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BOOK III PART 4.
6 Electrical Works
TABLE OF CONTENT BOOK III PART 4.6 ELECTRICAL WORKS
4.6.1. 4.6.2.
GENERAL ....................................................................................................... 1 POWER SUPPLY SYSTEMS ......................................................................... 3 4.6.2.1. GENERAL......................................................................................... 3 4.6.2.2. RATINGS .......................................................................................... 3 4.6.2.3. SYSTEM STUDIES .......................................................................... 4 4.6.2.4. MAIN GENERATOR AND UNIT SUPPLIES SYSTEM ..................... 4 4.6.2.5. ELECTRICAL AUXILIARIES SYSTEM ............................................. 5 4.6.2.6. ESSENTIAL SUPPLIES SYSTEM.................................................... 6 4.6.2.7. EMERGENCY AC SUPPLIES .......................................................... 7 4.6.2.8. AC AND DC SYSTEM EARTHING ................................................... 8
4.6.3.
CONTROL, PROTECTION AND METERING ................................................ 8 4.6.3.1. CONTROL ........................................................................................ 8 4.6.3.2. PROTECTION .................................................................................. 9 4.6.3.3. TARIFF METERING ....................................................................... 11
4.6.4.
GENERATORS AND ASSOCIATED EQUIPMENT ..................................... 12 4.6.4.1. GENERAL....................................................................................... 12 4.6.4.2. DESIGN REQUIREMENTS ............................................................ 13 4.6.4.3. STATORS ....................................................................................... 16 4.6.4.4. ROTORS ........................................................................................ 17 4.6.4.5. GENERATOR COOLING SYSTEM ................................................ 20 4.6.4.6. EXCITATION SYSTEM .................................................................. 21 4.6.4.7. TESTING ........................................................................................ 23
4.6.5. 4.6.6.
GENERATOR CIRCUIT BREAKER ............................................................. 25 CONNECTION BETWEEN GENERATOR , GENERATOR CIRCUIT BREAKER, GENERATOR TRANSFORMER AND UNIT AUXILIARY TRANSFORMER 27 TRANSFORMERS ........................................................................................ 28 SWITCHGEAR, CONTROL GEAR AND FUSEGEAR ................................. 30 MOTORS ....................................................................................................... 32 BATTERIES AND BATTERY CHARGER .................................................... 34
264.6.7. 4.6.8. 4.6.9. 4.6.10.
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BOOK III PART 4.6 Electrical Works
4.6.11. 4.6.12.
UNINTERRUPTIBLE POWER SUPPLY....................................................... 37 CABLING ...................................................................................................... 38 4.6.12.1. CABLING MANAGEMENT ............................................................. 38 4.6.12.2. CABLING DESIGN ......................................................................... 38 4.6.12.3. CABLE SEGREGATION AND SEPARATION ................................ 39 4.6.12.4. CABLE RATING ............................................................................. 39 4.6.12.5. CABLE SUPPORT AND FIXING SYSTEM .................................... 40 4.6.12.6. CABLE ENDS ................................................................................. 40 4.6.12.7. RACEWAYS SYSTEM ................................................................... 40
4.6.13. 4.6.14. 4.6.15. 4.6.16. 4.6.17. 4.6.18. 4.6.19.
CATHODIC PROTECTION ........................................................................... 41 LIGHTING ..................................................................................................... 42 OUTDOOR GROUNDING ............................................................................. 45 BUILDING, EQUIPMENT GROUNDING AND LIGHTNING PROTECTION 46 COMMUNICATION SYSTEM ....................................................................... 47 EMERGENCY DIESEL GENERATOR ......................................................... 49 20 kV SWITCHGEAR.................................................................................... 53 4.6.19.1. GENERAL....................................................................................... 53 4.6.19.2. RATINGS ........................................................................................ 53 4.6.19.3. PROTECTION ................................................................................ 53 4.6.19.4. CONTROL, ALARMS AND INDICATIONS ..................................... 53 4.6.19.5. INTERLOCKING ............................................................................. 53 4.6.19.6. AC AND DC ESSENTIAL SUPPLIES SYSTEM ............................. 54 4.6.19.7. COMMUNICATIONS ...................................................................... 54
4.6.20. 4.6.21.
CLOSED CIRCUIT TELEVISION (CCTV) FOR OBSERVING AND SECURITY SYSTEM .................................................................................... 55 SUMMARY OF ELECTRICAL SCHEDULES ............................................... 56
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PART 4.6. ELECTRICAL WORKS

4.6.1. GENERAL The Contractor shall design, supply, erect, test and commissioning the electrical equipment and system complete as required by the technical specifications and drawings to be fully functioning as to the satisfaction of the Owner. This section provides basic technical details and minimal acceptable standards which shall be applied to the Electrical equipment supplied as part of the Contract. All equipment designs shall be based on established and proven practice and suitable for tropical application. The Bidder shall fully describe the plant and equipment offered together the operation of the electrical system under normal, emergency, planned maintenance and abnormal/fault conditions. The Contractor shall provide energy / tariff metering compliance with all plant and transmission system requirements. This shall include all the equipment necessary to provide a complete metering system and accuracy according to Owner standard. The systems provided shall be safe under all normal and abnormal operating conditions in respect of danger to personnel and damage to plant, equipment, etc. The electrical systems, plant, equipment cabling etc., provided under this contract shall comply with all relevant International Standards, National (Indonesian) Legislation and Statutory requirements and all standard adopted by PLN. The numbering and color of equipment and system shall according to PLN standard. All data and signals as required by Area Control Center shall be provided. The design shall be such that all maintenance and operational activities may be performed with ease and safety fully in accordance with the Owner Safety Rules and Procedures. Means shall be provided to prevent unauthorized access to equipment. The plant and equipment shall be fully interchangeable between each unit and, where appropriate, between unit and common systems.
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The electrical plant and equipment shall be suitable for operation in its installed environment under all operating conditions and all extremes in the environmental conditions. This shall include measures for protection against insects such as ants and termites, gnawing from rodents and other harmful vermin. Measures to prevent internal condensation such as heaters, silica gel breathers, in particular during shutdown, shall be provided as necessary. All electrical equipment shall have satisfactorily passed all applicable routine, type special tests, in accordance with the IEC standards, relevant National or other acceptable standards. Copies of type test certificates and supporting documentation shall be supplied on request. A color coding system shall be used to identify a.c phase and neutral. d.c. polarity and grounding functions. The system employed shall be subject to approval and be in accordance with National Standards or practice. The electrical systems shall be designed to minimize the generation of harmonics and the effects of electrical interference between power and control/instrumentation circuits, and comply with international requirements on electromagnetic compatibility. No equipment shall cause radio or television interference in excess of the limits specified by National Standards and ClSPR. The Contractor shall include the entire works as described in or implied by the contract document. Any matter missing from the contract document which may be inferred and is obviously necessary for the completion of the works, shall be deemed to be included in the Contract Price. Works shown in the drawings but not mentioned or described in the Technical Specification and/ or Works described in the technical specification but not shown on the drawings will be deemed to be included in this contract and their execution is to be covered by Contract Price. Any conflict between drawings, technical specification or between drawing and technical specification, Owner decision shall governed.
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4.6.2. 4.6.2.1.
POWER SUPPLY SYSTEMS GENERAL The plant electrical shall be based on the use of a Generator Circuit Breaker scheme. Power generated from the steam turbine unit Generator shall be delivered to the 20 kV circuit system through the Generator Circuit Breaker, the Generator Transformer and 20 kV Circuit Breaker. 20 kV Network related criteria for the Generator/Generator transformer unit etc. (for example: voltage regulation range and response, reactance, time constants) shall be defined in co-operation with the Owner Interface arrangements with the existing system grid will be coordinated by the Owner. The above level of co-operation shall apply to these arrangements.
4.6.2.2.
RATINGS The Bidder shall select the system voltage levels to accommodate the range of plant and equipment required. With the exception of the Generator terminal voltage, the nominal voltages and voltage limits shall be in accordance with IEC 38. The Owner standard nominal voltage as the followings shall be adopted for the electrical auxiliary distribution system: 6.3 kVac, 3.3kVac,( 690/400) Vac, ( 400/230 ) Vac, 220 Vdc, 110 Vdc, 48 Vdc, 24 Vdc Control and instrumentation power supplies shall not exceed a nominal voltage to earth of 110 V ac and dc unless otherwise approved. Standard current ratings shall be used in accordance with applicable IEC The circuits shall be adequately rated for the normal (sustained, including where necessary harmonics), and fault currents (including overloads) calculated during the design, and in the case of switchgear, shall be capable of making and breaking current during normal and fault current operations. In particular, due account shall be taken of maximum ambient temperatures and solar heating. The voltage, and where applicable frequency, at the input terminals to plant and equipment shall not vary outside the manufacturer's rated limits during normal operation and shall meet the Owner requirements.
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The plant and equipment shall be designed to achieve and maintain satisfactory operation under such sudden input/output variations of load, voltage and frequency, as may be met under service conditions, including those due to transients, surges, short-circuits and other fault conditions. Insulation co-ordination above 1 kV shall be in accordance with IEC 71 selecting the higher of the standard insulation levels. Below insulation co-ordination shall be in accordance with IEC 664.
4.6.2.3.
SYSTEM STUDIES In order to substantiate that the electrical systems proposed are satisfactory, ac and dc system analysis studies shall be included for the Power Station complex as part of this contract. These shall be completed to the satisfaction of the Owner prior to the ordering of plant. The studies shall include fault levels, load flows, voltage regulator (both steady state and during motor starting) and stability studies. Fault level studies shall take full account of the contribution from motors and the increased fault levels arising from the running of diesel generators in parallel with the supply system during on-load testing. The Bidder, as part of the contract, shall coordinate with the system grid authority and shall initiate system studies to confirm the acceptability of connecting the station to the distribution system. These studies shall comprise of load flow, fault level and transient stability studies in various operational configurations. The studies shall be carried out at the start of the contract with design data to ensure the station design comply with system requirements. These studies shall be repeated at the end of the project with test data, to confirm compliance. Any changes required to the plant or systems to satisfy the system distribution authority shall be the responsibility of the Bidder. Similar system analysis studies undertaken on a previous contract shall also be submitted with the Bidder.
4.6.2.4.
MAIN GENERATOR AND UNIT SUPPLIES SYSTEM Each Main Generator shall be connected to the distribution system through a Generator Transformer. Each Unit Auxiliary Transformer shall
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be rated to supply all the unit auxiliary loads for one unit plus the common auxiliary loads. Each Main Generator/Generator Transformer combination shall be capable of providing the declared unit maximum continuous MW rating over the specified range of power factors and frequency/voltage variations. The voltage on the 20 kV lines of circuit system will normally remain within +/- 5 percent of the nominal value unless abnormal conditions prevail. The minimum voltage is -10 percent and the maximum voltage is +10 percent under abnormal conditions. The Generator shall be capable of operating continuous by at maximum rated KVA output at any power factor between the rated 0.85 power factor lagging and 0.95 leading and at any voltage between 5 percent below and 5 percent above rated volts, within guaranteed temperature limits. The Generator Circuit Breakers shall be provided with automatic and manual synchronizing facilities in the Main Control Room. Manual synchronizing shall include a check feature against operator error. The automatic equipment shall be tested under varying frequency and voltage conditions. Any generator circuit breakers offered must comply with IEEE Std. C37.013-(latest version). An insulation co-ordination study associated with the distribution connection shall be included as part of the contract to demonstrate that adequacy of the over-voltage protection measures applied. The extent of supply shall include any surge protection necessary to protect the substation and generator transformers.
4.6.2.5.
ELECTRICAL AUXILIARIES SYSTEM Electrical power for plant auxiliaries systems shall be supplied through Unit Auxiliary Transformers (UATs). Direct supply of power from Main Generator system to electrical auxiliaries system without using UAT is not permitted. The electrical auxiliaries system shall be designed on the unitized principle. Power for the supply of all the auxiliaries associated with starting and running of each unit shall be supplied from unit switchboards. Similarly, plant which does not have an immediate effect on the running of the unit, shall be supplied from common services switchboards.
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Switchboards (PDC and MCC) shall be provided with a permanent alternative supply where a second supply is needed for flexibility of operation or to cater for planned or forced outages. Where connection is provided between supplies that may be paralleled, but may be out of phase and frequency, check synchronizing shall be provided. Where connection would produce unacceptable fault levels at the switchboard an interlocking system shall be provided to prevent the two supplies being paralleled in the event of operator error. The Bidder shall provide a single line diagram of the power station main electrical system with his offer.
4.6.2.6. 4.6.2.6.1
ESSENTIAL SUPPLIES SYSTEM Design Requirement Essential supplies systems shall be provided to maintain unit output and to protect plant from damage following a loss of supply. These shall be sized to enable the station to be shut down in a safe manner following loss of the distribution supplies and allow supplies to be restored following re-connection.
4.6.2.6.2
DC Supplies DC supplies shall be provided for essential functions such as protection switchgear closing/tripping, alarms, control, emergency drives, emergency lighting, communication equipment etc. The supplies shall be maintained by means of batteries for a minimum period of not less than 2 hours in the event of loss of supply.
4.6.2.6.3
Uninterruptible Power Supplies. AC uninterruptible power supplies shall be provided for essential functions such as instrument, control and computer supplies which because of stringent supply requirements would not provide an adequate level of reliability if operated from the electrical auxiliary system. This shall include loads which are required for post incident monitoring and recordings following a main unit trip and loss of station ac supplies. The supplies shall be maintained for a minimum period of 2 hours. The UPS for the substation shall be capable to maintain for minimum of 8 hours without external ac supplies.
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Each unit uninterruptible power supplies system shall be supplied by one 100% systems of the on-line type capable of supplying the total system load and complete with static transfer switch and maintenance bypass switch. Maintenance and repair of the equipment, excluding batteries, shall not be required more frequently than once annually. The mean time to repair the equipment shall not exceed 2 (two) hours.
4.6.2.7.
EMERGENCY AC SUPPLIES To cater for a prolonged loss of all normal supplies in excess of 2 hours, one 100% diesel generators, complete with all associated auxiliary equipment shall be provided for the station to maintain the essential supplies. For this purpose, the essential load shall include all essential auxiliaries to ensure safe shutdown of the boiler/turbine plant, main offices, and welfare, and maintenance etc., facilities necessary to allow routine station activities to continue. The Bidder shall state and justify the rating proposed for the diesel Generators. The Diesel Generator shall be arranged for an automatic start on loss of normal supplies. The Bidder shall describe the method of disconnecting 'non-essential loads in the event of loss of normal supplies, prior to connection of the essential diesel generator. In addition, facilities shall be provided for manual starting and synchronizing together with on-load testing of each Generator. Precautions shall be taken to limit the effects of third harmonic circulating currents with more than one neutral point connected to earth.
The Diesel Generator shall be provided with facilities for automatic and manual starting, synchronizing and on-load testing of the Generator. The Generator shall have the facility to be operated from the central control room. The Emergency Diesel Generator shall not be used for construction, testing or commissioning purposes. The rating of the Emergency Diesel Generator shall be determined by the Bidder and shall be clearly stated in the Bidder. The Bid Proposal shall provide a full justification for the sizing of the Emergency Diesel Generator and provide an indication of the electrical loads to be connected to it.
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4.6.2.8.
AC AND DC SYSTEM EARTHING The ac systems shall be connected to earth as follows: 1. 2. Generator Transformer MV 20 kV side secondary winding shall be neutrals with- . Neutral Grounding Resistor Main Generator neutrals - earthed through a high resistance to restrict the fault current to a value, usually between 10 and 15 A, that avoids stator lamination damage and does not cause transient oscillations due to arcing faults. Electrical auxiliaries system Transformer LV secondary winding neutrals - solidly earthed. Emergency Diesel Generator LV neutrals shall be the same solidly earthed as other electrical auxiliary system Transformers
3. 4.
The time rating of the grounding resistors shall not be less than 10 seconds. The dc systems shall be either High resistance center-point earthed system or Positive pole earthed systems. Equipment connected to high resistance center-point earthed systems shall be connected through fuses to the positive pole of the system. A removable copper link shall connect the equipment to the negative pole. Single-pole switching shall be on the positive side for all circuit functions. Equipment connected to systems earthed at the positive pole shall be connected through fuses to the negative pole of the system. A removable link shall connect the equipment to the positive pole. Single pole switching shall be: a) b) c) On the negative side for control circuits. On the positive side for indication and alarm circuits, which are dead when the plant is healthy. On the negative side for indication and alarm circuits, which are energized when the plant is healthy
4.6.3. 4.6.3.1.
CONTROL, PROTECTION AND METERING CONTROL All equipment shall be provided with the facility for local control. Remote control of MV switchgear distribution circuits shall be provided from the
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electrical switching panel or discrete LCD/keyboard in the Central Control Room (CCR). Main unit and common switchboards shall be equipped with a microprocessor type monitoring system, enabling voltage current, active power and apparent power of individual circuits and total input powers to be remotely indicated on a LCD. The LCD and associated cabling shall be provided under this contract and the LCD will be located in the CCR. Other monitoring facilities such as circuit-breaker status shall also be provided. The Bidder shall include a description of the facilities provided and any optional facilities which form part of a modem monitoring system for a main switchboard. All necessary isolation points, interlocks, alarms, indications, instrumentation, data logging, condition monitoring/recording equipment, operational metering, test and diagnostic facilities etc, shall be provided for the secure, reliable and safe operation of the electrical systems. Initiating contacts in hard-wired circuits performing essential functions such as main electrical protection and safety interlocking shall operate directly into their associated control circuits and not via secondary devices such as interposing relays. The use of emergency stop switches should be restricted to those instances where it is not practical to make the associated electrical or mechanical plant inherently safe.
4.6.3.2.
PROTECTION The protection system shall comply with relevant international standards and shall be designed so that in the event of faults occurring, the faulty plant is safely disconnected, whilst continuity of supply consistent with system stability is maintained. The selection and setting of protection devices for the auxiliary system shall be based upon the following major requirements: 1. 2. Faults on plant items shall be disconnected as quickly as possible to minimize damage. Faults external to major power sources. e.g. unit transformers, shall only open the circuit breaker controlling these power sources after all other protection nearer the fault has failed.
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3.
4.
5.
Faults internal to major power sources shall cause their circuit breakers to open as fast as possible to ensure that the transmission system can restore itself within the limits of stability. The protection shall be designed to be stable in transient conditions such as motor starting and shall not operate for current surges caused by faults external to the auxiliary system, for which the main generator would recover and the item of plant protected would not be damaged. Protection of plant is designed to match the plant operating characteristics and provide discrimination with other plant.
The following is the minimum requirement for the main protection: 1. 2. 3. 4. 5. 6. 7. 8. 9. Generator Stator Earth Fault Protection Generator Differential Protection Generator Loss of Excitation Protection Generator Reverse Power Protection Generator Overvoltage Protection Generator Rotor Earth Fault Under-frequency Protection Voltage balance - VT Fuse Failure Overcurrent or Overcurrent and Earth Fault Protection
The minimum requirement for all induction motors shall be a thermal overload device (or approved electronic equivalent) with phase unbalance protection. The protection shall permit repeated motor starting. For motors up to 30 kW rating the protection may be provided by industrial pattern devices integral with the motor contactor, and which shall operate for out-of-balance current in accordance with IEC 292-1 Table V1II. Above 30kW rating motor protection relays with a more accurate and easily adjustable overload setting shall be used and shall include instantaneous earth fault elements. The earth fault protection shall be stable for any current surges or transients during motor starting. Where the motor circuit is not protected by primary fuses, then short circuit protection shall be provided by either : 1. 2. instantaneous overcurrent elements of the motor protection relay which trip the motor circuit breaker, or the motor circuit breaker may incorporate instantaneous short circuit protection.
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By agreement, the Generator circulating current protection may include the protection of the Generator Transformer with all the CTs provided by one supplier. A single line diagram of the proposed electrical protection system shall be submitted with the Bidder, together with a tripping logic diagram for the overall protection of each Generator unit. Full details of the protection devices and associated current and voltage transformers being offered shall be submitted with the Bidder, together with the Bidder's proposals for site testing of the electrical protection devices and associated equipment. A list of proposed alarm points shall also be given in the Bidder. During the contract stage, a.c. and d.c. protection circuit diagrams shall be provided for approval. An overall protection co-ordination diagram(s) shall be provided, to demonstrate that with the relay settings proposed, satisfactory discrimination can be achieved between the various protective devices supplied under this contract. The Bidder shall provide the necessary CTs or CT accommodation etc, for the connection, to the Transmission System. Correct discrimination shall be demonstrated. Site testing and functional checks shall be carried out on all relays and their associated CTs, VTs and protection circuits to confirm the correctness of operation of the protection.
4.6.3.3.
TARIFF METERING The Bidder shall provide export/import (bi-directional) metering compliance with all transmission system requirements. This shall include all the equipment necessary to provide a complete metering system and shall be capable of accurately measuring transfer of both active and reactive energy at the high voltage (20 kV) side of each Generator Transformer. Number of meters to be provided shall be two (2), having dedicated assignment of main and back up. The active and reactive energy shall be metered by solid state high precision electricity meters to Class 0.2, summation metering system shall
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also be included for the measurement of net station output i.e., export minus import energy. Discrete, Class 0.2, CTs to IEC 185 S and electromagnetic VTs to IEC 186 S shall be provided for metering only. The instrument transformers and metering devices etc, shall have a combined accuracy of +/-0.5% or better when measured by the meters at full power. Each metering system shall include sealable primary and check digital type meters, data collection and recording facilities. Remote data collection and on-site meter test facilities shall be provided. The metering system shall be powered from the essential supplies system. The primary and check meters shall utilize separate current and voltage transformer inputs for measurement. All data collection and recording facilities shall be time related to a GPS (Global Positioning System) reference source. The metering scheme shall include manufacturer's certification of accuracy for all the metering equipment and Initial calibration of the metering equipment including calculation and recording of voltage and current transformer errors. KWH meter and KVAR meter shall also be provided at the generator output as well as other necessary indication.
4.6.4. 4.6.4.1.
GENERATORS AND ASSOCIATED EQUIPMENT GENERAL The Generator shall be properly designed for application directly coupled to the turbine as its prime mover and to operate continuously at the steam turbine maximum output. The Generator shall be designed to operate safely and reliably and shall be capable of operation as a base load unit, i.e. minimum 8000 hours per annum. The Generator shall be supplied complete with all necessary auxiliary equipment to make a completely functional system and shall include the followings as a minimum : 1. 2. 3. Excitation system complete Generator stator housing Turbine Generator common lubricating system
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4. 5. 6. 7. 8. 9.
Generator cooling system Core monitor Bushing current transformers Terminal enclosure All special tools and instruments for rotor and cooler withdrawal and insertion gear All require instrumentation and controls
The Bidder shall describe the calculation methods and provide results for the following items: 1. 2. 3. 4. Generator reactance and time constant Efficiencies (the method and tolerances shall be subject to the approval of the Owner) Rated load excitation Calculated temperatures at rated load
4.6.4.2. 4.6.4.2.1
DESIGN REQUIREMENTS Rating The Generator and the exciters shall comply with IEC 60034-3 unless otherwise specified. Any deviations from IEC 60034-3 shall be clearly stated in the Bid Proposal. The Generator rated voltage shall be selected by the Bidder. The short circuit ratio based on the no-load excitation current at rated Generator voltage and the short circuit excitation current at rated Generator current shall not be less than 0.58p.u. The Generator shall be capable of continuously supplying 1.05 times its nominal rated output at rated voltage and power factor over the frequency range 48.5 Hz to 50.5 Hz, and at rated frequency and power factor with a voltage variation of +/-5%. It is appreciated that this overload capability could effectively increase the maximum continuous rating of the Generator. The Bidder shall provide full details of the effects of this overload condition. Moreover, the design shall be such as to meet the following condition or requirements:
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1.
2.
Operation at MCR, from 50.5 to 48.5 Hz, at rated load and power factor over a voltage range of 0.95 to 1.05 p.u. within temperature rise limits. Operation over the power factor range 0.85 lag to 0.95 lead.
The Bidder shall provide a diagram showing the permissible loading of the Generator at rated power factor over the specified range of voltage and frequency variations.
4.6.4.2.2
General Design Requirements Each Generator shall be the cylindrical rotor type and together with its excitation system shall be fully interchangeable with other units in the station. The extent of interchangeability shall be stated in the Bid Proposal. The Generator shall be fully capable of operating in parallel with other generating units connected to the transmission system, and if the circumstance arises, individually supplying the local load of an 'island system'. This shall apply during the specified steady state and system transient load conditions and load changes, without active or reactive load oscillations. The Generator shall be designed to withstand the forces and torques imposed during the conditions (a) and (b) listed below without sustaining damaging movement of the stator windings frame or core, or damage to the rotor or other major components. The Bidder shall quote the calculated maximum values of shaft torque occurring during conditions (a), (b) and (c). Design margins shall be stated in the Schedules. The Bidder shall provide curves of shaft torque versus time, with the most arduous fault clearance time identified, for condition (d). a) 3-phase zero-impedance short-circuit suddenly applied at the terminals from rated open-circuit voltage. b) Line-to-line zero-impedance short-circuit suddenly applied at the terminals from rated open-circuit voltage. c) Faulty synchronizing at rated voltage 120 deg out of phase. d) Clearance of system faults leading to the most arduous shaft torque condition.
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The Generator shall be capable of withstanding the effects of system harmonic frequency currents caused by loads such as large arc furnaces located in close proximity to the power station, without harmful deformation of the windings or shafting or other mechanical damage, and without significantly reducing the life of the Generator. The minimum negative sequence capability (I22t) shall be a minimum of 10. The phase ends shall be appropriately marked with the order of phase rotation sequence
4.6.4.2.3
Insulation Class and Temperature Rise The Generator insulation and packing materials shall be designed using Class F materials with class B insulation design temperature rise as defined in IEC Standards. After a 6 hour continuous run at the specified rated terminal output condition, with the cooling medium inlet temperature not exceeding 40C, the Generator temperature rises shall comply with those permitted for the class of insulation material used.
4.6.4.2.4
Control and Instrumentation The Bidder shall include a comprehensive list of the instrumentation to be provided for each Generator and associated equipment. The proposed level of instrumentation and method of indication shall be submitted for Owner review and approval. Calibrated thermocouples shall be provided in the regions of maximum temperature to provide indication of the temperatures of the generator components and the cooling media. The position and number of thermocouples shall be stated in the Bid Proposal. If thermocouples will not be provided for the stator end iron laminating, the Bidder shall demonstrate that the possibility of overheating in that part has been eliminated by design. Leads from thermocouples search coils and vibration transducers shall be brought out to sealed terminal boards mounted on the generator in a position accessible during normal operation of the unit. A minimum of 20% spare terminals shall be provided on the generator terminal boards. All
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terminals shall be suitable for duplex external connections. Indicating and recording equipment will be provided in the CCR via the control system. The rotor temperature shall be determined by a standard method and shall be indicated in the Central Control Room. The equipment shall be suitably damped to indicate a steady rotor temperature when operating on the national system. The damping shall be such, or a time delay be provided, so that alarm signals shall not be initiated under start-up, shut-down, tap changing and other transient loading conditions. The Contractor shall provide the local and CCR display and alarm for Owner approval.
4.6.4.3. 4.6.4.3.1
STATORS Stator Casing and Winding Facilities shall be provided at two positions on the Generator casing for connecting to the isolated phase busbar/station grounding system. Sufficient section of material to safely carry the maximum unrestricted earth fault current shall be provided. The stator core shall be made of high permeability low loss material, insulated on both sides. The material for the stampings, the insulation between stampings, and the procedure adopted in debarring the plates and checking the finished, stampings, shall be such as to eliminate the possibility of interstamping shorts and resultant core faults. The choice of materials, proportioning, clamping, and arrangement of the core in the casing, shall ensure the minimum noise and 100Hz vibration within the core plus the minimum transmission of vibration to the generator foundations, pipes and associated equipment. All fixing and locking components in the ends of the fully assembled Generator shall be non-magnetic. This shall apply to the volume enclosed by the core end plate and corresponding frame rib, the casing wrapper plate and the end shield inner covers. Any magnetic items in this enclosure shall be listed in the Bid Proposal.
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The stator winding shall be star connected with all winding ends brought out. Heaters shall be provided to prevent condensation in the Generator during shutdowns. The winding insulation system shall be designed and manufactured in such a way that it will meet the specified machine life for the given duty cycle. Insulation thickness and coil support structure shall be amply proportioned to withstand continuous operation at the maximum over-voltage, system switching surge voltages and the fault conditions specified in this specification. Class F materials will be used. Materials liable to shrink in the course of time or by heating, and moisture-absorbent materials shall not be used for packing and wedging. The general construction of the stator shall be such as to provide adequate cooling surfaces so that temperatures greater than those permitted for class B insulation do not occur.
The design shall prevent movement of the coils in the slots and the winding overhang under normal operating conditions. It shall eliminate slot discharge and ensure that slot wedge tightness and radial pressure on the coils is maintained to provide satisfactory operation over the life of the plant. The end winding structure shall incorporate provision for re-tightening the end winding clamping after a period of service. The Bidder shall state the re-tightening requirements or provide details of the maintenance free design, as appropriate. The design shall be such that no re-tightening is required between major maintenance overhauls. The methods by which all of the above are achieved shall be described in the Bid Proposal. Full instructions shall be given in the maintenance manual for this work. All equipment necessary for this operation shall be provided under this contract and the re-tightening interval shall be stated in the schedules. The stator slot wedges shall be capable of withstanding the bursting force imposed during the most arduous electrical short-circuit between adjacent coil connections of different phases at the turbine end, such that there is an indeed of fault current from the system.
4.6.4.4. 4.6.4.4.1
ROTORS Rotor and End Ring Forgings
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The rotor shall be manufactured from a single forging, except that separate couplings will be allowed. No castings shall be used in the rotor assembly and the number of small parts shall be minimized. The procedures proposed for inspection of the forgings in order to ensure their soundness and homogeneity shall be stated in the Bid Proposal together with particulars of the thermal treatment proposed. The non-destructive test methods and defect acceptance standards to be employed in the examination of the forgings and finished rotors, including the main shaft, couplings. end rings and all other forgings used in the rotating components of the Generator shall be declared in the Bid Proposal. The center of the shaft forgings may be bored to permit the inspection and testing of the interior. If, following metallurgical examination, it is necessary either to bore a previously unbored rotor, or to increase the bore diameter, it shall he demonstrated that the effect on the magnetic characteristics will not limit the performance of the unit. In the design of the shaft system particular attention shall be given to the quality of surface finish and the avoidance of sharp internal comers which may give rise to high stress concentration. The methods used to prevent stress corrosion cracking, particularly for the end rings, shall be described in the Bid Proposal. In the choice of material for the winding and in the design, manufacture and fitting of the coils, every precaution shall be taken to avoid permanent deformation or electrical faults in the winding under the conditions specified or during prolonged barring. The packing blocks used in the rotor winding shall be entirely suitable for the high temperature and mechanical forces existing in generator rotors. The rotor insulation system shall be of sufficient mechanical strength and flexibility to cope with the stress in service without cracking or otherwise becoming damaged. Attention shall be given to the insulation and securing of the coil connections to avoid vibration and possible failure of either the connections or their insulation. An effective damper winding shall be provided in the rotor and shall be described in the Bid Proposal. It shall be designed to divert negative
Revision 0 Part 4.6 - 18 PT PLNE Small CFSPP
sequence and 50Hz current from the rotor teeth, wedges, pole-faces and end rings. The Generator rotor shall be capable of withstanding without damage a suddenly applied line-to-line short circuit at the generator terminals from rated load and voltage followed by correct operation of the protective gear. A statement of the expected temperature rises and the effective value of I2 2 t assuming the maximum 50 Hz current component, and taking into account the d.c. component shall be provided in the Bid Proposal.
Under steady state and transient conditions of operation temperatures in the rotor shall not be high enough to change permanently the physical properties of the material, nor reduce interference fits to an operationally hazardous level. The Bidder shall state the means proposed to meet this requirement. Assembly and inspection procedures shall be such that the possibility of incorrect assembly leading to reduced negative-sequence capability is minimized, and details of these procedures shall be given in the Bid Proposal. The Bidder shall also state the maximum percentage negative phase sequence value his design will withstand without damage. A suitable discontinuity shall be provided on an accessible part of the rotating shaft system for use as a vibration phase reference. The rotor shaft shall be provided for detecting rotor winding shorted turns in service e.g., air gap search coil or similar device. The rotor shaft shall be earthed. The means by which this is achieved shall be described in the Bid Proposal . The satisfactory and consistent dynamic behavior of the generator rotor shall be assured by the design, manufacturing, testing, balancing and over speeding processes. The Bidder's tests, checks and procedures shall allow for inevitable rotor movements, thermal effects, the difference between test chamber and site supports, and coupling to adjacent rotors. Asymmetric rotor inertia compensation shall be incorporated. There shall be adequate provision for making in-situ correction to the generator rotor balance without major dismantling.
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Part 4.6 - 19
PT PLNE Small CFSPP
4.6.4.5.
GENERATOR COOLING SYSTEM Generator cooling system shall be closed air cooling system.
4.6.4.5.1
Closed Air Cooling System The Generator cooling system shall include all necessary equipment such as coolers, fans, pumps and control apparatus as appropriate for safe and efficient operation of the plant and comply with the requirements of IEC 60034.
Heat shall be extracted from the closed circuit by at least two (2) air - to water heat exchangers. Water for the air- to - water heat exchangers will be taken from the main cooling water system and the heat exchangers shall be of material appropriate to the water quality applicable to the turbine condenser. The heat exchangers shall comply with the relevant requirements of the heat exchanger specified under Closed Cooling Water System. By its location or by means of provision of drip trays and baffles, the design of the cooling water / heat exchanger system shall be such as to prevent the ingress of water into the generator should a tube leak occur.
4.6.4.5.2
Cooling System Control Panels One cooling system control panel and associate instrumentation for controlling and continuously monitoring the air and cooling water shall be provided for each generator. Each panels shall be furnished complete with all the necessary regulating and controlling devices, indicators, alarms, back-lighted window type annunciator of the hermetically sealed type, continuously rated alarm horn, purity, temperature and pressure gauges and recorders, etc. The following local and remote alarms shall be provided, among others, at the control panel : 1. 2. 3. Presence of moisture/water in the cooling air High temperature of cooling air leaving the cooler Low and high temperature of air supply
Annunciators shall be furnished with contacts to signal cooling system troubles to the plant computer alarm system.
4.6.4.6.
EXCITATION SYSTEM The excitation system shall be of either the brushless or static type. The excitation equipment shall be rated for continuous operation over the full range of generator rated conditions and comply with IEC 60034-3 The exciter ceiling voltage shall not be less than 2 p.u. at full load rated conditions. The excitation control equipment shall consist of an automatic voltage regulator (AVR) (with power factor controller). The AVR shall as a minimum, be of the dual auto channel type with manual control device and appropriate auto/manual changeover circuits. The automatic voltage regulator channels shall be of the continuously acting type. The auto channels shall sense all three phases of the generator terminal voltage. Its sensitivity shall be such that it is capable of maintaining the generator terminal voltage within 0.5% of the set value over the whole operating voltage, frequency and load range of the generator and over the operating temperature range. The AVR reference device shall be insensitive to changes in the ambient conditions and to changes in the frequency of generator voltage supplies over the operating range of the equipment. The voltage setting control shall be capable of adjusting the terminal voltage to give the required range. The AVR shall include an under-excitation limiter (VAR limiter) to prevent the excitation being reduced to a level which would endanger synchronous stability during automatic operation. The operating point and stabilizing controls shall be adjustable while the generator is on load. It shall respond to changes in real and reactive power, and to the square of the generator terminal voltage in such a manner that an increase in voltage will permit an increase in leading VAR. A follow up device shall ensure that, should the auto control fail the manual control will take over control with no significant change in excitation current. A balance indicator shall be provided to demonstrate that this feature is operating correctly. An automatic limiter shall prevent the manual controller follow-up device from reducing its setting below the prescribed safe limits of excitation for
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Part 4.6 - 21
PT PLNE Small CFSPP
the generator when under normal control. The operating point of the device shall be adjustable. Quadrature current compensation shall be provided if required to facilitate MVAR sharing between the units of the station. The compensation shall be adjustable and connected so that it can be readily taken out of service if necessary.
During run-up, the generator shall be automatically excited in a gradual controlled manner to rated voltage at rated speed. The voltage/frequency ratio shall be controlled when the generator is not synchronized. The excitation control shall include the following protective devices which remove the faulty equipment from service, trip to manual if necessary, and bring up appropriate alarms and indications: 1. 2. 3. 4. 5. 6. 7. Under-excitation - operates if the converter output is low in relation to demand. Over-excitation - operates if sustained high levels of excitation are attained. Over-current - operates when excessive current draw from the excitation supply. Over Voltage - operates when terminal voltage is high in relation to demand. supply failure - operates if the VT supply is lost. Over-fluxing - operates if the terminal voltage is high in relation to frequency AVR power Supply - Operates if the AVR system power supply fails
The excitation shall be rapidly suppressed in the event of a major fault or main protection trip. When on load the excitation control equipment shall be capable of restoring the generator terminal voltage, in a well damped manner, to within plus or minus 0.5% of the reference value within five seconds. With rated as supply voltage and frequency, the excitation system shall be capable of delivering continuously within temperature rise, any value of field current from zero to 110% of the field current required by the generator at its rated output, power factor and 90% to 107% rated voltage. The performance of the VAR limiter shall be demonstrated by testing its response to a 5% step decrease in reference voltage with the generator
operating just off the limit line. The resulting maximum VAR excursion shall be limited to 30% of its unlimited value.
4.6.4.7. 4.6.4.7.1
TESTING Works Tests The Bidder shall include details of all type and routine tests carried out to demonstrate consistent quality control, in accordance with IEC 60034. The following mechanical tests shall be carried at the manufacturer's works: 1. All steel forgings, stator core plate copper for windings, rotor wedge material, insulation and other specified materials, shall be tested to the manufacturer's approved quality plan. The generator rotor, after being fully machined and slotted, but before being wound, shall be subjected to a rotor stiffness test. The extent of inertia compensation, the resonant frequencies and mode shapes, shall be established from these tests. The tests shall be repeated on the completed rotor. Generator rotors, exciter rotors, and rotating rectifier assemblies, where appropriate, shall be tested for 5 minutes at an over speed of 20% above 50 Hz speed. All generators and exciters shall be assembled at the manufacturers works and run at rated speed. During running tests, vibration monitoring of bearing supports shafts, stator windings, stator core and casing shall be recorded, together with the flow rates and temperatures of bearing oil and of each main cooler circuit.
2.
3.
4.
The following electrical works tests shall be carried during manufacturer: 1. 2. Generator stator bar shall be subject to the routine tests as specified in IEC 60034-3. Tests as part of the quality control on bar dimensions shall include slot portion surface resistance, bar to core resistance and clearance of bar to slot. All terminal bushings shall be tested at a minimum high voltage test level consistent with the requirements of IEC 34. Demonstrate by an approved means that the rotor winding is free from inter turn faults, prior to fitting the end rings, after fitting the end rings and after completing works tests both stationary and at rated speed.
3. 4.
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Electrical works tests on completion of manufacture of the generator shall include the following: 1. 2. 3. 4. 5. 6. 7. 8. Insulation resistance and winding resistance measurement. Open circuit characteristics and losses. Short-circuit characteristics and losses. Open circuit and short circuit heat runs. Rotor impedance tests running and stationary. High voltage pressure tests in accordance with the requirements of IEC34-3. Dielectric loss measurements shall be taken on each phase of the stator winding. Rotor turn integrity test.
In addition to the above tests, on the first of a new or modified design the following type tests shall be carried out. 1. 2. Voltage waveform and harmonic analysis and phase sequence check. Instantaneous short-circuit
The test level shall be 65% of rated open circuit voltage. Electrical works test on completion of manufacture of each exciter and excitation system shall, as applicable, include the following: 1. 2. 3. 4. Rotating exciters subject to those routine tests described above for the completed generator. Load characteristic and stabilization test for permanent magnet generators. High voltage pressure tests on the exciters in accordance with IEC 60034-3. The performance of the field suppression equipment to be demonstrated as part of the works three-phase fault test.
In addition to the above tests, on the first of a new or modified design the following Type Tests shall be carried out: 1. 2. 3. Heat run at rated exciter output. Excitation response test. Combined tests with the automatic voltage regulator to demonstrate response to changes to input signal.
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Part 4.6 - 24
PT PLNE Small CFSPP
4.6.4.7.2
Site Commissioning Test The generator, excitation system, AVR and associated auxiliary systems shall be commissioned to an approved procedure. The site commissioning tests shall include: 1. 2. 3. 4. A dry out followed by high voltage tests at the levels specified IE 60034-3. Full functional checking and setting up of equipment with the generator at standstill. Open circuit testing, including terminal voltage response measurements and the testing of all control and protection facilities. On-load testing, including terminal voltage response measurements at full load rated leading and lagging power factors. Tuning and testing of the MVAR limiter and power system stabilizer. The Bidder shall provide detailed information on his proposals for on-loading testing for compliance with this requirement. Load rejection tests as a type test at least at 50% and 100% full load at the same time as load rejection tests are made on other controls for the turbo generator system. On-load excitation system parameter identification tests as a type test. The Bidder shall state in detail his proposals for compliance with this requirement.
5.
6.
4.6.5.
GENERATOR CIRCUIT BREAKER Generator Circuit Breaker and the associated components shall include but not be limited to the following: 1. 2. 3. 4. Generator Circuit Breaker including isolator and grounding switches. Operating mechanism. All instrumentation and controls. Supporting structures, etc
The Generator Circuit Breaker shall be of SF 6 type or vacuum type, metal clad design having electrically operated circuit breakers, three pole, single throw and shall comply with IEEE std. C37.013 1993 and 1997 for all aspect. The Bidder shall be responsible for the correct selection of the Generator Circuit Breaker, Grounding and Disconnecting Switches. The rating shall take into account the followings :
1. 2. 3.
4.
Max. capability of generator output at 90% voltage plus 10% margin. Transferred surges from HV side of Generator Transformer. Short circuit duties for faults supplied from the system and for fault supplied from the generator taking into account the asymmetrical fault make and fault break requirements. Load rejection from full load and rated power factor.
The calculation method and its results shall be submitted for approval. Circuit breakers shall be equipped with a complete set of necessary accessories for operation and maintenance, including and not be limited to : 1. 2. 3. 4. 5. 6. 7. 8. 9. 4.6.6. Position indicator Operation counter Pressure gauges Pressure switches Lifting devices Low voltage relays for monitoring the power supply to closing and tripping circuits. A complete charge of SF 6 gas for any gas filled portion of the circuit breaker (if require). Pressure switches to detect loss of SF 6 gas pressure (if require). Tools for slow opening and closing of contacts for maintenance
CONNECTION BETWEEN GENERATOR , GENERATOR CIRCUIT BREAKER, GENERATOR TRANSFORMER AND UNIT AUXILIARY TRANSFORMER MV Cable MV Cable shall be used for the primary connections between the Generator Circuit Breaker, Generator Transformer and Unit Auxiliary Transformer plus associated MV switchgear . The connections shall be fully phase isolated and designed to withstand the mechanical and thermal effects of 3-phase short-circuit and unrestricted earth faults at any point. In particular this applies to any tee-off connections which shall be designed to withstand the worst combination of generator and distribution system fault contributions. Any earth bar provided shall be designed to withstand the effects of an unrestricted earth fault at the most onerous point of the system.
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Part 4.6 - 26
PT PLNE Small CFSPP
The conductor temperature at flexible connections shall not exceed the maximum value recommended for the contact materials involved under the worst combination of ambient temperature and load conditions. The enclosure/sheath shall not exceed a safe touch temperature. The bus shall be of the naturally-cooled isolated phase, metal enclosed high current carrying capacity type. Equipment mounted out-of-doors shall be completely weatherproof (IP55) designed to be capable of withstanding the extremes of weather conditions, UV radiation and solar heating. Internal equipment shall be splash proof, dustproof and vermin proof (IP54). Grounding famines shall be provided on the busbars to enable maintenance to be carried out in accordance with the standard Safety Rules. Voltage transformer cubicles shall be of sheet steel construction. The cubicles shall be designed to permit the safe isolation and grounding of individual voltage transformers. Indication shall be given externally that the voltage transformer is isolated and earthed. Once access is gained to a voltage transformer it shall not be possible to make contact with any live parts. Anti-condensation heaters shall be provided in the cubicles. Tee-off connection to unit auxiliary transformers shall be equipped with the disconnecting link to enable the transformers to be disconnected from the bus duct for maintenance or reparation.
Non Segregated Phase Bus Non Segregated Bus will use to connect Terminal Generator to Generator Circuit Breaker The Non Segregated Phase bus shall be self cooled, heavy duty, metal enclosed and designed for indoor and outdoor services. The continuous current, short circuit level and other data shall be on the contractor calculation and for Owner approval. LV Cable The connection from the secondary of Unit Auxiliary Transformer to (690/400) V switchgear and from one (690/400) V switchgear to another (690/400 ) V switchgear shall be by LV Cable.
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Part 4.6 - 27
PT PLNE Small CFSPP
4.6.7.
TRANSFORMERS Transformers shall comply with IEC 60076. Generator transformer shall have ONAN/ONAF/OFAF cooling. Unit transformers shall preferably have ONAN/ONAF cooling. Generator transformer and unit transformers shall be oil immersed, free breathing, conservator type. All other auxiliary transformers or Power Distribution Center (PDC) transformers shall be either oil immersed with ONAN cooling or naturally air cooled dry or cast resin type. Dry and cast resin type transformers shall be enclosed in naturally air ventilated enclosures. Generator transformers shall be provided with on-load tap changing facilities to suit the specified operational and VAR import/export capability requirements for one unit and the second with off-load tap changer. The contractor shall provide calculation of capacity of Unit Auxiliary Transformer, which is subject to Owner approval. Unit transformers shall have off-circuit taps to suit the operational requirements. All transformers shall be provided with winding temperature indicator having contacts for temperature high alarm and trip functions. All transformers having bushing connections to external circuits shall be provided with coordinating gap structures or surge arresters. Oil samples for analysis of dissolved gases shall be taken before commencement of final testing of generator, town feeder and unit auxiliary transformers. Further samples shall be taken following power frequency testing, following impulse testing and before, during and after load current runs. Discharge measurements in accordance with IEC 60076 shall be carried out on all Generator, and Unit Auxiliary Transformers and all dry-type or cast resin insulated Auxiliary Transformers to IEC 726.
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PT PLNE Small CFSPP
Generator transformers shall be complete with the following fittings: 1. 2. 3. 4. 5. 6. 7. 8. 9. Refrigeration breather. Buchholz relay - double float with alarm and trip contacts. Buchholz gas, ground level on load sampling point. Spring operated self-resealing pressure relief device (two for oil quantities exceeding 45,000 litres). Tank drain valve. Combined filling and filter valve. Oil sampling device. Approved anti-vibration mountings. HV and LV winding temperature indicators having contacts for control of pumps and fans, and alarm and trip contacts for high temperature. Thermometer pocket. Oil flow indicator with alarm contact for loss of flow. Cooler isolating valves. Pump inlet and outlet Isolating valves. Low oil level alarm device. Grounding terminal.
10. 11. 12. 13. 14. 15.
Unit Auxiliary Transformers shall be complete with the following fittings: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Silica-gel breather. Buchholz relay - double float with alarm and trip contacts. Spring operated self-resealing pressure relief device. Tank drain valve. Combined filling and filter valve. Oil sampling device. Oil temperature indicator having alarm and trip contacts. Low oil level alarm device. Cooler isolating valves (if separate free-standing cooler is provided). Radiator inlet and outlet isolating valves for each radiator (if tank mounted radiators are provided). Grounding terminal.
All other auxiliary oil filled Transformers rated 1 MVA and above shall be complete with the following fitting:1. 2. 3.
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Silica-gel breather. Buchholz relay - double float with alarm and trip contacts, Spring operated self-resealing pressure relief device.
4. 5. 6. 7. 8. 9.
Tank drain valve. Combined filling and filter valve. Oil sampling device. Oil temperature indicator having alarm and trip contacts. Thermometer pocket Grounding terminal.
Oil filled Transformer tanks shall be routine oil leak tested according to IEC standard or other acceptable standard. The Transformer shall be equipped with all required protection, metering and all accessories including fault pressure device, thermal, over-current, differential, earth fault, restricted earth fault etc.
4.6.8.
SWITCHGEAR, CONTROL GEAR AND FUSEGEAR All switchgear, control gear and fusegear shall be located indoors, in metal-dad sheet steel cubicles with front access doors, and be manufactured and tested in accordance with relevant International Standards. Main switchboards shall be extendible at both ends. The main busbars together with the tee-off busbars connecting the main busbars to the isolating/protective devices on all incoming and outgoing circuits, shall be contained in a separate compartment(s) within the switchboard. The busbars shall be air insulated except where solid insulation is a design feature. The main busbars shall have the same current rating throughout their length. Apparatus which has to be removed from a panel or cubicle for maintenance purposes shall either be of the withdrawable type or shall be readily removable without disturbing other apparatus or wiring. Medium voltage switchgear shall be to IEC 56 with circuit-breakers of the vacuum or SF6 type. Fused switching devices used for motor and auxiliary transformer circuits shall afford both adequate protection and reliability in service. The Contractor shall propose suitable transfer scheme to achieve safe and reliable operation during start, normal operation, normal shutdown and emergency shutdown, of which the contractor shall demonstrate his proposed scheme for owner approval.
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Part 4.6 - 30
PT PLNE Small CFSPP
Low-voltage switchgear and control gear shall be to IEC 439 Form 4 with air break circuit-breakers, contractor units, fuse-switches or moulded case circuit-breakers. All points of isolation shall incorporate a feature for fitting a padlock when in the open position. The equipment shall be rated to withstand the mechanical forces and thermal effects of the maximum prospective fault current at the point of application. Where circuits and connections are fuse fed, the maximum prospective fault current applicable is that value as limited in magnitude and duration by the highest rated fuse-link permissible at the point of feed. MV switchboard busbar safety shutters shall be indelibly identified, in English, in accordance with the following: Busbars Incoming Collour - signal red; marking BUSBARS; lettering colour white; minimum lettering height - 35mm Colour - lemon; marking - DANGER LIVE CABLES; lettering coloursignal Feeder red; minimum lettering height - 35mm Colour - lemon
Circuit
On bus-section units both sets of shutters shall be painted signal red and labeled 'busbars'. Voltage transformer spout shutters shall be painted lemon yellow. Circuit earthing facilities shall be provided for all incoming and outgoing circuits of MV switchboards. In addition, provision shall be made to earth each MV busbar at two separate points. Withdrawable units shall be provided with lockable shutters to prevent inadvertent access to live connections when the unit is withdrawn. All operational and maintenance interlocking and any other feature necessary to comply with the Owner's Safety Rules shall be provided including a padlocking facility on: 1. 2. 3. 4. 5. Busbar and circuit shutters. Voltage transformer shutters. Truck position selector mechanism (busbar earth/service/circuit earth). Circuit-breaker/fused switching device open / close control switch. Circuit-breaker/fused switching device local/remote control selector switch.
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PT PLNE Small CFSPP
Generator Circuit-Breakers shall be provided with a disconnector on the generator transformer side. In addition, earthing switches (not links) rated to carry the full fault current shall be provided on both the Generator Transformer and the generator sides of the circuit-breaker. Operational interlocking shall be provided to ensure the correct sequence of operation of the generator and station transformer (if applicable) circuit switchgear. This shall be of the electrical type in compliance with a Standard for safety circuits to be agreed with the Owner. Full maintenance interlocking shall be provided to render the primary and tee-off connections safe for access by personnel from all points of supply. The maintenance interlocking shall be of the mechanical interference (trapped key) type employing a system of unique keys. The interlocking scheme shall include the substation end of the power station circuits and be coordinated with the substation-interlocking scheme as necessary. The drive circuits for the generator circuit switchgear shall be located in a dedicated control panel affording physical separation from all other circuits. Each power supply shall have its own external lockable isolator.
4.6.9.
MOTORS Motors shall comply with the following Standards as applicable: IEC 60034. IEC 72 and 72A Parts I to 9 & 12 Rotating Electrical Machines Dimensions and Output Ratings for Rotating Electrical Machines Classification of Insulation, Materials for Electrical Machinery and Apparatus on the basis of thermal stability in service.
IEC 85
Details of the motor design parameters used for the system analysis studies shall be provided. AC motors shall be suitable for a 3 phase 50Hz supply and unless otherwise specified or approved, shall be of the squirrel-cage induction type suitable for direct on-line starting. The rating of each motor shall be adequate to meet the requirements of its driven load and motors shall be continuously rated unless otherwise specified or approved.
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PT PLNE Small CFSPP
All AC motors up and including 750 W shall be rated either 230V, single phase , 50 Hz or 400 V, 3 phase, 50 Hz and shall be supplied from power panel or MCC. All AC motors up to and including 60 kW shall be 400 V, 3 phase, 50 Hz and shall be supplied from motor control centers (MCC). All AC motors less than 150 kW shall be 400 V, 3 phase, 50 Hz and shall be supplied from PDC switchgear. All AC motors including and larger than 150 kW shall be (690/400)V low voltage motors, and shall be supplied from (690/400)V LV Switchgear. All DC Motors which are to operate rom the station batteries shall be rated in accordance with specified DC voltage. All dc operated valve motors shall be rated for operation from +15% to 30% of rated voltage. All other dc motor shall be suitable for continuous full load operation from + 15% to 15% of rated voltage. The motors shall have 1.0 service factor. All motors shall be rated for not less than 115% of the requirements of the requirements of the driven equipment when operating under design requirements and not less than 100% of the power required to operate the driven equipment at its maximum capability. This relation shall apply for all operating speeds and conditions. Starting current for motors rated above 40kW shall not exceed the values given in IEC 60034-12. Starting torque shall not be less than the values given in IEC 34-12. Pull out torque shall not be less than 200% full load torque. The motor starting (run-up) torque at 100% rated voltage, shall not be less than 1.70 times the torque obtained from the load curve which varies as the square of the speed and is equal to 100% torque at rated speed. Motors shall be suitably rated for the short-circuit capacities of the electrical supplies to which they are connected. Motors shall be of the totally enclosed type and shall have a degree of protection not less than IP54. Motors, which are situated outdoors, exposed to weather, or situated in areas covered by water-spray fire fighting equipment, shall in addition be weatherproof, and have a degree of protection not less than IP55. Unless otherwise specified, all motors shall be air cooled.
Internal heaters shall also be installed on LV motors which are essential to the function of the plant. All motor components shall have adequate mechanical strength and robustness taking into accounts the conditions of service required, operating temperatures, ageing and thermal stability of the material. Glass fibre and plastic components shall be resistant to fire. Motors shall be suitable for operation and also prolonged periods of standstill. In ambient conditions with saline contamination as well as high humidity. Where standard motors of 25kW or less are supplied sealed for life bearings may be offered. Terminal boxes shall be designed so that they can safety withstand the maximum prospective fault current without mechanical damage to the terminal box other than the rupture of any pressure relief device. For motors up to and including 60kW terminal boxes shall have a degree of protection at least equivalent to that of the motor. For motors over 60kW terminal boxes shall be of the totally enclosed type (IP 57) to exclude the ingress of moisture and dust. For motors of 60kW and above the roller bearing assembly shall be provided with a grease relief device such that when the motor runs at its rated speed any surplus grease is automatically ejected out of the motor casing to a separate container. For plain type bearings the temperature of lubricating oil as it leaves the bearing shall be such as to ensure adequate oil life. The frequency of recommended oil changes shall be included in the Bid Proposal. The Bidder will be responsible for ensuring that all motors provided as part of the main contract are adequately protected against electrical faults, mechanical faults and overloads. Motors rated 50kW and above shall be provided with earth leakage protection.
4.6.10.
BATTERIES AND BATTERY CHARGER
The battery shall have sufficient plates per cell and ample ampere-hour capacity to supply all loads for specified period specified with the chargers out of service.
High performance plant batteries having a design life of at least 10 years shall be provided.The batteries system shall comply with the requirement of recognized international standard. 220 V and 24 V batteries shall be provided for each unit and common auxiliaries and 110 V and 48 V batteries shall be provided for the substation auxiliaries complete with mounting racks, the associated charger, panel, indicators and all accessories. The Contractor shall be responsible for the sizing of the battery and chargers in accordance with the standard and Owner criteria including 25 % spare capacity. The sizing calculation based on two hours capacity shall be submitted to the Owner for approval. The plant dc system shall be ungrounded. The 220 V dc systems are used for power plant supply dc power to dc motor, uninterruptible power supply, control power for switchgear, relays, etc. The 24 V dc systems are used for dc control power to plant control system. The 110 V dc systems shall supply dc system for the 20kV Switchgear equipment.
Batteries: The batteries shall be suitable for normally float operation and the character of the load to be supplied. The mean ambient air temperature surrounding the batteries shall be maintained in the range 20 250C unless otherwise approved. Adequate ventilation shall be provided for the removal of hydrogen. High performance Plant lead acid batteries shall be provided. Nickel cadmium batteries will be considered as an alternative if better suited to the environmental conditions. The batteries system shall comply with the requirement of recognized international standard. Adequate ventilation shall be provided for the removal of hydrogen. Accessories such as thermometer, hydrometer, spare acid etc shall be provided. Charging modes shall include boost charging for equalizing/refreshing purposes where suitable for the battery type. The recharge time shall be approved.
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PT PLNE Small CFSPP
The batteries shall be supplied complete with all necessary connectors, racks/cabinets. Stand insulators, connector bars and sundries together with local and remote alarms for abnormal conditions.
Battery Charger: The battery chargers shall normally float charge the batteries and shall also supply the normal dc load. The battery chargers shall equalize the batteries when needed. They shall also be capable of recharging their respective batteries in 8 (eight) hours at the end of the battery discharge load cycle while supplying the normal load of their respective batteries. The Contractor shall verify the estimated loads using the actual load data and/or conservative load estimates. It shall be the contractors responsibility to size the battery chargers adequately considering the recharge requirements for his proposed battery cells. The contractor shall submit his battery charger sizing criteria and calculations, including the recharge characteristic curves for the proposed cells, for the owners approval. The ac power supply for the battery charger shall be 400 V, 3 phases, 50 Hz. Each battery charger shall be design to prevent the battery from discharging back through the charger in case of ac power failure or other charger malfunction. The voltage ripple in the charger output shall not exceed 5 % RMS when not connected to the battery. Battery charger shall be equipped as minimum such as digital meter indicating dc output voltage, dc output ammeter with accuracy 1 %, float and equalizing voltage potentiometers, float and equalize switch, protection, etc. DC Distribution Panel : DC distribution panel shall be provided complete with the circuit breaker, transfer switch, grounding, control device, wiring and indicating instrument.
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4.6.11.
UNINTERRUPTIBLE POWER SUPPLY The station Uninterruptible Power Supplies shall consist of assembled equipment cabinets, each complete with all specified and/or required accessories and instrumentation for each unit, as follows: Single phase, 230 V, 50 Hz, 0.85 lagging to 1.0 PF, power supplies including, but not limited to, the associated input rectifiers, auctioneering diodes, inverters, and the output power distribution panels. The plant Uninterruptible Power Supplies shall furnish highly reliable 230 V ac auxiliary power for vital electrical loads in the power plant. The UPS shall be supplied for each unit, for common loads and for 20kV switchgear. Sizing capacity shall be supplied including 20 % spare for Owner approval. The Uninterruptible Power System shall operate on unit bases. Uninterruptible power supplies shall be furnished for each unit. Each Uninterruptible Power supply shall be an integrated system consisting of one 230V static inverter with a static switch, a solid state rectifier, one diode auctioneering input, circuit breakers and a fused distribution panel.
Each unit Uninterruptible Power Supplies system shall be supplied by one 100% systems of the on-line type capable of supplying the total system load and complete with static transfer switch and maintenance bypass switch. The contractor shall also provide one dc power feed from the station ungrounded battery that will serve as the power supply to the inverter during periods when the normal ac power to the rectifier is interrupted. Blocking diodes shall be included to prevent any transfer of fault current between the d.c. and a.c. supply systems. Naturally air ventilated enclosures for equipment cooling is preferred. Adequate diagnostic/test facilities shall be provided for fault finding. Data on reliability (mean time to failure) and maintainability (mean time to repair) shall be submitted for approval
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Part 4.6 - 37
PT PLNE Small CFSPP
4.6.12. 4.6.12.1.
CABLING CABLING MANAGEMENT The Contractor shall provide details of the cabling management system he proposes to use on this contract including the design, route and the connection schedule.
4.6.12.2.
CABLING DESIGN The Bidder shall be responsible for the design, supply, installation, terminating, testing und commissioning of all the power, control instrumentation and communications cable systems. All cable runs shall be continuous, straight-through joints not being permissible without the prior approval of the Engineer. The cables shall have flame propagation characteristics of bunched cables that meet as a minimum the requirements, of IEC 332 Part 3 Category B. Test evidence of the fire performance of the cable types offered at the specified volume of combustible material shall submitted. Cables exposed to direct sunlight shall have ultra-violet resistant oversheaths. Cables shall have either copper or aluminium conductors with extruded insulation/bedding/oversheath in accordance with internationally recognised Standards, and be of the following or equivalent types: 1. MV single core and multicore power cables shall have XLPE insulation rated for restricted earth fault current, PVC bedding, galvanised steel or aluminium wire armour, PVC oversheath in accordance with IEC 502. The oversheath of single core power cables shall have a suitable semi-conducting coating applied for oversheath testing, LV single core and multicore power cables shall be 600/1000V rating having either XLPE or PVC insulation, PVC bedding, galvanised steel or aluminium wire armour, PVC oversheath. The oversheath of single core power cables shall have a suitable semiconducting coating applied for oversheath testing. Earthing cables shall be single core, PVC insulated coloured as appropriate. Bare copper may also be used.
2.
3.
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4.
5.
Multicore control cables shall be 600/1000V rating, having PVC Insulation with numbered cores, PVC bedding, galvanised steel wire armour and PVC oversheath. Multipair control cables shall be 110 V twisted pair, having PVC insulation, an aluminium screen and drain wire, PVC bedding, galvanised steel wire armour, PVC oversheath. The conductors shall be single stranded plain annealed copper, identifiable by colour coded insulation. Minimum conductor size 0.5 mm2.
Fire resisting cable tested to the highest test temperature in IEC 331 shall be used for essential circuits required to remain functional in the event of a fire. This shall include the trip circuits necessary to safely, shut down the plant and isolate it from the distribution System, fire detection and fire fighting equipment and emergency communication and audible alarm circuits.
4.6.12.3.
CABLE SEGREGATION AND SEPARATION In order to limit economic loss in the event of a fire or similar incident segregation by a fire barrier shall be provided between cables in the following groups: each Generator unit, main and emergency supplies and alternate tripping supplies. Fire barriers and penetration seals through walls, floors and ceilings shall having a minimum fire rating of at least one hour to ISO 83-4. Adequate physical separation shall be provided between power cables and control and instrumentation cables to minimize the effects of electrical interference and other disturbances including those associated with unbalanced circuit working.
4.6.12.4.
CABLE RATING Power cable conductor sizes shall be determined having consideration for maximum conductor temperatures under sustained and three phase short-circuit/earth fault conditions, voltage regulation under steady state and motor starting conditions and, automatic disconnection time for protection by equipotential bonding.
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4.6.12.5.
CABLE SUPPORT AND FIXING SYSTEM Adequate provision shall be made in buildings for cable flats and risers, floor trenches, steel support structures, holes through walls/floors, ducts etc., for the accommodation of cable routes and access to plant and equipment. Enclosed cable ways shall incorporate suitable personnel access and emergency escape routes. Heavy duty galvanised steel ladder rack or perforated tray shall be used for cable support. Single core cable shall be installed in either trefoil or flat formation and secured using cleats.
4.6.12.6.
CABLE ENDS All cables are to be allocated unique numbers which shall be clearly and securely fastened to both ends of the cables. All cables shall be terminated using mechanical glands of the metallic or insulated type. MV cable terminations shall be fully insulated where the risk of failure due to condensation is high e.g., outdoors and in plant areas. Cable termination boxes for high current single core power cables shall have nonmagnetic gland plates etc., to avoid cable heating due to closed magnetic loops. Conductors shall be terminated using compression fittings. Solid aluminum conductors may be terminated using formed termination techniques. All cable cores shall be identified.
4.6.12.7.
RACEWAYS SYSTEM Race ways system includes cable trays, conduit and underground electrical duct system. Except road lighting cables with certain protection, cable shall not be directly buried underground. All cable shall be either in cable trays, conduit or electrical duct. Cable trays, fitting conduit and the support shall be hot dip galvanized. The average thickness of coating shall be 64 micrometers and the minimum thickness not less than 55 micrometers.
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Separate cable trays shall be used for medium voltage power cables and low voltage power cables and control and instrument cables. Low voltage power and control cables may be run in the same cable trays with Owner approval for special cases. Two hour rated fire stop shall be installed where tray penetrate floors or walls. The clearance of the trays shall for Owner approval. Cable tray covers shall be installed on all instrument trays, all cable trays installed outdoors and on trays under or within 2 meters of a gallery or tray crossing. The Contractor shall furnish all conduits, conduit bends, fittings, pull box devices, cabinets, junction boxes, supports, clamps and all other conduit appurtenances. Unless otherwise indicated, all conduit and fitting shall be hot dip galvanized rigid steel conform to ANSI standard. Conduit for indoor lighting in non-hazardous areas shall be electrical metallic tubing (EMT). Galvanized flexible conduit shall be used to dampen vibration or where relative movement is required between the conduit and connected apparatus, as at motors. Underground electrical duct shall be designed for efficient and safe installation of cables. The duct shall be provided with drainage system and be complete with all necessary accessories.
4.6.13.
CATHODIC PROTECTION Cathodic protection shall comply with the requirements of BS CP 1021 (Code of Protection for Cathodic Protection) and NEMA MR-20 (Semi Conducting Rectifiers Cathodic protection Units). The impressed current cathodic protection system shall be provided in conjunction with the appropriate plant material selection, for the plant listed below: 1. 2. 3. 4. 5. Intake screen and trash racks Pump casings Condenser Water Boxes Miscellaneous Heat Exchanger All other corrodible portions of water system, steel pile, pipework and valves, etc.
The bidder may proposed the sacrificial anode protection for certain areas such as scattered buried piping, off-shore steel piles, and part of water intake which not practical using impressed current system.
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The cathodic protection system shall be designed for a minimum of 30 years operation and shall include adequate margin for 20% coating deterioration. The cathodic protection system shall consist but be limited to the automatic control transformer/rectifier, anodes, reference cell, cablings and test points, volt and amperes monitoring system and high resistance voltmeter.
4.6.14.
LIGHTING The lighting and small power system shall be provided for the maintenance and operation of the whole Power Plant complete with distribution boards, fittings, lamps, socket outlets, switches and all necessary cabling. The lighting design shall be based on the recognized international standard. The lighting and accessories shall be manufacturer or assembly in Indonesia. Unless otherwise indicated, lighting shall be High Pressure Sodium (HPS) luminaries for high bay and outdoor lighting and fluorescent luminaries for low bay and indoor lighting. The lighting levels shall be designed to the applicable nominal illumination levels given in the Indonesian Standard (Standar Penerangan Buatan di Dalam Gedung-gedung) except where otherwise specified below. AREA Power house T/G operating floor Power house ground & Mezzanine floor CW Pump Area Boiler Main, ground & Mezzanine floor Boiler Galleries Control room Auxiliaries room Switchgear & Electrical room Cable room Diesel engine, Battery room Workshop/ machine shop/ store room Misc indoor area Miscoutdoor gallery & walkway Computer, conference room & office area Transformer area outdoor SOURCE TYPE HPS HPS* HPS HPS* HPS* Fluorescent Fluorescent Fluorescent Fluorescent Enclosed & gasket HPS Fluorescent/ HPS HPS Fluorescent HPS LUX 300 200 150 50 100 750 150 220 75 110 210 210 30 750 55
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Roadway lighting & Yard areas Building entrance Water treatment/ substation etc Case coal conveyor
HPS HPS HPS HPS
11 30 60 110
Note: Fluorescent will be used in low mounting height areas Unless otherwise indicated, lighting shall be HPS luminaries for high bay and outdoor lighting and fluorescent luminaries for low bay and indoor lighting. The Main control Room and other control room shall be provided with a louver-all ceiling which conceal all ventilating equipment and lighting luminaries. Road and yard lighting is preferred to be mounted on high mast. The Coal handling lighting including the bunker top conveyor floor of the boiler and similar place shall be provided with HPS lighting with dust tight gasket fixtures suitable for Class II group G, Division 2 locations in accordance with NFPA (NEC) classification. In general all lighting and all accessories located in hazardous areas shall be suitable for the hazardous area usage. Emergency Lighting : Emergency lighting shall be provided for personnel safety and for operational/access areas attended during an emergency. The emergency lighting shall be supplied from the essential supply. Emergency lighting shall be provided for boiler galleries operating floor, control room, exit door, stairways, escape walkways, diesel generator room, etc. Emergency lighting in the form of escape lighting shall be provided for cable spreading floor, machine shop, locker, toilet and all normally inhabited areas. Emergency lighting shall be provided by self contained luminaries complete with battery, charger, transfer switch etc, and shall have an operating time of at least 2 hours on self-contained battery power. Aircraft Obstruction Lighting : Complete obstruction lighting for aircraft warning system shall be provided in accordance with the Indonesian Transport Department Regulation for the stacks. The system shall be accessible for maintenance. The lighting shall have two power feeds equipped with automatic transfer switch. The
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normal power feed shall be from power distribution panel and the emergency feed shall be from emergency bus. Temporary Aeronautical Obstruction lighting shall be provided on chimney during the progress of construction. Clock system: The Contractor shall install a master clock and slave clock system complete with the wiring. The clock system shall be provided with device so that it can be synchronized with the international time which is transmitted GPS Satellite. All monitoring, oscillograph and sequential event recording shall be connected and synchronized to this clock system and SCADA system. The stability of the master clock shall be at least 0.1 second per day. A sufficient number of slave clocks shall be installed in Administration building, turbine hall, Main Control Room, BOP control room, 20kV Swicthgear room and relay room. Receptacles: The Contractor shall provide 230 V receptacles fed from the lighting panel throughout the areas of the power plant such as offices, control rooms, electrical control rooms kitchen areas, locker rooms, toilet and other indoor areas. The number of the receptacle shall be for Owner approval. For outdoor areas, receptacles shall be watertight and dust tight with hinged screwed equipped with interlocking or other means, whereby, only after insertion of the plug can the switch be activated. The receptacle shall be provided within reach 30 meter extension cord for outdoor areas. Welding receptacle shall be provided in plant areas within convenience reach of about 30 meter extension cord and also in location within convenience reach of all electrically operated hoist, trolleys, other potable equipment and near boiler access door. Welding receptacle shall be 3 pole plus neutral, plus ground and shall be rated 63 A at 400 V operating voltage, 3 phase. The receptacle shall be watertight and dusts tight comply with IEC 60309. The receptacle shall also be of the interlocking type with mechanical switching completed with fused.
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4.6.15.
OUTDOOR GROUNDING The contractor shall design and build the grounding system so that the design resistance, touch and step voltage of the overall grounding system are achieved for the ultimate fault current. The Contractor is responsible to calculate the ultimate total fault current, tolerable touch and step potential. The calculation shall be submitted to Owner for approval. Soil resistivity measurement shall be performed after the site area has been graded to its final elevation, which is required to establish the design parameters for design of grounding system as well as cathodic protection system The contractor shall be responsible for the grounding mat and grounding rods confirmation design. The final resistance to ground shall be 0.5 ohm (measured at driest season) or less. Ground Rod shall be installed if required to achive final grounding resistance. The Contractor shall be responsible to size grounding conductor taking into consideration all requirement of their equipment grounding. The buried grounding conductor size shall be minimum 240 mm2 copper and be buried 600 mm below grade. All buried connection shall be made by exothermic welding. Ground rod shall also be installed at locations that are subject to impulse current, such as arresters, outdoor transformers, transmission towers, shield wire support and lightning protection system ground conductors. Ground rod shall be about 20 mm diameter UL listed copper bonded at least 6 meters long, design for 30 years. Plant grounding grid shall be connected to Substation grounding grid through at least two grounding conductor. All above ground metallic object such as transformers, tanks, transmission towers, metal framing, long run expose piping and outdoor mechanical equipment shall be connected to the grounding system in at least two places. All fences shall be included in the grounding system and connected to the grounding system at interval of about 30 meters.
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4.6.16.
BUILDING, EQUIPMENT PROTECTION
GROUNDING
AND
LIGHTNING
The contractor shall connect all equipment to outdoor grounding using suitable grounding conductor, which is subject approval by Owner. Minimum grounding conductor for equipment supplied from 230 V and 400 V shall be 16 mm2 and equipment supplied from medium voltage ( 6 KV ) shall be 35 mm2. The ground conductor size for each kW rating shall be as per the applicable standard and subject for Owner approval. The minimum main ground conductor and safety ground conductor sizes for motors and equipment with the same KW rating shall be in accordance with the following table: MAIN GROUND CONDUCTOR SIZE (mm2) 16 50 70 120 185 35 70 120 120 185 240 300 SAFETY GROUND CONDUCTOR SIZE (mm2) 16 50 70 120 120 35 70 120 120 120 120 120
VOLTAGE
KW RATING
230 & 400 V
< 15 < 37 < 55 < 100 < 150 < 355 < 630 < 1000 < 1800 < 2800 < 4000 < 4000
6 KV
Cable tray shall be connected to grounded building steel with copper bonding jumper of at least 120 mm2 at 30 meter intervals or at least two places for shorter runs. Copper bonding jumper having area at least 120 mm2 shall be used at expansion joint or section of cable tray where required to ensure electrically continuity.
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Equipment such as switchgear and control cubicles shall be provided with a main earth bar for the equipotential bonding to earth of all exposed conductive parts which may become alive under fault conditions. Motors frame shall be connected to building steel at the nearest practical location by a bare copper safety ground conductor. Small motor frames shall be grounded through the conduit to cable tray system. All equipment provided with ground bus bar such as: switchgear, MCC hall be provided with grounding conductors bolted to both end of ground bus bars and connected to the nearest building steel. The Contractor shall design and installed lightning protection systems for all buildings and structures in accordance with NFPA 780 or other acceptable standard. Air terminal of the lightning protection shall be 60 cm long and connected to ground grid through down conductor, having size of at least 120 mm2, copper. At least two independent down conductor shall be provided on each structure. Additional down conductor shall be provided if the perimeter of the structure exceeds 75 meters, so that an additional down conductor is provided for each 30 meters of perimeters or fraction thereof.
4.6.17.
COMMUNICATION SYSTEM The communication system shall be furnished complete with required accessories, and devices for the following systems: Telephones A 200 extension solid state Private Automatic Branch Exchange (PABX) Public Address System A solid state Public Address System / intercom shall be used for through out the plant and substation. Marine Communication system A marine radio communication system shall be provided for communication with ship arrival and departure at Coal Jetty during unloading coal. It shall be VHF transceiver to be installed in Main Control Room. The system shall include the base station and mobile transceivers complete with all accessories, antennas and the support and power supplies.
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A complete land mobile radiotelephone system shall be provided for general plant communications including base station transceiver mobile transceiver and at least 20 battery operated hand held transceiver with the chargers. Telephone instruments shall be installed in all floors of the power house, all rooms, buildings and control rooms, boiler areas, chimney, coal and coal transfer areas diesel building, substation, water treatment and other area indoor and outdoor as required for operation and maintenance system. Telephone located in noisy areas shall be mounted in acoustic booths and equipped with power bell. Number of telephone instruments for desks, wall indoors, and wall outdoors, power bell and for outdoor acoustic booths shall be determined by the contractor taking into account plant operation requirement and subject for Owner approval. The PABX shall be fully automatic, a model approved by local authorities and fully compatible with public telephone system, and the contractor shall be responsible to connect plant PABX to public telephone system. The exchange shall be powered by a battery and charger combination as well as a separate power supply from a 230/400 V supply. The PABX shall also have facilities for connection to Owner Power Lines Carrier. Interface between the plants PABX with Owner Power Carrier Lines shall be contractors responsibility including removal and remounting the existing Power Lines Carrier to the new substation building completely. The PAPX shall also be interconnected with the plant public address system. Operating console shall be provided with the PABX. Public address system. Public address system shall be a complete solid-state public address/ intercom system designed for power plant. The system shall consist of a page channel for individual calls by the use of loudspeakers and party channels for two way and group communications using handset station. It is preferred that the system have a distributed amplifier system. The Public address system shall be provided with handset stations, which consist of hand set and amplifier cabinet. The hand set shall be of telephone type with receiver and low impedance, noise canceling
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transmitter designed for close talking. The paging system shall also be capable to be used as plant intercom system. Public address equipment shall be installed in all floors of the power house, all rooms, buildings and control rooms, boiler areas, chimney, coal and coal transfer areas diesel building, substation, water treatment and other area indoor and outdoor as required for operation and maintenance system. The number of Area public address, desk, indoor and outdoor wall shall determined by the Contractor subject for Owner approval. Except for office and similar area, all speakers for public address shall be of the heavy duty industrial type with permanent magnet drive, provided with bracket foe directional adjustment. For offices and administration building the speaker shall be ceiling mounted. For hazardous area, the telecommunication equipment shall be the type suitable for the hazardous area.
4.6.18.
EMERGENCY DIESEL GENERATOR The Contractor shall provide Emergency Diesel Generator for supplying essential load during plant emergency condition of which normal AC supply is not available at the system. 1. 2. 3. 4. 5. 6. 7. Diesel Generator set shall be capable to supply the emergency loads and additional essential loads, such as : Steam turbine and Boiler essential load 20 kV switchgear essential loads Plant control system Battery Charger Communication systems Other essential loads including but not necessarily limited to : DC loads, emergency lightings, etc.
The contractor shall be responsible to size capacity Emergency Diesel Generator meeting the above essential loads, provided with sufficient margin capacity of at least 20 % for overload facility. The Diesel Engine Generator set shall be capable in every respect to be operated in parallel with the power plant auxiliary system. Engine emission shall meet all Indonesian government regulation and the sound level requirement shall be maximum 85 dB
The Diesel Engine Generator set will be used for standby emergency 400 V, three phase, 4 wire power and shall have ability to start and achieve rated speed and be ready to pick up the load sequence within 10 seconds of start signals. The Diesel Generator set shall be complete with all necessary component as required for successful operation, such as : control panel, synchronizing facilities, radiator, fuel oil system, lubrication oil system, facilities for controlling from control room, etc.
4.6.19 4.6.19.1
20 KV SWITCHGEAR General The Contractor shall provide a 20 kV switchgear for the connection of the power station to the distribution system. The switchgear shall be a single busbar design containing sufficient space to accommodate the outgoing circuit, overhead line or cables plus the power station circuits. If open terminal design switchgears offered, full account shall be taken, in the design of the exposed coastal nature of the site under the likely extremes of weather conditions. Specific creepage distances shall not be less than IEC 815 pollution level IV - very heavy. The surge arrester shall be designed and supplied using standard IEC 99 (latest edition), type gapless metal oxide, and comply with IEC 815 for environmental heavy pollution level. For the insulator material, ceramic, for outdoor and indoor must comply with IEC 168. The Contractor shall provide a single line diagram of the switchgear room with his offer. The configuration of the busbars shall be designed to optimize the overall size of the switchgear room and to accommodate ease of entry of 20 kV overhead line. It should be noted that the details of the pole types/positions and route of the overhead line as it approaches the switchgear are still to be determined. The Contractor shall provide all the plant and equipment required for the operation and maintenance of the switchgear, and to permit the switchgear to be connected to the distribution system. The extent of supply shall include all circuit-breakers, disconnections (motorized), earthing switches (full set), conductors and fittings, insulators surge arresters, voltage and current transformers line traps, supporting structures protection, interlocking, metering, AC and DC electrical supplies, control, alarms, indications, data acquisition recorders, telecommunications,
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air conditioning, ventilation, lighting and small power, cabling, lightning protection, earthing and bonding etc. The switchgear shall be contained in a building for standby operation and control. The building will contain all protection relays, AC and DC Electrical supplies, special maintenance facilities, storage of spares, tools and earthing equipment etc. The design shall allow all maintenance and operational activities to be carried in accordance with Owner Safety Rules and Procedures. The plant and equipment shall comply with the applicable IEC Standards and be drawn from standard ranges having proven operating experience in a similar environment. The plant and equipment shall be arranged in an orderly manner and be of high integrity design to minimize the risk of faults. This standard shall be applied to all design levels. The interface (terminal) point with the grid system for the primary 20 kV overhead line/feeder conductors (if supplied by others) shall be at the 'down dropper' end conductor fittings; associated with the tension/support insulators of distribution pole. The Interface point for the communication systems employing overland telephone circuits shall be at the site boundary. Switchgear fencing shall be to an agreed standard. An independent earth electrode shall be provided for the switchyard. This shall be linked to the power station earth electrode with a removable link provided for test measurement purposes. Full lightning protection shall be provided. Power station requirements shall also apply to the switchgear as applicable. 4.6.19.2 Ratings The primary plant shall be designed for a single/three (symmetrical) phase fault level of ... kA for 1 second. The Contractor shall provide in his offer the value of maximum fault current infeed from the generators in order that the suitability of this design value of fault level may be confirmed. Busbar and circuit current ratings shall be continuous all year round ratings. Creepage and clearance (basic and safety) distances for operational and maintenance activities shall be agreed with the Owner. The System studies for the power station shall include the switchgear Parameter Rated service voltage Highest system voltage 20 kV system 20 kV 24 kV
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Rated lightning impulse voltage withstand to be determined later level Rated switching impulse voltage withstand to be determined later level Rated current line to be determined later (A) Rated current generator feeder to be determined later (A) Rated current distribution transformer N/A feeder Rated busbar current to be determined later(A) Rated peak withstand current Number of phases Frequency Rated short time withstand current System earthing Creepage distance Ambient Temperature to be determined later(A) 3 50HZ to be determined later to be determined later Very heavy pollution 33 C
The above information is to be confirmed by the Contractor 4.6.19.3 Protection The following protection shall be provided as a minimum for the switchgear works: bus bars - main and check protection plus independent IDMT over current/earth fault back-up protection. circuit-breakers - circuit-breaker fail protection. power station circuits - main protection consisting of MV connections circuits protection and independent back-up protection consisting of IDMT over current/earth fault plus high set instantaneous over current protection.
Any equipment required for the protection of the grid lines located at the switchgear remote from the power station shall also be provided. When a fault occurs, the protection equipment shall detect the fault rapidly and initiate the opening of only those circuit breakers which are necessary to disconnect the faulted item from the system. Protection equipment associated with adjacent plant which may detect the fault shall be able to discriminate between an external fault and a fault occurring on the primary plant that it is designed to protect. The protection scheme design and settings shall be coordinated as necessary with the distribution system Operator's protection schemes. The settings to be applied to the protection relays shall be submitted for approval by an agreed date together with supporting calculations.
Any limitations in the performance of the protection shall be declared by the Contractor with his offer. The protection shall remain stable for all load conditions, charging and discharging requirements, harmonic currents, oscillatory currents, resonant effects or traveling waves caused by the grid system or by primary transducers. In addition the protection shall not mal-operate in the presence of electrical noise caused by switching operations in the switchgear or on the grid system lightning, electromagnetic coupling, radio interference electrostatic discharges etc.
4.6.19.4
CONTROL, ALARMS AND INDICATIONS Comprehensive control, alarm, indication, data acquisition, event recorder etc, facilities shall be provided for the switchgear. The systems provided shall ensure reliable operation of the primary plant at all times and have a proven record in use elsewhere. The main control locations for the switchgear shall be the switchgear control room. Local control at the switchgear (field) for maintenance and commissioning purposes, at the bay control level located switchgear room shall also be provided to allow the circuit-breakers, disconnectors and earth switches to be opened and closed. A computer based control system using LCD mouse, track ball and the like computer system man machine interface equipment shall be located in the switchgear control room. The controls and plant status indications available from the control system shall be fully described in the Contractor. Manual synchronizing with check facilities shall be provided on all circuits. Sufficient instrumentation signals etc., shall be provided at the control points to enable personnel undertaking all operational actions. Means shall be provided to allow isolation of the control and motor circuits. The switchgear control system equipment and systems shall be manufactured in well known world wide reputable manufactures which have supplied successfully existing successful switchgear control system equipment and systems to several countries in the world
4.6.19.5.
INTERLOCKING A high integrity interlocking scheme shall be provided to minimize the risk of human error faults such as operating equipment by mistake, or gaining access to equipment which is still live. The scheme shall cover the operation of all the 20 kV circuit-breakers, disconnectors and grounding switches. The
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scheme shall be coordinated with the power station interlocking scheme as necessary. Operational interlocking shall ensure that switching operations are carried out without making or breaking load when system connections are to be rearranged. This shall be of the electrical type in compliance with a Standard for safety circuits to be agreed with the Owner. Maintenance interlocking of the mechanical interference (trapped key) type employing a system of unique keys shall be provided to prevent operation of switchgear or access gates and the closing of grounding switches on to live conductors.
4.6.19.6
AC AND DC ESSENTIAL SUPPLIES SYSTEM DC supplies and AC Uninterruptible Supplies shall be provided for power station. In addition, standby supplies, with manual changeover, to provide alternative supply to substation PDC bus in the event of failure or a maintenance outage, shall be derived from Essential services MCC of the power station. Remote control indication and alarm power supplies shall be derived from a separate source than that employed for protection/closing/tripping supplies. DC. Supplies and AC uninterruptible supplies system shall be sized to accommodate the ultimate design of the switchgear. The batteries shall be of sufficient capacity to supply the DC loads without any recharging for a period of 8 hours.
4.6.19.7
COMMUNICATIONS The Contractor shall provide all the necessary communication systems between the 20 kV switchgear and the distribution system Operator's regional control centers through other distribution network substations. These shall be linked for, teleprotection link for each line, link for remote tariff meter reading and links for voice communication systems. The communication systems shall be in accordance with the distribution System Operator's requirements as stipulated in the PLN Grid Code, employing equipment protocols fully compatible with that at the remote end. The communications systems shall include equipment for communications via the distribution network using power line carrier systems, telephone line communication systems including the provision of a telephone system (PABX) for voice communications via subscriber line,
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be one, party line with back-up voice communication systems e.g., cellular mobile telephone. Details of the above items will be informed during contract period.
4.6.20 .
CLOSED CIRCUIT TELEVISION (CCTV) FOR OBSERVING AND SECURITY SYSTEM The CCTV system shall be completely installed system including covers, cables, control, monitor, lights, cameras and other special features necessary for full surveillance and observing of the access road, entry gate area, boundary line (fence) and other power plant area. The CCTV will also used to monitoring/ observing the flue gas, stacking of coal in the coal storage silos and yard, coal transfer tower, water treatment area, switchyard, etc. The design of CCTV system shall be such that all the switchyard and all power plant perimeter area and halls (interior and exterior) shall be readily visible by use of the CCTV system All equipment shall be provided based the latest version of technology. The CCTV shall be high resolution and color signaling, and camera shall be outdoor type for very low light of surveillance standard considering the light incipient on the ground based on lighting specification Each camera used for general surveillance shall have a remotely control system lens of 10:1 ratio and an aperture control system. Each camera shall be water resistant, equipped with strip heater, viewing port windshield wiper with washer and storage bottle. The gate house camera shall have a fixed lens, outdoor housing as above. Each surveillance camera housing enclosure shall be mounted on a pantilt unit for outdoor construction with operating range of 340 degree horizontal, 15 degree upward and 60 degree downward. Control master and two duplicate color video monitor consoles for controlling and monitoring the CCTV system. One of the consoles shall be in the main control room in the power house and the other may be located in the security office room to be determined later. Each monitor shall independently be able to receive any camera input and both monitor able can be held on difference cameras.
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For each monitor, a remote control master for all cameras shall be provided using digital signaling techniques for all function of the camera including zoom, near-far focusing, tilt wiper and washer on-off, iris control manual and automatic, etc. 4.6.21. SUMMARY OF ELECTRICAL SCHEDULES The Bidder is required to complete and submit with his Bidders al of the Technical Schedules. Where appropriate, each required Schedule is requested in the particular Specification clause pertaining to the subject discussed. The Schedules shall be extended and supplemented as necessary by the Bidder. 7.3.1 7.3.2 7.3.3 7.3.4 7.3.5 7.3.6 7.3.7 7.3.8 7.3.9 7.3.10 7.3.11 7.3.12 7.3.13 7.3.14 7.3.15 7.3.16 7.3.17 7.3.18 7.3.19 7.3.20 7.3.21 7.3.22 7.3.23 7.3.24 7.3.25 7.3.26 7.3.27 7.3.28 7.3.29 7.3.30 7.3.31 7.3.32 7.3.33 7.3.34
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Generator MV Cable Generator Circuit Breaker 20 kV Medium Voltage Switchgear Non Segregated Phase Bus Distribution Center Transformer Power Distribution Center Switchgear Motor Control Centers Low Voltage Motor Batteries and Chargers DC Distribution Panels Uninterruptible Power Supply Emergency Diesel Engine Generator Cables and Wires Cable Tray System Conduits and Fittings Outdoor and Substructure Grounding Equipment Building Equipment Grounding and Lightning Protection Metering and Protection Lighting Generator Transformer Unit Auxiliary Transformer Low Voltage Circuit Breaker Air Isulated Buswork 20 kV Circuit Breaker 20kV Disconnector and Earthing Switch 20 kV Current Transformer Voltage Transformer 20 kV Surge Arrester 20 kV Control & Relay Panel Overcurrent & Earth Fault Protection Fault Recorder Telecommunication LV Cable
7.3.35 7.3.36 7.3.37
20 kV Control & Relay Panel: Busbar Protection 20 kV Control & Relay Panel: Clearance Time Communication
By Sejahtra Surbakti
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BOOK III PART 4.

TABLE OF CONTENT BOOK III PART 4.6 ELECTRICAL WORKS

264.6.7. 4.6.8. 4.6.9. 4.6.10.

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BOOK III PART 4.6 Electrical Works

4.6.13. 4.6.14. 4.6.15. 4.6.16. 4.6.17. 4.6.18. 4.6.19.

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BOOK III PART 4.6 Electrical Works

PART 4.6. ELECTRICAL WORKS

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BOOK III PART 4.6 Electrical Works

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BOOK III PART 4.6 Electrical Works

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BOOK III PART 4.6 Electrical Works

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BOOK III PART 4.6 Electrical Works

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BOOK III PART 4.6 Electrical Works

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BOOK III PART 4.6 Electrical Works

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BOOK III PART 4.6 Electrical Works

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BOOK III PART 4.6 Electrical Works

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BOOK III PART 4.6 Electrical Works

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BOOK III PART 4.6 Electrical Works

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BOOK III PART 4.6 Electrical Works

BOOK III PART 4.6 Electrical Works

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BOOK III PART 4.6 Electrical Works

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BOOK III PART 4.6 Electrical Works

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BOOK III PART 4.6 Electrical Works

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BOOK III PART 4.6 Electrical Works

ROTORS Rotor and End Ring Forgings

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BOOK III PART 4.6 Electrical Works

BOOK III PART 4.6 Electrical Works

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BOOK III PART 4.6 Electrical Works

BOOK III PART 4.6 Electrical Works

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BOOK III PART 4.6 Electrical Works

BOOK III PART 4.6 Electrical Works

BOOK III PART 4.6 Electrical Works

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BOOK III PART 4.6 Electrical Works

BOOK III PART 4.6 Electrical Works

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BOOK III PART 4.6 Electrical Works

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BOOK III PART 4.6 Electrical Works

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BOOK III PART 4.6 Electrical Works

10. 11. 12. 13. 14. 15.

BOOK III PART 4.6 Electrical Works

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