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ANNEXURE-6 .

2
PAC PROJECT
CONTRACT DOCUMENT - ELECTRICAL

DETAILED

SPECIFICATIONS

FOR

ELECTRICAL ITEMS

M/s GUJARAT NARMADA VALLEY FERTILIZERS &


CHEMICALS LTD.

P. O. NARMADANAGAR 392015

GUJARAT (INDIA)




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APPENDIX-A
PAC PROJECT- SCOPE FOR ISBL-OSBL ACTIVITIES

SCOPE FOR OSBL ELECTRICAL WORK

Sr Job description Engineering Supply Erection Testing &


no scope scope scope Commissioning
scope
1 The facilities for following supplies
are available in existing complex.
The same has surplus capacity to
feed load requirement for PAC
plant and shall be made available
at battery limit of the plant as per
below defined scope.
3.3KV supply
220V DC for circuit breaker
control supply
230V AC UPS supply for
control supply of contactor
operated motor feeders
415 V AC emergency
supply of DG set
2 3.3 KV supply
a 3.3 KV spare panels- 2 nos. at contractor GNFC GNFC contractor
existing TDI Process sub
station
b 3.3 KV cables from 3.3 KV contractor GNFC contractor contractor
switch board of existing substation
to primary of transformers ( 3.3
KV / 0.433 KV) to be installed in
PAC plant
c Control cables- from 3.3 KV contractor contractor contractor contractor
switch board of existing substation
to marshalling box of transformers
(3.3 KV / 0.433 KV) to be
installed in PAC plant
d Control cables- from 3.3 KV contractor contractor contractor contractor
switch board of existing substation
to incomer of 415V PMCC to be
installed in PAC plant
e Raychem make heat shrinkable contractor contractor contractor contractor
termination kit and cable
termination of 3.3 KV cables at
both ends i.e. 3.3 KV switch
board end and transformer primary
end
f Cable glands and termination of contractor contractor contractor contractor
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control cables at 3.3 KV switch


board end, transformer
marshalling box end and
incomer of 415V PMCC end

3 415 V AC Emergency power supply of DG set


a Power cables and control cables contractor GNFC contractor contractor
(Cables between Emergency PCC
located in existing Process
substation to incomer of PAC
PMCC
b Power & Control cable glands and contractor contractor contractor contractor
termination at both ends
4 220 V DC control supply for circuit breakers - 2 separate feeders for control supply of BUS-A and
BUS-B of PMCC.
a Power cables (Cables between contractor contractor contractor contractor
220V DC distribution board
located in existing Process
substation to incomer of PAC
PMCC
b Power cable glands and contractor contractor contractor contractor
termination at both ends
5 230 V AC UPS control supply for contactor operated feeders of PMCC -2 separate feeders for
control supply of BUS-A and
BUS-B of PMCC.
a Power cables (Cables between contractor contractor contractor contractor
230V AC UPS supply distribution
board located in existing Process
substation to incomer of PAC
PMCC
b Power cable glands and contractor contractor contractor contractor
termination at both ends
6 Cable rack and cable trays
a Cable rack and cable trays contractor contractor contractor N.A.
between existing substation and
existing cooling tower
b New cable rack from existing contractor contractor contractor N.A.
cooling tower to PAC
substation.
c Laying of cable trays between contractor GNFC contractor N.A.
existing substation and PAC sub
station
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SCOPE FOR ISBL ELECTRICAL WORK

Sr Job description Engineering Supply Erection Testing &


no scope scope scope Commissioning
scope
1 Hazardous area classification. Contractor N.A. N.A. N.A.
The selection of equipment shall
be done as per hazardous area
classification.
2 3.3KV / 0.433KV transformers - 2 Contractor Contractor Contractor Contractor
nos.
3 1C X 630 sq.mm. Aluminum Contractor Contractor Contractor Contractor
conductor XLPE insulated power
cables between transformer
secondary and PMCC incomer.
Bus duct is not required.
4 PMCC of required rating- 1 no. Contractor Contractor Contractor Contractor

5 Main power distribution board for Contractor Contractor Contractor Contractor


temporary power supply network
6 Main lighting distribution board ( Contractor Contractor Contractor Contractor
common for normal lighting and
emergency lighting)
7 Variable speed drives, if required Contractor Contractor Contractor Contractor

8 Motors Contractor Contractor Contractor Contractor


9 Local control stations Contractor Contractor Contractor Contractor
10 Field lighting distribution boards Contractor Contractor Contractor Contractor

11 Field power distribution boards Contractor Contractor Contractor Contractor

12 Temporary supply network for Contractor Contractor Contractor Contractor


following.
1. 1ph, 230V AC, 20A, PNE
2. 3ph, 415V AC, 63A, PNE
3. 1ph, 24V AC, 10A, PN
4. 3ph, 415V AC, 160A, PNE
13 Cable rack Contractor Contractor Contractor Contractor

14 Cable trays Contractor Contractor Contractor Contractor

15 1.1 KV grade power, control, Contractor Contractor Contractor Contractor


lighting and earthing cables

16 Lighting in substation, control room Contractor Contractor Contractor Contractor


and field area
Lighting design calculation shall be
submitted.
17 Earthing Contractor Contractor Contractor Contractor
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Earthing design calculation shall


be submitted.
18 Lightning protection Contractor Contractor Contractor Contractor
Lightning protection shall be given
if required & design calculation
shall be submitted. If there is no
requirement than vendor has to
justify with clause number of
reference IS.
19 FRP Canopy for motors, LCS, Contractor Contractor Contractor Contractor
Control gear box, junction box

20 Fault level calculation and relay Contractor NA NA NA


coordination
21 Documentation Contractor NA N.A. N.A.

22 Certification and approval for Contractor NA NA NA


equipment to be installed in
hazardous area, if applicable.
CIMFR/ ERTL test report & valid
PESO approval certificate shall be
submitted as per latest
amendments of IS.

23 Approval of Chief Electrical Contractor NA NA NA


Inspector for electrical installation
24 LAN network (FO cable from ISD Contractor Contractor Contractor Contractor
room till rack located at PAC
project control room shall be
supplied and laid by GNFC.The
termination of FO cable at rack
shall be in the scope of contractor.
Supply and installation of main
rack and further distribution shall
be in the scope of LSTK
contractor.)
25 Multi pair telephone cable from Contractor Contractor Contractor Contractor
telephone exchange till main
junction box located at PAC
project control room shall be
supplied and laid by
GNFC.Telephone network (The
termination of multipair telephone
cable in main junction box shall be
in the scope of contractor. Supply
and installation of Main junction
box and further distribution shall
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be in the scope of LSTK


contractor.)
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APPENDIX-B
SPECIFIC REQUIREMENTS FOR ELECTRICAL
SYSTEM
[A] GENERAL CODES AND STANDARDS:

The electrical design shall be in accordance with the latest edition of codes and
standards including:

1. Bureau of Indian Standards (BIS).

2. Indian Electricity Act & Rules (IEA & IER)

3. International Electrotechnical Commission (IEC)

4. National Electric Mfg. Association (NEMA).

5. Standards of Institute of Electronics & Electrical Engineers (I.E.E.E.).

6. Applicable State or Local Codes.

7. National Electrical Safety Code (NESC)

8. Standards of Underwriters Laboratory (UL)

9. American Society for Testing Materials (ASTM)

10. American National Standards Institute (ANSI)

[B] SCOPE
1. The scope shall cover design, detailed engineering, manufacture, inspection at works,
delivery in well packed condition to site, handling & transportation at site, erection, testing
and commissioning of complete Electrical system on LSTK (Lump Sum Turn Key) basis
required for PAC at Dahej, Gujarat.

2. Only materials defined in SCOPE of GNFC in Appendix-A shall be supplied by the


owner. All other equipment, as required, whether specified or not shall be in contractors
scope.

3. Contractor shall meet the most stringent requirement, where the parameter differs in two
or more documents i.e. parameter indicated in this section / engineering design
philosophy / equipment specifications.

4. The specifications given indicate only general minimum requirement of some of the major
equipment. Other specifications shall be given by owner or shall be provided by the
contractor as per mutually discussed. However, Contractor shall submit their
specifications for owners approval before procurement.

5. The contractor shall give at least 15 days notice in advance to the owner for witnessing of
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tests at manufacturers works for all equipment and the equipment shall be dispatched
from works only after obtaining clearance from owner.

[C] SPECIFICATIONS:
1. Basic Considerations:

Consistent with reasonable economy and considering both investment and


operating expenditure, the basic primary considerations are:

a. Safety of personnel during operation & maintenance (O&M)

b. Adequate protection to equipment and the system as a whole

c. Operability and adequate reliability for all equipments with consideration for special or
unusual requirements of the unit or installation

d. Ease of maintenance

e. Ready addition of equipment to cope with future loads

f. Severe site conditions as defined in basic philosophy.

g. Maximum interchangeability of equipments / parts and minimum inventory

2. Material and Workmanship

a. All material and equipment shall be new with latest technological applications, standard
design and shall be commercially available for at least 10 years from the date of
installation. These shall also conform to the latest additions of above codes or standards.
The materials and equipment shall be from Owners approved makes only as per
Approved vendor list provided in the ITB.

b. Where several installations of one type of material or equipment are supplied, the
respective parts / equipments shall be interchangeable.

c. All materials and equipment shall be suitable for installation in the applicable climate as
specified elsewhere in this specification.

d. Wherever the drawings or specifications or both, are called for to describe materials or
construction of a better grade or with larger size than as required by the codes or
standards above, then the provisions of such drawings and specifications shall
adequately prevail.

e. The equipment shall be standardized as far as possible to reduce the numbers and
types of various equipment, so that the spares required are minimum.
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3. Contractor / Vendor Documentation Schedule

Sr. Name of Document Documents Required ( Y / N)


No. With For Approval / For Information Final / Approved/
Bid  Review  As-Built
1.0 Load List indicating rated and absorbed Y -- Y Y
power of loads and duty type
(Continuous / Standby / Intermittent) at
different voltages including emergency
loads.
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2.0 Load Data indicating normal, peak, Y - Y Y


starting and construction power
requirement at various voltage levels.

3.0 Single line distribution diagram (power, Y Y - Y


lighting, DC supply and UPS supply)
including protection and metering details.

4.0 Enquiry Specification & Final purchase Y Y - Y


order specification of all Electrical
Equipment
5.0 Filled in Specification Sheets and Y Y - Y
Technical Particulars of all equipment.

6.0 General arrangement and foundation N - Y Y


drawings of all equipment.

7.0 Equipment layout in Sub Station, MCC N Y - Y


room, and plant area showing location of
all electrical equipment.

8.0 Cable schedule. N - Y Y

9.0 Cable rack / trench / pipe layout. N - Y Y

10.0 Power Layout. N - Y Y

11.0 Schematic diagram for all control panel & N Y - Y


switch boards.

12.0 Feeder Details of all switch boards N Y - Y

13.0 Interconnection & Terminal connection N - Y Y


diagram

14.0 List of controls, interlocks, indication & N - Y Y


metering at various locations for all
drives.

15.0 Characteristic curves for motor/ relays N - - Y


etc.
16.0 Design calculations (for equipment N Y - Y
sizing, earthing, lighting, HT/LT cables,
Distribution transformers, energy saver
& lightning protection etc.)

17.0 Earthing and lightning protection layout N - Y Y

18.0 Lighting layout N - Y Y

19.0 Catalogues for all bought out items Y - - Y


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Sr. Name of Document Documents Required ( Y / N)


No. With For Approval / For Information Final / Approved/
Bid  Review  As-Built

20.0 Bill of Materials covering all electrical Y - - Y


equipment and installation materials

21.0 Installation operation and maintenance N - - Y


(Manual)

22.0 Relay settings N - - Y

23.0 Spare Parts list Y - - Y

24.0 Test Certificates N - - Y

a. Type Test Certificates of major electrical


equipment

b. Routine Test Certificate of all equipment


c. Commissioning Test Reports of all
equipment

25.0 Guarantee Certificates N - - Y

26.0 Quality Assurance Plan & Formats N Y - Y

27.0 Hazardous area Classification Drawing Y Y - Y

28.0 Erection Drawings & Details N Y - Y

29.0 Construction & commissioning Y Y - Y


specification and procedure for all
equipment.

30.0 Wiring diagram of power & controls and N Y - Y


SCADA related communication facilities

31.0 Quality control plan of all Y


equipment

 4 hard copies + 2 soft copies


 6 hard copies + 2 soft copies
At completion of contract, a complete set of above drawings and documents in 06 (SIX) sets blue
prints of each drawing / document hard copies and 02 (TWO) sets soft copy on COMPACT DISC
/ DIGITAL VIDEO DISC (CD / DVD) in editable format shall be provided.

Composite system study report as indicated in Appendix C.

Compiled list of manufacturers for items supplied for electrical system with contact person
(West zone/ Gujarat region head & Country head), addresses, phone, e-mail details.

Statutory approval / registration certificates, licenses, application copies for all items / software.

3. ELECTRICAL SYSTEM DESIGN BASIS

Overall electrical system shall be designed considering basis given in this section and
Appendix C (Engineering Design Basis).
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a. Power Supply & Distribution

i) OWNER shall arrange the power supply to the plant having voltage level of 3.3KV, 3
phase, 50 Hz; through dual feeders.

ii) Permanent paralleling at the secondary of any step-down power transformer is not
permissible. All distribution transformers shall be Dyn11 only.

iii) Accurate information of the available maximum symmetrical fault-level of the existing
system 11KV bus shall be given by Owner. However, it will be the prime responsibility of
the contractor to analyze in detail and provide a suitable distribution system incorporating
the relevant features described below, and ensuring adequate interrupting capacities for
the various components of the system operating at different voltage levels. In arriving at
the maximum interrupting capacities of critical equipments such as circuit breakers, the
system X/R ratio shall be taken into account and ANSI / IEEE C.37 13-1981 shall be
referred to for guidance.

iv) Fault current calculations to determine both the steady state RMS symmetrical fault
current or KVA and the symmetrical peak current shall incorporate all fault current
sources and all components of circuit impedance in the primary system, secondary
system and branch circuit. Both the steady state symmetrical and peak symmetrical
fault currents or the values defined in the Appendix C, whichever is more from
severity view point, shall be considered in determining the required ratings of system
components.

vi) Supply and installation of 3.3KV cables from owners 3.3KV switch board located at TDI
Process sub station to Contractors primary of 3.3KV / 0.433 transformers shall be in
Owners scope. However, termination of above cables at both ends shall be contractor's
responsibility. Raychem make heat shrinkable termination kit shall be supplied by
Contractor. It shall be suitable for 3.3KV UE cable.

vii) Adequate Protection, Instrumentation and Controls for all above systems shall be in
contractors scope

viii) Two independent transformers (3.3KV / 0.433 KV) of adequate capacity shall be
provided. The rating shall be based on maximum operating power of PAC plant with
single feed + 25% margin for future load and taking into account the starting current of
largest rating motor. Distribution transformers shall not be located beneath any piping or
structure. Installations shall be very near to substations (preferably touching to substation
with adequate civil work for walls). Outside installations shall be protected with a
sunshade.

ix) The 3.3 / 0.433KV transformer secondaries shall be connected to the respective
switchgears through armored aluminium cables.

x) Power System shall consist of:


Transformers (3.3KV/ 0.433KV) 2 nos
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Even number of distribution Transformers shall be considered to facilitate operation of


Power Motor Control Centre (PMCC) with a normally open Tie-Breaker (bus-coupler).
Each transformer feeding a Bus-Section, shall be sized to handle 125% of the combined
full load on both the Bus-Sections.
Power Motor Cotrol Center-
The PMCC shall have three incomers and one bus coupler. Two incomers shall be fed
from each transformers and third incomer shall be fed from existing emergency power
supply board (having DG power backup). The bus coupler shall be designed to close
automatically on sustained loss of power on either of the Bus-Section after opening
respective incoming breaker. This change over shall be possible manually with synch
check facility also. The complete auto change over scheme shall be implemented in
numerical relays to be installed in incomers and buscoupler. In case of total power failure,
the third incomer from Emergency power supply board shall get on automatically.
Main Lighting distribution board (normal & emergency lighting)-
There shall be common distribution board for normal lighting and emergency lighting.
The board shall have two incomers and a buscoupler. The power supply to bus-A shall
be fed from bus A of PMCC through energy saver of adequate capacity to total lighting
load with 25% margin. The bus B shall be fed from Bus B of PMCC.
Main power distribution board-
MPDB shall have two incomers and a bus coupler.

xi) The electrical system components shall be completely coordinated to achieve TYPE-II
coordination so that the system will remain stable under all conditions with regard to the
following features:
Insulation levels
Protective relaying

xii) Special measures shall be incorporated to safeguard the power supply to essential drives
and circuits in case of power failure or a voltage dip of the network. These measures may
be;
Under-voltage time protection of all important L.V. motors of large rating.
Momentary power interruption ride through facility for VFD

b. Electrical System Protection & SCADA


i) The protection & SCADA system shall be designed considering numerical relays of ABB
make.
ii) Protection relays shall be selected as per matrix given in Appendix D

iii) SCADA system shall be arranged by owner.

c. Protection against short time voltage dips of the network

Special measures shall be taken to achieve high service continuity and especially to
overcome short-time voltage dips of the network. This shall be done in the following way:

i) Provide all HV / LV motors (>55KW / ACB feeders) with D.C. tripping coils and an under-
voltage time relay. Reacceleration schemes shall be designed & deployed to meet critical
requirement in this case.

d. Provision for Future Loads


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25% margin shall be kept in transformers for future loads.


e. Equipment Ratings

In case of switchgear / switchboards, cables and transformers the minimum


specification shall be as per Appendix C, requirements given in this document &
standard specifications of Owner attached as a part of this document (List of
Owner Standard Specifications: Appendix - E). The relevant IEC / BIS
requirements shall be referred to where no definition available for respective
equipment or parameter thereof.

f. Emergency Power Network

i) One feeder from existing emergency power control center shall be made available at
battery limit.
4. AREA CLASSIFICATION

a. All areas shall be classified in accordance with IEC / BIS norms as indicated in Appendix
C.

b. An area classification drawing shall be prepared to indicate the degrees of hazard and
areas of extreme corrosive characteristic.

c. Equipment installed in classified areas shall be suitable for these areas.

5. Switchgear rooms shall be designed to the following requirements:

a. Location of substation & control room building shall be within reasonable vicinity to avoid
voltage drop in interconnection cables from substation to instrument room.

b. Wind direction criterion w.r.t. hazardous gas leakage, corrosive gases & vapors and dust
shall be considered for the location of the substation building from safety view point.
Adequate quantity and types of fire extinguishers & TWO nos. Breathing air cylinders set
with Air Mask shall be placed in the substation.

c. Building shall be provided with means of ventilation of sufficient capacity to permit proper
operation of all equipment. The heat loss of all equipment shall be taken into account
when considering the cooling design.

d. Other requirements w.r.t. substation building are given in Appendix F (General


Requirement for Electrical Substation).

6. Major equipments specific requirements (in addition to those defined in Appendix


C & standard specifications) :

a. 0.433KV switchboards and 230V AC equipments shall be as per Appendix C,


requirements specified in this document & Owners standard specifications.
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b. TRANSFORMERS

i) Outdoor transformers shall be oil immersed and all transformers shall be provided with
Buchholtz relays and silica-gel breathers, temperature indicator and trip-contact.

ii) Primary and secondary terminations shall be enclosed in transformer mounted terminal
boxes suitable for cable connections. The cable box shall be air filled type and suitable
for cable sealing kits.

iii) For grounded systems neutrals of secondary windings shall be brought out thru an
insulated bushing.

iv) The transformer shall be so designed as to be able to operate in parallel satisfactorily


with similar transformers.

v) Dial type thermometers for indicating top oil temperature and winding temperature with
two hands; one showing oil / winding temperature at the time of reading and second
showing maximum temperature reached since last resetting.

Thermometers shall have hermetically sealed normally open alarm contact set to close at
maximum self-cooled operating temperature.

4-20mA signals from oil & winding temperature & oil level sensing system to be given to
numerical relay and reading shall be available in SCADA system through soft-link of
numerical relay.

vi) Transformer Foundations

Transformers with sliding wheels shall be placed on adequately designed concrete


foundations. Adequate channel shall be inserted for the placement of transformer and
facilitate the roll out the same for overhaul.

Foundation shall be with earthquake / vibration protection clamp & stopper blocks to
prevent sliding in fixed operating condition.
vii) The transformer yard shall have sun shed.

c. SWITCHGEARS:

i) 415 volts, Power Motor Control Centers (PMCCs) shall be furnished with 20% spare
feeders, at least one each of each type on each bus section.
ii) Control fuses for 415 volts switchgear potential transformers shall be accessible for
replacement. These devices shall be isolated by barriers or to be installed at a safe
distance from non-insulated current carrying parts of switchgear.

iii) All panels, 0.415KV SWBDs, shall be designed such that individual switch
boards have uniform height through out the width of the panels.

d. CONTROL POWER
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i) LV circuit breaker feeder control supply.

220V DC- The same shall be made available from existing charger and battery set
available at TDI process sub station.

ii) LV contactors operated DOL feeders control supply

240V AC uninterruptible power supply shall be made available from existing UPS set
available at TDI process sub station.

LT switchboards shall have control supply changeover module with TWO sources. ONE
from UPS & other tapped from main buses (415/ 240V isolation transformer). Normally
UPS supply shall remain in operation. In case of under voltage on main bus for more
than the set duration, it shall transfer to transformer supply.

e. HV / LV MOTOR CONTROLLERS

i) All motors must have dedicated STOP-START push-button stations (LCS) mounted
within 2 meters periphery such that while operating from LCS, the motor & driven
equipment / indicative instrument can be viewed clearly.

For critical motors as defined by process group, where reacceleration scheme is applied
and / or the motors to be fed from emergency power board shall have Auto / Manual
selection from control room DCS.

ii) The control voltage shall be 220V DC for 0.415KV ACB controlled motors while 240V
AC UPS supply for 0.415KV contactor controlled motors.

iii) Ammeters / speed indicators (only for VFD) shall be given on LCS as per requirement
defined by process group.

f. MOTORS

i) LT motors shall have minimum efficiency IE 3 as per IS-12615 (2011).


ii) Every effort shall be made to arrange that all motors from 0.37 thru 150 KW be
purchased from only one manufacturer with only one general specification covering.
This is to ensure maximum interchangeability for maintenance.
iii) Adequate space shall be kept around motor for easy access to remove and replace the
motor. For motors rated more than 22KW, adequate space for motor lifting mechanism &
fork lift / crane movement, as necessary, shall be prime criterion.
iv) Motor foundations shall be at least 450mm high above FFL for avoiding water logging &
adequate cable tray work for control & earthing etc. cables.

v) Horizontal mounting motors having solid shafts are preferred for applications except
those in which the connection to the driven equipment is a sectional shaft which may
unscrew and lengthen in the event of reversal of rotation. Hollow shaft motors with
special couplings shall be used for unavoidable applications only.
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vi) Lubrication and type of bearings:

415V LT motors:

All bearings shall be grease lubricated.

Motors having frame size 160 and above shall be provided with on line greasing facility
and grease draining facility.

g. EOT Cranes:

i) There shall be a single point isolation device for compete EOT crane system, located at
accessible point for operation during emergency.

ii) All motors shall be with Thermistors embedded in the winding for over temperature trip.
The control panel shall be equipped with Siemens make 3RB series relays suitable for
Thermistor connection to protect the motors.

iii) Walk way along the cross travel & long travel and adequate size of platform shall be
provided for maintenance of the control & power panel.
h. FIELD OUTLETS / SOCKET OUTLETS (Three Phase, Single Phase & 24 V Sockets)
shall meet the requirements as per Appendix C & Owner standard specifications. The
selection of enclosure and components shall be according to hazardous area
classification, where the unit is to be installed.

i) Bulk power outlets:

Total two nos. of 160A outlets shall be provided in the plant and one no. 160A outlets
shall be given near transformer yard depending upon numbers of transformers installed
in a row.

ii) Welding Outlets (63A 415V, 3 phase 5 Wire, 30mA ELMCB) (Model no is defined in the
ITB by GNFC)

Sufficient welding receptacles, located at convenient points to serve unit area shall be
installed on each floor. For the unit area in general, receptacles shall be located so that
approximately radius of 25 meters is covered per unit.

ONE 63A outlet shall be given near transformer yard. One 63A outlet shall be installed
in cable cellar.

Branch circuits supplying welding outlets shall serve no other equipment and not more
than THREE outlets shall be supplied by one circuit. Each branch circuit shall be
protected by thermal magnetic Moulded Case Circuit Breaker (160A) of suitable current
rating and 100mA earth leakage current protection, located at the 415 volt main power
distribution board (PDB).
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One 63A outlet at Mechanical workshop , Instrument workshop, Electrical workshop


(with starter) shall be provided.
iii) Convenience Outlets (20A, 230V, 1Phase 3 Wire, 30 mA ELMCB) (Model no is defined
in the ITB by GNFC)

These Convenience outlets shall be provided on each floor for adequate maintenance to
serve portable lights and power tools in plant area for alignments, inspection and
temporary work. For the unit area in general, receptacles shall be located so that
approximately radius of 10 meter is covered per unit.

ONE 20A outlet shall be given in each transformer yard. two 20A outlet on each wall
shall be installed in cable cellar.

Convenience outlets shall be provided in adequate numbers in offices, mechanical


workshop, Instrument workshop, electrical workshop etc. The configuration of the
sockets shall be of standard type, easily available.

i. Convenience Outlets (20A, 24V, 1Phase 2 Wire)

Permanent installation of 24V sockets is not required. Supply and installation of the same
is not required.

The 3 nos. portable 24V AC switch socket unit with 250VA, 230V / 24V transformer of
Hensel/Schneider or approved make (having polycarbonate / FRP enclosure) shall be
supplied..

7. GROUNDING / EARTHING AND LIGHTING PROTECTION

a. Non-current carrying parts of electrical equipments shall be grounded to comply with the
requirements of the BIS (IS: 3043 1987), prevailing statutory requirements as per IER
and IEC recommendations (with min. TWO independent earth current paths). It is
contractors responsibility to design, supply and install Plant earthing stations (earth pits)
network with interconnected earth pits so as to achieve defined acceptable resistance
values as per Appendix C.
b. Interconnection between existing Owner complex earth grid and new plant earth grid
shall be in contractors scope. Interconnection shall be carried out after successful
commissioning of new earth grid with acceptable values of resistance only. Connection
to existing grid shall be done by Contractor. Existing grid within the radius of 50 mtr
shall be made available by Owner.

c. Electrical system grounding shall be carried out as per the requirements of the BIS (IS:
3043 1987), prevailing statutory requirements as per IER and IEC recommendations.
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d. All grounding materials used shall be PVC insulated aluminum conductor cable, as
specified.

e. The tallest structures, columns and stacks in each area shall be grounded for full height.

f. Process equipment containing hazardous materials and located in hazardous areas,


shall be grounded to prevent static discharges.

g. Lighting panels shall be connected to grounding systems directly.

h. More than one grounding electrodes connected to the ground system shall be spaced at
least 3.5 meters apart.

8. ILLUMINATION:

a. Illumination shall be determined by IES methods and shall not be less than the minimum
averages (measured 914 mm.) (3 ft above floor) as listed below:

Illumination Level for Non-process Areas

Location Intensity
(in Lux)
Main roads and parking areas 10
Warehouses and storage buildings (walkways) 50
Building entries 50
Loading platforms and weight stations 200
Boilers, boiler walkways, fuel handling areas 100
Hallways, interior stairs, and service areas 100
Locker rooms, toilets and washrooms 200
Switch rooms 300
offices and laboratory 300
Control room (in front of inst. panel) 500
Control room (rear side of inst panel) 300

Illumination Level for Process Areas

Location Intensity
(in Lux)
General Illumination 50
Walkways 50
Stairways 100
Toilet 100
Pump / compressor rooms or areas 150
Face of instrument board 500
Loading / unloading areas 50

b. Lighting is required in all work areas.


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Lighting fixtures shall be approved for the area classifications. In the locations subject to
excessive vibration, fixtures shall be flexibly mounted.
General illumination of outdoor area shall be provided by suitably located flood lights,
where supplementary lighting is required for items such as instruments, gauge glasses,
etc., individual fixtures shall be used.
Lighting for general ambience, pathways, garden/ lawn lighting, office reception / corridor
/ Lobby / toilets shall be by using suitable light fittings .

c. Fixtures

i) All fixtures in the process area shall be of FRP Fixtures shall be selected on the basis of:
Efficient illumination.
Uniform distribution of light,
Accessibility and convenience for safe revamping maintenance,
Economy considerations / energy efficient lamps shall be used.

ii) Lighting fixtures for installation indoors shall be standard office and industrial types. LED
type fixtures may be used when economical for areas requiring a high level of illumination
(control room, switchroom, offices, laboratory etc.).

Reflectors shall, in general, be provided for all LED fixtures. Guards shall be furnished for
those fixtures not equipped with reflectors when located at stairs, walkways, and other
locations where they may be subject to accidental damage.

iii) Lamps (coated & protected), chokes & ignitors shall be of Venture make only for MH
lighting for normal lighting.
iv) Field Lighting panels for lighting circuits in all areas shall be located in non-hazardous
plant area (Locations shall be reviewed during detailed engineering stage). Field lighting
panels shall be weather proof type. Flame proof panels are not acceptable.

d. Obstruction and Warning Lights (Aviation Lights):

i) Obstruction and warning lights shall be installed as required by the civil Aeronautics
Authority or other regulatory authority for high structures and stacks.

ii) The lamps for this purpose shall be LED type BINAY / PRECIFINE make long life
(minimum 7 YEARS GUARANTEE) with built-in short circuit protection suitable for 240V
AC supply system.

e. Emergency Lighting System

i) The emergency lighting system shall have separate distribution panels.

ii) 50% of the lighting in control room / switchgear room / MCC room / control room and
25% of the process area lighting shall be powered from the emergency switch board.

iii) Emergency lighting in the process area shall cover all critical locations such as stairways,
decks, compressor house etc.

iv) LED lamp fitting shall be installed for emergency lighting having instant start feature.
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v) LED type escape (230V AC) lighting including exit sign with battery back up (only
for control room & substation) shall be provided. For exit routes in plant, LED type
escape (230V AC UPS supply) lighting only at exit routes shall be provided in the plant.

f. Street lights:

i) Street Lighting shall be with LED integral type fittings mounted on FRP pole (min. 10.6
mtr height). Street lighting cable shall be laid underground through pipe.

ii) Street lighting is of the multiple type and shall be controlled by a 415 volt magnetic
contactor in the module at Main Lighting Distribution Board (MLDB) at substation. The
contactor shall be operated by astronomical clock.

However, the selection of fixtures shall be only as per Table-1 attached

9. CABLE SUPPORTS AND FIXING METHODS

a. General

i) All cables routed above ground shall generally be laid in cable trays as indicated in
Appendix C. Trays shall be installed in horizontal plane (width wise) as far as possible.
Bends shall be standard & regular type only.

ii) The cables shall be carried or held in a neat and orderly manner in such a way as to
prevent sagging.

iii) The use of cable hangers shall not be allowed.

iv) The CONTRACTOR shall be responsible for ensuring that variation, expansion, heat due
to direct sun-rays and any other local conditions are taken into consideration.

v) On cable routes where a number of cables are installed on common racks, the
supporting steelworks and cable tray shall be of sufficient strength to accommodate in
the future additional cables to the extent of 25% (each tray shall have 25% space free).
Also adequate spacing between power cables shall be maintained, as per standards. LT
Power Cables shall be laid in single layer and Lighting and control cables shall be laid in
two layers in a tray.

vi) Where cables pass through floors, protecting covers for groups of cables and conduits for
single cable shall be provided. In either case the covers or conduits shall be sealed with
soft compound.

vii) Where cables enter a building, the cable entry shall be sealed with water-tight and flame
retardant filler. The filler to be used shall be polyurethane foam with a cover of
flammastic or rock-wool panels with a cover of flammastic.
viii) Attention shall be paid to cable racks entering a building. These racks shall be
interrupted.
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ix) In plant areas no cables shall enter electrical power and control equipment from the top.
This requirement applies to all equipment installed in the plant areas.

x) Due attention shall be paid to an adequate earthing and bonding of the cable racks and
trays.

b. Cable Racks

i) All steel work for supports, shall be free from blisters, scale and laminations or other
defects and shall be blasted and painted in accordance with the relevant painting
specification, but at least one layer of primer before and one layer after assembly.
Paint specification indicated in civil section shall be followed.

ii) Parts of the racks which have to be embedded in concrete or masonry shall be left
unpainted.

iii) Plant environment being humid and corrosive, epoxy coated racks and supports are
REQUIRED.

iv) Where the original coating has been damaged by bending, sawing, cutting, etc. the steel
work shall be repainted.

v) Racks shall be of sections of manageable length to facilitate assembly and disassembly.

vi) The routing of the racks shall be determined with reference to the general plan of the
installation to be served, but the racks shall never be routed beneath pipes.

vii) Clamps have to be used for all cables in a vertical plane.

c. Cable Tray

i) The MOC shall bee FRP only due to highly corrosive atmospehere.

d. Cable Cleats or Saddles

i) No cables shall be supported on cable racks and fixed with clamps or cable cleats.

ii) Single cables leaving a main cable run to a motor, motor control station, light fitting,
control gear box shall be routed through FRP perforated tray only.

e. Cable Termination And Identification

i) Each cable shall be clearly marked at both ends with an indestructible marker, preferably
a cable tag made of Aluminum tacked with indicating cable number & both end feeder
tags with switchboard tags. Cable tags at ends of cable shall be provided inside the gland
plate as well as out side the gland plate.
ii) Conductors of all cables shall be identified at both ends with reference numbers. All cable
lugs in power circuits shall be compression type. Control cables & other cables e.g.
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lighting, field outlets etc. shall be as per requirements specified in respective


specifications. Lighting cable shall be of single strand to avoid crimping of lug.

iii) Where conductors are connected to terminals, the wire shall have sufficient spare length
to allow for small changes (e.g., for reversing the direction of rotation at motors).

iv) Unused conductors of cables shall always be considered as spares for future use and
shall be left with the same length as the longest connected conductor.

10. TESTING

Commissioning tests of all the equipments shall be carried out as indicated in


installation & commissioning specifications, guideline in this document,
recommendations in BIS / IEC and prevailing norms of Government Authority.

a. Electrical Equipments and Installation

i) The OWNER or their representatives shall be allowed to WITNESS all the Routine and
type tests and the tests specified in item standard specifications. Copies of all test
reports will be furnished to the OWNER. During fabrication, the OWNER. or their
representatives are also allowed to visit the factories for inspection of the work. For final
tests the OWNER must be informed at least fourteen (14) days before the test will take
place.

ii) Loading details & foundation work detailed drawings shall be submitted. Engineering
recommendations given by manufacturer and the recommendations for installation
equipment in respective equipment BIS shall be followed. IER recommendations shall
also be followed.

iii) The installation practices shall be as per installation specifications attached herewith,
recommendations given by manufacturer and shall meet with the prevailing norms
stipulated by government authority at the time of declaration of final commissioning.
Installation & commissioning check list / certificates shall be dully filled up, signed and
stamped by contractor. The results recorded shall be part of commissioning reports.

iv) Before an installation or part thereof is permanently put into service, it shall be tested
jointly by the CONTRACTOR and the OWNER or their representatives. It shall be
checked to determine if the installation complies with the electrical specifications of the
contract.

b. Motor Testing

i) Motors fixed on the foundation should be uncoupled & checked for free running, proper
rotation.

ii) All motors shall be run uncoupled for a minimum period of four (4) hours before the
driven equipment is placed in regular service.
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iii) No-load current, vibrations in THREE positions, i.e. Axial Horizontal Vertical each on
NDE & DE side bearings shall be measured and recorded.

iv) Polarization Index value for all HT cables (including incoming & outgoing), transformers
(HV-LV, HV-E, LV-E) & motors shall be measured and recorded. Result sheets shall be
prepared with motors and cable tags.

v) Motor commissioning certificate (format attached with motor specifications) shall be


completely filled up signed and stamped by the contractor.

c. Transformers

i) Transformer loading & foundation details with drawing shall be submitted. Transformer
yard shall be filled with gravels with the layer thickness of as per standards but not less
than 200mm layer. Fire extinguishers and sand buckets (TWO buckets and TWO
extinguishers per transformer) with canopy & stand shall be provided.

ii) Transformer installation and commissioning shall be carried out as per


recommendations in IS:10028, prevailing norms (IER & IEA), manufacturers
recommendations, guideline given in this document and installation specifications
attached.

iii) Check insulating oil level gauge with both the valves of Buchholtz fully open, taking' into
account filling level at existing ambient temperature. Make sure that the gauge reads
properly. If required oil must be added (some transformers of this class are shipped dry
or partially filled or have radiators shipped separately and thus oil must be added), take
oil samples from drums and run dielectric test before filling. When filling a transformer
that has radiators mounted in field, take care to open the valves to one radiator at a
time so as not to drop oil level below core windings. After filling, check that all valves to
radiators are open.

iv) Check all gaskets, plugs, sample and drain connections for leaks.

v) Take samples of transformer insulating oil from the bottom sampling valve and have the
dielectric strength tested and recorded. If the transformer has just been filled or oil
added, let it set for 12 hours. Take care of following points while taking oil sample:
Let some oil run out and then draw off enough oil to get a true sample and check it
visually for traces of water.
Use a clean and dry bottle with a suitable cap for sample. Clean bottles with carbon
tetrachloride, or similar solvent.
The sample should be taken when the oil is at least as warm as the surrounding air.
Let the oil sample set in the test room several hours or overnight if possible.

vi) Oil must test 40 KV or higher for 1 minute based on testing of sample in accordance
with ASTM D-l 17 or equivalent national standard. Make sure the test cup is clean. If
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test is below 40 KV take another sample as the first sample may have been
contaminated by improper handling. If the oil tests below 40 KV, it will be necessary to
filter the oil until the breakdown voltage is raised to more than 50 KV. Oil filtering shall
be carried out at site.
d. Switchgear

i) Before switchgear is energized, following checks must be carried out & results shall be
recorded:

(a) Insulation resistance of each bus shall be measured from phase-to-phase and from
phase-to-ground with 500 / 1000V DC megger for LT & HT switchboards respectively.
Min. acceptable value of Insulation resistance measured in Mega-ohms is more than or
equal to twice of system design volts in KV + 1 i.e. 3.2Mega ohm for LT (1.1KV board).
Measurements shall be repeated with circuit breakers in ON position and OFF position
across contact.

(b) HV test with AC volts (Ph Ph and Ph E) with before & after IR value test shall be
carried out after complete installation of the switchboard. This shall be carried out with
ALL CIRCUIT BREAKERS put up in SERVICE position and in close contacts. Ph E
test shall be carried out with the CB contact away from the bus in EARTHED condition.
Apply HV test voltage according to BIS / IEC guideline.

(c) Insulation resistance of all DC circuits shall be measured from phase-to-ground.

(d) All commissioning and accuracy tests for each protection relay, as per relay
manufacturers testing guideline, shall be carried out for minimum TWO plus ONE
service setting value (total THREE). Special kits for impedance, directional and
frequency based relays simulation and testing shall be employed. Relays testing shall
be carried out through relay manufacturer or as per manufacturers recommended and
approved testing agency or otherwise through M/s Power Linkers (for numerical relays
& synchronizing relays). The agency shall have calibrated suitable relay test set having
good wave form Settings, calibration points, and test points shall be in accordance with
values given by the approved relay data sheets.

(e) Protection and metering circuits (CT & PT) shall be checked with primary injection
technique for each core. PT circuits shall be checked with full primary volts for LT board
and 500V AC 50Hz for HT boards. CT circuits shall be checked with minimum
3000Amps kit.

(f) Three phase primary injection shall be done for differential protection, restricted earth
fault protection.

(g) Test all current transformer secondary circuits by applying current to current transformer
secondary circuits and verifying that proper relay (s) and/or meter(s) operate.

(h) Current transformers for differential connections must be checked for KNEE POINT
voltage & B-H plot of all incomer protections and differential protection CTs shall be
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plotted. Results and plots shall be recorded.

(i) Test all potential transformer secondary circuits by applying voltage to potential
transformer secondary circuits and verifying that proper relay (s) and/or meter(s)
operate.

(j) Simulations for all the schemes like Auto / manual changeover, electrical closing /
blocking, inter-trips & protections, auto-starts / reacceleration, control supply
changeover etc. shall be carried out and status with problems faced and remedial
actions carried out shall be recorded. Drawings shall be updated in TWO copies
immediately i.e. ONE for site use till contractor submits final AS BUILT and OTHER for
contractors reference for preparation of final AS BUILT.

ii) The following tests shall be performed on all circuit breakers before they are operated:

(a) Contact alignment and wipe shall be checked and adjusted where necessary in
accordance with manufacturer's instructions.

(b) Each circuit breaker shall be drawn out of its cubicle, closed manually, and its insulation
resistance measured from phase-to-phase and from phase-to-ground. Acceptable
insulation resistance as given for switchboard.

(c) Contact resistance measurements and contact opening & closing time shall be
carried out for each pole of HT circuit breakers and results shall be recorded.

(d) All adjustable direct acting trip devices shall be set using values given in the approved
relay data sheets.

iii) Motor Control Centers

(a) Before energizing, the insulation resistance of each bus shall be measured from phase-
to-phase and from phase-to-ground with disconnected devices open. Repeat
measurements with disconnected devices closed but with contactor open, minimum
acceptable value shall be indicated more than or equal to twice of system design volts
in KV + 1 i.e. 3.2Mega ohm for LV (1.1KV board).

(b) Contact alignment and wipe for each contactor shall be checked and adjusted where
necessary in accordance with manufacturer's instructions.

(c) Before energizing, the insulation resistance on both the "line sides" and "load side" of
each contactor shall be measured separately from phase-to-phase and from phase-to-
ground. For minimum acceptable value, refer point (a) above.

(d) Set each adjustable relay and direct acting trip devices in accordance with values given
in the approved relay settings record.

(e) Each contactor shall be closed and tripped from its control switch and /or pushbutton
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station to test proper operation.

(f) Check sizes of overload relays and fuses.

(g) Before energizing control centers, switch racks, and all the power centers, the insulation
resistance of each bus shall be measured from phase-to-phase and from phase-to-
ground with circuit breakers open Measurements shall be repeated with circuit breakers
closed

e. Wire and Cable

i) Before energizing wire & cables, the insulation resistance of every circuit shall be
measured from phase-to-phase and from phase-to-ground. This requires 3
measurements for single phase circuits (2 measurements if one side is grounded) and
6 measurements for 3 phase circuits. The applied voltage shall be appropriate for the
voltage class insulation being measured.

ii) For wire and cable rated 1100 volts the insulation resistance of those circuits noted
below shall be measured as follows:

(a) Motor Feeders: With motors disconnected; measure insulation resistance from -load
side of contactors or circuit breakers.

(b) Motor Control Circuits: With push-button and over-current device connected, measure
insulation resistance from phase-to-ground only. Control circuit continuity and
operability can be checked by ohmmeter or buzzer.

(c) Lighting Feeders: Measure insulation resistance with circuit breakers, lighting
transformers, and panel-boards connected, but with the lighting branch circuit breakers
or switches open.

(d) Lighting Branch Circuits: Measure insulation resistance after all lamp holders,
receptacles, fixtures, etc. are connected but before lamping. Some lamp circuits with
ballasts may require only one reading to ground.

(e) High Voltage Test on Cable shall be in accordance with IS-1255.

iii) A DC high voltage test shall be made, after installation, on all cables operating at a
nominal system voltage of 1101 volts and above.

(a) The duration of the test for cables rated above 5 KV shall be as per IS. The initially
applied DC test voltage shall not be over 25% of the specified test voltage and the rate
of increase of applied voltage shall be uniform and reach 100% of specified test voltage
in not less than 10 seconds or more than 60 seconds.

(b) Test voltage for high voltage cables shall be in accordance with manufacturer's
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recommendation.

iv) When long runs of cables require splicing, each section of cable shall be "Meggered"
before each splice is made and again after each splice is completed. When all splices
and terminations in a cable run are completed the total run shall be tested as specified
above.

The DC high voltage tests shall be performed in accordance with the following:
Cables shall be installed in final positions, with all through splices complete.
Terminations shall be kept unfurnished so that motors, switchgear, transformers etc.
are not subjected to the test voltage; however, insulation shall be pencilled and
otherwise prepared for completion of the termination to the greatest extent possible for
protection of the cable, including making up and grounding of stress cones for shielded
cable.

f. Grounding

i) The resistance to earth shall be measured at the following location.

(a) All the earth pit resistances: in isolated from grid and connected with grid conditions.

(b) At each electrical system ground or system natural ground for transformers / DG set.

(c) Switchboards & equipment panels earth buses of VFD Distribution boards etc.

(d) Equipment earthing like motors / transformers / switchboards & panels.

(e) Field earth buses for vessels & structure earthing.

(f) Lightning arrestor earthing stations.

ii) Resistance of any single earth pit shall not exceed 0.5 ohm in connected with earth grid
and 5 ohms in isolated from earth grid conditions.

iii) Resistance shall not exceed 1 ohm between conductors for systems operating at 600
volts or less, solidly grounded systems.

iv) At each ground provided for structure lighting protection: Resistance shall not exceed 5
ohms.

v) At one point at each grounding system used to ground electrical equipment enclosures:
Resistance shall not exceed 1 ohms.

vi) At the point at each grounding system used to ground wiring system enclosures such
as metal conduits and cable sheaths or armour: Resistance shall not exceed 4 ohms.
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vii) Equipment to be grounded shall be disconnected from the ground system before
system is checked.

viii) The resistance of the grounding system shall be determined and recorded.

11. Electric Heat Tracing

a. Where electric heat tracing of certain process piping and vessels is indicated on the
flow sheets or called for in the specifications, monolithic core self regulating, self
limiting heat tracers shall be installed. The construction of tracer cable shall have
nickel plated copper bus wires, semi conductive heat matrix, fluoro polymer
dielectric insulation, tinned copper braid, fluoro polymer outer jacket as per latest
publication of IEEE 515. The tracer cable shall be burn out proof.

b. Required numbers temperature sensors with temperature transmitters shall


be installed in the field for different circuits to measure pipe surface
temperature / fluid. The same shall be hooked to DCS / PLC. The digital
contact s shall be wired to Electrcal heat tracing panel located in sub station
for ON / OFF control of each circuit of heat tracing system.

c. For heating requirements above 10 watts per square foot, heat transfer cement shall
be used in accordance with suppliers recommendation.

d. The installation shall, if necessary, be approved for operation in hazardous areas.

e. For electric heat tracing of instrument lines: see instrument specification.

f. The heat tracer control panel shall be located in sub station.

12. Compliance to statutory requirements:

a. It shall be the contractors prime responsibility to design, engineer, supply, install &
commission all the equipments to meet with the prevailing norms of the Government
Authorities. It shall conform to requirements prevailing at the time of declaration of
commissioning of the plant. All installations shall conform to requirements of :

i) Indian Electricity Rules


ii) Indian Electricity Act
iii) Gujarat State Pollution Control Board
iv) Central Pollution Control Board
v) Indian Boiler Regulation Act
vi) Tariff Advisory Committee & Insurance Companies Association Guidelines

b. It shall be contractors responsibility to take all statutory approvals as defined by the


respective Government Authorities, including preparation of documents for the
application. Contractor shall arrange for following, but not limited to this only, installations:

i) Substation building and layout approval


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ii) Transformer installation approval


iii) GPCB / CPCB approval for DG Set w.r.t. exhaust emissions and acoustic noise
iv) CCE approval for special equipments installed in hazardous area
v) Overall plant electrical system installation approval including earthing system.

13. Important points for document flow and approval:

Following documents shall be submitted to OWNER for review and approval. OWNER
shall offer comments within 7 days of submission, other wise it shall be presumed there
is no comment from OWNER:

a. Basic and detail engineering documents

b. Hazardous area classification drawings shall be prepared before plant equipment


specifications and submitted for review and approval.

c. Final enquiry specifications of major items i.e. LV switchboards, Motors, VFD, LV cables,
Relays,

d. Final Technical recommendations and purchase recommendations.

e. Equipment / packages order copy (un-priced) with all technical specs and testing,
inspection, installation & commissioning, guarantee / warranty terms.

f. Substation building General Arrangement, equipment layout for various rooms in


substation.

g. Switchboard bus bars, Transformer capacity calculations.

h. Cable selection calculations for all switchboard incomers, Transformers HV / LV sides, LV


motors

i. Earthing, lighting, field socket outlet, cable tray route, street light layout drawings

j. Lightning protection calculations and protection area coverage drawing with dimensions

k. Earthing calculations for numbers of earth pit and cross section of earthing strip.

14. Deviation / additions / deletions

a. Material supplied & expert services rendered shall be from OWNER approved vendors
and service providers only. The list of approved vendors and contractors attached with
this ITB.

b. Tentative Single Line Diagram (Appendix G) attached herewith for approximation of


switchboards requirement. The diagram is indicative of network only. Actual numbers of
boards & equipments shall be worked out based on actual load requirement and detail
engineering.
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c. List of mandatory spares to be procured for electrical items as per Appendix H, is


attached herewith.

d. Recommended spares (5 years) list for major items with unit price shall be provided.
Procurement of recommended spares is by OWNER.

e. Electrical erection work shall be carried out through reputed erection contractor as
mentioned in approved vendor list.

f. Deviations on requirement specified in this document, any other electrical documents &
standard specifications shall be separately indicated in the offer.

g. Deviation offered by equipment suppliers, in the case of deviations from all the suppliers
only, shall be discussed with OWNER in presence of or with the written intimation of
supplier w.r.t. same. Decision of OWNER shall be final in such cases.

h. Endeavour shall be made to deploy the most efficient equipments.

LT motors shall have efficiency class- IE3

i. In case the approved vendors for some items are not indicated in approved vendor list of
OWNER. following procedure shall be adopted:

i) Vendor shall be a ISO: 9001 2000 certified company. It shall be in the approved
vendor list of IOCL, IPCL, GSFC, RPL, RIL, RCF and shall have full fledged well
established manufacturing and service network for not less than 10 years.

ii) Client list and evidences for above points with the balance sheet of last THREE years
shall be submitted for the approval.

iii) OWNER and contractor shall discuss and decide the vendor on mutually agreed basis.
However, OWNER shall have final acceptance powers

15. INSPECTION :
a. OWNER shall witness test for all ELECTRICAL items including bulks &
pacakages at vendors works. In case witnessing by OWNER is not possible,
OWNER will waive it on case to case basis.
b. Inspection call shall be given to OWNER 15 days in advance for indigenous
items and 30 days in advance for imported items.

16. TRAINING:

a. Electrical training programme shall include O&M, troubleshooting and general


design aspects of VVFDs, LT air circuit breakers, overall electrical protection &
control system, Electrical - Instrument interface .
b. Individual equipment training shall be arranged at manufacturers place for
minimum TWO days and further as required for the topic involved.
At training centres of respective manufacturer e.g. L&T training centre, Pune
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for L&T equipment


Protection relays
VFD
Circuit breakers & switch board maintenance

17. CONTRACTOR shall follow Electrical Design philosophy and Specific Requirements
for Electrical system as base. The most stringent requirement shall be followed, where
conflict among Electrical Design Philosophy, Specific Requirements for Electrical
system and individual specs is found. Contractor shall brought out such
descripancies during offer stage.

18. CONTRACTOR shall record the temporary routes used for underground construction
cables and shall remove the same after completion of the project work.

Following shall be in contractors scope.

1) Arrangement of 11 KV (UE) / 3.3 KV (UE) cable and control cables


2) Laying (under ground / over head wherever rack is available) of HT power and LT
control cables from TDI process substation to PAC construction power sub station
3) Termination of power & control cable at both ends
4) Installation of earth pits for transformer neutral and body earthing
5) Supply & installation of switchboard to receive power from transformer and
distribution of bulk power to various field distribution board. The switch board shall
have incomer and outgoing feeders having short circuit, over load and earth fault
protections.
6) Approval of Chief Electrical inspector for installation of transformer
7) Installation of earth pits at various locations and inter connection by earth strip to
make a grid so as to bring down the earth resistance below 1 ohm
8) Field distribution board shall have out goinfg feeders with 30mA ELMCB for safety
of operating personnel.

Contractor shall arrange welding machines having VFD design for conservation of
energy during construction activities.

19. MANPOWER:

CONTRACTOR shall not be dependent on OWNERs manpower for the project. It shall
be CONTRACTORs responsibility to coordinate to complete the project in time.
OWNER may inject their manpower at OWNERs discretion for training and smooth
take over purpose.

20. BACK UP FOR SPARE PARTS & SERVICES.

a. CONTRACTOR to arrange for confirmation from all the vendors for 10 to 15


years backup for spares & services.
b. In addition to supply of the mandatory spares given in Appendix-H,
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CONTRACTOR to supply commissioning spares as per the requirement for


successful commissioning plant without delay.

21. STANDARD SPECIFICATION OF ELECTRICAL EQUIPMENT :

CONTRACTOR to follow OWNERs Standard for the items for which technical
specification are not available in Appendix-E.

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Engineering Design Philosophy
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APPENDIX - C
Engineering Design Philosophy

1.0 GENERAL INFORMATION


1.1 PARTICULARS OF SYSTEM
(a) Nominal Voltage 11KV / 3.3 KV / 0.415KV (Variation + 10
%)
(b) Rated Voltage 12KV / 3.6KV / 0.450KV
(c) Frequency 50Hz / +/ (-)5% (47.5 Hz ~ 52.5 Hz)
(d) Nos. of Phases 3/3/3+Neutral, for 11KV / 3.3KV /
0.415KV level
(e) Neutral earthing Neutral grounding resistor for 11KV and
3.3KV level exists so that earth fault
current is @ full load current of related
transformer. Solidly grounded for 0.415KV
system

1.2 (a) Location Dahej (non SEZ), TDI -II Site which is 40 Kms from
Bharuch. Bharuch is in Gujarat State and about 4 Km from
National Highway No 8.
(b) Height above 20.2 Metres Sea level
mean Sea level
(c) Variation in 1012.3 mbs to 995.2 mbs , 1006 mbs (average)
barometric
pressure
(d) Maximum temp. Dry Bulb - 48 Deg C
Wet Bulb - 27.8 Deg C
Min. Dry Bulb Temp. 5 Deg C
(e) Temperature to 50 deg. C.
be considered
for design
(f) Relative 80% for design
Humidity
(g) Rain Fall Maximum---65 mm/hr
Annual Avearge-1000mm
Average rainfall920 mm June to September
(h) Wind data Max. Velocity 44 m/sec as per IS-875 latest Wind direction-
as per Rose Diagram
(i) General climate Hot and Humid
(j) Earth quake As per IS-1893-1984 and Roorkee Earth Quake School
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Zone Report for Bharuch


(k) Snowfall/ Not Applicable
Frostline

1.3 CODES AND STANDARDS


The equipment including all the components shall conform to the relevant Bureau
of Indian Standard Specifications (BIS), International Electrotechnical Commission
(IEC) and currently applicable engineering practices.
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1.4 REGULATIONS
The design and operational features shall comply with the following :
(a) The Indian Electricity Act
(b) The Indian Electricity Rules
(c) Factories Act.
(d) National Electric Code
(e) Recommendations of Fire Insurance Companies and Tariff Advisory Committee
(f) State & Central Pollution Control Board guidelines
(g) Approval from Office of Chief Controller of Explosives

2.0 CIRCUIT BREAKER RELATED :


For 11KV/3.3KV level : Vacuum CB with surge suppressor
For 0.415KV level ACBs
Rated Voltage level 12KV / 3.6KV / 0.450KV
Minimum Creepage distance in air (mm)
To earth Between phases

For 11KV/3.3 KV: 130 mm For 11KV/3.3 KV: 130 mm


For 0.415KV: 19 mm For 0.415KV: 25mm
Rated short circuit breaking current
Symmetrical breaking current KA For 11 KV: 40 KA, 0.25 PF
For 3.3 KV :
26KA (outgoing) / 40 KA (incomer & bus coupler), 0.25
PF
For 0.415 KV: 50 KA, 0.25 PF
Rated short time current. For 11 KV : 40KA for 3 sec
For 3.3 KV: 26KA for 3 sec.
For 0.415 KV: 50KA for 1 sec.( 2 sec. value to be
furnished)
Rated short circuit making current. For 11KV : 2.5 x 40KA
For 3.3KV : 2.5 x 26 kA
For 0.415KV : 2.2 x 50KA
(n) Mechanism / Features For all levels:
- Arc resistant switchgear confirming to PEHLA / IEC
required. preferred.
- Service, test and isolated position.
- Safety shutters shall be of fibre glass / polycarbonate of
grade 94V-O as per UL.
- Mechanical trip free plus anti-pumping feature is
preferred.
- Electrical trip free plus anti-pumping feature is required
(Relays to be used, contactor use not allowed).
- Operation counter in Circuit Breakers is required.
- Operation, stored energy with dependent closing and
opening.
- Rated operating sequence 0-0.3 SEC-CO-15 SEC-CO
(Rapid auto closing).
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-Internal wiring of circuit breakers of given voltage level


(i.e. 11 / 3.3 / 0.415KV) shall be identical for the
purpose of interchangeability.
- Latching type relays MUST be used for contact
multiplication of test / service limit switch contact,
breaker ON / OFF contact with spare 20% contacts.
- Relays shall be mounted on panels itself in control
compartment.
- Anti-tracking material for insulation and auxiliary
switching required.
- Aux. switches minimum rating 2A, 220V DC at 20mS
TC, spare contact 20%.
(o) Temperature - Rise shall be as per the specifications attached in
Appendix-E
(p) Shrouding of circuit Each pole shall be completely shrouded to avert flash over
breaker poles between poles.

3.0 BUS BAR RELATED :


(a) Insulation system All switchgear:
- Paper / cotton base insulation not allowed.
- Non-flammable, high tracking index fibre glass / epoxy
insulation system required. (FR 4 grade as per NEMA)
- All barriers / partition shall be of fibre glass /
polycarbonate, grade 94V-O as per UL & FR4 grade as
per NEMA
- All the HT live parts shall be 100% insulated using
standard tapes (Product no. SCOTCH 130C of 3M
make) / heat shrinkable sleeves (Raychem make) /
shrouds of 3M or RAYCHEM make & LT bus bars
shall be PVC sleeved & joints shall be provided with
removable shrouds.
(b) Secondary insulation All switchgear:
system - All bus bar and jumper / links shall be with colour
coded non-flammable heat shrinkable sleeve.
- Bus / link joints shall have non-flammable shrouds.
(c) Other features For all switchgear:
Panel to panel entry of bus bars shall be effectively sealed
so that production of flashover do not travel from one panel
to other panel and create multiple faults.
For 0.415KV Switchgear:
Ionised gas travel (due to fault) from module to bus bar
chamber or from vertical bus bar to horizontal bus bar
chamber or from module / vertical bus bar chamber to cable
alley / compartment shall be effectively restricted to prevent
multiple fault / reduce damage.
(d) Temperature - Rise shall be as per the specifications attached in
Appendix-E
(e) Fault withstand For all switchgear
capability - Bus bar, bus bar jumpers / link and CTs / PTs shall
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withstand fault level as specified


Bus size calculations Switch board bus bar sizing calculations shall be taken from
switch board manufacturer during offer stage. Calculations
shall be as per INDALs book with 100% load. The same
shall be reviewed and submitted for approval to OWNER.
Fulfilment of the design / engineering requirement specified
shall be ensured by CONTRACTOR.

4.0 4.1 DISTRIBUTION PHILOSOPHY

Primary distribution - The power supply shall be tapped from bus-A and Bus-B
of 3.3KV switch board of TDI processs sub station.
- The 3.3KV cables shall be supplied by owner.
- Laying &Termination of power / control / signal cables
at both the ends, including supply of termination kits,
shall be by CONTRACTOR. Documentation related to
these activities shall be developed, prepared and
submitted by CONTRACTOR.
-
Secondary - The 3.3KV cables laid between TDI process sub station
distribution and PAC sub station shall be terminated at primary of
transformers (11KV / 0.433KV)
- Downstream distribution may be at 0.433KV with
DOUBLE LINE REDUNDANT BUS each bus fed
from different transformers.
- Maximum rating of LT SWBD bus shall be 3000A (~
2MVA 3.3/0.433KV transformer).

0.433KV - All motors up to 150KW rating & other LT load shall be


distribution fed from 0.433KV Switch board.
- There shall be one power motor control centre (PMCC).
The PMCC shall have three incomers and one bus
coupler. Two incomers shall be fed from each
transformers. The third incomer shall be fed from
existing Emergency power control centre located in TDI
process sub station. Emergency incomer shall be
interlocked for preventing paralleling of DG set supply
with grid supply / back feed.
- LT feeders with ACBs shall be fed from PCC section
and DOL feeders with contactors operated draw out
modules shall be fed from MCC section.
- All critical load shall be fed from section B of PMCC
where third incomer will be available.
- All out going feeders of MCC section shall have MCCB
instead of SFU.
- Electrical heating systems for process shall be used as a
last resort only. Systems with power requirement more
than 100KW shall have Semiconductor Power Device
control with necessary temperature sensing system. The
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PAC PROJECT

temperature sensing element shall be conneted to DCS


system through temperature tramnsmitter and analog
signal / digital contact shall be given to heater control
panel to be located in substation.

CONTRACTOR shall ensure that space for 2 panels on each


bus section is provided for future use.
- Beam width can be utilized for bus coupler panels,
where power cable entry is not feasible. However,
arrangement of control cable entries shall be considered

4.3 PMCC RELATED :


(a) ACB make L&T U power Omega/Siemens 3WL breakers
Incomer & buscoupler ACBs in PMCC shall be four pole
type only. Out going Motor ACB feeeders shall be three
pole type. O/G ACB tie feeders shall be 4 pole.
-PMCC shall be double front & MPDB & MLDB shall be
single front type.
(b) Control Supply - 220V DC for ACBs
- 240V AC, UPS supply for contactor operated feeder.
- 240V AC through control transformer for panel and
motor space heater
- 240V AC through control transformer for panel control
supply as back-up to UPS.
(c) Motor feeders - Cable alleys for MCC shall be 400mm
- 30KW and above feeder shall have 400A primary
disconnect contacts.
- All contactor operated motor feeders in MCC section
shall have L&T make M Comp relays.
- Ammeter shall be made available at
LCS/substation/control room as per process
requirement. However, provision shall be available in
outgoing feeders for motors 7.5KW and above.
(d) Features - Minimum motor feeder module size shall be 280mm
- DOL feeders shall have type 2 coordination as per
IS:13947 / IEC 947
(e) Feeder rated above - Any feeder rated above 250A shall be of desired rating
250 Amps in MCC ACB with protection relay.

5.0 SWITCHGEAR ACCESSORIES RELATED :


Switchboard CT-1 CT-2 CT-3
PMCC I/C s CL-5P20 for CL PS for REF
protection
PMCC O/G tie CL-5P20 for
protection
PMCC Motor feeders CL-5P20 for CL-1 for LCS & CBCT
protection DCS current (1 no.)
(b) Terminals - CT terminal shall be Elemex make CATD M4 type or
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PAC PROJECT

equivalent WAGO / Phoniex make.


-Spare terminal 20% shall be kept for all types.
(c) Wiring / Wiring - All wiring shall be fire retardant low smoke emission
Accessories type.
- Incomer and bus coupler shall have fire survival wiring
(FLUROPLASTIC TYPE) for protection relays and
closing / trip circuit.
- One terminal shall have one wire only.
- Insulated pin type lugs are to be used for flexible wires.
- Ring type/fork type lugs are to be used for CT/PT
wiring.

6.0 PROTECTION SYSTEM RELATED :


(a) Make ABB (numerical) preferred for protection purpose. Relays
to be used as shown in Appendix-D.
(b) Features Shall be as described below:
For All SWGRs: Shall be protected with microprocessor based numerical
relays with dynamic group changeover and disturbance
recording facility.
Over current & earth fault protections shall be with
LOCKOUT type, high burden and fast operating contact of
the relay only.
Auxiliary relays for contact multiplication shall be ABB
(combiflex type) make static / electromechanical type.
Waveform capturing and oscillography with fault analysis
tool / software features are required. (Waveform, vector &
tabular formats)
All relays shall be mounted on switchboard panel front,
Frequency based protections shall be provided for the
purpose of achieving system stability based on plant load
shedding philosophy.
Core balance protection is to be incorporated for quick fault
isolation, if situation demands. (For 415V ACB fed motors.)
Relays shall have features of group parameter setting,
disturbance recording, waveform capturing and sequence of
event recording. Necessary software, compatible to SCADA
SYSTEM, is included in the scope of Contractor.
One licensed software for Relay disturbance recording and
disturbance analysis shall be installed in engineering station.
Relays shall have two communication ports available for
simultaneous use.
Transformers: All distribution transformers shall be protected with
Microprocessor based numerical relays.
WTI / OTI / Oil level / Buchholtz / PRV Switch digital
signals shall be given to transformer relay for direct trip
with Annunciation.
Relays with Analogue input acceptability from WTI / OTI /
Oil level gauge is preferred otherwise same shall be
accommodated in centralized substation monitoring system.
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For 0.415KV All incomers / bus couplers shall be protected with


SWGR : microprocessor based numerical relays [ with composite
over current, earth fault, under voltage, over voltage, under /
over frequency protections.]
LT motors rated >55KW shall be protected by REM 615
(ABB) make relays.
All contactor operated metor feeders shall be provided with
L&T make M Comp relays/Siemens make Simocode relays

7.0 FUSES/INDICATION/METERING/
MONITORING SYSTEM RELATED :
(a) Fuses - All important fuses shall be monitored e.g. PT
secondary fuses.
- Separate fuse shall be provided for trip circuit, closing /
spring charging, indication, space heater, etc. for ease in
fault tracing.
- EE make SM32 / 63 type fuse base and carriers are not
acceptable.
(b) Indicating lamps - Long life LED type, with built-in short circuit & low
voltage glow protection, BINAY / Precifine make
indicating lamps are required.
- For All SWGR: Indicating lamp ON (Red), OFF)
(Green) Auto Trip (Amber (Yellow) are minimum
requirement.
- For Incomers of all SWGR: Wiring for sending end
breaker indication for ON and OFF shall be
provided on back side of incomer panel.
- ON / OFF indication on back side of ACB operated
LT feeders shall be provided.
(c) Annunciation Alarm/Annunciation for switch boards are available on
SCADA system. No separate PLC required for
annunciation.
(d) Monitoring - Continuous monitoring of electrical and process
parameters shall be done with adequate numerical relay
system with recording devices so that fault analysis as
well as process consequences can be analysed in detail
for corrective action.
(e) Indicating meter - Tru RMS composite indicating meters shall be digital &
communicating type having facility for measurement of
harmonics up to 32nd harmonics, THD unless specified.
- Incomers shall have ANALOGUE VOLTMETERS
with SELECTOR switch connected to line side PT
secondary respectively.
- All incomers & important feeders as decided by process
shall have communicating type, digital energy meter.
Accuracy class: - Revenue meters: CLASS 0.5
- KW / KWH meters: min. CLASS 1.0
- Ammeters / Voltmeters: CLASS 1.0
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8.0 SCHEMES :
(a) Manual changeover - 0.415KV switchgear shall have manual changeover
scheme (MCO) and scheme of make before brake type and automatic
automatic changeover changeover scheme shall be brake before make type to
scheme (ACO) ensure continuity / early resumption of power supply in
case of emergency shut-down of a section/failure of one
feeder.
- The scheme should incorporate adequate safety features
like non-closer on (a) bus fault, (b) upstream breaker
trip on fault (c) different bus frequency (synchro check
scheme) etc. (d) healthy bus residual voltage (e)
residual voltage on bus less than certain value etc.
- Time grading of auto changeover scheme shall be
carried out from 11KV switchgear to 0.415KV
switchgear.
- The Plant shall not be affected during Voltage dips or
momentary power interruption for the time equivalent
to auto change over situation i.e. duration of 1.5 sec
- Safe shutdown is expected only during POWER
FAILURE.
- If VFD is considered for any of drive application, it
shall be provided with appropriate technology to
facilitate momentary power loss ride through during 1.5
sec for voltage dips or auto changeover.
MCO / ACO for - Change over from normal to emergency power, in case
emergency power of power failure on respective board, shall be
supply boards AUTOMATIC giving signal to DG set to start.
- Manual dead bus live line closing facility for
emergency incomer shall be provided.
- Change over from Emergency power to normal power,
on resumption of normal supply, MANUAL change
over scheme with POSITIVE ISOLATION Break
Before Make system shall be deployed.
(b) Inter-trip scheme - Inter-trip scheme -Transformer Primary CB to
Secondary CB is to be incorporated, if overall plant
protection grading demands.
- Receiving end CB shall trip Sending end breaker, if
former is in TEST position.
(c) Re-acceleration Critical equipments are to be started immediately in case of
Scheme power resumption subsequent to failure. Drive groups shall
be made in consultation with process so that inrush current
do not exceed causing (a) nuisance tripping of incomers and
(b) voltage does not go below 85% nominal voltage.
(d) Auto start scheme Auto-start scheme shall be provided for drives which should
start automatically no sooner parameters like pressure/flow
reduce below specified limit as decided by process.
(e) Logic operated load Logic operated scheme shall be incorporated so that in the
shedding scheme event of power shortage, plant is stopped. The over-ride
feature to be provided so that scheme remains in service /
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out of service as decided later-on.


(f) Under voltage Under voltage motor trip shall be provided for motors rated
scheme > 55KW.
(g) Motor space heater - Motor space heater monitoring through ammeter / other
scheme method is required.
(h) Auto control power - Not applicable at all levels. Centrally controlled from
factor improvement MRS.
scheme - However, power factor of each switchboard shall be
separately monitored.
(i) Process logic scheme - Contactor auxiliary contact / CB auxiliary contact shall
be used for process logic.

9.0 TRANSFORMER RELATED :


(a) Rating - Rating should be 1.25 times prospective operating load
(single feed) plus operation of largest spare motor. The
minimum rating shall be 1 MVA.
- Voltage should not reduce below 85% in the event of
starting of largest motor with the base load equivalent
to operation load w/o this motor / reacceleration group
Ref.(8) (c) above with base load equivalent to operation
load of ONE section.
- All distribution transformer shall have OFF LOAD
TAP CHANGER with + /- 5% in steps of 2.5% each
(Rated Secondary volts shall be 0.433KV for centre
tap).
- The space for 6000x 6000 for 11/0.433KV transformer
yard.
(b) Features - Detachable disconnecting chambers shall be provided
for ease in removal of transformer.
- Pre-shrunk winding design with anti-loosening features
for core / winding holding system is required to avoid
transformer opening for looseness attending.
(c) Weather Protection & - Transformer shall have shed to avoid adverse effect of
surrounding space weather / environment.
- Earthing pits & Oil soak pits as per installation
requirement shall be provided. Space shall be available
in substation periphery as well as clearances around
transformer shall be met with standard requirements.
(e) Monitoring / - Neutral CT box after neutral bifurcation point shall be
Protection mountings provided for REF protection and stand by earth fault
protection.
- Buchholtz shall be provided.
- Shall be with Winding Temperature, Oil temperature
and Oil level measurement devices with local gauge.
The devices shall have digital contacts for alarm and
trip and alarm as per final scheme.
- Oil pressure relief valve with switch (2 nos.
NORMALLY OPEN contacts) shall be provided on
transformer tank.
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- The duplex type RTD shall be provided for Winding


and oil temperature measurement. The 4~20 mA
current transmitters shall be provided for remote signal
at SCADA and/ or relay for monitoring.
(f) Transformer oil The 15% additional transformer oil quantity shall be
supplied. However, it shall be sole responsibility of
CONTRACTOR to offer transformer completely oil filled
with acceptable parameters of oil as per IS: 335.

10.0 MOTOR RELATED :


(a) Motor rated voltage - All 0.433KV (up to 150KW) shall be Squirrel Cage
& type: Induction type (SQIM). The 415V motors shall be
energy efficient IE3 as per IS: 12615.
(b) Starting conditions HT Motors LT Motors
- Full valve opening - Successful start of 85% 80%
case motor for terminal
voltage
- 5 minute full load run of 85% 75%
motor for terminal
voltage
(c) Parameters :
Starting current - Max. value (IST / IN) 5.0 Full voltage
Locked rotor - Furnish values for 85%, Including IS starting
withstand time 100% and 110% rated tolerance current of
voltage for cold and hot motors shall
condition. not exceed
- The locked rotor 700%.for
withstand time at motor rated
110% voltage value up to and
shall be more by including 15
minimum 5 second of KW and
starting time at 85% 600% for
voltage value for HT motors rated
motor and 75% voltage above 15
value for LT motors. KW, without
any tolerance
PF & Efficiency - Values at 50%, 75%
and 100% of load to be
furnished.
Starting time - Values at 75%V /
85%V and 110%V to
be furnished. (with
discharge valve open
and with discharge
valve close condition)
Performance curves - Torque-speed, current
speed, thermal
withstand time (hot
and cold) to be
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furnished.
Matching of load & - Motor vendor to super impose driven load characteristic
motor (to be furnished by Contractor) in motor T.S. curve and
characteristics carry out application check. (with discharge valve
open and with discharge valve close condition.)
(d) Insulation system - Class F with temperature rise limited to Class B with
epoxy gel coat on overhang portion.
- Vaccum pressure impregnation insulation system shall
be done for 0.415KV motors.
- Motor shall withstand stresses developed due to 50%
residual voltage in opposition to 100% supply voltage
during auto changeover.
(e) Features :
- Motor TB - Terminal box of next higher dimensions than provided
normally in respective frame size shall be considered
for 415 V motors for ease in termination of aluminium
conductor cables.
- It shall withstand 36MVA fault level for 0.5 secs for
0.415KV CB operated motors respectively.
Hardware All hardwares shall be SS304 only.
- Space heater/ - Separate TBs shall be provided for space heaters, RTDs
RTDs/ BTDs and BTDs.
- Space heater shall be provided for 37 KW and above
motor rating.
- Mono-block / - Mono-block / gear mounted motors are not to be
gear mounted considered as failure rate is high. If not possible than
motors choose V1 mounting
- Motor operated - Motor operated valves (MOVs) are not to be
valves (MOVs) considered. If not possible to avoid than choose with
separate systems for electrical & instrument operation /
control. Details to be given by MOV supplier for their
requirement for operation & control.
- Electrical system shall be configured in supply module
at substation only.
- Instrumentation system shall be with its own auxiliary
supply and transmitters etc. meeting with instrument
standard specifications for relevant items.
(f) Motors for VFD - Vacuum pressure impregnated, tropicalization for
applications: insulation
- Winding wire shall be double coated.
- Insulation Class (class F) & temperature rise limit Class
(class B) can be reviewed w.r.t. extra heating
possibilities based on application.
- Cooling at low & high speed applications shall be taken
care.
- Effect on bearing at low speed for motors rated
>110KW shall be considered.
- Additional care shall be taken for switching frequency /
non-sinusoidal waves.
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- Thermistors (for all motors) / RTDs (for motors rated >


30KW) in winding shall be provided for temperature
monitoring.
- Care shall be taken for Acoustic & electromagnetic
noise related matters.
(g) Motor foundation LT motor foundation shall be at least 450mm high from
respective FFL.
(h) Approach for (a) Approach for replacement / maintenance of LT
maintenance motors & lighting shall be given due care.
(b) Arrangement of manual hoist / chain pulley block for
motor handling shall be provided for motors rated
above 22KW which are installed anywhere other
than the ground floor.
(i) Bearing LV motors 75kW and above shall have bearing temperature
temperature detectors also.
detector Motor winding and bearing temperature signals shall be
given to motor protection relay for monitoring / alarm / trip.
This is applicable for all the motors controlled by Circuit
breakers. The RTD shall be duplex type and are to be
connected to numerical motor protection relay. Temperature
information shall be available in SCADA through soft link
between relay & SCADA. Also, the information shall be
available at DCS through soft link between SCADA and
DCS.
(j) Start/ stop control LCS for each motor is must. Start / stop push buttons on
of motor package local control panels are not acceptable. Only
indications can be kept on package local panel.
POWER SYSTEM
Contractor to design Electrical system for successful starting
PERFORMANCE
of largest rating motor such a way that transformer terminal
DURING
voltage shall not drop below 85% of nominal voltage. The
STARTTING OF
type of starting system shall be suitably considered for this
largest rating
Motor.
MOTOR.

11.0 CABLE RELATED:


(a) Type - XLPE insulated, overall FRLSH PVC sheathed, flat /
round GI armoured required. Plant leakages (gases / HP
steam / liquids) / mechanical abrasion effects to be
evaluated and appropriate other insulation to be used as
required.
- Heat shrinkable joints / termination shall be
RAYCHEM make only.
- Signal & data cables shall be with copper screened or
Fibre Optic cable (Single Mode Jelly Filled). [LAPP /
BELDON make only]. For field laying, it shall be
armoured cable.
- Any specific data cable shall be employed with
respective equipment manufacturer recommendation.
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-
Armoured & shielded TRIAD cables shall be used for
RTD / BTD signals from equipment to switchgear.
Conductor type - Power cables: AL / CU stranded class 2
- Control / Signal cables: CU stranded class 2
- Lighting cables: CU single strand class 1
- Data cables: Twisted pair tinned CU
Insulation Grade - LT power (XLPE INSULAED, FRLS outer sheathed)
& all control & lighting (XLPE insulated, FRLS outer
sheathed) & earthing cables (PVC insulated, FRLS
green colour outer sheathed) shall be insulated for
1100V AC.
- HT power cables for 11KV shall be insulated for
11KV/3.3KV (UE)
Cable screen - 11KV, 3 core cables shall be with extruded semi
conducting compound conductor screen, extruded semi
conducting insulation screen and non magnetic metallic
cover over extruded semi-conducting insulation screen.
- 11KV, 1 core cables shall be with extruded semi
conducting compound conductor screen and extruded
semi conducting insulation screen. It will not have non
magnetic metallic cover over semi-conducting
insulation screen. Non magnetic armour will act as
metallic cover.
- All 3.3KV cables shall be un-screened.
(b) Rating - The cable sizes defined in the feeder selection chart in
LT switchboard specifications are minimum
requirement. For sizing of cables, contractor to also
take into account the voltage drop (motor starting
voltage drop of 7.5% and motor running voltage drop
of 3%). The larger size among the two shall be
considered..
- Consider 1.0 sec. short circuit rating for power feeders
& 0.5 sec short circuit rating for motor feeders w.r.t
respective SWBD design fault level.
(c) Fire stop / Fire Where cables enter a building the cable entry shall be sealed
coating with water tight and flame retardant filler. The filler to be
used shall be polyurethane foam with a cover of flammastic
or rock-wool panels with a cover of flammastic.
(d) Specific - Single core cable shall be sparingly used as sheath
faults are difficult to locate and special care is required
for termination, sheath earthing etc. (Shall be deployed
for 11KV cables with more than 1000mtr continuous
length requirement only).
- Any power cable in LT shall be used as per following
guideline:
Up to 6 sqmm Cu conductors.
Above 6 sqmm & above Al conductors.
- Cable glands shall be double compression anodised
Aluminium type made from hexagonal aluminium bar
Engineering Design Philosophy
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with PVC shroud.


- Any multicore control cable shall have 20% (or min.
TWO) cores shall be spare for use in emergency.
- Earthing cables shall have GREEEN outer sheath.
(e) Cable rack / Trench - Air supply lines shall not be laid on the cable rack level.
- Overhead cable rack system is required.
- Cable trays shall be of FRP for corrosion prone area.
- Minimum distance between TWO cable trays shall be
400mm vertically (bottom of lower tier tray to bottom
of upper tier tray). Max width of ladder tray shall be
750mm.
- Cable rack earth buses (AL 75 X 10mm) shall be
provided at every branch point and minimum at every
100mtr.
- Main rack buses shall be interconnected with 2 X 300
sq.mm. cable and shall be connected to SWBD earth
finally.
- Branched off tray earth bus (AL 40 x 10mm) shall be
interconnected with 2 X 150 sq.mm. cable shall be
connected to main tray earth bus finally.
- Cable rack shall have walkway alongside of cable rack
for cable inspection / fault tracing / replacement etc.
- Cable from substation to plant area shall be through 'H'
post. 'T' posts are not acceptable.
(f) Cable laying - Cables shall be laid in separate trays for each following
types:
HT Power cables (min. distance from other trays 400
mm)
LT Power cables & Electrical control cables (LCS
related)
Electrical Instrument interface cables
Signal cables (min. distance from power cables
600mm, except for only cross over taking place it
shall be 200mm min.)
Special instrumentation cables, intrinsically safe
circuit cables
- Field routing with less than 300mm (inclusive) tray
width shall be with perforated trays to avert the cleating
on structure.
(g) Safety point In case, cable trench is unavoidable in hazardous area than it
shall be filled with sand. The minimum width shall be 1
meter.

12.0 LOCAL CONTROL STATION (LCS):


General - IP-55 enclosure shall be of FRP & SS304 hardwares
with SS inserts.
- All LCS shall be with HOOD type FRP canopies.
- LCS shall have silicon gasket.
Engineering Design Philosophy
PAC PROJECT

16.0 HAZARDOUS AREA APPLICATIONS :


Hazardous Area - Hazardous Area Classification shall be done according
Classification to IS: 5572- 2009 (or latest edition) guidelines only.
- Three dimensional idea of Hazardous areas in the plants
shall be available on drawing with major equipments
(drawing shall be Orthographic with plan & elevation
for respective floor / area).
Equipment - Shall be as per IS:5571- 2009 (or latest edition)
selection: - Increased safety Ex e equipments / enclosures shall
conform to IEC: 60079 Part-7 (latest edition)
requirements.
- Flameproof Ex d equipments / enclosures shall
conform to IEC:60079 Part-1 (latest edition)
requirements.
Documents - Certification of conformation from relevant authority
availability at work (for Indigenous items CMRI certification) & CCE
place. approval for above applications shall be available at
work place.
- Equipment datasheet with Area, type of equipment with
make / model / temperature class with Te time, ratings /
make / model of each components in equipment shall be
available at work place.
- Document shall indicate following information.
Source of hazard - Please indicate whether release will
take place during normal operation or only during
abnormal condition
Operating pressure & Temperature
Flash point
Density relative to air
Gas group
Composition of various gases at operating temperature
Upper & lower explosive limits
State i.e. liquid or gas
Auto ignition temperature
Density
Vapour pressure at operating condition for volatile
Category of volatile product
Rate of release
Engineering Design Philosophy
PAC PROJECT

1. The area classification for battery room shall be


shown.

2. The battery set for fire alarm system shall be


installed in control room. The type of battery shall be
selected such that it should not generate hazardous
area in control room.

3. The hazardous area classification drawing for


following pipe rack shall be also developed.

a. Pipe rack between existing plant and PAC


plant

b. Pipe rack for RLNG pipeline

4. Following cylinders are normally kept outside plant


laboratory for carrying out instrument calibration.

a. Hydrogen cylinder of @ 10Kg

b. Argon cylinder of @10 Kg

c. CO cylinder of @ 5 Kg

d. Helium cylinder of @ 10 Kg

Please indicate hazardous area, if applicable, due


to above storage.
5. In Zone -2 area, LT motors shall be increased
safety EX e only. EX n Motors are not acceptable.

6. The motors to be installed for EOT crane shall be


of S4 duty and shall have 3 nos. 130 deg. C.
thermisters embedded in the winding. The motors
shall be Flameproof suitable for gas group IIC.

17.0 EARTHING RELATED:


(a) General - Complete design of earthing & lightning protection
shall conform to requirements defined in IS: 3043 and
IS -2309.
- Earth pit locations for plant area shall be on the plant
periphery, to the possible extent, to avoid non-
availability of bare soil access for the routine earth pit
resistance measurement (15 / 30 mtrs electrode
placement).
- Permissible limits of Earth pits resistance:
Connected with grid: Max. 1.0 ohm (installed), 0.5
Engineering Design Philosophy
PAC PROJECT

ohms (new installations)


Individual electrode installed: Max. 10 ohm
(installed), 5 ohms (new installations)
The individual earth pit resistance may vary between
5-10 ohms based on the soil resistivity. However the
total grid resistance shall be maintained as required.
(b) Type and methods - Single core aluminium cable earthing is required with
the size 16, 35, 70, 150 & 300 sqmm only as per
application requirement. (minimum permissible
16sqmm. The earthing cable shall have stranded
aluminium conductor, PVC insulated (red color) and
PVC (FRLSH) sheathed (green color).
- Poor integration of joint and corrosion creates high
resistance whereby earth fault current value decreases
and hence fuses / earth fault relay schemes operation is
delayed / fails to operate in reality.
- Hassian tape and bitumen paint of Berger make shall be
provided at welded joints to prevent corrosion.
- Cable rack earthing details as given in cable related
point 11(e).
- 75 X 10 mm hot dip GI strip for under ground main
earthing grid shall be used.
(c) For LT motors 3 / 4 core cable can be considered for motors, 4th /
reduced core can be used for earthing inside motor TB for
effective earthing.
(d) For LCS/ LDBs Local control station / lighting DB earthing shall be by 16
sq.mm. cables to avoid breakage.
(e) Safety point (Static - Flexible Aluminium insulated jumpers shall be
Electricity) provided at flange joints of hydro carbon carrying
pipelines to prevent fire explosion hazards due to spark
of static electricity.
- If the hydro carbon carrying pipelines are welded type
than pipe rack and related equipment shall be
effectively earthed at MINIMUM two points to prevent
fire / explosion hazards due to sparks of static
electricity.
(f) Earth pits & - Earth pit chamber size shall be min. 0.75 X 0.75 MTR
electrodes clear inside with 9 brick wall and FLUSHED type MS
chequered plate cover 5mm thick, 30 x 6mm angle
welded inside to prevent displacement from the
position, with TWO lifting handles on opposite sides.
- Earth electrode must be EARTHRITE MAKE only.

18.0 LIGHTING / FIELD OUTLETS RELATED :


- Illumination levels at various locations shall be as per prevailing factory rules
and other statutory guidelines.
- Commissioning report with illumination levels at various locations, covering
at least 10 samples per type of application, shall be submitted.
- In substation & control room wherever false ceiling is there a grid of cable
Engineering Design Philosophy
PAC PROJECT

trays shall be there above the false ceiling and below HVAC duct.
- The cables used for lighting shall be Unarmoured cables and PVC glands shall
be used.
- All Lighting Distribution Boards (LDBs) / Power Distribution Boards (PDBs)
shall be with 4 POLE incomers and bus couplers.
- All the lighting fixtures shall be as per Table-1 attached with ITB.
(a) Schemes for
Lighting
Normal lighting: - Main lighting distribution board common for normal
lighting and emergency lighting shall have TWO
power sources, one source from bus A of PMCC and
alternate source from bus B of PMCC(which is fed
from emergency feeder).
Emergency - 25% AC emergency lighting shall be considered.
lighting: - )RUPDWWHG%XOOHWVDQG1XPEHULQJ
Escape lighting: As per Table-1 attached with ITB..
Obstruction / - LED type BINAY / PRECIFINE make long life
Aviation lighting: (minimum 7 YEARS GUARANTEE) with built-in
short circuit protection suitable for 230V AC supply
system.
- It can be provided from MLDB with caution notice on
the board 'DO NOT SWITCH OFF W/O PERMISSION'.
(b) Lighting DBs - Shall have phase wise 2 POLE ELMCB (30 100 mA) &
(LDBs) for outgoing circuits MCBs shall be used.
- All LDBs shall have double door arrangement to ensure
weather- proofing. All LDBs shall have bottom cable
entry only.
- The field LDB shall have provision to feed 24 hour
lighting as well as night lighting.
- The MOC of enclosure of LDBs shall be FRP.
(c) Convenience - 230V AC 3W, Phase- neutral-earth, Single phase
outlets (PDBs) (SPSO) / 415V AC 5W three phase (TPNE socket
outlet) / 24V AC 2W outlets shall be provided power
from a separate PDB.
- The main PDB shall have two incomers, one from bus
A of PMCC and other from bus B of PMCC.
- The PDB shall have out going feeders of rating 160A,
125A and 63A 4 pole MCCB with earth fault protection
(having time delay facility to achieve cordination with
30mA ELMCB in down stream).
- All above outlets shall be provided considering process
and mechanical requirement.
- SPSO / TPNE socket outlet shall have ELMCB with
30 mA cut off.
- All Window / Split AC unit power supply shall be
given from PDBs and not from LDBs.
(d) Light source
Normal lighting As per Table-1 attached with ITB.
Emergency lighting - As per Table-1 attached with ITB.
Engineering Design Philosophy
PAC PROJECT

Escape lighting As per Table-1 attached with ITB.


Bulk area lighting As per Table-1 attached with ITB. based on application.
Street light As per Table-1 attached with ITB.
(e) Light fitting design Lighting fittings shall be NON-INTEGRAL type. Lighting
fittings in classified areas shall be Ex d T3type with
control gear boxes of Ex 'd T3 type.

19.0 MISCELLENEOUS POINTS :


(a) Cooling towers - Consider cooling tower electrical equipment suitable
for DIV.2 area in line with latest code of practice, if
heat exchangers handle hazardous gas / liquids.
(b) Sub-station - Consider cable cellar type with adequate clearance for
maintenance and future expansion.
- Useable loading platform of 2.0 meter width shall be
provided.
- For new substation building / floor on existing
substation, the dimensions shall be designed such that
approx. 60% floor space remains free. The approx. 40%
space shall be utilized for SWBDs, LDBs, PDBs.
- Substation lay out shall be prepared considering approx.
40% occupancy for new installations. Adequate FREE
movement space within substation for LT breaker
maintenance & emergency exit shall be maintained.
TWO doors at diagonally opposite walls preferred.
- Minimum two stair case are required for Sub station.
(d) SCADA system SCADA shall be arranged by owner.
20.0 SPECIFIC SYSTEM STUDIES:
(a) Electrical fault analysis & system stability studies
Electrical fault Fault MVA, currents & voltages with phase angles shall be
analysis worked out for L-L-L / L-L-L-E symmetrical, L-L, L-L-E,
(Impedance tables L-E faults at following locations [w.r.t. Main Receiving
shall be given for Station (MRS) end fault levels]:
each fault - PAC substation transformer primary & secondary
conditions given, as terminals.
a part of report) - PAC Plant substation 0.415KV SWBD bus.
- Highest rating motor terminal of 0.415KV.
- Farthest (cable length distance) single / lump load on
0.415KV.
(b) Transient voltage Shall be worked out for following (power factor for base
drop & voltage load shall be considered as 0.8 & for motor start up as 0.2
recovery time for with 6 times KVA, unless specified) :
resumption of 85% - Normal individual feed on each bus and start up of
of rated voltage highest rating motor of respective bus.
- In case of auto changeover at 11KV & re-acceleration
of each motor groups at 415V voltage levels.
- In case of auto changeover at 0.415KV & re-
Engineering Design Philosophy
PAC PROJECT

acceleration of each motor groups at 0.415KV. [All


motors rated <55KW & inclusive shall be considered in
reacceleration group].
- Single feed on 0.415KV bus with 100% operating load
and start-up of highest rating motor on 0.415KV.
(c) Relay coordination - Protective relay co-ordination to work out settings for
& time grading for over current, earth fault & under voltage protections
re-acceleration shall be carried out with time v/s current / voltage
charts & minimum 15 tabulated values between 1.3 to
20 times of rated current..
- Working out the group of motors for reacceleration
based on criticality defined by process group and work
out Time grading for each group so as to achieve
healthy voltage levels (>85% of rated) on bus
consistently. Respective incomers / bus under voltage
protection settings & time delays and motor under
voltage protection settings & time delays shall be
considered during this exercise.
(e) Harmonics After commissioning of all the equipments and system
running at full capacity (min. 75%) from process view point,
harmonic analysis for each bus of each switch board (up to
Main Lighting DB) shall be carried out. Report shall
contain:
- % THD w.r.t. fundamental at each bus & permissible
limits for trouble free operation of equipments
connected.
- % Harmonic contents for odd harmonics from 3 RD to
61ST level & permissible limits for trouble free
operation of equipments connected.
- Remedial action plan with schemes & filter design
proposal for each level, in case of crossing / touching
the 75% of the permissible limits at respective bus.
21.0 ELECTRICAL INSPECTION & APPROVAL:
Statutory Minimum, but not limited to, following approvals shall be
requirements: availed and copy of certificates shall be kept in substation:
Electrical - Substation, transformers & DG set layout & installation
inspection & approvals.
approval of - Installation approval of field Equipments / earthing
installations systems etc. as required as per prevailing Indian
Electricity Rules (IER).
- DG Set registration.
GPCB approval Approval for fulfilment of acoustic noise level and exhaust
emissions norms for DG set installation.
CCE approval Approval for installations as per prevailing norms for fuel /
petroleum storage and hazardous area equipment
installation.
22. VARIABLE # The drive shall not trip during voltage dip ( 50% for 1 sec)
SPEED DRIVE. and auto change over ( no voltage for 1.5 sec) of 11KV
switch board.
RELAY SELECTION MATRIX
APPENDIX-D

Sr. Digital Output


Feeder Type Protections Display CT/PT Measurement Communication Ordering Code
No Input Contact
Definite time O/C Relay (Low, high &
1 Incomers + Line PT 50/51
Inst, 3 Stages)
Definite Time E/F Relay(Low, high &
50N/51N
Inst, 3 Stages)
Under voltage (3 Stages) 27
Graphical REF-615
Over Voltage Relay (3 Stages) 59 Front RJ45
Display with 4 CT I/P+5 VT 3I,Io,3U,Uo,KW,KW (HBFHAEAGNDA1BNN1XD) +
Residual Voltage Earth Fault (3 16 10 Rear RJ45 on
59N One Object I/P H,KVAR,PF,f I/O Module for additional 8
Stages) IEC61850
Control Digital Inputs
Under/Over Frequency ( 3 Stages) 81U/O
Circuit Breaker failure CBFP
Trip Circuit Supervision Relay 95T
Closing Circuit Supervision 95C
Synchrocheck 25
Mater Trip Function (Two
86A/ 86B
Independent Units)
Graphical
Front RJ45 REF-615
Bus Bar Differential Display with
2 Bus Bar Differential 87BB 4 6 4 CT I/P I Rear RJ45 on (HBFHAEAGNDA1BNN1XD) + 3
Relay One Object
IEC61850 x Metrosil
Control
3 BUS PT Under/Over Frequency ( 6 Stages) 81U
Under voltage (3 Stages) 27 Graphical
Front RJ45
Over Voltage Relay (3 Stages) 59 Display with REU-615
12 10 5 VT I/P 3U, U0, f Rear RJ45 on
Residual Voltage Earth Fault (3 One Object (HBUAEAADNBA1BNN1XD)
59N IEC61850
Stages) Control
Synchrocheck 25
Mater Trip Function (Two
86A/ 86B
Independent Units)
Transformer
Definite time O/C Relay (Low, high &
4 O/G Feeder 50/51
Inst, 3 Stages) Graphical REF-615
(for 2 & 2.5 MVA) Front RJ45
Display with 4 CT I/P + 4 3I,Io,3U,Uo,KW,KW (HBFHAEAGNDA1BNN1XD) +
Definite Time E/F Relay(Low, high & 16 10 Rear RJ45 on
50N/51N One Object VT Inputs H,KVAR,PF I/O Module for additional 8
Inst, 3 Stages) IEC61850
Control Digital Inputs
Circuit Breaker failure CBFP
Trip Circuit Supervision Relay 95T
Closing Circuit Supervision 95C
Mater Trip Function (Two
86A/ 86B
Independent Units)
Transformer
Definite time O/C Relay (Low, high &
5 O/G Feeder 50/51
Inst, 3 Stages)
(for 7 MVA)
Definite Time E/F Relay(Through
50N Graphical RET-615
Virtual Channel, Internally Derived) Front RJ45
Display with 7 CT I/P + 4 3I,Io,3U,Uo,KW,KW (HBTHBCADNDA1BNN1XD) +
12 10 Rear RJ45 on
IDMT E/F Relay (Through Virtual One Object VT I/P H,KVAR,PF I/O Module for additional 8
51N IEC61850
Channel, Internally Derived) Control Digital Inputs + 1 x Metrosil
Restricted Earth Fault Relay 64R
Transformer Differential Relay 87T
Circuit Breaker failure CBFP
Trip Circuit Supervision Relay 95T
Closing Circuit Supervision 95C
Mater Trip Function (Two
86A/ 86B
Independent Units)
Motor Feeder
6 Definite time O/C Relay 50
Definite Time E/F Relay 50N
Under Voltage Relay 27
Negative Phase -Sequence O/C,
46
Current Unbalance Realy Graphical REM-615
Front RJ45
Start-up Supervision 48 Display with 4 CT I/P & 4 3I,Io,3U,Uo,KW,KW (HBMBCCAHNDA1BNN1XD) +
8 10 Rear RJ45 on
Thermal Over Load Relay 49 One Object VT Inputs H,KVAR,PF I/O Module for additional 8
IEC61850
Number of Starts Limitation 66 Control Digital Inputs
Locked Motor During Start up 50LR
Circuit Breaker failure CBFP
Trip Circuit Supervision Relay 95T
Closing Circuit Supervision 95C
6 RTD Inputs 38
Mater Trip Function (Two
86A/ 86B
Independent Units)
Capacitor
Definite time O/C Relay (Low, high &
7 O/G Feeder 50/51
Inst, 3 Stages)
Definite Time E/F Relay(Low, high & Graphical REF-615
50N/51N Front RJ45
Inst, 3 Stages) Display with 4 CT I/P & 4 3I,Io,3U,Uo,KW,KW (HBFHAEAGNDA1BNN1XD) +
16 10 Rear RJ45 on
over voltgae relay (3 Stages) 59 One Object VT I/P H,KVAR,PF I/O Module for additional 8
IEC61850
Neutral voltage displacement relay ( Control Digital Inputs
59N
3 Stages)
Circuit Breaker failure CBFP
Trip Circuit Supervision Relay 95T
Closing Circuit Supervision 95C
Mater Trip Function (Two
86A/ 86B
Independent Units)
General Common
8 Unique withdrawable Design
Features
Freely Programmable Digital Inputs with Adjustable Threshold
Native IEC-61850 with KEMA Certificate for Compliance to Perormance Class P1 Message Type 1A Trip
11 Nos Programmable LED's
Dedicated L/R key on Front HMI
Dedicated Breaker Control (ON/OFF) Push Buttons on the front HM
Flexible Disturbance Recorder
512 Event Records with Time Stamp in FIFO mode
32 Fault records with time Stamp in FIFO Mode
Web HMI Feature
Optional Arc Protection
RoHS Compliant

Page 1 of 1








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IEC 76 --1
Power Transformers- General
IS 2026 (Part 1)
Power Transformers- General

IEC 76 2 Power Transformers-


Temperature rise

IS 2026 (Part 2) Power Transformers-


Temperature rise

IEC 76 3 Power Transformers- Insulation


level & dielectric tests IS

IS-2026 (Part 3) Power Transformers- Insulation


level & dielectric tests

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Power Transformers- Guide to


IEC 76 4 Lighting Impulse & Switching
Impulse Testing
IS 2026 (Part 4) Power Transformers- Terminal
marking, tappings & Connections
IEC 76-5
Power Transformer- Ability to
withstand Short Circuit

IEC 76 8 Power Transformer-


Application Guide

IEC 76 10 Power Transformer-


Determination of Sound Level

IEC 85 Thermal Evaluation and


Classification of Electrical
Insulation

IEC 99 1 Surge Arresters

IEC 137 Bushings for Alternating


Voltages above 1000V

IS 2026 (Part 5) Power Transformers-


Transformer/Reactor bushings
Minimum external clearance in
air specification

IEC 214 Tap Changer

IEC 296 Unused Mineral Insulating Oils


for Transformers and
switchgears

IS 335 Insulating Oils

IS 2099 Bushings for Alternating Power


Transformer

IS 3639 Fittings & Accessories for


Power Transformers

IEC 542 Application Guide for On-load


Tap Changer

IS 8478 Application Guide for OLTC

IEC 354 Loading Guide for Oil-


Immersed Power Transformers

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Guide for Loading of Oil Immersed


IS 6600 Transformers
Degree of Protection provided by
IEC 529 Enclosures
Terminal & Tapping Markings for
IEC 616 Power Transformers
Installation and Maintenance of
IS 1886 Transformers
Code of Practice for selection,
I.S. 10028(part I to III) Installation & maintenance of
transformer
Method of determination of electric
I.S. 6792 strength of insulation oil
Code of practice for fire safety of
I.S. 1646 Building (General) Electrical
installation
Code of Practice for Earthing
I.S. 3043
Current Transformers
I.S. 2705
Specification for Gas Operated Relay
I.S. 3637
Industrial Cooling fans
IS. 62720

Indian Electricity Rules

        
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Stage inspection during transformer manufacturing will be carried out


by GNFC. The stages shall be indicated by Vendor at appropriate time
in QAP

Routine Tests

During manufacture and on completion, all transformers shall be


subjected to all the routine tests in accordance with latest IEC 60076 and IS
2026 P-1 with their respective different parts.

In addition, the following tests shall be performed on each transformer:

9.2.1.1. Transformer tank with coolers shall be tested for leaks with
normal head of oil plus 35 KN/m2 for a period of 8 hours. If any leak
occurs, the test shall be conducted again after all leaks have been
repaired

9.2.1.2. During fabrication stage, the tank shall be pressure tested with air
at a pressure corresponding to twice the normal head of oil or
normal pressure plus 35KN/m2 whichever is lower for a period of
one hour. Also the tank designed for full vacuum shall be tested
for maximum internal pressure of 3.33KN/m2 for one hour. The
permanent delection of lat plates shall not exceed CB:IP specified
figures on release of excess pressure of pressure test and on release of
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vacuum

9.2.1.3. Ater assembly, each core shall be pressure tested for one minute
at 2KV (r.m.s.) A.C. between an bolts, side plates, structural steel works
and the core

9.2.1.4. The wiring for auxiliary power and control circuitry shall be
subjected to withstand one minute power frequency test with 2.0KV
(r.m.s.) to earth

9.2.1.5. Dielectric special tests as per IEC60076-3

9.2.1.6. Determination of capacitances windings-to-earth and between


windings

9.2.1.7. Frequency Response Analysis test (This test shall also be


undertaken by the manufacturer at site after transformer is installed)

9.2.1.8. Measurement of acoustic sound level

9.2.1.9. Measurement of power consumption of fans and pumps

9.2.1.10. Measurement of zero sequence impedance(s) on three-phase unit

9.2.1.11. Measurement of dissipation factor (an delta) of insulation system


capacitances

9.3. Type Tests

9.3.1. In addition to routine test and acceptance test, type test as per IEC 60076
and IS 2026 will be witnessed by GNFC for one transformer of each type
and rating ordered to the bidder. Vendor shall offer quote separate price
for all the type test separately

9.4. Miscellaneous

9.4.1. All component parts and auxiliary equipment such as oil, bushings, C.Ts
etc. shall be routine tested as per relevant Indian Standards

9.5. Witness Test

9.5.1. Tests shall be performed in presence of consultant / Purchaser's


representative if so desired by the consultant / Purchaser. The Contractor
shall give at least seven (7) days' advance notice of the date when the tests
are to be carried out

9.5.2. The purchaser's/consultant's inspectors shall be granted the rights for


inspection at any stage of manufacture and testing

9.5.3. Purchaser / Consultant will require the presence of his nominated


representative to witness the final inspection and tests. The supplier shall

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inform the date of such tests at least four weeks in advance

9.5.4. Following witness test shall be performed on each transformer:

9.5.4.1. Vacuum withstand test

9.5.4.2. Pressure and leakage test

9.5.4.3. Inter-winding impedance measurement test

9.5.4.4. PRV operation test

9.5.4.5. Temperature rise test for HV winding, LV winding and average


oil temperature rise test

9.5.4.6. Measurement of harmonics of no load current test

9.5.4.7. HV tests for core bolt to core fixer and core fixer to core foot

9.5.4.8. Impulse withstand test

9.5.4.9. Acoustic noise level measurement test shall be carried out as per
IEC 551. Noise level measurement at 20 different locations at the
distance of 0.3 Mtr and 2 Mtr of the principal radiating surface shall
be carried out and average value shall be derived form these
measurements

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DatasheetIndicatingGNFCrequirementsfor3.3/0.433KVTransformer

Sr.no Description Unit Requirement vendorremark

A Climaticconditioin
1 design&ambienttemperature c 50c
2 altitude Mtrs 19aboveMSL
3 relativehumidity % 90Avg.inonemonth
4 annualrainfall mm 15002000
5 environment hot&humid

B Technicalparticulars
6 nameofmanufacturer
7 service outdoor
8 ratedKVAasperIS2026
a)HVwinding KVA
b)IVwinding KVA N.A
c)LVwinding KVA
9 ratedvoltage
a)HVwinding KV 3.3kv10%
b)IVwinding KV N.A
c)LVwinding KV 0.433+/10%
10 ratedfrequency Hz 50Hz+5%to5%
11 noofphases 3phase/4wires
12 connections
a)HVwinding delta
b)IVwinding N.A
c)LVwinding star
13 connectionsymbol
a)HVIVwinding N.A
b)HVLVwinding dyn11
14 incaseofOFFcircuitvariation
a)OFFcircuittapswitch (5)%instepof2.5%
b)OFFcircuitlinks
15 detailofonloadtapchanger
a)make
b)type
c)rating
i)ratedvoltage volt
ii)ratedcurrent amp.
iii)stepvoltag
iv)numbersofstepps.
d)control
e)auxiliarysupplydetails
f)voltagecontrol
g)paralleloperation
h)protectivedevices
i)approximateoverallweight kg
j)approximateoveralldimation mm
k)approximateoverallquantityofoil liter.
16 methodoftapchangecontrol N.A
a)manuallocal yes
b)electricallocal
c)electricalremote
d)automatic
17 tapping
a)range (5)%instepof2.5%
b)nos.ofsteps 5
c)forhighvoltagevariation required
d)forintermediatevoltagevariation N.A
e)forlowvoltagevariation N.A
18 systemofgrounding
a)HVwinding N.A
b)LVwinding solidlyearthrd
19 faultlevel
a)HVside MVA 26.5kAfor3sec
b)LVside MVA 50kAfor1sec
20 referenceambienttemperature
a)designtemperature c 50c
b)maximumambientairtemperature c 48c
c)maximumdailyaverageambientairtemperature c 39.25c
d)maximumyearlyweightedaverageambienttemperature c 27.8c
e)Minimumambientairtemperature c 13.2c
i)maximumcoolingwatertemperature c N.A
21 typeofcooling ONAN
22 temperaturerise
a)topoil c 45c
b)winding c 55c
23 totallossesatratedvoltageatprincipaltaping&ratedfrequency KW
24 componentlosses.
a)nolodlossesatratedvoltageatprincipaltaping&ratedfrequency KW
b)loadlossesatratedcurrentatprincipaltappingat75c KW
25 impedancevoltage(atretedcurrentforprincipaltapping)
a)HVIV % N.A
b)HVLV %
c)ILLV % N.A
26 zerophasesequenceimpedance(estimated) %
27 reactanceTratedcurrent&ratedfrequency.
a)HVIV % N.A
b)HVLV %
c)ILLV % N.A
28 noloadcurrentatratedvoltage&ratedfrequency AMPS
29 inputtocoolingplant KW N.A
30 insulationlevel
i)separatesourcepowerfrequencyvoltagewithstand
a)HVwinding kvpeak
b)IVwinding kvpeak N.A
c)LVwinding kvpeak
ii)includedovervoltagewithstand
a)HVwinding kvpeak
b)IVwinding kvpeak N.A
c)LVwinding kvpeak
iii)fullwavelightningimpulsewithstandvoltage
a)HVwinding kvpeak
b)IVwinding kvpeak N.A
c)LVwinding kvpeak
iv)switchingimpulsewithstandvoltage
a)HVwinding kvpeak
b)IVwinding kvpeak N.A
c)LVwinding kvpeak
31 stabilizing/tertiarywinding N.A
a)ratedvoltage KV
b)normalrating KVA
c)normalrating(expressedaspercentofmainwindingratinginthecaseof
stabilizingwinding) %
d)deltaclosedinside/outsideinthecaseofstabilizingwinding
32 efficienciesat75catunitypowerfactor
a)fullload %
b)at3/4fullload %
c)at1/2fullload %
33 loadatwhichmaxx.efficiencyshalloccur KW
34 maximumefficiency %
35 regulationatfullloadat75c
a)atunitypowerfactor %
b)at0.9powerfactor %
c)at0.8powerfactor %
36 equipmentforONANorONAF/ONANcooling
a)state
i)radiatoronmainbank
ii)separateenclosedtypecooler
b)stateonanratingincaseofmixedcooling N.A
37 numbersofcoolerorcoolerbankpertransformer
38 ratingofeachcoolerorcoolerbank
39 terminalarrangement
a)highvoltage bushingmounted
b)intermediatevoltage N.A
c)lowvoltage Cables
d)neutral
40 approximatemasses
a)core&winding kg
b)tank,fitting&accessories kg
c)oil kg
d)totalmass kg
41 approximatequantityofoilrequiredforfirstfilling liter.
42 approximateoveralldimation
a)length mm
b)breadth mm
c)Height mm
43 dispatchdetail
a)approximatemassofheaviestpackage kg
b)approximatedimensionoflargestpackage
i)length mm
ii)bredth mm
iii)height mm
44 untankingheight mm
45 transformerbushingvoltageclass
a)HVwinding kv
b)HVwindingneutral kv
c)LVwinding kv
46 creepagedistance mm/kv
47 cable/conductor/busbarsize sq.mm
48 painting
49 bidirectionalrailwheel/roller
50 radiators
51 detailsoffitting&accessories
a)oillevelgauge
b)buchholzrelay
c)oiltemperature
d)windingtemperature
e)anyother
52 noiselevel db
magnetizinginrushcurrent(peak)underworseconditionofresidual
53 magnetism&instantofswitching KA
54 thermaltimeconstant Hrs.
55 max.fluxdensityincoreatratedvoltage tesla
56 currentdensityatratedload
a)HVwinding
b)LVwinding
57 impulselevelwith1.2/50microseewaveform
a)highvoltage kv
b)lowvoltage kv
58 technicalrequirementofoil
oilshallbe
clear,trasperent&free
fromsuspendedmatter
a)appearanceofoil g/ml orsediment
b)densityat29.5c cSI 0.89max
c)kinematicviscosityat27c 27max
d)flashpoint,pmcc c 140min
e)pourpoint c 6max.
f)interfacialtension n/m 0.04min
g)neutralisationvalue
i)totalacidity
ii)inorganicacidity/alkanity mgKOH/gm 0.03max
h)watercontent ppm 50max
i)specificresistance
i)at90c ohmcm 35X1012min
ii)at20c ohmcm 1500X1012min
j)breakdownvoltagenewunfiltered/afterfilteration kv 30/60min
k)dielectricdissipationfactor(tan0at90c 0.002
l)approximateoverallquantityofoil
m)corrosivesulphurcopperstrip,140c,19Hrs. noncorrosive
theoilshalllnotcontain
antioxidantadditive
valueof0.05%max
shallberatedas
n)presenceofoxidationinhibitor % absenceofDBPC
o)oxidationstabilityat100c,164hrstotalaciditysludge mgKOH/gm% 0.4X0.1min
p)specificresistanceat27c ohmcm 2.5X1012min
q)resistivityat90c ohmcm 0.2X1012min
r)dielectricdissipationfactor(ten)at90c 0.2max
s)totalacidity mgKOH/gm 005max
t)totalsludge % 0.05max
59 switchinginrushcurrent&itsduration
60 insulatingmaterial
61 HVturninsulation
62 LVturninsulation
63 HVcoreinsulation
64 LVcoreinsulation
65 tankmaterial

C fitting&accessories
1 name&ratingplate yes
2 digramplate yes
3 aircelltypeconservator(constantoilpressuresystemtype) yes
4 silicageldehydratingbreatherwithoilseal yes
5 plainoillevelgaugewithminimum&fillinglevelmarking yes
150mmdialtypemagneticoilgaugewithlowlevelalarmcontact&minimum
6 &fillinglevelmarking yes
7 trasducerwith420mA(DC)outputforoillevelmonitoring yes
8 thermometerpocket yes
150mmdialtypeoiltemp.indicatorwithalarm&tripcontact&maximum
9 readingpointer,perfectcontrolmakemodel:PC252 yes
150mmdialtypewindingtemp.indicatorwithalarm&tripcontact&
10 maximumreadingpointer,perfectcontrolmakemodel:PC252 yes
11 pressurereliefvalvewithtripcontact(alltoexplosionvent) yes

12 trasducerwith420mA(DC)outputforwinding&oiltemperaturemonitoring yes
13 inspectioncover yes
14 airreleaseplug yes

15 explosionvent,doublediapharmwithsightglass&pressureequalizingpipe. yes
16 pressurereliefvalvewithpressureswitch(2NOcontacts) yes

17 weatherprotectioncanopywithadequatewiringspaceshallbeprovided. yes
reedtypebuchholzrelaywithtesting&samplingcocks&alarm&trip
18 contacts. yes
19 isolatingvalvesontankside&conservatorsideofbuchholzrelay. yes
valveswithtwosideflangeconnectionwithboltedblindplate(threadedpipe
20 extensionnotacceptable)
21 filtervalvetop yes
22 filtervalvebottom yes
23 drainvalve yes
24 samplingvalve yes
25 liftinglugs. yes
26 jackingpads yes
27 towingholeswithlugs yes
28 earthterminals2nos. flanged&broadgauge
29 bidirectionalrollers(flanged/flat)(broadgauge) yes
30 weatherproofmarshlingbox,completewithwiringfromdevices yes
31 transformercapableofwithstanding140%ratedvoltagefor5sec. yes

32 transformercorestabilityforworkingat6%frequency&+10%voltage yes
33 handholeofsufficientsizeforaccesstointeriorofthetank yes
34 ladderwithsafetydeviceforaccesstothetopoftransformertank no
coolerunitscompletewithvalves,fans,supportingstructurewithfixing&
35 foundationboltsetc.asrequired&coolercontrolpanel. no
tapchanginggearcompletewithtappositionindicator,operationcounter
36 etc. no
forOLTCgear,oilsurgerelaywithshutoffvalve,localcontrolcabinet&
37 remote(RTCC)panel. no
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TDI process substation - 3.3 KV switchboard - HVSB 753A - 202 Appendix-G
Annexure-A

3.3KV-2000A-40KA for 3 sec. Existing

VCB VCB VCB 415V


800A 800A Emergency feeder

1C X 300 sqmm cable


3.3/0.433 KV 3.3/0.433 KV
Transformer Transformer
PAC

PMCC
415V-50KA for 1 sec.

To ACB To Auxillary To motors To motors To Auxillary To ACB


operated Loads <= 55KW <= 55KW Loads operated
motors, motors,
>55KW >55KW

PDB MLDB

250A-3P+N+E 250A-3P+N+E
415V-50KA for 1 sec. 415V-50KA for 1 sec.

63A 160A 160A 63A 63A 63A 63A 63A

Notes:
- PMCC shall be drawout type with 3 pole ACBs for motor feeders VCB Vaccuum circuit
>55KW, 3 Pole MCCBs for Motor feeders <=55KW and 4 pole breakers
MCCBs for tie feeders and other auxillary supplies. Air circuit breakers
- The O/G from PMCC to PDB & MLDB and I/Cs of PDBs and
MLDBs shall be 250A MCCB,4 pole(in panel rating, considering MCCB
50deg. C ambient), draw-out feeder to be provided with O/L, S.C.
and earthfault protection.
- PDB and LDB are fixed type, single front, non drawout panels.


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Manufacturer shall carry out routine tests as per relevant IS / IEC & submit the
test reports to GNFC. GNFC will carry out inspection and witness all routine and
acceptance test at manufacturers work on the same cable drums.

Following tests are carried out as routine tests on every length of cable

Conductor resistance test

High voltage test for at 3Kv for 5 Min

Physical checks

Megger test before and after HV test with 500 V Megger

Following type test shall be carried out at manufacturers work

Tensile test for aluminum

Conductor resistance test

Physical test for Insulation

Physical test for outer PVC sheath

Test for amour wires

Test for thickness of insulation shield & sheath

High Voltage test

Heating Cycle Test

Flammability test (As per IS 10810 part-53)

Acceptance test as per IS-7098(Part 1)

Following additional test shall be carried out at manufacturer`s work for FRLSH-C2 :

Oxygen index test

Temperature index test

Acid gas generation

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Rodent & termite attack test

Type test certificate shall be provided for similar rating not earlier than 5 years along
with the offer

Vendor shall submit QA/QC plan for approval by client/consultant. All inspection/test
shall be performed as per QA/QC plan

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IS 325
Three phase induction motors
IEC 34.12
Starting Performance of Single
Speed Phase Cage Induction
Motors for Voltages upto and
Including 600V

IEEMA 19-2000 Energy efficient Induction


motors 3 phase squirrel cage

IS 12615 Induction motor - Energy


efficient 3 phase squirrel cage
specification

IEEMA 7-1987 Standard for Induction motors


driving compressors

IS 3682 Performance for mines

IEC 34 Rotating Electrical Machines


VDE 0530
Specification of electrical
machine
BS 2613
Electrical performance of
rotating electrical machines

IS 4722 Rotating electrical machines

IEC 34.5 Classification of Degree of


Protection Provided by
Enclosure

IS 4691 Degree of protection for


electrical machinery

IEC 34.7 Symbols for Type of


Construction and Mounting
Arrangements of rotating
machinery
  
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IS 2253 Types of construction and


mounting of motors

IEC 72 Dimensions and Output Ratings


for Foot Mounted Electrical
Machines

IS 1231 Dimensions of three-phase foot


mounted induction motors

IS 2223 Dimensions of flange mounted


AC induction motors

IS 2254 Dimensions of vertical shaft


motors for pumps

IS 4029 Guide for testing 3 phase


induction motors

IEC 34.2 Methods for Determining


Losses and Efficiency of
Rotating Electrical machinery
from tests

IS 4889 Methods of determination of


efficiency of rotating electrical
machinery

IS 12075 Mechanical vibration of rotating


electrical machines
measurements evaluation and
limits of vibration severity

IEC 34.9 Noise Limits


Permissible limits of noise level for
IS 12065 rotating electrical machines
Values of performance characteristics
IS 8789 for 3 phase induction motors
Designation of methods of cooling
IS 6362 for rotating electrical machines
Classification of Hazardous areas
IS 5572 (Other than mining) for electrical
installations
Electrical Apparatus for Explosive
IEC 79 Gas Atmosphere
Flameproof enclosures for electrical
IS 2148 apparatus
Construction and Test of Electrical
IEC 79.7 Apparatus-Type of Protection e
Specification for the construction of
VDE 0171 electrical apparatus for explosive gas
  
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atmosphere
Construction & testing of electrical
IS 6381 apparatus with Type of Protection 'e'
Electrical Apparatus with Type of
IEC 79.15 Protection n
Specification for 3 phase Induction
IS 9628 motors with type of protection n
Rotating electrical machines
IEC 60034(P30)

IS 12615


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IEC 79.10

EN 60079.10

NEC 505


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Full voltage starting
current of motors
shall not exceed
700%.for motor rated
up to and including
15 KW and 600% for
motors rated above
15 KW, without any
/^/ tolerance

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SPECIFICATION FOR WEATHERPROOF LOCAL CONTROL STATIONS


!

! ! !
c) Continuity and operation test.

d) HV test at 2 KV for one minute.


DOCUMENT SCHEDULE
7.8 Following type test shall be carried out and witness by GNFC/IBIC on selected
sample from the entire lot. Price of type test shall be inclusive in basic price.

a) HYDROTESTING : On one sample of each type.

b) Enclosure protection : On one sample of each type.

8.0 DOCUMENTS AND DRAWINGS

8.1 Bidders shall submit document and drawing as per below schedule:

Sr Description With offer For Approval Final


No documents
Hard Soft Hard Soft Hard Soft
1 Signed and stamped copy of 2 1 0 0 0 0
technical specification (All
pages)
2 GA drawing showing plan, front, 2 1 2 1 6 1
elevations, CS view, component
and mounting details etc.
3 Schematic wiring drawings in line 2 1 2 1 6 1
of Annexure-A.
4 Bill of Material for components 2 1 2 1 6 1
5 Test certificates for IP protection, 2 1 2 1 6 1
UV protection, Fire retardancy as
per UL94V0.
6 Routine & type test certificate as 0 0 2 1 6 1
per clause no. 7.0
7 Quality Assurance plan and 2 1 2 1 6 1
inspection test procedure.
8 Signed and stamped copy of 2 1 0 0 0 0
deviation sheet attached at
Annexure-C.
(If there is no deviation than fill
with no deviation in sheet and
submit signed stamp copy)

Page 9/23!
Unconditional acceptance by Bidder"!######################################################
!
!

SPECIFICATION FOR WEATHERPROOF LOCAL CONTROL STATIONS


!

! ! !

Page 10/23!
Unconditional acceptance by Bidder"!######################################################
!
!

SPECIFICATION FOR WEATHERPROOF LOCAL CONTROL STATIONS


!

! ! !

Page 11/23!
Unconditional acceptance by Bidder"!######################################################
!
!

SPECIFICATION FOR WEATHERPROOF LOCAL CONTROL STATIONS


!

! ! !

Page 12/23!
Unconditional acceptance by Bidder"!######################################################
!
!

SPECIFICATION FOR WEATHERPROOF LOCAL CONTROL STATIONS


!

! ! !
Annexure-B

Drawing, Certificate submission Index format


MOC to be
Sr Drg. No. & specified by
Description Certifications for offered equipment
no Catalog No. Bidder against
items
Certificate of Ingress protection
Local control station
With start and stop Certificate for UL94V0
1
push button without
Ammeter (TYPE A1) International certifications

Certificate of Ingress protection


Local control station
With start and stop Certificate for UL94V0
2
push button with
Ammeter (TYPE B1) International certifications

Certificate of Ingress protection


Local control station
With Emergency Certificate for UL94V0
3
stop push button
(TYPE T1 International certifications

Page 13/23!
Unconditional acceptance by Bidder"!######################################################
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Ref. No.

Rev. Descrption By Check Appr Date


Electrical Engineering

Project Name :

Project No. R1 For Enquiry GNFC GNFC GNFC


DATA SHEET FOR G.I. / Al CABLE TRAYS
A SITE CONDITION
1 Site Location Dahej - Gujarat (India)
2 Design Ambient 500 C
3 Altitude ~ 19 mtrs above MSL
4 Earthquake zone Seismic zone - III, Ssismic Co-eff. : 0.04
5 Climate Costal, Hot, humid, highly corrosive & chemical dust laden.
6 Humidity 90% RH average in one month and vapor pressure ~ 1018 mbar
Max. Rainfall : 65 mm/hr
7 Rain Fall
Annual Average : 1000 mm
B GENERAL BIDDER CONFIRMATION
1 Make *
2 Location Outdoor
C TRAYS & ACEESSORIES BIDDER CONFIRMATION
1 Type Ladder type cable tray
a Material G. I.
b Applicable standard for Material As per specification & applicable IS.
c Quantity As per Attachment - I (Price Schedule)
d Standard Length 3 meter
e Size
f Rung Spacing 300 mm
g Rung Width x Height As per Drawing - EL-SDD-077
h Maximum loading (kg / m) As per Specification
i Reference drawing EL-SDD-120-077
2 Type Perforated type cable tray BIDDER CONFIRMATION
a Material Aluminum
b Applicable standard for Material As per specification & applicable IS
c Quantity
d Standard Length 3 meter
e Size
f Maximum loading (kg / m) As per Specification
g Reference drawing EL-SDD-120-078
3 Tray covers BIDDER CONFIRMATION
a Material of construction
i. G.I For Ladder type tray
ii. Aluminum For Perforated tray
b Width
c Thickness 1.6 m.m. (minimum)
d Standard length 3050 m.m.
Aluminimum Clamps with necessary SS304
e Suitable to respective tray size
hardware (considering at every 1.5 meter)
D HARDWARE
1 Nuts, Bolts, Washers
a Applicable standards As per specification & applicable IS.
b Material SS 304
2 Coupler plates
a For Ladder type 2.5 mm thick
b For Perforated type 2.5 mm thick
c Material Same as tray material
3 Z clamps for ladder type tray
a Material Aluminium

Unconditional acceptance by bidder________________________________________________________________ 1 of 2


Ref. No.

Rev. Descrption By Check Appr Date


Electrical Engineering

Project Name :
Project No. R1 For Enquiry GNFC GNFC GNFC
DATA SHEET FOR G.I. / Al CABLE TRAYS
F TESTING & INSPECTION
Shall be performed on one sample of each
1 Routine Test:
size.
a) Physical & dimensional checks Required
b) Deflection load test Required
Shall be perfored on ramdomly selected
2 Non-destructive test (hammer test)
sample

a As per IS - 2629
i) Peeling hammer 210g. Required
ii) knife edge test, share edge. Required
As per IS-3203,zinc coating thickness
b Required
measured with magnetic guages reading
3 Uniformity test (P & EECE test) as per IS - Shall be performed on one sample of each
2633 size.
Shall be performed on one sample of each
4 Mass of zinc test
size.

NOTES:
1 Vendor shall furnish thickness based on relevant loading & deflection criteria.

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Unconditional acceptance by bidder________________________________________________________________ 2 of 2
CLASSIFICATION:
Q - WITH BID.
C - FOR REVIEW / COMMENTS / APPROVAL AFTER LOI/PO.
F - FINAL CERTIFIED AFTER FINAL APPROVAL
P - PDF (GNFC)
H - HARD PRINTS / COPIES. (GNFC)
R - INDICATES CD/DVD IN PDF & EDITABLE FORMAT (GNFC)
QUANTITY REQUIRED

Serial
Drawing / Data /Documents
Q C F
No. By By
P H P H Weeks R H Weeks

Filled data sheet of Technical &


1 Performance Particulars 1+1 3+4 1+1 4+4 2 1+2 1+6 2

Detailed catalogues & technical


2 1+1 3+4 1+1 4+4 2 1+2 1+6 2
literature.
Detailed drawings (including
3 sectional) for all type of trays & 1+1 3+4 1+1 4+4 2 1+2 1+6 2
accessories.
All test certificates as per
4 1+1 3+4 1+1 4+4 2 1+2 1+6 2
relevant IS standards

5 Other technical particulars. 1+1 3+4 1+1 4+4 2 1+2 1+6 2

6 Performance Data. 1+1 3+4 1+1 4+4 2 1+2 1+6 2

Test certificates as specified in


7 1+1 4+4 2 1+2 1+6 2
general specification
Guarantee certificates material
8 1+2 1+6 2
& loading strength

9 Manufacturing bar chart 1+1 4+4 2 1+2 1+6 2

10 QAP 1+1 4+4 2 1+2 1+6 2

Note: Drawings shall be in AUTOCAD-R4 Editable copy


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1. Z-Clamp (Typical) 20

2. Tray Cover (Typical)

12 mm

3. Clamp for Tray Cover Fixing (Typical)

25 x 3 mm



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SPECIFICATIONS FOR 70W MH LIGHTING FITTING FOR HAZARDOUS AREA
(Ex-nR/Ex-d LIGHT FITTING).
Sr. Parameters Compliance/Specifications
No.
1 Electrical system & ambient conditions
(a) Voltage 240VAC +/- 10%
(b) Frequency 50Hz, +3% to -6%
(c) Fault Level 63A HRC Fuse Protected
(d) System P + N + E, Solidly grounded
(e) Ambient operating Temperature - 500C
conditions Relative humidity - Average 90% in one month, average vapor
pressure 18 mbar
Air quality - Presence of corrosive gases, Urea/CAN/ANP dust,
Carbon soot
(f) Area of application For out door installation
2 Hazardous area details
(a) Classification of BIS- 5572 - Zone-2 (2009)
hazardous area having
flammable gases/ vapors
(b) Gas group IS/IEC-60079-12 IIA, IIB, IIC
( c) Temperature class IS/ IEC 60079-0 - 2004 T3
(d) Type of protection Non sparking Restricted breathing Ex-nR & Ex-d
required
3 Specification of fitting
(a) Type Ex-NR & Ex-d, Weather proof & dust proof non integral
well glass luminaries suitable for 1 X 70 W Metal Halide lamp
(b) Lamp data ( Coated 70W single ended metal halide lamp having color
only) temperature of 3700-4000 deg. K. The lamp is to be
supplied with fitting only.


( c) Lamp holder Lamp holder shall have anti vibration type terminals and anti
loosening arrangement for lamp. The making & breaking of
contact shall take place in sealed flameproof chamber.

The lamp holder shall have test certificate of CIMFR and


approval of PESO for installation in hazardous area. Vendor to
submit copy of CIMFR test certificate.

4 Specific requirements
(a) Ingress protection
Minimum IP-65- IS 13947: Part 1: 1993 Reaffirmed-2004
Superseding-IS 2147 and IS 4237 & IS 12063 : 1987
Reaffirmed 2004.
(b) Material of construction Aluminum alloy LM-6
Minimum thickness 3 mm
Sr. Parameters Compliance/Specifications
No.
(c) Construction Die cast
(d) Glass assembly Made from heat resistant toughened glass type A made from
borosilicate as per IS/IEC-60079-0
5 mm dia. hot dip GI wire guard to be provided
Hinge able glass assembly with chain arrangement / hook
(e) Dimensions & Catalog no. Vendor to furnish
(f) Cable entry One no. inch E.T. from side
(g) Terminals Phase & neutral anti loosening, vibration proof suitable for 2.5
sq.mm. Copper conductor
The terminals shall be tested by CIMFR and approved by
PESO(CCE).
(h) Wiring Lamp holder is to be prewired upto terminal block with 1.5 sqmm
class H insulated/fiber glass insulated wire
(i) Cable glands One no. flameproof (Exd) gas group IIC, weather proof,
aluminum anodized, double compression, manufactured out of
extruded aluminum bar cable gland with PVC shroud having
inch E.T. nipple suitable for 3C X 2.5 sq.mm. XLPE insulated
copper conductor armored cable. Cable size, nipple size & thread
type shall be punched on the gland.
(j) Plug 1 no. Flameproof (Exd) aluminum inch ET thread size to plug
the unused spare entry.
(k) Gasket Endless made of silicon rubber only.
(l) Paint Epoxy powder coating by electro static process in shade no. 692
of IS-5 on external surface & internal surface shall be painted
with white paint.
(m) Hardware- all internal & SS 304 The hardware shall have plain & spring washer. The bolt
external shall have hexagonal head with cheese head for screwdriver
operation. The SS inserts shall be provided to prevent
jamming of hardware.

SS INSERT shall be provided during process of die-casting only.


(n) Earthing 1 no. internal having screw size of M6. Internal earthing is to be
provided with SS insert.
(o) Name plate Stainless steel
(p) Mounting * 12mm SS 304 bolt suspension from top
* 1 no. 12 mm stainless steel bolt of suitable length shall be
provided
(q) Mounting clamp Clamp made from 5 mm thick epoxy painted M. S shall be
provided for ceiling mounting.
(r) Reflector- internal Anodized aluminum mirror optic

(s) Photometry curve and Vendor to submit photometry curve and data of efficiency of
efficiency of fitting fitting.
5 Certification/ approvals
Sr. Parameters Compliance/Specifications
No.
(a) CIMFR test report Vendor to submit copy of test report as per relevant IS/IEC
(b) PESO approval Vendor to submit copy of PESO(CCE) approval
6 Documentation
(a) Final documents * GA drawing with dimensions and internal wiring scheme
* Bill of material with technical details
* Internal test certificate
* Copy of CIMFR test certificate
* Copy of PESO(CCE) approval
* Quality assurance plan
* Operation & maintenance manual
(b) Final documents Six sets of hard copies and two sets of soft copies in AUTO CAD
& in DVD/CD of above documents shall be submitted.

THREADED TYPE PARTS NOT ACCEPTABLE (FOR EG. GLASS DOME


FIXING ARRANGEMENT ETC. SHALL BE BOLTED TYPE ONLY)

       
      
      

Sr. Parameters Compliance/Specifications


No.
1 Electrical system & ambient conditions
(a) Voltage 240VAC +/- 10%
(b) Frequency 50Hz, +3% to -6%
(c) Fault Level 63A HRC Fuse Protected
(d) System P + N + E, Solidly grounded
(e) Ambient operating Temperature - 500C
conditions Relative humidity - Average 90% in one month, average vapor
pressure 18 mbar
Air quality - Presence of corrosive gases, Urea/CAN/ANP dust,
Carbon soot
(f) Area of application For out door installation
2 Hazardous area details
(a) Classification of BIS- 5572 (2009) - Zone-2
hazardous area having
flammable gases / vapors
(b) Gas group IS/ IEC 60079-12 2004 - IIA, IIB & IIC
( c) Temperature class IS/ IEC 60079-0 - 2004 T3
(d) Type of protection IS/IEC 60079-1 Flameproof d
required
3 Specification of control gear box
(a) Type Flame proof, weather proof & dust proof and control gear box
suitable for 1 X 70 W Metal Halide lamp. Threaded type cover
not acceptable.
(b) Ingress protection Minimun IP-65 IS 13947:Part 1: 1993 Reaffirmed-2004
Superseding IS 2147 and IS-4237
(c) Material of construction Aluminum alloy LM-6
Minimum 3 mm thick
(d) Construction Die cast
(e) Dimensions in mm & Vendor to furnish
Catalog no.
(f) Cable entry Three nos. inch E.T. from bottom. Center to center distance
between holes shall be minimum 30 mm.
(g) Terminals * 6 nos. Phase, neutral & earth anti loosening terminals suitable
for 2.5 sq.mm. copper conductor for mains connection and loop-in
loop-out wiring catalog no.
* 3 nos. phase, neutral & earth anti loosening terminals suitable
for 2.5 sq.mm. For lamp, Earthing terminal must be green in color
with permanent short link. Terminals to be tested by CMRS and
approved by CCE
(h) Wiring Pre wired up to terminal blocks with 1.5 sq.mm. class H insulated
/ fiber glass insulated wire. as per wiring shown on Ballast only.
(i) Cable glands Three nos. flame proof (EXd) gas group IIC, weather proof,
Sr. Parameters Compliance/Specifications
No.
aluminum anodized, double compression, manufactured out of
extruded aluminum bar cable gland with PVC shroud having
inch E.T. nipple suitable for 3C X 2.5 sq.mm. XLPE insulated
copper conductor armored cable. Cable size, nipple size & thread
type shall be punched on the gland.
(j) Plug 1 no. flame proof (EX d) aluminum inch ET thread size to plug
the unused entry.
(k) Gasket End less made of silicone rubber only.
(l) Paint Epoxy powder coating by electro static process in shade no. 692 of
IS-5 on external surface & internal surface shall be painted with
white paint.

(m) Hardware- all internal & SS 304 The hardware shall have plain & spring washer. The bolt
external shall have hexagonal head with cheese head for screwdriver
operation. The SS inserts shall be provided to prevent jamming
of hardware.
SS INSERT shall be provided during process of die-casting only.
(n) Earthing 2 nos. internal having screw size of M6. Internal earthing is to be
provided with SS insert.
(o) Name plate Stainless steel
(p) Mounting Mounting Lugs with holes suitable for M6 bolts
(q) Canopy Made from 1 mm thick SS 304 as per drawing attached.
Jack bolt arrangement Jack bolt arrangement shall be provided
4 Accessories
(a) Igniter Venture make: 0&L Max Lead Capacitance (pf) 1000 pf.
Suitable for 70W metal halide lamp
Suitable for lamp connection away by maximum 10 meters
with XLPE insulated 2.5 sq.mm. copper conductor cable
* Type- Three wire type
(b ) Capacitor * For power factor correction
* Vendor to specify make & rating of capacitor
(c ) Ballast *Suitable for 70 W metal halide lamp VENTUREPDNH
/RZORVVGHVLJQ9HQGRUWRIXUQLVKYDOXHRIZDWWORVV
* Class F insulated with temperature rise OLPLWWRGHJ&RYHU
DPELHQWWHPSHUDWXUHRIGHJ&
* Open type
* Suitable for 3 wire type igniter

(d) Fuse 2 nos. Siemens make fuse base with fuse carrier type 3NW 20
NNSF and Siemens make 2 A HRC fuse type 3NW NS 2
5 Certification/ approvals
(a) CIMFR / CPRI / ERTL Vendor to submit copy of test report DVSHU,6,(&
test report
(b) PESO approval Vendor to submit copy of PESO approval
Sr. Parameters Compliance/Specifications
No.
6 Documentation
(a) Final documents * GA drawing with dimensions and internal wiring scheme
* Bill of material with technical details
* Internal test certificate
* Copy of CIMFR test certificate
* Copy of PESO(CCE) approval
* Quality assurance plan
* Operation & maintenance manual
(b) Final documents Six sets of hard copies and two sets of soft copies in AUTO CAD
& in DVD/CD of above documents shall be submitted

THREADED TYPE PARTS NOT ACCEPTABLE (FOR EG. CG BOX


COVER ETC. SHALL BE BOLTED TYPE ONLY)
Component make and type shall be as per bellow only.

&RPSRQHQW 0DNH 0RGHOQXPEHU


:%DOODVW 9HQWXUH +6'L+
,JQLWHU 9HQWXUH 0& L Max Lead Capacitance
(pf) 1000 pf.
:0+3URWHFWHGODPS 9HQWXUH +,3(:&8/8896.
)XVH EDVH ZLWK 16 W\SH 6LHPHQV 1:116)
+5&IXVHOLQN
3KDVH DQG QHXWUDO
:DJR 
WHUPLQDOV
VKRUWOLQN :DJR 
QR(DUWKLQJWHUPLQDOV :DJR 
Project n - Unit Material code Serial N Rev. Page

00766 902 JSS 1693 01 00 3 / 17

General Supply Specifications for LV Variable Speed Drive

TABLE OF CONTENTS
The present document or drawing is property of TECHNIP KT INDIA LTD. and shall not, under any circumstances, be totally or partially, directly or indirectly, transferred, reproduced, copied,

1. GENERAL ......................................................................................................................4
disclosed or used, without its prior written consent, for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use.

1.1 DEFINITIONS AND STANDARDS ......................................................................4


1.2 SPECIFICATIONS ..............................................................................................4
1.3 STANDARDS ......................................................................................................4
1.4 DOCUMENT REQUIREMENTS..........................................................................5

2. PROJECT.......................................................................................................................6
2.1 CLIMATIC CONDITIONS AND ENVIRONMENTAL INFLUENCES....................6

3. DESIGN..........................................................................................................................6
3.1 GENERAL ...........................................................................................................6
3.2 OPERATING CONDITIONS:...............................................................................6
3.3 AMBIENT CONDITIONS .....................................................................................7
3.4 POWER SUPPLY FEATURES ...........................................................................7
3.5 MOTOR & DRIVE CO-ORDINATION..................................................................8
3.6 CABLING...........................................................................................................13
3.7 HARMONIC LIMITS & HARMONICS CONTROL .............................................14
3.8 RADIO FREQUENCY INTERFERENCE (RFI) .................................................14
3.9 EARTHING........................................................................................................14

4. CONSTRUCTION AND FABRICATION ......................................................................14


4.1 ENCLOSURE ....................................................................................................14
4.2 SAFETY FEATURES ........................................................................................15
4.3 COMPONENT LAYOUT....................................................................................16
4.4 MISCELLANEOUS............................................................................................16
4.5 PAINTING .........................................................................................................17

5. INSPECTION AND TESTS ..........................................................................................17


5.1 FABRICATION AND QUALITY CONTROL PLAN AND INSPECTIONS ..........17
5.2 TEST PROCEDURE .........................................................................................17

6. PACKING .....................................................................................................................17
Project n - Unit Material code Serial N Rev. Page

00766 902 JSS 1693 01 00 4 / 17

General Supply Specifications for LV Variable Speed Drive

1. GENERAL
The present document or drawing is property of TECHNIP KT INDIA LTD. and shall not, under any circumstances, be totally or partially, directly or indirectly, transferred, reproduced, copied,

1.1 DEFINITIONS AND STANDARDS


disclosed or used, without its prior written consent, for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use.

This specification along with the relevant data sheet covers the requirement for supply of
AC Variable Speed Drive (VSD) system.

1.2 SPECIFICATIONS

If any conflict arises among the documents, the datasheet / Scope of supply will prevail
over the others including this Specification.

Manufacturer must declare in the offer any exception and / or deviation from this
specification. The lack of any declaration and / or deviation will be considered as full
compliance with the general supply rule.

1.3 STANDARDS
All equipments and components of VSD unit shall comply with the relevant Indian
Standards / current editions of relevant latest IEC specifications and in particular to
following standards:

STANDARDS TITLE
IEC 146 Semiconductor Converters General
Requirements and Line commutated
converters
IS 13703 Low voltage fuses for voltages not
Exceeding 100V AC or 1500V DC Part 1
and 2.
IS 13703 Part(4) Fuses for protection of semiconductors
IS 1248 Electrical Indicating Instruments
BS 2709 (IEC 119) Electrical performance of semiconductor
rectifiers (Metal Rectifiers)
BS 4417 (IEC 146) Semi Conductor Rectifier equipment
IS 8623 (IEC 439) Low voltage switchgear and control gear
assemblies
IS 694 (IEC 228) PVC insulated cable for working voltages
upto and including 100V
BS 9720 Custom built transformers and inductors of
assessed quality
IS 3700 Essential ratings and characteristics of
semiconductor devices.
IS 5001 Guidelines for preparation of drawings for
semiconductor devices.
IS 4411 Code of Designation of Semiconductor
Devices
Project n - Unit Material code Serial N Rev. Page

00766 902 JSS 1693 01 00 5 / 17

General Supply Specifications for LV Variable Speed Drive

IS 5469 Code of Practice of use of Semiconductor


Junction Devices
The present document or drawing is property of TECHNIP KT INDIA LTD. and shall not, under any circumstances, be totally or partially, directly or indirectly, transferred, reproduced, copied,

IS 3751 Letters and Symbols for Semiconductor


disclosed or used, without its prior written consent, for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use.

Devices
IS 13947 Low Voltage Switchgear and Controlgear

IEEE 444 Protection standard for converter


IEEE 519 Harmonic control and reactive
compensation of converter

The design and operational features of LV Variable Speed AC Drives and its associated
equipment shall also comply with the provisions of the latest issue of the Indian electricity
Rules and other relevant statutory acts and Regulations. The supplier shall wherever
necessary, make suitable modifications in the equipment to comply with the above.

1.4 DOCUMENT REQUIREMENTS

This section of the Technical Specification is complementary to the "Document requirements


form", part of the Requisition. The purpose is to complete the list of documents to be provided
by the Vendor and define more specifically their contents.

x Any changes in subsequent revisions shall be clearly marked with revision markers (e.g.
triangles and/or clouds). Major changes shall be described in the index/revision sheet.
x Each multiple sheet document shall be preceded by a cover sheet and an index revision
sheet.
Documents to be submitted in Bid stage:
x General arrangement drawings showing :
Plan and sectional view showing outline dimensions,
Cable entry openings,
Weights and door openings,
Test certificates for standard prototype performance.

Documents to be submitted for approval, in addition to the above:


x Front and cross section views showing arrangement details of equipment and terminals
and with a bill of material for all equipment.
x Fixing/foundation details,

x Schematic diagram indicating terminal number for external connections and block
diagram of control system.
x Detailed diagram of converter showing layout of power semiconductors, fuses, heat
sinks, cooling system etc.
x Detailed diagram of complete inverter. This shall be based on approved schematic
drawing. The correctness of this drawing shall be the responsibility of the vendor.
x Details of testing procedures for power semiconductors and power converters as per
standards/ code of practice for approval.
Project n - Unit Material code Serial N Rev. Page

00766 902 JSS 1693 01 00 6 / 17

General Supply Specifications for LV Variable Speed Drive

x Test certificates for brought out items and QAP for the entire equipment.
x The Vendor shall complete the Purchaser's data sheet(s) with the following information:
The present document or drawing is property of TECHNIP KT INDIA LTD. and shall not, under any circumstances, be totally or partially, directly or indirectly, transferred, reproduced, copied,

Data indicated with "*" under the heading "General data"


disclosed or used, without its prior written consent, for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use.

All data requested under the heading "Data from vendor".

Final submission before/ alongwith dispatch in addition to all of the above:

x Operation and maintenance manuals.


x Manufacturers technical literature on various equipments supplied.
x Test certificates for the cabinet and all individual equipments and performance load
tests.

2. PROJECT
2.1 CLIMATIC CONDITIONS AND ENVIRONMENTAL INFLUENCES

Design minimum temperature : +10 C


Design maximum temperature : +50 C
Relative humidity : 100 %
Altitude above sea level : 19 m
Environmental influences : Industrial (refinery), coastal

The equipment shall be suitable for the site conditions, in combination with the ambient
temperature range, indicated on the individual data sheet or this Technical Specification
and be constructed in full compliance with the applicable standard(s). Design ambient
temperature shall be 50 0C for all electrical equipment.

3. DESIGN
3.1 GENERAL

The Vendor is obliged to inform the Purchaser in writing of any specific requirement to ensure
safe and satisfactory operation of the goods.

The goods shall be supplied complete with all accessories and associated equipment
necessary for safe and trouble-free continuous operation under all operating and ambient
conditions specified in the Documents.

3.2 OPERATING CONDITIONS:

The following voltage levels and conditions are prevailing at site:


Project n - Unit Material code Serial N Rev. Page

00766 902 JSS 1693 01 00 7 / 17

General Supply Specifications for LV Variable Speed Drive

Voltage Usage Remarks


415 V (10%), 3Ph, 50 Hz x Motors rated less than 150 36 MVA max. design
The present document or drawing is property of TECHNIP KT INDIA LTD. and shall not, under any circumstances, be totally or partially, directly or indirectly, transferred, reproduced, copied,

(+3% and -6%), TN-S system, kW (DOL) fault level (short time
combined variation of voltage x Sub-distribution boards rating 50 KA, 1 sec.)
disclosed or used, without its prior written consent, for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use.

and frequency (10%),


unbalance voltage (2.5%).
415 V (10%), 3PNE, 50 Hz x Main feeders lighting
(+3% and -6%), TN-S system, x Outlets
combined variation of voltage
and frequency (10%).

Control voltage of contactors for x Control voltage MCC


motor ratings upto 55 kW to be contactors
230 V AC from UPS. Output
variation max. UPS + 1%
voltage.
Control voltage for circuit x Control voltage MCC CBs
breakers, 220 V DC. Voltage
variation max. + 1%.

Unless otherwise specified VSD shall be suitable for rated capacity and short circuit rating as
per relevant IS under the ambient conditions in data sheet without exceeding the permissible
temperature rise and without any detrimental effect on any part.

3.3 AMBIENT CONDITIONS


The Variable Speed AC Drives shall be suitable for indoor installation with typical
atmosphere of chemical plant or refinery (dusty, marine and corrosive). The VSD shall be
suitable for operation at ambient conditions stated at 2.1 above satisfactorily.

3.4 POWER SUPPLY FEATURES


The equipment shall be designed for continuous operation from AC supply source,
including variations in supply voltage, frequency as specified in data sheet and as stated in
3.2 above

Typically VSD shall be provided with inbuilt battery back up for the DC link or an UPS of
suitable rating to ensure that the drive does not trip during under voltage stated above.
Alternatively, if only capacitors are provided, specific calculation basis shall be provided to
ensure drive ride through for 50 % voltage dip for 1 second.

The inverter unit shall have inherent self protection against transient over voltages
introduced by input power supply and against short circuits, open circuits, earth faults at
output terminals.

Vendor shall provide information on level of harmonics presented to the supply system by
inverter as called for in data sheets. Necessary measures shall be provided to limit the
harmonics as specified in Clause No. 3.7.
Project n - Unit Material code Serial N Rev. Page

00766 902 JSS 1693 01 00 8 / 17

General Supply Specifications for LV Variable Speed Drive

3.5 MOTOR & DRIVE CO-ORDINATION


The present document or drawing is property of TECHNIP KT INDIA LTD. and shall not, under any circumstances, be totally or partially, directly or indirectly, transferred, reproduced, copied,

3.5.1 General Requirements


disclosed or used, without its prior written consent, for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use.

Wherever supply of motor is included in vendors scope along with the VSD, the same will
be indicated on Scope of supply / data sheet. Supply of motor shall be as per General
Supply specification and data sheet enclosed with Scope of supply of VSD.

Unless specified elsewhere, the main drive electric motor shall be capable of operating
continuously at any of the load/speed conditions of the driven equipment within the range
stated on VSD data sheets. Vendor shall state derating factor, if any, for the motor, based
on information given in datasheets.

The system shall be capable of withstanding the thermal and dynamic stresses and the
transient mechanical torques resulting from short circuit.

The system shall be either speed, torque or power controlled as dictated by the driven
equipment.

Separate cooling fan motor, if required shall also be as per the standard requirement for
main motor.

Motor shall be provided with Winding RTD for temperature indication in VSD. Motor shall
be so selected that the motor temperature with due consideration of harmonic losses shall
not rise beyond its Temperature class(T3) for Hazardous Area classified motors.

Power, control and communication components shall be housed in different compartments


in the drive unit.

Vendor shall indicate the minimum, maximum length, type and size of cable between the
drive and the motor for satisfactory operation.

3.5.2 Specific Requirements

The responsibility for coordination of motor and VSD design with the load/speed and load /
torque requirements will be with VSD Vendor. Vendor shall be responsible for this drive
coordination, irrespective of whether the motor is supplied or not by the VSD Vendor in
particular to the following:

x To ensure that main drive motor and VSD are both adequately rated and sized for the
drive requirements stated and to recommend alternative configurations where
appropriate (like separate cooling fan, choice of frequency range etc.).

x One additional spare VSD for each type and rating shall be provided with all power and
control cables suitably wired up to plug such that in the event of failure and one VSD the
power and control plugs could be inserted at suitable points in the failed VSD such that
the spare VSD becomes operationally ready.

x To ensure that the motor design is suitable for temperature rise limited to Class B limits
for Class F insulation taking into consideration the additional harmonic losses.
Project n - Unit Material code Serial N Rev. Page

00766 902 JSS 1693 01 00 9 / 17

General Supply Specifications for LV Variable Speed Drive

x To ensure that the motor shall be constructed to withstand torque pulsations resulting
from current harmonics.
The present document or drawing is property of TECHNIP KT INDIA LTD. and shall not, under any circumstances, be totally or partially, directly or indirectly, transferred, reproduced, copied,

x To ensure that the motor mechanical design shall be suitable for 20% overspeed above
disclosed or used, without its prior written consent, for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use.

rated induction speed.

x To arrange, if specified in the Scope of supply / Data sheet where necessary for testing
of motor with VSD unit to confirm compliance with requirements of load, noise, vibration,
temperature rise, temperature class and hazardous area certification.

x To ensure smooth running of motors at all possible speed.

3.5.3 Data Requirements

Drive Data enclosed with data sheets, will generally give following information:

Torque / Speed characteristics of driven equipment.

Driven equipment BkW.

Maximum locked rotor torque required at motor shaft.

Speed range required.

GD value of driven equipment.

3.5.4 Power Supply Arrangement

Unless stated otherwise, the VSD will be fed from an Air Circuit Breaker.

Unless otherwise specified, output voltage shall be within +/- 2 % under steady state
condition and +/- 10% under transient condition of 100% step load change with recovery
time of 5 ms.

The drive shall be able to accelerate the load over the full speed range of the speed torque
curves and with incoming line voltage regulation of +/- 10%.

The frequency regulation shall be +/- 0.02 % of rated maximum frequency under steady
state and +/- 0.5 % during transient condition.

3.5.5 Drive System Controls

a) The system shall be suitable for single quadrant operation and the range of speed
variation shall be with range 1:100 unless otherwise specified. The static speed
control error shall be in the range of r0.1% to r0.5% of motor nominal speed and
dynamic speed control error shall be r0.4% at 100% load torque step.

b) Depending on speed regulation and range the supplier shall select the appropriate
Drive Control

Open Loop Control without speed feedback.


Project n - Unit Material code Serial N Rev. Page

00766 902 JSS 1693 01 00 10 / 17

General Supply Specifications for LV Variable Speed Drive

Sensor less Vector Control by calculated motor speed instead of having an actual
The present document or drawing is property of TECHNIP KT INDIA LTD. and shall not, under any circumstances, be totally or partially, directly or indirectly, transferred, reproduced, copied,

speed measurement from an encoder.


disclosed or used, without its prior written consent, for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use.

c) The relationship between the speed, torque or power and the reference signal within
the operational speed shall be linear.

A reference signal of 4 mA shall correspond with the minimum operational speed or


torque or power and a reference signal of 20 mA with the maximum operational
speed or torque or power of the VSD.

Upon complete loss of users speed/torque/power reference signal, the drive shall
automatically run at constant speed/torque/power as determined by the last reference
available prior to loss of signal.

The VSD shall be self-powered without the aid of auxiliary supplies, with the
exception of space heaters.

The fault diagnostic and indication logic shall be equipped with a memory function to
retain information regarding the cause of tripping of the VSD.

The control system shall be immune from spikes and voltage distortions due to
operational and/or fault conditions within the VSD.

d) The system shall be equipped with an automatic restart facility which will restart the
system in case of voltage dip over 20% or power interruptions less than 4 seconds,
upon recovery of the voltage to 95% with a facility to block the automatic restart.
Reacceleration feature for the system shall be provided . The number of starts shall
be as specified in motor data sheet.

e) The power controller shall be regulated to always start the motor in the forward
direction. Logic shall be provided to prevent reverse rotation of the motor.

f) The variable speed AC drive cubicle shall be provided with following but not limited to:

Incoming fuse / switch unit


Start/ stop P.B. (front of panel - FOP)
Speed Control (FOP)
Raise/Lower P.B. (FOP)
Audio visual alarms as described below (FOP)
Power on indicating lamps (FOP)
Output kW meter (FOP)
Input voltmeter and ammeter (FOP)
Output speed, frequency indicating meter (FOP)
Alarm acknowledge / reset P.B.
Terminals for remote control / indication
Standard options (to be stated by vendor)
Provision for wiring external sequential / process interlocks / signals for starting
/running/ tripping.
Facilities for on site adjustments for current limit, trip time in current limit maximum
frequency (speed), minimum frequency (speed) start compensation (volt boost), slip
(IR) compensation, Accuracy rate, deceleration rate others (if any).
Project n - Unit Material code Serial N Rev. Page

00766 902 JSS 1693 01 00 11 / 17

General Supply Specifications for LV Variable Speed Drive

Slip (IR) Compensation: Provide frequency compensation to maintain speed under


varying load conditions (more significant for smaller motors with higher natural slip at
The present document or drawing is property of TECHNIP KT INDIA LTD. and shall not, under any circumstances, be totally or partially, directly or indirectly, transferred, reproduced, copied,

full load).
Start compensation (voltage boost): Compensates for increased effect of stator
disclosed or used, without its prior written consent, for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use.

resistance at very low frequencies improving starting torque.

Any other equipment necessary for the AC Drives shall be included by the
manufacturer.

h) The variable speed AC drive shall be provided with (but not limited to) following
Alarms and Annunciations:

Low DC Link Voltage


Main ac failure
IGBT Fail
Inverter overload
IGBT high temperature
Panel/Motor Cooling failure
Motor Grouped Fault
Motor failed to Start
Motor over speed

i) The variable speed AC drive shall be provided with (but not limited to) following
indications:

Drive On
Drive Off
AC mains ON
Rectifier output ON
Inverter ON
System ready to start
Motor zero speed

j) Drives shall have the following input and output functions as a minimum unless
specified otherwise:

1. Inputs from dry contacts.

a. Motor start (N.O.)


b. Motor stop (N.C.)
c. Jog enable (N.O.)

2. 4-20 mA speed reference

3. Outputs

a. Run status (N.O.)*


b. Drive fault (N.C.)*
c. Isolated 4-20 mA speed signal.
d. Isolated 4-20 mA programmable analog output. (torque, power, current, etc.)

*Note: Both contact functions must be independent.


Project n - Unit Material code Serial N Rev. Page

00766 902 JSS 1693 01 00 12 / 17

General Supply Specifications for LV Variable Speed Drive

Vendor shall specify signal/ communication cable maximum length requirement so that the
drive operation is not affected.
The present document or drawing is property of TECHNIP KT INDIA LTD. and shall not, under any circumstances, be totally or partially, directly or indirectly, transferred, reproduced, copied,

3.5.6 Speed Control


disclosed or used, without its prior written consent, for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use.

The system shall be suitable for continuous speed control of the motors in single or multiple
drives system as per data sheet and soft start feature shall be provide reduce the
disturbances in the electrical system.

3.5.7 Fault diagnostic and indication

Fault diagnostic, indication and sequence of event recording facility shall be built into the
system to supervise the operation and failure of the system. Sufficient memory back up
shall be provided to keep the information.

SOR facility shall be considered as an option, if not available as a standard feature. The
resolution time shall be 1msec.

3.5.8 The salient basic design, functional and performance features of converter

a) Insulated Gate Bipolar Transistor (IGBT) switched pulse width modulated (PWM)
converter to operate at automatically produced fixed ratio of V/F throughout the
complete speed range of motor.

b) Independently adjustable volts boost at low end of frequency.

c) Separately adjustable ramp up and ramp down time.

d) Comprehensive protection and fault display circuit including under / over voltage
(supply), output under / over voltage, overspeed or overfrequency, over current /
short circuit / earth fault, transient overvoltage, motor electrical fault (short circuit,
earth fault, overload, phase unbalance, single phasing, locked rotor, phase reversal),
Heat sink overtemperature, High Motor Temperature, internal / external fault
provisions for tripping unit. All the above faults shall also be paralleled and connected
to terminal block for remote grouped fault indication.

e) Any additional requirement for remote output signals shall be as detailed out in data
sheet.

i) The drive shall be preferably self cooled without ventilating fans. However in case
forced ventilation is offered, the same shall include redundant ventilating fans and the
system shall shut down in case of ventilating system failure.

j) Maximum noise level from the complete drive system at 1 metre distance under rated
load with all normal cooling fans shall not exceed 70 dB.

k) Converter Transformer shall be provided as required. The transformation ratio,


impedance, taps and secondary voltage shall be chosen by the vendor to optimise
system performance.
Project n - Unit Material code Serial N Rev. Page

00766 902 JSS 1693 01 00 13 / 17

General Supply Specifications for LV Variable Speed Drive

The converter transformer shall be suitable for operation with the non-sinusoidal
current waves and DC components under normal and abnormal conditions of the
The present document or drawing is property of TECHNIP KT INDIA LTD. and shall not, under any circumstances, be totally or partially, directly or indirectly, transferred, reproduced, copied,

system without exceeding the temperature.


disclosed or used, without its prior written consent, for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use.

In case of 12 pulse converter system, the impedances of transformer with two


secondary windings shall be selected to ensure equal load / current sharing between
the two secondary transformer windings, the converters and the motor windings
under all operational conditions including starting.

l) DC Link reactor shall be designed to sufficiently decouple the rectifier and


inverter portion of the converter and to limit fault currents in this circuit.

m) It shall be possible to vary the speed of the drive either manually or in auto mode from
the drive. If specified in data sheet, it shall also be possible to start / stop, raise /
lower the speed of the drive from Local Control Station.

n) The system shall have a provision to control and monitor through the owners
control panel / operator console (DCS). Unless otherwise specified in the data sheet,
VSD shall be provided with RS485 /RS232 serial link port for communication with
remote system (DCS). Universal MODBUS protocol can be used for transmitting the
data.

p) Flux optimization: This feature shall be provided to reduce total energy consumption
and motor noise level in case of drive operating below nominal load.

q) The system shall have power loss ride through feature In case of power supply
failure, the drive system shall continue to operate by using the kinetic energy of the
motor.

r) The controller shall avoid certain motor speeds or speed bands (critical speeds) to
avoid mechanical resonance problems.

s) Speed controller tuning (Auto / Manual) feature to be provided.

3.6 CABLING
The incomer of VSD shall be 3 core Al armoured cable. The cable from VSD to Motor shall
be 3C or 4C, Al, XLPE armoured cable.

Limits of motor cable lengths shall be specified by the manufacturer so that

a) Cable characteristic impedance matches the impedance of the motor to minimize


transient over voltage caused by reflected waves.

b) Cable charging capacitive current shall be limited especially for small motors.

Cable lengths shall be specified for both shielded (braided or armoured) cable and
unshielded cable.
Project n - Unit Material code Serial N Rev. Page

00766 902 JSS 1693 01 00 14 / 17

General Supply Specifications for LV Variable Speed Drive

In case the cable length requirement is more than the above limits, necessary cost-
effective measures like Output Reactors or Output dv/dt filters are to be considered by the
The present document or drawing is property of TECHNIP KT INDIA LTD. and shall not, under any circumstances, be totally or partially, directly or indirectly, transferred, reproduced, copied,

manufacturer. As a general it shall be envisaged to limit the cable length from the VSD to
the motor upto 300m.
disclosed or used, without its prior written consent, for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use.

3.7 HARMONIC LIMITS & HARMONICS CONTROL


3.7.1 Current Harmonics

Current harmonics shall be as per IEEE519 Table 10.3 Current distortion limits for
general distribution. In order to meet this requirement suitable arrangement like input filters
in addition to input choke if needed are to be considered by the vendor.

3.7.2 Voltage Harmonics

The total Harmonic distortion (THD) shall be d 5% as per table 10.2 of IEEE 519.
If the harmonics exceed the above limits, any of the following suitable cost effective
measures shall be employed:

a) Isolation Transformers with suitable winding connections for circulating triple N


harmonics.
b) Phase shifted Isolation transformers shall be utilized such that one-half of VSD load
connected to feeder transformer will be phase shifted by 30 degrees.
c) Using higher pulse converters.
d) Using Harmonic filters.

3.8 RADIO FREQUENCY INTERFERENCE (RFI)


The RFI limits generated from high frequency PWM inverter shall be as per relevant
standards.
Manufacturer should specify special installation standards if any to avoid conduction of
common mode RF noise to surroundings.
Radio Frequency Filters shall be considered if RFI is not controlled by other measures.

3.9 EARTHING
Earthing of VSD units shall be done as per vendors recommendation. Vendor has to
submit necessary drawings / documents for the same.
Manufacturer shall recommend all feasible measures to prevent conduction of all types of
Common mode noise to ground.

4. CONSTRUCTION AND FABRICATION


4.1 ENCLOSURE
Variable Speed Drives shall be floor mounting, free standing, totally enclosed and dust,
damp and vermin proof. Non-deteriorating gaskets to be used between all adjacent units
and beneath all covers and doors for dust proofing.
Project n - Unit Material code Serial N Rev. Page

00766 902 JSS 1693 01 00 15 / 17

General Supply Specifications for LV Variable Speed Drive

The VSD shall be provided with integral base frame for each vertical panel. The Panel
The present document or drawing is property of TECHNIP KT INDIA LTD. and shall not, under any circumstances, be totally or partially, directly or indirectly, transferred, reproduced, copied,

integral base frame shall be suitable for directly bolting with the help of foundation bolts and
shall be suitable for tack welding to the Purchasers floor mounted channels.
disclosed or used, without its prior written consent, for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use.

Sheet steel used for fabrication shall be cold rolled, cold annealed. Minimum thickness of
various members shall be as follows :-

Base Frame / Channel : 3 mm


Load Bearing Members : 2.5 mm
Internal Partitions : 2.0 mm

Construction of VSD shall be rigid and robust. All steel work shall be flawless and have a
smooth finish.

All hardware shall be corrosion resistant. All joints, connection of the panels member shall
be made by Cadmium plated high quality steel bolts, nuts and washers, secured against
loosening. Star washers shall be used to ensure effective continuity.

Suitable removable type lifting hooks and / or jacking pad shall be provided on each panel
or shipping section for each of lifting of VSD. These hooks when removed shall not leave
any open area in the panels.

Hinges provided for doors shall not be visible from front.

Non-magnetic cable gland plate shall be provided in case of single core cables.

All indicating instruments and relays shall be mounted within 400 mm to 1900 mm height.

The enclosure shall be suitable for specified environment and climatic conditions. The
cubicle shall be fully assembled, factory wired, floor / wall mounting, cubicle protection for
minimum IP42 if not specified otherwise in the data sheets.

It shall be suitable for installation in reasonably clean room without any special conditioning
of ambience.
The converter cabinet shall be self-supporting. The maximum height of the cabinet shall not
exceed 2350 mm excluding fans, fan hoods or ducts and the maximum door width shall be
800 mm.

Converter components should be accessible from the front. A design, which makes use of
modular plug-in/ draw-out assemblies for both the system control electronic equipment and
power electronic equipment.

The converter elements shall be arranged in a logical segregated manner to all easy
recognition of components and safe maintenance work.

4.2 SAFETY FEATURES


All power feed busbars, any live terminals, shall be properly shrouded against accidental
contact while carrying out any maintenance work.
Project n - Unit Material code Serial N Rev. Page

00766 902 JSS 1693 01 00 16 / 17

General Supply Specifications for LV Variable Speed Drive

All terminals which remain live when main isolator is off shall be properly shrouded and
labeled with danger warning.
The present document or drawing is property of TECHNIP KT INDIA LTD. and shall not, under any circumstances, be totally or partially, directly or indirectly, transferred, reproduced, copied,
disclosed or used, without its prior written consent, for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use.

4.3 COMPONENT LAYOUT


The layout of components inside the cubicle shall be done with specific attention to
following aspects:

Layout shall be neat and clean

Easy accessibility to components while carrying out any replacement / maintenance work..
Access for components shall be from front of cubicle.

Safety while carrying out any maintenance work

Shrouds/barriers for live parts

Neat wiring preferably using plastic trunking

4.4 MISCELLANEOUS
All power / control wiring inside cubicle shall be carried out in 1100V grade PVC insulated
flexible copper wires unless otherwise stated. The minimum size for shall control wiring
shall be 1.5 sq.mm. Lower cross section is acceptable in case of special wires (flat cables)
as a vendor standard.

Cabling terminating facilities and terminals shall be suitable for the specified cable type,
gland, and conductor size.

Manufacturer shall provide an undrilled gland plate at bottom of sufficient dimensions to


terminate specified cables.

Positioning of cable terminations shall avoid obstructions and removable covers etc.

All wiring for external connections shall be brought out to individual terminals on a readily
accessible terminal block. All terminals shall be shrouded.

All non current carrying metal work shall be bonded together and connected to an
adequately sized earth bus provided inside the panel. Facility for external earth connection
shall be provided at two points of earth bus.

The unit shall be provided with all necessary labels having black letters on white
background. Warning labels shall have white letters on red background.

Cubicles and components shall be identified by labels. Cubicle designation labels shall be
as per design data sheets.

The colour and finish of cubicle shall be as per manufacturers standards, unless otherwise
stated.

Indicating instruments shall be flush mounting type, SIF 96 size or as per manufacturers
standards.
Project n - Unit Material code Serial N Rev. Page

00766 902 JSS 1693 01 00 17 / 17

General Supply Specifications for LV Variable Speed Drive

Where fan cooling is used, it shall be connected to mains. In case of fan failure cubicle
The present document or drawing is property of TECHNIP KT INDIA LTD. and shall not, under any circumstances, be totally or partially, directly or indirectly, transferred, reproduced, copied,

shall operate satisfactorily at full load without damage or duration to internal components
for specified time.
disclosed or used, without its prior written consent, for any purpose and in any way other than that for which it is specifically furnished or outside the extent of the agreed upon right of use.

4.5 PAINTING
All metal surfaces shall be thoroughly cleaned and de-greased to remove mill scale, rust,
grease and dirt. The under-surface shall be prepared by applying a coat of phosphate paint
and a coat of yellow zinc chromate primer.

After preparation of under surface, the Panel shall be spray painted with two coats of epoxy
based final paint. The colour shade of the final paint shall be shade 692 of IS:5 unless
otherwise specified.

5. INSPECTION AND TESTS


5.1 FABRICATION AND QUALITY CONTROL PLAN AND INSPECTIONS
Inspection and testing activities shall be defined by the Manufacturer on the Fabrication
and quality control plan based on the minimum requirements established on TECHNIP
Inspection and Test Plan ITP if any.

During the manufacturing period, the Variable Speed AC Drives could be subject to
inspection by TECHNIP inspectors or by others appointed by TECHNIP or by the Client.
Accessory material could be subject to inspection too.

The Manufacturer shall allow the free access of inspectors to the workshop, shall give all
information required and shall make available all copies of internal orders to other sub
suppliers.

5.2 TEST PROCEDURE


The tests shall be carried out in Manufacturer workshop at his care and expense.

Test shall be witnessed by GNFC/ Technip at manufacturer workshop.

Even in case client waives to witness the tests the Manufacturer shall draw up the
certificate of the tests carried out containing a full report and all the results and the
measures of the tests.

The tests shall be carried out in accordance with the requirements of IS codes and the
Inspection and Test Plan.

6. PACKING

The VSD panel shall be transported to site in wooden crates. They shall be wrapped with
polythene sheets before being placed in crates to prevent damage.