralleling of two supplies shall be avoided by interlocking except for switchgear where auto-changeover or live changeover is provided.6. Module details (a) Incomers & bus couplers ISSUE R0 TCE FORM NO. shrouded to prevent accidental operation. 329 R5 11.18 197 . All indicating lamps shall be self-coloured clustered LED type of size 22. red 'trip' push button.13 11.14 11.15 11.6. Breaker contact multiplication if required shall be through latch relays.6.5mm.9 11.11 11. All protective relays shall be of numerical type.6.10 11. Necessary voltage monitoring contactors. Mechanically operated.16 11. The cable alleys shall be liberally designed considering the size and number of cables.6.6. NO. Interposing relays shall be provided for control from remote. For breaker control.17 11.6. For CT & VT circuits disconnecting type of terminals shall be provided.6 11.6.6.7 11.6.6. 220V DC control supply shall be provided with a manual selection for changing over to either supply. indication lamps shall be provided.11 1X 700 MW CCPP AT NEDUNOOR.5 11.12 11.6. Minimum of two NO and two NC spare contacts of all contactors & relay devices shall be wired to terminal block. easy and safe maintenance. SECTION: D3. Transducers required for remote metering shall be provided. KARIMNAGAR DIST.6. The switches.8 11. For each vertical section a separate set of vertical bus bars shall be provided to serve the modules. ELECTRICAL SYSTEMS - SHEET 5 OF 17 SPEC. Space heater with MCB and thermostat shall be provided for each vertical panel.

However the metering shall be done through the numerical relay and shall be communicated to the DCS.5960A-H-500-001 400V SWITCHGEAR & MCC (i) The incomer modules and bus coupler modules of 400V switchgear/ MCC shall be air circuit breaker controlled from local and DCS. They shall be provided with: • One no. Service & test position limit switches with required no. TCE.G set shall also be provided with composite numerical feeder protection relay. fuses for 220V DC control supply Breaker control switch Local remote control switch. of contacts. Tripping from remote shall be possible when either breaker in service position or selector switch being in remote position. trip circuit healthy etc ISSUE R0 TCE FORM NO. Closing from local shall be possible only in test position whereas closing from remote shall be possible in either service or test position. off and fault. E/F relay connected to the bushing CT provided in transformer neutral circuit Lock out relay with supervisory lamp Indicating lamps for on. spring charged.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. 329 R5 • • • • • • • • • • • 198 . 3 phase inverse time over current relays & 1 no. SECTION: D3. ELECTRICAL SYSTEMS - SHEET 6 OF 17 SPEC. Composite Numerical feeder protection relay shall be provided for breaker feeders other than motor feeders. CT shall be used for the Numerical protection relay. Incomer from Emergency D. E/F relay 1 no. NO. for checking synchronising during live manual changeover Switch. Line VT 400/110V.11 1X 700 MW CCPP AT NEDUNOOR. KARIMNAGAR DIST. Tripping from local shall be possible only when local/remote selector switch is in local position.

11 1X 700 MW CCPP AT NEDUNOOR. Total changeover time shall not exceed 1 seconds. TCE. load factors to be considered shall be 0. This auto changeover shall be blocked if the incoming breaker had tripped either on a bus fault or manually. fault alarm. ACB’s shall be provided for the incomers & Bus couplers. such that if there is a prolonged under voltage on any one of the bus sections. SECTION: D3. incomers.5960A-H-500-001 400V SWITCHGEAR & MCC • • • Synchronising switches. ELECTRICAL SYSTEMS - SHEET 7 OF 17 SPEC. The continuous current rating of the bus bars.4 for intermittent loads.9 for continuous loads. provided voltage is available on the other bus section. Necessary circuitry and devices for auto trip. Auto changeover facility shall be provided for switchgear/MCC. Changeover scheme The switchgear with sectionalised buses will be normally operated with the bus coupler breaker open. double frequency meter. However for MCC’s with important feeders like LOPs and where auto change over is required. 329 R5 (iii) 199 . the respective incoming breaker shall trip and the bus coupler breaker shall close. and for control/ alarm of the breaker as required. Changeover back to the normal source of supply shall be effected manually. NO.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. KARIMNAGAR DIST. For the load calculation. bus couplers of the switchgear fed from other switchgears shall be the maximum load on the bus due to all the running auxiliaries during any operation condition plus 20% margin rounded off to the next higher standard rating. a set of double voltmeter. Selector switch for tripping selected breaker after live changeover (in bus coupler for locally controlled switchboards) All incomers for MCC’s and DB’s rated from 630A shall be ACB’s and for <630A MCCBs shall be provided. synchroscope shall be provided. • • (ii) The incomer modules shall be interlocked with their upstream breakers such that they can be closed only when upstream breaker is closed and trips automatically when upstream breaker is tripped or faulted. Manual live changeover ISSUE R0 TCE FORM NO. 0.

(i. a selection shall be provided by the Contractor suitably on the DCS in plant control room for selecting the incomer to be tripped. After carrying out the changeover within 1sec.. TCE. under voltage timer.0 with adequate VA burden. (iv) For this purpose.T. fuse failure relay. A timer with a time delay on pick up of 0.5 – 5 sec for annunciation of the running breaker failing to trip within a preset time. 220V DC control supply switch & fuses. interposing VTs for synchronising circuit.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. the incomer breaker shall be closed where upon the bus coupler shall trip automatically. (i) Bus VT modules shall be provided with suitable 400/√3 / 110/√3V VTs with primary and secondary fuses. When planned outage of one of the normal incoming supplies is required. the respective incomer shall be tripped automatically after the bus section breaker has been closed manually. voltage available relays (2 nos. depending on the selection made. The accuracy class of VT shall be 1. (b) VT modules Each bus section of main switchboard and MCCs shall be provided with a bus VT module along with one voltmeter with selector switch and energy meter. etc. incomer to bus section – A or to bus section – B will be tripped once bus section breaker has been closed manually.5960A-H-500-001 400V SWITCHGEAR & MCC facility shall be provided for the switchgear/MCC. whether specifically listed out in the specification or not. KARIMNAGAR DIST. modules in 400V main switchboard/MCC shall be provided with all necessary relay devices for auto changeover function like under voltage relays (2 nos). When the normal supply is to be brought back into operation. ELECTRICAL SYSTEMS - SHEET 8 OF 17 SPEC. (v) All hardware required for meeting the functional requirements stated above.). ISSUE R0 TCE FORM NO. SECTION: D3. Thus.11 1X 700 MW CCPP AT NEDUNOOR. all the critical motors which are identified during the detailed engineering shall be re-accelerated automatically. 329 R5 (ii) 200 . thus maintaining continuity of supply. shall be included in the Contractor’s scope of supply. NO. V.e if the two sources remain paralleled for more than a preset time) shall be provided.

The modules rated 200Amp & above shall be provided with a CT and ammeter. 1 phase. 3 – ph cast resin transformers incoming side switch fuse.) Suitably rated 400 / 230 V. ELECTRICAL SYSTEMS - SHEET 9 OF 17 SPEC. and supply indicating lamp and connection to the space heating buses in the particular bus section. KARIMNAGAR DIST. MCB outlets shall be provided for feeding 230 V space heating / lighting supply required by other panels in the plant. (iv) In case of fuse failure. 230V. secondary side fuse. suitably rated 400/230V cast resin type transformer (expected heating loads of the switchboard + 30% margin) Secondary fuse. fuses.e the supply for the module in bus A shall be from bus B and vice versa. panel. air break contactors (For motors above 100kW.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. (c) Feeders provided for supplying lighting distribution boards. 1-ph. power sockets etc.5960A-H-500-001 400V SWITCHGEAR & MCC (iii) Earth fault alarm with voltage relay connected to open delta formed on secondary side of VTs shall be provided on each bus. 4 wire outlets MCBs shall be provided for providing space heating supply for 400V switchboards. TCE. 1-ph cast resin transformer. remote controlled electrical circuit breakers. fuse. 329 R5 201 .11 1X 700 MW CCPP AT NEDUNOOR. switch-fuse contactor feeders shall be (d) (e) (f) (g) ISSUE R0 TCE FORM NO. SECTION: D3. and for smaller motors. Suitably rated 400V / 420V. Motor modules (i) • The motor modules shall be provided with Switch. local control panels. (v) In the 400V main switchboard buses an additional timer (with a higher time delay) shall be provided for sending signal for AMF start of the DG sets.. NO. incoming side switch fuse. The 400V power supply for these modules shall be obtained from the other bus (i. secondary side fuse. supply indication. supply indication 3 – ph. shall be provided with suitably rated switch & fuses. the under voltage timer operation shall be blocked. space heating module (for motor. space heating) shall be provided with incoming side switch.

The modules for motors rated 50 KW and above shall have a CT and an ammeter. off command from local push buttons. off PBs for non reversible modules and forward ‘reverse’ and ‘Off’ PBs for reversible modules Appropriate circuitry for receiving the on. Off and fault indicating lamps Necessary auxiliary contactors for fault alarm circuit. and AC 22A category for other applications. (ii) (iii) (iv) ISSUE R0 TCE FORM NO. NO. Instantaneous short circuit protection on all phases through HRC cartridge type fuses rated for 80 kA rms (prospective breaking capacity at 400V) On. TCE. KARIMNAGAR DIST. interlocks. For modules of motor rated 100 kW and above ACB’s shall be provided. Module on.11 1X 700 MW CCPP AT NEDUNOOR. The other outgoing feeders would be switchfuse units or moulded case circuit breakers) Thermal overload relays with integral single phase preventors. The CT connection shall be so wired to the terminal block so that provision for remote current indication is available. 230V space heating circuit Isolating switches shall be of AC 23A category when used in motor circuit. ELECTRICAL SYSTEMS - SHEET 10 OF 17 SPEC. off and forwardreverse commands from remote panels/ systems. Interposing relays for control from remote. Transducers shall be provided for remote metering for all motors rated18 KW and above. 1 phase space heating arrangement. Isolating switches and MCCBs shall have door interlocks and padlocking facility The motor modules rated 30 KW and above shall be provided with 230V. 329 R5 202 . Any additional motor. for which monitoring is required. etc. (Thermal overload relays for all motor feeders upto 100kW and with integral single phase preventors for motor feeders >45kW). SECTION: D3.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. shall be added during detailed engineering. MCB for space heating/winding heating circuit.5960A-H-500-001 400V SWITCHGEAR & MCC • • • • • • • • • • • provided.

lube oil pumps.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. (for eg.8 11.1 400 V A C Distribution Board / Control Panel Bidder shall include in his scope required no. Outdoor switchgears and switchgears/ panels located in close proximity to gas turbine shall be provided with HR PVC cables. aux contactors and associated circuitry in the module.7 The internal wiring shall be with 1.5 mm2 copper. Bidder shall provide one or two (depending on the ISSUE R0 TCE FORM NO. 11.8. NO. etc. seal oil pumps. (vii) (viii) The 400V single phase connection control supply transformer. of 400V AC power supply distribution board/control panel for feeding packaged auxiliary load like centrifuge. Essential service modules During auto changeover of the supply the contactors in the affected bus would have dropped off.). KARIMNAGAR DIST. TCE. 329 R5 203 . Motor modules – Remote start/Stop and ON/OFF /Trip indication shall be provided from DDCMS for all motors of the main plant. winding heating modules etc. Local operations shall be provided for motors like sump pumps etc which are neither controlled from DDCMS nor PLCs.11 1X 700 MW CCPP AT NEDUNOOR. Such auxiliaries shall restart automatically without any action by the operator after an auto changeover. These modules shall have additionally hardware like timer. SECTION: D3. Motor in other areas shall be controlled from respective PLCs. space heating.5mm2 for CTs and suitably sized for power wiring with a minimum of 2. The services which shall be restarted immediately without time lapse to keep the unit running are considered essential services. ELECTRICAL SYSTEMS - SHEET 11 OF 17 SPEC. 11. Such essential services shall be identified during the detailed engineering stage and suitable module/scheme shall be provided.. All abnormal conditions shall be alarmed to DDCMS.5960A-H-500-001 400V SWITCHGEAR & MCC (v) (vi) For modules of motors rated 100 kW and above shall be provided with composite numerical motor protection relay.5 mm2 stranded copper conductor for control wiring and 2. shall be distributed between different phases to keep the loading on all phases uniform 400V/230V control transformer. auxiliary cooling water pumps etc.

Each circuit of welding distribution board shall feed maximum of 2 Nos. The DG sets shall be connected to emergency switchgear with required interconnections to GTG and STG switchgears. quick starting emergency diesel generator sets with automatic mains failure (AMF) feature shall be provided.C. These DG sets are provided with one stand-by generator of same rating as a back up. cubicle lamp and power plug.5 11. NO. if it is <400A other wise ACB shall be used.2 A.4 11.8.11 1X 700 MW CCPP AT NEDUNOOR. battery chargers. All the incoming and outgoing feeders shall be of switch fuse controlled. emergency lights. The A. KARIMNAGAR DIST. 100%Unit+ 50% STG + 50% station emergency loads).9 11. When the normal A. distribution boards/control panels shall be provided with thermostatically controlled space heater.) shall be provided with a reliable A. SECTION: D3. 11.C supply is restored. emergency bearing lube oil pumps. Required ACDB shall be provided to cater to the auxiliary power requirements of 400kV switchyard. turning gear motor.C.5960A-H-500-001 400V SWITCHGEAR & MCC criticality of the service) incomer from 400V main switchboard to feed the distribution board/control panel.1 Emergency Power Supply To enable safe unit shutdown during complete A. 400V. welding / Power receptacles.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. ELECTRICAL SYSTEMS - SHEET 12 OF 17 SPEC. distribution board/control panel shall comply with technical requirements table. TCE. Tests ISSUE R0 TCE FORM NO. 329 R5 11. these essential loads will be manually changed over to the normal power supply. the DG sets will start automatically and feed the essential loads connected to GTG and STG switchgears. power supply through a separate source.8. When the normal station A.9. 2x100% capacity feeders shall be provided in the main switchgear for serving this ACDB. For this purpose. certain important plant auxiliaries (such as the A. Also applicable clauses of 400V switchboard and MCCs shall be complied with for these boards/panels.C supply failure in the station. supply fails. etc. Separate 400V welding distribution boards along with Isolation Transformer (2x100%) shall be provided in each area. 11.C.9 204 .2 11. Each DG set shall cater to the emergency loads of each of the GTG units (i.C.e.C.8. essential instrument power supply feeders.8.9.3 11.

5960A-H-500-001 400V SWITCHGEAR & MCC Switchboard/MCCs shall be subjected to routine tests as spelt out in Indian Standards and typical type test certificates for identical switchgear / MCC shall be furnished. 11. SECTION: D3. ELECTRICAL SYSTEMS - SHEET 13 OF 17 SPEC.11 1X 700 MW CCPP AT NEDUNOOR. TCE. ISSUE R0 TCE FORM NO. measurement. 329 R5 205 . synchronising are indicated in I&C system section No. NO.10 Minimum electrical system requirements in respect of control. D2. annunciation.4. monitoring.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. KARIMNAGAR DIST.

NO.5 3 1.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LIMITED DATA SHEET – A 3.10 1.) Momentary current Switchboard / MCC Construction Fully draw out Double front / single front Cable entry (Power & Control) rms Peak 50 kA for 1 Sec.7 1.5960A-H-500-001 SL.3.6 2. NO.3.7.5 1.6 Switchboard & Bus bars Rated voltage.BY DATE TCE FORM NO.11 SECTION : D 3. .2 1.11 SHEET 14 OF 17 SPEC. BY CKD. DATE REV.2 1.6 2. 3ph.0 JOB NO.3 1.3 1.8. DESCRIPTION 400V SWITCHGEAR / MCC UNITS VALUES / REQUIREMENTS 1. BY Modular construction Degree of protection for as per IS : 2147 Thickness of sheet steel Cold rolled Hot rolled Gland plate thickness R0 JUNE’ 10 RKD HA 2.9 1. 5960A CLIENT : APPDCL PROJECT : 700MW CCPP AT NEDUNOOR. droppers at site reference ambient of 500C Short circuit withstand Short time current (1 sec.10. NO. 3 wire Solidly earthed V V V 0 2500 1500 2000 50 Aluminium C C 90 1. KARIMNAGAR DIST.8.4 1.8 1. 50.10.1 1.8.2 1.3 1.8. TCE.4 1. 330 R3 206 0 V/P/Hz 400.10.2 1.0 1. phases & frequency System neutral earthing One minute power frequency voltage withstand Power circuits Control circuits Auxiliary circuits Reference ambient air temperature Material of bus bars Maximum temperature of bus bars contacts.1 1.3.2 1.7.3 REV.5 2. 105kA Switchboard / MCC Yes Single front / Double front Cable : Bottom Entry NSPBD: Top Entry Yes IP 54 Frame Door Cover mm mm mm PPD.0 1.1 1.1 1.1 1.

2 3. BY CKD. V/DC 220 3.4 External : Opaline Green Internal : Semi Glossy white.2 2.5960A-H-500-001 SL.6. BY Based on breaker short circuit current rating and duration RKD HA JOB NO.6. NO.2 3.0 3.0 2.1. DESCRIPTION UNITS VALUES / REQUIREMENTS 1.5 Contactors & O/L relay Utilisation category for contactors Contactor rated duty Reset feature for thermal O/L relay Starter type Circuit breakers Circuit breaker type Rated operated duty Type of operating mechanism Short circuit rating Control voltage for spring charging motor and tripping & closing Emergency manual operation required in addition to electrical operating devices For spring charging & closing For tripping Anti-pumping feature CTs and VTs Short time withstand current and duration for CT Breaker controlled R0 JUNE’ 10 PPD. 2. 5960A CLIENT : APPDCL PROJECT : 700MW CCPP AT NEDUNOOR.3 3.3 2.3 4.11.11 Clearances in air for live parts 1.6 3.6.BY DATE TCE FORM NO.12 Phase to phase Phase to earth Paint shade mm mm 25. TCE.1 Required Required Required 50 kA for 1 sec.2 1. NO. .11. 330 R3 207 AC3 for non-reversible & AC4 for reversible Uninterrupted Hand DOL Air break with shunt trip B-3min-MB-3min-MB Motor wound spring charged 50 kA for 1 sec.11 SECTION : D 3.4 3.1 3.4 19. KARIMNAGAR DIST. 4.1 REV. DATE REV. NO.4 3.0 4.11 SHEET 15 OF 17 SPEC.1 3.1 1.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LIMITED DATA SHEET – A 3.1 2.

4.11 6.BY DATE RKD HA JOB NO.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LIMITED DATA SHEET – A 3.2 Overvoltage withstand capacity for VT 4.11 SECTION : D 3.6 6.1 6. DATE REV.5 Digital 0.5 6.7 6.1 4. NO.2 5.2 1.3 Continuous 30 seconds Meters Class of accuracy Applicable Standards Switchboard general requirements AC circuit breakers Factory built assemblies of switchboard and control gear for voltages upto & including 1000V AC & 1200 V DC pu pu 1. KARIMNAGAR DIST.1 6. NO.9 6.8 6.10 Air break switches Miniature circuit breakers HRC cartridge fuses D type fuses Contactors Starters Control switches / push buttons and maintenance of switchboard Code of practice for phosphating iron and steel Wrought aluminium & aluminium alloys for electrical purposes R0 JUNE’ 10 PPD.0 6.5960A-H-500-001 SL.12 REV.0 for others IS : 4237 IS : 13118 6. BY IS : 6005 IS : 5082 CLIENT : APPDCL PROJECT : 700MW CCPP AT NEDUNOOR.2.2. TCE.2 6. TCE FORM NO.5 for energy meters and 1. 5960A IS : 4064 & IEC 60947-3 IS : 8828 IS : 9224 IS : 8187 IS : 29259 IS : 8544 IS : 6875 6. 330 R3 208 .4 6. NO.0 5.2 DESCRIPTION Switchfuse controlled UNITS VALUES / REQUIREMENTS To match with fuse withstand 4. BY CKD.11 SHEET 16 OF 17 SPEC.1.

5960A CLIENT : APPDCL PROJECT : 700MW CCPP AT NEDUNOOR.13 Control transformer for switchboard and control gear for voltages not exceeding 1000V AC IS : 12021 7. DESCRIPTION UNITS VALUES / REQUIREMENTS 6.0 Technical requirements Table for 400V AC Distribution Boards / Control Panels Location / mounting Current rating Cable entry Design ambient temperature Codes and standards 0 7.11 SHEET 17 OF 17 SPEC.11 SECTION : D 3.2 7. NO. 330 R3 209 . TCE FORM NO. NO.3 7.5 Indoor / floor mounted Max. KARIMNAGAR DIST. NO. BY CKD. expected load current + 20% margin Bottom Cable entry C 50 As indicated for 400V switchboards / MCCs. BY R0 JUNE’ 10 PPD.1 7.5960A-H-500-001 SL. TCE.4 7. REV.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LIMITED DATA SHEET – A 3.BY DATE RKD HA JOB NO. DATE REV.

7. The neutral of the transformers shall be connected to the earth bus through a link in the respective board.2 12. Generator neutral shall be high resistance earthed. ISSUE R0 210 12.7. 12. The neutral of GTs are independently connected to earth.12 SHEET 1 OF 3 SPEC.2 TCE FORM NO. which is in turn connected to the plant earth grid.1 400 kV system is solidly earthed.4 12. The neutral earthing resistor will be connected across the secondary of the neutral earthing transformer. Sizing of Neutral Earthing Equipment The neutral grounding resistor ohmic value for generator neutral earthing shall be so selected that during an earth fault on one of the phases of the generator. the capacitive kVA due to capacitance of generator. generator bus duct and associated equipment including surge protection capacitor. 6. 400V system shall be a solidly earthed system.6 kV systems shall be medium resistance earthed. The neutral of service transformers shall be independently connected to the earth. 329 R5 . generator transformer. 230V systems for lighting and the space heating shall be solidly earthed system. 230V AC control supply shall be a solidly earthed system.5960A-H-500-001 1X 700 MW CCPP AT NEDUNOOR. the kW power consumed in the resistor shall be atleast equal to 1. The neutral earthing resistor ohmic value for unit aux. SECTION: D3. The earth fault current shall be limited to 300A. NO.0 METHODS OF EARTHING The neutral earthing equipment shall conform to the latest editions of relevant national and international standards.6 12. TCE. ELECTRICAL SYSTEMS NEUTRAL EARTHING EQUIPMENT 12. transformer neutral earthing shall be such that earth fault current is limited to 300A.5 times. These shall comply with the specific requirements indicated below. KARIMNAGAR DIST.5 12. The mid point of the secondary winding of the transformers shall be connected solidly through a link to the earth bus in the respective modules of switchgear / control panels. The neutral shall be connected to a suitably rated neutral earthing transformer.7 12.5.3 12.4 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. The neutral of the unit auxiliary transformers shall be independently connected to the earth through a suitable resistance.1 12.

The resistor cubicle shall be mounted on suitably rated insulators.3 12.5m. The resistor cubicle shall be located in transformer yard at a height of 2.12 SHEET 2 OF 3 SPEC. ELECTRICAL SYSTEMS NEUTRAL EARTHING EQUIPMENT 12.9 12.8.8.5960A-H-500-001 1X 700 MW CCPP AT NEDUNOOR.4 12.8. even though located within the fenced transformer yard.5 12.10 12.2 12.8. SECTION: D3. Alternatively it can be painted with heat resistant paint suitable for 2500C the neutral grounding equipment shall be completely assembled.8.8.1 Specific Requirements Duty rating of the earthing resistor for generator neutral and UATs shall be 30 seconds.8 12. The neutral grounding transformer shall be cast epoxy resin type natural air cooled single phase connected between generator neutral and ground. The transformer and resistor shall be located in separate cubicles/compartment adjacent to each other.8. The loading resistor shall be formed of non-aging.8. The transformer cubicle shall be made of angle frame steel construction with formed sheet sides. Each neutral earthing resistor unit shall be air cooled and self supporting type. The resistor cubicle shall be made of angle frame steel construction with hot dip galvanised screen sides.8 12. 12. TCE. protection and indication leads shall be wired upto terminal blocks shall be mounted in a IP:54 enclosure suitable for flush mounting and having a fully hinged cover with lock. NO.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.8. corrosion resistant punched stainless steel grid element provided with necessary insulation and designed for indoor service for a temperature rise not exceeding 3000C. All alarm. KARIMNAGAR DIST. canopy shall be provided.11 ISSUE R0 211 TCE FORM NO.6 12.7 12.8. The cubicles shall have hinged access doors capable of being pad locked. If located at ground level the resistor area shall be fenced separately. The minimum degree of protection for the resistor element shall be IP 34.8. 329 R5 . Cable boxes shall be provided for receiving the cables from the transformers. wired and connected to the neutral bus tap through seal-off bushing. For outdoor cubicle.

12. 329 R5 . TCE. NO. SECTION: D3.2 iii) Heat run test on complete assembly iv) Insulation resistance measurement test ISSUE R0 212 TCE FORM NO.9.12 SHEET 3 OF 3 SPEC.8. ELECTRICAL SYSTEMS NEUTRAL EARTHING EQUIPMENT 12.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. so as to prevent bypassing of resistor in case of shorting of resistor from inside.5960A-H-500-001 1X 700 MW CCPP AT NEDUNOOR. The following tests on resistors shall be performed and test certificate shall be furnished prior to dispatch: i) ii) High voltage withstand test Ohmic value test on off-load on complete resistor 12.9. KARIMNAGAR DIST.1 TESTS All Acceptance and routine tests as per IS/IEEE shall be conducted on NGR assembly.9 12.12 Enclosure shall not be earthed.

1.1 13. 2 x 100% battery bank with associated float cum boostcharger. 220V DC.1 DC power supply with high discharge plante lead acid cells forming bank shall be the source of the power supply for control. (a) (b) (c) (d) Loads of Steam Turbine Generator (STG) unit Loads of HRSG UPS loads catering to the I&C requirements Other DC supply loads as required by I&C system which shall be derived from 220 V DC through DC/DC converters. NO.5 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. Common station DC auxiliaries and emergency lighting loads.1. 2 x 100% battery banks with associated float cum boostchargers and 1 No. annunciation of the complete plant including I&C system during the running of the plant as well as for a safe shutdown at the time of the total power supply failure. 2 x 100% battery bank with associated float cum boostcharger.5960A-H-500-001 13. 1 No. ELECTRICAL SYSTEMS .5960A-EL-SK-2006. TCE. For feeding the DC supply for the above.5960A-ELSK-2006. The scheme shall be as per sketch TCE. 1 No.1. KARIMNAGAR DIST. the DC system and its accessories shall comply with the requirements indicated in Data Sheet – A 3. 13. DC switchboard having 2 Incomers & one bus coupler shall be provided for each gas turbine generator (GTG) unit. The scheme shall be as per sketch TCE.13 SHEET 1 OF 14 700 MW CCPP AT NEDUNOOR. HRSG system loads and common station auxiliaries (excluding 400 kV system auxiliaries). SECTION: D3. DC switchboard having 2 Incomers & one bus coupler shall be provided for each steam turbine generator (STG) unit loads.13 Also. the following shall be provided.6 kV switchgear and 400 V switchgear.0 DC SYSTEM The DC System and its accessories shall conform to the latest editions of national and international standards indicated in Data sheet – A 3. protection. DC switchboard having 2 Incomers & one bus ISSUE R0 213 TCE FORM NO.5.DC SYSTEM SPEC. The GTG unit DC system shall be sized to cater complete unit GTG loads.2 (e) (f) 13.13 and specific requirements indicated below: 13. interlock. 329 R5 .3 220V DC. 220V DC. 6.

SECTION: D3. 6. 13.85 V/cell for lead acid batteries. 13.2 Emergency & Continuous Load (For 10 hours duration) (a) (b) (c) Running currents of essential DC motors. ELECTRICAL SYSTEMS .3 13.6 kV & 400V breakers.4 48V DC. 24V DC. Detailed sizing / selection calculation shall be subject to Owner’s approval. NO.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.1. Starting current of all automatically started DC drives.13 SHEET 2 OF 14 700 MW CCPP AT NEDUNOOR.5 13.5960A-H-500-001 coupler shall be provided for 400kV system (switchyard) auxiliaries. The switchyard DC system shall be sized to cater the following loads: (a) (b) DC load of 400kV switchyard Emergency lighting building The 400 kV system DC battery. DC switchboard having 2 Incomers & one bus coupler shall be provided for PLCC system of 400kV switchyard.DC SYSTEM SPEC.1 13. TCE.3. Battery shall be sized to cater for the following loads with minimum duration as indicated. The voltage at the end of duty cycle shall be 1. 2 x 100% battery banks with associated float cum boostchargers and 1 No.2 Scheme for earth fault detection shall be provided for each DC bus and feeders. 13. 2 x 100% battery banks with associated float cum boostchargers and 1 No. Solenoid valves. Emergency lighting Indicating lamps on switchgears and control panels ISSUE R0 214 TCE FORM NO. (a) (b) (c) (d) Tripping / closing load of 400 kV. In rush current of excitation system.3. Momentary Load (For duration upto 1 minute). 329 R5 .1. DC switchboard having 2 Incomers & one bus coupler shall be provided for catering the I& C and DCS system application. battery chargers and DCDB shall be located in the switchyard control building. KARIMNAGAR DIST.

KARIMNAGAR DIST. For this purpose.5 13. TCE.1 13.3.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.4 13. NO.5960A-H-500-001 (d) (e) Control room emergency lighting Auxiliary relays 13. starting or tripping whichever is higher.3 13. SECTION: D3.4.2 The boost charger unit shall be rated such that the battery can be fully charged from fully discharged condition within 8 hours. 329 R5 .4. the following shall be considered.5. electrolyte temperature shall be considered as 10 deg. C above the ambient temperature.5. A design margin of 10% shall be considered for each of the GTG Unit Batteries & Common Station Batteries and 20% margin shall be considered for the 400 kV System Batteries. 25% margin for ageing as per IEEE guidelines. for arriving at the battery capacity.1 (d) (e) 13.DC SYSTEM SPEC.4 I & C system loads UPS requirement for 4 hours. 13.3 13. Further.2 13. 20 % spare capacity over above loads The float voltage output of the float charger shall be automatically adjusted depending upon the ambient temperature such that the batteries remain floating through out the range of variation of temperature as specified in Section – B.4. ELECTRICAL SYSTEMS . Standing load due to all units running. The temperature correction factor as given in IS. ISSUE R0 215 TCE FORM NO.3.13 SHEET 3 OF 14 700 MW CCPP AT NEDUNOOR. Battery Chargers Float charger will be rated to cater the following: (a) (b) (c) Trickle charging current of the battery 10 hours load indicated above.

ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.

SECTION: D3.13 SHEET 4 OF 14

700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS - DC SYSTEM

SPEC. NO. TCE.5960A-H-500-001

13.6 13.6.1

Specific Requirements 220V Batteries (a) The battery offered shall be High Discharge plante Lead Acid batteries confirming to IS: 1652 suitable for indoor application. The battery shall be of closed top or sealed in type. Open type cells are not acceptable. The battery shall be complete with accessories and devices, including but not limited to the following: (i) (ii) (iii) (iv) (d) Battery racks Porcelain insulators, rubber pads etc. Set of lead coated intercell, inter-tier and inter bank connectors as required for the complete installation. Electrolyte (KOH) for first filling +10% extra.

(b)

(c)

One set of variable resistor load suitable for carrying out discharge tests at 5 hour discharge rate & suitable shunt for measuring current on all batteries shall be supplied. Alternatively, electronic controls for carrying out discharge test of the batteries at selectable rate can also be provided. The battery should be periodically charged/discharged to avoid loss of performance due to memory effect.

(e)

13.6.2

220V Battery charger (a) The float cum boost charger offered shall be static type composed of silicon controlled rectifiers and diodes (complete with resistor/capacitor network for surge protection) connected in three phase wave bridge circuit. It shall be provided with an adequately rated isolation transformer and filters on input to minimise harmonics on the output to keep ripple factor within acceptable limits. Charger shall have provision for manual control if the automode fails. Load limiting features shall be provided. The same shall be designed for adequate short time over load to take care of the starting of the largest DC motor/testing of lamps, etc. with other DC loads connected to bus. The rectifier shall utilise power semiconductors and heat sinks rated to carry 200% of the load
ISSUE R0
216

(b)

TCE FORM NO. 329 R5

ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.

SECTION: D3.13 SHEET 5 OF 14

700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS - DC SYSTEM

SPEC. NO. TCE.5960A-H-500-001

current continuously. The heat sink temperature shall not be permitted to exceed 85°C irrespective of the panel temperature. The chargers shall be suitable for operation from remote. (c) The chargers shall be provided with automatic voltage regulation in float mode and automatic constant current regulation in boost mode. The charger shall essentially comprise the following items but not limited to: (i) One (1) moving coil DC voltmeter of size 96mm x 96 mm of suitable range with selector switch for float, boost, and load voltage. One (1) moving coil DC ammeter, with shunts, size 96 mm x 96 mm to read output current of float-cum-Boost charger. One (1) moving coil centre zero ammeter, with shunt, size 96 x 96 mm to read discharge/charge current of the battery, with suitable range. One (1) cubicle space heater suitable for 230V AC, 50Hz, single phase supply. One (1) 230V AC lamp for cubicle internal lighting. Two (2) - On/Off switches with fuses for space heater and internal lighting. One LED lamp on DC load side to indicate DC "On" condition. One (1) set of LED lamps on AC main input to indicate mains AC "ON" condition. All indicating lamps shall be self-coloured clustered LED type with less than 0.5 W burden. Indication lamps for battery on boost charge & load limiter operated.

(d)

(ii)

(iii)

(iv)

(v) (vi)

(vii)

(viii)

(ix)

(e)

Fault indicating lamps shall be provided on the charger cubicle and initiating contacts shall be provided for remote alarm for each of the following faults:
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SECTION: D3.13 SHEET 6 OF 14

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SPEC. NO. TCE.5960A-H-500-001

(i) (ii) (iii) (iv) (v) (vi) (vii) (viii) (f)

Mains AC failure Float charger AC input fuse blown Charger DC output fuse blown Charger U/V and current limit protection Charger over voltage protection Charger overcurrent protection Charger filter condenser fuse blown Charger rectifier fuse blown

Type of cooling for the charger panel shall be such that no external fans are required to dissipate the heat developed within the panel. The adequate number of dropper diodes shall be used in order to meet the load voltage & maintaining the battery float charging voltage as per the battery manufacturer recommendations. Suitable scheme shall also be made that during the power failure, the dropper diodes shall be bypassed, thereby giving the required voltage to the connected load. One complete set of all accessories and devices required for maintenance and testing of batteries shall be supplied for each battery bank. Each set include at least the following: (i) (ii) Hydrometer Set of hydrometer syringes suitable for the vent holes in different cells Thermometer for measuring electrolyte temperature Specific gravity correction chart Wall mounting type holder for hydrometer thermometer Cell testing voltmeter (3-0-3 V). Rubber apron Pair of rubber hand gloves 2 nos. 2 nos.

(g)

(h)

(iii)

-

5 nos.

(iv) (v)

-

2 nos. 2 nos.

(vi) (vii) (viii)

-

2 nos. 2 nos. 2 nos.
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SPEC. NO. TCE.5960A-H-500-001

(ix) (x) (xi) (xii) (xiii)

Set of insulated spanners No smoking notice Goggles (industrial) Instruction card Minimum and maximum temperature indicator for each battery room Acid / Alkali mixing jar

-

2 nos. 2 nos. 2 nos. 10 nos. 1 no.

(xiv) (xv) (xvi)

-

2 nos. 20 Nos. 2 nos

Battery maintenance record book Safety gears -

13.7 13.7.1

D.C. Switchboards For feeding the 220V DC loads 220V DC Switchboard as per clause 13.1.1 to 13.1.3 shall be provided. The switchboards shall be provided with suitable quantity and type of outgoing feeders for the auxiliaries, control supplies to various panels/systems. For each load and auxiliary, one separate feeder shall be provided. In addition, the following feeders shall be provided in switchboard. (a) Spare feeders - 20% of each type and rating with a minimum of two nos. feeders. This is the minimum quantity at the time of handing over the plant. Switchboard 230V 1 phase space heating module - 1 No.

13.7.2

(b) 13.7.3

Current ratings The short circuit current rating of the switchboard shall be arrived considering the contribution from charger & battery with 5% margin, with a minimum of 25 kA. The continuous current rating of the bus bars, incomers, ties for 220V DC switchboards shall be the maximum D.C. load (excluding the momentary
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700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS - DC SYSTEM

SPEC. NO. TCE.5960A-H-500-001

load) on the bus plus 20% margin rounded off to the next higher standard rating. 13.7.4 Specific requirements (a) DC switchboards shall comply with all the requirements of this specification and technical requirements table. Positive and negative bus bars in the DC switchgear shall be completely segregated from each other by sheet steel partitions. The DCDB incomers and Buscoupler shall be suitable for operation from remote. All the DCDB compartments shall have bottom cable entry through individual cable gland for each power, control and instrumentation cables. Metallic enclosure shall be provided between cable tray & cable entry.

(b)

(c)

(d)

(e)

Module details (i) Incomer The incomer modules shall be MCCB controlled. Each incomer shall be provided with • • • • • • ammeter & voltmeter earth fault relay with potential free contact for remote annunciation. under voltage relay with timer indicating lamps for ON, OFF, earth fault, under voltage conditions (22.5 mm size LED) one no. current & voltage transducer for remote indication necessary hardware & circuitry for fault alarm and for lamp test & reset.

(ii)

Outgoing feeders & tie feeders/Bus coupler • These feeders shall have DC MCB/MCCB,"ON" & "Fault" indicating lamps, supply supervision relays, lamp test, accept & reset push button through common alarm module.
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SPEC. NO. TCE.5960A-H-500-001

The feeders rated 200 Amps & above shall be provided with a shunt & ammeter.

(iii) Motor modules • For motors, starters shall be preferably housed within the DC switchgear module. However the resistors can be separately located in boxes/panels within the DC switchgear room. The starting current of the motor shall be limited to 200% of full load current.

The motor modules shall be provided with • • • • • • • • • Switch (rotary type suitable for DC application), fuses, air break contactors Thermal overload relays Starting resistors with associated timers ON, OFF, Fault indicating lamps Necessary auxiliary contactors for fault alarm circuit 230V space heating circuit ON, OFF PBs for testing purposes One shunt & ammeter Appropriate circuitry for receiving the ON, OFF commands from remote panels/systems, interlocks, 'OFF' command from local push buttons, etc. MCB for space heating circuit

(iv) Space heating module • 230V 1 ph, space heating module shall be provided with incoming side switch fuse, suitably rated 400/230V cast resin type transformer (expected heating loads of the switchgear and the connected motors + 30% margin) secondary fuse, and supply indicating lamp and connection to space heating buses. The 400V power supply for these modules shall be obtained from the 400V main switchboard.

13.8

Tests for Batteries
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SPEC. NO. TCE.5960A-H-500-001

All tests shall be conducted as per the relevant standards. Tests shall comprise: 13.8.1 Type Tests: Performed at Manufacturer's works or type test report on identical rating and type of cell issued by an authorised test house shall be furnished Acceptance Tests: Acceptance tests as per relevant standards shall be performed at vendor’s works. Also acceptance tests shall be performed at site after installation and commissioning of the battery including capacity test and test for voltage during discharge. A loading resistor bank which can be automatically controlled using time and current signals along with the charger shall be supplied to facilitate discharging of voltages as a part of routine maintenance tests. Tests for battery chargers The following routine tests shall be conducted at works 13.9.1 13.9.2 13.9.3 13.9.4 13.9.5 Visual checks for dimensions and general arrangement. Wiring checks Functional checks Voltage regulation for rated input supply for loads from 0-100%. Load test to show the charger can deliver the rated duty without the current limiter device operating. Ripple measurement by oscilloscope at different loads. Demonstration of guaranteed efficiency and power factor. Insulation test (with 500V megger) High voltage test, excluding electronic controller, at 2kV AC for one minute. Heat run test shall be conducted at full load for 24 hours at the vendor works on charger. Tests for DC distribution board
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13.8.2

13.8.3

13.9

13.9.6 13.9.7 13.9.8 13.9.9

13.9.10

13.10

TCE FORM NO. 329 R5

ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.

SECTION: D3.13 SHEET 11 OF 14

700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. ELECTRICAL SYSTEMS - DC SYSTEM

SPEC. NO. TCE.5960A-H-500-001

13.10.1

All routine tests as per applicable standards shall be conducted on the board. Type test reports on identical switchgear issued by an authorised test house shall be furnished.

13.10.2

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TCE FORM NO. 329 R5

0 2.6 1% maximum 3.0 1.1 1.3 2. DATE REV.0 4.5 0. 1.2 (i) +1% of set DC voltage for + 10% voltage and +5% frequency variation in power supply + 5% during transients (ii) 3.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LIMITED DATA SHEET – A3.1 REV. at rated continuous load Permissible ripple content at rated continuous load Degree of protection/paint shade 3. TCE.1 DC SYSTEM DESCRIPTION UNITS VALUES / REQUIREMENTS Type of charger DC system voltage (Nominal) DC system earthing Ambient design temperature BATTERY DETAILS Maximum time for boost charging of battery Battery type Minimum end cell voltage Nickel / Lead Acid Battery capacity BATTERY CHARGER DETAILS DC voltage setting adjustment of AVR for float charging Voltage stabilisation for constant voltage regulator Hrs 0 float-cum-boost 220 V /48V /24V Unearthed C 50 8 High Discharge Plante Lead Acid 1.13 12 OF 14 SPEC.4 2. NO.3 1. BY DC BOARD Reference ambient air temperature R0 JUNE’ 10 PPD.13 SECTION: SHEET D3. 5960A CLIENT : APPDCL PROJECT: 700MW CCPP AT NEDUNOOR.5960A-H-500-001 SL. NO.f.2 2.85V per cell By Bidder + 10% of nominal voltage 3.3 DC current adjustment for boost charging 30% to 100% of maximum boost charging current + 2% 3.4 Current stabilisation for constant current regulator for boost charger Minimum permissible p.4 3. 4.8 3. BY CKD. .2 1.1 2. KARIMNAGAR DIST.7 IP 42/ External : Opaline Green Internal : Semi Glossy White. NO. 330 R3 224 50 0C RKD HA JOB NO.0 3.BY DATE TCE FORM NO.

pulse and switching) for electronic equipment Printed wiring boards Environmental requirements for semiconductor devices and integrated circuits Terminals for electronic equipment Factory build assemblies of switchgear and control gear for voltages upto and including 1100V AC and 1200V DC Air break switches Miniature circuit breakers HRC cartridge fuses Contactors Control switches / push buttons Indicating instruments Degree of protection Code of practice for phosphating iron and steel Semi-conductor converters R0 PPD.2 IS 9000 5.15 5.8 IS 4007 IS 8623 5.0 5.5 5. BY IS 4064 IS 8828 IS 9224 IS 2959 IS 6875 IS 1248 IS 2147 IS 6005 IEC 60146-1-1/2/3 CLIENT : APPDCL PROJECT: 700MW CCPP AT NEDUNOOR.14 5. 5960A . RKD HA JOB NO.BY DATE TCE FORM NO.3 4.10 5.6 IS 7405 IS 6553 5.13 13 OF 14 SPEC.4 IS 6297 5.1 APPLICABLE STANDARDS Basic climatic and mechanical durability tests for components for electronic and electrical equipment Environmental tests for electronic and electrical equipment Metal clad base material for printed circuits for use in electronic and telecommunication equipment Transformers and inductors (power.7 5.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LIMITED DATA SHEET – A3.3 IS 5921 5. NO.13 SECTION: SHEET D3. audio.4 DESCRIPTION Degree of protection for enclosure Type of construction Paint shade UNITS IP 54 VALUES / REQUIREMENTS Fully draw-out. BY JUNE’ 10 CKD.5960A-H-500-001 SL.16 5.13 5.9 5. DATE REV.2 4. compartmentalised External : Opaline Green Internal : Semi Glossy White 5. TCE.11 5.17 REV. 4. KARIMNAGAR DIST. NO. NO. 330 R3 225 IS 9000 5.12 5.

KARIMNAGAR DIST.5960A-H-500-001 SL. 5960A CLIENT : APPDCL PROJECT: 700MW CCPP AT NEDUNOOR.22 5.BY DATE RKD HA JOB NO.21 5. DATE REV. NO. TCE FORM NO.20 5.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LIMITED DATA SHEET – A3. BY CKD.13 14 OF 14 SPEC. BY R0 JUNE’ 10 PPD. NO. 5. NO.23 DESCRIPTION Semi-conductor rectifier equipment safety code Stationary cells & batteries High Discharge Plante Lead acid Water for storage battery Pasted +ve plates General requirements UNITS VALUES / REQUIREMENTS IS : 6619 IS : 1652 IS : 1069 IS : 6071 IS : 8320 REV. TCE.19 5. 330 R3 226 .18 5.13 SECTION: SHEET D3.

0 UNINTERRUPTIBLE POWER SUPPLY SYSTEM The Uninterruptible power supply system (UPS System) shall cater to the complete plant instrumentation and control system loads such as HMI. HRSG & common station loads UPS system catering to the requirements of 400kV SCADA system. The components of UPS shall isolate power line voltage transients. the UPS system and its accessories shall comply with the requirements indicated in Data Sheet – A 3. inverter and static switch. Microprocessor based controls shall be employed for rectifier.14 and specific requirements indicated below: 14. NO.3. other necessary protection devices & accessories.5960A-H-500-001 14. 14.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. KARIMNAGAR DIST. DCS & SCADA panel lighting & other critical loads.1 The UPS shall be of “parallel redundant with static bypass to regulated supply” type with 2 x 100% chargers & inverters and 2X100% battery bank. One set of parallel redundant UPS system shall be provided for the plant which will cater power to locations as indicated below: • • • UPS system for GTG UPS system for STG. except DCS & SCADA panel loads. SECTION: SHEET D.2 System Requirements UPS shall employ IGBTs as power components. The UPS system shall have static switches for added protection and transfer of loads with no break during under voltage condition to the healthy inverter or to standby regulated supply. ELECTRICAL SYSTEM UNINTERRUPTIBLE POWER SUPPLY SYSTEM SPEC. The output shall confirm to stringent requirements in respect of voltage & frequency regulation. Master clock. frequency variations and high/low voltage conditions from the critical load and act as a line filter and voltage regulator. Large Video Screens.14 Also. bypass line transformer and voltage stabiliser. AC distribution board. apart from providing no-break power at constant frequency during normal ISSUE R0 227 TCE FORM NO. The UPS shall be sized considering full load plus spare loops plus 25% margin. 329 R5 . The UPS and its accessories shall conform to the latest editions of national and international standards indicated in Data sheet – A 3. harmonic content & transient recovery. TCE.14 1 OF 13 1X 700 MW CCPP AT NEDUNOOR.

The UPS shall be sized considering full load plus spare loops plus 20% margin. TCE. 329 R5 .5960A-EL-SK-2005. the healthy inverter shall supply the full 100% load by the operation of the static switch. The operating inverter shall continuously monitor the frequency of standby source and upon restoration of proper frequency of the standby source. If one inverter fails.3. sharing 50% load each. TCE. KARIMNAGAR DIST. The system shall have a selector switch. the inverter frequency control shall get disconnected from the standby synchronising signal. In addition to the two inverter systems. each having isolating facility from the critical bus by a static switch. SECTION: SHEET D. 14.3.The system shall have a combination of two inverters (UPS modules) operating in synchronism.5960A-EL-SK-2005.3. When the selector switch is in bypass position the standby source shall cater 100% load. NO.3 TCE FORM NO. UPS Battery shall be High Discharge Lead Acid Plante type with 4 hour duration. 14.3.1 Static UPS system provided shall be of the type described below: UPS shall derive power from station service switchgear and Normal/ Emergency switchgears as shown in the sketch for UPS scheme Drawing No. the respective UPS loads shall be supplied by its own inverter. by using synchronising signal from the master inverter. the inverter shall use the frequency of the standby source as the synchronising signal. When any one of the UPS is under maintenance. ISSUE R0 228 14.5960A-H-500-001 power outages. the selector switch shall be suitably changed and the branch circuit supplying 100% load shall be synchronised with the frequency of the standby source. The output of the UPS shall feed all the essential loads through the ACDB. a backup from a regulated AC supply through transformer and voltage stabilizer derived from Station service switchgear shall be provided. In the `Normal' position.2 If the frequency of the standby source is beyond the preset limit. It shall be ensured by the contactor that the bandwidth selected for the UPS to remain locked with the SCVS frequency shall be maximum & the downstream instrumentation system should be capable of accepting the above frequency variations.3 14. isolating both inverters from the critical load bus. TCE.14 2 OF 13 1X 700 MW CCPP AT NEDUNOOR. ELECTRICAL SYSTEM UNINTERRUPTIBLE POWER SUPPLY SYSTEM SPEC. with output of both inverters being automatically synchronized with each other.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. Parallel redundant UPS with static bypass to regulated supply shall be as per sketch No.

3. The rectifier shall be capable of supplying the inverter full load. The type of batteries shall be High Discharge Lead acid Plante. The BIDDER shall choose the required voltage of the battery. Battery The batteries shall be 2 X100% rated with backup time of 10 hours.7 Loss of inverter square wave/inverter failure Loss of inverter AC output Retransfer to the inverter circuit shall be manual.4 Rectifier The rectifier shall essentially be a three phase 6 pulse design with input isolation transformer. enabling loads to be connected to the standby regulated AC supply.5960A-H-500-001 Typical scheme/connections to be adopted for the UPS is shown in the sketch TCE. For Redundant UPS design the two rectifiers input isolation transformers shall have vector grouping and connections to ensure 12 pulse operation seen from the source side. SECTION: SHEET D. The AH capacity of battery shall be chosen by BIDDER. TCE.14 3 OF 13 1X 700 MW CCPP AT NEDUNOOR.5960A-EL-SK-2005.3. based on the battery ISSUE R0 229 TCE FORM NO. Automatic initiation of the transfer from a faulty branch circuit to the standby regulated source shall be accomplished during following conditions: (a) (b) (c) 14. KARIMNAGAR DIST.5 Inverter PWM (Pulse Width Modulation) type. NO. ELECTRICAL SYSTEM UNINTERRUPTIBLE POWER SUPPLY SYSTEM SPEC. 329 R5 . 14.6 Static Transfer Switch Inverter output shall be connected to the AC bus through a static switch and fast acting fuses. The static switch comprises an interrupter and transfer switch.3.3.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. adequately designed to meet the requirements as specified. in addition to charging the fully discharged batteries in 8 hours or as recommended by battery manufacturer and then maintain the battery on trickle charge mode. The rectifier shall be provided with soft start feature. 14. The rectifier shall have features for temperature compensation charging of the batteries. 14.3.

3.9 UPS system shall be connected to the AC switchgear. Each of the UPS AC Distribution Boards shall be provided with two bus sections and a bus coupler as shown in dwg.0 or better) mimic diagram.3. TCE.11 (b) ISSUE R0 230 TCE FORM NO.3. The AC switchgear shall comply with the requirements indicated in section D3. local indication/alarm conditions and protection as indicated below. TCE.14 4 OF 13 1X 700 MW CCPP AT NEDUNOOR. 14.“400V Switchboard / MCC”. no. KARIMNAGAR DIST.8 Regulated Stand-by AC Supply Regulated standby AC supply shall be derived from standby supply through a step-down transformer of appropriate rating and a servo controlled voltage stabiliser with isolation transformer and power conditioning equipment viz. 14. SECTION: SHEET D.3.. based on the UPS parameters including temperature protection. and minimum ambient temperature as specified in Project Information. Protection The UPS system components and assemblies shall be provided with the necessary protection associated with all components.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. 20% spare feeders shall be provided in each of the UPS distribution boards The UPS system shall be provided with necessary meters (accuracy class 1. Necessary potential free contacts shall be provided from UPS to plant DCS/SCADA as appropriate.11 .5960A-EL-SK-005. Tests on the following equipment shall as per the relevant standards listed under the respective equipment specification. spike arrester. Tests for components shall be as per relevant standards. Necessary logics shall be derived in the controlling microprocessor. 329 R5 . etc.12 Tests (a) Type and routine tests certificates for all components made use in the UPS system shall be furnished. BIDDER shall furnish calculation for sizing of the battery based on the requirements of entire plant UPS loads. ELECTRICAL SYSTEM UNINTERRUPTIBLE POWER SUPPLY SYSTEM SPEC. 14.3.5960A-H-500-001 backup time / duty cycle. The guaranteed DC/AC efficiency of the UPS system offered shall be mentioned. 14.3. Grouped alarms and analog parameters (4-20 mA) of each branch of parallel redundant UPS shall be made available in DCS/SCADA as appropriate. UPS load consumers shall be fed with redundant power supply feeders from each bus section. NO.10 14.

Endurance test on static switches shall be performed for not less than 10 transfer/ retransfer cycles at full load. Contractor’s Details 2.13 Minimum electrical system requirements in respect of control.3. No. Test certificates of type tests shall be submitted for review. 1–phase ISSUE R0 231 TCE FORM NO. 329 R5 . D2. System tests shall include frequency regulation. Description Type Unit Specification Requirement Parallel redundant UPS with static bypass to regulated supply. Short circuit conditions etc.3. voltage regulation. measurement. NO. synchronising are indicated in I&C system section No. monitoring.14 5 OF 13 1X 700 MW CCPP AT NEDUNOOR. overload and under voltage conditions. ELECTRICAL SYSTEM UNINTERRUPTIBLE POWER SUPPLY SYSTEM SPEC. KARIMNAGAR DIST. current limiting feature and harmonic content tests in addition to the tests to prove the functional requirements such as transfer of static switch for conditions of loss of square wave. One parallel redundant UPS. TCE. annunciation. SECTION: SHEET D. 4.5960A-H-500-001 (c) System tests shall be performed on the completely assembled UPS system at vendor’s works.4. LVS . Application 3. Routine tests covered under clause 7.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. Sl. Uninterruptible Power supply for loads of HMI. Master clock etc. 1. Number required Ambient temperature 0 C 50 5 Output Voltage 230V. The complete assembled UPS system shall be operated at rated load under relevant ambient conditions for not less than 96 hours continuously prior to release for shipment.3 of IEC-60146-4 shall be conducted on the UPS system in addition to the system tests. (d) (e) (f) 14.

4 12. ELECTRICAL SYSTEM UNINTERRUPTIBLE POWER SUPPLY SYSTEM SPEC.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. 11. 9.8 p. Input Supply Voltage 10. Installation / paint shade (External). 329 R5 . 50 Hz.5 12. Material of Enclosure 2.3 Inverters Type Number required Suitable for parallel operation Service Output rating of each Output Voltage Static Two per unit Yes 12.7 Voltage regulation ISSUE R0 232 TCE FORM NO.8 power factor within 50 milli seconds 12.3. NO.C. KARIMNAGAR DIST. SECTION: SHEET D. 3 Phase.1 12. Degree of protection Cable entry Unit kVA Specification Requirement Contractor’s Details * IP 32 Will be decided during detail engineering stage 400V. TCE. No.0 12. 50Hz supply from N/E switchgear and for bypass from station service switchgear Indoor.5960A-H-500-001 Sl.2 12. Semi glossy white (Internal).0mm thick Cold rolled sheet steel 12. 8. Single phase Combined Voltage regulation ± 2% from 0 to 100% load at 0. natural ventilated. shade Opaline Green 7. 3 wire..f lagging load.14 6 OF 13 1X 700 MW CCPP AT NEDUNOOR.6 Indoor * 230V A. 6 Description Output rating at 0.

11 12.14 7 OF 13 1X 700 MW CCPP AT NEDUNOOR.15 Efficiency 12.f.8 Description Frequency regulation Unit Specification Requirement ± 0.14 Short circuit current withstandability 12.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.3.13 Short time rating 1 second for short circuit at inverter output terminals Shall be capable of withstanding short circuit current for the largest fuse to clear the fault in less than ¼ cycle Not less than 80% at rated load Natural air cooled / forced cooled Yes 12. SECTION: SHEET D. 12. ELECTRICAL SYSTEM UNINTERRUPTIBLE POWER SUPPLY SYSTEM SPEC.8 p. 329 R5 . KARIMNAGAR DIST.1 Hz for 0 to 100% load variation (continuous or step load change) and full range of input variation ± 8% Contractor’s Details 12. 12.to normal voltage ms 50 12.10 Total harmonic content 5% RMS maximum with not more than 3% distortion in any single harmonic Continuous 125% for 15 minutes at 0.16 Cooling 12.5960A-H-500-001 Sl.17 Synchronization with alternate source required ISSUE R0 233 TCE FORM NO. No.12 Duty Overload capacity 12. 150% for 10 sec. TCE. NO.9 a) Transient voltage regulation on application or removal of 100% load b) Time to recover from transient.

single phase Short circuit rating of the inverter for 1 second and 150% of full load current for 2 min. Indicating lamp for static switch in normal position. 13.2 13.7 Frequency Transfer time Retransfer 13.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.8 p. III. NO. Protection of all semiconductor devices against short circuit and transients. Indicating lamp for static switch connected to alternate source.5 13. ISSUE R0 234 TCE FORM NO. SECTION: SHEET D.0 Description Static Transfer Switch Capacity Continuous Unit Specification Requirement Contractor’s Details 13.1 Make and carry full load current of inverter at 0. 329 R5 . No.4 Type Voltage Short time rating 13. 13.6 13.5960A-H-500-001 Sl.14 8 OF 13 1X 700 MW CCPP AT NEDUNOOR. Automatic retransfer shall occur after approximately 2 sec time delay during which normal source voltage must remain at 230V ± 2% I.3. Hz 50 Less than 5 milli sec. TCE.8 Indication protection / Annunciation II.3 13. ELECTRICAL SYSTEM UNINTERRUPTIBLE POWER SUPPLY SYSTEM SPEC. KARIMNAGAR DIST.f Make before break 230V.

ELECTRICAL SYSTEM UNINTERRUPTIBLE POWER SUPPLY SYSTEM SPEC. TCE.4 15. Description Unit Specification Requirement iv) Annunciations for the following conditions.5 Dry type double wound * 15.2 14.8 p. SECTION: SHEET D.3 15. No. NO.5960A-H-500-001 Sl. Contractor’s Details 14.0 Standby AC supply with isolation transformer and servo controlled voltage stabilizer Number Rating Single or poly phase unit Type Voltage ratio at no load Type of cooling Winding insulation class One Same as UPS rating * 15.6 15.7 Natural Air cooled Class-H ISSUE R0 235 TCE FORM NO.f Make before break Short time rating of the inverter for 1 second and 150% of full load current for 2 minutes.3.14 9 OF 13 1X 700 MW CCPP AT NEDUNOOR.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.1 Bypass Switch Capacity Continuous Make and carry full load current of inverters at 0.1 15.3 Type Short time rating 15. 329 R5 .2 15. KARIMNAGAR DIST. 14. a) Static switch connected to alternate source b) Alternate source voltage deviation greater than ± 2% from nominal.0 14.

2 ** IP52 16.0 16.1 Data to be furnished with the Bid Technical particulars as per Data Sheet ISSUE R0 236 TCE FORM NO.10 System fault level on 400 V side Output voltage setting range Synchronising between inverter and standby supply ACDB Fully drawout/ Semidraw out/ fixed Dimensions of the board Degree of protection kA 50 ± 5% of nominal voltage Required Within ± 2. SECTION: SHEET D. 329 R5 .8 p. 7.12 16.5960A-H-500-001 Sl.f Contractor’s Details 15. ELECTRICAL SYSTEM UNINTERRUPTIBLE POWER SUPPLY SYSTEM 13 SPEC.11 15. KARIMNAGAR DIST.3 Note: ‘*’ indicated above shall be filled by the Contractor.14 10 OF 1X 700 MW CCPP AT NEDUNOOR. ‘**’ Contractor shall furnish the data after placement of order.8 15.1 ** 16. TCE.5 Hz 15.0 7. 15.3. NO.9 Description Location Voltage regulation Unit Specification Requirement Indoor ± 2% from 0 to 100% load at 0.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. No.

1 11. Semi glossy white (Internal). Common station. DESCRIPTION UNITS REQUIREMENTS 1.0 7. Ph 230V. Ambient Standby AC supply with isolation transformer and servo controlled voltage stabilizer Rating Type Ratio & frequency R0 JUNE’ 10 PPD. Two winding RKD HA JOB NO. NO. NO.5960A-EL-SK-2005 2.8 Lagging Application By Bidder For supplying the loads of HMI.0 Output Voltage AC voltage accuracy(steady state) over entire load. shade Opaline Green (External).ANDHRA PRADESH POWER DEVELOPMENT COMPANY LIMITED DATA SHEET . KARIMNAGAR DIST. 330 R3 .5960A-H-500-001 SL.0 Installation /paint shade 5.0 Input supply 6. Ph.0 4. 400 kV system SCADA & other critical loads Indoor. natural ventilated. 400V AC (From Normal cum Emergency board and Station service switchgear) V.C 50 10. 1 PH 3. 3-PH.0 Power Rating at Load PF 0. DATE REV. TCE FORM NO. NO.0 9.0 11.0 Design Ref.14 SHEET 11 OF 13 SPEC.0 Type Static Parallel redundant UPS with static bypass to regulated supply as per sketch TCE.13 SECTION: D3. 3% for any single harmonic Deg. 5960A CLIENT : APPDCL PROJECT : 700MW CCPP AT NEDUNOOR.3 REV.BY DATE 237 11. BY Same as UPS rating Dry cast resin type. BY CKD. V.0 ±5% at rated load voltage 5% total. TCE. load PF & DC voltage range Range of adjustment of AC output AC harmonic content By Bidder 8.A3.2 11.

A3. KARIMNAGAR DIST. TCE FORM NO.1 16. 5960A CLIENT : APPDCL PROJECT : 700MW CCPP AT NEDUNOOR.3 IS . 50 Hz Required (servo-controlled) ±2 ±10 for bypass ±5 of nominal voltage Auto/manual switch Load to bypass.0 16.BY DATE 238 By Bidder 230 V. BY RKD HA JOB NO.0 13.0 15.2 17.0 14. DATE REV. 1 PH.5Hz) % % % 12.0 17.13 SECTION: D3. BY CKD.589 17. TCE.1 Static Maximum of 1/4 cycle IS .5Hz to 52.2106 17.2 IS .6297 REV. DESCRIPTION UNITS REQUIREMENTS (a) Primary (b) Secondary 11.4 IS .4 Automatic voltage regulator • Percentage voltage regulation • Transient response • Output voltage setting range Bypass transfer selection Manual bypass PBs Manual bypass switch Synchronising between inverter and standby supply Static switch Type Maximum transfer time Codes and Standards Basic Climatic & Mechanical durability tests for components for electronic & electrical equipment Environmental tests for electronic and electrical equipment Metal clad base material for printed circuits for use in electronic and telecommunication equipment Transformer and inductors (power.14 SHEET 12 OF 13 SPEC.0 16. NO.5 Hz (47.5960A-H-500-001 SL. 330 R3 .5291 17.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LIMITED DATA SHEET . audio pulse & switching) for electronic equipment R0 JUNE’ 10 PPD. load to inverter Required Required ±2. NO. NO.

7 17.1248 IS .5960A-H-500-001 SL.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LIMITED DATA SHEET .13 SECTION: D3. KARIMNAGAR DIST. BY RKD HA JOB NO.13 17. TCE FORM NO.2208 IS .A3.8 IS .11 17. DESCRIPTION UNITS REQUIREMENTS 17.3202 17.6619 17.5 17.14 17.8263 17.4064 IS .14 SHEET 13 OF 13 SPEC. TCE.10 17.4007 IS .6875 IS . BY CKD.BY DATE 239 IS .15 IS . NO.2859 IS . NO. DATE REV.18 17.6 Printed wiring boards Environmental requirements for semi-conductor devices and integrated circuits Terminals for electronic equipment Factory built assemblies of switchgear and control gear for voltages upto and including 1000 V AC and 1200 V DC Air break switches HRC catridge fuses Contactors Control switches/ push buttons Indicating Instruments Degree of protection Climatic proofing in electrical equipment Semiconductor converters Semiconductor rectifier equipment code Thyristor converters Emergency Standby power systems R0 JUNE’ 10 PPD.12 17.9 17.19 IS – 5082 IEEE – 446 REV. 330 R3 .7405 IS .60146 IS .6553 17.16 17. 5960A CLIENT : APPDCL PROJECT : 700MW CCPP AT NEDUNOOR.17 IEC .2147 IS . NO.

protection.1 CABLING SYSTEM Cable Types For 6. cores screened with triple extruded semi conducting compound in combination with copper tape.2 For 400 V power supply services.. extruded PVC compound type A insulated. TCE. solenoids. space heating. multi core.15 SHEET 1 OF 19 1X 700 MW CCPP AT NEDUNOOR. 6600 volts unearthed grade single or multi core.6 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.5960A-H-500-001 15. XLPE insulated. triple extruded. XLPE power cables with the following specifications shall be provided: 1100 volt grade. inner sheathed with extruded PVC compound type ST2. lighting in the hazardous areas.6 kV services. power supplies to lighting panels etc. ELECTRICAL SYSTEMS .1. 329 R5 . stranded annealed high conductivity copper conductor (class 2 as per IS 8130). gas cured.3 For control. KARIMNAGAR DIST. inner sheathed with extruded PVC compound type ST2. XLPE insulation shall be suitable for continuous conductor temperature of 900C and short circuit conductor temperature of 2500C. Part-1. laid up. screened by triple extruded semi conducting compound. outdoor lighting. armoured with galvanised steel wire or strip for multicore cables and aluminium wire or strip armoured for single core cables.1 15. ISSUE R0 240 TCE FORM NO. CT / PT connections and interlocks. single or multi core. metering. armoured with galvanised wire or strips for multicore cables and aluminium wire armoured for single core cables and overall sheathed with extruded FRLS PVC type ST2 cable complying with IS : 7098 part-2. stranded aluminium conductor. PVC control cables with the following specifications shall be provided: 1100 volt grade.1. gas cooled. cores laid up. outer sheathed with extruded FRLS PVC compound type ST2 complying with IS: 7098. tree retardant. and for digital signals from the field devices/junction boxes/switchgears to terminal cabinets of the control system etc. 15. It shall not stick to insulation and inner sheath. armoured with galvanised single steel wire/strip and outer sheathed with extruded FRLS PVC compound type ST1 cable complying with IS: 1554.CABLING SYSTEM SPEC.0 15. The cable cores shall be laid up with fillers between the cores wherever necessary. stranded aluminium conductor.1. cross linked polyethylene insulated. with signal voltages more than 60 volts. NO. SECTION: D3. inner sheathed with extruded PVC compound type ST1. cores laid up. cores identified by numerals. XLPE cables with following specification shall be provided. 15. It shall not stick to insulation and inner sheath.. The cable cores shall be laid up with fillers between the cores wherever necessary.5.

cables overall screened with tinned copper wire braids of 0. short circuit rating and permissible voltage drop. TCE. cores wrapped by non hygroscopic material by taping or extrusion. The design ambient air temperature and ground temperature for this plant shall be considered as 500C and 300C respectively. shall be of fire survival type (FRLS cables). instrumentation cables with following specification shall be provided : Single pair.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.Part 1&2. barring gear motors. Trailing power and control cables for cranes & hoist.04 mm thick or copper tape of 0. NO. 329 R5 . For this purpose. individual pair/triplet/quadruplet screened with aluminium mylar tape of 0. KARIMNAGAR DIST.CABLING SYSTEM SPEC. ELECTRICAL SYSTEMS . The HV & LV power cables shall be selected on the basis of current carrying capacity.15 SHEET 2 OF 19 1X 700 MW CCPP AT NEDUNOOR. extruded PVC compound type-A insulated.1 TCE FORM NO. DC cables from battery to charger and DCDB etc.4 For low voltage digital signals to instrumentation and control system and for the analog signals.1. non metallic rip cord under wrapping. annealed. jacking oil pump motors. inner sheathed with extruded PVC compound type ST1. stranded tinned.2 15. suitable derating factors shall be considered due to: (a) Thermal resistivity of soil (b) Ambient ground / Air temperature (c) Derating factor for grouping of cables over the current ratings at normal conditions given in standards. high conductivity copper conductor (class 2 as per IS 8130).5960A-H-500-001 15. cabling elements suitably grouped. individual pair/triplet/quadruplets twisted. Current carrying capacity The cable shall be able to carry the full load current of the circuit continuously under the specified ambient temperature and other conditions of installation. SECTION: D3. multi pair or triplets or quadruplets as required. colour coded. armoured with steel strips/wires and outer sheathed with extruded FRLS PVC compound type ST1 complying with IEC 60189 .04 mm thick or copper laminated plastic tape with 30% overlap.5 mm² tinned copper drain wire for each cabling element.2. provided with 0. ISSUE R0 241 15. 15. cores identified by colour and coding.5 Cables for important auxiliaries such as emergency lube oil pump motors.04 mm thick with overlap of 30%.1.15 mm dia with minimum coverage of 85% or aluminium mylar tape of 0.

Control cables 15. All D. service transformer (Protected by instantaneous over current protection) (b)Tie feeders (with no IDMT relays on downstream) (c) Others . (a) Motor.0 mm2 aluminium or 2.5 Minimum conductors cross-section for the power cables shall be 4. which are protected by fuse. ELECTRICAL SYSTEMS .5 sec .2.0. the voltage drop in cables between PCC/MCC to the motor terminals for full load motor current shall be limited to 3%. NO.2. power supply cables shall be single core cables. these voltage drops may be adjusted in specific cases so that total voltage drop is within 5%.3 ISSUE R0 242 TCE FORM NO. However.C. 329 R5 .5 mm2 copper. The screen of the 6. for all other motors it shall be 15%. (b) 15.1 sec For circuits.2.16 sec . TCE.3 Permissible voltage dip normal running 400V System: Voltage drop in cables between the transformer and the switchgear (PCC) or between PCC and MCC for full load current shall be limited to 2%. SECTION: D3.5960A-H-500-001 15.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.2 Short circuit rating The cables for circuit breaker controlled circuits shall withstand the fault currents for the following fault clearing times. Further. 6.2.CABLING SYSTEM SPEC.4 Permissible voltage dip during starting (a) 400V system: The voltage dip during starting of individual 400V motors shall be limited to less than 15% of the full load voltage. 15.0.6kV system for 2 sec.2. KARIMNAGAR DIST.15 SHEET 3 OF 19 1X 700 MW CCPP AT NEDUNOOR.6kV cable shall be capable of carrying the earth fault current of 6.6kV system: The voltage drop during starting of HRSG cooling pump motors shall be limited to less than 20% of the full load voltage.6 15. 15. short circuit rating capability need not be checked.

The name of the project shall be provided at regular intervals of the outer sheath.5 15. TCE.1 Core Identification Colour coding shall be acceptable for all cables upto 5 cores.To be embossed / printed. In case 2.5. 329 R5 .5mm2 based on the requirement of I&C system employed.3. VA capacity and knee point voltage.1 15.3 15.To be embossed Word 'FRLS' at every 5 meter .5. NO. 4 mm2 cross-section cables shall be used.5. ELECTRICAL SYSTEMS . In addition to manufacturer's identification on cables as per IS.To be embossed Sequential marking of length of the cable in meters at every one meter . KARIMNAGAR DIST.4.2 15.5960A-H-500-001 15. automatic. Instrumentation Cables The cross sectional area shall be 0. Core numbers with a minimum letter size of 2 mm shall be printed serially on each core of the Instrumentation cable at intervals of not more than 200 mm and each core shall be colour coded as per IEC-60189 Part-2 FRLS PVC compound for outer sheaths of all the cables shall meet the following performance requirements and cables shall pass these tests. SECTION: D3.5 mm2 Copper Conductor is not adequate.5. Specific Requirements of Cables The following aspects are applicable for all types of cables: 15. 15.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. The embossing / printing shall be progressive.4.4 TCE FORM NO.1 Current transformer leads shall be checked for lead burden.CABLING SYSTEM SPEC. in line and marking shall be legible and indelible. The instrumentation cables carrying digital signals shall have overall screening along with drain wire and analog signal carrying cables shall have each pair screening and overall screening along with each pair drain wire and overall drain wire. following marking shall also be provided over outer sheath: (a) (b) (c) Cable size and voltage grade .4 15. Cables with more than 5 cores shall have printed numerals on each core.2 Core numbers with a minimum letter size of 3 mm shall be printed serially on each core of the control cable at intervals of not more than 200 mm.15 SHEET 4 OF 19 1X 700 MW CCPP AT NEDUNOOR. ISSUE R0 243 15.

5. In addition it shall also pass flammability test as per class F3 of Swedish Standard S5-424-1475. fish eye. A tag containing same information shall be attached to the leading end of the cable. NO. storage and erection.5960A-H-500-001 The bidder shall furnish the necessary type test certificates. Owner's name.6 15. are not acceptable. Wood preservative anti-termite treatment shall be applied to the entire drum. 329 R5 . Pimples.9 ISSUE R0 244 TCE FORM NO. TCE.5 The finished cables shall pass the flammability test as per IEC-60332-1 and IEC-60383. The surface of the drum and the outer most cable layer shall be covered with water proof cover. when tested as per IEC 60754-1.CABLING SYSTEM SPEC. An arrow and suitable accompanying wording shall be marked on one end of the reel indicating the direction in which it should be rolled. 15. Each drum shall carry manufacturer's name. ELECTRICAL SYSTEMS . The maximum total acid gas generation as determined by titration shall be less than 20% by weight.5. blow holes etc. The cross-sectional area of the metallic screen strip/tape shall be considered in design calculations.5. address and contract number.5. In plant repairs to the cables shall not be accepted. (a) The critical oxygen index value shall be minimum 29 at room temperature and the temperature index value shall be minimum 250°C at oxygen index of 21 when tested as per ASTM-D-2863-77. The maximum smoke density rating expressed in percentage light absorption at any point on the curve during testing period shall not exceed 60 % when tested as per ASTM-D-2843-77.15 SHEET 5 OF 19 1X 700 MW CCPP AT NEDUNOOR. (b) (c) (d) 15.5. The cables shall pass the hydrolytic stability and ultraviolet test as per DIN 53387. The measured values of ultimate tensile strength and elongation after the test shall not be less than 60% of that measured before the test. KARIMNAGAR DIST.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. item number and type. size and length of cable and net gross weight stenciled on both sides of the drum.7 15. SECTION: D3. Both the ends of the cables shall be properly sealed with heat shrinkable PVC/ rubber caps secured by 'U' nails so as to eliminate ingress of water during transportation.8 15. Cables shall be supplied in non returnable wooden or steel drums of heavy construction. Wooden drums shall comply with IS: 10418.

NO.6. Cable tranches shall be provided in switchyard and transformer yard.60189-1 for instrumentation cables Cable carrier system (a) Cables shall be always laid above ground to all locations including outgoing areas with cable trays supported on overhead steel structure works. (i) Control room building . Any deviation may e subjected to Owner’s approval.6.Cable vault 15. ELECTRICAL SYSTEMS .5960A-H-500-001 15.CABLING SYSTEM SPEC. Tests certificates of all type tests as per applicable standards conducted on similar cables shall be submitted for review. Routine tests shall include but not limited to the following for instrumentation cables.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. KARIMNAGAR DIST. SECTION: D3.6.6 15. smoke generation.5 : : Cable trays (ii) (iii) (iv) (v) GTG building STG building Switchyard and transformer yard : Cable trays : Cable trays / conduits : Cable trays / conduits : Cable trench ISSUE R0 245 TCE FORM NO. from different batches. Following cable carrier system shall be adopted in various areas as indicated below.1 Tests The Contractor shall conduct the routine tests on each drum length. Test for dielectric strength for one minute (as per IEC-60189-1) Insulation resistance test (as per IEC-60189-1) The vendor shall carry out all routine tests as per IEC. acid gas generation.3 15. flammability test. temperature index values.15 SHEET 6 OF 19 1X 700 MW CCPP AT NEDUNOOR.6. 329 R5 . acceptance test on the cables as per applicable standards. Also special tests for critical oxygen index. effects of light and water test as specified shall be conducted on specimen.Cable vault Switchgear room .2 15.4 15. TCE.6.

8 m considering the obstruction due to light fittings. SECTION: D3. ISSUE R0 246 TCE FORM NO. TCE. KARIMNAGAR DIST. Preferred working space between the cable support arms and the wall are as follows. ELECTRICAL SYSTEMS . Trench depth Width of Trays 600 mm 600 mm 600 mm 300 mm Working Space 750 mm 750 mm 750 mm 500 mm (c) (ii) 1500 mm (5 tiers) 1200 mm (4 tiers) 1000 mm (3 tiers) 700 mm (2 tiers) (iii) PCC flooring of buildup trenches shall be sloped for effective drainage with sump pits and sump pumps.CABLING SYSTEM SPEC.5960A-H-500-001 (vi) (vii) (viii) (ix) HRSG area HRSG platforms Road / Rail crossings Cable carrier system connecting outlying areas Off-side buildings and utilities : Cable rack : Cable trays : Hume or steel pipes : Cable Trays (x) : Cable trays (b) Cable tunnels shall have minimum head room of 1. sprinkler piping. Cable trench (i) Cable trenches shall be of different sizes depending on the number of cables laid in that route. NO.15 SHEET 7 OF 19 1X 700 MW CCPP AT NEDUNOOR. Contractor shall design the trenches accordingly.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. 329 R5 . etc.

These shall be U-shaped. accessories and covers shall be hot dip galvanised. accessories and covers shall be hot dip galvanised. crosses etc.. Troughs shall be standard width of 50 mm & 75 mm with depth of 25 mm. KARIMNAGAR DIST. shall be fabricated from 14 gauge (2. 300 mm & 600 mm and standard lengths of 2. Cable trays shall have standard width of 150 mm. (iii) (iv) (v) (vi) (vii) ISSUE R0 247 TCE FORM NO.. Prefabricated cable trays.5 metre. hook etc. bends.I.0 mm thick) mild steel sheets. accessories and covers shall be epoxy painted. (ii) Cable trays. G.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. SECTION: D3. Cable tray shall be ladder type for power & control cables and perforated for instrumentation cables. brackets. The spacing of rungs for ladder type of trays shall be not more than 250 mm.70 mm thick) MS sheets. fabricated of mild steel sheets of minimum thickness 2 mm and shall be hot dip galvanised as per relevant IS. (d) Cable trays (i) Cable trays of ladder and perforated types and the associated accessories such as coupler plates.15 SHEET 8 OF 19 1X 700 MW CCPP AT NEDUNOOR. ELECTRICAL SYSTEMS . and hardware such as bolts. strap. nuts. washers. tees. NO. 329 R5 . In battery rooms and water treatment plant. TCE.5960A-H-500-001 (iv) No sub zero level cable vault / trenches shall be provided below control building/ switchgears rooms in main plant. The thickness of side coupler plates shall be minimum 3 mm. Cable troughs shall be required for branching out few cables from main cable route. reducers. Vertical raceways shall be formed by either structural members and slotted angles or by running the prefabricated trays vertically. the cable trays. Cable tray covers shall be fabricated from 16 gauge (1.CABLING SYSTEM SPEC. elbows. Site fabricated cable trays shall be painted with cold galvanisation paint at site.

However. Welding of the components shall not be allowed. structural steel. The typical arrangement of flexible support system is described briefly below: The main support channel and cantilever arms shall be fabricated out of minimum 2. c. stud nuts. floor plates. channel nut. The support system shall be the type described hereunder. d. support hooks. 329 R5 . fixing studs. Any cutting or welding of the galvanized surface shall be brushed and red lead primer.5960A-H-500-001 (viii) Cable tray support system shall be pre-fabricated similar or equivalent to "Uninstrut make”. hard wares fittings and accessories shall be prefabricated factory galvanized. cutting. TCE FORM NO. hexagon nuts. b. All cable supporting steel work. oil primer & aluminium paint shall be applied All steel components. TCE. clamps. accessories. fittings. nuts and other hardware etc. various brackets. Cable supporting steel work for cable racks/cables shall comprise of various channel sections. The system shall be designed such that it allows easy assembly at site by using bolting. SECTION: D3. etc. The main support channel shall be of two types : (i) C1:.e. hexagon head screw. ELECTRICAL SYSTEMS . clamps. welding of the bracket (to which the main support channel is bolted) to the overhead beams. cantilever arms. The main support and cantilever arms shall be fixed at site using necessary brackets.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.5 thick rolled steel sheet ISSUE R0 248 (ix) a.CABLING SYSTEM SPEC.having provision of supporting cable trays on one side and (ii) C2:-having provision of supporting cable trays on both sides. Support system for cable trays shall essentially comprise of the two components i. e. drilling and other machining operation. NO. KARIMNAGAR DIST. channel nut with springs. hexagon head bolt. bolts. all hard wares such as lock washers. fittings and hardware shall be hot dip galvanized after completing welding.15 SHEET 9 OF 19 1X 700 MW CCPP AT NEDUNOOR. main support channel and cantilever arms. to form various arrangements required to support the cable trays. insert plates or reinforcement bars will be permitted.

and 2667. 600 mm and 750 mm in length are required. Galvanised steel pipes shall be used for sizes from 80mm on wards. the support system shall be designed by the bidder to fully meet the requirements of type tests as specified.15 SHEET 10 OF 19 1X 700 MW CCPP AT NEDUNOOR. (ii) (iii) (iv) (f) Cable/Cable tray supports ISSUE R0 249 TCE FORM NO. and shall be as shown in the enclosed drawing. The back plate shall allow sufficient clearance for fixing bolt to be tightened with tray in position. 3837.5960A-H-500-001 conforming to IS. NO. The size of structural steel members or thickness of sheet steel of main support channel and cantilever arms and other accessories as indicated above or in the enclosed drawings are indicative only. Cantilever arms of 300 mm. KARIMNAGAR DIST. The flexible conduits and their fittings shall comply with IS: 3480. 329 R5 .5 mm. The arm portion shall be suitable for assembling the complete arm assembly on to component constructed of standard channel section. The pipes and fittings shall comply with IS. ELECTRICAL SYSTEMS . The conduits shall be manufactured by electric resistance welding process and shall be hot dip galvanised. f. SECTION: D3. The pipes shall be manufactured by electric resistance welding and hot dip galvanized. TCE. In case the system fails in the tests. The bidder shall submit the detailed drawings of the system offered by him along with the bid. Nevertheless.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. The hume pipes/RCC pipes shall comply with IS: 458. The conduits and fittings shall comply with IS: 1653. They shall be medium duty class-B type as per IS.CABLING SYSTEM SPEC. the components design modification shall be done by the Contractor without any additional cost to the Owner. 4649. Flexible steel conduits shall be manufactured with electro galvanising process. (e) Conduits & Pipes (i) The galvanised steel conduits shall be used for sizes upto 63.

Cable trays shall be welded to the mounting/carrier structures. KARIMNAGAR DIST. 400V/230V power. For outdoor & corrosive areas like battery room.15 SHEET 11 OF 19 1X 700 MW CCPP AT NEDUNOOR.Hot dip galvanised. control cables and instrumentation & communication cables. In vertical race ways with multi-tiers the tiers shall be located atleast with 400 mm intervals. The sizes selected shall be adequate for the weight of cables/trays encountered. 6.One shop coat of red oxide zinc chromate primer and two site coats of aluminium alkyd paint. TCE.6 kV power. SECTION: D3.. (ii) (iii) (iv) (v) (vi) ISSUE R0 250 TCE FORM NO. 329 R5 . Cable trays shall be supported at every 1000 mm interval.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. In trenches & tunnels the width of the cable tray shall be limited to 600 mm. (ii) • (g) Cable Carrier Installation practice (i) Minimum level difference between two tiers of horizontal cable trays in building. Communication links wherever redundant shall be run in different conduits and in separate trays.CABLING SYSTEM SPEC. The steel members shall be cleaned thoroughly for rust and painted as follows: • For indoor . DM plant . trenches shall be 300 mm. NO. Vertical trays (raceways) and all outdoor cable trays shall be provided with removable 16 guage galvanised MS sheet covers.5960A-H-500-001 (i) Cable tray supports shall be fabricated from standard steel structures of different sizes. Cable trenches around the transformer shall be filled with sand. Separate cable trays/tiers shall be provided for different voltage grade cable viz. In case of horizontal trays it shall be limited to 800 mm. ELECTRICAL SYSTEMS .

For good sealing arrangement at entry points.3 Cables in Trays / on Racks ISSUE R0 251 TCE FORM NO.CABLING SYSTEM SPEC. 15. At least 300mm clearance shall be maintained between the top tray and beams. steam pipe.7 15. adequate in number and of adequate sizes shall be provided in building walls/slabs for passage of cables into a building from cable trays/racks/cable trenches located outside the building. etc. When cables are taken in vertical raceways / trays and they pass from one floor & other floor pipe sleeves in concrete shall be provided. piping or other obstacles to facilitate installation of cables in the tray. ELECTRICAL SYSTEMS . nylon cord at an interval of 5000 mm and also at bends. the cables shall be laid in hume or steel pipes.1 Cable Installation Cables to each circuit shall be laid in one continuous length. KARIMNAGAR DIST. Jointing will be allowed only for the cases where the route length is more than the maximum possible drum length. For road crossings.15 SHEET 12 OF 19 1X 700 MW CCPP AT NEDUNOOR. Cable jointing and splicing shall be avoided. gas or sewage pipes.7. NO. (viii) (ix) (x) 15.5960A-H-500-001 (vii) Each continuous laid out length of cable tray shall be earthed at minimum two places by MS flats of minimum size 25mm x 3mm. the pipe for the cable shall be buried at not less than 600 mm.7. the distance between earthing points shall not exceed 10 metres. Hume pipes shall be preferred to steel pipes from the point of view of corrosion.7. A working space of not less than 600mm shall be maintained on atleast on one side of each tray. TCE. 329 R5 .2 (b) (c) 15. Outdoor cable installation (a) Where cables cross roads and water. oil. The cables shall be tied to tray rungs by means of 3mm dia. No cables shall be mounted near hot zones like hot flue gas duct. suitable pipe sleeves.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. SECTION: D3.

Control and instrumentation cables can be laid upto a maximum of three layers in each tray/rack. (h) ISSUE R0 252 TCE FORM NO. TCE. Cables removed from one duct/conduit shall not be reused without approval of Owner. At an interval of 750 mm when laid in trenches without cable trays. When trays are arranged in tiers. The cables shall be tied to tray rung by means of 3 mm dia.15 SHEET 13 OF 19 1X 700 MW CCPP AT NEDUNOOR. All cables assigned to a particular duct / conduit shall be grouped and pulled in simultaneously using cable grips and suitable lubricants. (d) (e) (f) (g) Control cables and small power cables on racks shall be run in ladder type cable trays supported on rack carrier arms. NO. nylon cord as follows: (i) (ii) At an interval of 1m when laid in cable trays/racks. nylon cord at an interval of 5000 mm and also at bends. SECTION: D3. The trefoil groups of cables shall be additionally tied by means of 3 mm dia. where required.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.5960A-H-500-001 (a) Different voltage grade cables shall be laid in separate trays. Smaller 1100V grade power cables below 120 mm² may be run in double layers. HV cables shall be laid in top trays and cables of subsequent voltage grades in lower tiers of trays. Single core cables to be laid in trefoil groups. 3 core cables to be laid in touching formation. ELECTRICAL SYSTEMS . (b) (c) 1100V grade power cables of 120 mm² size and above shall normally be laid in single layer in trays/on racks.CABLING SYSTEM SPEC. Single core power cables for 3 phase AC circuits laid in trays/racks/ trenches in trefoil groups shall be held in trefoil clamps placed at an interval of 3 m. due to space restrictions. KARIMNAGAR DIST. Approximately 10% space on the cable trays shall be provided for future. 329 R5 . The HV power cables shall be laid in trays/on racks as follows: i) ii) iii) In single layer only without exception.

4 Bending radii for cables The bending radii for various types of cables shall not be less than those values specified by the cable manufacturer. All cable terminations shall be done with solderless crimping type lug. at 750mm interval. clamping and miscellaneous details (a) Cable entry to motors.15 SHEET 14 OF 19 1X 700 MW CCPP AT NEDUNOOR.7. Saddle type clamps to suit number of cables to be clamped at a particular location shall be used for clamping cables running along walls. (b) (c) (d) ISSUE R0 253 TCE FORM NO. Top entry of the cables is not acceptable particularly for outdoor equipments. Nos. provided in Owner's approved format at both the ends as well as at an interval of 5 meters.5 Terminations. SECTION: D3. 329 R5 . 15.6 kV tray system From 400V tray system From control cable tray system 914 mm 610 mm 305 mm (j) The cables emanating from redundant equipment / devices shall be routed through different routes. Tags shall be additionally put at an interval of 30 metres on long runs of cables and in pull boxes. The above segregation of cables & wiring for redundant equipments/ devices shall be in accordance with IEEE-Std-422. In vertically stacked trays. KARIMNAGAR DIST. Identification tags made from aluminium sheet shall be attached to each end of each cable by means of GI binding wire. structures. etc. All cables shall be identified by tag.5960A-H-500-001 (i) Cables shall be segregated as per IEEE Std. The distance between instrumentation cables and those of other: system shall be as follows : From 6. ELECTRICAL SYSTEMS .-422. ceilings.7. TCE. Cable terminations shall be done with double compression type brass cable glands. 15.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.CABLING SYSTEM SPEC. the higher voltage cable shall be in higher position and instrumentation cable shall be in bottom tier of the tray stack. push button stations and other electrical devices shall be from the bottom as far as possible or from the sides. NO.

7. For long lengths of cables multiple earthing may have to be adopted to safeguard against the presence of standing voltages under normal as well as fault conditions. ELECTRICAL SYSTEMS . within a single fire-area or fire. (b) 15.7.8 Earthing (a) Metallic sheaths. Sheath and armour of single core power cables shall be earthed at switchgear end only.CABLING SYSTEM SPEC. screens and armour of all multicore cables shall be earthed at both equipment and switchgear end. 329 R5 . High voltage testing All cables of 1. 6. Termination kits and jointing kits shall be heat shrinkable type/push on type.1 kV grade Straight Through Joint shall be of proven design. SECTION: D3.1 kV grade 400 mm² and above and all HV cables shall be subjected to DC or AC (preferably DC) high voltage test after terminating but before commissioning as per Table 4 in IS: 1255. Cable jointing shall be carried out only by Raychem certified jointers only. TCE. NO. which is separated from others by fire-resistant barriers.7. through brick or RCC walls/floors.7 (b) 15.6 kV grade XLPE insulated cables shall be of proven design and make which have already been extensively used and type tested. to prevent the spread of fire from one area. KARIMNAGAR DIST.5960A-H-500-001 15. 1.6 kV grade joints and terminations shall be type tested as per IS:13573.9 Fire proof sealing system (FPS) (a) Fire proof sealing system shall consist of (i) Fire-stops/fire-seals for sealing of cable/cable tray and conduit/pipe penetrations. Straight through joint and termination shall be capable of withstanding the fault level for the system.7. 15.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.6 Termination and jointing kits for 6.15 SHEET 15 OF 19 1X 700 MW CCPP AT NEDUNOOR. Testing and commissioning of cables (a) Cables shall be checked for insulation resistance before and after jointing. `Fire-breaks' provided on long runs of cable racks/trays to prevent the propagation of fire along the cable rack.zone. ISSUE R0 254 (ii) TCE FORM NO. both horizontal and vertical.

shall constitute a `fire-break' and shall be provided by applying a suitable fire-resistant coating on cables and cable trays for the required length. NO. at the point of the fire break to obtain the fire-rating specified. The materials used in the fire stops shall be nonhygroscopic. (e) Fire Break The fire proofing system. KARIMNAGAR DIST. in an event of a fire.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. adopted to retard flame propagation along long runs of horizontal or vertical cable trays in the same fire zone or area. other than fire-stops. or cables passing through embedded conduits/pipes/ pipe-sleeves. (f) Performance Requirements (i) Requirement of fire stops • The material. compatible with the type of cables.15 SHEET 16 OF 19 1X 700 MW CCPP AT NEDUNOOR. SECTION: D3. holding in position. ISSUE R0 255 • TCE FORM NO.CABLING SYSTEM SPEC. design and construction of the fire stops shall be such as to provide the fire rating of 120 minutes for a fire on any side and meet all requirements listed in this specification and the relevant codes and standards. TCE. constitutes a `fire stop/seal'. 329 R5 .5960A-H-500-001 (b) The FPS system shall also include all the necessary accessories and equipment required for supporting. The FPS system shall comply in all respects with the requirements of the codes and standards listed below IEEE-634 ASTM-E-814 ANSI-IEEE-383 IEC-60331 IEC-60332 (c) (d) Fire Stop/Seal The FPS system adopted for cables or cable trays penetrating through walls and floor openings. ELECTRICAL SYSTEMS . which is meant to prevent spreading of fire between areas separated by fire-resistant barriers. with or without a fire resistant panel. fixing and installation of the fire-stop/fire-break.

ELECTRICAL SYSTEMS . (g) Application of fire proof sealing system (i) Fire stops Fire stops shall be provided for cable penetration openings listed below • The passage of cables/cable trays pipe sleeves/embedded conduits through walls / floors. which carry cables between successive floors.5960A-H-500-001 • The fire stops shall be suitable for retrofitting of cables through the penetration seal without disturbing the sealing of the cables already existing. a fire on any side of the fire break. ISSUE R0 256 • TCE FORM NO. shall be sealed by fire stops at each floor level. • • (ii) Location of fire breaks • Fire breaks shall be provided on both cable rack and trenches at all cable tray intersections and tee-offs. various control and relay panels and other bottom entry panels. KARIMNAGAR DIST.CABLING SYSTEM SPEC. 329 R5 . NO. shall be effectively sealed by fire stops. (ii) Requirements of fire breaks • Each firebreak shall have a fire rating of 30 minutes and shall be capable of withstanding for the duration specified. TCE. MCCs. Vertical raceways. On linear runs of cable trays between fire stops or fire breaks. Cable entry through openings in floor slabs below MV/LV switchgear.15 SHEET 17 OF 19 1X 700 MW CCPP AT NEDUNOOR. SECTION: D3.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. through openings provided in the RCC floor slab. fire breaks shall be provided at intervals of 15 metres on horizontal cable runs and 5 m on vertical cable runs.

5960A-H-500-001 • Fire breaks in linear runs of cable trenches between intersections and tee-offs shall be provided at intervals of 30 metres. 329 R5 . ELECTRICAL SYSTEMS . fire stops and fire breaks shall be identical (or better) with the system which is successfully type tested for the specified rating i.7. The sizes of the fire stop test specimens shall be similar to the largest of the sizes being used in the plant. thickness of coating in case of fire breaks and any other properties of the material / system offered shall be identical or better than the tested system and shall be subject to Owner’s approval.11 Type tests shall be conducted on different fire stop test specimens described above as per IEEE-634.7. 15. TCE.e. water immersion and vibration.e. the transmission of heat through the cable penetration fire stop shall not raise the temperature on its unexposed surface above the self ignition temperature of the outer cable covering. each test specimen shall be preconditioned for thermal ageing. or material in contact with the cable penetration fire stop. Performance Tests: Tests on Fire Stops (a) The fire stops shall be subjected to the following type tests: (i) (ii) (b) Fire Rating Test Hose Stream Test 15. with a maximum temperature limit on the unexposed surface of 200oC.CABLING SYSTEM SPEC.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. The offered system i.15 SHEET 18 OF 19 1X 700 MW CCPP AT NEDUNOOR.10 Contractor shall furnish the test certificates for the fire stops and fire breaks after award of contract for Owner’s review. If the certificates are not satisfactory all the tests shall be conducted free of cost. Test on Fire Stops During the fire rating test. the cable penetration fire stop material. the composition density of the material. KARIMNAGAR DIST. Preconditioning of fire stop test specimens Before conducting the fire rating and hose stream tests. (c) (d) (e) Tests on fire breaks ISSUE R0 257 TCE FORM NO. NO. SECTION: D3.

329 R5 . NO. ELECTRICAL SYSTEMS .5960A-H-500-001 Fire breaks shall undergo the following tests as per ANSI-IEEE383: (i) (ii) Ampacity test Flame test ISSUE R0 258 TCE FORM NO. TCE. KARIMNAGAR DIST.CABLING SYSTEM SPEC.15 SHEET 19 OF 19 1X 700 MW CCPP AT NEDUNOOR.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. SECTION: D3.

4 Emergency DC lighting system ISSUE R0 259 TCE FORM NO.1.5. SECTION: D3. 16. NO. yards. In this system the lighting circuits shall be fed from another lighting distribution board from normal/emergency section of the 400V main switchboard. having good aesthetics and designed to provide the required illumination levels in all areas and to meet the fire and safety codes. ELECTRICAL SYSTEMS . the lighting fixtures connected to this system will go off and shall come back as soon as the DG set starts feeding power to the 400V normal-emergency bus section.1.0 LIGHTING SYSTEM Lighting system shall be provided for the proposed plant covering all the buildings. outdoor areas. 3 phase. roads.7 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. 4 wire.LIGHTING SYSTEM SPEC. 16. boundary.1. normal AC supply available from the normal lighting distribution boards.2 Normal 230V AC lighting system In this system. etc. KARIMNAGAR DIST. 329 R5 . The lighting fixtures connected to this system will be available whenever normal supply is available in the plant and also whenever emergency DG set supplies the power to this bus section during blackout conditions. The lighting system shall be to owner’s approval.. TCE. During blackout conditions. the lighting circuits shall be fed by the 400V.1 16.1 Categories of Lighting The plant lighting system shall comprise the following four (4) categories: (a) (b) (c) (d) Normal 230 V Single phase AC lighting system Normal-cum-Emergency 230 V Single phase AC lighting system Emergency 220V DC lighting system Maintenance 24V AC Lighting System 16.1.16 SHEET 1 OF 16 1X 700 MW CCPP AT NEDUNOOR. 16. All the lighting fixtures connected to this system shall be available as long as supply is available from normal source viz.3 Normal cum emergency 230V AC lighting system Certain lighting fixtures considered essential shall be connected to this system.5960A-H-500-001 16. auxiliary transformer.

STG. landings etc. 24V single phase 3 pin sockets with switches shall be provided at selected points such as HRSG area. Cable galleries and any other areas considered necessary by CONTRACTOR.LIGHTING SYSTEM SPEC. incandescent lamp DC lighting fixtures shall be provided for movement of personnel in GTG and STG buildings. TG building Hall.6 80% 80% 20% 20% * * 260 TCE FORM NO.. (b) (c) (d) 16. maintenance area etc. All the area in the plant shall have the same philosophy & DC lighting for these areas shall also be from the station battery. control ISSUE R0 16.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. Minimum one number of instalite shall be provided in all switchgear rooms pump houses and control rooms where DC lighting not envisaged. Necessary outlets shall be made on the inside walls of the building near equipments.5960A-H-500-001 (a) During station emergency involving total AC failure. KARIMNAGAR DIST. These lighting fixtures shall be normally kept `OFF'. NO. and for lighting the control room and DG set area.1. Control & Switchgear Building. TCE. Such sockets for routine maintenance shall be clearly identified by colour coding in order to distinguish them from the normal 230V power outlets. ELECTRICAL SYSTEMS . near entrance. The area-wise distribution of lighting fixtures connected to the systems discussed above shall be as follows: ---------------------------------------------------------------------------------------------------------------Percentage wise distribution of Lighting Area /Building ------------------------------------------------------------------Normal Normal & Emergency 220 V DC ----------------------------------------------------------------------------------------------------------------GTG. required during the routine maintenance work.. Lighted exit signs shall be provided and installed in the control & switchgear room.5 Maintenance 24V AC Lighting System For lighting facilities comprising portable hand lamps and/or connection of portable hand tools etc. staircase. These fixtures shall be connected to lighting panels supplied from 220V DC station battery. SECTION: D3.1. 329 R5 . Switchyard Relay Building at strategic locations viz. buildings Switchyard control room Switchgear and battery rooms.16 SHEET 2 OF 16 1X 700 MW CCPP AT NEDUNOOR. relay room.

Lighting panels feeding the Lighting fixtures in indoor areas shall be controlled from the respective lighting panels located in various buildings in the plant. the distribution shall be by 400V. 3 wire. 50 Hz unit service switchgear by providing a 400 / 400V delta/star lighting transformers.LIGHTING SYSTEM SPEC. KARIMNAGAR DIST. NO. The LDBs will be provided with number of outgoing circuits controlled by MCBs to feed the lighting panels and by MCCB/Contactors to feed around the plant as well as to directly feed three phase street lighting and yard lighting supplies. ELECTRICAL SYSTEMS .2. 3 phase. 16.2. 329 R5 . TCE. (b) 16. 3 phase. AC lighting distribution boards (LDBs) having 2x100% incomers & a bus-coupler. Admin building Canteen Roads & out going areas 80% 80% 100% 100% 100% 20% 20% * - - - DG set control room 80% 20% * ---------------------------------------------------------------------------------------------------------------* Adequate for personnel movement and also located at strategic locations.2 16. 4 wire. AC lighting panels shall have 3 phase. 4 wire. The secondaries of lighting transformers shall be connected to 400 V. 50 Hz supply with effectively earthed neutral.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. yard lighting and aviation warning lights also shall be contactor controlled. 3 phase.2 220 V DC lighting system ISSUE R0 261 TCE FORM NO.1 Lighting Supply Distribution System Normal and normal emergency AC systems (a) For these systems. Provision to bypass the timer or photocell shall be provided in the panel. 4 wire incomer with ELCB and number of 1 phase outgoing circuits controlled by MCBs. SECTION: D3. This supply shall be derived from 400 V. The Infrared sensing system shall be used for the control of lighting in unmanned substations. Road.5960A-H-500-001 room in Control & Switchgear building HRSG area Transformer area & 400kV switchyard Pump houses. Also manual switching `on and off' facility shall be provided.16 SHEET 3 OF 16 1X 700 MW CCPP AT NEDUNOOR. All outdoor lighting system and aviation warning lighting system shall be automatically controlled through photoelectric controllers.

This panel shall have an incoming switch.LIGHTING SYSTEM SPEC. 2 wire unearthed system. ISSUE R0 (c) All switchgear room area (including off-site building control room) GTG Building 250 (d) 200 262 TCE FORM NO. Industrial type with vitreous enamel reflector Industrial type with vitreous enamel reflector Industrial high bay with anodised aluminium reflector 1 x 70 W / 1 x 150 W HPSV lamp (b) Cable vault 150 2 x 36W fluorescent lamp (F. DC lighting panel shall be provided for distribution of lighting supply. 329 R5 .16 SHEET 4 OF 16 1X 700 MW CCPP AT NEDUNOOR.L). 16. KARIMNAGAR DIST.3 Illumination levels and choice of lighting fixtures The area-wise distribution of average illumination levels and type of luminaires shall be as given below. STG Building / Control & Switchgear building General (auxiliary equipment areas) 200 Medium /low bay fittings / Industrial well glass vitreous enamel reflector integral mounted control gear/ industrial bulk head with integral mounted control gear. The control box shall be fixed on the wall/column for the easy maintenance. Metal Halide Lamp. SECTION: D3.5960A-H-500-001 Emergency DC lighting supply distribution shall be on 220V DC. Sl. NO.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. No voltage at the normal emergency switchgear shall be sensed and DC contactor shall be switched on thus extending DC supply to the lighting circuits. Minimum 10% of 220V DC lighting shall be provided. ELECTRICAL SYSTEMS . Area/ Structure Average Illumination Level in Lux. No.L)-Trulite 1x400 W. TCE. (a) GTG. This power supply shall be obtained from station 220V DC switchboard. undervoltage relay and number of outgoing circuits controlled by switch fuses.Trulite 2X36W fluorescent lamp (F. Type of Fixture Type of Luminaire 1. All the lighting fittings shall have separate control & gear box arrangement.

Industrial High with Anodised Aluminium Reflector 2X 36W F.-Trulite 2 x 36W F. ISSUE R0 263 TCE FORM NO. KARIMNAGAR DIST. 329 R5 . (a) 150 50 Dust proof / dust tight well glass fixture 70W HPSV lamp 3. ELECTRICAL SYSTEMS .ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. -Trulite 2 X 36W F. Type of Fixture Type of Luminaire Industrial High with Anodised Aluminium Reflector (e) Control room 500 Decorative recessed with wide angle mirror optic anti glare type Vapour proof Totally enclosed vapour proof with clear acrylic cover Industrial high bay Energy efficient Lamp – T5 2X36W F. chemical laboratory (air-conditioned) Chemical laboratory (non-air conditioned) HRSG area HRSG area and platforms (i) (ii) Indoor Outdoor 250 Decorative recessed with wide angle mirror optic anti-glare type Corrosion proof (j) 250 2. NO. TCE.L. Metal Halide Lamp. No.LIGHTING SYSTEM SPEC. (a) (b) (c) Transformer Area General Near equipment Switchyard Area General Near equipment Switchyard Control room 30-35 35-50 500 Flood light medium beam type Post top lantern with HDP reflector Decorative recessed with wide angle mirror optic anti glare type 1 x 150W HPSV lamp 70W HPSV Energy efficient Lamp – T5 30-35 35-50 Flood light medium beam type Dust proof / dust tight well glass on fire partition walls 1 x 150W HPSV lamp 1 x 70W HPSV 5. Area/ Structure Average Illumination Level in Lux.L. SECTION: D3. (a) Various Off-site building Switchgear room (All pump 200 Industrial type with vitreous 2 x 36W F.L -Trulite 1x400 W. -Trulite (f) (g) Battery rooms A/C plant room 250 200 (h) Unloading and maintenance bay 250 (i) Electrical / Instrument laboratory.16 SHEET 5 OF 16 1X 700 MW CCPP AT NEDUNOOR.L.L.5960A-H-500-001 Sl. (a) (b) 4.

No.do 1 x 250 W HPSV 2X36W F. . (a) Corrosion proof 1 X 70 WHPSV Street light with clear acrylic cover cut-off type with integral mounted control gear or LED fixtures with control gear. toilets.L. 150 Industrial type with vitreous enamel reflectors/channel mounted box type compact flourescent lamp Channel mounted box type Industrial well glass with integral mounted control gear/industrial bulk head with 2 x 36 W F.L.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. wash rooms. TCE. (a) (b) Administration Building Main office areas cabins (air conditioned areas) Main office areas. Compressor & DG house) DM Plant / Filtration Plant General Road and yard lighting Main roads Secondary roads 20 10 250 70 250 enamel reflector mounting height of 8M Flood light medium beam upto Industrial high bay / medium bay depending on height 1x400W / 1x150W Metal Halide Lamp (HPMV) 6.L.L. (b) (c) Lockers. Perimeter (compound) lighting Parking area (Indoor / sheds) Workshop building 20 70 300 . ELECTRICAL SYSTEMS . 1 x 70 W HPSV lamp ISSUE R0 264 TCE FORM NO. (a) 150 2 x 36W F. 200-250 200-250 Decorative recessed type with mirror optic reflector . high/medium beam flood light Industrial type with vitreous enamel reflectors/industrial high bay 1 x 70W / 150W HPSV (b) (c) 8.LIGHTING SYSTEM SPEC.do 2 x 36W F. Area/ Structure Average Illumination Level in Lux. 329 R5 .5960A-H-500-001 Sl. walk-ways. (a) 7. canteen.do General purpose flood light. KARIMNAGAR DIST. NO. cabins with false ceiling but non-airconditioned Main office areas. Building periphery lighting 100 - 2 x 36 W F. etc. staircase. etc. cabin non airconditioned areas without false ceiling Warehouse.do - (d) 10. SECTION: D3.do - (c) 200-250 Decorative with wide angle mirror optic reflector Industrial type with vitreous enameled reflector .L x 250W HPSV 9.16 SHEET 6 OF 16 1X 700 MW CCPP AT NEDUNOOR. Type of Fixture Type of Luminaire house) (b) (c) Outside working areas Equipment room (Pump house. . medical centre General Corridors.

(a) Maintenance factor (i) (ii) Control room and system cabinet room .ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. ELECTRICAL SYSTEMS . The lighting layout shall be designed to provide uniform illumination with minimum glare. Executive canteen Elevator Elevator machine room Elevator well 100 20 Industrial type enamelled reflector vitreous 2 x 36W F. Type of Fixture Type of Luminaire integral mounted control gear (d) 11. The system design shall consider principles of lighting specified in following paragraphs. TCE.7 ISSUE R0 265 TCE FORM NO. SECTION: D3. No. Area/ Structure Average Illumination Level in Lux.5960A-H-500-001 Sl. shall be decided based on illumination levels indicated for similar areas or in relevant standards.4 Lighting System Design The lighting system design shall comply with the acceptable norms and the best engineering practices. which are not specifically covered above. Time office. 16. 329 R5 . 1 x 100 W incandescent lamp / 1 x 70W HPSV 150 Decorative with louver 2x36W F. Gate house.LIGHTING SYSTEM SPEC.0.L.1 Indoor lighting The illumination level for various areas in the plant is indicated in the table above.4. (a) (b) Security.8 All other indoor areas . 16. KARIMNAGAR DIST.L Industrial bulk head/ industrial bulk head with integral mounted control gear 12.0. (a) (b) DC Light Fitting Control room Other areas Decorative recessed type with cylindrical reflector Industrial industrial reflector bulk head or well glass with 1 x 100 W incandescent lamp 1 x 100 W incandescent lamp The illumination levels for areas. Following factors shall be considered while arriving at the utilisation factor to determine the number of fixtures for each area/building in the plant. The layout design shall meet all the statutory requirement. local rules etc. NO.16 SHEET 7 OF 16 1X 700 MW CCPP AT NEDUNOOR.

The lighting poles shall be galvanised steel poles with reasonably thick layer of galvanising for ensuring long life.0.3.3. KARIMNAGAR DIST..3 wall (ii) (c) The value of the ratio of spacing (S) to mounting height (H) shall be commensurate with the type of fittings selected. (d) 16. uniformity of illumination. shall be selected based on the plant area in which they are intended to be used. The control gear for street light shall be of non integral type i.6 for average conditions. 0.1 Selection of lighting fixtures and accessories The type of luminaires and accessories like switches.0. The control room lighting shall be designed such that no glare from the lighting appears on the DCS-CRT from any angle.5960A-H-500-001 (iii) (b) Out door areas .16 SHEET 8 OF 16 1X 700 MW CCPP AT NEDUNOOR. the control gear of the light fixture shall be mounted at the foot of the pole. Ratio of minimum to average illumination shall not be less than 0. ISSUE R0 266 TCE FORM NO.7 ceiling.5 wall Other areas .5 ceiling 0.4. Lighting fixtures shall be explosion proof in hazardous and fuel oil areas. (b) (c) (d) (e) 16.. receptacles etc.4. The suspension height for suspended fixtures shall not exceed 1 metre.e.LIGHTING SYSTEM SPEC.0.4. NO. ELECTRICAL SYSTEMS .6 Reflection factor for wall and ceiling (i) Control room and system cabinet room .2 Roadway lighting (a) Lighting design for roadways shall consider a maintenance factor of 0. on either side or in the central reserve. The road lighting layout shall consider the width of the road to decide whether the lighting poles shall be located on one side. 329 R5 . TCE. SECTION: D3. The mounting height of the luminaires shall be generally 9 metres.3 16.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.

SECTION: D3. 329 R5 .2 All fluorescent fixtures. in built power tool.3. 16. ELECTRICAL SYSTEMS .3.3. KARIMNAGAR DIST.4. All fluorescent fixtures except for Class-I. The louvers of these fixtures shall be designed for 'T5' type fluorescent lamps.7 Pull out boxes shall be provided at approximately 4 (four) metre interval in a conduit run. swaged tubular and joined together. continuous stainless steel wire rope.3.8 The poles shall be of ERW tubes of specified lengths.LIGHTING SYSTEM SPEC.4.9 Lighting Mast shall be of continuously tapered polygonal cross section hot dip galvanised. 16. Pull out boxes used outdoor shall be weather proof type suitable for IP :55 degree of protection and those used indoor shall be suitable for IP :52 degree of protection. The complete pole shall be hot dip galvanised. shall have electronic chokes with low harmonics & energy efficient 'T5' type fluorescent lamps except the fluorescent fixtures used for division 2 hazardous area. TCE. NO. Pull-out boxes shall have cover with screw and shall be provided with good quality gasket lining. Columns. The mirror optics type fluorescent fixtures shall have no iridescence effect.5 Rigid steel conduits shall be heavy duty type.3. Double Drum Winch. Pull out box & its cover shall be hot dip galvanised.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.6 Flexible conduit shall be water proof and rust proof made of heat resistant lead coated steel. Boxes shall be suitable for mounting on Walls.16 SHEET 9 OF 16 1X 700 MW CCPP AT NEDUNOOR.3 All HPSV and HPMV lamp fixtures or LED fixtures shall be provided with wire-wound ballasts. 16.4.3. lightning along with necessary power cables within the mast. The mast shall be delivered only in three sections & shall be joined together by slip stressed fit method at site.4 Conduits. etc. suitable aviation warning light. All fluorescent lamps shall be have "Cool day light" colour designation. hot dip galvanised conforming to IS : 9537 Part-I & II shall be suitable for heavy mechanical stresses. No site welding or bolted joints shall be done on the mast.4.3. Structures.4. Pipes and Accessories Galvanised heavy duty steel conduits for normal area and galvanised heavy duty steel conduits with an additional epoxy coating for corrosive area shall be offered.4. 16. luminaries.4. including the Head Frame.4.3. threaded on both sides and threaded length shall be protected by zinc rich paint.5960A-H-500-001 16. Div-II fittings/ increased safety fittings (Div-II/Hazardous Area) shall be provided with electronic ballasts. ISSUE R0 267 TCE FORM NO. 16. The Mast shall be of 30M height with lantern carriage to enable raising/lowering for ease of maintenance. The terminal boxes for the lighting pole shall be IP55 protected & of glass reinforced epoxy type. Conduits shall be smooth from inside and outside. 16. 16.

C industrial heavy duty receptacles shall be provided for outdoor plant for welding purpose. aerodynamically designed well balanced MS blades (3 Nos.10 Suitable collapsible / telescopic ladder shall be provided to approach lighting fixture installed at height. It shall be metal enclosed with SFU and housed inside with suitable connection for cabling and receptacles.4. 329 R5 .3. 1200mm sweep. with a degree of protection of IP 54. Ceiling fans.54 degree of protection. finished in stove enamelled white. 400V industrial heavy duty type receptacle shall be provided in each building. canopies etc. 3 phase. The LDBs and LPs shall be sheet steel enclosed and shall be fully dust and vermin proof. Wherever the lighting panel is not in the same area.). 50 Hz. in an enclosed area. Power factor of fans shall not be less than 0.4 Switches and receptacles (a) In the plant areas. of 63A. LDBs. separate switches shall be provided for each point. Inside each cabins atleast two receptacles shall be provided. For cabins. shall be suitable for operation on 230 V. etc. building periphery lighting separate switches shall be provided. At-least two 63A. 3 phase.LIGHTING SYSTEM SPEC.5 Lighting distribution boards (LDB) & lighting panels (LP) Each of the LDBs shall be provided with voltmeter and ammeter along with selector switches. Outdoor panels shall be weather proof type with IP . receptacles shall be provided at regular intervals so that any point of the building is not more than 10 m with a minimum of 2 nos. Each fan shall cover approximately 10m2 area.9. KARIMNAGAR DIST. suspension hook. to be provided in non air conditioned office/control room area. Similarly for entrances.16 SHEET 10 OF 16 1X 700 MW CCPP AT NEDUNOOR. LPs shall be explosion proof wherever provided in hazardous and fuel oil areas. capacitor. Receptacles with MCB (5A and 15A) shall be provided in all building/areas of the plant. 16. 400VA. `Supply On' indicating lamps. ELECTRICAL SYSTEMS . rooms etc. Suitable no.5960A-H-500-001 16.4. down rod. The industrial receptacle shall be provided at an average distance of 50 mts. (b) (c) 16. The ISSUE R0 268 TCE FORM NO.. die cast aluminium housing. Also inside a building. NO. The same shall be indoor/outdoor/flameproof as per the location. AC supply comprising of class ‘F’ insulated copper wound single phase motor. separate switches shall be provided. SECTION: D3.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. TCE..4. the lighting circuits shall be controlled directly from the MCBs in the lighting panels.

The buried cables shall have suitable bedding. ISSUE R0 (b) 269 TCE FORM NO. In case of room the lighting shall be arranged from two phases.6 The distribution of lighting fixtures/receptacles shall be such that the loading on each phase of the LDB is approximately equal. GI wire armoured and overall PVC sheathed cables to IS: 1554 shall be adopted.8 Lighting circuit design (a) In an area.16 SHEET 11 OF 16 1X 700 MW CCPP AT NEDUNOOR. 16. TCE.5960A-H-500-001 switch boxes. PVC inner sheathed. However wires of same phase but having different circuit nos.4.. Wiring (a) 1100 V grade stranded copper conductor. the cable shall be buried at a minimum depth of 750 mm from ground level. 16. For outdoor areas like transformer yard. KARIMNAGAR DIST. Minimum size of wires in case of conduit wiring shall be 2. shall be made up of 18 SWG sheet steel. Wires of different phases shall be run in separate conduits.7 (b) (c) (d) (e) 16.LIGHTING SYSTEM SPEC. PVC insulated wires to IS: 694 laid in GI conduits shall be used for lighting in nonhazardous area. The wiring in the conduit shall be such that 20% space in the conduit is free. SECTION: D3. can be run in same conduit. In the hazardous areas cable wiring with 1100 V grade stranded aluminium conductor. switchyard and road lighting also cable wiring as above shall be adopted.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. protective covers & markers. receptacle boxes etc.4. For outdoor lighting. Wires of AC and DC lighting systems shall be carried out in separate conduits. Wires of lighting and power receptacles will be carried out in separate conduits and on separate circuits. PVC insulated. Minimum cable size in case of cable wiring shall be 4 mm2 for lighting and 6 mm2 for receptacles. The circuit loading on each circuit shall be restricted to 80% of the MCB rating. the lighting fixtures shall be arranged in different phases/LPs such that even in case one lighting panel goes faulty complete lighting is not affected. NO. ELECTRICAL SYSTEMS .5 mm2 in case of lighting and 4 mm2 in case of receptacle wiring.4. 329 R5 .

the third core of each singlephase armoured cable circuit shall be used as earthing conductor. Lighting fixtures of each type Lamps of each type and rating.5960A-H-500-001 (c) (d) The voltage drop from LDB and any fixture shall not exceed 3%.(life cycle and rating test only) Lighting panel of each type (Degree of Protection) Junction Box of each type Receptacles of each rating M. 270 TCE FORM NO. Contractor shall demonstrate the same at location decided by Owner. iv.9 Earthing (a) Lighting fixtures. of each rating. For fixtures in hazardous areas. 16.1 Tests Type test reports of the following items as per relevant standards shall be submitted for approval.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.LIGHTING SYSTEM SPEC. ii. 25 X 6 GS Flat. NO. ISSUE R0 iii. SECTION: D3. The earth conductor shall be connected to the nearby main earthing grid at the first and last poles of each feeder circuit and at some intermediate poles.B. conduits and junction boxes shall be properly earthed using 12 SWG GI wire run along the entire length of the conduit between the fixture and the corresponding lighting panel where it will be connected to the station earth. switches. KARIMNAGAR DIST. junction boxes on the poles.5 16. shall be run buried in ground at a depth of 600 mm and tapped to each lighting pole. vi.16 SHEET 12 OF 16 1X 700 MW CCPP AT NEDUNOOR. 329 R5 .C. (b) (c) 16. i. TCE. v.4. receptacles. ELECTRICAL SYSTEMS .5. For outdoor earthing of lighting poles. The contractor shall submit design calculation for sizing of LDBs and also provide lumen contour for the main road and other areas.

6.LIGHTING SYSTEM SPEC.6.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.5.6.14 Waterproof Electric Lighting Fittings Watertight Electric Lighting Fittings 271 TCE FORM NO. TCE. KARIMNAGAR DIST. Type test certificates shall be furnished for review.13 16.16 SHEET 13 OF 16 1X 700 MW CCPP AT NEDUNOOR.3 16. Applicable Standards 16. 329 R5 .9 IS:4013 Part (I&II) IS:2148 IS:10322 Pt-V SECT-5 IS:10322 Pt-V SECT-3 IS:3528 IS:3553 ISSUE R0 16.11 Flame Proof Enclosure Flood Lights 16.7 16.6.6.6.2 All acceptance tests & routine tests for the lighting fixtures and accessories covered in this specification shall be carried out as per the relevant standards listed under "Codes and Standards” given below for the respective fixtures/ components.6.5960A-H-500-001 16.6.4 IS:6665 IS:3646 (Part-III) IS:1777 16. SECTION: D3.12 Luminaries for Street Lighting 16.6.8 IS:5077 IS:4012 IS:4013 IS:8224 16.6.6 16.1 Electric Lighting Fittings General and Safety Requirements Code of Practice for Industrial Lighting Calculation of Co-efficient of Utilisation Industrial Lighting Fittings with Metal Reflectors Decorative Lighting Outfits Dust Proof Electric Lighting Fittings Dust Tight Electric Lighting Fittings Electric Lighting Fittings for Division 2 Areas as per IS:5572 (P1) Flame Proof Lighting Fittings IS:1913 16. NO.5 16.6 16.10 16.6.6. ELECTRICAL SYSTEMS .6.2 16.6.

23 IS:2215 IS:3324 IS:1534 (Part 1) IS:7027 IS:6616 IS:1569 16.6.6.LIGHTING SYSTEM SPEC.6.33 16. ELECTRICAL SYSTEMS .6.6.5960A-H-500-001 16.17 Bayonet Lamp Holders Edison Screw Lamp Holders Bi-Pin Lamp Holders for Tubular Fluorescent Lamps Starters for Fluorescent Lamp Holders for Starters for Tubular Fluorescent Lamps Ballast for Use in Fluorescent Lighting Fittings Transistorised Ballast for Fluorescent Lamps Ballast for HP Mercury Vapour Lamp Capacitors for Use in Fluorescent.6.6.29 IS:2418 (Part 1) IS:9900 IS:418 IS:7569 IS:10322 Pt-III 16.16 16.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. SECTION: D3.26 16.31 16.30 16.19 16. HPMV & LP Sodium Vapour Discharge Lamp Circuits Vitreous Enamel Reflector for Tungsten Filament Lamp Tubular Fluorescent Lamps High Pressure Mercury Vapour Lamps Tungsten Filament General Electric Lamps Cast Acrylic Sheets for Use in Luminaires Screwless Terminal and Electrical Connections for Lighting Fittings High Pressure Sodium Vapour Lamps Emergency Lighting Units Ignition Proof Enclosures.22 16.27 16.6.34 IS:9974 IS:9583 IS:11005 IS:10322 IS 5578 IS 11353 ISSUE R0 272 TCE FORM NO.21 16. Main Connections and Auxiliary Wiring and Marking IS:1258 IS:10276 IS:3323 16.6.6.25 16.16 SHEET 14 OF 16 1X 700 MW CCPP AT NEDUNOOR. TCE.18 16. 329 R5 . NO.15 16.6.6.6.6.32 16.20 16.6.28 16.24 IS:8017 16. Dust-Tight for Electrical Equipment Luminaires (Part 1 to V) Arrangement for Busbars.6.6.6. KARIMNAGAR DIST.6.6.

Switch Disconnectors and Fuse Combination Units for Low Voltage Switchgear and Controlgear Miniature Air Break Circuit Breakers for AC Circuits HRC Cartridge Fuse Links upto 650 V Current Transformers Voltage Transformers Direct Acting Electrical Indicating Instruments AC Electricity Meters Electrical Relays for Power System Protection Flameproof Enclosures of Electrical Apparatus Guide for Selection of Electrical Equipment for Hazardous Areas Switches for Domestic and Similar Purposes Three-Pin Plugs and Socket Outlets Fans and Regulators.48 16.52 IS 3854 IS 1293 IS 374 ISSUE R0 273 TCE FORM NO.6.6.6.6.6.6.40 IS 13947 Part-3 16.LIGHTING SYSTEM SPEC.50 16.42 16. Ceiling Type.6. SECTION: D3.47 16. 329 R5 .49 IS 8828 IS 9224 IS 2705 IS 3156 IS 1248 IS 722 IS 3231 IS 2148 IS 5571 16.35 Enclosed Distribution Fuse Boards and Cut-outs for Voltages not exceeding 1000 V General Requirements for Switchgear and Control gear for Voltages not exceeding 1000V Code of Practice – Installation and Maintenance of Switchgear Factory Built Assemblies of Switchgear and Controlgear for Voltages upto and including 1000 V AC and 1200 V DC Degree of Protection of enclosed equipment for Low Voltage Switchgear and Controlgear Switches.6.6. KARIMNAGAR DIST.43 16.44 16.41 16.5960A-H-500-001 16.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.16 SHEET 15 OF 16 1X 700 MW CCPP AT NEDUNOOR.6.38 IS 8623 16. NO.45 16. ELECTRICAL SYSTEMS . Electric IS 2675 16.6.6.46 16. TCE.6.6.39 IS 13947 16.6.36 IS 4237 16.6.51 16. Disconnectors.6.6.37 IS 10118 16.

6.6.6. 329 R5 .6.54 Rigid Steel Conduits for Electrical Wiring Accessories for Rigid Steel Conduits for Electrical Wiring Flexible Steel Conduits for Electrical Wiring Rigid Non-Metallic Conduits for Electrical Installations Fittings for Rigid Non-Metallic Conduits PVC Insulated Cables for Working Voltages upto and including 1100 V Tubular Steel Poles Wrought Aluminium and Aluminium Alloys. Traction and Telecommunication Lines Methods of Test for Concrete Poles for Overhead Power and Telecommunication Lines IS 9537 IS 3837 16.53 16.16 SHEET 16 OF 16 1X 700 MW CCPP AT NEDUNOOR.6.61 16.64 IS 2905 ISSUE R0 274 TCE FORM NO.55 16.6. TCE.6.6.6.6. Rods.5960A-H-500-001 16.58 IS 3419 Part-2 IS 694 16. KARIMNAGAR DIST. SECTION: D3.57 16.56 IS 3480 IS 9537 Part-2 16. Bars.6.62 16.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. ELECTRICAL SYSTEMS .LIGHTING SYSTEM SPEC. NO.63 IS 6005 IS 2667 IS 13158 16.6.60 IS 2713 IS 5082 16.59 16. Tubes and Sections for Electrical Purposes Code of Practice for Phosphating Iron and Steel Fittings for Rigid Steel Conduits for Electrical Wiring Prestressed Concrete Circular Spun Poles for Overhead Power.

5. ISSUE R0 275 TCE FORM NO. ELECTRICAL SYSTEMS EARTHING & LIGHTNING PROTECTION SYSTEM SPEC. 17.1 17. 17. metallic structures are connected to have earth continuity for safety reasons.3 Size of Conductors (a) Main Earthing Conductors The earthing conductor sizes shall be calculated as per IS 3043 and shall comply with Indian Electricity rules and IEEE-80.1.5960A-H-500-001 17.1.8 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. 329 R5 .0 EARTHING SYSTEM Earthing system shall consist of earth grids and electrodes buried in soil in the plant area. TCE. KARIMNAGAR DIST. Earthing system shall be in strict accordance with IS:3043 and Indian Electricity Rules/Acts. NO. SECTION: D3. 17. embedded in concrete inside the buildings to which all the electrical equipment.2 Conductor Material The earthing system conductors and accessories as proposed are to be as follows : (a) Conductors above ground level : Galvanised steel and in trenches Conductors buried in ground or : Mild Steel embedded in concrete Electrodes : GS Pipe / Rod (b) (c) (d) Lightning protection air termination : GS Flat and down conductors for buildings Exposed lightning protection air : Lead coated copper termination on chimney top (e) The Contractor shall undertake the soil resistivity measurements at site and select suitable type and cross section of conductors.1 Design Criteria Fault Current & Duration The earthing conductor shall be designed for 50 kA for duration of 1 second.1.17 SHEET 1 OF 7 1X 700 MW CCPP AT NEDUNOOR.

5 The minimum steel corrosion shall be 0. However the min.5 4.0 7.12 mm/year. For test pits electrodes shall be heavy duty type (Class – C) GI pipe of suitable diameter with perforations. TCE. (d) Conductors for lightning protection system The size of conductors for lightning protection system shall be decided based on mechanical strength. SECTION: D3.17 SHEET 2 OF 7 1X 700 MW CCPP AT NEDUNOOR. Electrodes installed in the test pits will have disconnecting facilities. IEEE-80 and Indian Electricity Rules.2. 329 R5 . Resistivity of Soil Ohm– Metric >0 <10 >10 <25 >25 <50 >50 <75 >75 <100 >100 Reduction in thickness/diameter.2 TCE FORM NO.5960A-H-500-001 The calculated size shall be suitably (depending on the resistivity of soil) increased as per table below to account for the loss of material (steel) due to corrosion in soil. supporting structures adjacent to current carrying conductors. mm 8. lightning ISSUE R0 276 17. (b) Rod Electrodes Galvanised steel rod electrodes of suitable diameter (min dia 40mm) and length shall be used as per the recommendation of IS-3043. size of the of equipment earthing lead shall be 65x10 mm GS flat. General (a) Metallic frames of all current carrying equipment.5 3.0 5. ELECTRICAL SYSTEMS EARTHING & LIGHTNING PROTECTION SYSTEM SPEC.0 1.2. (c) Equipment Earthing Leads The size of the earthing leads shall be decided based on the type of equipment and structure to be earthed and shall be provided generally as per IS-3043.1 Earthing System Layout The earthing system design and installation shall generally comply with IS-3043. 17.2 17. NO.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. KARIMNAGAR DIST.

Neutral of the auxiliary transformers shall be directly connected to two nos. metal pipes and conduits shall also be effectively earthed at two points. one earth lead shall be provided. All cable trays in the plant buildings as well as inside the trenches shall be connected to earth grid at an interval of about 10 m.2. Metallic sheaths/screens. ISSUE R0 277 TCE FORM NO.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.. and rails etc. of the building housing electrical equipment shall be connected to the nearby earthing grid conductor by one earthing ensured by bonding the different sections of hand rails and metallic stairs. number of parallel conductors. Steel RCC columns. Metallic Sheaths and armour of single core cables shall be earthed at switchgear end only unless otherwise instructed by the Owner. etc.5960A-H-500-001 protection system conductors and neutral points of various systems shall be connected to a single earthing system. and armour of multi-core cables shall be earthed at both ends.17 SHEET 3 OF 7 1X 700 MW CCPP AT NEDUNOOR. treated pipe earth electrodes. appliances and welding equipment shall be earthed by flexible insulated cable (b) Earthing conductors in outdoor areas shall be installed at a minimum depth of 600 mm. tracks. ELECTRICAL SYSTEMS EARTHING & LIGHTNING PROTECTION SYSTEM SPEC. Crane rails. metallic stairs. 329 R5 . treated pipe earth electrodes. NO. The earth pipe electrodes shall be further interconnected to the buried earth grid. SECTION: D3. Metallic structures adjacent to electrical equipment shall be earthed by one earthing lead. (c) (d) (e) 17.3 Earthing Conductor Layout in Switchyard (a) Main earthing conductors shall be laid in the form of a grid. If the rated voltage is 250V or below. shall be decided such that step and touch potential are within safe limits. KARIMNAGAR DIST. The earth pipe electrodes shall be further interconnected to the buried earth grid. Spacing between conductors. Each side of the generator neutral earthing resistor shall be terminated at two nos. TCE. Every alternate post of the switchyard fence shall be connected to earthing grid by one GS flat and gates by flexible lead to the earthed post. Portable tools. Two earthing leads shall be used if rated voltage of equipment is above 250V.

steel columns. The earth grids of different areas of the plant shall be interconnected through separate conductors & with 2 Nos. each floor shall be provided with earth grid. All earth electrodes in turn shall be connected to station earthing system. the building has more than one floor.2. ELECTRICAL SYSTEMS EARTHING & LIGHTNING PROTECTION SYSTEM SPEC. test pits to enable measurement of earth resistance for each area separately.. lightning arrester earth leads. Minimum two taps-off from this earthing loop shall be taken inside the building and connected to the earthing grid embedded in the floor slab with approximately 50 mm concrete cover. CVT’s earth leads shall be directly connected to two separate electrodes. KARIMNAGAR DIST. etc. Earthing grid design shall be done in such a manner that the grid resistance is less than 0. This shall be connected to the switchyard earthing grid. NO.5 ohm. (c) (d) (e) (f) 17. In case. An earthing mat comprising closely spaced (about 150 mm) conductors shall be provided below the operating handles of disconnecting switches and breaker operating kiosk for the additional safety of the operating personnel.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. Each earth leads of transformer neutral.17 SHEET 4 OF 7 1X 700 MW CCPP AT NEDUNOOR. (b) (c) (d) ISSUE R0 278 TCE FORM NO. given in IEEE-80. Floor earthing grids shall be interconnected. steel pipes / conduits. Cable trays. with treated earth pits. test pits. Lightning protection down conductor shall be directly connected to a separate earth electrode. 329 R5 . Each RCC / Steel column of the building shall be interconnected to the floor earthing grid in the ground floor. TCE.4 Earthing Conductors Inside Building (a) Main earthing conductors shall be buried in earth around the building. shall not be used as earth continuity conductors. SECTION: D3. Earthing conductors shall be provided around the outside edge of fence at a distance of approximately 6000 mm.5960A-H-500-001 (b) The maximum permissible step and touch potentials shall be calculated in accordance with the formula.

. etc. Earthing grid design shall be done in such a manner that the grid resistance is less than 0.9 17. When earth conductor passes through floors. the welds shall be treated with zinc chromate primer and coated with zinc rich paint.4 17.3. their junction boxes shall be connected to the earthing conductor to be run along with supply cable.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. ELECTRICAL SYSTEMS EARTHING & LIGHTNING PROTECTION SYSTEM SPEC. at intervals of 750 mm. 329 R5 .3. operating handles.3. KARIMNAGAR DIST.3. Street lightning poles.5 ohm. (f) (g) 17. This earth conductor shall be in turn connected to earth grid at two extreme points.5 17.3.1 Earthing System Installation The spacing between two electrodes shall be atleast equivalent to twice the length of the electrode.7 17. shall be supported by suitable cleating.5960A-H-500-001 (e) Instrumentation system and computer system shall be provided with a dedicated earthing system suitable for the equipment and shall confirm to DCS manufacturer’s specification. SECTION: D3. Connection between the equipment earth lead and the grid conductor shall be welded. Flexible earth conductors shall be provided at expansion joints for earthing the gates. walls.10 TCE FORM NO. Earthing conductor running exposed on column.8 17. Earthing grids of all the buildings. flood light poles & towers.3.3.3.2 17. suitable pipe sleeves shall be provided and the same shall sealed after installation. etc. The earthing conductor crossing the road / track shall be laid in hume pipe or laid at a greater depth to avoid damage.3 17. ISSUE R0 279 17. Metallic conduits and pipes shall not be used as earth continuity conductor.3. TCE. etc.6 17.3 17. The connection between earthing pads / terminal to the earth grid shall be made short and direct and shall be free from kinks & splices. walls. NO. For rust protection. Equipment bolted connection after being checked and tested shall be painted with anti-corrosive paint / compound. outdoor yards shall be interconnected to form a single grid for the plant.3..17 SHEET 5 OF 7 1X 700 MW CCPP AT NEDUNOOR.

17. All bimetallic connections shall be treated with suitable compound to prevent moisture ingression.17 SHEET 6 OF 7 1X 700 MW CCPP AT NEDUNOOR.4 17.3. TCE.5960A-H-500-001 17. SECTION: D3.4. 17. Contractor shall demonstrate the effectiveness of earthing system by measurement of earth resistance. air termination system will comprise of horizontal circumferential conductors at the top.11 The cable sheaths. shall be provided with lightning protection. Alternate switchyard fence posts shall be connected to the earth grid.13 17. 329 R5 . rods interconnected by circumferential conductors will be provided at the apex of flue and also upon outer shell of the stack. etc. NO.. Calculation for sizing.1 Need for Protection The need for providing the lightning protection system shall be established by calculating risk index value for each building structure.4. as per procedure given in IS-2309 and any building whose over all risk factor is more than 10-5 (as per IS-2309). The air termination system will be formed by lead coated copper conductors to prevent corrosion of conductors due to flue gas. Lightning masts shall be provided for switchyard. ELECTRICAL SYSTEMS EARTHING & LIGHTNING PROTECTION SYSTEM SPEC. Lightning Protection System Lightning protection system shall consist of vertical air termination rods. For stack air termination. screens armour shall be earthed at both ends for multi-core cables. of lightning mast etc shall be furnished for approval of Owner.14 17. KARIMNAGAR DIST. test links and pipe electrodes.3. horizontal roof conductors.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. step and touch potential at different location. no.3. down comers. Shield wire shall be provided between gantry support & Power house building wall over phase conductors and shielding ISSUE R0 280 (b) (c) (d) TCE FORM NO.3.2 Lightning Protection System Layout (a) The lightning systems design and installation shall generally comply with IS: 2309 code of practice for the protection of building and allied structure against lightning. For single core cables the same shall be done at one end (switchgear end) only. For cooling towers.12 17.

3 Lightning Protection System Installation (a) Conductors of lightning protection system shall not be connected with conductors of safety earthing system above ground level. 17. Each down conductor shall be connected to a rod electrode which in turn shall be connected to the station earthing system through test links. NO. KARIMNAGAR DIST.5960A-H-500-001 network shall be connected to switchyard earth mat. For switchyard down conductors from the shield wires shall be run along the tower and connected to rod / electrode. All joints in the down conductors shall be welded type. the weld locations shall be treated to provide rust protection. The zone of coverage for the shield wires and 450 on end conductor shall be considered as 600 between two conductors. Each down conductor shall be provided with a test link at a height of about 1000 mm above ground level. All the metallic structures within a vicinity of 2000 mm shall be connected to the lightning protection conductors. SECTION: D3. Wherever welded. (b) (c) (d) ISSUE R0 281 TCE FORM NO.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. ELECTRICAL SYSTEMS EARTHING & LIGHTNING PROTECTION SYSTEM SPEC.17 SHEET 7 OF 7 1X 700 MW CCPP AT NEDUNOOR. 329 R5 . TCE. The down conductors shall be welded to steel structures at 1000 mm interval or cleated to wall at 750 mm interval. (e) Down conductors shall be as short and straight as practicable and shall follow a direct path to earth electrode.4.

fully integrated. It should have computer (PC) compatibility for data transmission. TCE. fully non-blocking principle. The system shall have 100% non-blocking feature. KARIMNAGAR DIST. The system shall be 100% fault tolerant. and PC shall have provision to come over office automation LAN. modular construction type.18 SHEET 1 OF 15 1X 700 MW CCPP AT NEDUNOOR.1.1 18.5960A-H-500-001 18. The system shall have compatibility for analogue telephone instruments. digital (key) telephone instruments. SECTION: D3. These cables shall be laid in the suitable conduits.0 18. which shall include 20 direct lines. (b) (c) ISSUE R0 282 TCE FORM NO. call times etc. The entire job shall be the scope of Bidder. These direct lines will be for the use of management cadre & control room staff for direct communication with P&T subscriber without operator intervention.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.1 COMMUNICATION SYSTEM Intrasite Communication System Intercom Telephone System (EPABX System) (a) Micro-processor based. modularly expandable digital electronics EPABX system with capacity of 600 ports extendable to 800 ports shall be supplied. One spare port for operator console shall be provided. The system shall be supplied with the operator console as an in-built feature. suitable for mounting in a non-air-conditioned area. Additionally two cables of 50 pairs each shall be laid from the plant EPABX system to the colony utility building as mentioned in the section C2. and the special feature telephones. ELECTRICAL SYSTEMS – COMMUNICATION SYSTEM SPEC. 329 R5 . The system shall be based on Pulse Code Modulation (PCM)/Time Division Multiplexing (TDM). The cable from P&T exchange to power plant EPBAX shall be included in the contractor’s scope. This EPABX shall be hooked to P&T system by 40 tie lines. Operator console shall be equipped with a PC with tracking provision for all calls. The system shall be equipped with necessary electronic cards for trunk lines and extension lines. NO. Redundancy for control and processor card shall be provided. housed in a weatherproof enclosure. Electronic cards with intelligent processors shall be provided. The state of the art technology shall be used for designing the system. The quantity of the trunk cards and extension cards shall be selected in such a way so as to provide 10% spare capacity.

the EPABX shall be provided with two Combo drives with provision and facility including software to store/retrieve all the above parameters to/from a disk. duration of each call. Using this software. Three (3) line man hand held telephone sets with DC pulsing and DTMF switchable with built in ringer unit and crocodile clip. FAX as well as connectivity to Wireless System specified in this section. KARIMNAGAR DIST. Computer (Local Area Network) LAN & Wide Area Network (WAN). One (1) operator console. SECTION: D3.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. (e) (ii) (iii) (iv) (v) (vi) (f) Call Billing software shall be provided with dedicated personal computer with SVGA colour monitor. software and any / all other accessories) for Integrated Digital Network (ISDN). One (1) float-cum-boost charger of suitable capacity to supply power to the exchange. pager/wireless set with number called. The system shall be so interconnected that it shall be possible to access any of the systems (Intercom/ Wireless) from any other system without human intervention in any way. 329 R5 . number of metered calls.5960A-H-500-001 (d) The EPABX system shall have connectivity (hardware. The battery charger shall be suitable for the High Discharge Plante Lead Acid battery specified above. EPABX system shall be provided with the following: (i) One (1) 48V DC High Discharge Plante Lead Acid battery of adequate AH capacity with 10% margin suitable for twelve (12) hours uninterrupted service of exchange working at 100% capacity including its allied systems. NO. Required number of telephone instruments. Dual Tone Multi-Frequency (DTMF) Connectivity. extension/wireless/fax set from which call was made. it shall be possible to read from screen/obtain a print out of calls made. date of each call. time at which each call was made. called station.18 SHEET 2 OF 15 1X 700 MW CCPP AT NEDUNOOR. The call billing software shall ISSUE R0 283 TCE FORM NO. ELECTRICAL SYSTEMS – COMMUNICATION SYSTEM SPEC. TCE. dedicated printer. Two (2) dial testers for DC pulsing and DTMF telephone instruments. Besides the above.

Telephone Instruments (i) The telephone instruments shall be indoor desk type or indoor wall mounted type or outdoor wall mounted type as required. TCE. Annunciation (audio and visual) shall be provided for each power supply unit fail and also auto-changeover fail. (h) (i) (j) (k) (ii) ISSUE R0 284 TCE FORM NO. On failure of main unit. ELECTRICAL SYSTEMS – COMMUNICATION SYSTEM SPEC. The locations shall be decided during detailed engineering. NO.5960A-H-500-001 also have facility for printing all / selected parameters listed above at regular (site adjustable) time intervals as well as facility to browse on screen/print any of the above parameters in any desired format eg. But the Bidder shall supply at least 200 telephone instruments. besides being annunciated by high intensity LED on the EPABX and audio alarm. None of the stored data shall be lost for failure of power supply. 329 R5 . It shall have provision of 100 lines for interfacing with colony. shall be displayed on the PC with component level fault being displayed in English. The EPABX shall be provided with 120% capacity main power supply unit with 100% standby power supply unit. standby unit shall automatically cut-in. SECTION: D3. All faults. All desk type instruments for all subscribers shall have keypad with push buttons. Software lock shall be provided to prevent unauthorised personnel gaining entry to above.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. The EPABX system shall be capable to accommodate the EPABX system of the colony (which is not in scope of Bidder). The type of handset shall be selected based on its location. KARIMNAGAR DIST. Changeover time shall not affect the EPABX/its allied systems in any way. (g) EPABX shall have full self-diagnostic feature. All above parameters shall be capable of being stored automatically for a minimum period of 3 months. The Bidder shall provide all the telephone instruments in the plant areas at each working areas.18 SHEET 3 OF 15 1X 700 MW CCPP AT NEDUNOOR. Number of calls made from a particular extension for a given period of time (selectable). Erasure of this information shall only be after adequate warning alerting operator to take back up.

This feature shall re-route a call for an extension (A) to extension (B).ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. The caller’s number shall be stored to reduce / prevent the incidence of mischievous calls. Emergency alert – Dialling a number shall intimate a fire or emergency alarm. (iv) (v) (l) The following special features shall be provided on selected instruments: (i) Call interruption / priority – the handsets shall be provided with a priority push button. While waiting for the call back. Conference call . NO. Broadband connectivity ISSUE R0 285 TCE FORM NO.This shall enable the subscribers to set up telephonic conference involving atleast 5 parties. who receive a busy tone when calling another extension to come on the busy extension. if engaged tone is received. (ii) (iii) (iv) (v) (m) 18. ELECTRICAL SYSTEMS – COMMUNICATION SYSTEM SPEC. TCE.1. KARIMNAGAR DIST. Landline Telephones. Automatic call back – This shall enable the selected subscribers. Selected instruments shall be provided with additional features to meet the special facility requirements as mentioned below. calling party can use his telephone for other calls as usual. This arrangement shall function for all calls till it is reset. Automatic call diversion .5960A-H-500-001 (iii) The instruments mounted outdoor shall be provided with weather proof type enclosure.2 Cell phones with group arrangement to be provided. Telephone instruments located in high ambient noise level area shall be provided with loud ringing device and sound proof booths. the caller can cut into the conversation by pressing the priority service button. 329 R5 . The call back equipment shall make the connection as soon as the called extension is free. SECTION: D3.18 SHEET 4 OF 15 1X 700 MW CCPP AT NEDUNOOR. After dialling from this handset station.

3 Walkie Talkie( Wireless system) 18. Battery charger for hand-set batteries – 20 Nos. TCE.1.1. The exact details of requirements. The system shall be capable of being coupled with the EPABX and PA systems such that any wireless set can be contacted from any of the EPABX-intercom extensions or PA system and from the DTMF keypad of the portable radios it should be possible to contact any of the EPABX – intercom number through the EPABX. ELECTRICAL SYSTEMS – COMMUNICATION SYSTEM SPEC.1. installation design and specifications shall be worked out during detailed engineering. 18. ISSUE R0 286 TCE FORM NO. The mobile system shall be interfaced with plant EPBX and PA systems. The system shall have a minimum operating range of 15 kms between one base station to another base station. voltage stabilisers and all other accessories. Handset to handset is about 3 kms. to allow the radio communications during “Black Out” conditions also.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. hand held two way transmitter receiver sets.1 This system shall include the following: (a) Base stations with antennae. Range from base station to handset is about 8 kms. Broadband connectivity would be provided at strategic locations for online access of data from remote station. (b) (c) (d) (e) (f) (g) (h) 18.3. power supply units. inverters.2 GPRS/CDMA mobile system of any reputed service provider can be provided for wireless system.18 SHEET 5 OF 15 1X 700 MW CCPP AT NEDUNOOR. NO.5960A-H-500-001 a) Necessary number of ISDN / PSTN landlines would be provided at strategic locations within the plant boundary. The power supply to the entire base stations shall be through the UPS. Twenty (20) Nos. 329 R5 . The mobile system coverage in the power plant area should be 100%. The wireless sets shall be addressable type and light weight. SECTION: D3. But the contractor shall consider the modern communications system with above specifications for the purpose of bidding. KARIMNAGAR DIST.3.

2. whether these are specifically mentioned herein or not. TCE. ELECTRICAL SYSTEMS – COMMUNICATION SYSTEM SPEC. 329 R5 . sub-zones and Exchanges to interface all these zones among them selves. earth wire and accessories like standard brackets.. etc. type testing.1. The Contractor’s scope shall also include successful demonstration of performance testing specified herein complete in all respects along with cables.2 18. glands.5960A-H-500-001 18.1 Public Address System General Requirements This specification covers requirements for selection.5. 18. engineering. NO. manufacture. The zones shall also cover all off-site Plant Auxiliary Systems and shall be finalized during detailed engineering. IS: 1882 of all the equipments supplied as covered in this specification. SECTION: D3. design. 18. Type test certificates shall be submitted for review. All the above-mentioned zones shall be connected with a central exchange to be located in Control room/ Control Equipment Room. conduit sleeves. as required.1.18 SHEET 6 OF 15 1X 700 MW CCPP AT NEDUNOOR. taking into consideration the configuration of the combined cycle plant.5 Tests All the equipment covered in this specification shall be subjected to routine tests as per relevant standards. to complete the proper installation conforming to IS: 1881. junction boxes. shop testing.4 Cables The type of cables and their technical particulars shall be as per the requirement of the system for giving best performance. (b) (c) ISSUE R0 287 TCE FORM NO. lugs. KARIMNAGAR DIST. All equipment. accessories and facilities required for completeness of this system shall be furnished by the Contractor. nut-bolts. erection and commissioning of Public Address System as described below: (a) The Public Address System shall consist of zones.9 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.

3 System description (a) Communication within a zone ISSUE R0 288 TCE FORM NO. TCE. cable erection hardware.1/ IEEE standard 472-1989 equivalent.5960A-H-500-001 (d) The equipment furnished under this section shall meet the requirements of all-applicable codes and standards as specified or their equivalent international codes and standards. including Public Address system erection hardware.2.2. as may be required to make the PA system complete and functional are to be furnished by the Contractor on as required basis. to make the offered system compatible with specified power supply arrangement. The details shall be finalized during detailed engineering stage. 18. the Bidder shall provide all required hardware. The system shall be adequately protected from signal and power line noise and meet the Surge Withstand Capability (SWC) requirements of ANSI C37. In case the Bidder's offered equipment is operating at any other voltage level. The design and manufacture shall be such that equipments/ components of same type and rating shall be interchangeable. (e) (f) (g) (h) (i) 18. ELECTRICAL SYSTEMS – COMMUNICATION SYSTEM SPEC.90. telephone cables etc.14 of technical specifications. tested and commissioned a distributed amplifier type industrial Public Address systems as specified in power plants or large industrial installation as on the date of bid opening.2 Power supply arrangement The Bidder shall provide power to the Public Address System from UPS system as detailed in Section D3. All the items.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. The Bidder shall guarantee satisfactory performance of the equipment under stipulated variations of voltage and frequency. cables. 329 R5 . KARIMNAGAR DIST. manufactured. The Public Address System (PAS) offered by the Bidder shall be from reputed manufacturer who should have designed. In addition to the facilities to be provided by the Bidder as mentioned in relevant clauses of this section the Bidder shall make his own arrangements for any other requirements that are necessary to put the system in service. SECTION: D3. NO. The system shall be fully functional during the total power supply failure of the plant.18 SHEET 7 OF 15 1X 700 MW CCPP AT NEDUNOOR.

some handsets on party channel and some handsets on paging channel. Paging mode shall be used for locating a person and for general instructions. Each of the two modes shall be open line. SECTION: D3. Portable type handsets with Multipin plugs shall be used at certain locations where operational personnel are not present normally. The locations (distributed in each zone) etc. shall be provided at these locations. shall be possible without any crosswalk between the two channels. i.5960A-H-500-001 (i) PAS shall have two modes. ISSUE R0 289 (ii) (iii) (iv) TCE FORM NO. When 'Press to Page' push button is released. ELECTRICAL SYSTEMS – COMMUNICATION SYSTEM SPEC. Whenever the 'Press to page' push button is pressed on any of the handset stations. During conversation on 'page' mode within a zone.. When a handset station is being used for party mode. common talking type.. announcements/ communication within a zone shall not be audible in other zones. etc.e. the centralized equipment/hardware of the associated zone shall have the feature to monitor and identify the handset from where conversation is being continued with the 'page' button depressed and the access code of the person. KARIMNAGAR DIST. the operator shall have the option of silencing the associated loudspeaker by pressing "Loudspeaker mute' push button.18 SHEET 8 OF 15 1X 700 MW CCPP AT NEDUNOOR. the associated handset shall return to party mode. Paging mode and Party mode. NO. shall be finalized during detailed engineering. a pleasant chime shall be broadcast over all loudspeakers except the one associated with that handset station to attract attention. Conversation. should he find it disturbing his conversation on party mode. suitable indication of 'Power Supply on' and 'Party channel busy' shall be provided on hand set stations. Simultaneous operation on both modes. Party mode shall be used for conversation between individuals without broadcasting the same over the loudspeaker.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. Necessary sockets. 329 R5 . in paging mode shall be heard over all loudspeakers except the loudspeaker associated with the handset station whose 'Press to Page' push button is being held in pressed condition. i. The loudspeaker shall return to normal operation automatically when the 'loudspeaker mute' push button is released. its associated loudspeaker shall be free to receive all paging calls. Further.e. wiring. TCE. However. Unless requested.

It shall be possible from a station in one zone to communicate with another station in a different zone. Communication/ announcements within a zone shall not be heard in loudspeakers of other zones. 329 R5 . music etc.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. TCE.(Type . The exact type of the same shall be decided during detailed engineering. KARIMNAGAR DIST.2.5960A-H-500-001 (b) Inter Zone Communication (i) Each of the zones shall be connected to a Central exchange to be located in Central Control room/ Control Equipment Room. All the communication facilities like paging and party mode communication as described above between these two zones shall be possible as if they have now become a single zone. it shall be possible to broadcast recorded speech. All the master control units shall be connected in parallel.18 SHEET 9 OF 15 1X 700 MW CCPP AT NEDUNOOR.4 Handset Stations (a) Handset stations shall be of the following types: (i) (ii) Outdoor Wall/ column mounting type. (ii) (iii) (iv) (v) 18. Any inter-zone communication shall be possible through this master control unit. both in party/ page mode through the master control units located on each module control desk at Control room and Shift Incharge Room. Suitable built-in interface shall be provided for connection with Owner's main telephone exchange in the Central Exchange and/or Master Control Units through which it shall be possible to communicate with any station in any zone from any telephone set through Central Exchange and/or Master Control Unit. The Central Exchange shall have one master control unit for each of the modules and one more master control unit for Shift In charge Room. ELECTRICAL SYSTEMS – COMMUNICATION SYSTEM SPEC. (Type . It shall be possible to communicate from a station in one zone to another station in other zone through the master control unit(s) only. SECTION: D3.A) Indoor desk-top mounting type. NO.B) ISSUE R0 290 TCE FORM NO. Further. over the loudspeakers.

The outdoor wall/ column mounting type handset stations shall have covers with padlocking facility. One (1) . All handset stations and their components shall be capable of continued satisfactory operation at an ambient temperature at 55°C. robust. All handset stations shall have a compact.18 SHEET 10 OF 15 1X 700 MW CCPP AT NEDUNOOR. ingress of dust and moisture conforming to IP-55 degree of protection as per IS: 2147. (c) The outdoor wall/ column mounting type handset stations shall be dust-tight and weather-proof.C) Mosaic grid compatible telephone set. 329 R5 .D) Each handset station shall have following: (i) (ii) (iii) (iv) (v) (vi) (vii) One (1) . One (1) . KARIMNAGAR DIST. NO.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. The control-desk mounting type handset stations shall be suitable for flush mounting on Unit Control desk. Pre-amplifier and Power amplifier.5960A-H-500-001 (iii) (iv) (b) Indoor control desk flush mounting type. The indoor desk-top mounting type handset stations shall have a degree of protection of at least IP-32. TCE."Press to Page" push button.telephone handset. Handset transmitter/microphone shall have filters to protect from dust. rust resistant.Cradle switch for resetting the handset. shock-resistant body made of high impact polystyrene or ISSUE R0 291 (d) (e) (f) TCE FORM NO. SECTION: D3. (Type . Handset transmitter/ microphone shall be noise canceling type and all switches and push buttons provided on the handset station shall be of encapsulated contact type. ELECTRICAL SYSTEMS – COMMUNICATION SYSTEM SPEC. Each handset shall be provided with one meter (extended) retractable coiled type of cable. Indication for 'POWER SUPPLY ON'. Indication for 'PARTY CHANNEL BUSY'. One (1) -"Press to Mute Loudspeaker" push button. (Type . with appropriate protection against direct rain.

with facility for coarse and fine setting along with following controls which shall be located inside the Handset Station. An industrial type free standing. in built with the handset fully conforming to IS: 1301 & IS: 10426 or equivalent international standard. counter-sunk) screws which can be loosened only with special keys. (i) (ii) (iii) (iv) Input sensitivity control Receiver volume control Bass cut filter Anti side tone control feature (b) 18. triangular head. (h) 18.6 Loudspeakers (a) Indoor loudspeakers shall be cone type housed in sturdy metal cabinet suitable for wall/ column mounting. BFPs. Terminal connections of different PCBs should not be interchangeable.5960A-H-500-001 equivalent. class-B. etc. The handset stations in the noisy areas like Turbine Hall. The Type-A handset shall be inside an enclosure with transparent glass door.18 SHEET 11 OF 15 1X 700 MW CCPP AT NEDUNOOR. Amplifiers shall have 0-100% volume control setting. TCE. KARIMNAGAR DIST. floor mounted hood shall be used for providing the above requirements.2. NO.2. Push-pull type. shall be housed in Acoustic hoods. 329 R5 . The cabinet shall be ISSUE R0 292 TCE FORM NO. (g) The wall/column mounting handset stations shall be tamper-proof. using internal anchoring bolts and peculiar (e. The design noise level within the hood shall be limited to a maximum of 60 dB SIL. SECTION: D3.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. which can be opened through number padlock only.5 Amplifiers (a) Amplifiers shall be solid state. Constructions where the entire electronic part shall be modular type and can be removed from the handset station enclosure for easy maintenance. ELECTRICAL SYSTEMS – COMMUNICATION SYSTEM SPEC..g.

it shall be possible to announce any message from any intercom phone and then communicate with the handset selected by field user on party line. measurement of all the voltages and load conditions of the entire system. required for operation. All the handsets shall have the necessary arrangement for using it as a intercom telephone instrument. NO. Suitable hardware for communication between any handset of the Public Address System with Owner's Telephone Exchange shall be provided. all the programming tools that will be required to program/reprogram the system shall also be provided.2. (b) ISSUE R0 293 TCE FORM NO. SECTION: D3. KARIMNAGAR DIST. They shall have IP-55 degree of protection as per IS: 2147.18 SHEET 12 OF 15 1X 700 MW CCPP AT NEDUNOOR. indication. Also. protection.7 Central exchange & master control unit (a) Central exchange shall be wide band microprocessor based having associated circuitry for calling station identification and of modular design. fire alarm tone generation etc. They shall have IP-52 degree of protection as per IS: 2147. Systems bandwidth shall be at least 200-10 kHz (±10 dB) and shall not alter frequency response of the open line system. 329 R5 . (b) Outdoor loudspeakers shall be industrial horn type and of pressure die cast aluminum construction. facility for checking of the operation of all the stations and quality of speech from the master control units etc. testing.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. alarm tone generation. It shall be possible to call to any of the intercom number from any handset. 18. shall be plug in type. This shall be able to cater all the specified zones along with the ability to interconnect at least ten (10) more zones for future expansion. monitoring.5960A-H-500-001 treated with acoustic under-coats to prevent resonance. The mounting bracket shall be with adjustable base suitable for vertical and horizontal orientation. switching. Master Control Units shall be microprocessor based and of modular design. ELECTRICAL SYSTEMS – COMMUNICATION SYSTEM SPEC. These units shall be mosaic grid compatible flush mountable type along with flexible goose neck type microphone. All the central exchange shall be enclosed in a freestanding cabinet to be located in control equipment room all the cable entries shall be from bottom only. luminous miniature push buttons for inter-zone communications. This exchange shall consist of all the necessary control hardware. All the card etc. Solderless termination shall be provided for every wiring. TCE. Further.

Mains cable : Multicore of minimum 1. minimum 0.2. SECTION: D3.5960A-H-500-001 18. TCE. twisted pair.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. KARIMNAGAR DIST.9 Junction boxes The junction boxes shall be supplied on as required basis.18 SHEET 13 OF 15 1X 700 MW CCPP AT NEDUNOOR. Loud Speaker cable 18. twisted pair. The cables shall be of FRLS type.2. NO. ELECTRICAL SYSTEMS – COMMUNICATION SYSTEM SPEC.5 mm² cross section annealed copper (shielded and armoured) : Multicore multistrand with at least two spare cores. minimum 0. 18.8 Cables and junction boxes The Contractor shall supply the cables required for PA system on as required basis.2. Signal cable c.5mm² cross-section Copper conductor cable armoured with atleast two spare cores. Colour of the outer sheath shall be YELLOW. : Multicore multistrand with at least two spare cores. Sizes and details of cables are given below : a.5 mm² cross section annealed copper (shielded and armoured) b.10 Technical particulars Public Address Systems shall conform to the following technical parameters. 329 R5 . (i) Overall Installation Band width (± 3 db) (ii) Amplifiers (a) (b) Band width (± 3 db) THD 200-10000 Hz not more than 1 % at 1 kHZ at rated output 60 dB 400-6000 Hz (c) Signal to Noise Ratio (iii) Microphones ISSUE R0 294 TCE FORM NO.

----------------------------------------------------------------------------------------------S.) 10 3 (iii) 2 2. ELECTRICAL SYSTEMS – COMMUNICATION SYSTEM SPEC. Loudspeakers (i) Outdoor Industrial Horn type .(nos. NO.) Indoor desktop mounting type with extension amplifier.) 30 10 ISSUE R0 295 TCE FORM NO.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.2.5960A-H-500-001 (a) (b) Band width (±3 db) Type 200-7000 Hz Noise canceling type (iv) Loudspeakers (a) Outdoor wall/column mounted Horn Type Capacity Bandwidth(± 3 db) Indoor wall/column mounted Cone Type Capacity Bandwidth (± 3 dB) 4W (RMS) 200-7000 Hz 15W (RMS) 200-7000 Hz (i) (ii) (b) (i) (ii) 18.(nos.18 SHEET 14 OF 15 1X 700 MW CCPP AT NEDUNOOR. TCE.No Item Description PAS For Common Plant (for each module) -------------------------------------------------------------------------------------------------1. Handset Stations (i) (ii) Outdoor wall/column 30 mounting type . (nos. 329 R5 . SECTION: D3.11 The quantities for PA system mentioned below are minimum required and will be finalised at the time of detailed engineering. KARIMNAGAR DIST..(nos.) Indoor control desk 2 mounting type with extension amplifier.

As required Signal cable .(km).) Portable handset stations with plug (nos.I. Cables (i) (ii) (iii) Mains cable .) 2 4. 329 R5 . only. Rigid conduit on as required – As Required (Sizes to suit the cable) Acoustic hood (nos. 8.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. KARIMNAGAR DIST. Mosaic grid compatible telephone set Portable handset stations with multi-pin plug and sockets (i) (ii) Sockets-(nos. 7.I. ISSUE R0 296 TCE FORM NO. As required 6.) Master Control Unit 8 1 9. NO.) 2 3 3. ELECTRICAL SYSTEMS – COMMUNICATION SYSTEM SPEC. G. for interconnection of loud speaker with handset station. earthling wire-(km) As required Junction boxes – As required G.(km) As required Loudspeaker Cable-(km). TCE.(nos.18 SHEET 15 OF 15 1X 700 MW CCPP AT NEDUNOOR. 10.5960A-H-500-001 (ii) Indoor wall mounted Cone type. SECTION: D3. 10 2 5.

TCE.19 1X 700 MW CCPP AT NEDUNOOR.1 FIRE DETECTION AND ALARM SYSTEM Fire Detection and alarm system shall be redundant Microprocessor based intelligent.2.2 19. Central Mining Research Institute (CMRI).0 19.4 19. Fire Officer’s Committee (FOC). ELECTRICAL SYSTEMS FIRE DETECTION AND ALARM SYSTEM SHEET 1 OF 5 SPEC. Fire detectors shall discriminate between false and real fire.5960A-H-500-001 19. NO. 329 R5 . It shall give a pre-alarm when it requires maintenance. SECTION: D3.72E IS .1 19. fire alarm panel. manual call points.3 19. analogue addressable type.2175 The system shall be approved by any or all the following bodies besides Tariff Advisory Committee (TAC) and Local Fire Authorities. National Fire Protection Association (NFPA).2 19. cables. It shall have automatic calibrating features by decreasing/ increasing sensitivity levels.2. Underwriters Laboratory (UL). Fire alarm system shall be designed to provide continuous surveillance against fire in the areas covered by the system under all conditions. fire warning siren.5 Rate of rise of temperature detector with fixed temperature element (corrosion proof) and MCPs ISSUE R0 297 TCE FORM NO. any other items to complete the system shall be provided for the power plant.2.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. The equipment/system supplied shall comply with the standards listed below: IS . The type of detectors to be provided in the various areas of the plant shall be as indicated below: Area GTG / STG Building Switchgear room. Battery charger room Control & electronic Cubicle rooms Battery room Type of Detector Manual call points (MCP) & UV detectors Multi sensor detector & MCPs 19. Factory Mutual (FM). Dhanbad. KARIMNAGAR DIST.3 19. Fire detection and alarm system comprising automatic fire detectors. junction boxes.2189 NFPA .

The Sensor cable shall be Optical fibre LHS cables. ELECTRICAL SYSTEMS FIRE DETECTION AND ALARM SYSTEM SHEET 2 OF 5 SPEC. interface units and necessary hardwares required for installation. To meet this requirement the detector shall respond to visible combustion products in the form of smoke as well as in visible particles.19 1X 700 MW CCPP AT NEDUNOOR.9.6 Pedestal mounted MCPs Rate of Rise of Temperature Detector with Fixed Temp. KARIMNAGAR DIST.7.5960A-H-500-001 Below false floor of Control room Above false ceiling of Control room Cable galleries Photoelectric smoke detector and linear heat sensor cables Multi sensor detectors Photoelectric smoke detectors and liner heat Sensing cables Fuel gas pump house Flame proof type MCPs Transformer yard & switchyard 19.8 19. NO. aerosols and pyrolysis products from a clear burning fire.9. 19.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. 329 R5 ..1 Linear Heat Detection System (LHS) Linear heat detection system shall be provided in area below false floor & in cable galleries. Element These shall be resettable type i.1 Multi Sensor Detectors This detector shall be capable of detecting a fire both in its incipient or smouldering stages as well as visible flames.7 19.e.3 ISSUE R0 298 TCE FORM NO.9. Linear heat detection system shall essentially comprise sensor cables. 19. 19. Optical Smoke Detectors Optical smoke detectors shall work on light scattering principle. the same detector shall be capable of being reset after it goes to the alarm state. SECTION: D3. TCE.9 19.2 19.

so as to obtain complete coverage.10.. Main Fire Alarm Panel Fire alarm system shall be redundant Microprocessor based intelligent.5960A-H-500-001 19. they shall generally be located near all the entrances/exists for all buildings.5m.15. etc. KARIMNAGAR DIST. The sensor cables in cable vault end shall be supported from ceiling to cover the top most tray and from underside of the cable trays for bottom tiers. response indicators with test switch shall be mounted directly below the detector (on the false roof).10 19. in view of value concentration. etc. 329 R5 .13 19. external hooter/lamp control. response indicator for each of the detectors and test switch shall be mounted on a separate box. TCE. Contractor shall prepare layout drawings indicating the locations of detectors. manual call points duly taking into account the regulations of local fire authorities and submit for Owner’s approval. SECTION: D3.4 Linear heat sensor cables shall be run on all the trays below the false floor of the control room.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. 35 to 40 sq. When the detectors are mounted below the false floor or in inaccessible position. output modules.. However.1 TCE FORM NO.15 19.1 19. ELECTRICAL SYSTEMS FIRE DETECTION AND ALARM SYSTEM SHEET 3 OF 5 SPEC. Also.19 1X 700 MW CCPP AT NEDUNOOR. The quantity of fire detectors and call points to be installed in each of the areas shall be based on an average coverage area mentioned below.10. the actual quantity of detectors required. taking into consideration the obstruction due to floor beams. shall be complete with annunciator (with windows) provided with necessary input modules. 15 to 20 sq. analogue addressable type. NO.m per smoke detector for general application areas considering an average room height of 5.14 19. The zones of individual detectors shall overlap and no blind zone shall be left. shall be worked out by the Contractor based on the final drawings of the various buildings during detailed engineering. interface units wherever required for various control functions through relay contacts & communication ISSUE R0 299 19.2 19. Each detector shall be provided with an indicating lamp glowing steadily to indicate that it has operated which will otherwise flash intermittently to indicate the healthy condition of the detector and sensing circuits.9.11 19. which shall be suitable for mounting on the wall.m per detector for I&C panel room. relay room. control room.12 19. Manual call points shall be provided as per the guidelines listed in NFPA 72E/IS 2189. If the detectors are mounted above the false ceiling.

15. push buttons. STG hall. 19. The panel shall be located in the control room.19 1X 700 MW CCPP AT NEDUNOOR. interlocks etc. All the constructional/functional features of this panel shall be same as the main fire alarm panel.15.2 The main fire alarm panel will continuously monitor the status of the detectors and the connecting lines. ELECTRICAL SYSTEMS FIRE DETECTION AND ALARM SYSTEM SHEET 4 OF 5 SPEC. etc.4 Contacts for initiating fire protection system. switchgear room.15.3 Necessary grouping of the detectors/call points to actuate the above shall be done by the contractor and the same shall be subject to Owner’s approval. The detectors proposed to be provided for 400kV switchyard area shall be connected to an independent fire alarm panel (with battery back-up) located in Switchyard control room. A dedicated operator station shall provide in the Main control room.15.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. The battery shall supply the normal power requirements for a period of 48 hours from the instant of charger AC supply failure.5 19. Full load being defined as the load of all hooters sounding simultaneously along with operation of all the associated visual signals. I&C panel room. for satisfactory operation of the system. This panel shall be suitably interfaced with the main fire alarm panel in power plant control room. test. 19. after which sufficient capacity would still be available to provide full load operation for atleast 30 minutes. lamp test.5960A-H-500-001 modules. The paint shade of panel shall be shade Opaline green (External) and semi glossy white (Internal). Necessary interface shall be provided between the fire alarm panel and plant DCS for monitoring the system. reset. KARIMNAGAR DIST.Control room. 329 R5 . etc. SECTION: D3.GTG hall. Main fire alarm panel shall be provided with necessary contacts for performing the following functions. High discharge plante Lead Acid batteries and battery chargers adequate capacity shall be provided. NO. Relay room . The annunciation system shall have visual and audible alarms. TCE.15. (a) Tripping of the air conditioning and ventilation system in the . battery room&any other area which is air conditioned /forced ventilated of the affected area.6 ISSUE R0 300 TCE FORM NO. with acknowledge. The panel shall have 'ON / OFF' PBs for operation of fire siren. (b) 19. 19.

15 Tests Contractor shall furnish test certificates/approval certificates for the equipment/ system offered from the Regulatory bodies indicated in the specification after the award of contract for Owner’s approval.7 19.15.5960A-H-500-001 19. 329 R5 .15. The repeater panel shall be located in the fire station.1 Cabling The cables shall conform to specification indicated in Section D3. Canteen. 19. Performance tests shall be conducted at site on the system to prove that the guarantees indicated for the individual components shall completely satisfy all specific requirements.8 Visual alarm shall be povided in all the Control rooms.19. The cabling upto the repeater panel is included in the Contractor’s scope. Degree of protection shall be IP-65. 19.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. All the fire alarm panels in the plant shall be of the same make. This shall include the annunciations/indications of fire alarm panel located in switchyard control building.2 ISSUE R0 301 TCE FORM NO.19 1X 700 MW CCPP AT NEDUNOOR. offices.10 The main fire alarm panel in the control room shall communicate with all the fire alarm provided in the Gas / Steam Turbine area & in any other if any. 19.18 19.16 Repeater Panel All annunciation / indications in the main fire alarm panel shall be repeated in the repeater panel to be supplied by Contractor. conference halls and any other place where the sound of the fire siren is not audible. The paint shade of panel shall be shade Opaline Green (External) and semi glossy white (Internal).19 19. All tests required by the relevant standards shall be conducted. Electronic cubicle room.1 19.18. SECTION: D3.15.17 Junction Boxes (JB) Junction boxes required for indoor and outdoor installations shall be 2 mm thick sheet steel and shall be hot dip galvanised. KARIMNAGAR DIST.15. 19. Suitable size & number of the sirens shall be used so that is audible in all the direction & parts of the station.19. TCE. 19.9 19. ELECTRICAL SYSTEMS FIRE DETECTION AND ALARM SYSTEM SHEET 5 OF 5 SPEC. NO.

6 ISSUE R0 302 TCE FORM NO. KARIMNAGAR DIST.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. The supply voltage and frequency variation for 6. The locked rotor withstand time under hot condition at 110% rated voltage shall be more than the starting time at minimum permissible voltage specified above by atleast three seconds or 15% of the accelerating time whichever is greater.20 SHEET 1 OF 10 1X700 MW CCPP AT NEDUNOOR. Provision of speed switch shall be avoided to the extent possible. the pull out torque of the motor shall be atleast 205% of full load torque.0 20. NO. Motors shall withstand for 1 second the voltage and torque stresses developed due to the vector difference between the motor residual voltage and the incoming supply voltage equal to 150% of the rated voltage during fast change over of buses. Motors shall be capable of developing the rated full load torque even if the supply voltage drops to 70% of the rated voltage.5 20. ELECTRICAL SYSTEMS . The motors rated 175 kW and above shall be 6.1.1.2 20.1.1 AC Motors The motor and its accessories shall generally comply with the requirements specified in the national and international standards indicated in Data sheetA3.20 and specific requirements indicated below: All HT motors shall be suitable for 6.MOTORS SPEC.20. crane motors shall be rated for S4 duty.1 20. If such operation is envisaged for a period of one second. Locked rotor current of motors rated 1500 kW and below shall be limited to 600% inclusive of 20% tolerance of the full load current of the motors and motor rated above 1500 kW shall be limited to 450% (inclusive of 20% tolerance) of full load current of the motor. 3 Phase. 50 Hz and LV motors shall be suitable for 400 V. 329 R5 . 50 Hz power supply. The combined voltage and frequency variation shall be of 10%.5960A-H-500-001 20.6 kV. Also Motors shall additionally comply with the specific requirements of data sheet – A3. The motors shall be suitable for starting at 110% of the rated voltage. SECTION: D3. However. Motors shall be continuously rated (S1).1. commencing from hot condition. All LT motors shall be energy efficient. 40% cyclic duration factor. HT motors shall also be capable of satisfactory operation at full load at a supply voltage of 80% of the rated voltage for 5 min. TCE.1.4 20.3 20. Motors shall be capable of starting and accelerating the load with the applicable method of starting without exceeding acceptable winding temperatures when supply voltage is 80% of the rated voltage for HT motors and 85% for LV motors. 20.1.6 kV & 400 V shall be ±10% and +3/-5% respectively.6kV and motors rated upto 175 kW shall be 400 V. 3 phase.

8 20. current transformers. SECTION: D3.1. 6.7 The degree of protection for the motor enclosure shall be IP-55 and IP-54 for outdoor & indoor respectively and outdoor and indoor cable boxes shall be provided with IP-55 and IP-54 respectively. The three phases shall be connected to form the star point after they pass through the CTs. The CTs shall be of relay accuracy and the CT characteristics shall be compatible with the differential relay. 6 nos. For 6. 329 R5 .20 SHEET 2 OF 10 1X700 MW CCPP AT NEDUNOOR. 20.1.9 20.1. Motors rated 1000 kW and above shall be provided with differential protection.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. These motors shall be provided with star connected stator windings. TCE. maximum double amplitude vibrations upto 1500 rpm shall be 40 microns and 15 microns upto 3000 rpm. CTs of identical characteristics shall be provided in the 6. In addition to temperature monitoring & alarms in DCS local temperature indicators shall be provided for motor bearings.6kV & 400V motors wherever their protection is through the numerical relay then energy meter reading shall be taken through relay itself by communicating with it.1. The additional 3 nos. All HT motors shall be provided with vibration pads (in both X & Y directions and at both DE & NDE) for mounting vibration detectors.6 kV switchgear panel.1.MOTORS SPEC. The maximum double amplitude vibrations for motors upto 1500 rpm shall be 25 microns and 15 microns upto 3000 rpm.5 metre from the outer surface of the motor shall not exceed 85 db(A).11 20. ELECTRICAL SYSTEMS . Each bearing shall be provided with duplex thermocouple for bearing temperature monitoring. Motor bearing shall not be subjected to external thrust loads. KARIMNAGAR DIST.13 ISSUE R0 303 TCE FORM NO.10 The ring oiling system shall be adequate for starting and continuous operation of the motor for atleast one half hour without pressure oiling system in operation.1. The 3 nos. These motors shall be designed to withstand atleast 2% unbalance in supply voltage. NO.1. one for each phase shall be mounted in a separate compartment in the neutral side terminal box.6 kV motors. 20.5960A-H-500-001 20. Maximum noise level measured at a distance of 1. Requirements of vibration monitoring system shall be as specified in relevant I&C section of specification. duplex RTDs for winding shall be provided.12 20. For 400 V motors.

Torque speed characteristics of motor superimposed on torque speed characteristics of drive equipment at 100%.3. All terminal boxes shall be provided with two earthing studs for termination of protective earth conductor.15 20. 329 R5 .2 / 50 microsecond wave and shall withstand a power frequency voltage of 14.1.1. Terminal boxes shall have fault withstand capacity equal to at least rated short circuit level of the system voltage for 0.3 / 3.25 sec.1.2. Variable frequency controller shall be provided for motors requiring speed control. KARIMNAGAR DIST.1 Actuator Motors The actuator motors shall be designed for short time duty (S2) in accordance with IEC 60034-1.1.1. ELECTRICAL SYSTEMS .17 20. All 6. NO. TCE.19 20. 20. The terminal boxes shall be reversible to suit cable entry from bottom or top. Canopy shall be provided for outdoor motors. DC Motors DC motors shall be suitable for the DC system voltage available in the plant.1. when the supply voltage is in the range of 85% to 110% of rated motor voltage. The insulation system for 6.5960A-H-500-001 20.20 20.6 kV AC motors shall have BIL of 36 kV (Peak) 1.20 SHEET 3 OF 10 1X700 MW CCPP AT NEDUNOOR.18 20. Double compression type brass cable glands and crimping type copper lugs shall be provided for termination. SECTION: D3.7 pu rated peak line to earth operating voltage) switching surges originating from non-effectively earthed power system.2 20. ISSUE R0 304 TCE FORM NO. without exceeding acceptable winding temperatures. Separate terminal boxes to be provided for space heater. Motor shall be capable of starting and accelerating the load with the applicable method of starting.14 Cable boxes of all 6. RTDs for winding bearings temperature.0 microsecond wave (2.16 20.1.2 kV (rms) for one minute.3 20.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.MOTORS SPEC.1 20.6 kV motors shall be provided with quick disconnecting type terminal connectors to facilitate easy disconnection and removal of the motors without requiring unsealing or otherwise disturbing the external cable connections and leaving the phase segregated terminal box intact.6 kV AC motors shall withstand the negative or positive 0. 90% and 80% shall be furnished by the contractor. vibration monitors etc.

thermostat. Complete actuator shall be tested at factory as per IS 9334. NO. The DC and AC actuator shall be provided with accessories viz.3. all routine and acceptance 400V and DC motors as per relevant ISSUE R0 305 TCE FORM NO. standards.4 20.1 20. else it shall be conducted.5. Remote operation of the valve shall also be possible. integral starter.2 20.4. All the valves shall be of Integral type with field bus compatible.6 20.3. General Requirements For small rating motors cooling shall be of TEFC type but for higher rating motor TETV. end of travel switch. hand wheel motor.5.1 20. Degree of protection for actuator motor enclosure shall be IP-55 and IP-67 for indoor and outdoor respectively.3. torque limit switch.3. KARIMNAGAR DIST. if type test certificates are motors offered. motors.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.3.. ELECTRICAL SYSTEMS . adjustable limit switch. using the API Recommendation No. For 6.MOTORS SPEC. 400 V motors and DC available for the same rating of the furnished. All electric motors shall be chosen from the supplier’s standard manufacturing program and in accordance with the absorbed load of the driven machine. 617 and 618 for the overrating ratio. TCE. The remote position of the valve along with its status indication with trip shall also be shown in the DCS & local.2 20. Two normally open and two normally closed or two changeover potential free contacts corresponding to open and close positions of the valve shall be provided.6 kV.7 20. etc.3.8 20. SECTION: D3. CACA & CACW type cooling shall be considered.6 kV.2 Tests Tests on all types of motors shall be conducted as per relevant standard. tests shall be conducted on all 6.20 SHEET 4 OF 10 1X700 MW CCPP AT NEDUNOOR. 329 R5 .5960A-H-500-001 20.4 20.3.4.610.5 20. 20. the same shall be However.5 20. Open / Close limit switches used for interlock operation shall be of proximity type.3 Hand wheel operation shall be provided in addition to motor drive.

core temp.3 For 6.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. Momentary overload test (subject to test bed constraint).6 (f) (g) 20.5. wave on each type of motor coils with at least five such impulses. the temperature shall be measured by ETD's also for the record purpose.5. NO.20 SHEET 5 OF 10 1X700 MW CCPP AT NEDUNOOR.1. where U is the line to line voltage in kV. winding temp. These tested sample coils shall not be used in the motors to be supplied. ELECTRICAL SYSTEMS .5. Di-electric tests to establish the insulation withstand level of motors as indicated in Clause 20. in addition to all the tests specified above.5960A-H-500-001 20. List of tests to be conducted The following type tests shall be conducted on each type and rating of HT motor: (a) No load saturation and loss curves upto approximately 115% of rated voltage (b) (c) (d) (e) Measurement of noise at no load.MOTORS SPEC. C & Tan delta and polarisation index test shall be carried out as a routine test on each motor (the minimum value of polarisation index for all motors shall be 2 when determined according to IS : 7816).2/50 micro sec. KARIMNAGAR DIST. bearing temp. for HV motors only. Surge withstand test on the sample coil after placing it in stator core at (4U + 5 KV) and with at least five impulse of 1.5. Surge-withstand test at 20 kV with 0.7 List of tests for which reports have to be submitted The following type test reports shall be submitted for each type and rating of HT motor ISSUE R0 306 TCE FORM NO.5 20. SECTION: D3. followed by one minute power frequency high voltage test on turn to turn insulation..17 shall be performed on a sample coil (identical to those to be used in the motor quoted for) for each type of motor. Noise level measurement test shall be conducted on one motor of each type.6 kV AC motors. Wherever ETD's are provided.. 20. partial discharge. Full load test Temperature rise test at rated conditions.5. coolant flow and its temp. wave. specific approval for the test method and procedure is required to be obtained. In case the temperature rise test is carried at load other than rated load. During heat run test.3/3 micro sec. after cutting the coil and bringing out the turns suitably. 329 R5 . shall also be measured. The power frequency test voltage shall be decided during detailed engineering.4 20.. TCE.

MOTORS SPEC. KARIMNAGAR DIST. Type test report on Elastimold Termination kit as per relevant standard.20 SHEET 6 OF 10 1X700 MW CCPP AT NEDUNOOR. (b) (c ) ISSUE R0 307 TCE FORM NO.5960A-H-500-001 (a) Degree of protection test for the enclosure followed by IR. HV and no load run test. TCE. Terminal box-fault level withstand test for each type of terminal box of HT motors only. NO. ELECTRICAL SYSTEMS . 329 R5 . SECTION: D3.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.

DESCRIPTION UNITS VALUES / REQUIREMENTS 1. NO. TCE. Ambient temperature Temperature resistance Location (a) Hazardous area division (IS:5572 or equivalent) rise by winding C C 50 70 for class-B 0 1.0 1. BY Type of cooling (IS : 6362) Designation for degree of protection (IS : 4691) Colour shades of paint R0 JUNE’10 PPD. NO.5 1.2 AC Motors Type of Motors Supply (a) Rated voltage 6.11 REV.8 As per classification (for flame proof zone – 1) TEFC/TETV/CACA/CACW IP 55 Opaline Green JOB NO.4 1. BY CKD.1 1.20 7 OF 10 SPEC.6 kV for motors above 175 kW & 400V for rating upto 175 kW phases & 3 Phase. 5960A CLIENT : APPDCL PROJECT : 700 MW CCPP AT NEDUNOOR.9 1. NO. 1.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.10 1.7 Ref.5960A-H-500-001 SL. DATE REV. DOL For 6. 50 Hz Squirrel cage except for cranes (b) Number of Frequency (c) System Neutral Medium resistance earthing (6. KARIMNAGAR DIST. DATA SHEET – A3. 330 R3 308 .2 of IS:325 or equivalent) Method of starting Class of Insulation 1.3 Type of duty (Clause 9.20 SECTION: SHEET D3.BY DATE RKD HA TCE FORM NO.6 1.6kV&400V-Class F with temperature limited to Class B 0 1.6kV) / Effectively earthed (400V) Continuous / Intermittent depending on application.

2 DC Motors Rated voltage Class of insulation 0 V. 1.1 2.1 3. TCE.4 REV.20 8 OF 10 SPEC. DATA SHEET – A3. NO.3 Indoor / Outdoor / Explosion proof 4. 330 R3 309 4. BY Power supply R0 JUNE’10 RKD HA JOB NO. NO. DC 220 Class F with temperature limited to Class B 2.4 C -doReduced voltage 3 Motors for Application Hazardous Area 3.12 Space heaters for motors Required for motors rated 30 kW and above for 400V motors and for all 6.2. 3 Wire PPD.2 Type of construction Degree of protection All items indicated above under AC motors are applicable here also. 5960A CLIENT : APPDCL PROJECT : 700 MW CCPP AT NEDUNOOR. NO. DESCRIPTION UNITS VALUES / REQUIREMENTS 1.6 kV motors 2 2. Flame proof type IP-55 4 4. 3 Phase. DATE REV.1 4. .BY DATE TCE FORM NO.4 Temperature rise Method of starting All items indicated above under AC motors are applicable here also except 1. BY CKD.20 SECTION: SHEET D3.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.3 2.5960A-H-500-001 SL.2 Valve Actuator & its Motor Application Degree of protection Valves as per requirement IP 55 for Indoor IP 67 for Outdoor As per requirement at the location where it is installed 400V. KARIMNAGAR DIST.

1 5.5960A-H-500-001 SL.4 Degrees of protection provided by enclosures for rotating electrical machinery Classification of hazardous areas for electrical installation Terminal marking electrical machinery for rotating IS 4691 5. NO.8 Supply condition applicable for motor variation 4.2 Codes and Standards Induction motors – three phase Measurement and evaluation of vibration rotating electrical machines Code of proofing practice for climate IS : 325 IS : 12075 5.7 Designation of methods of cooling for rotating electrical machines Guide R0 JUNE’10 IS 6362 5. BY CKD.6 Actuator type Typical connection applicable diagram Bidder to decide No drawing is enclosed. 330 R3 310 . KARIMNAGAR DIST.5 IS 5572 5.5 4.9 Class of insulation for motor Class of insulation for motor Class F but limited to Class B 5 5. BY for testing three phase RKD HA JOB NO. DATA SHEET – A3. Contractor to furnish his proposed scheme.8 REV.7 Type of duty & duty designation for motor 4.20 SECTION: SHEET D3. DESCRIPTION UNITS VALUES / REQUIREMENTS 4.6 IS 4728 5.3 BS – CP 1014 5. Short time (15 minutes) or twice the valve stroking time whichever is higher As per 400V AC motors 4.20 9 OF 10 SPEC. NO.BY DATE TCE FORM NO.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. PPD. NO. DATE REV. TCE. 5960A IS 4029 CLIENT : APPDCL PROJECT : 700 MW CCPP AT NEDUNOOR.

5960A CLIENT : APPDCL PROJECT : 700 MW CCPP AT NEDUNOOR. NO. 330 R3 311 .BY DATE RKD HA JOB NO.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. DESCRIPTION UNITS VALUES / REQUIREMENTS induction motors 5. TCE FORM NO.5960A-H-500-001 SL.12 IS 2148 REV. KARIMNAGAR DIST. DATA SHEET – A3. BY R0 JUNE’10 PPD. BY CKD. NO.10 IS 2253 5.20 10 OF 10 SPEC. TCE.20 SECTION: SHEET D3.11 IS 8239 5.9 Dimensions of slide rails for electric motors Designations for types of construction & mounting arrangements of rotating electrical machines Classification of maximum surface temperatures of electrical equipment for use in explosive atmospheres Flame proof enclosure of electrical apparatus IS 2968 5. NO. DATE REV.

One (1) passenger-cum-goods lift of capacity 1500 kg and speed of 1. The car and counter weights shall be suspended by stainless steel wire ropes.1 ELEVATORS One (1) no.4 21. Special care and precaution shall be taken regarding handling of lift cable loops between the points of suspension as the loops are prone to twist / distortion.ELEVATORS SPEC.21 SHEET 1 OF 10 1X 700 MW CCPP AT NEDUNOOR. SECTION: D3.3.0 21.5 mm and the minimum factor of safety shall not be less than 12. Any code.3 21. NO. The suspension ropes shall conform to IS: 2365 latest edition "Specification for steel wire suspension ropes for lifts and hoists". 21.20 of this specification.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. Accordingly.3. ISSUE R0 312 21. 329 R5 . The A.3.5 TCE FORM NO. or equivalent international standard. KARIMNAGAR DIST. The minimum diameter of the standard rope shall not be less than 12.75 m/sec shall be provided for proposed Control and Switchgear building. statutory requirements. TCE. 21. Bidder shall decide the number of landings required and the total rise of the lift for both control building and HRSG area elevators.3.3.0 m/sec shall be provided in HRSG area.2 21.5960A-H-500-001 21.3 21. passenger lift of capacity 600 kg and speed of 0.1 Specific Requirements The capacity of the lift shall be 600 kgs (8 passengers) for passenger lift and 1500 kgs for goods cum passenger lift.3. Chain shall not be used for suspension.2 The lift for control building shall cater to various floors of the control room building. An enclosed machine room shall be provided for the control panel of the lift. specific requirements at the place of installation shall be complied with in all respects.5 21.C motors of the lift shall comply with Section D3. ELECTRICAL SYSTEMS . Not less than 4 (four) independent standard steel wire suspension ropes shall be used for car or counter weight and all these ropes shall be in one piece and without intermediate joints.

Actuation will check and reverse door movement. the doors then revert to an open position. The car door shall be of hollow metal construction. Besides this Bidder is also to provide "Electronic Door Detector".ELEVATORS SPEC. A retractable safety shoe shall extend to the full height and project beyond the front edge of each car to open the closing door if and when it touches a person or object that is Bidder to provide "Electro-Mechanical Pressure Detection".3. The car entrance shall be able to withstand the thrust of 35 kg.10 21. ISSUE R0 313 21.8 21.21 SHEET 2 OF 10 1X 700 MW CCPP AT NEDUNOOR. which is to be fitted with safety glass / plastic transparent cover mounted inside the car.3. the same shall be informed to successful Contractor.3.12 21. The entrance shall be securely fitted with car floor and frame in order to become working loose or becoming displaced during the service. The car platform shall be robust in construction and elegant in appearance.6 The car shall be provided with fittings & accessories. If there is any change/changes in the elevations of landing. SECTION: D3. In the first method. KARIMNAGAR DIST. The second method will also take carry by the screen of Infrared beams as a safety curtain across the door entrance detects an obstacle when the doors are closing. Car doors & landing doors shall be electrically operated by torque motor.5960A-H-500-001 21.3. 329 R5 . ELECTRICAL SYSTEMS .3. Conversely the lift will not move until all the landing doors are closed and interlocked properly. allowing passengers to pass. Sides of the door shall flush with all seams continuously welded.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.11 21.3.3. Glass exceeding 930 cm² in area shall be of laminated type. A load plate displaying the rated load of the lift in terms of persons and kilograms shall be fitted in the lift car in a conspicuous position. with scratch resistant coating. Guide shoes shall be rubber of roller type designed for operation on un-lubricated guides. TCE. The car door shall be provided with locking gear of heavy and robust construction so arranged mechanically and interlocked that the doors cannot under any circumstances be opened unless the lift car is within a particular landing zone. Glass shall not be used in the roof except to protect electric light.3.9 21. The successful Contractor shall comply with the changes in the elevation without claiming extra price. The car doors shall be so designed that their closing and opening is not likely to injure a person. The car floor shall be of smooth non-slip surface.13 TCE FORM NO. NO. 16 gauge thick stainless steel. slight body contact pressure is detected by sensors incorporated into door drive mechanisms.7 21.

ELECTRICAL SYSTEMS . It should preferably be equal to that of the car weight plus 40% of the rated load. Sheaves and pulleys shall be made of cast steel to IS:1030 and free from cracks. They shall have sufficient rigidity and bearing surface. The application of safety device shall not cause the lift platform to become out of level in excess of 3 cm/m measured in any direction. Guide rails section shall be adequate to withstand the forces resulting from the application of the safety gear when stopping the counter weights or fully loaded car. The number of buffers shall be so fixed as to ensure proper sharing of the impact loads by all of them.5960A-H-500-001 21.16 21. NO.ELEVATORS SPEC.18 21. The guide shoes or their lining shall be easily renewable.3.17 21. adjustable and self lubricated guides shall be of such length that it shall not be possible for any of the car or the counter weights shoes to run off the guides. The diameter of the sheave of pulley shall be as specified in the latest edition of Indian Standard of equivalent International Standard.19 TCE FORM NO.15 21.14 All sheaves and pulleys fixed to and revolving with the shaft shall be fixed by means of sunk keys of sufficient strength and quality. TCE. The buffers shall be capable of stopping the car or counter-weights without permanent damage or deformation to itself or any part of the lift equipment. Sufficient number of buffers of spring loaded/oil type shall be fitted below lift car and counter weights. shall be turned to a reasonable radius at the point of reduction in diameter. The counter weight shall consist of cast iron weight contained in structural steel frame. The lift shall be provided with safety device attached to the lift car frame and placed beneath the car. International Standards. The elevator shall be provided with suitable counter weights located in the lift shaft.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. Guide rails for the car and counter weights shall be machined 'T' sections and continuous throughout the entire length and shall be provided with adequate steel brackets or equivalent fixing of such design and spacing that avoid any deflection during the normal operation. 329 R5 . sand holes and other injurious defects. Any shaft when stepped.3. Shafts and axles shall be of forged steel. They shall have suitable flanges and smoothly machined rope grooves.3. The counter weight shall be designed for smooth and easy operation of the lift and shall be in accordance with Indian Standards referred earlier or equivalent.3. shall also be provided. The counter weight shall be provided in the lift shaft. ISSUE R0 314 21. Slack rope switches if necessary.21 SHEET 3 OF 10 1X 700 MW CCPP AT NEDUNOOR. The traction should be such that no appreciable slip may occur but that slip shall be free to take place upon the landing of either the car or the counter weight.3. SECTION: D3. The safety device shall be capable of stopping and sustaining the lift car up at governor tripping speed with full rated load in car. KARIMNAGAR DIST.3.

The lift shall be provided with upper and lower normal terminal switches arranged to stop the car automatically within the limit of top car clearance and bottom run from any speed attained in normal operation. KARIMNAGAR DIST. Final limit switches shall be provided to stop the car automatically within the top and bottom clearance independently of the normal operating device and the terminal limit switches.26 TCE FORM NO.21 21. NO.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.24 21.3.23 21.3. Governor ropes shall not be less than 8mm in diameter and shall be of steel or phosphor bronze and of suitable construction. Governors shall be located where there is sufficient room for their proper operation and where they cannot be struck by the lift car or counterweight in the event of overrun.22 21.20 Contractor to provide a modern Advanced electronic drive system of ''RESCUING passenger Trapped in a ELEVATOR".3. Sound reducing materials shall be provided under the machine base by the bidder. Such limit switches are to act independently of the operating device. The drive system for the elevator should be variable voltage variable frequency Drive system. SECTION: D3. The lift shall be driven by a drive suitable for method of control offered by the bidder. The ropes shall run clear of the governor jaws during normal operation of the lift.3. The final limit switch shall not act to prevent motion of the car under power in both direction of travel and ISSUE R0 315 21. The maximum load transmitted by the single heaviest equipment both during erection and maintenance of the lift to the machine room floor and other structures like guides etc. except such apparatus and equipment which function in the lift well or other portion shall be placed in the machine room which shall be located at the top of the lift well.ELEVATORS SPEC.25 21.5960A-H-500-001 21.21 SHEET 4 OF 10 1X 700 MW CCPP AT NEDUNOOR. The lift drive shall be equipped with brakes. The system should be fully microprocessor control with latest IGBT power device.3. ELECTRICAL SYSTEMS . The lift drive controller and all other apparatus and equipment for lift installation. shall be furnished by the contractor within 30 days of placing the award letter. TCE.3. and the motor control and brake control circuit shall be opened before or at the time of governor trips. No friction gearing or clutch mechanism shall be used for connecting the main driving gear to the sheaves. This system should be able to rescue during main power failure and elevator control system failure. the final limit switches and buffers. Each governor shall be marked with a tripping speed in terms of car speed in m/sec. 329 R5 .3.

39 ISSUE R0 316 TCE FORM NO.3. NO.3.3. This shall include application of anticorrosion paint/zinc plating.32 21. KARIMNAGAR DIST. 21.30 21.31 21.21 SHEET 5 OF 10 1X 700 MW CCPP AT NEDUNOOR. remain open until the lift car has been moved by a hand winding within the limit of safe operation. To make the equipment/system complete in all respects.33 21. cancelling all the registered calls.ELEVATORS SPEC.34 21. are included in the scope of the bidder. 329 R5 . The elevator is to provide service in power station.3. The contractor shall carryout all the tests necessary & take the clearances / permissions from the Electrical inspector or any other agencies who certify the operation of lift. The lift shall be provided with automatic levelling device to take care of over run and under run of the car and rope stretch such that any floor is within 6 mm from the landing level.3. ELECTRICAL SYSTEMS . The electrical equipment shall have enclosure meeting IP-54 and other relevant protection. arranging the materials for scaffolding and for any other functional requirement of erection.3.35 21.3.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. fixtures in walls for indicators and push buttons etc.5960A-H-500-001 shall after operation. The mechanical interlock with auxiliary door closing device shall be provided so that the elevator can be operated only after the interlock circuit is established. An emergency switch shall be provided to stop the elevator at a particular landing.3.28 21.3.27 Emergency safety device and over speed governor and buffers shall be provided. An electric contact for the car door shall be provided which shall prevent elevator movement away from the landing unless the door is in the closed position. Fireman's switch at ground floor shall be provided. it shall automatically cause the car door and hoistway door to return to open position.29 21. The scope of the bidder also includes supply of erection consumables. The car door shall be provided with a protective device extending to the full height and shall be so arranged that should it touch a person or any obstruction in its path while the door is closing. any requirement of supply & fixing of steel sections for door frame. It is necessary for the equipment to be specifically treated. SECTION: D3. TCE. 21.3.

SECTION: D3.5960A-H-500-001 21.40 The following operating devices / indications shall be provided in the car / on the landing / in the machine room as indicated below: Operating devices In the car In the landing In the m/c room Up PB On top of the car Up (a) Up push button (PB) Down PB Number PBs for each landing Up PB Down PB Lift PB Down PB Hand cranking device Down Stop 230V 1φ receptacle Non-stop PB Door open PB Door close PB Alarm PB Emergency stop PB Key operated selector for attendant operation Bell PB Stop PB - - - - (b) Indicating devices. ELECTRICAL SYSTEMS . KARIMNAGAR DIST.21 SHEET 6 OF 10 1X 700 MW CCPP AT NEDUNOOR. In the car Up direction of travel Down direction of travel Floor position indicator & voice inside and outside car (Illuminated numeral for each landing) Landing car registering unit On the landing Up direction of travel Down direction of travel Car position indicator with direction (Illuminated numeral for each landing) Call registered ‘Up’ indicator ISSUE R0 317 TCE FORM NO. 329 R5 .3. NO.ELEVATORS SPEC. TCE.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.

ELEVATORS SPEC. The contractor shall carryout all the necessary tests & take the clearances / permissions from the Lift inspector or any other agencies who certify the operation of lift. ISSUE R0 318 TCE FORM NO. Automatic rescue device including siren etc : To be provided by bidder as an emergency rescue measure.5960A-H-500-001 In the car Load plate in kg & no. of persons Over load indication On the landing Call registered ‘Down’ indicator (c) Additional requirement (a) Car ventilation fan with switch Fire extinguisher Telephone handset PB for emergency indication in control room Ventilation/pressurisation : 2 x 100% capacity blower of adequate size along with cyclonic filter for pressurising the machine room to make it dust proof. Hoist way machine room & pit lighting: To be provided by lift supplier. SECTION: D3. If AC is required for the lift control room. ELECTRICAL SYSTEMS . blow out panels. Hoisting beam in machine room roof slab : To be provided by lift supplier. KARIMNAGAR DIST. 329 R5 . etc. TCE. then it should be taken through the Main Control room Air Conditioning System only. Any other equipment / accessories required for satisfactory operation of the lift shall be supplied by the Contractor. Individual ladder for access to inside pit : To be provided by lift supplier. Emergency DC light shall be provided in car.21 SHEET 7 OF 10 1X 700 MW CCPP AT NEDUNOOR. NO. The enclosure for electrical equipment located outside the machine room shall be dust tight and the car shall be provided with fluoroscent lighting. (b) (c) (d) (e) (f) (g) (h) (i) (j) The material of doors and lift rope shall be stainless steel.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.

ISSUE R0 319 TCE FORM NO. ELECTRICAL SYSTEMS . 329 R5 .ELEVATORS SPEC. KARIMNAGAR DIST. The contractor shall be responsible for obtaining the necessary License / Permission from the relevant authorities.21 SHEET 8 OF 10 1X 700 MW CCPP AT NEDUNOOR. NO. SECTION: D3.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. TCE. and the same shall be subject to approval by Owner.5960A-H-500-001 The interior decor of the lift shall be aesthetically pleasing.

2 8. NO.0 5.5 ISS or approved equal. DATA SHEET – A3. 330 R3 320 TATA CONSULTING ENGINEERS LTD . BY Indoor kg m/sec 1500 1.21 SECTION: SHEET D3.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. elevators & hoists. steel 1 or 2 depends on layout Required VVVF IP-54 IS:14665 (Latest edition) 9. DATE REV.BY DATE UNITS Indoor kg m/sec 600 0. BY CKD. Specification for carbon steel castings for general engg.0 7.0 5. NO. TCE FORM NO. 1.1 8. Specification for lift door locking devices and contracts Material specification Goods Cum Passenger Lift Installations Capacity Rated speed Levelling device Operation R0 MAR’ 10 PPD.21 9 OF 10 SPEC.0 4. KARIMNAGAR DIST.75 VALUES / REQUIREMENTS Two way automatic maintaining Automatic microprocessor based Selective & Collective Centre opening sliding.3 9. NO.1 DESCRIPTION Passenger Lift Installations Capacity Rated speed Levelling device Operation Automatic operation type Type of door & material Type of doors in car Emergency exit Speed control Degree of protection for lift motor Codes & standards Specification for electric passenger and goods lift. 1.0 8.0 8.2 IS:2365-1977 9.0 2.0 3.0 4.4 IS:7759-1975 9. 5960A CLIENT : APPDCL PROJECT : 700 MW CCPP AT NEDUNOOR.5960A-H-500-001 SL. purpose.3 IS:1030-1982 9.0 REV. TCE.0 9.0 2.0 3. Specification for steel wire suspension ropes for lifts.0 6.0 Two way automatic maintaining Automatic microprocessor based JOB NO.

DATA SHEET – A3. 5960A CLIENT : APPDCL PROJECT : 700 MW CCPP AT NEDUNOOR. KARIMNAGAR DIST.2 IS:2365-1977 9. elevators & hoists.21 SECTION: SHEET D3.21 10 OF 10 SPEC.4 IS:7759-1975 9. DATE REV. 7. 330 R3 TATA CONSULTING ENGINEERS LTD 321 . TCE. REV.1 8.0 NO.0 9. Specification for lift door locking devices and contracts Material specification UNITS Selective & Collective UIREMENTS VALUES / REQ Centre opening sliding.BY DATE JOB NO.5960A-H-500-001 6. purpose.3 IS:1030-1982 9.3 9.0 8. BY CKD. BY R0 MAR’ 10 PPD. Specification for carbon steel castings for general engg.0 8. Specification for steel wire suspension ropes for lifts.5 ISS or approved equal. SL. NO.1 Automatic operation type ION DESCRIPT Type of door & material Type of doors in car Emergency exit Speed control Degree of protection for lift motor Codes & standards Specification for electric passenger and goods lift.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. steel 1 or 2 depends on layout Required VVVF IP-54 IS:14665 (Latest edition) 9. NO. TCE FORM NO.2 8.

1 No.5A-2 nos. 2. 1 No.1 EQUIPMENT TO BE SUPPLIED The list of items / equipment to be supplied by the Contractor indicated here is only indicative. Portable secondary injection test set 500VA.01 Ohms. 2 Nos.10 ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. 10A-2 nos. 500 resistivity test facility Ohms in three ranges Digital Insulation resistance tester (transistorised) 0-100. (ii) 50 Ohms. Automated oil BDV test set 0 – 75 kV 1 No.0 22. (a) Qty. (v) 500 Ohms. ISSUE R0 322 TCE FORM NO. ELECTRICAL SYSTEMS – ELECTRICAL LABORATORY EQUIPMENT SHEET 1 OF 7 SPEC.5. Sl. 20AMPS / 100AMPS for 30 secs Digital Earth resistance tester with 0. 1 No.22 1X 700 MW CCPP AT NEDUNOOR. (iii) 100 Ohms. 500-10002500-5000 Volts 1 No. (d) (e) 2 Nos. SECTION: D3. TCE. 0. 2. NO. Category – I – High Voltage Test Instruments Instrument Range High potential test set AC / DC 0 – 50 kV Sl. (a) (b) (c) Category – II – Miscellaneous Laboratory Instruments Instrument Range Qty. No. LV cable) Relay tool kit Hot stick with indication & audible alarm Temperature controlled soldering iron Thermovision equipment (INFRA RED CAMERA) Upto 11 kV Upto 400 kV 50W 1 No. Any other equipment considered necessary by the Contractor for the installation.5 A-2nos. 329 R5 . 5A-2 nos. (iv) 250 Ohms. shall form a part of the scope. No. testing and commissioning of the plant shall be included in the offer.5960A-H-500-001 22.5A-2nos. Also any additional equipment required or considered necessary during detailed engineering stage. 000 Mega Ohms. 1AMP/ 5AMPs Normal. KARIMNAGAR DIST. (f) (g) (h) (i) (j) Cable fault locator (HV. Rheostats of following ratings 650 Volts 1 Set (i) 25 Ohms. 1 No. 2 Nos.

ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. 3 wire & 3ph. 7. Volt. Amp. 2 Nos. KWh. 1 No. 1 No. SECTION: D3. 1 No. Circuit breaker analyser 1 ms to 999 secs Turn ratio meter with vector group 1 to 99000 ratio testing facility Online DC circuit fault locator Tan delta test kit for generator/transformer Vibrometer Capacitance and tan delta measurement kit Partial discharge measurement kit Earth loop tester Battery capacity test kit Battery impedance measurement kit Motor checker Capacitor measurement kit Live line detector Category – III – Meters & Accessories Instrument Range Qty. ELECTRICAL SYSTEMS – ELECTRICAL LABORATORY EQUIPMENT SHEET 2 OF 7 SPEC. KVAr.22 1X 700 MW CCPP AT NEDUNOOR. 2 Nos. (k) (l) (m) (n) (o) (p) (q) (r) (s) (u) (v) (w) (x) (y) (z) (aa) Category – II – Miscellaneous Laboratory Instruments Instrument Range Primary Injection kit 5000 A.2 ISSUE R0 323 TCE FORM NO. Sl. 1 No.5960A-H-500-001 Sl. 2 Nos 1 No.1 micro-ohm-1999 Ohm.5 kVA Milli volt drop test set 600A DC continuous variable Illuminometer 0 to 50. 1 No. 1 No. No. 329 R5 . for measurement of KW. 7KVA 0-270 Volts. KVA. 1 No. 1 No. (a) (b) Qty.000 Lux. 1 No. NO. TCE. 3 Nos. 2-16KVA 0. Three Phase sequence testing meter Clip on Ammeters AC / DC (100 – 600 V) (a) 0-2000-25003000A (b) 0-250-500A (c) 0-100-150-200A (d) 0-5A (e) 0-1A 0-500 Volts. 4 wire system (c) (d) (e) (f) Auto-transformers – 3 Phase Auto-transformer – 1 Phase Digital micro-ohm meter Portable power analyser meter Accuracy=0. PF. in 1 ph & 3 ph. KARIMNAGAR DIST. 1 No. 1 No. 3Nos 1 No. Volt 600 V. No. 100A Amp-1A/5A.

ISSUE R0 324 (h) TCE FORM NO. Harmonics generation. 2 Amps. probes. SECTION: D3. shields. rain jackets. 1 No. Ground fault relays. Current 0 – 2 AMPS DC. 100 VA 0. ELECTRICAL SYSTEMS – ELECTRICAL LABORATORY EQUIPMENT SHEET 3 OF 7 SPEC. Requsite software and Laptop shall be included as a part of test kit.5) 3 Nos. 329 R5 . connectors. clips. Digital multimeter (Class 0. All necessary accessories like jacks.1500. Differential relays. DC. F/V/I relays. Hydrogen leak detectors 2 Nos. Energy meters testing /calibration. No. All the necessary accessories shall also be supplied with the instruments.5000. Synchronising devices. Sl.22 1X 700 MW CCPP AT NEDUNOOR. adapters. 0-+5V 10 Amps. etc. These shall include but not be limited to : (a) (b) Two meter length power supply cord with plug. NO. Composite universal microprocessor based test kit with 0.+ 30V. (c) (d) (e) (f) (g) Digital tachometer (non-contact type) 2 Nos. (a) Category – IV – Electronic Instruments Instrument Universal microprocessor based relay testing kit to test 1) Current relay 2) Voltage relay 3) Frequency relay 4) Differential relay 5) Distance relay 6) Synch.02 accuracy for testing following: Distance relays.5960A-H-500-001 (g) (h) (i) LCD type portable scope meter (Wave form analysis with Harmonic measurement facility) Analog voltmeter AC/DC Analog ammeter AC/DC 1 No.3000. KARIMNAGAR DIST. protective covers. Relay 7) Timer relays Regulated DC power supply equipment Range Qty. 2 Amps. 0-5-10-25-50-100-500 V 0-5-10 A 1 No.. wherever applicable. 1 no (b) Voltage 0-+300V DC. Transient playback. TCE. Transducers. Over current relays. 10000 rpm 2 Nos. carrying / transporting cases.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. 0 . Naphtha & fuel gas leak detectors 2 Nos.

22.1 Category – I – High Voltage Test Instruments (a) The test transformers shall be supplied with: (i) A control desk incorporating all necessary indication. 329 R5 . TCE. of rollers for easy transport of the testing unit. The transformer test set impedance shall be such that the input MCCB trips within a suitable time (0. normal operational / testing of all types of equipment. Solid copper / graphite brushes with pressure springs shall be provided to ensure low contact resistance. Mobile base with adequate no. (ii) (b) Rheostats and Phantom Loads The rheostats shall be 650V grade wire wound type of copper nickel alloy having a low temperature co-efficient.2 Specific Requirements 22. totally enclosed type with louvers.) for a secondary short circuit.22 1X 700 MW CCPP AT NEDUNOOR. ELECTRICAL SYSTEMS – ELECTRICAL LABORATORY EQUIPMENT SHEET 4 OF 7 SPEC. All necessary cooling equipment if required.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. (ii) (iii) (iv) (v) (b) The insulating material used for bushings and top covers shall be as per BS for Class F/A installation. All necessary accessories for erection. The test set shall be so designed that the short circuit current drawn from the system exceeds 8 times the rated current. SECTION: D3. KARIMNAGAR DIST.2.2. Shall incorporate built-in safety features to ensure complete safety of operating personnel.02 sec. protection and control equipment.5960A-H-500-001 22. commissioning.2 Category – II (a) Automatic Oil Test Sets (i) This equipment shall have an output voltage of 0 – 75 kV variable AC. whether specified or not. (c) Portable Secondary Injection Test Set ISSUE R0 325 TCE FORM NO. continuously rated 1 kVA with class of insulation being ‘A’. annunciation. NO.

400 kV. 5. 50 A etc.00. nominal S. TCE. Accuracy shall be 5%. single phase AC as well as in-built rechargeable batteries. (d) Earth Resistance tester with resistivity test facility This equipment shall be suitable for measuring the ground resistance. (e) Insulation Resistance Tester (Transistorised) The insulation resistance shall be measurable to a value of 1.5 mA. A guard terminal shall be provided to eliminate error due to surface leakage. The insulating handle of stick shall be with Class F / H insulation as per IEC / BS specifications with scaled detector having high quality viewing windows. This kit shall work on in-built batteries. The tester shall be suitable for an input supply of 230 V. ISSUE R0 326 TCE FORM NO. 10.22 1X 700 MW CCPP AT NEDUNOOR. The hot stick should be light weight and portable. (g) Hot Stick The hot sticks shall be supplied in different ratings viz.6 kV. NO. three spare heating elements & separate stand to rest the soldering iron while in use. KARIMNAGAR DIST.000 mΩ in five ranges. 2500V and 5000V. 50 Hz. The instrument shall have built in ammeter and voltmeter having adequate range. This tester shall also provide Polarisation Index Measurement. For 6.5960A-H-500-001 This equipment shall be designed to deliver a normal continuously adjustable current with multirange selector switch for 1. 329 R5 . The equipment shall be supplied with all necessary accessories and in-built batteries.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. SECTION: D3. Should give audio visual indication of pressure of voltage.C current 2 mA. 1000V. This kit shall include Time Domain Reflectometer (TDR) and cable identifying kit and all necessary accessories & transport cases. specific soil resistance and ohmic resistances. (h) Temperature Controlled Soldering Iron The soldering iron rated at 50 W having thermostatic temperature control shall be supplied complete with set of soldering bits of different sizes and shapes. maximum short circuit terminal current 2. (f) Cable Fault Locator for LT Cables Portable cable fault locator which shall identify the fault in a LT cable distinctly. ELECTRICAL SYSTEMS – ELECTRICAL LABORATORY EQUIPMENT SHEET 5 OF 7 SPEC. The test voltage shall be adjustable at 500V.

KARIMNAGAR DIST. ELECTRICAL SYSTEMS – ELECTRICAL LABORATORY EQUIPMENT SHEET 6 OF 7 SPEC. determining temperature co-efficient and temperature rise by resistance methods. Any conducting part of the meter/ shall withstand 2 kV for 1 minute. Output current range shall be 1-5-50-100A. The software for testing.2. winding resistance of transformer & motor. 50 Hz. Overload and short circuit protection shall be provided. 329 R5 . 22. The kit shall be computerised. They shall also be suitable to be used in finding ground faults in electrical equipment. 1 Phase.2. ISSUE R0 327 TCE FORM NO. measurement and analysis of the different types of the relays shall be included. broadly compatible software which is an image processing software to perform post-imaging analysis.5960A-H-500-001 (i) Thermovision Equipment (Infra thermographic common) The system shall be very light weight.4 Category – IV (a) Automatic Composite Relay Test Kit Relay test set shall be suitable for input voltage 230 V.22 1X 700 MW CCPP AT NEDUNOOR. etc. busbars. portable unit and used to test various types of protective relays quickly and more accurately. SECTION: D3. The operative range of the meter shall be 100V to 600V. etc.3 Category – III (a) Phase sequence Testing Meter This shall be suitable for testing 3 phase 400V supply and shall be suitably marked for clockwise and anti-clockwise directions. and single hand-operated instrument. 22. NO. TCE. This instrument shall have user friendly. Phase angle adjustment shall be 0-360 deg. (c) Digital low resistance ohm-meter The instrument shall be suitable for measuring the contact resistance of switch and circuit breaker contacts. (b) Clip on Ammeter The meter shall have a large digital display unit and the jaws shall open adequately to facilitate introduction of the conductor having a size corresponding to the maximum current range.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.

Adequate memory shall be built-in to hold the last reading for atleast 1 minute.1% variation in voltage 0. probes. ELECTRICAL SYSTEMS – ELECTRICAL LABORATORY EQUIPMENT SHEET 7 OF 7 SPEC. They shall have an audio alarm for continuity testing.22 1X 700 MW CCPP AT NEDUNOOR.2% variation in current. The instrument shall be complete with rechargeable batteries and charging equipment.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. etc. 329 R5 . It shall have safety features to prevent damage to instrument if voltage is applicable inadvertently current or resistance measuring range. TCE. a peak hold feature on current and voltage ranges. padded carrying case.5960A-H-500-001 (b) Regulated DC Power Supply Voltage range (continuously controlled) Current range (continously variable) Indication meters Load regulation - 0 to + 300 V DC 0 to 2A DC Digital voltage/current integral with the unit 0. which does not necessitate mechanical contact with the machine shaft. - (c) Digital Tachometer Tachometer shall be of the photoelectric type with a digital display. A “push to read” push button shall be provided and also an LED to indicate when the light beam is on the target. automatic polarity and over range indications. NO. ISSUE R0 328 TCE FORM NO. SECTION: D3. leads. adapters. KARIMNAGAR DIST. (d) Digital Multimeter These meters shall have built in overload protection and protection against HV transients.

. Local push button stations Junction Boxes (JBs) 3 phase power receptacles Danger boards Rubber mats 50 nos. TCE.1.which shall comprise Three.5960A-H-500-001 23. (a) Push button station type A .3 23.2 23.4 (b) TCE FORM NO. `Close' and `Stop' for control of reversible motors. Minimum of fifty (50) nos.8 23. All stop push buttons shall be lockable type (provided with key for locking) Following types of LPBs shall be provided for the various drives as applicable.1.3 23. Sufficient quantity of gas masks shall be provided in line with rule no.1. first aid charts shall be provided for display in the plant area.2.1.2.. `Open'.2 23. SECTION: D3. `Start' and `Stop' for control of the rest of the drives in the plant. Local Push Button Stations (LPB) Local push button stations shall be provided for all the drive motors of the plant.1 23.1. First aid boxes shall be provided at various locations in the plant.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. 43 of IE rules.2 23. LPB’s for outdoor installation shall be weather proof type provided with a GI canopy and those intended to be used in hazardous areas shall be flameproof type and the degree of protection shall be IP 55 for both outdoor and indoor application.1 23. NO.6 23.1. 329 R5 . KARIMNAGAR DIST. Push buttons viz.1 23.1. ELECTRICAL SYSTEMS MISCELLANEOUS ELECTRICAL EQUIPMENT SPEC.1. The LPBs shall be power coated with shade Opaline green (External) & semi glossy white (Internal). ISSUE R0 329 23.0 23.which shall comprise two push buttons viz.23 SHEET 1 OF 3 700 MW CCPP AT NEDUNOOR.4 23.2. Push button station type B .7 MISCELLANEOUS ELECTRICAL EQUIPMENT Following equipment shall be included in the Contractors’ scope.2.5 23.

1 Type-C push button station: With start. Receptacles boxes shall be fabricated out of MS sheet of 2mm thickness and hot dipped galvanized or of die-cast aluminium alloy of thickness not less than 2. hot dip galvanised as per relevant IS. SECTION: D3.3. columns. 329 R5 . 3 Phase Receptacles 32 A and 63 A. Terminal blocks shall be 650 volts grade. 3 phase. Top of the boxes shall be arranged to slope towards rear of the box.3 23.5. transformer yard. 400 kV switchyard such that distance between any two of each rating in indoor and outdoor area does not exceed 15 m and 30 m respectively.4 23. ELECTRICAL SYSTEMS MISCELLANEOUS ELECTRICAL EQUIPMENT SPEC. JBs / MBs shall be hot dip galvanised and shall be powder coated with paint shade Opaline green (External) & Semi glossy white (Internal). The junction boxes shall be installed at 1 m accessible height. The boxes shall include brackets.2 23.23 SHEET 2 OF 3 700 MW CCPP AT NEDUNOOR. Plug and Socket shall be shrouded Diecast aluminium. The boxes shall be provided with two nos.3. Cable entry shall be bottom/side entry for indoor as well as outdoor mounted junction boxes.5 mm. Junction Boxes (JBs) / Marshalling boxes (MBs) Junction boxes as required for the power plant shall be supplied as required for marshalling cables of devices located in an area/equipment. structures etc. suitable for AC supply.3 23. nuts. KARIMNAGAR DIST. mounting brackets suitable for surface mounting on wall/column/structure. screws M8 earthing stud etc. shall comprise of a case with hinged door constructed from cold rolled sheet steel of minimum thickness 2mm.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. The JBs used in outdoor areas shall be weatherproof type.2 TCE FORM NO. TCE. bolts. Sheet steel thickness of the JBs shall be minimum 2 mm. Robust mechanical interlock shall be provided such that the switch can be put ON only when the plug is fully engaged and plug can be withdrawn only ISSUE R0 330 23. terminal blocks for loop-in loop-out for cable of specified sizes. NO. gasket to achieve IP55 degree of protection. The ONOFF switch shall be rotary type heavy duty. double break.5. and suitable for mounting on wall. earthing terminals. required for installation. Junction Boxes with IP:55 degree of protection. Socket shall be provided with lid safety cover. stop & ammeter. Gland plate shall be 3mm thick sheet steel with neoprene/synthetic rubber gaskets. All junction boxes shall be of adequate strength and rigidity. AC23 category. gland plate etc. 4 pin heavy duty type power receptacles shall be provided in proposed building plant areas.1 23.3. rated for 10 Amps and in one piece moulding.5960A-H-500-001 (c) 23.

23.1 Danger Boards / Rubber Mats Danger boards and rubber mats shall be provided as required by the statutory Authorities. ISSUE R0 331 TCE FORM NO.5. SECTION: D3. NO.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. The Terminal blocks shall be of 750 V grade. Wiring shall be carried out with 1100 V grade PVC insulated stranded aluminium/copper wire of adequate size. The thickness and length of the rubber mats shall be as per the guidelines of Indian Electricity Rules / local electrical inspectorate.5960A-H-500-001 when the switch is in OFF position.23 SHEET 3 OF 3 700 MW CCPP AT NEDUNOOR. ELECTRICAL SYSTEMS MISCELLANEOUS ELECTRICAL EQUIPMENT SPEC.5 23. KARIMNAGAR DIST. TCE. 329 R5 . Also cover can be opened only when the switch is in OFF position.

Adequate metering and protection shall be provided for transformers and incomer feeders. This shall be installed at each LT distribution board preferably. All the equipments used in construction power shall ensure full safety to the working personnel and no live parts which are accessible shall be exposed.24 SHEET 1 OF 4 1X700 MW CCPP AT NEDUNOOR. 3φ. 4 wire distribution lines to distribute power around plant area. ELECTRICAL SYSTEMS – CONSTRUCTION POWER SUPPLY SPEC.5 TCE FORM NO. The power shall be further extended by the Contractor to different users by armoured cables or overhead lines.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. The Contractor shall obtain all necessary statutory clearance for the purpose. The Owner will not be responsible for power cuts. The contractor shall be responsible for periodic payment of bills for the energy consumed by him. The Contractor shall make arrangements to receive power from the Owner line through DP structures with fuse protection. ISSUE R0 332 24.0 24. Capacitor banks of automatic PF adjustment arrangement shall be provided by the Contractor depending on the actual load to maintain power factor at 0. 400V switchgear with two incomer ACBs.1 CONSTRUCTION POWER SUPPLY EQUIPMENT Construction power shall be made available at a single point at 11kV inside the plant premises from nearest substation of APTRANSCO by the Owner. the same shall be paid by the contractor to the Owner. Power failure for whatever reason. two bus sections and bus coupler & required number of outgoing 400V. To take care of failure of this supply. 2 x 100% suitably rated 11kV / 420V transformers. KARIMNAGAR DIST.5960A-H-500-001 24. GA and layout drawings required for getting clearance from local electrical inspector / Electricity Board shall be prepared by the contractor and it will be the complete responsibility of the Contractor to obtain the approval for the installation and all related works in this regard. should not disturb 11kV power supply arrangement. 329 R5 . Contractor shall provide necessary protection for the construction power supply arrangement to ensure that any fault in his system. Contractor shall provide suitable DG sets.95 for optimising the power bills. NO.3 24. PT units and two trivector meters of suitable accuracy which shall have MD registering facility. The Contractor shall provide metering arrangement consisting of two CT. fluctuation in voltage and frequency and consequences thereupon. The Contractor shall estimate the construction power requirement and indicate the same to Owner to enable them to enter into an agreement with APTRANSCO for its supply. caused by low power factor. Contractor shall supply and install fire fighting equipment as per the regulations of the local electrical inspectorate / statutory bodies for the electrical installation.2 24. If APDISCOMS imposes any penalties to APGENCO .4 24. TCE. SECTION: D3.

24. Earthing system shall consist of adequate number of earth electrodes interconnected. these shall meet the requirements covered in D3. of 400V.2 The distribution boards shall be provided with the following: a) b) c) d) 24. Metallic supports.2 Number of earth electrodes for LT substation shall be decided considering soil resistivity.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.10 EARTHING SYSTEM 24. Cable armour shall be suitable for carrying system earth fault current.1 Earthing of all substation equipment and overhead line shall be carried out as per IS:3043. shall be given by the Contractor at specified location. HT cables shall be XLPE insulated type. ISSUE R0 333 TCE FORM NO.8. 24. each LT substation shall have minimum two earth electrodes for neutral earthing. 24. TCE. buried in earth pit.10.1 In general. each of 100% rating. the Contractor shall furnish the electrical scheme.9 CABLES Pad locking arrangement with hinged door Sloped canopy to prevent ingress of rain water Caution notice Earthing at two points 24. etc.8 24. 329 R5 .10. Earth electrodes shall be of 40mm dia. 02 Nos. busbar and cable alley shall be available only after the outer door is opened. NO.6 On award of contract.24 SHEET 2 OF 4 1X700 MW CCPP AT NEDUNOOR. KARIMNAGAR DIST.8. SECTION: D3. 24. ELECTRICAL SYSTEMS – CONSTRUCTION POWER SUPPLY SPEC. However. two earth electrodes for body earthing and two earth electrodes for lightning arrestor earthing. galvanised steel pipe. for Owner’s approval.5960A-H-500-001 24. 250A feeder of adequate capacity for Administration building & Colony construction. LT DISTRIBUTION BOARDS 24.9. However.11 section.10.1 Cables shall be armoured and suitable for direct underground buried installation. fencing.7 24.3 All non-current carrying metal parts shall be connected to earth system at two points. shall also be connected to earth system. the board shall be provided with outer enclosure so that access to individual compartments.

11. The plug & socket arrangement provided shall be of industrial type with switch provided for proper isolation at the time of insertion or withdrawal of plugs. The wire shall be laid with proper fixing without any hindrance to personnel or vehicular movement. 24. KARIMNAGAR DIST. 24. 24. 24.12 WORKING PROCEDURES ISSUE R0 334 TCE FORM NO. ELECTRICAL SYSTEMS – CONSTRUCTION POWER SUPPLY SPEC.1 The electrical installation shall generally be carried out as per Indian electricity rules and acts. 329 R5 .11.10.4 Size of earthing conductor shall be selected considering fault current.5 Overhead lines shall be earthed by continuous galvanised steel overhead earth wire fastened to each pole and connected with earth at minimum three points in every km length.11. Surface shall be covered with gravel of 15 to 20 mm size. etc.11. 24. 24.5 All cable connection parts within the switchgear shall be shrouded with insulating materials.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.11. duration of fault and corrosion rate. SECTION: D3. Earthing conductor shall be of galvanised steel strip/wires. 24.7 The flexible cable used shall have heavy duty insulation.24 SHEET 3 OF 4 1X700 MW CCPP AT NEDUNOOR. The clearance for the lowest conductor from ground shall be decided keeping in view the vertical clearance required for movement of vehicles/cranes.e.10.11. protective guarding shall be provided.5960A-H-500-001 24. 24.3 The LT substation area shall be graded and sloped to prevent any stagnation of rain water. neutral & earth as per IE rules. 24. TCE.4 The LT substation shall be enclosed by barbed wire fencing on mild steel angle iron posts to a height of not less than 2500mm with suitable gates for entrance.11.9 All the working areas shall be adequately illuminated for safe working with proper fittings/fixtures.11 INSTALLATION 24.11. 24. Cross section of earth wire shall not be less than 25 mm2.2 For road crossing. 24. phase.6 The extension boards provided for hand held equipments shall have 3 wire system i.11.8 All equipment used for construction activities shall be fed from separate switching/isolating devices. NO.

head gear.12. KARIMNAGAR DIST. 329 R5 .24 SHEET 4 OF 4 1X700 MW CCPP AT NEDUNOOR.5960A-H-500-001 24. ELECTRICAL SYSTEMS – CONSTRUCTION POWER SUPPLY SPEC. ISSUE R0 335 TCE FORM NO. like hand gloves. 24.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. etc.2 Only ITI qualified workers shall be allowed to handle the electrical or electrically operated equipments. SECTION: D3.1 Adequate safety equipments shall be provided to all the workers.12. Meggers & testers shall be provided in sufficient quantity. TCE. NO.

5% of full scale 0.TRANSDUCERS SPEC. of output channel (c) Accuracy (d) Repeatability (e) Linearity : : : : : 4-20 mA DC Two (2) 0..5 seconds 120% continuous : : : : Galvanic Isolation Self powered Zero and span 500 Ohms (h) Out put Isolation (i) Power (j) Adjustment (k) External resistance. switchgears.1% of full scale 0. distribution boards.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.5% of full scale 25. both inside and outside (if the equipment is mounted on door) for identification. (l) Power frequency withstand capability : 2 kV rms for 1 minute (m)Open circuit and short circuit protection shall be provided. Transducers The transducers supplied shall meet the following specifications.5960A-H-500-001 25.1 GENERAL REQUIREMENT Bidders shall note that each and every device/equipment mounted in panels. ELECTRICAL SYSTEMS . chargers. MCCs. shall be properly tagged. 329 R5 .0 25. NO. (n) All transducers shall have local mA digital display. SECTION: D3. KARIMNAGAR DIST. ISSUE R0 336 TCE FORM NO. (a) Output range (b) No.25 SHEET 1 OF 2 1X 700 MW CCPP AT NEDUNOOR.5 seconds 120% continuous 2 times for 0.2 (f) Residual ripple output current (g) Over load capacity (i) (ii) Current Voltage : : : : 3 to 5% 10 times for 0. TCE. etc.

Note:(*) .4 25. 329 R5 .Administration building not in EPC scope. NO. 25. However the Bidder shall install the LED display and wire the same.ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. TCE. ELECTRICAL SYSTEMS . KARIMNAGAR DIST.3 Digital LED displays for the following parameters shall be provided in two (2) locations in the Main control room and three (3) locations in the administration building (*) (a) Total plant load for each block (b) Frequency (c) Ambient temperature For all outdoor equipment. IS : 14570 ISSUE R0 337 TCE FORM NO. which are not protected by sun cover.6 The following IS standards shall be followed: IS: 12784 : Electrical measuring transducers for converting AC electrical quantities into DC electrical quantities : Electrical measuring transducers for converting AC electrical quantities to analog or digital signals. the heating effect due to solar radiation shall be considered while considering the temperature rise.5960A-H-500-001 25.25 SHEET 2 OF 2 1X 700 MW CCPP AT NEDUNOOR.TRANSDUCERS SPEC. LEDs shall be provided with Low Voltage Guard protection.5 25. Location of the building will be intimated later. SECTION: D3.

1 3. Soft copies may be required both in native file format (e.1 2. all sheets of the specification shall be furnished by each bidder with the signature and company seal affixed thereon.0 2.0 Wherever required.3 3. chemical.5 3.0 3. The successful bidder shall submit the Quality Assurance Plan (QAP) in attached format for BHEL/ Customer approval after the award of contract. testing. PE-TS-I59-888-E001 1. routine and sampling tests shall be as per IS: 15652. Insulating mats to be supplied shall be BIS approved and the same shall be engraved on insulating mats also. As a mark of technical conformance. MS Word/ MS Excel) as well as PDF files.3 2. manufacturing. 2. 5. Mats shall be supplied preferably in units of 2X1 (length X width) metre.4 4. packing and delivery to site of protective mats for placing in front of all 6. 338 . Dispatch of materials shall be permitted only after acceptance of type test certificates. SPECIFIC QUALITY ASSURANCE REQUIREMENTS All type.11 TECHNICAL SPECIFICATION FOR INSULATING MATS SPECIFICATION NO. Insulating mat to be supplied shall be type tested at ERDA.2 3.2 2. mechanical and electrical properties of the insulating mats shall be as per IS: 15652. Packing and marking shall be as per IS 15652.6kV/400V/220V Switchboards.4 2.g. soft copy of all approved technical/ quality documentation shall be submitted as specified without any additional commercial implication. TECHNICAL REQUIREMENTS The physical.0 COMPLIANCE TO SPECIFICATION Bidder shall confirm total compliance to the specification without any deviations from the technical requirements stipulated. inspection.1 SCOPE The scope includes design. and inspection and testing of materials. The mats should have been type tested in accordance with the applicable standards.5.0 1.

depth. Fabrication and installation details of test stations. 19. 8.2 2. 16. Design package on anodes essential incorporating composition. including anode. fabrication and installation details. Power supply arrangement for each T/R set. weather protection cover details and support details for T/R sets. 10. Detail engineering and final design report. IS: 8062 : Code of practice for cathodic protection of steel structure. Test Station.5. 2. Basic design package and system optimisation studies.4 2. 1. 11. GENERAL REQUIREMENT: 2. handling. 12. Anode installation drawings representing all variations in type.5. Material and equipment specifications. Complete CP system layout drawings for each CP station. During detailed engineering the Contractor shall furnish the following for Purchaser’s approval : 2. 339 . II. 6. 4. installation and commissioning checks. 2. 7. IS: 8289 : Construction & testing of electrical apparatus with type of protection ‘n’ 2.  5. If the soil is very corrosive. 22. Connection schemes for all applicable type of test stations and their schedules. 3. 17. CODES & STANDARDS I. 21. Design package on T/R sets essentially incorporating circuit diagrams.5. Procedures for testing during installation. sectionalisation.3 2. 9. data sheets.1 Calculations for arriving at the number and dimension of anodes. Preferably LIDA type anode shall be used.3 Layout of CP system. to prevent corrosion due to any pin holes / holidays. 20. Cable layout schedules and terminals. description on operation and maintenance. 18.5.4 Mounting arrangement of anode and reference electrode. environment. isolation schemes for all structures to be protected and those to be isolated but to be checked out for interaction. Foundation. test stations distribution boxes etc. Interconnection. The CP system shall only be of impressed current type. 14. 2. Design and drawings that may be required for mitigation purposes.12 TECHNICAL SPECIFICATION FOR CATHODIC PROTECTION  SPECIFICATION NO. Safety earthing details. 13. supports etc. 5. 2. Key diagrams of each discrete systems and complete CP system. distribution boxes and cables of all description. fabrications and installation details. PE-TS-I59-888-E001   1. Field Quality Plan covering site storage. schedules and connection schemes.2 Calculations for arriving at the rating of transformer–rectifier set. 2. Installation details of T/R sets. Fabrication and installation details of anode and cathode junction boxes. Corrosion survey report with interpretation. Bidders shall furnish in their BID a brief write up indicating the type of CP system envisaged for various metallic structures in contact with sea water & under ground metallics. commissioning and monitoring of (after installation) complete CP system & each equipment. all underground structures shall be protected against corrosion by providing suitable CP system. parts list. placement. anodes. Quality plans for all equipment/ items.5 The following minimum design documentation [not essentially limited to these only] shall be furnished by the successful vendor (for review and approval) at contract stage.1 All the metallic structures which are in contact with sea water & underground metallics shall be provided with Cathodic Protection (CP) system irrespective of the material of structures. 15.

27. 24. Performance Test Report. 30. 25. 340 . Composite Operation and Maintenance Manual. 26. 29. Final check list and completion report. Billing break-up Note : The list of deliverables shall be finalised during kick-off meeting at contract stage. Monitoring formats. Monitoring schedules.12 TECHNICAL SPECIFICATION FOR CATHODIC PROTECTION  23. 32. PE-TS-I59-888-E001   Cable to pipe joint arrangement using thermite welding. 28.  5. SPECIFICATION NO. Material test certificate for the materials purchased by the vendor along with copy of manuals. List of E&C Spares. 31. Inspection and test certificates for items fabricated and erected.

ANNEXURE-II 341 .

342 .

343 .

344 .

345 .

346 .

INSPECTED AND TESTED AS PER THE BHEL/ CUSTOMER APPROVED QUALITY PLAN. BHEL QPs ARE ENCLOSED FOR REFERENCE. MANUFACTURED. INSPECTION & TESTING: ALL MATERIALS. COMPONENTS AND EQUIPMENT’S COVERED UNDER THIS SPECIFICATION SHALL BE PROCURED. 347 .Doc. QUALITY ASSURANCE. PE-TS-I59-888-E001 700MW KARIMNAGAR CCPP TECHNICAL SPECIFICATION FOR GENERAL ELECTRICAL WORKS Rev. THERE SHALL BE NO COMMERCIAL IMPLICATION TO BHEL ON ACCOUNT OF QP APPROVAL. No. : Page : 0 of 8.

/SPEC RELEVENT IS/ LOG BOOK 3 - - 2. MANFR'S DRG.CUSTOMER : QUALITY PLAN SHEET 1 OF 9 COMPONENT/OPERATION CHARACTERISTIC CHECK BIDDER/ VENDOR SYSTEM CAT.SURFACE CONDITION MA MECH.3 CASTING 1.DIMENSIONS MA MEASUREMENT SAMPLE MANFR'S DRG. MANFR'S DRG. PLATES. REPORT 3 - - MA VISUAL 100% FREE FROM CRACKS. NO. PROP. -DO- 3 - - 2. SHADE. : PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-007/2 ITEM: AC ELECT. EYEBOLTS 3 4 5 6 7 8 9 10 11 1.1 1. TEST -DO- INSPEC./SPEC LOG BOOK 3 - - 1. SHELF LIFE & TYPE MA VISUAL 100% MANFR'S CONTINUOUS DRG.PROOF LOAD TEST (EYE BOLT) 1./SPEC -DO- LOG BOOK 3 - - 2. SECTION. SUPPLIER'S TC 3 - 2 HEAT NO.MAKE./SPEC BOOK RELEVENT IS/SPEC.0 2 RAW MATERIAL & BROUGHT CONTROL SHEET STEEL. MANUFR'S DRG.CHEM.SURFACE CONDITION MA VISUAL 100% - FREE FROM BLINKS.2 HARDWARES 1. CRACKS. WAVINESS ETC MANFR'S DRG. & PHY. BLOW HOLES ETC. SHALL BE VERIFIED 3./SPEC -DO- -DO- 3 - - 3. MOTORS 75KW & ABOVE (LV & MV) REFERENCE ACCEPTANCE FORMAT DOCUMENT NORM OF RECORD SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION VOLUME III AGENCY REMARKS P W V SL. UNEVENNESS ETC.4 PAINT & VARNISH 1. TYPE/ METHOD OF CHECK EXTENT OF CHECK 1 1.DIMENSIONS MA MEASUREMENT 100% MANUFR'S DRG./SPEC LOG BOOK 3 - - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR 348 BIDDER'S/VENDORS COMPANY SEAL .PROPERTY CLASS MA VISUAL SAMPLES SUPPLIERS TC & LOG 3 - 2 PROPERTY CLASS MARKING SHALL BE CHECKED BY THE VENDOR 1. MA CHEM & MECH TEST 1/HEAT NO. MANFR'S DRG.SURFACE CONDITION MA VISUAL 100% FREE FROM CRACKS.

CABLES. DESIGN MANUFR'S DRG.PERFORMANCE/ CALIBRATION MA MEASUREMENT SAMPLE MANUFR'S DRG. MANUFR'S DRG. CONNECTORS. SURFACE COND. -DO- 3 - - 2. SUPPLIER'S TC 3 - 2 3.5 2 SHAFT (FORGED OR ROLLED) 3 1. DRG. & PHYSICAL TESTS 1/HEAT NO. DETECTORS. DIMENSIONS MA MEASUREMENT 100% -DO- MANUFR'S DRG.INTERNAL FLOWS CR UT -DO- ASTM-A388 -DO- 3 2 1 FOR DIA OF 55 MM & ABOVE 1.6 SPACE HEATERS. SPEC. MAKE & RATING MA VISUAL -DO- MANUFR'S DRG. MA -DO- -DO- - NO BREAKAGE ON OTHER PHY. REPORT 3 - - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 349 . NO. RTD.DIMENSIONS (WHEREVER APPLICABLE) 4. CARBON BRUSH TEMP. / SPEC. & PHYSICAL PROPERTIES MA CHEM. BTD'S 1. OR HEAT TREATMENT BATCH NO MFG. TYPE/ METHOD OF CHECK EXTENT OF CHECK 1 1. CHEM. : PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-007/2 ITEM: AC ELECT. CABLE LUGS. MANUFR'S SPEC. TERMINAL BLOCKS. MOTORS 75KW & ABOVE (LV & MV) REFERENCE ACCEPTANCE FORMAT DOCUMENT NORM OF RECORD SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION VOLUME III AGENCY REMARKS P W V SL.CUSTOMER : QUALITY PLAN SHEET 2 OF 9 COMPONENT/OPERATION CHARACTERISTIC CHECK BIDDER/ VENDOR SYSTEM CAT./ SPEC. -DO- 3 - - 3. SPEC. -DO- 3 - - MA TEST 100% -DO- -DO- INSP. SPEC. BHEL SPEC. PHYSICAL COND. MA 4 VISUAL 5 100% 6 - 7 8 FREE FROM VISUAL DEFECTS RELEVANT IS -DO- 9 3 10 - 11 VENDOR'S APPROVAL IDENTIFICATION SHALL BE MAINTAINED 2. LOG BOOK 3 - - 4.

CUSTOMER : QUALITY PLAN SHEET 3 OF 9 COMPONENT/OPERATION CHARACTERISTIC CHECK BIDDER/ VENDOR SYSTEM CAT. REPORT 3 10 - 11 2.DIMENSIONS INCLUDING BURS HEIGHT 3.8 SHEET STAMPING (PUNCHED) 1. BINDINGS CORDS.7 2 OTHER INSULATING MATERIALS LIKE SLEEVES.ELECT. : PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-007/2 ITEM: AC ELECT. NO. PAPERS. 3 1. ACCEPTANCE TESTS MA MEASUREMENT SAMPLE MANUFR'S DRG. 3 - - 2. REPORTS 3/2 - 2 BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 350 . LOG BOOK AND OR SUPPLIER'S TC LOG BOOK 3 - 2 1. SURFACE FINISH MA VISUAL 100% FREE FROM VISUAL DEFECTS RELEVANT IS/ BS OR OTHER STANDARDS LOG BOOK 3 - - 2. & MECH TESTS -DO- MANUF'S SPEC. & MECH. -DO- 3 - 2 FOR MV MOTOR INSULATION/VARNISH THICKNESS SHALL BE MORE THAN THE BURS HEIGHT MA ELECT. & MECH. SURFACE COND. PROP./ RELEVANT IS - RELEVANT IS SUPPLIER'S TC 3 - 2 1. PRESS BOARDS ETC. SURFACE COND. MANUF'S SPEC. PROP MA ELECT.TEST SAMPLES RELEVANT IS/ BS OR OTHER STANDARDS SUPPLIERS TC & VENDOR'S INSPN. . MA VISUAL 100% - NO VISUAL DEFECTS (FREE FROM BURS) MANUFR'S DRG. MA 4 VISUAL 5 100% 6 - 7 8 NO VISUAL DEFECTS 9 INSPT. OTHER CHARACTERISTICS MA TEST SAMPLE MANUF'S SPEC.9 CONDUCTORS 1. TYPE/ METHOD OF CHECK EXTENT OF CHECK 1 1. MOTORS 75KW & ABOVE (LV & MV) REFERENCE ACCEPTANCE FORMAT DOCUMENT NORM OF RECORD SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION VOLUME III AGENCY REMARKS P W V SL.

MAKE & TYPE 2. MA VISUAL 100% MANUF'S DRG/SPECS - MANUF'S DRG. -DO- 3 - - 3. NO.HV/IR MA ELECT.CUSTOMER : QUALITY PLAN SHEET 4 OF 9 COMPONENT/OPERATION CHARACTERISTIC CHECK BIDDER/ VENDOR SYSTEM CAT.DIMENSIONS MA MA MA 4 5 MEASUREMENT VISUAL 6 -DO100% 7 -DOMANFR'S DRG.SURFACE FINISH MA VISUAL 100% - -DO- 3 - - 1. : PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-007/2 ITEM: AC ELECT. 2.MATERIAL OF GASKET 2.TEMP.DIMENSIONS MEASUREMENT SAMPLE 3.SURFACE COND./ SPECS.12 OIL SEALS & GASKETS 1. MOTORS 75KW & ABOVE (LV & MV) REFERENCE ACCEPTANCE FORMAT DOCUMENT NORM OF RECORD SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION VOLUME III AGENCY REMARKS P W V SL.TEST -DO- -DO- 3 - - MA -DO- 100% -DO- -DO- -DO- 3 - - 1.DIMENSIONS MA MEASUREMENT SAMPLE MANUF'S DRG -DO- 3 - - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 351 .DIMENSIONS MA VISUAL 100% - -DO- -DO- 3 - - MA MEASUREMENT SAMPLE MANUF'S DRG MANUF'S SPEC. BHEL DATA SHEET BEARING MANUF'S CATALOGUES FREE FROM VISUAL DEFECTS 9 Log Book -DO-DO3 3 3 10 - 11 1. MANUF'S DRG MANUF'S SPEC.SURFACE COND. TYPE/ METHOD OF CHECK EXTENT OF CHECK 1 2 3 3. FREE FROM VISUAL DEFECTS MANUF'S DRG -DO- 3 - - MA VISUAL 100% -DO- 3 - - 3. BHEL DATA SHEET 8 -DOMANFR'S DRG.11 SLIP RING 1.10 BEARINGS 1.WITHSTAND CAPACITY 4.

0 2./ BHEL SPEC. SAME AS COL.WORKMANSHIP & CLEANNESS MA VISUAL 100% -DO- GOOD FINISH LOG BOOK 3 - - 2.CUSTOMER : QUALITY PLAN SHEET 5 OF 9 COMPONENT/OPERATION CHARACTERISTIC CHECK BIDDER/ VENDOR SYSTEM CAT. : PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-007/2 ITEM: AC ELECT.FINISH 2. MOTORS 75KW & ABOVE (LV & MV) REFERENCE ACCEPTANCE FORMAT DOCUMENT NORM OF RECORD SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION VOLUME III AGENCY REMARKS P W V SL.SHAFT SURFACE MA FLOWS PT -DO- -DO- 3 - 1 2./ RELEVANT STAND -DO- MANUF'S DRG GOOD FINISH MANUF'S DRG MANUFR'S SPEC.DIMENSIONS MA MA VISUAL 100% LOG BOOK -DO- 3 3 - - MEASUREMENT -DO- 3.PAINT THICKNESS MA (BOTH PRIMER & FINISH COAT) 3.2 MACHINING 1.1 IN PROCESS 2 3 4 5 6 7 8 9 10 11 STATOR FRAME WELDING (IN CASE OF FABRICATED STATOR ) 1.SURFACE PREPARATION MA VISUAL 100% LOG BOOK 3 - - 2.7 -DO- 3 - - 2. NO.3 PAINTING 1. TYPE/ METHOD OF CHECK EXTENT OF CHECK 1 2./ BHEL SPEC.DIMENSIONS MA MEASUREMENT -DO- MANUF'S DRG -DOMANUF'S DRG RELEVENT SPEC./ ASTM-E165 MANFR'S SPEC/BHEL SPEC.SHADE 4.ADHESION MA MA MEASUREMENT SAMPLE BY ELCOMETER -DO- -DO- 3 - 2 VISUAL CROSS CUTTING & TAPE TEST -DO-DO- -DO-DO- -DO-DO- Log Book Log Book 3 3 - - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 352 .

CLEANLINESS 3.COMPLETENESS MA MEASUREMENT 100% Log Book 3 - - MA ELECT.IR-HV-IR 4.RESISTANCE 5.6 IMPREGNATION 1.SURGE WITH STAND AND TAN. TEST PROCESS CHECK AT STARTING -DOCONTINUOUS -DO- -DO-DO- Log Book Log Book 3 3 - - MA -DO- -DO- -DO- -DO- Log Book 3 - 2 THREE DIPS TO BE GIVEN BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 353 .VISCOSCITY 2.COMPRESSION & TIGHTENING 3.CUSTOMER : QUALITY PLAN SHEET 6 OF 9 COMPONENT/OPERATION CHARACTERISTIC CHECK BIDDER/ VENDOR SYSTEM CAT. -DO-DO-DO-DO- Log Book 3 - - 2. DELTA TEST 2.INTERTURN INSULATION 6. : PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-007/2 ITEM: AC ELECT. -DO-DO-DO-DO- MANUFR'S SPEC.CORE LOSS & HOTOPOT 2./BHEL SPEC.TEMP.5 WINDING 1.TEST -DO- -DO- -DO- Log Book 3 - 2 (FOR MOTORS OF 2MW AND ABOVE) CR VISUAL 100% MANUFR'S SPEC.4 2 SHEET STACKING 3 1. PRESSURE VACCUM 3. -DO- 8 MANUFR'S SPEC. -DO- 9 Log Book 3 10 - 11 MEASUREMENT SAMPLE 2. TYPE/ METHOD OF CHECK EXTENT OF CHECK 1 2. MOTORS 75KW & ABOVE (LV & MV) REFERENCE ACCEPTANCE FORMAT DOCUMENT NORM OF RECORD SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION VOLUME III AGENCY REMARKS P W V SL. NO.COMPLETENESS MA 4 5 6 7 MANUFR'S SPEC.NO. OF DIPS CR CR CR CR -DOELECT./BHEL SPEC. TEST -DO-DO- -DO-DO-DO-DO- Log Book Log Book Log Book Log Book 3 3 3 3 2 2 - CR -DO- -DO- -DO- -DO- Log Book 3 2 1 FOR MV MOTOR MA MA PHY.

CUSTOMER : QUALITY PLAN SHEET 7 OF 9 COMPONENT/OPERATION CHARACTERISTIC CHECK BIDDER/ VENDOR SYSTEM CAT.9 COMPLETE ROTOR ASSEMBLY 1.SOUNDNESS OF DIE CASTING 2.DURATION 4 MA MA -DOVISUAL 5 6 -DO100% -DO-DO- 7 -DO-DO- 8 9 Log Book Log Book 3 3 10 2 - 11 2.COMPLETENESS 2. (GROWLER TEST) MEAS. : PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-007/2 ITEM: AC ELECT. MOTORS 75KW & ABOVE (LV & MV) REFERENCE ACCEPTANCE FORMAT DOCUMENT NORM OF RECORD SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION VOLUME III AGENCY REMARKS P W V SL./ MFG SPEC.COMPACTNESS & CLEANLINESS 1./ ISO 1940 MFG. DWG.CORRECTNESS.ALIGNMENT 2. SPEC. SPEC. DRG/ RELEVANT IS MFG SPEC. NO.HV 2. -DO- -DO- MFG.10 ASSEMBLY 1.8 CR CR -DOMALLET TEST & MV TEST ELECT.AXIAL PLAY 4. VISUAL MEAS. BALANCE -DO-DO- -DO-DO- -DO-DO- Log Book Log Book 3 3 - - 3.RESIDUAL UNBALANCE 2.DIMENSIONS MA CR -DO-DO- -DOMFG SPEC.DRG. -DO-DO-DOMFG. RELEVANT IS Log Book Log Book Log Book Log Book 3 3 3 3 - 2 - 5. COMPLETENESS TERMINATIONS/ MARKING/ COLOUR CODE MA VISUAL 100% MFG SPEC. TYPE/ METHOD OF CHECK EXTENT OF CHECK 1 2 3 4. TEST DYN.WORKMANSHIP 3. Log Book Log Book 3 3 2 1 VERIFICATION FOR MV MOTOR ONLY CR ELECT. RELEVANT IS Log Book 3 - - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 354 .SOUNDNESS 2. Log Book 3 2 - MA MA MA MA -DO-DO-DO-DO- -DO-DO-DOMFG. -DOMFG.7 COMPLETE STATOR ASSEMBLY BRAZING/COMPRESSION JOINT 1.

AND DATA SHEET IS-325 & DATA SHEET IS-3682 IS-8239 IS-8240 -DOINSPC.NAMEPLATE DETAILS 7.TYPE TESTS INCLUDING SPECIAL TESTS AS PER BHEL SPEC. & DATA SHEET TC 3 2. 2. TYPE/ METHOD OF CHECK EXTENT OF CHECK 1 3.1 TC FROM AN INDEPENDENT LABORATORY NOTE-3 - 6.VIBRATION MA 4 5 ELECT.1 - 4. & DATA SHEET BHEL SPEC.2 1. NO. THICKNESS & FINISH MA VISUAL 100% IS-325 & DATA SHEET IS-3682 IS-8239 IS-8240 INSPC./ DATA SHEET 9 TEST REPORT 3 10 1 11 1. : PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-007/2 ITEM: AC ELECT.0 TESTS 2 3 1.1 - SAMPLING PLAN TO BE DECIDED BY INSPECTION AGENCY BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 355 .1 NOTE-3 MA VISUAL & SAMPLE MEASUREMENT BY ELKOMETER BHEL SPEC. TEST 1/TYPE/ SIZE RELEVANT IS TC 3 - 2.1 MA -DO- 100% -DO- -DO- -DO- 3 1./ DATA SHEET 8 IS-325/ BHEL SPEC.2 NOTE .ROUTINE TESTS INCLUDING SPECIAL TEST AS PER BHEL SPEC.OVERALL MA DIMENSIONS AND ORIENTATION MEASUREMENT 100% & VISUAL 5. REPORT TC 3 2.EXPLOSION FLAME PROOF NESS (IF SPECIFIED) 8.PAINT SHADE. & MECH. REPORT 3 3 1.CUSTOMER : QUALITY PLAN SHEET 8 OF 9 COMPONENT/OPERATION CHARACTERISTIC CHECK BIDDER/ VENDOR SYSTEM CAT.2 NOTE .2 MA -DO- 100% IS-12075 APPROVED DRG/DATA SHEET IS-12075 APPROVED DRG/DATA SHEET & RELEVANT IS BHEL SPEC. 3.DEGREE OF PROTECTION MA ELECT.TEST 6 1/TYPE/SIZE 7 IS-325/ BHEL SPEC.2 2. MOTORS 75KW & ABOVE (LV & MV) REFERENCE ACCEPTANCE FORMAT DOCUMENT NORM OF RECORD SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION VOLUME III AGENCY REMARKS P W V SL.1 MA EXPLOSION FLAME PROOF TEST 1/TYPE 3 - 2.

MOTORS 75KW & ABOVE (LV & MV) REFERENCE ACCEPTANCE FORMAT DOCUMENT NORM OF RECORD SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION VOLUME III AGENCY REMARKS P W V SL. THE SAMPLING PLAN SHALL BE MUTUALLY AGREED UPON. SIZE AND DESIGN OF MOTOR FROM INDEPENDENT LABORATORY ARE AVAILABLE. NO. THESE TEST MAY NOT BE REPEATED. BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 356 . : PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-007/2 ITEM: AC ELECT. WITNESSING BY BHEL SHALL BE DECIDED.CUSTOMER : QUALITY PLAN SHEET 9 OF 9 COMPONENT/OPERATION CHARACTERISTIC CHECK BIDDER/ VENDOR SYSTEM CAT. AGENCY (1) SHALL MEAN BHEL AND CUSTOMERS BOTH TOGETHER. 3 IN CASE TEST CERTIFICATES FOR THESE TESTS ON SIMILAR TYPE. 2 ROUTINE TESTS ON 100% MOTORS SHALL BE DONE BY THE VENDOR. BHEL SHALL WITNESS ROUTINE TESTS ON RANDOM SAMPLES. HOWEVER. 4 WHEREVER CUSTOMER IS INVOLVED IN INSPECTION WITH THE CUSTOMERS. TYPE/ METHOD OF CHECK EXTENT OF CHECK 1 2 NOTES: 3 4 5 6 7 8 9 10 11 1 DEPENDING UPON THE SIZE AND CRITICALLY.

WORKMANSHIP 2.CUSTOMER : BIDDER/ VENDOR SHEET 1 OF 2 SYSTEM COMPONENT/OPERATION CHARACTERISTICS CAT. SPEC. DRG./ MFG./ RELEVANT IS MANUF'S SPEC MFG. DRG.DIMENSIONS MA MA VISUAL -DO- 100% -DO- -DO-DO- 3 3 - - 3.ROUTINE TEST INCLUDING SPECIAL TEST AS PER BHEL SPEC.7 TEST REPORT 3 2. REPORT 2 1 - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 357 . MFG.O PAINTING 2 1. MFG./ MFG. NO. MOTORS BELOW 75KW (LV) EXTENT OF REFERENCE ACCEPTANCE FORMAT CHECK DOCUMENT NORM OF RECORD SPECIFICATION : NUMBER : SPECIFICATION TITLE SECTION VOLUME III AGENCY REMARKS P W V SL.0 TESTS 1. RELEVANT IS 2.SPEC.1 NOTE -1 MA MEASUREMENT 100% & VISUAL APPROVED DRG/DATA SHEET APPROVED DRG/DATA SHEET & RELEVANT IS INSPN.SPEC.1 2.0 ASSEMBLY 1. SPEC. SPEC/BHEL SAME AS SPEC. 2. CHECK QUALITY PLAN : PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-006/0 ITEM AC ELECT.CORRECTNESS COMPLETENESS TERMINATIONS/ MARKING/COLOUR CODE 3./ DATA SHEET SAME AS COL.7 STANDARD MANUF'S SPEC MFG.OVERALL DIMENSIONS & ORIENTATION MA VISUAL 100% -DO- 3 - - MA -DO- 100% IS-325/ BHEL SPEC. TYPE/ METHOD OF CHECK 1 1.SHADE 3 MA 4 VISUAL 5 6 SAMPLE 7 8 9 LOG BOOK 3 - 10 - 11 MANUFR'S BHEL SPEC./RELEVANT COL.

REPORT 3 10 1 - 11 NOTES: 1 2 3 ROUTINE TESTS ON 100% MOTORS SHALL BE DONE BY THE VENDOR. BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 358 .NAMEPLATE DETAILS MA 4 VISUAL 5 100% 6 7 IS-325 & DATA SHEET 8 IS-325 & DATA SHEET 9 INSPN.CUSTOMER : QUALITY PLAN BIDDER/ VENDOR SHEET 2 OF 2 SYSTEM COMPONENT/OPERATION CHARACTERISTICS CAT. THE SAMPLING PLAN SHALL BE MUTUALLY AGREED UPON WHERE EVER CUSTOMER IS INVOLVED IN INSPECTION. BHEL SHALL WITNESS ROUTINE TESTS ON RANDOM SAMPLES. TYPE/ METHOD OF CHECK PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-006/0 ITEM AC ELECT. (1) SHALL MEAN BHEL AND CUSTOMERS BOTH TOGETHER. FOR EXHAUST/VENTILATION FAN MOTORS OF RATING UPTO 1. CHECK : SL. NO.5KW . HOWEVER. ONLY ROUTINE TEST CERTIFICATES SHALL BE FURNISHED FOR SCRUTINY. MOTORS BELOW 75KW (LV) EXTENT OF REFERENCE ACCEPTANCE FORMAT CHECK DOCUMENT NORM OF RECORD SPECIFICATION : NUMBER : SPECIFICATION : TITLE : SECTION VOLUME III AGENCY REMARKS P W V 1 2 3 3.

DRGS.0 1.DIMENSIONS 3.3 GALVANISING 1. DRGS. MA MA MEASUREMENT 100% VISUAL 100% IS-1730/ SPECIFICATION IS-1730/ SPECIFICATION QC RECORD QC RECORD 3/'2 3/'2 - - IS1079 (for hot rolled) IS1079 (for hot rolled) IS-513 (for cold rolled IS-513 (for cold rolled) IS-209 IS-209 MA CHEM TEST EACH HEAT QC RECORD 3/2 - 1/2 MA MA MEASUREMENT 100% VISUAL 100% APPD.0 2. COMPONENT/OPERATION CHARACTERISTIC CHECK BIDDER/ VENDOR SYSTEM CAT.1 2 RAW MATERIAL ROLLED SHEET 3 4 5 6 7 8 9 10 11 1.COMP. PROPERTIES MA VERIFICATION OF TC'S 100% IS1079 (for hot rolled) IS1079 (for hot rolled) IS-513 (for cold rolled IS-513 (for cold rolled) MILL TC 3/2 - - AS PER CONTRACT & AS APPLICABLE IN TECH.TEMPERATURE OF BATH MA VISUAL 100% SPECIFICATION QC RECORD 2 - 1 MA MEASUREMENT PERIODIC IN EACH SHIFT IS:2629 IS:2629 QC RECORD 2 - - MA VISUAL 100% IS:2629 IS:2629 QC RECORD 2 - - MA TEMPERATURE INDICATOR CONTINUOUS IS-2629 IS-2629 QC RECORD 2 - - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 359 .CUSTOMER : PROJECT TITLE SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION AGENCY P W V VOLUME III REMARKS QUALITY PLAN SHEET 1 OF2 SL.WELDING QUALITY CHEM.2 SURFACE PREPARATION 1. NO.& PHY. : TYPE/ METHOD OF CHECK EXTENT OF CHECK QUALITY PLAN NUMBER PED-507-00-Q-013/00 ITEM : CABLE TRAY SUPPORT MATERIAL & ACCESSORIES (BOLTABLE) REFERENCE ACCEPTANCE FORMAT DOCUMENT NORM OF RECORD 1 1. PICKLING. SPECIFICATION 2.SURFACE FINISH 2. RINSING & FLUXING 2. FREE FROM DEFECTS & SLAG SPECIFICATION QC RECORD QC RECORD 2 2 - 1 1 WELDING IS TO BE DONE BY QUALIFIED WELDERS 3.DIMENSIONS 2.SURFACE FINISH 1.CLEANING. SURFACE QUALITY 2.CHEM.2 2.1 ZINC IN-PROCESS FABRICATION 1. GOOD WELDING PRACTICE APPD.

WELD INTEGRITY TEST TO CHECK THE WELD SOUNDNESS/ ACCEPTANCE SHALL BE DONE BY MANUFACTURER NOTE: INSTRUCTIONS FOR QUALITY PLAN IS ATTACHED AS ANNEXURE-1.MASS OF ZINC COATING 4. COMPONENT/OPERATION CHARACTERISTIC CHECK BIDDER/ VENDOR SYSTEM CAT.SURFACE QUALITY 4 MA MA VISUAL 5 6 CONTINUOUS IS .2629 7 IS . TEST IS-4759 / SPECIFICATION IS-4759 / SPECIFICATION IS-6745 / SPECIFICATION IS-2633 INSP. INSP. FLUX.1 FINISHED ITEMS SINGLE / DOUBLE CHANNELS.1 TYPE TESTING MA CHEM.ADHESION 3.THICKNESS OF ZINC COATING 6. CLAMPS 1. TEST IS-2633 INSP.2 WELD INTEGRITY TEST SOUNDNESS CR MPI SAMPLE TESTED SPECIFICATION. DRG INSP. ETC. SPECIFICATION/ INSP. SPECIFICATION. STAIN. BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 360 .0 3.UNIFORMITY OF ZINC COATING 5. TYPE TEST PROCEDURE INSP.SURFACE FINISH MA MEASUREMENT IS-2500 LEVEL IV VISUAL IS-2500 LEVEL IV APPD.CUSTOMER : PROJECT TITLE SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION AGENCY P W V VOLUME III REMARKS QUALITY PLAN SHEET 2 OF 2 SL.2629 / MFR'S PRACTICE FREE FROM BURRS. REPORT 2 1 - AFTER CARRYING OUT TYPE TEST. DURING TYPE TESTING NO DEFECT INSP. REPORT 3 2. 1 - MA CR MECH. ETC. REPORT 3 2. REPORT 2 1 - MA ELCOMETER IS-4759 / SPECIFICATION SPECIFICATION. FLUX. REPORT 3 2. RATE OF IMMERSION 4. 1 1 - 3. REPORT 3 2 2. SLAG. ROUGHNESS.2629 8 9 QC RECORD QC RECORD 2 3 10 2 11 VISUAL / 100% MEASUREMENT VISUAL 100% IS . ROUGHNESS. NO.2629 / IS . CANTILEVER ARMS. 1 - 3. MA QC RECORD 2 - - 3./ APPD. DRG APPD. TYPE TEST PROCEDURE IS-2629 SPECIFICATION. REPORT INSP. STAIN. 1 - MA CHEM.TEST TEST IS-4759 1 SAMPLE IS-2629 SPECIFICATION.2629 / MFR'S PRACTICE IS . : TYPE/ METHOD OF CHECK EXTENT OF CHECK QUALITY PLAN NUMBER PED-507-00-Q-013/00 ITEM : CABLE TRAY SUPPORT MATERIAL & ACCESSORIES (BOLTABLE) REFERENCE ACCEPTANCE FORMAT DOCUMENT NORM OF RECORD 1 2 3 2. 1 FASTENERS SHALL BE OF REPUTED & APPROVED MAKE MA SPECIFICATION FREE FROM BURRS. REPORT 3 2./ APPD. DROSS 3.DIMENSIONS DISTORTION 2.1. SLAG.1.

Agency . Wherever inspection by BHELs Purchaser/Third Party/Statutory authorities are mandatory. such as. Column 4Category -‘CR’ stands for critical characteristic . This Quality Plan is also applicable to spares. log shets. When this is not possible for casting. In absence of correlation with the test certificate(s) (e. formats etc. Column 9Format of Record . according to which acceptability or otherwise of the characteristics being checked is decided. When welders qualified by reputed inspection agencies or statutory bodies are not available. They shall include all stages of operation such as materials. such as technical specification. this shall be compiled with. When materials and components are initially identified and stamped by BHEL QS engineer. reports. processes. etc. visual examination radiography etc. 1 percent etc. ‘2’ Stands for Vendor ‘3’ stands for sub-Vendor of the Vendor and so on. Inspection reports. If there are contradictions in respect of column 7 & 8 between this Quality Plan and the approved drawings specifications.affecting appearance etc.The agency which performs the test/instruction shall be written in sub-column ‘W’ The agency which verifies test certificates/inspection records and carries out audit check of the components/operation shall be written in sub-column ‘V’ The agencies are codified as 1. the identification marks shall be presserved till despatch. etc. etc. the identification mark shall be transferred to the components in the presence of BHEL QS Engineer unless other wise agreed..g. log sheets. NOTES : 1.affecting safety of equipment and personnel ‘MI’ stands for minor characteristic . chemical analysis tensile testing./inspection to be witnessed by Vendor’s QC Entry ‘1’ in column ‘V’ means verification shall be done by BHEL and next stage to be started only after the hold point is cleared by BHEL Column11I. Column 7Reference Documents . qualification tests shall be conducted in the presence of BHEL QS Engineer.g. Column 1Column 2Column 3- 3. 10./inspection to be performed by sub-Vendor’s QC Entry ‘2’ in column ‘W’ means test. assembly.Remarks . if witnessing of test by BHEL is called for. 361 . 9. 5. Column 6Extent of check. This Quality Plan is liable to be modified as per the requirements of approved drawings and changes in technical specifications/drawings. chemical composition. as required.g. 4. 2. Characteristics check. surface defects etc.The component and/or operation being checked shall be given here. material identification) samples shall be drawn bgy BHEL and all tests as per relevent specifications shall be carried out in their presence or in recognized Government Laboratory. Column 10.2 & 3 ‘1’ stands for (BHEL) ‘1’ * means the operation shall be cleared by BHEL before the start of the next operation. BS ETC..affecting safety of equipment and personnel ‘MA’ stands for major Characteristic .Any special remarks shall be given here. 7. Standard log sheets. Wherever this is not possible.Standards etc. under scope of supply of Vendor. of the Vendors shall be numbered and such reference numbers shall be included here. according to which check is done. hydraulic test.) procedure. The following guide lines may be noted: Serial Number Component/Operation. Column 8Acceptance Norms . they shall be poured in the presence of BHEL QS Engineer unless otherwise. mechanical properties. in which the observations are recorded. manufacture. reports. Example : Entry ‘3’ in column ‘P’ means test. leak tightness. packing and despatch. test reports/certificate.The characteristics being checked shall be given here. standard specifications (IS. if any. e.Documents.ANNEXURE – 1 INSTRUCTIONS FOR QUALITY PLAN The Quality Plan shall include all the Quality Control Measures and Checks adopted by the Vendor to ensure that the material/component/assembly/services supplied by him meet/will meet the requirements as per specifications and good practices. For castings and forgings integral test specimens shall be provided. 8. 6. 100. Column 5Type/Method of check e. shall be furnished to BHEL at the approproate stages or at the time of final inspection. the latter shall prevail. The quality plan shall be submitted in minimum 4 copies with a soft copy of the same or in line with contract requirements.Formats. drawings.

DRGS INSPN. ANGLES & CHANNEL 1. BIMETAL THERMAL RELAYS. 5. INSTRUMENT. IS RELEVANT./ RELEVENT IS 100% -DO- BHEL SPEC. HARDWARES. TYPE TESTS MA ELECTRICAL EACH TYPE BHEL SPEC.1 2. FUNCTIONAL TEST MA VISUAL 100% NO BREAKAGES/ DAMAGES BHEL SPEC./ TEST DRG./ BHEL TECH. -DO- 3/2 - 2 1. TRANSF.S & MCCB. NO.0 1./ APPD. BREAKAGES/ DAMAGES BHEL SPEC. SPEC. & RELEVANT. SURFACE PROTECTION (HARDWARES) MA VISUAL SAMPLE -DO- BHEL SPEC.2 SWITCHGEAR COMPONENTS A) SWITCH./ APPD. /DATA SHEETS/ CERT. : PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-002/01 ITEM :BOUGHT OUT ITEMS EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION NUMBER SPECIFICATION TITLE SECTION AGENCY P W V SL. DIMENSIONS MA MEASUREMENT SAMPLE BHEL TECH. ISOLATORS.1 MATERIAL 2 3 4 5 6 7 8 9 10 11 SECTIONS.S 1. PHYSICAL CONDITION 4. SURFACE CONDITION MA VISUAL 100% 3/2 - 2 TC FOR PLATING QUALITY TO BE PROVIDED 3. /DATA SHEETS/ DRG. TYPE/ METHOD OF CHECK FORMAT OF RECORD VOLUME III REMARKS 1 1. MCB. SFU'S SWITCH SFU'S. MAKE TYPE RATING ETC.FOREM NO./ RELEVENT IS -DO- TEST CERTIFICATE ROUTINE TEST CERTIFICATE 3/2 - 2. CONTACTORS AIR CIRCUIT BREAKERS. FLATS. REPORT -DONO VISUAL DEFECTS -DO- 3/2 - 2 NO VISUAL DEFECT 2. REPORT -DO- 2 - - MA VISUAL 100% 2 - - TO BE PROCURED FROM APPROVED MAKE MA ELECTRICAL 100% RELEVENT IS RELEVENT IS -DO- 2 - - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDOR'S COMPANY SEAL 362 . ROUTINE TESTS (FOR METERS CT'S & PT'S) MA ELECTRICAL 3/2 - 2 IF THESE ARE TAKEN FROM BHEL APPROVED SOURCE THEN TC NOT REQUIRED 3. PEM-6041-0 CUSTOMER : QUALITY PLAN SHEET 1 OF 3 COMPONENT/OPERATION CHARACTERISTIC CHECK BIDDER/ VENDOR SYSTEM CAT. DRGS NO. IS INSPN. FUSES. SPEC.

TEST SAMPLE SAMPLE -DO-DO- 2 3/2 - 1 1 MA VISUAL 100% NO VISUAL DEFECT BHEL SPECN.SMC. RELEVANT IS INSPECTION REPORT -DO- 2 - - MA VISUAL 100% 2 - - TO BE PROCURED FROM APPROVED MAKE MA ELECTRICAL 100% -DO- 2 - - REFER TO QP NO………PED-557-00-Q-002 1./ APPD. RELEVANT IS NO BREAKAGES/ DAMAGES BHEL SPEC. 2. DRGS. DRGS. 3.ETC. DRGS.) MA VISUAL 100% NO BREAKAGES/ DAMAGES BHEL SPEC. FERRULES./ APPD. PVC SLEEVES/ CHANNELS C) RELAYS & TIMERS 1.DMC. SURFACE FINISH 2. PEM-6041-0 CUSTOMER QUALITY PLAN SHEET 2 OF 3 COMPONENT/OPERATION CHARACTERISTIC CHECK BIDDER/ VENDOR SYSTEM CAT. 3. RELEVANT IS NO BREAKAGES/ DAMAGES BHEL SPEC. LUGS. TEST ELECT. PUSHBUTTONS. IS:694 NO VISUAL DEFECT BHEL SPECN. MAKE. MAKE. TEST SAMPLE BHEL SPEC. STD.FOREM NO./ APPD. TYPE. PHYSICAL CONDITION 2. REPORT -DO-DO- 2 - - MA CR HV MEASUREMENT ELECT. B) INSTRUMENTS. FUNCTIONAL STICKERS. STD.THERMOSTAT. IS:694 LOG BOOK/ INSP./ RELEVANT IS MANUFS. -DO-DOTEST CERTIFICATE 2 1 2. NAMEPLATES. FUNCTIONAL TEST D) PCB ASSEMBLY 1. RATING ETC SWITCHES. RATING ETC 3. GAUGES INSTRUMENTS GAUGES. GLANDS CONDITION SPACE HEATER. -DO-DOBHEL SPEC. TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 2 3 4 5 6 7 8 9 10 11 1./ APPD./ RELEVANT IS MANUFS. HV TEST AT 80% OF ORIGINAL BHEL MA MA MECH. SMALL . TYPE.4 WIRES/CABLES 1. NO. LAMPS. PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-002/01 ITEM :BOUGHT OUT ITEMS EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION NUMBER SPECIFICATION TITLE SECTION AGENCY P W V VOLUME III REMARKS SL. LABELS. 1 PHYSICAL CONNECTORS. PROPS. DIMENSIONS 3. TERMINAL BLOCKS. ELECTRICAL CR ELECT. TRACKING INDEX 1. MECH. RELEVANT IS INSPECTIONN REPORT -DO- 2 - - MA VISUAL 100% 2 - - TO BE PROCURED FROM APPROVED MAKE MA ELECTRICAL 100% -DO- 2 - - MA VISUAL 100% NO BREAKAGES/ DAMAGES BHEL SPEC.3 INSULATING MATERIALS (FRP. TEST SAMPLE 100% 2 2 - - PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDOR'S COMPANY SEAL 363 . DRGS.

2 2. DRGS. REPORT TEST CERT. -DO- 9 LOG BOOK/ INSP. MA ELECT TEST ELECT. SPEC……. OF TC 1/LOT -DO- -DO- TEST./ BHEL SPEC / APPD. TYPE/ METHOD OF CHECK FORMAT OF RECORD VOLUME III REMARKS 1 1. PEM-6041-0 CUSTOMER QUALITY PLAN SHEET 3 OF 3 COMPONENT/OPERATION CHARACTERISTIC CHECK BIDDER/ VENDOR SYSTEM CAT.5 15 BUSBARS 2 3 1. & STD BHEL SPEC. MANUFACTURER'S STD. NO. DIMENSION MA MEASUREMENT SAMPLE MANUFACTURER'S DRGS.2 MA VISUAL 100% …. -DO- RELEVANT STD. SHORE HARDNESS 3. 2 - 1 CR MA MA CR ELECT.7 TRANSFORMER & REACTORS 1 ROUTINE TESTS 1. REPORT -DO2 10 - 11 2. CERT 2 2 2 2 - 1 - 17 1. SURFACE FINISH 3. TEMP. TEST 1/RATING -DO- 3 - 1. RUBBER ( ONLY) 1. WAVINESS 3. & STD BHEL SPEC. MATERIAL GRADE 4.9 GASKETS (SYN. RISE TEST 1. THICKNESS 2. AGEING MA TEST -DO- 2 - - MA TEST -DO- 2 - - BHEL PARTICULAR NAME SIGNATURE DATE BIDDER / VENDOR BIDDER'S/VENDOR'S COMPANY SEAL 364 . IS-3400/ BS-2752 2 - - 2. 100% RELEVANT STD. CERT./ BHEL SPEC / APPD. DRGS./ INSP. IS-3400/ BS-2752 MANUFACTURER'S DRGS. PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-002/01 ITEM :BOUGHT OUT ITEMS EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION NUMBER SPECIFICATION TITLE SECTION AGENCY P W V SL.6 SHEET STEEL 1. ELECT TEST MEASUREMENT MEASUREMENT BEND TEST -DODO SAMPLE 100% SAMPLES -DODO -DO-DO-DO- -DODO -DO-DO-DO- -DODO -DO-DOTEST. 4 CONDUCTIVITY 1. 1 DIMENSION 4 MA 5 MEASUREMENT 6 SAMPLE 7 SPEC.AS PER PAINTS MANUF'S.8 PAINTS SHELF LIFE MA ELECT. -DO- 3 - 12 1. DUCTILITY MA VISUAL 100% 2 - - MA VERIF. INSPN REPORT INSPN REPORT INSPN REPORT INSPN REPORT 2 - - 1. CERT.FOREM NO. MANUFACTURER'S STD. -DO- 8 SPEC.

0 CONDUITS 2 3 1.1239 INSPT.9537 IS . DIMENSIONS MA MEASUREMENT IS .1239 IS . NO.1239 IS .9537 INSPT. BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 365 . REPORT 3 2 1 3.1239 IS . CHECK QUALITY PLAN : PROJECT: TITLE : QUALITY PLAN NUMBER PED-507-00-Q-006/02 ITEM : GALVANISED RIGID STEEL CONDUITS & PIPES REFERENCE ACCEPTANCE FORMAT DOCUMENT NORM OF RECORD SPECIFICATION : NUMBER : SPECIFICATION : TITLE : SECTION VOLUME III AGENCY REMARKS P W V SL.9537 IS:9537 7 IS:9537 8 9 INSPT.1239 IS .0 PIPES 1. REPORT 3 10 2 1 11 2. TYPE/ METHOD OF CHECK EXTENT OF CHECK 1 1. DIMENSIONS MA MEASUREMENT IS .9537 IS . REPORT 3 2 1 NOTE : INSTRUCTIONS FOR QUALITY PLAN IS ATTACHED AS ANNEXURE . TESTS MA TESTING IS .1.1239 IS . REPORT 3 2 1 3.MECH.1239 INSPT.1239 IS .CUSTOMER : BIDDER/ VENDOR SHEET 1 OF 1 SYSTEM COMPONENT/OPERATION CHARACTERISTICS CAT. & CHEMICAL IS . TESTS MA TESTING IS . REPORT 3 2 1 2. MATERIAL 4 MA 5 VISUAL.9537 IS .MECH.9537 INSPT. MATERIAL MA VISUAL. & CHEMICAL 6 IS .1239 INSPT. REPORT 3 2 1 2.9537 IS .

etc.affecting safety of equipment and personnel ‘MI’ stands for minor characteristic . this shall be compiled with. processes. test reports/certificate. Column 1Column 2Column 3- 3. according to which check is done. formats etc.The characteristics being checked shall be given here. reports. Column 6Extent of check.affecting appearance etc. standard specifications (IS. NOTES : 1.ANNEXURE – 1 INSTRUCTIONS FOR QUALITY PLAN The Quality Plan shall include all the Quality Control Measures and Checks adopted by the Vendor to ensure that the material/component/assembly/services supplied by him meet/will meet the requirements as per specifications and good practices. the identification marks shall be presserved till despatch. Example : Entry ‘3’ in column ‘P’ means test. 5. hydraulic test.Formats. qualification tests shall be conducted in the presence of BHEL QS Engineer. if any. 366 . the latter shall prevail. in which the observations are recorded. When this is not possible for casting.Agency . For castings and forgings integral test specimens shall be provided. etc. if witnessing of test by BHEL is called for. 100. chemical analysis tensile testing. reports. 6. The following guide lines may be noted: Serial Number Component/Operation.. Column 8Acceptance Norms .) procedure. 7. Characteristics check. as required. Wherever this is not possible. packing and despatch. Column 9Format of Record . assembly. visual examination radiography etc. under scope of supply of Vendor.. When welders qualified by reputed inspection agencies or statutory bodies are not available. This Quality Plan is also applicable to spares. The quality plan shall be submitted in minimum 4 copies with a soft copy of the same or in line with contract requirements.Any special remarks shall be given here. Column 10. In absence of correlation with the test certificate(s) (e. manufacture. They shall include all stages of operation such as materials. mechanical properties. they shall be poured in the presence of BHEL QS Engineer unless otherwise. Wherever inspection by BHELs Purchaser/Third Party/Statutory authorities are mandatory. When materials and components are initially identified and stamped by BHEL QS engineer. material identification) samples shall be drawn bgy BHEL and all tests as per relevent specifications shall be carried out in their presence or in recognized Government Laboratory.g. ‘2’ Stands for Vendor ‘3’ stands for sub-Vendor of the Vendor and so on.The agency which performs the test/instruction shall be written in sub-column ‘W’ The agency which verifies test certificates/inspection records and carries out audit check of the components/operation shall be written in sub-column ‘V’ The agencies are codified as 1. drawings. log sheets. shall be furnished to BHEL at the approproate stages or at the time of final inspection. 4. Inspection reports.Documents. BS ETC. chemical composition.g. the identification mark shall be transferred to the components in the presence of BHEL QS Engineer unless other wise agreed. leak tightness.The component and/or operation being checked shall be given here.2 & 3 ‘1’ stands for (BHEL) ‘1’ * means the operation shall be cleared by BHEL before the start of the next operation. Column 7Reference Documents . surface defects etc. If there are contradictions in respect of column 7 & 8 between this Quality Plan and the approved drawings specifications. Standard log sheets. Column 5Type/Method of check e. of the Vendors shall be numbered and such reference numbers shall be included here.Standards etc. 8. 10./inspection to be performed by sub-Vendor’s QC Entry ‘2’ in column ‘W’ means test./inspection to be witnessed by Vendor’s QC Entry ‘1’ in column ‘V’ means verification shall be done by BHEL and next stage to be started only after the hold point is cleared by BHEL Column11I. This Quality Plan is liable to be modified as per the requirements of approved drawings and changes in technical specifications/drawings. according to which acceptability or otherwise of the characteristics being checked is decided. 2. 1 percent etc. etc. Column 4Category -‘CR’ stands for critical characteristic .affecting safety of equipment and personnel ‘MA’ stands for major Characteristic . log shets. 9.g.Remarks . such as. e. such as technical specification.

& PERIODIC MEASUREMENT IN EACH SHIFT IS:2629/ RELEVENT:IS IS:2629/ RELEVENT:IS IR 3/2 - - PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 367 . APPD. APPD.0 2. DRGS/ DATA SHEETS -DORELEVANT IS. -DOO TECH. NO.COATING 1. -DO- MILL TEST CERTIFICATE 2 - - MA VISUAL 100% IR 3/2 - 2 MA MA MEASUREMENT 1/ LOT/SIZE SU / O /S MEASUREMENT 100% -DOO TECH. -DO- APPD. SPEC.CHEM. IR 2 - - 2.1 ZINC FOR GALVANISATION IN-PROCESS CUTTING. DRGS/ DATA SHEETS/ TECH. SPEC. -DOO -DO- 2 3/2 - 2 1.2 WELDING MA VISUAL & MALLET TEST SAMPLE MFR'S.3 2. DRGS/ TECH.CUSTOMER : PROJECT TITLE SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION AGENCY P W V QUALITY PLAN SHEET 1 OF 3 COMPONENT/OPERATION CHARACTERISTIC CHECK SL.TEST SAMPLE SAMPLE -DOTC 3/2 3/2 - 2 2 MA VISUAL & 100% MEASUREMENT APPD.COMP.SURFACE FINISH 3 3.DIMENSIONS SO S MA CHEM & PHYS TESTS 1/ LOT/SIZE APPD. APPD.WORKMANSHIP DIMENSIONS & DISTORTION 1. DRGS/ TECH. SPEC.3 SURFACE PREPARATION FOR 1.1 2 RAW MATERIAL MILD STEEL & COPPER (AS SPECIFIED) 3 4 5 6 7 8 9 10 11 1. : TYPE/ METHOD OF CHECK EXTENT OF CHECK QUALITY PLAN NUMBER PED 509 00 Q 001/01 PED-509-00-Q-001/01 ITEM : EARTHING COND. SPEC. BIDDER/ VENDOR SYSTEM CAT.CHEMICAL & PHYSICAL PROPERTIES 2. SPEC. DRGS/ DATA SHEETS -DORELEVANT IS. DRILLING 1.CLEANING GALVANISING PICKLING & RINSING. & ELECTRODES REFERENCE ACCEPTANCE FORMAT DOCUMENT NORM OF RECORD VOLUME III REMARKS 1 1.WELDING QUALITY 1. STD MFR'S.2 HARDWARES 1. SPEC. MA MA VISUAL CHEM.STD. IR 2 - - 2. DRGS/ DATA SHEETS/ TECH. BATH STRENGTH/ PURITY & TEMPERATURE BHEL MA CHEM.DIMENSIONS 2.0 1.

IS-2633 IR 2 1 - 2.DRG. TECH.SPEC.TEMPERATURE OF BATH 2.DURATION OF DIP 3.CUSTOMER : PROJECT TITLE SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION AGENCY P W V QUALITY PLAN SHEET 2 OF 3 COMPONENT/OPERATION CHARACTERISTIC CHECK SL.SPEC.SPEC.SURFACE PREPN.SPEC.DRG./ APPD. LOG BOOK 2 - - MA MEASUREMENT SAMPLES -DO- -DO- -DO- 2 - - 3.SURFACE QUALITY 4 MA VISUAL 5 100% 6 7 IS:2629/ RELEVENT:IS 8 IS:2629/ RELEVENT:IS -DOIR 9 3/2 10 - 11 2.0 FINAL TESTS 1.DIMENSION MA MEASUREMENT -DO- TECH. : TYPE/ METHOD OF CHECK EXTENT OF CHECK QUALITY PLAN NUMBER PED-509-00-Q-001/01 ITEM : EARTHING COND. DEGREASING & DERUSTING 2. IS:4759 IR 2 1 - 3./ APPD.5 PAINTING 1. BIDDER/ VENDOR SYSTEM CAT.APPEARANCE MA VISUAL SAMPLE IS:2629 IS:2629 FREE FROM ROUGHNESS LUMPS ETC TECH. TEST 100% TECH.BATH AGITATION 5.SURFACE QUALITY MA TEMPERATURE INDICATOR VISUAL CONTINUOUS -DO- -DO- 3/2 - - MA PERIODIC -DO- -DO- -DO- 3/2 - - MA TEST PERIODIC RELEVENT:IS RELEVENT:IS -DO- 2 - - MA VISUAL PERIODIC MFR'S STD MFR'S STD -DO- 2 - - MA VISUAL 100% -DO- -DO- IR 3/2 - 2 2.THICKNESS & ADHESION MA CHEM.UNIFORMITY OF COATING MA DIP TEST SAMPLE AS PER IS-2633 IR 2 1 - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 368 .ROSS QUANTITY AGITATION 4. & ELECTRODES REFERENCE ACCEPTANCE FORMAT DOCUMENT NORM OF RECORD VOLUME III REMARKS 1 2 3 2.4 GALVANISING 1. NO.

ADHESION 4 MA 5 PREECE TEST HAMMER/ KNIFE ELKOMETER 6 IS-4739 IS-6745 7 8 TECH. : PROJECT TITLE QUALITY PLAN NUMBER PED-509-00-Q-001/01 ITEM : EARTHING COND.THICKNESS MA SAMPLES TECH. WEIGHT OF COATING 5. AND IS-2629 IR 2 1 - BHEL PARTICULAR NAME SIGNATURE DATE BIDDER / VENDOR BIDDER'S/VENDORS COMPANY SEAL 369 . SPEC. SPEC. TYPE/ METHOD OF CHECK EXTENT OF CHECK VOLUME III REMARKS 1 2 3 4. TECH. SPEC.CUSTOMER : QUALITY PLAN SHEET 3 OF 3 COMPONENT/OPERATION CHARACTERISTIC CHECK BIDDER/ VENDOR SYSTEM CAT. NO. IR 9 2 10 1 - 11 MA -DO- IS-2629 IS-2629 IR 2 1 - 6. & ELECTRODES REFERENCE ACCEPTANCE FORMAT DOCUMENT NORM OF RECORD SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION AGENCY P W V SL.

CHEM.0 1.209 IS .209 QC RECORD 3/2 - 1/2 2. OF TC'S 100% IS:1079 IS:1079 MILL TC 3 - 2 STEEL SHALL BE PROCURED FROM SAIL/ TISCO/ RINL/ AUTHORISED RE-ROLLERS/ MANUFACTURERS AS PER BHEL APPROVED SOURCES. : TYPE/ METHOD OF CHECK EXTENT OF CHECK QUALITY PLAN NUMBER PED-509-00-Q-001/02 ITEM : EARTHING & LIGHTNING PROTECTION MATERIALS REFERENCE ACCEPTANCE FORMAT DOCUMENT NORM OF RECORD VOLUME III REMARKS 1 1.DIMENSIONS 2.CUSTOMER : PROJECT TITLE SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION AGENCY P W V QUALITY PLAN SHEET 1 OF 3 COMPONENT/OPERATION CHARACTERISTIC CHECK SL.CHEMICAL & PHYSICAL PROPERTIES MA VERIFICATION.SURFACE FINISH MA MA MEASUREMENT 100% VISUAL 100% SPECIFICATION SPECIFICATION SPECIFICATION SPECIFICATION QC RECORD QC RECORD 2 2 1 1 2.COMP. 2.1730 IS : 1079 IS . RINSING.SURFACE QUALITY BHEL MA VISUAL 100% IS:2629 IS:2629 QC RECORD 2 - - PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 370 .CLEANING PICKLING. DRILLING 1. NO.1 IN-PROCESS CUTTING. BIDDER/ VENDOR SYSTEM CAT.SURFACE FINISH 1.0 2.DIMENSIONS 3. MA MA MEASUREMENT 100% VISUAL 100% IS .1 2 RAW MATERIAL MILD STEEL (FLATS & RODS) AS PER SPECIFICATION 3 4 5 6 7 8 9 10 11 1.2 SURFACE PREPARATION 1.1730 IS : 1079 QC RECORD QC RECORD 3/2 3/2 - - MA CHEM.2 ZINC 1. & FLUXING MA MEASUREMENT PERIODIC IN EACH SHIFT IS:2629 IS:2629 QC RECORD 2 - - 2.TEST SAMPLE IS .

2629 FREE FROM BURRS.0 FINISHED ITEMS 1.THICKNESS OF ZINC COATING 6.ADHESION MA CHEM. QC RECORD 2 - - 3.2629 IS . SPECIFICATION INSP. FLUX. FLUX.TEMPERATURE OF BATH 2.CUSTOMER : PROJECT TITLE SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION AGENCY P W V QUALITY PLAN SHEET 2 OF 3 COMPONENT/OPERATION CHARACTERISTIC CHECK SL.2629 8 9 QC RECORD 2 10 - 11 MA CONTINUOUS IS . 1 - MA CHEM.DIMENSIONS MA MEASUREMENT RANDOM SPECIFICATION SPECIFICATION INSP.SURFACE FINISH MA VISUAL RANDOM SPECIFICATION FREE FROM BURRS. 1 - MA ELCOMETER IS . STAIN. TEST IS . DROSS 4 MA 5 TEMPERATURE INDICATOR VISUAL 6 CONTINUOUS IS . BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 371 . REPORT 3 2. ROUGHNESS.2629/ MFRS PRACTICE QC RECORD 3 - 2 4.4759 SPECIFICATION SPECIFICATION INSP. : TYPE/ METHOD OF CHECK EXTENT OF CHECK QUALITY PLAN NUMBER PED-509-00-Q-001/02 ITEM : EARTHING & LIGHTNING PROTECTION MATERIALS REFERENCE ACCEPTANCE FORMAT DOCUMENT NORM OF RECORD VOLUME III REMARKS 1 2. 1 - 2.MASS OF ZINC COATING 4. 1 - 3.SURFACE QUALITY MA VISUAL 100% IS . RATE OF IMMERSION MA VISUAL/ 100% MEASUREMENT IS . STAIN ETC. 1 - NOTE: INSTRUCTIONS FOR QUALITY PLAN IS ATTACHED AS ANNEXURE-1. REPORT 3 2. REPORT 3 2. ROUGHNESS. ETC. REPORT 3 2. NO. SLAG. TEST IS .2629/ MFRS PRACTICE IS . 1 - MA MECH.2629 QC RECORD 3 - - 3. SLAG.3 GALVANISING 2 3 1.4759 IS-2633 INSP.2629 7 IS .4759 IS-6745 / SPECIFICATION IS-2633 INSP. BIDDER/ VENDOR SYSTEM CAT.UNIFORMITY OF ZINC COATING 5. REPORT 3 2.TEST IS-4759 IS-2629 IS-2629 INSP. REPORT 3 2.

affecting safety of equipment and personnel ‘MI’ stands for minor characteristic .ANNEXURE – 1 INSTRUCTIONS FOR QUALITY PLAN The Quality Plan shall include all the Quality Control Measures and Checks adopted by the Vendor to ensure that the material/component/assembly/services supplied by him meet/will meet the requirements as per specifications and good practices.Agency . surface defects etc. Column 5Type/Method of check e. When this is not possible for casting. assembly. They shall include all stages of operation such as materials. reports. 2. This Quality Plan is also applicable to spares./inspection to be witnessed by Vendor’s QC Entry ‘1’ in column ‘V’ means verification shall be done by BHEL and next stage to be started only after the hold point is cleared by BHEL Column11I.affecting appearance etc. visual examination radiography etc.Any special remarks shall be given here. chemical analysis tensile testing. 100. processes.The agency which performs the test/instruction shall be written in sub-column ‘W’ The agency which verifies test certificates/inspection records and carries out audit check of the components/operation shall be written in sub-column ‘V’ The agencies are codified as 1. When welders qualified by reputed inspection agencies or statutory bodies are not available. Inspection reports. mechanical properties.g. When materials and components are initially identified and stamped by BHEL QS engineer. qualification tests shall be conducted in the presence of BHEL QS Engineer. The following guide lines may be noted: Serial Number Component/Operation.. Column 4Category -‘CR’ stands for critical characteristic . chemical composition. as required. NOTES : 1. BS ETC. they shall be poured in the presence of BHEL QS Engineer unless otherwise. such as. ‘2’ Stands for Vendor ‘3’ stands for sub-Vendor of the Vendor and so on. If there are contradictions in respect of column 7 & 8 between this Quality Plan and the approved drawings specifications. This Quality Plan is liable to be modified as per the requirements of approved drawings and changes in technical specifications/drawings. under scope of supply of Vendor. etc. according to which acceptability or otherwise of the characteristics being checked is decided. Standard log sheets.g. shall be furnished to BHEL at the approproate stages or at the time of final inspection. hydraulic test. Wherever inspection by BHELs Purchaser/Third Party/Statutory authorities are mandatory. 9.affecting safety of equipment and personnel ‘MA’ stands for major Characteristic . drawings. log shets.) procedure. Column 9Format of Record . The quality plan shall be submitted in minimum 4 copies with a soft copy of the same or in line with contract requirements. if witnessing of test by BHEL is called for. 6. such as technical specification.. material identification) samples shall be drawn bgy BHEL and all tests as per relevent specifications shall be carried out in their presence or in recognized Government Laboratory. formats etc. etc. 8. of the Vendors shall be numbered and such reference numbers shall be included here.Formats./inspection to be performed by sub-Vendor’s QC Entry ‘2’ in column ‘W’ means test. Example : Entry ‘3’ in column ‘P’ means test. Wherever this is not possible. Column 7Reference Documents .The characteristics being checked shall be given here. the identification marks shall be presserved till despatch.Standards etc. reports. e. Column 8Acceptance Norms . Column 1Column 2Column 3- 3. in which the observations are recorded. standard specifications (IS. the latter shall prevail. Characteristics check. 5. In absence of correlation with the test certificate(s) (e. according to which check is done. packing and despatch. 1 percent etc. Column 6Extent of check.2 & 3 ‘1’ stands for (BHEL) ‘1’ * means the operation shall be cleared by BHEL before the start of the next operation. 10. manufacture. etc. Column 10. test reports/certificate. the identification mark shall be transferred to the components in the presence of BHEL QS Engineer unless other wise agreed. For castings and forgings integral test specimens shall be provided. leak tightness. 7. 372 . if any.Remarks . log sheets. this shall be compiled with.The component and/or operation being checked shall be given here. 4.g.Documents.

SURFACE CONDITION 3./ RELEVANT IS MFR. PEM-6041-0 CUSTOMER QUALITY PLAN SHEET 1 OF 2 COMPONENT/OPERATION CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT.) 2. -DO- 8 APPD. PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-003/01 ITEM ELECTRICAL IN-PROCESS EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION NUMBER SPECIFICATION TITLE SECTION VOLUME III GENCY REMARKS P W V SL. DRG. PROCESS PARAMETERS (SOLUTION STRENGTH. STD. DRG.0 SURFACE PREPARATION & PRE-TREATMENT 1. FINISH/ SURFACE DEFECT 2. DIMENSION 2./ BHEL SPEC. TEMPERATURE DIPPING TIME ETC. STD. NO. -DO- 9 INSP.REPORT 2 -DO2 - 10 - 11 3. ALIGNMENT MA MA 4 5 MEASUREMENT MEASUREMENT & VISUAL VISUAL 100% 100% 6 7 APPD./ BHEL SPEC.0 FABRICATION 2 3 1.0 PRIMER & PAINTING (SPRAYED & STOVED) 1. ADHESION BHEL MA 100% -DO- -DO- -DO- 2 - - CR PROCESS CHECK PERIODIC MFR. TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 1./ RELEVANT IS LOG BOOK 2 - - MA VISUAL 100% -DO- -DO- -DO- 2 - - MA VISUAL 100% -DO- -DO- -DO- 2 - - MA MEASUREMENT SAMPLE -DO- -DO- -DO- 2 - - MA MA VISUAL -DO-DO- -DO-DO- -DO-DO- -DO-DO- 2 2 - - CROSSOUT TAPE PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDOR'S COMPANY SEAL 373 . FILM THICKNESS 3. SHADE 4. SURFACE FINISH & COVERAGE 2.FORM NO.

STD. 9 LOG BOOK 2 - 10 - 11 2. SHEET 2 OF 2 COMPONENT/OPERATION CHARACTERISTICS CHECK TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 4.0 MARKING/LABELLING 1. BHEL SPEC. DRG. PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-003/01 ITEM ELECTRICAL IN-PROCESS EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION NUMBER SPECIFICATION TITLE SECTION VOLUME III GENCY REMARKS P W V SL. DRG.0 PRE-FINAL INSPECTION 1.0 2 MOUNTING OF VARIOUS ITEMS 3 1. CORRECTNESS & COMPLETENESS 4. CERTIFICATE. PERFORMANCE 3. & RELEVANT. PEM-6041-0 CUSTOMER QUALITY PLAN BIDDER/ VENDOR SYSTEM CAT. TEST 2 & RELEVANT. STD. IR & HV CR CR ELECTRICAL ELECTRICAL 100% 100% - - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDOR'S COMPANY SEAL 374 . RIGIDITY MA 4 VISUAL 5 100% 6 7 MANUFACTURER DRAWINGS -DOAPPD. CORRECTNESS MA MA VISUAL VISUAL 100% 100% -DO-DO- 2 2 - - MA MA VISUAL VISUAL 100% 100% -DO-DO- -DO-DO- -DOINSPN REPORT -DO- 2 2 - - 2. NO. ADHESION/ FIXING 6. -DO-DO-DO-DO-DO-DO2 2 - - 2. ALIGNMENT MA VISUAL 100% -DO- -DO- 2 - - MA VISUAL 100% BHEL SPEC. ACCESSIBILITY 5. 8 MANUFACTURER DRAWINGS -DOAPPD.TIGHTNESS 3.FORM NO.

0 2. 3 4 5 6 7 8 9 10 11 1. STD -DO2 - MA VISUAL 100% -DO- -DO- -DO- 2 - - CR VISUAL AT 10% 100% -DO- -DO- -DO- 2 - - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 375 . MOUNTING & ORIENTATION 3. SOLDERING DEFECTS & FINISH MA VISUAL SAMPLE MANFR. CMOS ETC.3 MA SAMPLE -DO- 2 - 2 2. & MECH VISUAL 100% 100% BHEL SPEC. CORRECTNESS OF COMPONENTS 2. LCSO/ BARC COMPONENT TO BE USED BHEL SPEC./DRG. LCSO/ BARC COMPONENT TO BE USED INSPC. LCSO/ BARC COMPONENT TO BE USED -DO-DO- 2 2 - 1 1 1.2 POWER DIODES/THYRISTORS/ 1. RELV. TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 1.1 2 BOUGHT OUT ITEMS ELECTRONIC COMPONENTS ACTIVE. MAKE/ RATING TRANSISTORS 2. LCSO/ BARC COMPONENT TO BE USED BHEL SPEC./DRG. MAKE/RATING MA VISUAL SAMPLE BHEL SPEC.CUSTOMER : QUALITY PLAN SHEET 1 OF 2 COMPONENT/OPERATION CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT. REPORT 2 - 2 1. : PROJECT TITLE QUALITY PLAN NUMBER PED-557-00-Q-002/01 ITEM ELECTRONIC PCB ASSEMBLY EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION : NUMBER : SPECIFICATION TITLE SECTION VOLUME III AGENCY REMARKS P W V SL.1 PROCESS COMPONENTS MOUNTING & SOLDERING 1. IS/ BS/ BHEL SPEC BS/ BHEL SPEC BHEL SPEC.0 1.ROUTINE TEST PCB CONNECTORS 1. MAKE/TYPE MA MA VISUAL ELECT. IS/ RELV. STD MANFR. NO. BHEL SPEC. PASSIVE ICS.

CYCLE: RAPID TEMP. FUNCTIONAL CHECK CR 1. STD. HV/ IR/ HV/ SWC MA ELECT. AT ENERGISED CONDITION DO -DO- 2. STD. 2 ELECTRICAL AFTER SOAKING OR 3. CYCLE AT+ 700C-200C FOR 30 MINTS. : SL. STD INSPN. TEST CERT 2 - 1 100% DO -DO- DO -DO- DO -DO- 2 - 1 100% -DO- -DO- -DO- 2 - 1 TEMP. CYCLE TEST 100% BHEL SPEC. AT EACH TEMP. TESTS 100% RELEVANT IS/ ANSI-C-37-90197 BHEL SPEC./ MFR.2 ASSEMBLED PCBS (INTERCONNECTED TOGETHER AS SYSTEM/ EQUIPMENT) 1. ELECTRICAL BEFORE SOAKING 2. REPORT 2 - - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 376 . ELECTRICAL AFTER TEMP./ MFR./ MFR. STD -DO- -DO- 2 1 - 3. BHEL SPEC./ MFR. SHEET 2 OF 2 COMPONENT/OPERATION CHARACTERISTICS CHECK TYPE/ METHOD OF CHECK PROJECT TITLE QUALITY PLAN NUMBER PED-557-00-Q-002/01 ITEM ELECTRONIC PCB ASSEMBLY EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM FORMAT OF RECORD SPECIFICATION : NUMBER : SPECIFICATION : TITLE : SECTION VOLUME III AGENCY REMARKS P W V 1 2 3 4 5 6 7 8 9 10 11 SOAKING AT 700C FOR 72 HRS. FIVE SUCH CYCLE 2.CUSTOMER : QUALITY PLAN BIDDER/ VENDOR SYSTEM CAT. UNIFORMITY & FINISH OF CONFORMAL COATING ON BOTH SIDES CR VISUAL 100% BHEL SPEC. NO.

DIMENSIONS 3. TYPE/ METHOD OF CHECK FORMAT OF RECORD VOLUME III REMARKS 1 1.1 MA MA MEASUREMENT 100% VISUAL/MEAS.0 2 CABLES & WIRES 3 1.0 JUNCTION BOXES. SAMPLE BHEL DRG.TYPE 3 TYPE TESTS MA CR MEASUREMENT SAMPLE ELEC.HV/IR/HV MA -DO- SAMPLING -DO- 3 2 1 MA -DO- 100% -DO- -DO- -DO- 3 - 2.FRLS PROPS. IS:694 IS:1554 8 BHEL SPEC. REPORT & TEST REPORT FROM MANUFACTURER -DOTEST CERT CERT. BHEL SPEC/DRG BHEL DRG. IS:694 IS:1554 9 INSPN. NO. SPEC IS:694 IS:1554 -DO- 3/2 3 2 2 1 1 4.PAINT SHADE/ THICKNESS 3. REPORT -DO- 3 3 - 2 2 COMPONENTS TO BE OF APPROVED MAKE MA ELECT.TESTS 100% 2KV AC FOR 1 MINUTE 2KV AC FOR 1 MINUTE -DO- 3 - 2 BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 377 .ROUTINE TESTS 6.SURFACE DEFECTS 4 MA VISUAL 5 6 SAMPLE 7 BHEL SPEC.CUSTOMER : QUALITY PLAN SHEET 1 OF 3 COMPONENT/OPERATION CHARACTERISTIC CHECK BIDDER/ VENDOR SYSTEM CAT. BHEL SPEC/DRG INSP. LIGHTING PANELS AND DISTRIBUTION BOARDS JUNCTION BOXES 1.TESTS ELEC TESTS ONE/TYPE & SIZE -DOBHEL SPEC.ACCEPTANCE TESTS 5. 3/2 10 2 1 11 TO BE PROCURED FROM APPROVED SOURCE 2.1 CR FRLS TESTS SAMPLES BHEL SPEC BHEL SPEC -DO- 3 2 1 2. : PROJECT TITLE QUALITY PLAN PED-558-00-Q-001/01 NUMBER PED 558 00 Q 001/01 ITEM :ILLUMINATION EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION AGENCY P W V SL. SPEC IS:694 IS:1554 -DO- -DOBHEL SPEC. 2.DIMENSIONS 2.

BHEL SPEC.PERFORMANCE TESTS MA MA MEASUREMENT SAMPLE VISUAL/ -DOMEASUREMENT TESTS 1/SIZE BHEL DRG.1 2. REPORT 3 3 2.PAINT SHADE/ THICKNESS 3. REPORT 3 2.DEGREE OF PROTECTION 5.DIMENSIONS 2. THOUGH EACH ITEM SHALL BE CHECKED BY THE MANUFACTURER -DO- 5. REPORT 3 2. 4 MA TEST 5 6 1/SIZE IS:2147 7 IS:2147 8 9 TEST CERT.SPECIAL TESTS IF ANY.1 11 MA TEST 1/SIZE IS:2148 IS:2148 TEST CERT. BHEL SPEC/DRG BHEL DRG.0 TUNGSTEN FILAMENT LAMPS. REPORT INSPT.2 LIGHTING PANELS AND LIGHTING DISTRIBUTION BOARDS 1.EXPLOSION PROOF ETC. 2.HV/IR/HV MA ELECT 100% 2.5KV AC FOR 1 MINUTE BHEL SPEC. BHEL SPEC/DRG INSPT.1 - 6.TEMP. INSPT. 100% BHEL SPEC. 1. ACCEPTANCE TUBULAR FLUORESCENT TESTS LAMPS. TYPE/ METHOD OF CHECK FORMAT OF RECORD VOLUME III REMARKS 1 2 3 4.1 - BHEL SHALL WITNESS ON RANDOM ONE SAMPLE. SL NO. LUMINAIRES BHEL MA ELECT 1/RATING -DO- 3 2 1 MA TESTS SAMPLE BHEL SPEC/ RELEVANT IS BHEL SPEC/ RELEVANT IS TEST CERT 3/2 - 1 PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 378 .CUSTOMER : QUALITY PLAN SHEET 2 OF 3 COMPONENT/OPERATION CHARACTERISTIC CHECK BIDDER/ VENDOR SYSTEM CAT. CAT : PROJECT TITLE QUALITY PLAN NUMBER PED-558-00-Q-001/01 ITEM :ILLUMINATION EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION AGENCY P W V SL. - - 2. HP MERCURY VAPOUR LAMPS.RISE TEST (FOR CO S ( O COMPLETE ASSEMBLED LDB) 3. 10 2. SODIUM VAPOUR LAMPS.1 - COMPONENTS TO BE OF APPROVED MAKE MA BHEL SPEC/ RELEVANT IS BHEL SPEC/ RELEVANT IS TEST CERT - - 2.DEGREE OF PROTECTION (INCLUDING EXPLOSION PROOF IF ANY) 4.1 MA ELECT.5KV AC FOR 1 MINUTE BHEL SPEC. BALLASTS. INSPT.1 2.

THE ITEM SHALL BE TESTED AT AN INDEPENDENT LAB. REPORT 3 2 1 5.1 2.1 MA VISUAL & MEAS SAMPLES BHEL DRG./ IS 9537 IS:9537 7 IS:9537 8 9 INSPT.PHYSICAL PROP.CHEMICAL COMP. MA CHEM.DIMENSIONS 3.0 CONDUITS 2 3 1.1 2./ IS:2713 -DO-DOIS-2713 -DO- 3/2 2. ANALYSIS SAMPLE IS-2713 IS:228 & IS:1894 -DOIS-2713 IS:228 & IS:1894 -DO-DO3/2 2.1 ELECTRIC POLES MATERIAL 1.WORKMANSHIP AND FINISH 2.1 - MA MA MA -DO-DO-DO- -DO-DO-DO- -DO-DO-DO- 3/2 3/2 3/2 2. BHEL PARTICULAR NAME SIGNATURE DATE BIDDER / VENDOR BIDDER'S/VENDORS COMPANY SEAL 379 .MECH.TESTS -DO- -DO- 3/2 - 2.OTHER TESTS MA AS PER SPEC. NO.TESTS AS PER IS-2713 IS 2713 MA PHY.DIMENSIONS MA MEASUREMENT AS PER SPEC. TYPE/ METHOD OF CHECK FORMAT OF RECORD VOLUME III REMARKS 1 4.0 5./ IS:2713 -DO-DOIS-2713 BHEL DRG.1 - NOTE: IN CASE TYPE TEST CERTIFICATE FOR DEGREE OF PROTECTION/EXPLOSION PROOFNESS FROM INDEPENDENT LAB. IS NOT AVAILABLE. & CHEMICAL 6 AS PER SPEC./ IS 9537 IS:9537 INSPT. 5./ IS 9537 IS:9537 IS:9537 INSPT./ IS 9537 TEST AS PER SPEC. REPORT 10 3 2 1 11 2.CUSTOMER : QUALITY PLAN SHEET 3 OF 3 COMPONENT/OPERATION CHARACTERISTIC CHECK BIDDER/ VENDOR SYSTEM CAT.2 FINAL INSPECTION 1. REPORT 3 2 1 3.WEIGHT 4. : PROJECT TITLE QUALITY PLAN NUMBER PED-558-00-Q-001/01 ITEM :ILLUMINATION EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION AGENCY P W V SL.MATERIAL 4 MA 5 VISUAL.1 2.

-do-do-do- 3/2 - 2 MA MA MA Electrical Tests Visual Physical & Electrical Tests Measurement Galv. IS-5831/BHEL Specification -doPlant Std. Chemical Composition & purity MA 3. Physical properties and sheath) 2.4 Screen & drain wire 1. Data ahwwt TC & IR 3/2 - 2 BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 380 . Properties 2. Dimension MA MA MA Chemical analysis -doElectrical Tests Measurement visual -do-dosample -do-do-doTC & IR 3/2 3/2 3/2 3/2 - 2 2 2 2 MA Measurement -do- Appd.0 1. Surface Finish 2.Properties 3. Physical Properties MA 2.Electrical properties 4.1 2 RAW MATERIAL 3 4 5 6 7 8 9 10 11 PVC Compound(for insulation 1. Make & Type MA Physical Tests Sample IS-5831/BHEL Specification -doPlant Std. Data Sheet Appd.CUSTOMER : QUALITY PLAN SHEET 1 OF 5 COMPONENT/OPERATION CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT. IS-3975/BHEL Specification -do-doIS-613 IS-5484 IS-8130 AND BHEL Specification -do-do-doBHEL SPEC. Dimension MA -do-do-do- -do-do-do- 3/2 3/2 3/2 - 2 2 2 3. NO.2 Galvanised steel wire/strip 1. Phy. Log Book/ Test Cert. TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 1. 1. Elec.Tests Physical Tests Sample 100% Sample* 3/2 2 3/2 - 2 2 * Sample from each Batch/Lot.Dimension 1. IS-3975 BHEL Specification -do-doIS-613 IS-5484 IS-8130 AND BHEL Specification -do-do-doBHEL SPEC.Galvanization Quality MA 1.and Elec. : PROJECT TITLE QUALITY PLAN NUMBER PED-507-00-Q-004/01 ITEM :INSTRUMENTATION CABLES EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION : NUMBER : SPECIFICATION TITLE SECTION VOLUME III AGENCY REMARKS P W V SL.3 Copper/Aluminium Rods/ Wires 1.

Surface finish MA MA MA Visual. 9 TC & IR 3/2 - 10 2 11 2.Dimension 2. Appd.of wires MA Counting Sample Vendors/BHEL Specn. No. NO.3 Core Insulation (No repair permitted) 1.2 Stranding of wires 1. Finish & dimension 2.data sheet IS-1554 -do- 2 - - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 381 . Physical. 8 MFRS.CUSTOMER : QUALITY PLAN SHEET 2 OF 5 COMPONENT/OPERATION CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT. Tests Sample Visual & Meas. Sequence. Mech. Data Sheet & Relevant IS -do- 2 - - 2. Data Sheet & Relevant IS Vendors/BHEL Specn. & Apprd. STD.1 IN PROCESS Wire Drawing . & Apprd. Chemical test for Tinning CR Phy. Meas Visual Measurement Visual Sample Sample Sample 100% -do-do-do- -do-do-doFree from bulging burnt particles lumps.&Elect. : PROJECT TITLE QUALITY PLAN NUMBER PED-507-00-Q-004/01 ITEM :INSTRUMENTATION CABLES EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION VOLUME III AGENCY REMARKS P W V SL.data sheet IS-1554 -do-do-do-do- 2 2 2 2 - 1 2 Insulation thickness CR Measurement Sample Appd. lay length & Direction MA 3 Surface Finish 4.. IS-8130 -doLog Book 2 1 CR -do- 2 - - 2. Chemical Test Sample BHEL Specn. Electr.0 2. TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 2 3 3. MA 4 5 Mech test -do- 6 7 MFRS. IS-8130 -doBHEL Specn. cuts & Scratches. Tinning and Annealing 1. Prop. STD.

4 Core pairing.5 InnerSheath Extrusion 1. Surface finish MA Measurement 100% -do- 2 - - CR Elect./Appd. Screen 2. IS-1554 data sheet -do- 2 - - 2. & appd. & MFRs. Continuity of drain & drain wire with alum. Test 100% <--------No Discontinuity ----------> -do- 2 - - MA Visual 100% -- Free from bulging. Std. data sheet -doMfr's Std. 9 Log Book 2 - 10 1 11 # To be checked at starting & finish end of Extruded Length 4 Dia over insulation MA Measurement Electrical Sample 100% -do-do- 2 2 - 1 5. IS-1554 data sheet -do- 2 - - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 382 . Pair identification MA MA Visual Visual 100% 100% IS-1554 BHEL Spec. NO.CUSTOMER : QUALITY PLAN SHEET 3 OF 5 COMPONENT/OPERATION CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT. -do- 2 - 1 MA Measurement Sample -do- -do- -do- 2 - - MA Measurement -do- -do- -do- -do- 2 - - MA Elect. screening (provision of drain wire & laying) 1. Core identification 2. & MFRs. Sheath thickness MA Measurement Sample IS-5831. Data sheet -do- IS-1554 BHEL Spec. Sequence of lay and lay length 5. TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 2 3 3.Test for capacitance 4. Spark Test or Water CR Immersion test 6. burnt particles. data sheet -doMfr's Std. & appd.Wire size & tape size 3. Std. lumps cuts & scratches. Concentricity # CR 4 5 Measurement 6 Sample 7 Mfr's Std. Dia over laid up core 7. 8 Mfr's Std. IS-5831. BHEL Spec./Appd. Screen overlap & coverage 6. : PROJECT TITLE QUALITY PLAN NUMBER PED-507-00-Q-004/01 ITEM :INSTRUMENTATION CABLES EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION VOLUME III AGENCY REMARKS P W V SL. Test 100% -do- -do- -do- 2 - 1 MA Visual meas Sample BHEL Spec. Data sheet -do- -doLog Book 2 2 - - 2.

IS-1554 & BHEL Specn -do-/Apprd. No. Data Sheet -do- Log Book 2 - - 4. 100% Test Report 2 - 1 2. Coverage 5. IS-1554 & BHEL Specn -do-/Apprd. Meas. TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 2 3 3. Routine Test CR Elec. -dothe process Data sheet Data sheet IS-3975 & IS-1554 IS-3975 & IS-1554 -do-do-do-do- 2 - - 2.7 Outer Sheath Extrusion 1../Appd. Marking MA Measurement Sample -do- 2 - - MA Visual 100% IS-1554 & BHEL Specn.6 Armouring 1. BHEL Specn.data sheet IS-1554 & BHEL Specn.Sheath thickness MA Measurement Sample IS-5831 & IS-1554 Appd. At the start of BHEL Specn. IS-1554 data sheet -do- 9 2 - 10 - 11 2. Lay Length MA Visual. Lay Direction MA Visual 2 - - 3.of wires/Strips MA Counting At the start of BHEL Specn. Sample * Test Report 2 - 1 * One Drum/Size/Lot BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 383 . Type & FRLS Tests CR Elec./ Appd. cuts & scratches IS-5831 & IS-1554 Appd. the process Data sheet Data sheet IS-3975 & IS-1554 IS-3975 & IS-1554 -do-do100% -do-do-do-doFree from Bulging Burnt particles.Dia over inner sheath MA 4 5 Measurement 6 Sample 7 IS-5831. Surface Finish MA MA MA Measurement Measurement Visual -do-doLog Book 2 2 2 - - 2.CUSTOMER : QUALITY PLAN SHEET 4 OF 5 COMPONENT/OPERATION CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT. Dia over outer sheath 4. NO. Dia over armouring 2. : PROJECT TITLE QUALITY PLAN NUMBER PED-507-00-Q-004/01 ITEM :INSTRUMENTATION CABLES EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION VOLUME III AGENCY REMARKS P W V SL. lumps./Appd. & Meas.8 Finished Cable 1. Phy & Meas. BHEL Specn.data sheet Test Report 2 - - Sequential marking shall be done by printing 2. IS-1554 data sheet 8 IS-5831. Data Sheet -do- Log Book 2 - - 3./ Appd.

Tests 20% Measurement Sample# -doBHEL Specn. TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 3.0 2 Final Inspection 3 1. Acceptance Tests 7. THE SAME SHALL BE AS PER VENDORS SAMPLING PLAN VENDOR SHALL FURNISH COMPLIANCE CERTIFICATE TO THE INSPECTION AGENCY CONFIRMING THE PACKING AS PER BHEL SPECIFICATION. VENDOR TO CERTIFY THE SAME. Marking/Colour/ pair identification 5. Type & FRLS Tests MA Visual & Meas. Apprd. SHALL BE AS PER BHEL SPECIFICATION WHEREVER EXTENT OF CHECK FOR STAGE IS MENTIONED AS SAMPLES. Apprd.CUSTOMER QUALITY PLAN SHEET 5 OF 5 COMPONENT/OPERATION CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT. FILLERS/DUMMY CORES ETC. IS-1554 2. Dimension MA Measurement Sample Lengths Appd. NO. PROCESS & ALL STAGES SHALL BE CERTIFIED BY VENDORS QC. W: WITNESSER V: VERIFIER (1) BHEL/BHEL's CUSTOMER: 2-VENDOR : 3 SUB VENDOR LEGEND : P : PERFORMER BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 384 . Sample -do- 2 1 - MA Visual -do- -do- -do- -do- 2 1 - CR Elect. Finish & Length MA 4 Visual 5 6 7 8 Free from Bulging Burnt particles.of Wires/Strips 4. lumps. NO REPAIR OF CORE INSULATION PERMITTED CABLE ENDS SHALL BE SEALED AS PER BHEL SPECIFICATION PURCHASER SHALL HAVE RIGHT TO WITNESS THE SPARK TEST AT CORE STAGE RECORD OF RAW MATERIAL. Test -do- -do- -do- -do- 2 1 - CR CR Phy & Elect.Data Sheet -do-do- 2 2 1 1 #Type Test shall be witnessed on one sample of every lot NOTES:(A) (B) (C) (D) (E) (F) (G) (H) JOINTS IN WIRE SHALL BE AS PERMITTED BY IS / BHEL SPECIFICATION. AND ARE LIABLE TO AUDIT CHECK BY PURCHASER.Data Sheet/ IS-1554 & IS-10810 -do- Test Report 2 1 - 3. cuts & scratches Appd. Test for screening 6.Data Sheet -doBHEL Specn. Armouring Coverage No of No. : : PROJECT TITLE QUALITY PLAN NUMBER PED-507-00-Q-004/01 ITEM :INSTRUMENTATION CABLES EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION VOLUME III AGENCY REMARKS P W V SL.Data Sheet/ IS-1554 & IS-10810 -do- 9 Test Report 2 10 1 - 11 One drum in a Lot (See remark) BHEL specn.

3 ZINC INGOT FOR GALVANISING CHEM. IR 3.2 WIRES 1./ IS-1554/IS-694/ RELEVANT. MA EACH IS-209 IS-209 TEST CERT 3/2 - 1.2 1. 3/2 3 - 1. IR. THICKNESS MA VISUAL 100% -DO- 3/2 - - MA MEASUREMENT 100% BHEL SPEC. ONENT/OPERATION NO. TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 1. IS -DO-DO- BHEL SPEC. SURFACE FINISH DEFECTS 3. PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-005/01 ITEM :LCC'S / M. COMP.2 BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDOR'S COMPANY SEAL 385 ./ IS-1730 BHEL SPEC. HV.0 2 RAW MATERIAL & BOUGHT OUT CONTROL SHEET STEEL/CHANNELS 3 4 5 6 7 8 9 10 11 1.1 1./ IS-1730 BHEL SPEC. TYPE / ROUTINE TESTS MA MA ELECTRICAL VERIFICATION OF TYPE / ROUTINE TEST CERTIFICATE CHEM. BOXES/ JN.CUSTOMER QUALITY PLAN SHEET 1 OF 6 CHARACTERISTIC CHECK BIDDER/ VENDOR SYSTEM CAT./ IS-1554/IS-694/ RELEVANT. SURFACE DEFECTS. TEST SAMPLE 100% -DOMFR'S TEST CERT. IS -DO-DO- -DO- 3/2 - 2 1. BOXES EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION NUMBER SPECIFICATION TITLE SECTION VOLUME III GENCY REMARKS P W V SL. MA VISUAL 100% -DO- 3/2 - - ONLY APPROVED MAKES TO BE USED 2. DUCTILITY CR BEND TEST SAMPLE IS-1079/IS-513/ IS-226 FACTORY STD IS-1079/IS-513/ IS-226 NO RUSTING LOG BOOK 3/2 - 2 FOR SHEET STEEL 2.

TERMINALS GASKETS TERMINALS.0 2. IR. BOXES EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION NUMBER SPECIFICATION TITLE SECTION VOLUME III AGENCY REMARKS P W V SL. PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-005/01 ITEM :LCC'S / M. & BOM 9 LOG BOOK 3/2 - 10 - 11 2 OPERATION/ 2.1 2 MA ELECTRICAL 100% -DO- -DO- -DO- 3/2 2.1 IN-PROCESS CONTROL NIBBLING/PUNCHING 1. NO. SWITCHES. DRGS LOG BOOK 3/2 2. CUTOUT SIZES MA MEASUREMENT 100% APPD. PUSH BUTTON.FORM NO. DRGS MFR'S STD -DO- -DOAPPR. INDICATING LAMPS. ALIGNMENT 3. HV.2 PANEL FABRICATION 1. & BOM 8 BHEL SPEC.3 2 ELECTRICAL COMPONENTS LIKE FUSE.1 STANDARD CUT OUTS TO BE DONE WITH DIES & PUNCHES ONLY 2. DRGS APPD. DRGS MFR'S STD -DO- -DOLOG BOOK LOG BOOK -DO- 3/2 3/2 3/2 3/2 2 2 2 - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDOR'S COMPANY SEAL 386 . BOXES/ JN. IR CR ELECTRICAL TEST SAMPLE RELEVANT IS AND RELEVANT IS AND CATALOGUE CATALOGUE DO -DO- 3/2 21 2.OPERATION/ FUNCTIONAL CHECK 3.1 2 2. DIMENSIONS 2. TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 1. WELDING QUALITY MI MA MA MI VISUAL MEASUREMENT MEASUREMENT VISUAL 100% 100% 100% 100% -DOAPPR. CABLE GLANDS AND LUGS 1.DEBURRING 2. PEM-6041-0 CUSTOMER QUALITY PLAN SHEET 2 OF 6 COMPONENT/OPERATION CHARACTERISTIC CHECK BIDDER/ VENDOR SYSTEM CAT. MAKE TYPE RATING 3 MA 4 VISUAL 5 6 SAMPLE 7 BHEL SPEC.

SPEC. NO. SURFACE FINISH & COVERAGE 2. Q MA VISUAL 100% -DO- -DO- -DO- 3/2 - - 2.. ACID PICKLINGS IS NOT REQUIRED. SURFACE QUALITY AFTER EVERY DIP MA 4 5 PROCESS CHECK 6 PERIODIC 7 BHEL SPEC.FORM NO. DIPPING/ REMOVAL TIME 2. PROCESS PARAMETERS LIKE BATH TEMP. PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-005/01 ITEM :LCC'S / M. FILM THICKNESS 3.. IS-6005 MFR. SPEC.. MFR. IS-6005 LOG BOOK 3/2 - - MA MEASUREMENT 100% -DO- -DO- -DO- 3/2 - 2 MA MA VISUAL SCRATCH TEST / CROSS OUT TAPE 100% TEMPLATE -DO-DO- -DO-DO- -DO-DO- 3/2 3/2 - 2 2 BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDOR'S COMPANY SEAL 387 . BOXES EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION NUMBER SPECIFICATION TITLE SECTION VOLUME III GENCY REMARKS P W V SL. ADHESION MA VISUAL 100% MFR. BOXES/ JN. SPEC. MFR. IS-6005 9 LOG BOOK 3/2 - 10 - 11 IF SAND/SHOT BLASTING. CONCENTRATION. TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 2.. SPEC. IS-6005 8 BHEL SPEC.4 PRIMER APPLICATION & PAINTING 1. PEM-6041-0 CUSTOMER QUALITY PLAN SHEET 3 OF 6 COMPONENT/OPERATION CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT. SHADE 4... .3 2 SURFACE PREPARATION AND PRE-TREATMENT (7 OR 8 TANK PROCESS) ( ) 3 1.

1 - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDOR'S COMPANY SEAL 388 .6 GALVANISATION PROCESS 1. DURATION OF DIP MA VISUAL 100% -DO- 3/2 - - MA TEMP. -DO- 8 APPD . BOXES EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION NUMBER SPECIFICATION : TITLE SECTION VOLUME III GENCY REMARKS P W V SL. GASKET. -DO- 9 LOG BOOK 3/2 - 10 - 11 PVC CHANNELS TO BE USED 2. FREE FROM ROUGHNESS. WORKMANSHIP & FINISH.1 FINAL INSPECTION COMPLETE JUNCTION BOX/ LCC'S MARSHALLING BOXES 1. DRGS & SPEC. APPD. PEM-6041-0 CUSTOMER QUALITY PLAN SHEET 4 OF 6 CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT. STAIN ETC. DRG RELEVANT. IS BHEL SPEC. PAINT SHADE/GALV. GROSS QUANTITY & AGITATION 3 3. FLUX. ONENT/OPERATION NO. WORKMANSHIP AND FINISH CORRECTNESS COMPLETENESS 2. COMPONENT MOUNTING ETC. IS -DO- 2 - - MA VISUAL 100% BHEL SPEC. THICKNESS & ADHESION MA TESTS PERIODIC RELEVANT. IS -DO- 2 - - 3. SURFACE QUALITY MA VISUAL 100% -DO- 2 - - 4. BOXES/ JN. TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 2.5 2 WIRING. PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-005/01 ITEM :LCC'S / M. IS INSPN REPORT 3/2 2.FORM NO. APPD. RELEVANT. NAME PLATE. 3 1. -DO- MANUFACTURER PRACTICE. DRG RELEVANT. INDICATOR VISUAL CONTINUOUS -DO- IS-2629 IS-2629 QC RECORD 2 - - MA MANUFACTURER PRACTICE. DRGS & SPEC. TEMP OF ZINC BATH 2. WIRING LAYOUT MA 4 VISUAL 5 100% 6 7 APPD .

DRG. DRG. DOOR LOCK FUNCTIONING MA OPERATON 100% APPD. BHEL SPEC. APPD. BOXES/ JN. ALL TERMINATION TO BE LUGGED NO MISMATCH -DO- 3/2 2. TEST 6 IS-5358 IS-2633 7 IS-2633 8 9 INSPN REPORT 2 10 1 - 11 MA ELCOMETER -DO- BHEL SPEC. TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 2 3 2. UNIFORMITY OF ZINC COATING 3. WIRING LAYOUT 5. COMPONENT LAYOUT & FIXING. COMPONENT IDENTIFICATION (MARKING/ NAME PLATES) 7.1 - MA PULLING SAMPLE -DO- NO LOOSE CONNECTIONS.1 - 8. PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-005/01 ITEM :LCC'S / M. THICKNESS OF ZINC COATING 4.1 - MA VISUAL 100% APPD. DRG -DO- 3/2 2. PEM-6041-0 CUSTOMER QUALITY PLAN SHEET 5 OF 6 COMPONENT/OPERATION CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT. -DO- 3/2 2. ACCESSIBILITY AND SAFETY 6. NO. -DO- 2 1 - MA MA VISUAL VISUAL 100% 100% -DO-DO- -DO-DO- -DO-DO- 3/2 3/2 2.1 - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDOR'S COMPANY SEAL 389 .FORM NO.1 2. PROPER WIRE TERMINATION MA 4 5 CHEM. BOXES EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION NUMBER : SPECIFICATION TITLE SECTION VOLUME III AGENCY REMARKS P W V SL.

BOXES EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION NUMBER SPECIFICATION TITLE SECTION VOLUME III AGENCY REMARKS P W V SL.. & RELEVANT IS -DO- 3/2 2. DRG.OVERALL DIMENSIONS 10. FLAME/ EXPLOSION TESTS -DO- 3/2 2 - FLAME/EXPLOSION PROOF TEST. NO TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 2 3 9. IF SPECIFIED IN BHEL SPEC. BOXES/ JN.. PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BHEL BIDDER'S/VENDOR'S COMPANY SEAL 390 .FORM NO.1 - 13. SIZE RELEVANT IS ONE/ TYPE -DO- BHEL SPEC. PEM-6041-0 CUSTOMER QUALITY PLAN SHEET 6 OF 6 COMPONENT/OPERATION CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT.1 - IR-HV-IR TEST TO BE DONE BEFORE OPERATIONAL TESTS 12. & RELEVANT IS -DO- APPD. DRG. 8 APPD.. BHEL SPEC. PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-005/01 ITEM :LCC'S / M. TEMP RISE (IF APPLICABLE) 14. DRG. DEGREE OF PROTECTION & FLAME/ EXPLOSION PROOF NOTE: CR ONE/ TYPE/ BHEL SPEC. BHEL SPEC. REPORT -DO3/2 10 2.OPERATION INTERLOCKS ETC CR ELECTRICAL OPERATION AND FUNCTION IN ENERGISED CONDITION ELECTRICAL 100% -DO- -DO- -DO- 3/2 2..1 - CR WATER AND DUST TESTS. DRG.1 - 11 CR ELECTRICAL 100% APPD. RELEVANT IS -DO- -DO- 3/2 2. IR-HV-IR CR ELECTRICAL 100% -DO- 3/2 2. IF TC'S FOR DEGREE OF PROTECTION/EXPLOSION PROOFNESS IS AVAILABLE FROM AN INDEPENDENT LABORATORY FOR IDENTICAL DESIGN (SIZE SHALL BE SMALLER THAN THAT INDICATED IN THE TC) THESE TESTS NEED NOT BE REPEATED.1 - 11. 9 INSPN. CONTINUITY MA 4 5 MEASUREMENT 100% 6 7 APPD.

VISUAL AND DIMENSIONS MA TEST 2 2.TYPE TEST MA 4 TEST 5 6 IS:1651 & 1652/BHEL SPEC BSI:6290 Pt-4 -DODO 7 IS:1651 & 1652/BHEL SPEC BSI:6290 Pt-4 -DODO 8 IS:1651 & 1652/BHEL SPEC BSI:6290 Pt-4 -DODO 9 INSPN REPORT 3.1 21 - MA TEST 100% BHEL DRG BHEL DRG INSPECTION 3. SHEET 1 OF 1 COMPONENT/OPERATION CHARACTERISTICS CHECK TYPE/ METHOD OF CHECK 1 1.ACCEPTANCE 2 ACCEPTANCE TEST 2.2 2.0 ACCESSORIES 1.1 11 2. : PROJECT TITLE QUALITY PLAN NUMBER PED-508-00-Q-002 ITEM LEAD ACID BATTERY (DC SYSTEM) EXTENT OF REFERENCE ACCEPTANCE FORMAT CHECK DOCUMENT NORM OF RECORD SPECIFICATION : NUMBER : SPECIFICATION : TITLE : SECTION VOLUME III AGENCY REMARKS P W V SL.2 - 10 2. NO.0 2 FINISHED BATTERY / CELL 3 1.CUSTOMER : QUALITY PLAN BIDDER/ VENDOR SYSTEM CAT.1 - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 391 .

DATA SHEET. PED-506-00-Q-003 1. TYPE/ METHOD OF CHECK 1 1. TESTS -DO- APPD.& OTHER RELEVANT IS IS-8623 IS-3427 BHEL SPEC.FORM NO. APPD. -DO- 2 1 - MA VISUAL 100% -DO- -DO- -DO- 2 1 - MA MECH. TESTS 10% -DO- -DO- -DO- 2 1 - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDOR'S COMPANY SEAL 392 .0 2 BOUGHT OUT ITEMS IN-PROCESS FINAL INSPECTION 3 4 5 6 7 8 9 10 11 REF. QUALITY PLAN NO. DRG/ APPD . QUALITY PLAN NO. NO. DIMENSION 4. PHYSICAL BLEMISHES 2. PAINT SHADE 5. BD EXTENT OF REFERENCE ACCEPTANCE FORMAT CHECK DOCUMENT NORM OF RECORD SPECIFICATION NUMBER SPECIFICATION TITLE SECTION VOLUME III AGENCY REMARKS P W V QUALITY PLAN BIDDER/ VENDOR SHEET 1 OF 3 SYSTEM COMPONENT/OPERATION CHARACTERISTIC CAT. DRG. SHIPPING SECTION JOINTS PLATES TO BE SUPPLIED 6. PEM-6041-0 CUSTOMER PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-001/01 ITEM LT SWGR/CONTROL PNLS/DIST.0 2.M. INTER CHANGEABILITY MA MECH. PED-506-00-Q-002 REF. DRG/ APPD . PAINT ADHESION 7. APPD. APPD. DRG.& OTHER RELEVANT IS 2 2 2 2 1 1 1 1 2. INSP. REPORT -DO-DO-DO-DO- 2 1 - MA MA MA MA VISUAL MEASUREMENT VISUAL MEASUREMENT 100% 100% 100% FEW PLACES IS-8623 IS-3427 BHEL SPEC. PAINT THICKNESS MA VISUAL 100% BHEL SPEC. GLANDS & LUGS TO BE SUPPLIED ALONG WITH BOARDS 1. BHEL SPEC.0 3.DATA SHEET. ALIGNMENT 3. 8. VERIFICATION OF B.O. CHECK SL.

BUS BAR TIGHTNESS MA VISUAL 100% BHEL SPEC. CHECK SL.DRG. PEM-6041-0 CUSTOMER PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-001/01 ITEM LT SWGR/CONTROL PNLS/DIST. ACCESSIBILITY MA OF COMPONENT & SAFETY (SHROUDING) 15. TESTS SECONDARY INJECTION 1/ITEM 100% -DO- -DO- -DO- 2 1 - SHALL INCLUDE REMOTE SIMULATION SEE NOTE 'C' PHYSICAL VERIFICATION DURING INSPECTION CR CR -DO-DO- -DO-DO- -DO-DO- 2 2 1 1 - MA MECH. DRG. INTERLOCKS. TESTS 100% -DO- -DO- -DO- 2 1 - 14. BD EXTENT OF REFERENCE ACCEPTANCE FORMAT CHECK DOCUMENT NORM OF RECORD SPECIFICATION NUMBER SPECIFICATION TITLE SECTION VOLUME III AGENCY REMARKS P W V QUALITY PLAN BIDDER/ VENDOR SHEET 2 OF 3 SYSTEM COMPONENT/OPERATION CHARACTERISTIC CAT. 8 APPD. & MECH. DRG. 100% TESTS ELECT. -DO- 2 1 - PULLING SAMPLE -DO- -DO- -DO- 2 1 - MECH. FUNCTION PERFORMANCE 11. DRG. -DO- 9 2 10 1 - 11 CR ELECT. TESTS 6 100% 7 APPD. EASE OF WITHDRAWAL & INSERTION CR 4 5 ELECT . TYPE/ METHOD OF CHECK 1 2 3 9.FORM NO. TYPE TESTS 12. TESTS SAMPLE MANUFACTURER'S STANDARD MANUFACTURER'S -DOSTANDARD 2 1 - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDOR'S COMPANY SEAL 393 ./ APPD. BHEL SPEC./ APPD. PROTECTION & METERING 13. ROUTINE TESTS 10. WIRING NEATCR NESS & FIRMNESS 16. NO.

FUNCTIONAL/PERFORMANCE CHECKS TO BE CONDUCTED ON ENTIRE BOARD AND ALL POWER SUPPLIES SWITCHED ON. P & Q TEST REGARDING ACCEPTANCE OF AVAILABLE TYPE TCS. 9. ONLY APPROVED MAKE OF COMPONENTS ARE TO BE USED.4 OF SPECIFICATION NO. TYPE TESTS WILL INCLUDE (BESIDES OTHERS) 1. D. CHECK SPECIFICATION NUMBER QUALITY PLAN SL.FORM NO. TEMPERATURE RISE TEST 2. 3 4 5 6 7 8 9 10 11 C. IF ANY 3. PEM-6041-0 CUSTOMER PROJECT TITLE BIDDER/ VENDOR SHEET 3 OF 3 SYSTEM COMPONENT/OPERATION CHARACTERISTIC CAT. BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDOR'S COMPANY SEAL 394 . INDIVIDUAL BREAKER SHALL BE TESTED AT VARIOUS POSITIONS AND AT NORMAL +10% AND -10% OF CONTROL SUPPLY.NO. E. DEGREE OF PROTECTION TEST AND EXPLOSION PROOF TEST. B. CABLE TYPE/ METHOD OF CHECK SPECIFICATION TITLE NUMBER PED-506-00-Q-001/01 SECTION VOLUME III ITEM LT SWGR/CONTROL PNLS/DIST. PES-506-01. NO. BD EXTENT OF REFERENCE ACCEPTANCE FORMAT AGENCY REMARKS CHECK DOCUMENT NORM OF RECORD P W V QUALITY PLAN 1 2 NOTE : A. SHORT TIME CURRENT TEST 4. REFER CL.

0 1./LOG BOOK -DO- 3 - 2. IS/ NO PHY. IS:513 / BHEL SPECS.FLATNESS 4.2 - 2. DIMENSION MA 4 5 MEASUREMENT 100% 6 7 BHEL SPECS. SEAL OFF BUSHING. IS/PHY.ROUTINE TEST MA MA MA VISUAL VISUAL VISUAL 100% 100% -DO-DO- -DO-DO-DO- -DO-DO-DO- 2 2 2 - - 1PIECE/LOT -DO- MA ELECTRICAL/ MEASUREMENT 100% BHEL SPECS.SURFACE FINISH 3.SURFACE FINISH 3.FLATNESS 4./ BHEL SPECS.BEND TEST (MS ONLY) 1./ IS:5082/IS:736 IS:737/IS:1897 -DO-DO-DO- 8 BHEL SPECS. : PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-004/01 ITEM :LV & MV BUSDUCT EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION : NUMBER : SPECIFICATION TITLE SECTION VOLUME III AGENCY REMARKS P W V SL. DIMENSION MA MA MA VISUAL VISUAL ELECTRICAL 100% 100% SAMPLE -DO-DO-DO- 2 2 3. CONDITION BHEL SPECS. SPACE HEATERS 1.1 FOR INSULATOR BUSHING 3./ RELEV. CONDITION -DO- 2 - - 4./ RELEV IS BHEL SPECS./ RELEV./ IS:5082/IS:736 IS:737/IS:1897 -DO-DO-DO- 9 TEST CERT 2 - 10 - 11 2./ RELEV.TYPE TEST MA ELECTRICAL/ MEASUREMENT VISUAL 1/TYPE -DO- -DO- 3 - 2. TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 1. INSP REPORT 2 - - 2.3 INSULATORS. RELEV.CUSTOMER : QUALITY PLAN SHEET 1 OF 6 COMPONENT/OPERATION CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT.ELECTRICAL CONDUCTIVITY 1. IS MRF TEST CERT.SURFACE CONDITION RATING & MARKING MA 100% BHEL SPECS. IS/ NO PHY./ -DORELEV.1 2 MATERIALS/COMPONENTS ALUMINIUM AND COPPER BARS & FLEXIBLES 3 1.1 2. CABLES.2 ENCLOSURE MATERIALS 1.1 MA MEASUREMENT 100% IS:513 / BHEL SPECS.DIMENSIONS PHY. MA CONDITION MEASUREMENT SAMPLE BHEL SPECS. WIRES. DAMAGE DAMAGE 2 - - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 395 . IS/PHY. NO.

DIMENSION & MATERIAL CERTIFICATE MA MA AGEING TEST MEAS & TESTS 3 3. : PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-004/01 ITEM :LV & MV BUSDUCT EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION VOLUME III AGENCY REMARKS P W V SL./ RELEV.1 IN-PROCESS FABRICATION OF ENCLOSURES BHEL DIMENSION MA MEASUREMENT 100% APPD./BS-2752 -DOMANUFS STD RELV.2 - 2. STD 3 - 1./ RELEV.TRACKING INDEX (FOR INSULATION MATERIAL) MA 4 5 ELECTRICAL 6 SAMPLE 7 BHEL SPECS. IS 9 INSP. REPORT & TC 2 - 1 MA MEASUREMENT 1PIECE/LOT IS-3400/BHEL SPEC. NO. STD IS-3400/BHEL SPEC.4 BELLEVILLI WASHERS.SHORE HARDNESS 1. DISC WASHERS 1.0 2.2 - 1./MFG DRG APPD.CUSTOMER : QUALITY PLAN SHEET 2 OF 6 COMPONENT/OPERATION CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT.AGEING TEST 1. TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 2 3 5.DIMENSION MA MEASUREMENT RANDOM CHECK -DO- -DO- LOG BOOK 2 - - 2./BS-2752 -DO1/LOT -DOMANUFS STD RELV.5 NEOPRENE RUBBER BELLOWS & GASKET 1. REPORT TEST REPORT -DOINSP./MFG DRG INSP REPORT 2 - PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 396 .2 2. IS 8 BHEL SPECS.2 - 10 1 11 1. & SPRING WASHERS & FASTENERS. PLAIN SPRING.OIL ABSORPTION MA VISUAL -DO- -DO- -DO- -DO- 2 - - MA MEASUREMENT SAMPLE MANUFS STD MANUFS STD INSP. REPORT 3.6 BUS BAR SLEEVES 1.SURFACE FINISH 3.

TYPE OF FINISH MA MA 100% PERIODIC -DOIS-6005 RELV. BHEL SPEC/FAB DRG/IS SPEC.PROCESS PARAMETERS (SOLUTION STRENGTH TEMP.FINISH 3 MA MA 4 VISUAL 5 100% 100% 6 7 MANUF'S STD -DO- 8 MANUF'S STD -DO- 9 INSP REPORT 2 -DO2 - 10 - 11 3. TIME ETC. : PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-004/01 ITEM :LV & MV BUSDUCT EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION VOLUME III AGENCY REMARKS P W V SL.CUSTOMER : QUALITY PLAN BIDDER/ VENDOR SYSTEM CAT.FILM THICKNESS 2.1 MA VERIFICATION 100% ASSEMBLY DRG/ BHEL SPEC.3 INITIAL PAINTING (PRIMER) 1. 2./PAINTING/ SLEEVING) ASSEMBLY BUSBAR ASSEMBLY 1.SURFACE FINISH & COVERAGE 2.SURFACE CONDITION 2.ALIGNMENT VISUAL & MEASUREMENT VISUAL PROCESS CHECKS 4. -DO- 2 - - 3.2 SURFACE PREPARATION INCLUDING PHOSPHATING & PASSIVATION 1.0 3.ORIENTATION 2. NO.PHASE SEQUENCE 1.4 FINISHING OF BUSBARS/ FLEXIBLES (TINNING/ PLATING. BS-159/BS-162 ASSEMBLY DRG/ BHEL SPEC. BS-159/BS-162 -DO- 2 - - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 397 . IS -DO-DO- 2 2 - - MA VISUAL 100% -DO- -DO- -DO- 2 - - MA VISUAL 100% -DO- -DO- -DO- 2 - - MA MEASUREMENT 100% -DO- -DO- -DO- 2 - - MA VISUAL 100% BHEL SPEC/FAB DRG/IS SPEC. SHEET 3 OF 6 COMPONENT/OPERATION CHARACTERISTICS CHECK TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 2 2. IS -DOIS-6005 RELV.

TERMINATIONS 5. MANUFS STD BHEL SPEC.PREPERATION & APPLYING CONDUCTING MEDIUM 5. TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 2 3 2.SIZE & MATERIAL 2.TIGHTNESS TO SUPPORTS MA VISUAL 100% MANUF'S STD MANUF'S STD INSP REPORT 2 - - MECHANICAL 100% BHEL SPEC. -DO-DO-DO-DO- -DO- 2 - - MA MA MA MA VISUAL VISUAL VISUAL MECHANICAL 100% 100% 100% 100% - 2 2 2 2 - - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 398 .BUSBAR MARKING MA 3.CLEARANCE TO BODY /EARTH & PHASE TO PHASE 3. ASSEMBLY DRG. ASSEMBLY DRG.LOCATION 3. -DO-DO-DO-DO- BHEL SPEC.TIGHTNESS OF JOINTS AND FLEXIBLE 6.CUSTOMER : QUALITY PLAN SHEET 4 OF 6 COMPONENT/OPERATION CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT. : PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-004/01 ITEM :LV & MV BUSDUCT EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION VOLUME III AGENCY REMARKS P W V SL. NO.SURFACE MA PREPARATION FOR JT. MANUFS STD INSP REPORT 2 - 1 MA MEASUREMENT 100% -DO- -DO- -DO- 2 - 1 ALUMINIUM BUS BARS JOINTS WILL BE BOLTED WITH BILLET WASHER AND THIGHTENING SHALL BE DONE BY TORQUE WRENCH ALSO THE JOINT SURFACE SHALL HAVE SUITABLE COMPOUND MA MEASUREMENT 100% BHEL SPEC.TIGHTNESS OF SUPPORTS MA 4 VISUAL 5 100% 100% 6 -DO-DO- 7 -DO-DO- 8 -DO-DO- 9 2 2 - 10 - 11 MECHANICAL 4.MARKINGS 4.2 EARTHING 1.

LOG SHEET 100% BHEL SPEC LAYOUT DRGS/ FAB. VARNISH BEFORE PACKING REPORTS TO BE SUBMITTED TO BHEL IT SHALL BE POSSIBLE TO ADJUST TEMP KNOB THERMOSTAT FROM INSPECTION COVER.FITTING OF INSPN.DRG.0 4.ALIGNMENT OF SECTION 6.3 2 IDENTIFICATION MARKINGS & NAME PLATES 3 1.COVERS 5. -DO-DO- 2 1 - 3. MA VISUAL 100% -DO- -DO- -DO- 2 1 - MA VISUAL 100% -DO- -DO- -DO- 2 1 - MA VISUAL 100% -DO- -DO- -DO- 2 1 - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 399 .DIMENSIONS MA MEASUREMENT 100% APPD. INSPN.1 COMPLETE ASSEMBLY APPEARANCE AND CLEANLINESS 1. REPORT 2 1 - 2.COMPLETE LAYOUT MA VISUAL BHEL SPEC LAYOUT DRGS/ FAB. : : PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-004/01 ITEM :LV & MV BUSDUCT EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION VOLUME III AGENCY REMARKS P W V SL.DRG. TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 3. NO..BUSBAR MARKING 4.GENERAL & MARKINGAPPEARANCE 4.SECTIONAL IDENTIFICATION 2.DRG.DRG.CUSTOMER QUALITY PLAN SHEET 5 OF 6 COMPONENT/OPERATION CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT.EARTH MARKING 3. -DOAPPD.EARTH BUS ALIGNMENTS & MARKING MA VISUAL 100% 2 1 - ALL HARDWARES WHICH ARE EXPOSED TO OUTDOOR SHALL BE TOUCHED WITH ANTI CORROSSION RUST PREVENTION SOLUTION.NAME PLATES AND DANGER NAME PLATES MA 4 VISUAL 5 100% 6 -DO- 7 -DO- 8 -DO- 9 2 - 10 - 11 MA VISUAL 100% -DO- -DO- -DO- 2 - - MA VISUAL 100% -DO- -DO- -DO- 2 - - MA VISUAL 100% -DO- -DO- -DO- 2 - - 4.

ROUTINE TESTS 2.ADHESION MA 4 VISUAL 5 100% 6 -DO- 7 -DO- 8 -DO- 9 2 10 1 - 11 MA VISUAL 100% APPD.2 - 2 MA MA SCRATCH TEST ELECTRICAL TEMPLATE 100% -DOTEST CERT/ REPORT 3.DEGREE OF PROTECTION 4.CUSTOMER QUALITY PLAN SHEET 6 OF 6 COMPONENT/OPERATION CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT.0 IDENTIFICATION. PRESERVATION & PACKING 1. TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 2 3 7.2 2 1 2 - 4.OTHER TYPE TESTS.SHORT CKT TEST 5. -DO- APPD. IF ANY 5.IDENTIFICATION MARKING ON PACKING CASES MA ELECTRICAL SAMPLE -DO- 2 1 - MA AS PER SPEC SAMPLE -DO- -DO- -DO- 2 1 - MA ELECTRICAL SAMPLE -DO- -DO- -DO- 2 1 - MA ELECTRICAL SAMPLE -DO- -DO- -DO- 2 1 - MA AS PER SPEC SAMPLE -DO- -DO- -DO- 2 1 - MA VISUAL 100% PURCHASER'S INSTRUCTION PURCHASER'S INSTRUCTION 2 - - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 400 .2 TESTS 1.IMPULSE TEST 6. : : PROJECT TITLE QUALITY PLAN NUMBER PED-506-00-Q-004/01 ITEM :LV & MV BUSDUCT EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION VOLUME III AGENCY REMARKS P W V SL.TEMPERATURE RISE 3.MARKINGS ON THE SECTIONS 8. NO.DRGS/ BHEL SPEC MFR SPEC -DOIS-8084 ANSI C37 20/ ANSI-C37-20/ BHEL SPEC. -DO- LOG BOOK 3.DRGS/ BHEL SPEC MFR SPEC -DOIS-8084 ANSI C37 20/ ANSI-C37-20/ BHEL SPEC.PAINT THICKNESS SHADE 9.

DRAWING MFG.1 MATERIALS 2 3 4 5 6 7 8 9 10 11 SHEET STEEL AND STRUCTURES 1. 2 SURFACE FINISH 3. REPORT -DODO 2 - - 2 - - MA MI MA MEASUREMENT 10% VISUAL 100% IS-1897 -DO-do- IS-1897 -DO-do- -DO-DOTEST CERT.CUSTOMER QUALITY PLAN SHEET 1 OF4 COMPONENT/OPERATION CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT./SPEC. DIMENSIONS 2. BHEL DRG.3 RESISTOR GRIDS 1. DIMENSIONS MA MEASUREMENT 100% -DO- -DO- -DO- 3/2 - - 3. DIMENSIONS MA MEASUREMENT 10% 2.0 1. PROJECT TITLE QUALITY PLAN NUMBER PED-505-00-Q-002/01 ITEM NEUTRAL GROUNDING RESISTOR EXTENT OF REFERENCE ACCEPTANCE FORMAT CHECK DOCUMENT NORM OF RECORD FORM NO. MFG. CHEMICAL COMPOSITION MI MA VISUAL BEND TEST 100% SAMPLES IS-1079 IS-2026 IS-513 -DODO IS-1079 IS-2026 IS-513 -DODO INSPN. SURFACE FINISH CR VISUAL 100% BHEL DRG. TYPE/ METHOD OF CHECK 1 1. REPORT 2 2 3/2 - 2 CHEM ANALYSIS 1/ MELT 1. PEM-6041-0 SPECIFICATION: NUMBER SPECIFICATION TITLE SECTION VOLUME III AGENCY REMARKS P W V SL.2 COPPER FLATS 1. DRAWING 3/2 - - 2. RESISTANCE VALUE MA ELECTRICAL 10% -DO- -DO- -DO- 3/2 - - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDOR'S COMPANY SEAL 401 . DUCTILITY OF SHEET 1. SURFACE FINISH 3./SPEC. NO. FROM SUPPLIER INSPN.

DRAWING MFR'S.3 PAINTING MA VISUAL 100% -DO- -DO- -DO- 2 - - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDOR'S COMPANY SEAL 402 . SURFACE CONDITION 1. DRAWING MFR'S. DRAWING 1. DIMENSIONS 2.CUSTOMER QUALITY PLAN SHEET 2 OF 4 COMPONENT/OPERATION CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT./SPEC. PEM-6041-0 SPECIFICATION NUMBER SPECIFICATION TITLE SECTION VOLUME III AGENCY REMARKS P W V SL. TYPE/ METHOD OF CHECK 1 2 3 4. FINISH MA MA MA MEASUREMENT 100% VISUAL VISUAL 100% 100% APPD. 100% - PORCELAIN INSULATORS SHALL BE OF APPROVED MAKE 1. CHEMICAL COMPOSITION MA 4 5 6 7 8 9 TEST 3/2 CERTIFICATE -DO-DODO -DO-DO2 2 2 2 - 10 1 11 CHEM ANALYSIS 1/ LOT BHEL DRG. STEEL WASHER PORCELAIN INSULATORS (POST & BUSHING TYPES) 1. STD.5 MEASUREMENT 10% MEASUREMENT 100% MA ELEC. DRAWING MFR'S. 2 SURFACE 1. DRY P.1 FABRICATION CUTTING. SURFACE FINISH & DEFECTS 3. DRAWING MFG. STD. IS BHEL SPECN IS TEST CERT. DRILLING ETC 1. HV TEST MA MA MA MA MEASUREMENT 100% VISUAL INSPN INSPN. NO. 2 - 1 2 2. STD. STD. DRAWING MFR'S. DIMENSIONS 2. 100% BHEL SPECN. -DO-DOINSPN REPORT -DO-DO2 2 2 - 2.2 SURFACE PREPARATION 1. DIMENSIONS 2. BHEL DRG. PUNCHING./SPEC. SURFACE FINISH & COVERAGE 2. BENDING. PROJECT TITLE QUALITY PLAN NUMBER PED-505-00-Q-002/01 ITEM NEUTRAL GROUNDING RESISTOR EXTENT OF REFERENCE ACCEPTANCE FORMAT CHECK DOCUMENT NORM OF RECORD FORM NO.4 MICA INSULATED TIE-RODS MICA WASHERS. MFG./MFG.F./MFG -DO-DOAPPD.

FILM THICKNESS MA 4 5 MEASUREMENT 100% 6 7 APPD. DIMENSIONS 4 4.RESISTANCE VALUE 3.1 FINAL ASSEMBLY COMPLETE NGR 1. DIMENSIONS CR ELECTRICAL 100% 2 1 - MA MEASUREMENT 100% -DO- -DOBIDDER/VENDOR 2 1 - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER'S/VENDOR'S COMPANY SEAL 403 .CUSTOMER QUALITY PLAN SHEET 3 OF 4 COMPONENT/OPERATION CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT. HV TEST CR ELECTRICAL 100% BHEL SPECN/ IS-1822/ BS-587 -DOBHEL SPECN IS-1822/ BS-587 -DOTEST REPORT 2 - 2. HV TEST CR ELECTRICAL 100% -DO- 2 - - MA MEASUREMENT 100% -DO- -DO- 2 - - CR ELECTRICAL 100% BHEL SPECN/ IS-1822 BS-587 -DO- BHEL SPECN IS-1822 BS-587 -DO- TEST REPORT 2 1 - 2./MFG 8 APPD.1 SUB-ASSEMBLY RESISTOR UNIT FRAME ASSEMBLED 1. PEM-6041-0 SPECIFICATION NUMBER SPECIFICATION TITLE SECTION VOLUME III AGENCY REMARKS P W V SL. PROJECT TITLE QUALITY PLAN NUMBER PED-505-00-Q-002/01 ITEM NEUTRAL GROUNDING RESISTOR EXTENT OF REFERENCE ACCEPTANCE FORMAT CHECK DOCUMENT NORM OF RECORD FORM NO. CABLE TYPE/ METHOD OF CHECK 1 2 3 2. 9 INSPN REPORT 2 - 10 - 11 3 3. NO./MFG.RESISTANCE VALUE 3.

/ IS:1822 BS:587 IS-2147 8 BHEL SPEC./ IS-5 -DO- BHEL SPEC. NO. SHORT TIME RATING/TEMPERATURE RISE TEST 5./ IS-5 -DO- 2 1 - 7. PROJECT TITLE QUALITY PLAN NUMBER PED-507-00-Q-002/01 ITEM NEUTRAL GROUNDING RESISTOR EXTENT OF REFERENCE ACCEPTANCE FORMAT CHECK DOCUMENT NORM OF RECORD FORM NO. PEM-6041-0 SPECIFICATION NUMBER SPECIFICATION TITLE SECTION VOLUME III AGENCY REMARKS P W V SL. PAINT FINISH MA 4 5 HEAT RUN 6 1/TYPE 7 BHEL SPEC. TYPE/ METHOD OF CHECK 1 2 3 4.CUSTOMER QUALITY PLAN SHEET 4 OF 4 COMPONENT/OPERATION CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT. PAINT SHADE MA GAUGE ALL 2 1 - MI VISUAL-SHADE CARD ALL -DO- -DO- 2 1 - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDOR'S COMPANY SEAL 404 . PAINT THICKNESS 8. DEGREE OF PROTECTION 6./ IS:1822 BS:587 BHEL SPEC 9 3 10 1 - 11 MA AS PER IS-2147 IS 2147 VISUAL 1/TYPE TEST REPORT 2 - 1 MA 100% BHEL SPEC.

0 3. ACCEPTANCE TEST 3. OUTPUT CHARACTERISTICS 5.WORKMANSHIP MA AS PER IS -DO- 3/2 2 1 MA MA -DO-DO- 100% AS PER IS -DO-DO- -DO-DO- -DO-DO- 3/2 3/2 2 - 1/2 MA VISUAL 100% BHEL/SPEC RELV. NO. ROUTINE TEST 4.0 HANDSET 1. PED-557-00-Q-002 1. TYPE TEST MA ELECT. IS7527 -DOTEST CERT. SPEC.CUSTOMER : QUALITY PLAN SHEET 1 OF 4 COMPONENT/OPERATION CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT. : PROJECT TITLE QUALITY PLAN NUMBER PED-557-00-Q-001/01 ITEM PUBLIC ADDRESS SYSTEM EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION : NUMBER : SPECIFICATION TITLE SECTION VOLUME III AGENCY REMARKS P W V SL.LIMITING BHEL MA MA VISUAL ELECT. IS7741. SPEC. PED-506-00-Q-003 AS PER QUALITY PLAN NO.0 4. SIDE TONE 6. PED-506-00-Q-002 2. IS7527 -DOBHEL.IS/BS/ IEC -DO-DO- BHEL/SPEC RELV.0 AS PER QUALITY PLAN NO. DEGREE OF PROTECTION 5.INPUT CHARACTERISTICS 4. IS7741.0 2 MATERIAL/ BOUGHT OUT ITEMS IN-PROCESS PCB ASSEMBLY SPEAKERS 3 4 5 6 7 8 9 10 11 AS PER QUALITY PLAN NO. MEAS SAMPLE -DO- -DO-DO- 3 3 1/2 1/2 - MA -DO- -DO- -DO- -DO- -DO- 3 1/2 - MA MA -DO-DO- -DO-DO- -DO-DO- -DO-DO- -DO-DO- 3 3 1/2 1/2 - PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 405 . TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 1. 3/2 2 1 2. COLOUR 3. & MEAS -DO1/TYPE BHEL.IS/BS/ IEC -DO-DO- -DO- 3 1/2 - 2.

& RELV.WIRE TERMINATION(SOLDERING OR CRIMPED LUGS) 4.IS/BS/ IEC -DO-DO- 9 3 10 1. OPERATION MA 4 5 ELECT.2 11 8.IS/BS/ IEC -DO- 8 BHEL/SPEC RELV. IS/ BS -DO-DO- TC 2 1 - 2.TERMINAL BLOCK ARRANGEMENT MA MA -DOPULL TEST -DO-DO- -DO-DO- 2 2 1 1 - MA VISUAL -DO- -DO- -DO- -DO- 2 1 - MA -DO- -DO- -DO- -DO- -DO- 2 1 - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 406 . : PROJECT TITLE QUALITY PLAN NUMBER PED-557-00-Q-001/01 ITEM PUBLIC ADDRESS SYSTEM EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION VOLUME III AGENCY REMARKS P W V SL. FERRULE NUMBERING 5. DRG. 6 FINAL ASSEMBLY ( SYSTEM ) 1. WORKMANSHIP MA MEASUREMENT -DO- -DO- 3 - 1/2 MA DROP & VIBRATION TEST -DO- -DO- -DO- -DO- 3 - 1/2 MA VISUAL 100% BHEL SPEC APPD. TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 2 3 7. DATA SHEETS. WIRING LAYOUT 3. MEAS 6 SAMPLE 7 BHEL/SPEC RELV. DATA SHEETS. NO. DRG. DEGREE OF PROTECTION 9. RIGIDITY.CUSTOMER : QUALITY PLAN SHEET 2 OF 4 COMPONENT/OPERATION CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT. IS/ BS -DO-DO- BHEL SPEC APPD. & RELV. SOUNDNESS OF MOUNTING & CONSTRUCTION ETC.

NO. IS/ BS -DO- 8 BHEL SPEC APPD. IS/ BS -DO-DO- 9 2 10 1 - 11 7. DATA SHEETS.IDENTIFICATIONMARKS 11.COMPONENT LAYOUT MA -DO- -DO- -DO- 2 1 - MA -DO- -DO- -DO- -DO- -DO- 2 1 - MA -DO- -DO- -DO- -DO- -DO- 2 1 - 10.SMOOTH OPERATION OF VARIOUS CONTROLS 9. DRG.OPERATION/ FUNCTIONAL CHECK BHEL CR ELECTRICAL -DO- -DO- -DO- 2 1 - PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 407 .CORRECTNESS OF ITEM 8.PAINT THICKNESS 13. TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 2 3 6.CUSTOMER : QUALITY PLAN SHEET 3 OF 4 COMPONENT/OPERATION CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT. : PROJECT TITLE QUALITY PLAN NUMBER PED-557-00-Q-001/01 ITEM PUBLIC ADDRESS SYSTEM EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION VOLUME III AGENCY REMARKS P W V SL.DRIFT -DOETC 15.DIMENSION 14 SCREENING MA -DO- -DO- -DO- -DO- -DO- 2 1 - MA -DO- -DO- -DO- -DO- -DO- 2 1 - MA MEASUREMENT -DO- -DO- -DO- -DO- 2 1 - MA MA MEASUREMENT SYSTEM SOAKING -DO-DO- -DO48HRS AT MAX 45 DEGREE C SITE TEMP -DO- -DO- -DO- 2 2 1 1 - NO FAILURE.PROPER MA MOUNTING OF ITEM 4 VISUAL 5 100% 6 7 BHEL SPEC APPD. PAINT SHADE & FINISH 12. DRG. & RELV. DATA SHEETS. & RELV.

MARKING 7. NO.POWER SUPPLY.WATER PROOF COVER FOR EQUIPMENT 5.PACKING SLIP MA -DO- -DO- -DO- 2 - 1 MA MA -DO-DO- -DO-DO- -DO-DO- -DO-DO- -DO-DO- 2 2 - 1 1 MA -DO- -DO- -DO- -DO- -DO- 2 - 1 MA MA -DO-DO- -DO-DO- -DO-DO- -DO-DO- -DO-DO- 2 2 - 1 1 BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 408 .CUSTOMER : QUALITY PLAN SHEET 4 OF 4 COMPONENT/OPERATION CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT.IR-MV IR 7 PACKING 1.WOOD SPECIES CR MA -DOVISUAL -DO100% -DOBHEL SPEC/ MFR STD -DO- -DOBHEL SPEC/ MFR STD -DO- -DO-DO- 2 2 1 1 2. : PROJECT TITLE QUALITY PLAN NUMBER PED-557-00-Q-001/01 ITEM PUBLIC ADDRESS SYSTEM EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION VOLUME III AGENCY REMARKS P W V SL.STURDINESS 4.WOOD PRESERVATIVE TREATMENT 3. TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 2 3 16.EFFICIENCY CR 4 5 ELECTRICAL -DO- 6 -DO- 7 -DO- 8 -DO- 9 2 10 1 - 11 CR -DO-DO- -DO-DO- -DO-DO- -DO-DO- -DO-DO- 2 2 1 1 - 18.SILCAGEL PACKETS 6.CR VARIOUS CHECKS 19.INTER-CHANGEABILITY 17.

Physical properties MA and sheath) 2.Dimension MA Chemical analysis -doElectrical Tests Measurement -do-do- -do-do-do- 3/2 3/2 3/2 - 2 2 2 BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 409 .Tests Physical Tests Sample 100% Sample* 3/2 2 3/2 - 2 2 * Sample from each Batch/Lot.2 Galvanised steel wire/strip 1. Elec. TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 1.Galvanization Quality MA 1. Phy.Electrical properties MA 4. Chemical Composition & purityMA 3. Physical Properties MA 2. Dimension MA -do-do-do- -do-do-do- 3/2 3/2 3/2 - 2 2 2 3.1 2 RAW MATERIAL 3 4 5 6 7 8 9 10 11 PVC Compound(for insulation 1. -do-do-do- 3/2 - 2 Electrical Tests Visual Physical & Electrical Tests Measurement Galv. Properties 2. IS-3975/BHEL Specification -do-doIS-613 IS-5484 IS-8130 AND BHEL Specification -do-do-do- Log Book/ Test Cert. IS-3975 BHEL Specification -do-doIS-613 IS-5484 IS-8130 AND BHEL Specification -do-do-do- IS-5831/BHEL Specification -doPlant Std.Properties 3. NO. : PROJECT TITLE QUALITY PLAN NUMBER PED-507-00-Q-002/02 ITEM :PVC POWER & CONTROL CABLE EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION : NUMBER : SPECIFICATION TITLE SECTION VOLUME III AGENCY REMARKS P W V SL. Make & Type MA MA MA Physical Tests Sample IS-5831/BHEL Specification -doPlant Std.3 Copper/Aluminium Rods/ Wires 1.0 1.and Elec.CUSTOMER : QUALITY PLAN SHEET 1 OF 5 COMPONENT/OPERATION CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT. 1.

& Apprd. TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 2. Appd. NO. & Apprd.of wires MA Counting Sample Vendors/BHEL Specn. cuts & Scratches. CR Finish & dimension 2.data sheet IS-1554 -do-do-do-do- 2 2 2 2 - 1 2 Insulation thickness CR Measurement Sample Appd.0 2. No.Dimension 2.3 Core Insulation (No repair permitted) 1.data sheet IS-1554 -do- 2 - - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 410 . Meas Visual Measurement Visual Sample Sample Sample 100% -do-do-do- -do-do-doFree from bulging burnt particles lumps. Physical. Tests Sample Visual & Meas. Sequence.2 Stranding of wires 1.&Elect. : PROJECT TITLE QUALITY PLAN NUMBER PED-507-00-Q-002/02 ITEM :PVC POWER & CONTROL CABLE EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION VOLUME III AGENCY REMARKS P W V SL. lay length & Direction MA 3 Surface Finish 4.1 2 IN PROCESS Wire Drawing . Electr. Data Sheet & Relevant IS Vendors/BHEL Specn. IS-8130 do -do- Log Book 2 - 1 do -do- 2 - - 2. 2 Chemical test for Tinning CR Phy.CUSTOMER : QUALITY PLAN SHEET 2 OF 5 COMPONENT/OPERATION CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT. IS-8130 do -do- BHEL Specn. Tinning and Annealing 3 4 5 6 7 8 9 10 11 1. Surface finish MA MA MA Visual. Data Sheet & Relevant IS -do- 2 - - 2. Chemical Test Sample BHEL Specn.

Concentricity # CR 4 5 Measurement 6 Sample 7 Mfr's Std./relevant IS -do- 2 - - Visual 100% -- Free from bulging. TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 2 3 3. Sample Mfrs.5 InnerSheath Extrusion 1. BHEL Specn. Surface finish MA Visual & Meas. burnt particles.Dia over inner sheathMA 2. Lay Direction MA Visual 2 - - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 411 .Std. IS-1554 data sheet -do- -do- 2 - - 3. MA Lay length & direction up core 2. Spark Test or Water CR Immersion test 6. data sheet -doMfr's Std. Core identification 2. Sheath thickness MA Measurement Sample IS-5831. data sheet -doMfr's Std.Std. 8 Mfr's Std. IS-1554 data sheet -do- -do- 2 - - 2. -dothe process Data sheet Data sheet IS-3975 & IS-1554 IS-3975 & IS-1554 -do-do-do-do- 2. IS-5831.4 Core Laying MA Visual Measurement 100% Sample IS-1554 -do- IS-1554 -do- -doLog Book 2 2 - - 1./Appd./Appd./ Appd.CUSTOMER : QUALITY PLAN SHEET 3 OF 5 COMPONENT/OPERATION CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT. Dia over laidup core MA 2. lumps cuts & scratches./relevant IS Mfrs. 9 Log Book 2 - 10 1 11 # To be checked at starting & finish end of Extruded Length 4 Dia over insulation MA Measurement Electrical Sample 100% -do-do- 2 2 - 1 5.of wires/Strips MA -doCounting -do- -do- 2 2 - - At the start of BHEL Specn.Sequence of lay. NO. No. : PROJECT TITLE QUALITY PLAN NUMBER PED-507-00-Q-002/02 ITEM :PVC POWER & CONTROL CABLE EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION VOLUME III AGENCY REMARKS P W V SL./ Appd.6 Armouring 1.

Sample * Test Report 2 - 1 * One Drum/Size/Lot 3.8 Finished Cable 1. Type & FRLS Tests CR Elec.0 Final Inspection 1.data sheet Free from Bulging Burnt particles. lumps. Coverage MA Measurement Measurement Visual 2 2 2 - - 5. Dia over outer sheath 4. Surface Finish MA 2. 6 7 8 9 2 - 10 - 11 At the start of BHEL Specn. : PROJECT TITLE QUALITY PLAN NUMBER PED-507-00-Q-002/02 ITEM :PVC POWER & CONTROL CABLE EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION VOLUME III AGENCY REMARKS P W V SL. Lay Length MA 4 5 Visual. Meas. Log Book the process Data sheet Data sheet IS-3975 & IS-1554 IS-3975 & IS-1554 -do-do100% -do-do-do-doFree from Bulging Burnt particles. NO. 100% Test Report 2 - 1 2.7 Outer Sheath Extrusion 1./ Appd.Sheath thickness MA Measurement Sample IS-5831 & IS-1554 Data Sheet -do- Log Book 2 - - 3. lumps. cuts & scratches IS-5831 & IS-1554 Data Sheet -do-do-doLog Book 4./ Appd.data sheet IS-1554 & BHEL Specn. Marking MA Measurement Sample -do- 2 - - MA Visual 100% IS-1554 & BHEL Specn. & Meas. Routine Test CR Elec.CUSTOMER : QUALITY PLAN SHEET 4 OF 5 COMPONENT/OPERATION CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT. BHEL Specn. cuts & scratches Test Report 2 - - Sequential marking shall be done by printing 2. Dia over armouring MA 2.. IS-1554 & BHEL Specn -do-/Apprd. TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 2 3 3. Phy & Meas. IS-1554 Test Report 2 1 - One drum each for Power & control cables in a Lot BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 412 . Finish & Length MA Visual (See remark) BHEL specn. IS-1554 & BHEL Specn -do-/Apprd.

Data Sheet -do-do- 2 2 1 1 Type Test shall be witnessed on one sample per type(Power/control) of every lot 6. As per IS -do- 2 1 - MA Visual -do- -do- -do- -do- 2 1 - CR Phy & Elect. AND ARE LIABLE TO AUDIT CHECK BY PURCHASER. NO. : : PROJECT TITLE QUALITY PLAN NUMBER PED-507-00-Q-002/02 ITEM :PVC POWER & CONTROL CABLE EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION VOLUME III AGENCY REMARKS P W V SL. W: WITNESSER V: VERIFIER (1) BHEL/BHEL's CUSTOMER: 2-VENDOR : 3 SUB VENDOR LEGEND : P : PERFORMER BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 413 . NO REPAIR OF CORE INSULATION PERMITTED CABLE ENDS SHALL BE SEALED AS PER BHEL SPECIFICATION PURCHASER SHALL HAVE RIGHT TO WITNESS THE SPARK TEST AT CORE STAGE RECORD OF RAW MATERIAL. Armouring Coverage No. PROCESS & ALL STAGES SHALL BE CERTIFIED BY VENDORS QC.of Wires/Strips 4.CUSTOMER QUALITY PLAN SHEET 5 OF 5 COMPONENT/OPERATION CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT.Data Sheet -doBHEL Specn. VENDOR TO CERTIFY THE SAME. Type & FRLS Tests CR NOTES:(A) (B) (C) (D) (E) (F) (G) (H) JOINTS IN WIRE SHALL BE AS PERMITTED BY IS / BHEL SPECIFICATION. THE SAME SHALL BE AS PER VENDORS SAMPLING PLAN VENDOR SHALL FURNISH COMPLIANCE CERTIFICATE TO THE INSPECTION AGENCY CONFIRMING THE PACKING AS PER BHEL SPECIFICATION. Dimension MA 4 5 Measurement 6 As per IS 7 Appd. Tests -doMeasurement (SEE REMARK) -doBHEL Specn. SHALL BE AS PER BHEL SPECIFICATION WHEREVER EXTENT OF CHECK FOR STAGE IS MENTIONED AS SAMPLES. Marking/Colour Coding 5. Apprd.Data Sheet/ IS-1554 & IS-10810 -do- 8 Appd. TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 2 3 2.Data Sheet/ IS-1554 & IS-10810 -do- 9 Test Report 2 10 1 - 11 3. Acceptance Tests MA Visual & Meas. Apprd. FILLERS/DUMMY CORES ETC.

NO. SCREW THREAD 4.1 - MA CHEMICAL -DO- IS-2633 IS-2633 -DO- 3 2. : PROJECT TITLE QUALITY PLAN NUMBER PED-507-00-Q-006/01 ITEM RIGID STEEL CONDUITS & PIPES REFERENCE ACCEPTANCE DOCUMENT NORM SPECIFICATION : NUMBER : SPECIFICATION TITLE SECTION VOLUME III AGENCY REMARKS P W V SL. BEND TEST MI MI VISUAL MEASUREMENT -DO-DO- 2 2 1 1 - MA MECH. WT.1 - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 414 .FINISH 3.UNIFORMITY OF ZINC 8.CUSTOMER : QUALITY PLAN SHEET 1 OF 1 COMPONENT/OPERATION CHARACTERISTICS CHECK BIDDER/ VENDOR SYSTEM CAT. ADHESION TEST MA MECH. 1 SAMPLE OF EACH SIZE -DO- -DO- -DO- -DO- 2 1 - 5. COMPRESSION TEST 6.1 - MA PIVOT/HAMMER TEST -DO- IS2629 IS-2629 -DO- 3 2. TYPE/ METHOD OF CHECK EXTENT OF CHECK FORMAT OF RECORD 1 2 FINISHED PRODUCT 3 1. TEST -DO- -DO- -DO- 2 1 - MA MEASUREMENT ONE SAMPLE IS-6745 IS-4736 -DO- 3 2. OF ZINC COATING 7. DIMENSIONAL CONFORMITY MA 4 5 MEASUREMENT 6 5 SAMPLES PER SIZE PER LOT -DO-DO- 7 AS PER IS-9537 PT I & II AND OTHER IS -DO-DO- 8 AS PER IS-9537 PT I & II AND OTHER IS -DO-DOIR 9 2 10 1 - 11 2.

: QUALITY PLAN NUMBER PED-507-00-Q-005/03 ITEM : CABLE TRAYS & ACCESSORIES TYPE/ METHOD OF CHECK EXTENT OF CHECK REFERENCE DOCUMENT ACCEPTANCE NORM 1 1.RIGIDITY (CABLE TRAYs) MA VISUAL 100% SPECIFICATION QC RECORD 2 - 1 MA DEFLECTION TEST SAMPLE SPECIFICATION SPECIFICATION QC RECORD 2 - 1 600 MM OR 450 MM WIDE CABLE TRAY SIZE TO BE TESTED 2.2 SURFACE PREPARATION 1. NO. MA CHEM TEST EACH HEAT IS-209 IS-209 QC RECORD 3/2 - 1/2 1. APPD.DIMENSIONS 3. 2.1 2 RAW MATERIAL ROLLED SHEET 3 4 5 6 7 8 9 10 11 1.CHEM.SURFACE FINISH MA MA MEASUREMENT 100% VISUAL 100% IS-1730/ SPECIFICATION IS1079/ SPECIFICATION IS-1730/ SPECIFICATION IS1079/ SPECIFICATION QC RECORD QC RECORD 3/2 3/2 - - 1. PROPERTIES MA VERIFICATION OF TC'S 100% IS1079/ SPECIFICATION IS1079/ SPECIFICATION MILL TC 3/2 - - STEEL SHALL BE PROCURED FROM SAIL/TISCO/RINL/ AUTHORISED RE-ROLLERS/ MANUFACTURER AS PER BHEL APPROVED SOURCES.0 1.& PHY.CLEANING.0 2.CUSTOMER : PROJECT TITLE SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION FORMAT OF RECORD AGENCY P W V VOLUME III REMARKS QUALITY PLAN SHEET 1 OF 2 SL.SURFACE FINISH 4.WELDING QUALITY MA VISUAL 100% GOOD WELDING PRACTICE FREE FROM DEFECTS & SLAG SPECIFICATION QC RECORD 2 - 1 3.DRGS. RINSING & FLUXING 2. COMPONENT/OPERATION CHARACTERISTIC CHECK BIDDER/ VENDOR SYSTEM CAT.DRGS. SURFACE QUALITY MA MEASUREMENT PERIODIC IN EACH SHIFT IS:2629 IS:2629 QC RECORD 2 - - MA VISUAL 100% IS:2629 IS:2629 QC RECORD 2 - - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 415 .DIMENSIONS MA MEASUREMENT 100% APPD. QC RECORD 2 - 1 INSPECTION AT BLACK STAGE BY BHEL/ BHEL AUTHORISED INSPECTION AGENCY WELDING IS TO BE DONE BY QUALIFIED WELDERS 2.2 2.1 ZINC IN-PROCESS FABRICATION CHEM. PICKLING.COMP.

STAIN. 1 FASTENERS SHALL BE OF REPUTED & APPROVED MAKE. DRGS.CUSTOMER : PROJECT TITLE SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION FORMAT OF RECORD AGENCY P W V VOLUME III REMARKS QUALITY PLAN SHEET 2 OF 2 SL.2629 / MFR'S PRACTICE IS .0 3.SURFACE QUALITY 4 MA 5 TEMPERATURE INDICATOR VISUAL 6 CONTINUOUS IS-2629 7 IS-2629 8 9 QC RECORD 2 10 - 11 MA MA CONTINUOUS IS . FLUX. FLUX. 1 - . REPORT 3 2. BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 416 .2631 IS . ROUGHNESS.SURFACE FINISH MA VISUAL IS-2500 LEVEL IV SPECIFICATION FREE FROM BURRS. APPD. SPECIFICATION INSP.2629 IS . 1 - NOTE: INSTRUCTIONS FOR QUALITY PLAN IS ATTACHED AS ANNEXURE-1. TEST IS-4759 / IS-6745 SPECIFICATION SPECIFICATION IS-4759 / IS-2633 SPECIFICATION SPECIFICATION INSP. 2.2629 IS . DRGS.DIMENSIONS MA MEASUREMENT IS-2500 LEVEL IV APPD.RIGIDITY (FOR TRAYS) MA DEFLECTION TEST 1/ LOT SPECIFICATION INSP. ETC. REPORT 3 2. REPORT 3 2. 1 - MA MECH.2629 / MFR'S PRACTICE FREE FROM BURRS ROUGHNESS.TEMPERATURE OF BATH 2. ETC. SLAG . TEST IS-2633 INSP.3 GALVANISING 2 3 1. REPORT 3 2. SLAG. NO.MASS OF ZINC COATING 5. 1 - MA CHEM.ADHESION MA CHEM.. QC RECORD QC RECORD 2 3 - 2 VISUAL 100% MEASUREMENT VISUAL 100% MA QC RECORD 2 - - 3. REPORT 2 1 - 600 MM OR 450 MM WIDE CABLE TRAY TO BE TESTED 4.1 FINISHED ITEMS (CABLE TRAY. STAIN. REPORT 2 1 - MA ELCOMETER IS-4759 / SPECIFICATION SPECIFICATION SPECIFICATION INSP. REPORT 3 2. DROSS 3. RATE OF IMMERSION 4. COMPONENT/OPERATION CHARACTERISTIC CHECK BIDDER/ VENDOR SYSTEM CAT.TEST IS-4759 IS-2629 IS-2629 INSP.UNIFORMITY OF ZINC COATING 6. 3. ACCESSORIES & HARDWARES) 1.THICKNESS OF ZINC COATING 7. INSP. : QUALITY PLAN NUMBER PED-507-00-Q-005/03 ITEM : CABLE TRAYS & ACCESSORIES TYPE/ METHOD OF CHECK EXTENT OF CHECK REFERENCE DOCUMENT ACCEPTANCE NORM 1 2.

: TYPE/ METHOD OF CHECK EXTENT OF CHECK QUALITY PLAN NUMBER PED-509-00-Q-001/02 ITEM : EARTHING & LIGHTNING PROTECTION MATERIALS REFERENCE ACCEPTANCE FORMAT DOCUMENT NORM OF RECORD VOLUME III REMARKS 1 1. OF TC'S 100% IS:1079 IS:1079 MILL TC 3 - 2 STEEL SHALL BE PROCURED FROM SAIL/ TISCO/ RINL/ AUTHORISED RE-ROLLERS/ MANUFACTURERS AS PER BHEL APPROVED SOURCES. DRILLING 1.SURFACE QUALITY BHEL MA VISUAL 100% IS:2629 IS:2629 QC RECORD 2 - - PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 417 .TEST SAMPLE IS .CHEMICAL & PHYSICAL PROPERTIES MA VERIFICATION.1730 IS : 1079 QC RECORD QC RECORD 3/2 3/2 - - MA CHEM. PICKLING RINSING.1 2 RAW MATERIAL MILD STEEL (FLATS & RODS) AS PER SPECIFICATION 3 4 5 6 7 8 9 10 11 1.209 QC RECORD 3/2 - 1/2 2.CLEANING PICKLING.DIMENSIONS 2.SURFACE FINISH 1.1 IN-PROCESS CUTTING.COMP.2 SURFACE PREPARATION 1. & FLUXING MA MEASUREMENT PERIODIC IN EACH SHIFT IS:2629 IS:2629 QC RECORD 2 - - 2. BIDDER/ VENDOR SYSTEM CAT.CHEM. MA MA MEASUREMENT 100% VISUAL 100% IS . NO. SOURCES 2.2 ZINC 1.CUSTOMER : PROJECT TITLE SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION AGENCY P W V QUALITY PLAN SHEET 1 OF 3 COMPONENT/OPERATION CHARACTERISTIC CHECK SL.0 1.DIMENSIONS 3.1730 IS : 1079 IS .0 2.209 IS .SURFACE FINISH MA MA MEASUREMENT 100% VISUAL 100% SPECIFICATION SPECIFICATION SPECIFICATION SPECIFICATION QC RECORD QC RECORD 2 2 1 1 2.

DIMENSIONS MA MEASUREMENT RANDOM SPECIFICATION SPECIFICATION INSP. RATE OF IMMERSION MA VISUAL/ 100% MEASUREMENT IS .CUSTOMER : PROJECT TITLE SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION AGENCY P W V QUALITY PLAN SHEET 2 OF 3 COMPONENT/OPERATION CHARACTERISTIC CHECK SL. ROUGHNESS. STAIN. ETC.2629 QC RECORD 3 - - 3.0 FINISHED ITEMS 1.3 GALVANISING 2 3 1. REPORT 3 2.2629 FREE FROM BURRS. 1 - NOTE: INSTRUCTIONS FOR QUALITY PLAN IS ATTACHED AS ANNEXURE-1.ADHESION MA CHEM.THICKNESS OF ZINC COATING 6. TEST IS .4759 IS-2633 INSP. . REPORT 3 2. REPORT 3 2.2629/ MFRS PRACTICE IS .MASS OF ZINC COATING 4.2629 8 9 QC RECORD 2 10 - 11 MA CONTINUOUS IS . SLAG. REPORT 3 2.2629 7 IS . NO.2629/ MFRS PRACTICE QC RECORD 3 - 2 4.4759 SPECIFICATION SPECIFICATION INSP. SPECIFICATION INSP.UNIFORMITY OF ZINC COATING 5. STAIN ETC.SURFACE FINISH MA VISUAL RANDOM SPECIFICATION FREE FROM BURRS. 1 - MA MECH. 1 - 3. 1 - MA ELCOMETER IS . NO BIDDER/ VENDOR SYSTEM CAT. ROUGHNESS.TEST IS-4759 IS-2629 IS-2629 INSP. REPORT 3 2.SURFACE QUALITY MA VISUAL 100% IS . SLAG.2629 IS . FLUX.4759 IS-6745 / SPECIFICATION IS-2633 INSP. 1 - 2. . TEST IS .TEMPERATURE OF BATH 2. BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 418 . QC RECORD 2 - - 3. FLUX. 1 - MA CHEM. : TYPE/ METHOD OF CHECK EXTENT OF CHECK QUALITY PLAN NUMBER PED-509-00-Q-001/02 ITEM : EARTHING & LIGHTNING PROTECTION MATERIALS REFERENCE ACCEPTANCE FORMAT DOCUMENT NORM OF RECORD VOLUME III REMARKS 1 2. DROSS 4 MA 5 TEMPERATURE INDICATOR VISUAL 6 CONTINUOUS IS . REPORT 3 2.

Chemical & Elect. Physical properties MA Physical Tests Sample/ lot IS:5831/BHEL Specification -do- IS:5831/BHEL Specification -do- 3/2 - 2 2. Physical properties MA Physical Tests Sample/ Lot IS:7098 & Mfrs Std. Galvanization MA MA Measurement Galv. Data sheet IS:1897 Log Book 2 - 2 2. requirement -do-do- -do-do- 3/2 3/2 - 2 2 BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 419 . Dimensions MA Measurement -do- Manufacturer's std. & Elect. Chem. Elec.2 Semi Conducting Compound 1. Tests -do- Manufacturer's standard Manufacturer's standard -do- 3/2 - 1. Phy.and Elec. NO.and Elec.Properties MA Electrical Test -do- 3/2 - 2 1. Elec. SHEET 1 OF 5 COMPONENT/OPERATION CHARACTERISTIC CHECK TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 1. Properties MA Phy.5 15 Galvanised steel wire/strip 1. 1 Phy and Elec Elec. 3/2 - 2 2.2 Raw material verification as per approved subvendor list 1. R-02 ITEM : XLPE P Power C bl Cables EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION VOLUME III AGENCY REMARKS P W V SL.0 1. Dimension 3. : PROJECT TITLE QUALITY PLAN NUMBER PED-507-00-Q-001.Properties MA Electrical Tests -do- -do- -do- 3/2 - 1.2 1.4 PVC Compound (for sheath) 1. Tests -do- Supplier's test report & log book Log Book/ Test Report -do- 3/2 - 2 1. Phy. Properities MA Phy. Test Report Log Book -do- 3/2 - 2.CUSTOMER : STANDARD QUALITY PLAN BIDDER/ VENDOR SYSTEM CAT..3 Copper Foil 1.1 2 RAW MATERIALS XLPE Compound 3 4 5 6 7 8 9 10 11 1. IS:7098 & Mfrs Std. Properties MA Physical & Electrical Tests Sample from IS:3975/ BHEL each batch/ Specification lot -do-do-do-do- IS:3975/ BHEL Specification Log Book/ Test Cert./ Appd. Physical./ Appd. Data sheet IS:1897 Manufacturer's std.2 1.

Data Sheet Data Sheet BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 420 . SHEET 2 OF 5 COMPONENT/OPERATION CHARACTERISTIC CHECK TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 1. Chemical test for Tinning 2.1 IN PROCESS Wire Drawing .6 2 Copper/Aluminium Rods/ Wires 3 1. IS:8130 & BHEL Specn. : PROJECT TITLE QUALITY PLAN NUMBER PED-507-00-Q-001. Data Sheet & Data Sheet & Relevant IS Relevant IS -do- 2 - - 2.2 Stranding of wires 1. IS:8130 & BHEL Specification -do- 9 -do3/2 10 2 11 MA Chemical analysis Electrical Tests Measurement -do- -do- 3/2 - 2 MA MA -do-do- -do-do- -do-do- -do-do- 3/2 3/2 - 2 2 2. 2 Chemical Composition & purity 3. Finish & dimension CR Phy. Physical Properties 2. Tinning and Annealing 1. & Elect. lay length & Direction 3 Surface Finish 4. BHEL Specn & Apprd. NO. IS:8130 & BHEL Specn. Apprd. Electrical. Meas. Log Book 2 1 2. IS:8130 & BHEL Specification -do- 8 IS:613. Dimension 2. Tests Sample Visual / Meas. of wires CR Chemical Test -do- -do- -do- -do- 2 - - MA Counting -do- BHEL Specn.CUSTOMER : STANDARD QUALITY PLAN BIDDER/ VENDOR SYSTEM CAT CAT.Electrical properties 4. Physical.0 2. Sequence. Apprd. No. Dimensions 4 MA 5 Physical Tests -do- 6 7 IS:613.3 Conductor Screening 1. IS-5484. BHEL Specn. Radial thickness MA Visual. IS-5484. R-02 ITEM XLPE Power Cables EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION VOLUME III AGENCY REMARKS P W V SL SL. -do- -do- -do- -do- 2 - - MA MA MA Visual Measurement -do- -dodo -doSample -dodo -do- -dodo -do- -dodo -doLog Book 2 2 2 - - BHEL Specn & Apprd.

: PROJECT TITLE QUALITY PLAN NUMBER PED-507-00-Q-001./ data sheet BHEL Spec. Concentricity # CR Measurement Sample Mfr's Std. Test on XLPE (Tensile & Elongation./ data sheet Plant Std.CUSTOMER : STANDARD QUALITY PLAN BIDDER/ VENDOR SYSTEM CAT./Apprd. (Non Metallic & Metallic ) 1. Thickness MA -do- -do- BHEL Spec. Thickness of Insulation I l i 4 Dia over insulation CR Measurement -do- BHEL specn./Appd. -do- 2 - - 3 Overlap of Tape Band 4 Tightness of Tape Band MA Measurement -do- -do- 2 - - MA Visual -do- -do- 2 - - BHEL PARTICULARS NAME SIGNATURE DATE BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 421 . Log Book 2 - - 2./Appd. SHEET 3 OF 5 COMPONENT/OPERATION CHARACTERISTIC CHECK TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 2. Hot Set & Aging Test) 2./ data sheet BHEL Spec. BHEL Spec. R-02 Q . data sheet Log Book 2 - 1 # To be checked at starting & finish end of Extruded Length 3. Dats Sh / IS:7098 Sheet/ IS 098 D -do- Inspection Report R -do- 2 1 - MA Measurement -do- 2 1 - 5. Surface finish 4 MA Visual 5 100% 6 - 7 -do- 8 9 Log Book 10 2 1 11 2. Dats Sh / IS:7098 Sheet/ IS 098 D -do- BHEL specn. Surface finish MA Tests -do- -do- -do- -do- 2 1 1 MA Visual Sample - Free from bulging burnt particles lumps. ITEM XLPE Power Cables EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION VOLUME III AGENCY REMARKS P W V SL.5 Insulation Screening./Apprd./ data sheet Plant Std. NO. cuts & Scratches.4 2 Core Insulation (XLPE) ( (No repair permitted) p p ) 3 1. data sheet Mfr's Std.

8 Armour 1. Lay Length 4. Data Sheet Data Sheet -do-doFree from Bulging Bulging. & direction 3.9 29 Outer Sheath Extrusion 1. Dia over outer sheath 4. IS:7098.7 InnerSheath Extrusion 1. BHEL Specn. 8 Apprd. 6 Sample Sample 7 Apprd. Coverage MA MA MA Visual Meas. Visual -do100% Mnfrs. & Appd.of wires/Strips MA MA -doCounting -do- -do-do- 2 2 - - At the start of BHEL Specn. Data Sheet & Appd. Lay Direction 3. 1 Surface Finish MA MA Measurement Visual -do100% -doLog Book 2 2 - - 2./ Appd. NO NO. cuts & scratches Appd. No. Surface finish 2. Data Sheet 5. Data Sheet BIDDER/VENDOR BIDDER'S/VENDORS COMPANY SEAL 422 . Free from bulging. SHEET 4 OF 5 COMPONENT/OPERATION CHARACTERISTIC CHECK TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 2.Data sheet IS:7098 Plant Standard -do-do- 2 2 - - 2. 9 Log Book -do2 2 10 - 11 MA MA Meas. Data Sheet Log Book 2 - - 3. IS:7098 -do- do -do- 2 - - 3.6 Core Laying 2 3 1. BHEL Specn. Data Sheet. Dia over inner sheath 2./ Apprd.Std.Sheath thickness MA Measurement Sample Appd. lumps cuts & scratches. Data Sheet IS 7098/ Mfrs. Data Sheet. burnt particles. BHEL Specn. lumps. IS:7098 -doBHEL Specn./ the process Apprd. Dia over armouring 2. Std. Appd. Marking BHEL MA MA -doVisual -do100% -do- -do- -doTest Report 2 2 - Sequential marking shall be done by printing PARTICULARS NAME SIGNATURE DATE IS:7098. -- Mnfrs. Dia over laid up core 2. Data Sheet IS 7098/ Mfrs. burnt particles./ Appd.Data sheet -do-do-doIS:7098 Plant Standard 2.Sequence of lay.Std. Lay Length 4 MA MA 5 Measurement Visual & Meas. : PROJECT TITLE QUALITY PLAN NUMBER PED-507-00-Q-001. Std. R-02 ITEM XLPE Power Cables EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION VOLUME III AGENCY REMARKS P W V SL. Measurement -doLog Book -do- 2 2 2 - - BHEL Specn. Sheath thickness MA Measurement Sample Appd.CUSTOMER : STANDARD QUALITY PLAN BIDDER/ VENDOR SYSTEM CAT.

NO.10 2 Finished Cable 3 1. Apprd. IS:10810 -do-dodo Sample * * As per specn specn. Elect. & IS:7098 -do- 2 1 - One drum in each Lot 2. -do- -do- 2 1 - MA Visual -do- -do- -do- -do- 2 1 - CR Phy. & Meas. THE SAME SHALL BE AS PER SAMPLING PLAN AGREED BY PURCHASER.0 Final Inspection 1. IS:10810 -do- -do- 2 1 - 3. Armouring Coverage No. Acceptance Tests MA Visual & Meas. Dimension MA Measurement As per IS Appd. 3. R-02 ITEM XLPE Power Cables EXTENT OF REFERENCE ACCEPTANCE CHECK DOCUMENT NORM SPECIFICATION : NUMBER : SPECIFICATION : TITLE SECTION VOLUME III AGENCY REMARKS P W V SL SL. cuts & scratches Specn. (B) NO REPAIR OF CORE INSULATION PERMITTED (C) CABLE ENDS SHALL BE SEALED AS PER BHEL SPECIFICATION (D) PURCHASER SHALL HAVE RIGHT TO WITNESS THE SPARK TEST AT CORE STAGE (E) RECORD OF RAW MATERIAL.Data Sheet/ IS:7098./ Free from Bulging Burnt particles. Measurement 100% 6 7 8 9 2 2 10 1 1 11 IS:7098 & BHEL specnIS:7098 & BHEL specn. lumps. AND ARE LIABLE TO AUDIT CHECK BY PURCHASER.Data Sheet BHEL Specn. LEGEND : P : PERFORMER BHEL W: WITNESSER PARTICULARS NAME SIGNATURE DATE V: VERIFIER (1) BHEL/BHEL's CUSTOMER: 2 VENDOR : 3 SUB VENDOR BHEL/BHEL s 2-VENDOR BIDDER/ VENDOR BIDDER'S/VENDORS COMPANY SEAL 423 . Data Sheet -do- -do- 2 1 NOTES:(A) JOINTS IN WIRE SHALL BE AS PERMITTED BY IS / BHEL SPECIFICATION. Physical & Electrical Tests Visual. Marking & Colour Coding 5. (H) VENDOR SHALL FURNISH COMPLIANCE CERTIFICATE TO THE INSPECTION AGENCY CONFIRMING THE PACKING AS PER BHEL SPECIFICATION. (F) FILLERS/DUMMY CORES ETC. Data Sheet BHEL Specn Specn. SHALL BE AS PER BHEL SPECIFICATION (G) WHEREVER EXTENT OF CHECK FOR STAGE IS MENTIONED AS SAMPLES. Data Sheet/ IS:7098. 2 Type Tests * 4 CR CR 5 Elec. : PROJECT TITLE QUALITY PLAN NUMBER PED-507-00-Q-001. Apprd. Tests -do- BHEL Specn Apprd. Test Report BHEL Specn Specn. Routine Test 2.of Wires/Strips 4./ Appd.CUSTOMER : STANDARD QUALITY PLAN BIDDER/ VENDOR SYSTEM CAT CAT. SHEET 5 OF 5 COMPONENT/OPERATION CHARACTERISTIC CHECK TYPE/ METHOD OF CHECK FORMAT OF RECORD 1 2. VENDOR TO CERTIFY THE SAME. Finish & Length MA (See remark) BHEL specn. IN EXPORT ORDE PACKING SHALL BE AS PER BHEL SPECIFICATION & THE SAME SHALL BE WITNESSED. PROCESS & ALL STAGES SHALL BE CERTIFIED BY VENDORS QC.

6kV and motors rated upto 175 kW shall be rated upto 175 kW shall be 400V.6kV and motors 6. No. (b) A manually fitted ………….5960AEL-SK-2001 Technical Specification Clarification ANNEXURE-B 1 III D3. The voltage transformer. (c) Generator side current ……………………. fault level at 6. Further HT cable.GT side. lightning arresters & surge capacitors are envisaged as a part of SPVT & VT cubicle provided as part of generator busduct & associated equipement. (a) A switched short………. 424 . on each bus).: TCE.2 2 OF 8 2.9 (c & d) (d) Voltage transformers with ……………transformer side. LT power/control cables & LT switchgear for the same are excluded from BHEL scope of supply. LT service transformer.6kV system is 40kA. transformer feeder on each bus (colony supply) for Owner’s use shall be provided. Volume Section Page No.disconnector. rated 2000kVA for Colony supply(in customer scope) are considered in BHEL scope as per clause no.6 kV systems .10 (a & b) 4 III D3. LT busduct. Manual shorting link has been offered..9 Vol-III of customer specification. 1 III D3. I-59) BHEL Clarification (ELECTRICAL) submitted to customer S. Clause No.2 2 OF 8 2.0 1 OF 17 Fault level shall be limited to 44 kA rms for 6.0 12 OF 17 1.. 1. 2 III D 3.6 kV system with fault level limited to 40 kA rms has been offered. & as per key SLD.3 & Electrical key line diagram dwg.0(f) & Electrical key line diagram dwg. Two nos.3 of section D3. No.18( c) The motors rated 175 kW and The motors rated above 175 kW shall be above shall be 6... 3 III D 3. KARIMNAGAR (job no.: TCE. No..700MW CCPP AT NEDUNOOR. 9. The generator side current transformer is envisaged as a part of the isolated phase busduct.connection. 400 V.9 2 OF 15 9.5960AEL-SK-2001 Additionally One (1) no. transformer feeders (One (1) no. 6.

DC battery is sized for Emergency DC loads for 1hour & continuous DC loads( ie. Indicating lamps. KARIMNAGAR (job no.2 Emergency & Continuous Load (For 10 hours duration)…..13 2 OF 14 13. Technical Specification Deviation 1 III D3. GRP. I-59) BHEL deviations (ELECTRICAL) submitted to customer S. No. 425 .) for 10 hours.3. Volume Section Page No.700MW CCPP AT NEDUNOOR. Clause No. ECP7 AVR panel etc.

No. SCHEDULE OF TECHNICAL DEVIATION S. PE-TS-I59-888-E001 700MW KARIMNAGAR CCPP TECHNICAL SPECIFICATION FOR GENERAL ELECTRICAL WORKS Rev.Doc. Technical Specification Clarification 426 . No. : Page : 0 of 10. Vol/ section/ Clause No. Page No.

1 1.9 1.1.2.1. 5Set 10No.1.2 1. of each colour 2 Nos.7 1. PE-TS-I59-888-E001 700MW KARIMNAGAR CCPP TECHNICAL SPECIFICATION FOR GENERAL ELECTRICAL WORKS Rev. of each ratio & type VTs.2 1.10 1.1. : Page : 0 of 11. Fuses of each rating Transducers of each type & rating Non-Segregated Phase Busducts Bus support insulator Seal-off bushing Flexible connector (for equipment connection) Gasket DC System ( Spares applicable separately for each battery bank) 2. Local/ Remote selector switch. of each ratio & type Meters. limit position switches. S.2.1.13 1.4 1. breaker control switches & other switches Relays of each type used Clustered type LED CTs. 5 No.15 1.1.3 1.1 1.2 1.Doc. 427 . of each rating 1 No. 5 Nos. of each rating 2 sets of each rating 2Set 2No.1. 10 Nos.14 1. 2 Nos. AN INDICATIVE LIST OF MANDATORY SPARES IS GIVEN BELOW FOR REFERENCE.11 1.2.3 1.1 1.1. of each type & rating. 1 Set 1 Set 1 No. for each rating 1 No.5 1.1.s Quantity 1.4 2 1 No.1. No.1. 2 Nos. for each rating 1 set 2 Nos.1 1. 1 No. 1No.1. No.8 Description LT SWITCHGEAR & LT BUSDUCT 400V Switchgear Complete pole of breaker Breaker complete with operating mechanism and truck mounted Closing & tripping coils Fixed and moving contact assemblies of each breaker Spring charging motors Set of gasket Bus bar support insulators Aux switch assembly.12 1.1.1 Battery (a) Battery Cell of each type (b) Positive Plate of each Type (c) Negative Plate of each Type (d) Connectors with Nuts & Bolts (e) Vent Plugs 1No. SPARES: BIDDER TO QUOTE FOR MANDATORY SPARES.1.1.6 1. 1No. ERECTION & COMMISSIONING SPARES & RECOMMENDED O&M SPARES (FOR 3 YEARS OF OPERATION).2. for each rating 2 No.

of 32A & 5 Nos of 63A. 5 nos. of each rating 1 no.2 Battery Chargers (a) Silicon Diodes (b) Control Switch (c) Current Regulator (d) Off-Load Tap Changing Device (e) Fuse of each type (f) D. 428 . No. 1 no.C. Ammeter (g) Miniature circuit Breaker (h) Neon Lamps 3 3. PE-TS-I59-888-E001 700MW KARIMNAGAR CCPP TECHNICAL SPECIFICATION FOR GENERAL ELECTRICAL WORKS Rev.1 3.Doc. : Page : 1 Set 1 no. 1 no. 2 nos.2 3. of each rating 1 no.3 Lighting Fixtures Lighting fixtures (along with lamps) Lighting Panels MCBs 3% of each type 1 No. 5 No. 1 no. of each type. 0 of (f) Terminal Post 2.

NOIDA BHEL(RUDRAPUR) BHEL(REGION) BHEL(TRICHY) 6 B(JH) 7 B(PC) 8 B(PE) 9 B(RR) 10 B(RG) 11 B(TY) B. BANGALORE BHEL(HARDWAR) BHEL(HYDERABAD) BHEL(ISG).700MW KARIMNAGAR CCPP PROJECT ANNEXURE-A PROPOSED SCOPE SPLIT OF ELECTRICAL SYSTEMS BETWEEN BHEL & EPC PARTNER SL. 1 2 3 4 5 B B(BP) B(ED) B(HR) B(HY) B(IS) EXPANSION BHEL BHEL(BHOPAL) BHEL(EDN). BANGALORE BHEL(JHANSI) BHEL(PIPING CENTRE). ABBREVIATION A. CHENNAI BHEL(PEM). NO. P EPC-PARTNER .

2 Generator Circuit Breaker 1.700MW KARIMNAGAR CCPP PROJECT PROPOSED SCOPE SPLIT BETWEEN BHEL & EPC PARTNER SCOPE BASIC ENGINEERING SUPERVISION OF ERECTION & COMMISSIONING ERECTION EXECUTION & COMMISSIONING DETAILED ENGINEERING Sl.7 Electrical Control Panel(For main plant.5 NGR for MV system 2.5 Generator. DDCMIS for electrical systems 1.3 LT Switch gear {PMCC. no.1 Insulated phase busduct / Segregated phase busduct 1. SUPPLY SYSTEM / EQUIPMENT TERMINAL POINT REMARKS 1 POWER EVACUATION EQUIPMENT / SYSTEM 1.6 DC Power Supply 220 V dc P/B(PE) B(PE) B(PE) P/B(PE) B(PE) P/B(PE) P/B(PE) B(RR) B(PE) B(BP) B(JH) B(BP) B(RR) B(ED) P/B(PE) P/B(PE) B(ED) B(IS) B(RR) B(PE) B(BP) B(JH) B(BP) B(RR) B(ED) B(ED) B(IS) P P P P P B(PE) P P P P P P B(PE) P P P P P Design & Layout by 'P' based on inputs by respective BHEL units.6 Generator NGT & NGR 1.8 DCS (station C&I) 1.2 LT Aux.4 UAT 1. PCC. ACDB local PB stns for LT / HT Drives} 2. MCC.4 LV Bus Duct & Accessories 2.9 Diesel Generator 2 AC/DC POWER. P/B(PE) P/B(PE) P P P P B(BP) B(JH) P P P P B(BP) B(JH) P P P P P P P P P P P P P P P . GT & UAT protection panels 1.DISTRIBUTION CONTROL 2. located in CCR).1 MV (6.6 kV) Switch gear 2. Transformers ( dry type) 2.3 Generator Transformer 1.

1 Plant Lighting Equipment (Supply & E &C) 3. shall be prepared by 'P' in consultaion with B(PE) Interface among inputs from respective BHEL units is in 'P' scope.5 Electronic Earthing Material 5.5 4.6 Lightning Protection Material 5. cable tray support.8 DC Starter . Fire sealing material) 5.2. Cables [ for Cranes.3 Cabling Material (Cable trays & accessories.4 Equipment Earthing Material (Above ground & below ground grade) 5.4 4. Turbine and Generator 3 STATION -ELECTRICAL AUXILIARY PKG 3. jointing kits.1 TG Trunk Cabling (Field-UCD) Material P 5. P P P P P P P P P P P P P P P P P P P P P P P P P P P P P P * As per Cable Scope detailed matrix (Table1) 5 STATION CABLING.7 Plant Lighting . trefoil clamps. Electrical single line diagram & Design Memorandum for all Electrical package Electrical Layout/ Cable Listing/ cable routing/ cable interconnection diagram P P P P P P P P P P P P P P P B(ED) P P P P P P P P P P P P NA P P P P NA P P P P NA For main plant & BOP areas.3 4.7 DC Distribution 220 V dc 2.6 HT Power Cables LT Power Cables LT Control Cables Screen Cables (instrumentation) Spl.2 4.erection material 6 Main system design .2 PA System 4 POWER / CONTROL /SCREENED CABLES 4.for Boiler. Drg.] Fire Survival Cables P P P P P P P B(HY/TY) B(HY/TY) B(HY/TY) P P P P P P P P P P For complete plant. 7 P P NA NA NA ./doc.2 Boiler Trunk Cabling (Field . EARTHING & LIGHTING-MATERIAL 5. cable glands & lugs.1 4.UCD) Material 5. Hoists etc.

/doc.8 Preparation of Electrical load data P P NA NA NA Load list shall be prepared by 'P' in consultaion with B(PE). Data sheet/ OGA/ scheme/ Test certificates/ Quality Plans etc. . customer/ obtaining approval from customer engineering of electrical system and equipment including layout / cable routing engineering and furnishing details/BOM/technical Note:-Design & 9 particulars shall be in Partner's scope./ follow-up with P' shall provide support to 'B(PE)'.e.(i. P P NA NA NA Submission of drg.) for all electrical packages NA NA NA NA NA 10 Submission of drg. & doc.

G B(HY) B(HY) B(HY) P B(HY) B(HY) 00 00 E 1 2 3 4 220 V DC SYSTEM BATTERY/ CHARGER TO DCDB DCDB TO STARTER PANEL FOR DC DRIVE DCDB TO PANEL/ DC LOAD STARTER PANEL TO FIELD LV PC LV PC LV PC CC P B(HR) P B(HR) P B(HR) P B(HR) 00 00 00 00 F 125 V DC SYSTEM 1 2 3 4 BATTERY/ CHARGER TO DCDB DCDB TO STARTER PANEL FOR DC DRIVE DCDB TO PANEL/ DC LOAD STARTER PANEL TO FIELD LV PC LV PC LV PC CC B(HY) B(HY) B(HY) B(HY) B(HY) B(HY) B(HY) B(HY) 00 00 00 00 G 24 V DC SYSTEM 1 1 3 4 415V SWGR TO BATTERY CHARGER BATTERY/ CHARGER TO DCDB ALL OUTGOING POWER CABLES FROM 24V DCDB VARIOUS LOADS BIANRY & ANOLOG SIGNALS FROM 24V SYSTEM TO DDCMIS LV PC LV PC LV PC F.G P B(ED) B(ED) B(PE)-C&I P P P P 00 00 00 00 H UPS INCOMING POWER CABLE FROM SWGR 1 TO UPS PC P P Page 1 of 2 . G P P P P P B(PE)-C&I P P P P P P 00 00 00 00 00 00 D LV SYSTEM (GAS TURBINES) 1 INCOMER CABLES ALL OUTGOING CABLES TO DRIVES/ 2 MARK-VI PANESL/ FIELD 3 SWGR TO LPBS LV PC PC.G LV PC G F.700MW KARIMNAGAR COMBINED CYCLE POWER PROJECT TABLE-1: CABLE SCOPE DOCUMENT ELECTRICAL SYSTEMS SCOPE OF CABLE LISTING P B(PE)-C&I P P SCOPE OF CABLE SUPPLY P P P P SL No. CC F. A MV SYSTEM 1 2 3 4 ITEM CABLE TYPE REMARKS REV SWGR TO OUTGOING FEEDER SWGR TO DDCMIS/ UCP SWGR TO LPBS INTERCONNECTING CABLES FOR MV SWGR MV PC G CC LV PC.F.G P B(PE)-C&I P P P P 00 00 00 C LV SYSTEM (UNDER B(PE).BOPs) 1 2 3 4 5 6 SWGR TO DRIVES SWGR TO PLC/ LCP SWGR TO LPBS LCP TO DRIVES PLC/ LCP TO FIELD PLC/ LCP TO DDCMIS LV PC G F. CC.G 00 00 00 00 B LV SYSTEM (UNDER STATION C & I) 1 2 3 SWGR TO DRIVES SWGR TO DDCMIS/ UCP SWGR TO LPBS LV PC G F.

& AVT LV PC CC F. DCS. G. ACDB & BATTERY PC F. G: G-Type Instrumentation cable.G P P M ANY OTHER CABLE MV PC. CC. FS: Fire Survival cables Page 2 of 2 .G PC/ CC CC. F. ECP.G.F. LV PC: LV Power cable. CC: LV Control Cable. DDCMIS PC CC CC CC PC PC CC B(ED) B(ED) B(ED) B(ED) P P P P P P B(ED) P P P 00 00 00 00 00 00 PC PC B(ED) B(ED) P P 00 J 1 2 3 4 5 6 7 K 415V EMERGENCY DG SYSTEM 1 2 3 4 5 415 DG PCC TO DG TERMINALS 415 V SWGR TO DG AUX MCC DG AUX MCC TO DG ROOM (VENTILATION FAN. ECP.F. CABLES BETWEEN DG EQPT TO ECP/ DDCMIS/TRANS. CC. TRANSFORMERS. DDCMIS ALL CONTROL CABLES TWO BETWEEN SWYD EQPT LV PC LV PC CC. GRP.2 3 4 ALL OUTGING POWER CABLE FROM UPS ACDB TO VARIOUS LOAD BIANRY & ANOLOG SIGNALS FROM UPS TO DDCMIS ALL INTERCONNECTING POWER CABLES BETWEEN UPS. FO LV PC LV PC CC. F. F. F. VENDOR SCOPE P P P P M ALL INTERCONNECTING CABLES FOR GRP. G CC. FS P P MV PC: MV Power cable. LIGHTING ETC) POWER & CONTROL CABLES WITH IN DG SYSTEM CONTROL & INSTT. G P P P P SWYD.G P P B(IS) B(IS) P P P B(IS) B(IS) P 00 00 00 00 00 L 1 2 3 4 5 6 7 SWITCHYARD LT SWGR TO BATTERY CHARGER LT SWGR TO ACDB ALL SAS/ SCADA CABLES ALL OUTGOING CABLES FROM SWYD DCDB ALL OUTGOING CABLES FROM SWYD ACDB CONTROL CABLES BETWEEN SWYD EQPT & GT. LV PC. G PC B(ED) B(PE)-C&I B(ED) P P P 00 00 00 I 1 2 ELECTRONIC EARTHING BETWEEN DDCMIS CABINETS DDCMIS CABINETS TO ELECTRONIS EARTH PIT STATIC EXCITATION EQUIPMENT (SEE) EXCITATION TRANSFORMER TO THYRISTOR CUBICLES THYRISTOR CUBICLES TO FF / FB CUBICLES FB CUBICLE TO GENERATOR SLIP RINGS INTERCONNECTING CABLES WITHIN SEE AUX AC SUPPLY FROM SWGR TO SEE AUX DC SUPPLY FROM DCDB TO SEE CONTROL & INSTRUMENTION CABLES BETWEEN SEE TO GRP. LV PC. ECP. F: F-Type Instrumentation cable.