400-Eng-9336-003 Rev 00 (Technical Specification For 220KV Switchyard) PDF

PROJECT: 2 X 150 MW COAL BASED TPP, BHADRESHWAR, GUJARAT
DOCUMENT TITLE:
SPECIFICATION FOR 220kV GIS CUM AIS SWITCHYARD
Client Project Consultant Project No. Document No.
OPGS POWER GUJARAT PVT LTD.
Aquatherm Engineering Consultants (India) Pvt. Limited 9336 400-ENG-9336-003
PROJECT CONSULTANT:
Aquatherm Engineering Consultants (India) Pvt. Limited, 2nd Floor, St. Thomas Building, # 68, (Old No. 150), Luz Church Road, Mylapore, Chennai 600 004, India, Tel: (044) 24994032, 24660462, 24660464, Fax: (044) 24996085.
Project Client Document Title
: : :
2x150MW Coal Based TPP, Bhadreshwar, Gujarat OPGS Power Gujarat Pvt. Limited
Technical Specification for GIS Cum AIS 220kV Switchyard
Project Consultant
Document Number
:
:
Aquatherm Engineering Consultants (India) Pvt. Ltd.,

400-ENG-9336-003 Rev. No 00
REVISION SUMMARY
Rev. No.
00
Date
24.12.2012
Prepared by
M.C.M
Checked By Approved by
T.S.S T.S.S
Revision Details
First Issue
Aquatherm Engineering Consultants India Pvt Ltd
Page 2 of 69
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
TABLE OF CONTENTS
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19.
INTRODUCTION ........................................................................................................... 4 SWITCHYARD CIRCUITS AND EQUIPMENT ............................................................. 4 BASIC INSULATION LEVEL ....................................................................................... 5 GAS INSULATION SWITCHYARD .............................................................................. 5 AIR INSULATION SUBSTATION ............................................................................... 29 220 KV SWITCHYARD LAYOUT REQUIREMENTS ................................................. 37 220 KV SWITCHYARD RELAY AND CONTROL PANELS....................................... 38 POWER LINE CARRIER COMMUNICATION (PLCC)............................................... 43 SCADA ....................................................................................................................... 44 ANNUNCIATORS ....................................................................................................... 50 LIGHTING SYSTEM ................................................................................................... 52 GALVANISED STEEL STRUCTURES....................................................................... 52 SWITCHYARD MARSHALLING BOXES ................................................................... 58 EARTHING SYSTEM .................................................................................................. 58 PRECOMMISSIONING WORKS ................................................................................ 58 DC SYSTEM ............................................................................................................... 58 SPECIFICATION FOR POWER AND CONTROL CABLES ...................................... 60 SPECIFICATION FOR TRAYS AND ACCESSORIES ............................................... 67 REFERENCE DRAWING ........................................................................................... 69
Page 3 of 69
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
1.
INTRODUCTION
This specification is intended to cover complete design, engineering, manufacture, assembly testing at manufacturer's works, supply, installation, commissioning and delivery, properly packed for transport to site of all equipment and accessories, Steel Structures & Structural work, complete and efficient erection, testing, commissioning & putting into successful commercial operation GIS cum AIS 220 kV switchyard of OPG power Gujarat PVT Ltd., Gujarat, India for 2x150 MW units. The bid for all items of equipment and system covered under this specification shall be complete in all respects and any item of equipment or accessory not specifically mentioned in this specification document but considered essential for efficient and satisfactory operation of individual equipment and system as a whole shall be included in the offer. The evacuation of generator power shall be through two nos of 220kV outgoing lines. The 220kV switchyard shall have Double Main Bus scheme with GIS as shown in the Drawings.
2.
SWITCHYARD CIRCUITS AND EQUIPMENT

The Design of the GIS Double main bus scheme shall have: 1. Generator transformer Feeder 2. Outgoing line bays 3. Station transformer Feeder 4. Bus coupler bay 2 no 2 no 1 no 1 no
The switchyard equipment shall be supplied and installed with all accessories to make the switchyard complete in all respects. The switchyard shall consist of, but not be limited to the following: 245 kV SF6 circuit breakers, isolators, current transformers and capacitor voltage transformers / EMVTs. 198 kV, 10kA lightning arrestors. Bus bar material & accessories, insulator, assemblies, clamps & connectors. Switchyard structures, supports. Switchyard control & relay panels such as outgoing line CRP, GT CRP, ST CRP, Bus Bar CRP, Bus Coupler CRP & unit transformer relay panel.
Aquatherm Engineering Consultants India Pvt Ltd Page 4 of 69
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
220kV GIS Bus duct from GIS to Transformer yard and its support materials SCADA & associated equipment. Power Line Carrier communication & associated equipment. Switchyard lighting & earthing materials. Power & control cables. 220V Battery & battery charger for switchyard 48V Batter & battery charger for PLCC ACDB & DCDB as required no.of outgoing feeders. 20% spare feeder should be provided by the contractor Design of switchyard civil works such as buildings for GIS & control room, isolator/CT/PT/LA foundation, tower & gantry foundation, bus duct support design & its footing design, fence & trenches.
3.
BASIC INSULATION LEVEL

Rated one minute Power Frequency Withstand Voltage kV (rms) Rated Lightning Impulse Withstand Voltage kV (peak) : 460 kV (RMS) : 1050 kV peak
4.
4.1.
GAS INSULATION SWITCHYARD

General The complete gas insulated switchgear shall be constructed in accordance with IEC 62271 - 203, unless otherwise stated in this Specification. It shall be fully tested in accordance with IEC 62271-100, 62271-102 and 60694. All type tests shall be either, carried out by independent testing laboratories not associated with the manufacturers, or, witnessed by independent observers. The Contractor shall supply suitable test equipment, interface transducers and connections to fully test the equipment offered. All Capacitive Couplers for Partial Discharge monitoring and site testing of GIS installations prior to energisation, shall be left in position for later use by the Client, to monitor periodically the levels of discharge. Only the analyzer shall be included in the list of spares.
Page 5 of 69
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
The signature records taken by the manufacturer prior to energisation shall be made available to the Client for future comparison purposes. Continuous partial discharge monitoring on the installation is not required. However, an optional cost for a continuous partial discharge monitoring system should be provided. 4.2. CODES & STANDARDS High voltage metal-enclosured switchgear High voltage AC Circuit Breaker Current Transformer Voltage Transformer AC Disconnectors & Earthing switches Cable connections for gas insulated metal enclosed switchgear Lightning Arrester All relevant IEC standards IEC 62271-209 IEC 60099-4 IEC 62271-203, 60694 IEC 62271-100 IEC 60044-1, 60044-6 IEC 60044-2 IEC 62271-102
4.3.
Gas Insulated Switchgear (GIS) Enclosures Enclosures shall be designed in accordance with the requirements of IEC 62271 - 203. The arrangement for bolting together and the method of ensuring electrical conductivity between enclosures shall be to approval of the Client. The live parts of the switchgear and busbars shall be supported on barriers of insulating material with proven long-term compatibility with SF6 gas and its arc degradation products. The insulating barriers shall be discharge free at all working voltages. The design of the enclosure shall be such as to keep loss of SF6 gas to a minimum. It is expected that replenishment of gas shall not be necessary for at least 10 years. Therefore, the gas leakage rate of any gas zone must not exceed 1 per cent of its volume per year. Gaskets and seals shall be designed for a life expectancy of at least 30 years and this shall be demonstrated by tests or otherwise. The switchgear gas enclosures must be sectionalised into gas zones with gas tight barriers between sections or compartments. The sections shall be arranged to minimize the extent of plant rendered inoperative when gas pressure is reduced, either by excessive leakage or for maintenance purposes, and to minimize the quantity of gas that
Page 6 of 69
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
has to be evacuated and then recharged before and after maintaining any item of equipment. In order to minimise the extent of equipment outage in the event of gas loss when gaining access inside equipment for maintenance or when an item of equipment needs to be removed, the overall equipment shall be divided into discrete gas zones isolated from each other by gas-tight bulkheads. Separate gas-zones shall be provided for busbars and isolators. The gas-tight support insulating barriers shall be capable of withstanding a pressure differential of a vacuum on one side and on the other a pressure equal to the design gas pressure or the maximum gas pressure under conditions of an internal fault if this is greater. The design of the enclosure assemblies shall be such that in the event of a fault, the damaged items can be replaced with minimum disturbance to the adjacent compartments. Each gas-tight zone shall be provided with a device to relieve any pressure rise developed during internal flashover. Overpressure created by arcing within an enclosure shall preferably be relieved by means of bursting discs venting into the atmosphere. The method of pressure release shall prevent permanent distortion of adjacent enclosures. Pressure relief by collapse of internal gas barriers is not acceptable. The arrangement of any pressure relief device shall be such that any expulsion of disc debris or gas will be directed in a manner that will not endanger any personnel and relief vents shall be provided with deflectors or vent pipes as appropriate to satisfy this requirement. The duration of the fault arc shall be determined by the operation of the main and back up protection equipment under all fault conditions as defined and specified in IEC 62271 - 203 and verified by relay setting calculations. During this fault period burn through of the enclosure by the fault arc is not permitted. 4.4. Gas Insulated Switchgear - Busbars and Connection Chambers The switchyard main buses of GIS shall be designed for 2000 A continuous current, 40kA short-circuit. The switchyard shall be designed for a fault level of 40 kA for 1sec and dynamic rating of 100 kA peak. To minimise the extent of dismantling necessary to remove a part of a main busbar, it is required that discrete lengths of busbar shall be able to be withdrawn without disturbing
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
adjacent busbar lengths; this may be achieved by the use of compressible bellows or other approved means. The equipment shall be arranged to avoid excessive dismantling in the event of a main busbar fault. Information shall be provided with the tender to indicate the facilities incorporated in the equipment to allow removal of busbars and the consequential maximum extent of dismantling that may be involved in the event of such a fault. All busbar connections and busbar chambers (where phase segregated busbars are employed) shall be colour coded to indicate the phase colour associated with the connection. All gas pipe work shall be colour coded and where more than one pipe follows a common route, each pipe shall be ring coded or labelled at regular intervals to identify the gas zone with which it is associated. 4.5. Enclosure Gas Zones The switchgear gas enclosures must be sectionalised into gas zones with gas tight barriers between sections or compartments. The sections shall be arranged to minimize the extent of plant rendered inoperative when gas pressure is reduced, either by excessive leakage or for maintenance purposes, and to minimize the quantity of gas that has to be evacuated and then recharged before and after maintaining any item of equipment. 4.6. Expansion Joints and Flexible Connections Expansion joints or flexible connections shall be provided in the busbars and metal enclosures to absorb the thermal expansion and contraction of the SF6 equipment. This shall include the switchgear supporting structures and shall accommodate differential settlement of the foundations and floors on which the equipment is mounted. The method of compensating for temperature variation and differential settlement as well as the number and position of the compensating devices shall be stated in the Schedules. 4.7. Future Extensions The design of the switchgear shall be such that it is possible to extend each end of the existing busbars without having to take more than one busbar out of service. Other circuits shall remain available for continuous uninterrupted service.
Page 8 of 69
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
Where the distance between adjacent circuits is the width of a switchgear bay or greater, a removable straight through busbar section shall be included. It shall be possible to interchange this section with a future bay, if required, without having to take more than one bar out of service and without interruption of other connected circuits. 4.8. Gas Monitoring and Handling All gas zones shall be filled to the design pressure with pure SF6 gas (to IEC 60376/BS 5207) and shall be monitored individually by temperature compensated pressure switches and pressure gauges. A two-stage alarm system shall be provided for each gas section, including all relays, fascias, etc, these shall be accommodated adjacent to the switchgear. Additional repeat alarms to announce remotely each alarm stage for the group alarms of each switch bay shall be provided. The local control cubicle shall be adequately labelled to allow easy identification of signals from each gas section. The low pressure/density alarm switches shall be arranged to provide an instruction for the operation, either automatically or manually of the circuit breakers and disconnectors adjacent to a faulted gas zone and to subsequently inhibit their further operation until suitable remedial action has been taken. In view of the dependence of system security on the reliability of the gas density relays, and in view of the large number of relays involved in any regular relay checking procedure, the gas density relays shall have a high degree of reliability. Consideration shall be given in the design of the relay to allow easy checking of its proper operation. Provision shall be made to enable routine measurement of the gas density in each gaszone. The location of such measuring points shall be reasonably accessible. Each gas density device shall be connected to the gas compartment via a self-sealing valve to facilitate easy removal of the device for maintenance. The use of stop valves for this purpose is not acceptable. Facilities shall be provided to constantly monitor the gas density. A two-stage low gas pressure alarm and lock out system with local and remote indications shall be provided on each circuit breaker. 4.9. Local Control Cubicles Local control cubicles shall be separate, floor mounted cubicles, provided adjacent to each switchgear section which shall contain all facilities for control, indication,
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
local/remote control selection, protection and alarms associated with that switchgear section. A mimic diagram incorporating switches, contactors and relays necessary for local electrical control of circuit breakers, disconnectors and earth switches together with position indication shall be included. Any plug and socket cable connections between switchgear sections and their associated local control cubicles shall be provided with a secure means of locking the connection to prevent inadvertent disconnection. 4.10. Gas Insulated Bus Duct and Bushings SF6 insulated gas bus ducts and supporting structures and foundations shall be provided between circuits as required. The type of 245kV busduct ie isolated or non segregated, shall suit the arrangement of the main GIS switchgear to which the bus duct is connected. The SF6 enclosures shall be constructed from the same materials as the bus bar enclosures provided with the main GIS switchgear. The materials used shall prevent overheating at the specified rated currents. To reduce the effect of solar gain all SF6 insulated bus duct exposed to direct sunlight shall be covered with metallic sun shielding. The bus duct shall be complete with all components, enclosures, gas seals, gas monitors, gas compartments, gas filters, gas barrier and supporting insulators as defined in previous subsections. The bus ducts shall be terminated at one end direct on to the GIS switchgear and at the other end on to outdoor porcelain-clad, or approved composite-material-clad bushings for OHL feeders & Generator transformer/Station transformer feeders. The design of the bus ducts shall make full allowance of the thermal expansion associated with the switchgear, wall mounted bushings and any other equipments between which the bus ducts are connected. The Contractor shall fully co-ordinate the requirements of the SF6 insulated bus duct connections between the GIS switchgear feeders and the overhead line landing gantries & Generator/station transformer gantries, especially with regards to the differential settlement of the concrete floors of the switchgear room and the bus duct supporting structures. The design and installation of the bus ducts shall as such be fully co-ordinated with the manufacturers of the equipments to be connected and shall also be co-ordinated with the civil design and works in relation to the building height, wall openings, wall/roof embedment, structural, etc, apart from the foundation requirements described herein.
Page 10 of 69
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
The bus ducts and their supports shall be designed and tested for the specified rated normal and short time currents and for the maximum system voltage and specified test voltages. The ducts and their supports shall include any non-magnetic material or insulation necessary to prevent overheating or the induction of over-voltages in the secondary circuits. Provision shall be allowed for access and disconnection links for equipment HV testing as may be required at site. 4.11. 4.11.1. 245 kV GIS HV Circuit Breakers General SF6 gas insulated (GIS) circuit breakers shall be single-pressure puffer or Self-blast or Self- blast/Rotating Arc type, suitable for indoor installations. Circuit breakers shall be designed to IEC 62271 - 203 and fully tested in accordance with IEC 62271100, IEC 60694 and IEC 62771-110 and with the requirements of this Specification and shall be capable of carrying the specified rated current continuously under the Site conditions. All type tests shall be either carried out by independent testing laboratories or witnessed by independent observers. The design of the circuit breaker shall be such that inspection and replacement of contacts, nozzles and any worn or damaged component can be carried out quickly and easily. The circuit breaker shall be fitted with the open/closed position indicators easily visible from ground level. The inherent design of the circuit breakers shall be such that one set of contacts and nozzle (or nozzles as the case may be) shall be able to successfully interrupt at least twenty 100% fault currents without excessive erosion. When switching Capacitive (capacitor banks) and Inductive (including reactors) currents (IEC 62771-110), they produce very low over-voltages. The over-voltages produced on any switching duty must be considerably less (<<) than 2.5 pu. The sound pressure levels of the breaker during the mechanical operations shall comply with the local and national health and safety regulations. A suitably sized molecular sieve shall be used in the circuit breaker tank to absorb any moisture and contaminants for at least ten years in service.
Page 11 of 69
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
The circuit breakers shall be suitable for at least 10,000 satisfactory open and close mechanical operations in accordance with IEC 62271-100. A two-stage low gas pressure alarm and lockout system with local and remote indications shall be provided on each circuit breaker. The low pressure/density alarm switches shall instantly provide an instruction to the operator and subsequently inhibit their further operation until suitable remedial action has been taken. The circuit breaker shall be fitted with the necessary transducers to allow regular monitoring of circuit breaker travel characteristics and all routine and site test records shall be made available to the Client for ongoing comparison purposes. The provision of suitable test equipment for measurement of the circuit breaker timing cycle in included under this contract. 4.11.2. Spring Mechanisms Spring operated mechanisms are the preferred type Provision should be made for remote indication of 'Spring charged' and 'Spring charge fail' conditions. A spare normally open spring-drive limit switch shall be provided. It shall be possible to hand charge the operating springs with the circuit breaker in either the open or closed positions. In normal operation, recharging of the operating springs shall commence immediately and automatically upon completion of the closing operation and shall be completed within 30 seconds. Closure whilst a spring charging operation is in progress shall be prevented, and release of the springs shall not be possible until they are fully charged. The state of charge of the operating springs shall be indicated by a mechanical device which shows 'SPRING CHARGED' when operation is permissible and 'SPRING FREE' when operation is not possible. A local manual spring release device shall be provided and so arranged as to prevent inadvertent operations. Means shall be provided for hand charging the operating springs. 4.11.3. Hydraulic and Hydraulic/Spring Mechanisms Operating pressure shall be maintained automatically, a gauge being provided to give indication of the pressure. The pressure gauge shall be suitably damped to ensure that it is not subject to transient pressure oscillations either during pumping or during operation of the circuit breaker.
Page 12 of 69
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
A lockout device with provision for remote alarm indication shall be incorporated in each circuit breaker to prevent operation whenever the pressure of the operating medium is below that required for satisfactory subsequent operation at the specified rating. Such facilities shall be provided for the following conditions: Trip lockout pressure. Close lockout pressure. Auto reclose lockout pressure.
Alarm contacts shall be provided to indicate conditions a, b and c. If two trip systems are specified, then trip lockout shall apply to both systems. A sudden fall in pressure of the operating medium to a level below which a safe operation is not possible shall not result in slow opening or closing of the circuit breaker contacts. The mechanism shall be locked in position and electrical trip and close signals shall be isolated during this period. Facilities shall be provided to enable the available operating energy stored by the mechanism to be determined prior to operating the circuit beaker, together with an alarm in the event of the potential energy falling below a minimum rated level. Facility for hand charging of hydraulic systems shall be provided. Circuit breakers having independent operating mechanisms on each phase shall block tripping, closing, and auto-reclosing of all phases if the operating pressure is below a minimum rated level in one or more of the mechanisms. A pump running time meter shall be fitted and an alarm shall be provided to indicate excessive running time. 4.11.4. Mechanism Housings Where heaters are provided, these shall be permanently connected. Where two-stage heaters are provided, one stage shall be permanently connected and the other switched. Means for locking shall be provided for the doors of each mechanism housing. Mechanism housings for use outdoors shall have an IP rating of 55, those for indoor shall be IP 30.
Page 13 of 69
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
4.12.
GIS Disconnect Switches The GIS disconnect switches shall be constructed and fully tested in accordance with the requirements of IEC 62271-102, IEC60694, IEC61128, IEC62271 - 203, and IEC 60265 and this Specification. The design shall incorporate features, which shall reduce or eliminate very high frequency voltage transients during disconnect switch operation. The disconnecting function of disconnect switches shall still be effective when adjacent equipment components are dismantled. It is preferred that disconnect switch contacts are able to be maintained and replaced with the associated earthing switch closed. Disconnect switches shall be fitted with position indicators visible from ground level. Viewing windows for confirming the positions of disconnect switches and earth switch contacts shall be provided unless prior agreement is reached with the Client. The disconnect switches shall be provided with power and manually operated mechanisms. The power operation of the disconnect switches shall be capable of being controlled from a local or remote point. Each power-operated disconnect switch shall be complete with a lockable
LOCAL/REMOTE selector switch and OPEN/NEUTRAL/CLOSE control switch or push buttons. The function of all control and selector switches shall be clearly labelled. Power operating mechanisms shall be capable of being locked in the open or closed positions. The power operating mechanisms shall be suitable for the operation from voltages specified in the Schedules of this Specification. Operating motors shall be provided with thermal overload protection and in the case of 3 phase motors, phase unbalanced protection. The disconnect switches shall be suitable for slow closing operation. Manual operation of the disconnectors for maintenance purposes shall be provided. The number of normally open and normally closed auxiliary switches required shall be as dictated by the particular scheme of application. Where any particular scheme requires special timing of auxiliary contacts, these shall be provided. Electrical control circuits shall be so arranged that once initiated, an operation shall be completed unless prevented by loss of supply or operation of the motor protection. On restoration of supply the operation shall be completed.
Page 14 of 69
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
Emergency hand operation shall be provided on power-operated disconnect switches and the power drive shall be mechanically disconnected during hand operation. It is required that the manual effort to operate the disconnectors or earth switches shall not be greater than 150 N. There shall be adequate access for the manual operation. In the case where the operating mechanism comprises an energy storage system followed by triggering for completion of the operation, the design shall exclude any possibility of operation by accidental triggering. Switch operation shall be effective only after full charging of the operating mechanism and after deliberate operator action. The operating handles for manual operation of power-operated mechanisms may be detachable, in which case only two handles of each type are required per substation. 4.13. 4.13.1. Earth Switches and Maintenance Earthing Devices GIS Earth Switches Earth switches shall comply with IEC 62271-102 IEC60694 and IEC 62271 - 203 and the requirements of this Specification. They shall be provided with power and manually operated mechanisms and shall be provided on one or both sides of the disconnect swiches dependent upon the locations. The electrical operation shall be performed from their control cubicles. The position indicators shall be clearly visible from the permanent working platform level. Each separate section of switchgear that can be disconnected shall have provision for earthing in accordance with the following requirements: (a) All incoming and outgoing supply circuits shall be earthed by a device having a
making current rating and short time rating equal to that of the associated circuit breaker. When specified, the earth switch shall be fully insulated and the connection to earth brought out through the enclosure by means of an insulating bushing in order that the earth switch may be used for various test purposes. A removable bolted link shall be provided for connecting the insulated earth switch connection to the actual earthing terminal. The earth switch and connection bushing shall be capable of withstanding an applied power frequency voltage of 10 kV. (b) Sections that can be established as having been disconnected shall be earthed by
a device having a short time rating equal to that of the circuit breaker.
Page 15 of 69
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
The earthing switch and the test injection point arrangement shall be suitable for a test current equal to the rated normal current of the connected busbars for a duration of 5 minutes minimum. Earth switches on line circuits shall be capable of closing onto an energised circuit and of interrupting the current induced in the line by a parallel fully loaded line. The interrupting duty required is as specified in the schedules. The earth switch operating mechanism shall be capable of being locked in the open or closed position. 4.13.2. Portable Maintenance Earthing Devices Where portable earthing is required, provision shall be made for applying fully rated portable maintenance earthing devices to the primary conductors of the equipment. The design of the device shall be such that the chamber in which the device is applied can be refilled with SF6 gas when the device is in the closed position. 4.14. GIS Current Transformers Gas insulated current transformers shall be of the bar primary type. The pressure of the gas at normal temperature and pressure shall be such that it remains in its gaseous state when operating at the lowest temperature stated in the Schedules. Facilities shall be provided for constant local monitoring of the current transformer gas pressure, and topping up or sampling the gas. For safety reasons, a bursting disc shall be fitted to the current transformer housing. Current Transformer Primary Injection Tests Facilities shall be provided which allow primary injection testing of the current transformers with the minimum disturbance to the switchgear. 4.15. GIS Voltage Transformers The inductive voltage transformer shall be housed in a metal tank, which complies with the internal arcing requirements of IEC 62271 - 203. The tank shall have a suitable lifting facility.
Page 16 of 69
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
The high voltage cast resin insulators (barriers) shall be suitable for withstanding the differential pressure i.e. the normal working pressure on one side and the vacuum on the other side. They shall be compatible with SF6 gas and its degradation products. The pressure of the gas at normal temperature and pressure shall be such that it remains in its gaseous state when operating at the lowest temperatures stated in the Schedules. Facilities shall be provided for constant local monitoring of the SF6 gas pressure inside the tank, topping up or sampling the gas. Facilities shall be provided for isolating the voltage transformer during the injection testing of GIS equipment. For safety reasons, a bursting disc shall be fitted to the transformer housing. 4.16. 4.16.1. Sulphur Hexafluoride Gas (SF6) General The sulphur hexafluoride SF6 gas shall comply with the requirements of IEC 60J7j and BS 5207. The SF6 gas shall be supplied in 45 kg cylinders. The dew point of the gas shall be lower than -45C. Sufficient quantity shall be provided to fill all SF6 equipment supplied under this contract plus an additional 20 per cent. The high-pressure cylinders in which the SF6 gas is transported to, and stored on site, shall comply with the requirements of local regulations and bye laws. Under normal conditions the SF6 gas of temperature and pressure is colourless, odourless and nontoxic. It is however five-times heavier than air and the arced gas and degradation products are toxic and harmful. It is therefore important that all personnel working on GIS equipment are kept fully informed of the potential risks and appropriate health and safety regulations. It is therefore the responsibility of the gis equipment supplier to provide: Adequate safety training to the Client's staff regarding gas detection, the disposal of arced products and storage. Sufficient number of facemasks, goggles, hand gloves and respirators, protective clothing and gloves.
Page 17 of 69
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
4.16.2.
First aid equipment including an eye wash bottle filled with distilled water.
Gas Handling Equipment A mobile gas handling plant for filling, evacuating, and processing the SF6 gas in the switchgear equipment, is to be supplied as part of the Contract to enable any maintenance work to be carried out. The plant shall include all the necessary gas cylinders for temporarily storing the evacuated SF6 gas as well as any other gases that may be used in the maintenance process. The capacity of the temporary storage facilities shall be at least sufficient for storing the maximum quantity of gas that could be removed when carrying out maintenance or repair work on the largest section of the switchgear and associated equipment. The plant provided shall be suitable for evacuating and treating the SF6 gas by the use of desiccants, driers, filters etc to remove impurities and degradation products from the gas. The capacity of the plant shall be such that the largest gas zone, with the exception of the circuit breaker, can be evacuated in less than one hour. The plant shall also be capable of reducing the gas pressure within the circuit breaker to a value, not exceeding 8 millibars, within a time not greater than two hours. It shall be capable of operating in the temperature range -27C to +50C.
4.16.3.
Pipes and Couplings for the Connection of SF6 Gas All the necessary pipes, couplings, flexible tubes and valves for coupling to the switchgear equipment for filling or evacuating all the gases to be used, with all necessary instructions for the storage of this equipment, shall be provided.
4.17. 4.17.1.
Overhead Travelling Crane General This contract includes the supply of all materials and works for a crane with all operating machinery, structural steel, control equipment including cables and all other parts and accessories required for proper and safe operation. The travelling crane shall be used for erection work as well as for normal maintenance, repair and overhaul purposes. The crane shall be complete, including, crab, hoisting machinery with motor and brakes, all lubricating devices, ropes, sheaves, hooks, flood lights, control apparatus
Page 18 of 69
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
including switchgear, runway rails, push-button controls, interlocks, limit switches, governors, protecting and alarm devices and all electric connections (cables and live rails including insulators) between all parts supplied. 4.17.2. Construction Features The design of the travelling crane has to guarantee fail-safe and satisfactory operation and has to be easy to access for service, inspection and repair. A safety factor of 1.5 times of the maximum load is to be taken into account for all stress calculations to allow shock loading. Adequate guards shall be provided to protect personnel from accidents caused by moving mechanism, live terminals, live conductors, etc. The guards shall be removable for inspection and maintenance without disturbing any other part of the plant. The Contractor shall supply suitable nameplates, giving details of the lifting capacity of the travelling crane. These nameplates shall be clearly visible to anyone who may use the cranes. The nameplates shall be inscribed in English Language. Operating machinery and other exposed parts shall be suitably housed so that the exterior of the travelling crane will consist of smooth surface and pleasing lines. 4.17.3. Structure The minimum plate thickness for the steel construction shall be 7 mm, unless otherwise demonstrated suitable by the Contractor. 4.17.4. Crane Rails Travelling crane rails shall be provided by the Contractor. Joints between rails on opposite runway girders for the cranes shall be staggered with respect to each other and to the wheelbase of the cranes. All joints of rails shall be welded. Rail joints shall not be located over the runway girder splices. Provision for rail expansion shall be made at the end stop locations only. Guiding of rails on the girders should be carried out with rail clamps to distance adjustment. Welded clips are not allowed. End stops shall be designed and located to limit the maximum crane travel. The end stops shall be capable of stopping the travelling crane fully loaded and travelling at the rated speed.
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
4.17.5.
Crane Bridge The travelling crane bridge shall consist of two girders rigidly attached to the end trucks. Gusset plates shall keep the crane in alignment. Welded joints shall be used for the main structure of the crane, bolted joints shall be avoided whenever possible. -In load bearing members, if a bolted joint is necessary, black bolts shall not be used. -The strength of welded joints or joints made by friction grip bolts in structural members shall not be less than the net strength of the member. Friction grip bolts shall comply with BS 3139 and shall be fitted in accordance with the recommendations of BS 3294. -The calculated strength of other bolted joints in structural members shall be not less than the net strength of the member plus 25 per cent. The calculated stress in screws, bolts and welds shall not exceed the appropriate permissible stress given in BS 2573. The travelling crane girders shall be welded in structural steel box sections, with wide flange beams, standard "I" beams or reinforced beams. Girders must be symmetrical and line-of-sight must be considered along with girder design, as well as suspended crane supports. Trellis girder shall be prohibited. The girders shall be designed to withstand all vertical loads and horizontal forces that may arise under service conditions. The vertical deflection of the girders, caused by the safe working load and the weight of the crab in the central position shall not exceed 1/1000 of the span. The larger of the following load combinations shall control the design of the girders: The sum of the maximum stresses due the dead load, the weight of the trolley, the rated load, and the impact allowance. The sum of the maximum stresses due to the dead load, the weight of the trolley, the rated load, and an allowance for the lateral load due to acceleration and deceleration of the travelling crane. The bridge girders shall be security braced to the end carriages to prevent cross racking. It must be impossible for the travelling crane to fall from the gantry in the
Page 20 of 69
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
event of derailment. The carriages shall be of the bogie type and shall be equipped on each end with spring buffers (bumpers). 4.17.6. Electrical Parts The travelling crane and hoists shall be so designed that adequate access for maintenance of the electrical control and operating gears is provided with suitable access facilities to enable removal of parts for maintenance and repair. The power supply shall be provided via adequately protected contact wires along the crane track and a suspended cable on the crane girders. The supply to the contact wires shall be via a manually operated load break isolating switch mounted at a convenient height above floor level, the switch being capable at being locked in the open position. Red indicating lights shall be arranged at collector level to show when the isolator is closed. Motors shall be provided with quick action brakes; controllers, resistors, magnetic contactors and overload protection switches. Heavy dust and splash-proof limit switches shall be provided to prevent over hoisting, over transversal and over travelling motions. 4.17.7. Motors All motors shall be totally enclosed, wound rotor type specifically designed and built for crane service. Motors shall be equipped with sealed antifriction, grease lubricated bearings, with provision for grease renewal. Motors shall have tapered shaft extension on the brake end for easy removal of the brake wheel. 4.17.8. Push Button Control Station The push button control station shall be suspended by means of flexible galvanised wire rope and connected to the crane control panel by means of flexible multicore cable. The arrangement shall permit movement of the control station along the entire length of the bridge at all levels of operation. The push button control station shall have a cast aluminium housing and shall have mechanical protection class of IP 44. The Control station shall contain besides all necessary individual push buttons for controlling operation of all crane motors, an emergency push button of the lockable type. This shall function as a master switch to
Page 21 of 69
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
cut off all power supply to the crane control panel, by switching off the master magnetic contactor. 4.17.9. Overload Relays Each motor shall be protected by overload relays adjustable for values between 50 and 150 per cent of the full load motor current. 4.17.10. Switchgear The power supply from the main collectors shall be controlled by means of a 3phase, manually operated circuit breaker, and a 3-pole master magnetic contactor provided with under-voltage and phase reversal protection. The operating coil of the contactor shall be wired in series with the auxiliary contacts of the adjustable, instantaneous relays in the circuit of each hoist and each travel motor, and in the circuits of all limit switches. The circuits shall be so arranged that, on the functioning of an overload relay or the tripping of the limit switch, the flow of power to the crane will be interrupted. 4.17.11. Circuit Breaker Cabinets The main circuit breaker, lighting supply circuit breaker, master contractor, relays and protective devices shall be enclosed in a suitable steel cabinet with hinged doors. The main circuit breaker shall be so arranged that it can be operated without opening the cabinet door and that it can be locked in the open position. 4.17.12. Limit Switches Limit switches shall be provided to control the upper limits of travel of all hoist motors and at each end of travel for the bridge and trolley. Switches shall be of the totally enclosed safety type operated by the hooks or hook blocks. 4.17.13. Tools One steel toolbox shall be provided containing complete set of ordinary and special tools needed for overhauling and repair of cranes furnished. General list of such tools shall be indicated in Tenderer's offer, and shall be detailed and submitted by the Contractor to the Client for checking and approval. 4.18. EARTHING SYSTEM FOR GIS GIS supplier should generally provide or be responsible for:
Page 22 of 69
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
Providing the sub assembly to subassembly bonding to ensure safe voltage gradients between all intentionally grounded parts of the GIS assembly and between those parts and the main ground bus of GIS. Furnishing readily accessible connectors of sufficient mechanical strength to withstand electromagnetic forces and thermal abuse and that are capable of carrying the anticipated maximum fault current in that portion of the circuit without overheating. Providing ground pads or connector or both, allowing at least for two paths to ground from the main ground bus or from each metallic enclosure and auxiliary piece of GIS equipment designated for a connection to the stations ground if the main ground bus of GIS assembly does not actually exist. Recommending proper procedure for connections between dissimilar metals typically between a copper cable or a similar or (steel) ground conductor and aluminium enclosure. Grounding recommendation of GIS and interfacing with the overall switchyard grounding including limiting touch & step potentials. Providing EMI mitigation techniques caused by transients. 4.19. 4.19.1. Interlocking Equipment Extent of Supply The Contractor shall be responsible for the designing, supply and commissioning of all interlocking schemes to the satisfaction of the Client. Designs are to cover the 220 kV switchgear, ac station services, dc station services. 4.19.2. General All disconnecting switches and earthing devices shall be provided with interlocking features of the mechanical sequential locking type or electromechanical bolt type, and the scheme of interlocking shall be subject to approval and shall include the hand operation of apparatus which is normally electrically operated. All mechanical interlocks shall be applied at the point at which hand power is used, so that stress cannot be applied to parts remote from that point. Where key interlocking is employed, tripping of the circuit breaker shall not occur if any attempt is made to remove the trapped key from the mechanism. Any local
Page 23 of 69
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
emergency tripping device shall be kept separate and distinct from the key interlocking. All electrical interlocks shall so function as to interrupt the operating supply. Failure of supply or connections to any electrical interlock shall not produce or permit faulty operation. Electromechanical bolt interlocks shall be energized only when the operating handle of the mechanism is brought into the working position. Visible indication shall be provided to show whether the mechanism is locked or free. Means shall be provided whereby the bolt can be operated in the emergency of a failure of interlock supplies. Earthing switches are to be interlocked with the appropriate disconnect switches such that the earth switch cannot be closed unless the disconnect switches are open. Conversely, the disconnect switch cannot be closed unless the earth switch is open. When made of steel or malleable iron, operating boxes, handles, rods, tubes and other fittings for outdoor equipment shall be galvanized.
4.20.
Technical Requirements OF 220kV GIS SWITCHYARD
General technical data Rated service voltage (kV rms) Rated maximum voltage (kV rms) Rated frequency (Hz) Rated continuous current Bus (arms) Terminal (arms) Rated short circuit current (kA rms) Short time current duration (s) Peak withstand current (close and latch) (kA rms) Withstand Voltage: Power frequency (kV rms) Full wave impulse (BIL)
User requirements 220 kV 245 kV 50 Hz 2000A
Supplier proposal
40 kA 1 sec
460 1050
Page 24 of 69
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
Switching impulse (SIL), if required Maximum acceptable moisture level: Circuit breaker (PPMV)* Compartments where arcing is not expected (PPMV) Enclosure and conductor (for each rating) Inductance (H/m) Capacitance (pF/m) Resistance: Enclosure (/m) Conductor (/m) Surge impedance Weight of gas for largest gas zone (kg) Length of bus section (m) Bus enclosure data (for each rating) Type of material Outside diameter (mm) Wall thickness (mm) Internal SF6 GIS pressure at 20C (kPa) Circuit Breakers Voltage range factor Rated continuous current (A rms) Rated short circuit current (kA rms) Rated short time current duration (s) Rated peak withstand current (closing and latching) (kA rms) Rated interrupting time (ms) Rated reclosing time (ms) Rated permissible tripping delay (s) Rated capacitor switching current (a rms)
600 kPa
245 kV 2000 A 40 kA 3 sec 104 kA
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
Rated operating duty cycle Type of operating mechanism Breaker operating time for rated control voltage and pressure Operating time from for rated energizing of trip coil to contact parting Closing resistors (if applicable) Ohmic value of closing resistors per phase Insertion time during closing (ms) Gas pressures Pressures at 20C Maximum foundation loading during operation: Horizontal (N) Vertical (N) Motor capacity Number and type Power of each (W) Voltage and number of phases (V) Current, start/run (A) Total heater power per three pole breaker (W) Control circuit Rated dc control voltage (V) Closing voltage range (V) Tripping voltage range (V) Maximum tripping current (A) Number of trip coils per breaker pole Number of operations before the breaker Must be removed from service for maintenance inspection No-load mechanical Full load non fault Rated short circuit current Expected number of hours required to perform a complete maintenance inspection of one breaker
O 0.3s CO 3 min CO Spring operated/ hydro mechanical with energy storage in springs
220 V DC 220 V DC 220 V DC
Two
40 kA
Page 26 of 69
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
Number of breaker operations without recharging (dB) Number of full reclosing operations without overheating the closing resistors (specify the closing duty for the thermal rating) Disconnect Switches Rated full wave impulse withstand voltage Across the open gap (kV peak) Power frequency 1 withstand voltage: Across the open gap (kV rms) Number of switch operating mechanism operations before internal visual inspection or servicing Maximum operating current (A) Minimum closing current (A) Heater power per three pole switch (W) Main current carrying contact material Base material and specification Contact insert Plating material Control data for operating mechanism Operating time (s) Maximum charging current interrupting (A) Grounding Switches Rated Peak withstand current (close and latch) (kA rms) Number of the mechanical operations before internal visual inspection or servicing Number of closing operations into energized bus without damage Ground switch interrupting capacity, if specified and agreed (A) Voltages Transformers Name of the supplier Applied test voltage (kV rms) Power-frequency field test voltage with VT Connected (kV rms) 1050
460
2000
Page 27 of 69
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
Ratio of high-voltage to low-voltage windings Thermal rating of each secondary winding (VA) Thermal rating of the primary winding (VA) accuracy classification List burdens for which the above accuracy classifications apply Current Transformers accuracy class Ratio in terms of primary and secondary current ratings Continuous thermal current rating factor Secondary winding insulation class Are all current transformers external to the GIS enclosures? (yes/no) Are CTs split-core type? (yes/no) Gas-to air-bushing Name of the supplier Type designation of the supplier Material Rated power frequency withstand Dry-1 min (kV rms) Wet-10s (kV rms) External strike distance; Phase-to-ground (mm) Phase-to-phase (mm) External creep distance (mm) Cantilever strength (N.m) Acceptable terminal load (N) Gas System Total quantity of SF6 gas required with the original equipment (kg) Total quantity of SF6 gas required per breaker (kg) Guaranteed maximum SF6 gas leakage rate from the complete GIS (Kg/year) Number of gas monitoring systems included with the equipment.
220 kV/3/110V/3 As per SLD
As per SLD
As per SLD As per SLD
31 mm/ kV
Page 28 of 69
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
* PPMV = Parts per Million per Volume
5.
AIR INSULATION SUBSTATION
5.1.
Clearances In line with the recommended insulation levels above, the following minimum clearances shall be adopted for 220 kV switchyard equipment & connections Phase to phase Phase to earth Sectional clearance Minimum Ground Clearance 2100 (min) mm 2100 (min) mm 4600 (min) mm 5500 (min) mm
5.2.
Creepage Distance Considering the location of the switchyard, minimum creepage distance of 31mm/kV shall be provided for the following equipment. For Generator Transformer and Station Transformer bushings creepage distance shall be 31mm/KV. Circuit breakers Bus post, isolators and lightning arresters Insulator strings Current and voltage transformers
5.3.
Bus Bars Bus bars shall be of stranded ACSR conductor (aluminium conductor steel reinforced) and tubular aluminium of suitable size according to standard metricised iron pipe size (IPS). The conductor size for bus shall also be based on maximum load current that the conductor can carry with allowable temperature rise within limits, short circuit conditions and permissible corona / voltage gradient. The final temperature of the conductor when carrying full load current shall not exceed 90 deg. C with a design ambient of 50 deg. C. reduce corona effect. The short time rating shall be 40 kA for 1sec. The tension in strung bus shall be such as to limit the sag within about 3% of the span. The tension for power conductor shall be 1000 kg/sub-conductor. The conductor size and spacing shall be checked to limit the voltage gradient to 17 kV/cm to
Page 29 of 69
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
Voltage gradient criteria, which determine the minimum OD of the tube, shall be applicable for tubular buses as well. 5.4. Shield Wire The size of the shield wire shall be based on the lightning impulse current expected and time duration. Allowance shall be given to the final size of the earth wire to account for corrosion during service, at a rate of at least 0.03 mm per annum. However, the minimum size of the shield wire shall not be less than 70 mm2. Earth wire tension shall be 800 kg/conductor. 5.5. Insulators Tension and suspension insulator strings shall be fog type selected based on the voltage, insulation level, and pollution level and electro-mechanical strength. Creepage chosen shall be suitable for heavy pollution, i.e., 31mm / kV. Electromechanical strength shall be selected with factor of safety of 2.5. 5.6. Bus Post Insulators Bus post shall be solid core / post insulator type and shall be selected based on the system voltage, insulation level, and mechanical strength and pollution level requirements. Insulator hardware shall be corona free up to a falling power frequency visible discharge test voltage of 1.2 times the maximum system voltage. All steel components shall be double hot dip galvanized iron. 5.7. Lightning Protection of Switchyard The lightning protection of switchyard shall be by means of providing tower peaks. The zone of coverage shall be considered as 60 deg. between the two lightning conductors, inside the switchyard and 45 deg. on end conductors, outside the switchyard. The criteria for deciding phase to phase clearance in case of strung conductors shall take into account the conductor swing of one of the conductors (say R Phase) with maximum wind velocity and the adjacent conductor (say Y phase) with 80% of maximum wind velocity at maximum sag conditions. In the transformer yard, the power conductor termination shall not be tapped off directly to the generator transformer / station transformer from the strung bus between the TG building and the switchyard. The tap-off conductor shall be routed through a bus post insulator located near the transformer. For the layout proposed by the Contractor, the adequacy of the cantilever strength adopted shall be checked considering the following factors of safety:
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
Sum of all permanent normal loads (wind load on tubular bus + wind load on stack + dead weight of the tubes) = 2.5. Combination of all normal loads plus either short circuit or earth quake load, whichever is higher than 1. The switchyard shall be designed for the seismic coefficient and wind pressures as per the site data. 5.8. 220 kV ISOLATORS 220kV, 2000 Amps, 40 kA for 3 sec, double break, and center pole rotating type isolators shall be provided. A.C motor drive mechanism for main blade and manual operation mechanism for earth blade shall be provided. 5.8.1. Specific Requirements Isolators shall be electrically interlocked with the circuit breakers in accordance with the switchyard safety interlocking scheme. The required number of auxiliary contacts shall be provided for interlocks, DCS and panel indications. The flexible tinned copper connection between the rotating shaft of the earth switch and the frame shall have adequate cross-section to withstand short time current. 5.8.2. Technical Requirements The isolators shall comply with the requirements indicated in the following table: 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 2.0 2.1 2.2 2.3 2.4
RATING Application Quantity Nominal / Highest system voltage Frequency No. of phases Rated current Short time Current rating and duration Rated peak short circuit current Design Requirements Ambient temperature Insulation level Phase spacing Type of break 50 deg.C 1050 kV peak 3350mm (min) Horizontal double break(centre 100 kA (Peak) Switchyard As Required 220 / 245 kV 50 Hz 3 Phase 2000 A 40 kA for 3 sec.
Page 31 of 69
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
rotating) 2.5 2.6 Type of mounting Operating device (a) (b) 3.0 3.1 For isolator For earth switch Motor driven (Both local & remote) (Emergency Manual) Manual Insulation Data 1.2 / 50 micro sec. lightning impulse withstand (a) (b) To earth Across open disconnect lightning impulse 1200 kV peak. 31 mm/kV. 600 kg 460kV rms 530kV rms 1050 kV peak Horizontal upright
voltage applied to - One terminal 3.2 3.3 3.4 Minimum total creepage distance Minimum cantilever strength Power frequency withstand voltage (a) (b) 4.0 4.1 4.2 5.0 5.1 5.2 To earth Across terminals if open disconnect Miscellaneous Auxiliary supply Interlocks with circuit breakers Applicable standards Insulators Isolators IEC-296,BS:148 IEC 129,529,694,1128 & 1129 220 V DC for control and interlock; 230AC, 3 phase for motor drive electrical interlock
5.9.
220 KV CURRENT TRANSFORMERS 220 kV oil filled hermetically sealed single phase current transformers of the current ratios specified below shall be provided in the generator transformer bays, line bays and station transformer bays, as per Drg. Multi-ratio CT tappings shall be provided on the secondary side to obtain different ratios in order to permit different transformation ratios on each core, as desired.
5.9.1.
Specific Requirements The 220 kV current transformers shall comply with the requirements in the following table:
Page 32 of 69
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
1.0 2.0 3.0 4.0 5.0 5.0 6.0 7.0 8.0 9.0 10.0 11.0 12.0
Type Nominal System Voltage Highest System Voltage No. of cores Primary current Secondary current Short time thermal rating Dynamic rating Class of Insulation Rated Burden Accuracy class - Core Maximum temp. rise of winding above ambient of 50 deg.C Cantilever strength of CT at the terminal (min) 1.2 / 50 sec. impulse positive & negative One minute power frequency withstand voltage Creepage distance (min) Partial discharge level Applicable standards Current transformers Bushings Large Hollow Porcelains Insulators Hot dip galvanising Insulating oil
: : : : : : : : : : : : : : :
Outdoor, oil filled, dead tank heremetically sealed. 220 kV, 50 Hz 245 kV As per Drg As per Drg 1A 40 kA for 3 sec. 100 kA (Peak) Oil immersed Class A. As per Drg As per Drg 40 deg.C 600 kg 1050kV (Peak) 460 kV
13.0 14.0 16.0 16.1 16.2 16.3 16.4 16.5 17.0
: : : : : : : :
31mm/kV <10 pico-coulomb IEC-185,IEC 60044,BS:3938, IEC-137,BS:223 IEC137, IEC233, IEC 273, IEC 815 IEC-296,BS:148 IS : 2633 & IS : 2629 IS : 335
5.10.
220 KV CAPACITIVE VOLTAGE TRANSFORMER Capacitor voltage transformers shall be provided for the 220 kV switchyard As per Drg.
5.10.1.
Specific Requirements Fuses / fast acting MCBs of adequate rating shall be provided in each secondary output leads of each VT to protect the VT secondary branch circuit from the abnormal voltage surges that may occur on the VT primary side. The secondary shall also include suitable number of links for each secondary as per the requirement of fuse failure detection relays. The burden of the CVTs shall be adequate for the loads connected.
5.10.2.
Technical Requirements
S.No
Particulars
Data
Page 33 of 69
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
S.No 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 13.
Particulars Quantity Application Nominal / Highest system voltage Power frequency System neutral earthing type Co-efficient of earthing Rated primary voltage Rated secondary voltage No. of secondary windings Application Rated burden Accuracy class - Core 1 - Core 2 - Core 3 Rated voltage factor Class of winding insulation Max. Winding temp. at 110% Excitation & rated burden Creepage distance (min) 1.2 / 50 micro sec. impulse voltage withstand One minute power frequency voltage withstand One minute power frequency test Withstand voltage between low - voltage terminal and earth terminal Withstand voltage for secondary winding Applicable Standards Voltage transformers Coupling capacitors and capacitor dividers Capacitor voltage transformer Bushings Large Hollow porcelains Insulators Hot dip galvanizing : : : : : : : : : : : : : : : : : : : :
Data As per Drg Outdoor 220 kV / 245 kV 50 Hz Effectively earthed 0.8 220 kV / 3V
110 / 3V / 110 / 3V / 110 / 3V

Three (3) Metering / protection As per Drg As per Drg As per Drg As per Drg 1.2 continuous & 1.5 for 30 seconds Oil immersed, Class A As per Table II of IEC 186 considering design ambient of 50 deg.C 31mm/kV 1050 kV (Peak) 460 kV (rms)
14. 15. 16. 17. 20. 21. 24.
: : : : : : : : :
4 kV (rms) 2 kV (rms) IEC 186,IEC 517,1EC60044 IS : 9348, IEC : 358 IS : 3156, Part IV, IEC : 186 IS : 2099 IEC 137, IEC 233,IEC 273, IEC 815 IEC 137, IEC 168, IEC 815 IS: 2629.
25. 25.1 25.2 25.3 25.4 25.5 25.6 25.7
5.11.
LIGHTNING ARRESTERS 198 kV, 10kA nominal discharge current, discharge Class - III, metal oxide gapless lightning arresters shall be provided. Three lightning arresters shall be used in each of the generator transformer, station transformer & line bays.
Page 34 of 69
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
5.11.1.
Specific Requirements Surge monitor comprising a digital type counter and leakage current detector shall be provided for each arrester and the same shall be mounted at eye level height to facilitate easy reading of the counter and leakage current detectors. The arrester shall be mounted on an insulating base. The surge monitor shall be inserted between the lightning arrester and earth. Insulated copper conductor of adequate size and length shall be used for connecting the discharge counter terminal and the lightning arrester earth terminal. Insulation level of the conductor shall not be less than 5 kV. Suitably sized bypass copper shunts shall be provided for bypassing the discharge counter for removal / maintenance of the counter.
5.11.2. S.No 1.0 1.1 1.2 1.3 1.4 1.5 2.0 2.1 2.2 2.3 3 4 4.1 4.2 4.3 5.0 5.1 5.2 5.3
Technical Requirements Particulars GENERAL Quantity Installation System Voltage (a) Nominal (b) Highest Type of earthing Type of arrester RATING Rated arrester voltage / maximum continuous operating voltage Rated frequency Nominal Discharge current of 8 / 20 micro second wave shape Minimum total creepage distance mm Additional requirements Minimum cantilever strength of arrester assembly Pressure relief class (As per IEC 99) Minimum prospective symmetrical fault current (as per IEC 99) Applicable Standards Lightning arrester For alternating current systems Insulators Large hollow porcelain insulators : : : : : : : : : : : : : : : Data As per Drg. Outdoor 220 kV 245 kV Effectively earthed Gapless 198 kV 50 Hz 10kA 31mm/kV 600 kg 40 kA 40 kA
: : : :
IEC-99-4, 99-3,99-1 and IEC 694 IEC 99 IEC 137, IEC 168 , IEC 815 IEC 137, IEC 233,IEC 273, IEC 815
Page 35 of 69
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
5.12.
INSULATORS AND HARDWARE
Bus post insulators and insulator strings with fittings / hardware as required shall be provided for the entire switchyard. 5.12.1. Specific Requirements The hardware shall be corona free up to a falling power frequency visible discharge test voltage. All hardware components shall be smooth and as far as possible have round exposed surface. 5.12.2. Technical Requirements Sl. No. 1.0 1.1 1.2 1.3 1.4 1.5 1.6 2.0 2.1 2.2 2.3 2.4 3.0 3.1 3.2 3.3 3.4 Description Bus Post Insulator Type Voltage class Total creepage distance (min) Cantilever strength (min) Withstand voltages (a) 1 min. power freq. (b) 1.2/50 micro sec. Impulse Puncture voltage Disc Insulator Voltage class Type Creepage distance (min) Electromechanical strength Applicable Standards Post insulators Suspension Insulators Insulator fittings Hot dip galvanising process Unit Data Solid Core / Post type 245kV 31mm/kV 600 460 1050 1.3 times corresponding flash over voltage of the unit. 11 kV Anti Fog type 31mm/kV 8200 kg (min) IEC 137, IEC 168, IEC 815,IEC 273 IS : 731 IS : 2486 IS : 2629 & IS : 2633
kV mm kg kV kVp
mm
5.13. 5.13.1.
BUS CONDUCTORS, CLAMPS AND CONNECTORS Applicable Standards The conductors, clamps and connectors shall comply with the following standards: 1.0 1.1 1.2 1.3 1.4 AAC, ACSR conductors Copper conductors Galvanisation of steel wires Copper tubes Aluminium / Aluminium Alloys Bars, Rods, Tubes, Sections for Electrical Purposes : : : : : IS : 398 IS : 282 IS : 4826 BS : 159 IS : 5082
Page 36 of 69
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
1.5 1.6 1.7
Fittings for Aluminium and steel cored aluminium conductors for overhead lines Electric power connectors Hot dip galvanised process
: : :
IS : 2121 IS : 5561 IS : 2629 & 2633
5.14.
LINE TRAP Line traps with all accessories such as terminal connected tuning device, line trap arrester, etc., having a suitable inductance value shall be provided in the state electricity Boards norms.
5.14.1. 1.0 1.1 1.2 1.3
Technical Requirements General Quantity Installation System Voltage (a) Nominal (b) Highest Type of earthing Rating Rated frequency Short time current rating Line trap arrester discharge current Type of installation Winding material Line traps Methods of test for line traps
: : : : : : : : : : : : :
As per drawing Outdoor 220 kV 245 kV Effectively earthed 2000A 50 Hz 40 kA for 3 sec 10 kA With support bushings Copper/Alu IEC : 353 IEC : 353
1.4 2.0 2.1 2.2 2.3 7.0 8.0 9.0 10.0
6.
220 KV SWITCHYARD LAYOUT REQUIREMENTS

The switchyard layout shall incorporate suitable dimensions in respect of bay width, phase spacing, clearances, etc., based on the actual dimensions of the equipment keeping in view the design criteria / requirements and without sacrificing any maintenance space / conveniences. Bolted type connectors for tubular bus conductors, fixed type of terminal connectors for isolator terminals, flexible type of terminal connectors for circuit breakers, current transformers and power transformers and flexible jumper connectors for connecting lightning arresters and voltage transformers shall be provided.
Page 37 of 69
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
The switchyard shall be provided with access ways near the current transformers and circuit breakers. Cable trenches for equipment shall be run as close to their foundations as possible. The fence provided around the switchyard shall be not less than 1.8m height and at a minimum distance such that section clearance is available from any live part. It shall be suitably earthed, if required by relevant rules. Entire switchyard shall be filled with 40mm granite at a height of 150mm The switchyard equipment shall be suitable for outdoor installation and shall have tropical and fungicidal treatment. The design ambient temperature shall be 50 deg. C.
7.
220 KV SWITCHYARD RELAY AND CONTROL PANELS

One complete set of control & relay panels for the 220kV switchyard shall be provided. Control & Relay panels housing various controls, Protection, metering, indication, annunciation, synchronizing (Line), remote control functions, mimic diagram, etc., shall be provided in the 220kV switchyard control room except Generator Control & Relay Panel. The generator transformer & UAT relay panel will be in central control room (CCR). Switchyard protection relay panels, Bus bar differential relay panels, Distance relay panels, Metering panels, PLCC panels, SCSDA system, switchyard battery and battery charger with DCDB, I/O cabinet/ Rack for switchyard shall be located in the Switchyard Control Room. Switchyard DCDB, ACDB, remote I/O units for interfacing with the plant DCS system, switchyard LDB, shall be housed in a switchyard control room.
7.1.
The Control & Relay Panels shall consist of One complete set of control & relay panels for 220 kV systems. One complete set of fault locating panels/ Distance to Fault Location (DFL) One complete set of fault recording panels / Disturbance Recorders
One complete set of metering panels. One complete set of follower / auxiliary relay panels (if required). One set of bay marshalling boxes. Remote Terminal Units (RTU) Sequence of Events Recording panels (SER) Synchronising panels Power Line Carrier Communication panel.
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
220V Battery and Battery charger for Switchyard equipments with redundancy 48V Battery and Battery charger for PLCC Panels SCADA & associated equipment
The switchyard control and interlocking shall be a hard wired system. Control and interlocking scheme suitable for double main bus scheme shall be provided. Line bays shall be provided with auto reclosing feature. All the necessary relays, trip relays and auxiliary relays shall be provided. Live line dead bus closing and dead line-live bus closing facilities shall be provided using dedicated relays for this purpose. Indicating lamps for fulfillment of the permissive condition shall be provided. Synchronizing facility shall be provided for all line circuit breakers. Synchronizing facility will be available in switchyard and Generator circuit breakers on control panels to be located in the central control room (CCR). In auto mode, synchronizing shall be done with a permissive from check synchronising relay and in manual mode the same shall be done by manually ensuring synchronism with the aid of the synchroscope, double voltmeter, double frequency meter and synchronising lamps. Mosaic MIMIC panel will be provided for switchyard protection scheme in the Switchyard Control Room. Control and indication shall be provided for each of the breakers and isolators. Discrepancy type control switch shall be used for the control. The measurement requirements for each of the bays shall be as per the enclosed drawing.
Switchyard scheme is to be provided in DCS Graphics. Each of the abnormal conditions of each circuit breaker, each protective relay alarm & trip condition, DC supply failures, each abnormal condition of the isolator such as drive overload, AC & DC supply failure for a group of isolators shall be annunciated and shall also be displayed on the CRP provided in the unit control room. All relay panels shall have separate annunciation systems. Bay marshalling boxes shall be located in the switchyard. All interfacing works with DCS & other Control panel etc shall be included in this scope. Transducers shall be provided for the indication of electrical parameters related to the 220kV switchyard bays. The minimum quantity of transducers shall be as indicated in the drawing.
Page 39 of 69
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
The transducers shall be either located in the respective control panels or in a separate transducer panel. In the event of shortage of contacts in circuit breakers, isolators, earth switch, contact multiplying relays shall be used. The same shall be two coil, latching type with electrical reset. The Main & Check Bi-Directional Trivector meters with 0.2 S Accuracy class capable of time differentiated measurements (Fifteen Minutes integration) of active energy and voltage differentiated measurement of reactive energy as specified by the GETCO. This shall be of ABT regime meters capable of recording both import & export parameters shall be provided for the 220kV Line outgoing lines, HT side of generator transformer & station transformer and the generator side has to be provided with one TVM of class 0.2S in the Generator control panel for recording the generation only. 7.2. Protection Philosophy The Main Protective Relays & Other backup and auxiliary relays shall be numerical type. The protections to be provided for each 220kV switchyard bay are listed below and also mentioned in the SLD diagram. 7.3. Line Bay Relay panel (Each Line Bay) 3 zone Non-switched carrier aided distance protection (21-1) Main 1 & (21-2) main 2 with measuring elements. Fuse fail relay (FFR) for each secondary of CVT Directional over current relay (67) Directional inverse time earth fault protection (67N) Under voltage relays for live line/dead bus and dead line/live bus closing and safe grid establishment (27-1, 27-2, 27S). Two stage over voltage relay (59) (Instantaneous and time delayed) Bus bar differential protection relay (B/B) with main &check protection scheme. Line Breaker Backup protection relay (50LBB) Pole discrepancy & Anti Pumping Relay for Breaker Fault locator (FL)
Vector Surge Relay (78) Negative sequence current indications and alarm
Page 40 of 69
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
Fault recorder (FR) Auto reclosing scheme relays with single phase & three phase reclosing, dead line charging and live line reclosing.
Islanding scheme for 220 kV lines in case of Grid disturbances.Settings for the scheme will have to be done in consultation with GETCO. 7.4. Bus Coupler Panel IDMT O/C relay with instantaneous element (50/51) IDMT E/F relay with instantaneous element (50/51N) Bus bar protection Breaker Backup protection relay (50LBB) 7.5. Generator Transformer, Unit Transformer & Station Transformer Relay Panel Over fluxing relay (24) Overall differential relay (87U) for GT Transformer differential relay ( 87T) Restricted earth fault relay ( 64R) IDMT O/C relay with instantaneous element (50/51) IDMT E/F relay with instantaneous element (50/51N) Breaker Backup protection relay (50LBB) Buchholz relay (63) Magnetic oil level gauge (26) Standby Earth Fault relay (51S) Under voltage relay (27) Over voltage relay (59) DC Supervision relay (80) 7.6. For trip functions (63TX/49TX) for Transformer panel Buchholz II stage Winding temperature very high
Page 41 of 69
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
Oil temperature very high Pressure relief device operated OLTC oil surge relay operated Fire protection trip Oil level low 7.7. For annunciation functions for Transformer panel Buchholz I stage Winding temperature high Oil temperature high Oil level low Transformer restricted earth fault protection (64) Transformer phase over current protection (50/51) 7.8. Busbar Protection Relay Panel Suitable bus bar protection scheme for the selected bus arrangement shall be provided. 7.9. Common Items/protections to be included in all relay panels Local breaker back up protection (50 LBB for each breaker) Pole discrepancy protection (78) Trip coil supervision relay for each trip coil (95L1 to L-) High speed trip relays (86L1 to L-) Anti pumping device for breaker closing (94). This protection may be provided in the breaker marshalling box also. Supervision relays for tripping relay (98 LT1 to LTX) to supervise the coil of each trip relay. Auxiliary relays and timers in adequate numbers to make the protection scheme and discrepancy switch scheme complete. Auxiliary CTs and auxiliary VTs as required Every control panel should have remote/local switches for breakers and isolators. Busbar in & out switch
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
Carrier protection in & out switch Trip Transfer Switches (Normal/Inter/Transfer Switch) Line Synchronizing Switches CT Switching relay CT wire supervision relay for busbar protection PT Selector switch The functional requirements and characteristics of the relays specified are the minimum required. Any additional protection considered necessary by the Contractor shall also be provided. The responsibility of establishing the equivalence or superiority of the relays offered vis-a-vis the stipulation of the specification rests with the Contractor. DC Distribution Philosophy for Controls, Protection, Indication, Annunciation, Fault Recording and Event Recording Systems Two numbers independent 220V DC feeders shall be provided for the above systems with the provision to changeover automatically/ manually from one feeder to another in the event of failure of one feeder.
8.
POWER LINE CARRIER COMMUNICATION (PLCC)

PLCC mode of communications is required for intertripping, protection, equipment status condition. Speech & Generator data is transmitted to LDC. The following Generator data & line parameters shall be transmitted to LDC: MW Output MVAR KWHr & MD PF The PLCC terminal shall include transmitter, receiver, high/low pass filters and HF hybrid filters for speech, protection, telex and data services. It shall also include line matching units, balancing transformers and other necessary items in the switchyard. The PLCC terminals shall use Amplitude Modulation and shall have Single Side Band transmission mode. These shall be equipped for fixed frequency duplex working. The carrier set shall be suitable for operating with Four Wire Group Selector, Single Line Transmission Relay Set (SLTR), PAX and EPAX of all reputed manufacturers. Each of 220 kV lines shall be provided with one protection channel. Each channel shall have three codes. The code with highest priority shall be used for direct inter tripping of remote
Page 43 of 69
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
end circuit breaker, the next lower priority code for permissive inter tripping and the least priority code for loop checking. A speech cum data channel shall also be provided to link the generating station with each of the receiving stations at which the 220 kV lines emanating from the generating station terminate. To avoid incompatibility, the carrier equipment provided at the other end shall be similar to that provided at the generating station. The PLCC system shall have phase to phase coupling. A dedicated 1 x 100% 48V battery and 2 x100% battery charger with a suitable distribution board shall be provided to supply reliable power to the PLCC panels.
9.
SCADA
SCADA system comprising of various controls, metering, indication, annunciation, synchronising, remote control functions, mimic diagram, sequence of events recording, etc., shall be provided for the switchyard. The controller shall be configured with redundant CPU. The redundant CPU shall be configured to operate as hot standby. The SCADA system shall be generally in line with the details shown in SCADA System Configuration Drg. No. 2-9336-400-017; Rev 00. All the SCADA switches and servers shall be located in switchyard control room. All SCADA servers & Front End Processor servers (if any) shall be rack mounted. The control location for the switchyard equipment shall be Switchyard control room (SCR) by default. But provision shall be made available in the CCR-SCADA to monitor the switchyard from Central Control Room (CCR). The generator transformer bay equipments will be controlled from CCR-SCADA and GCP. The generator transformer bay equipments shall not be possible to control two locations simultaneously. The required selection shall be provided in the operator station of SCR. The SCADA system shall be based on a de-centralized concept with bay oriented distributed intelligence devices, for safety and availability reasons. The offered SCADA system shall be of latest state of art design with capability to interface with bay control units (separate for each bay). The offered SCADA system shall be based on internationally accepted Open Protocol IEC 61850, Scalability and Open Architecture. The communication between the numerical relays and SCADA system shall be with fibre optic cable. SCADA system shall be fail safe design. The BIDDER shall furnish documents to establish and prove that the system is highly reliable with very high MTBF (Mean Time between Failures). One (1) no. Operator Station & 1No. Engineering station for SCADA (for control and monitoring of complete 220 kV switchyard equipment) shall be located in Switchyard Control
Page 44 of 69
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
Room (SCR). One (1) no. Operator Station shall be provided in CCR to monitor the switchyard equipment as well as to control the Generator transformer bay. SCADA configuration changes and system settings can be done only in Engineering station located in SCR. The Engineering Station located in SCR shall also be configured as Operator Station to act as standby in case of failure of the Operator Station in SCR. The OS and ES display/monitors shall be dual headed, 24 inches size, LCD type and the make shall be finalised during detailed engineering. The required redundant special cable from the redundant SCADA server along with necessary hardwares from switchyard control room to central control room shall be provided. In the SCR, necessary printers shall also be provided for SCADA system. All printers shall be equipped with USB port and enough USB cables (minimum 5m length) to enable the printers to be placed in a convenient location. It shall be possible to configure the printers to print on demand/online or at specified intervals. Control room furniture for mounting the operator station along with 3 nos. chairs shall be provided in the CCR & SCR. The console on which the operator station is mounted shall be properly ventilated (forced cooled if required). Information exchange shall be provided from SCR-SCADA to CCR-SCADA through suitable, fast, reliable and redundant serial communication interface. The required special cable along with the necessary hardware shall be provided. The approximate length will be 350 meters. Synchronizing facility shall be provided for all lines in SCADA. In check synchronizing position, the synchronizing criteria shall be fulfilled as indicated by the closing permissive provided by check synchronizing relays in-built in BCUs (separate sync check relays are not envisaged). In dead bus/line mode, closure is possible only if either the line or the bus is dead. Display of voltages and frequencies of incoming and running supplies, synchroscope and the sync. permissive signal shall be simulated in the SCADA operator station. The synchronism and energizing check functions shall be bay oriented and distributed to the bay control units and/or protection devices. All features shall be available viz. a) Setting voltage, phase angle, and frequency difference b) Energizing for dead line - live bus, live line - dead bus or dead line dead bus with no synchro-check function c) Synchronizing between live line and live bus with synchrocheck function. The correct voltage for synchronizing and energizing is derived from the auxiliary switches of the circuit breakers and the isolators and shall be selected automatically by the bay control and protection IEDs. The closing operation of line breaker shall involve the following steps, viz. a) selection of the breaker to be closed,
Page 45 of 69
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
b) mode of closing operation i.e. whether both the line and the bus are live or only one of them is dead as sensed by voltage relays connected to the respective CVTs. In live-bus/liveline case, synchronisation between the two voltages is checked by the check synchronisation relay which generates permissive only if the synchronization criterion is met. If either the line or the bus is dead, the logic develops using the contacts of bus voltage and line voltage relays which generates permissive for closing of the breaker, c) issuing the closing command after obtaining the synchro permissive or live-bus/dead-line or live-line/dead-bus permissive as the case may be. This permissive shall be displayed on the SCADA HMI. The generator transformer breaker will be controlled from CCR-SCADA and GCP. It shall be possible to control from both CCR-SCADA (through auto/manual synchronisation) and SCRSCADA with the help of a selection available in the SCADA software. The selection shall have two positions i.e. SCR-SCADA and CCR-SCADA. If SCR-SCADA is selected, all the required signals including PT signals for synchronizing shall be transferred to SCRSCADA system. If CCR-SCADA is selected, all the required signals shall be transferred to CCR-SCADA/GRP (Generator Relay Panel). The control of breaker from SCADA shall be suitably interlocked such that its closure is not possible when it is used as generator synchronizing breaker. Transducers shall be provided, wherever necessary, for the indication of electrical parameters related to switchyard bays as required. Transducers shall be used for electrical quantities such as battery charger voltage, battery charger current, 220 kV bus voltages. For monitoring of all other bay wise electrical quantities, IEDs such as BCUs shall be used. The exact no. of analog and digital IO (input/output) points shall be decided during detailed engineering. All the auxiliary contacts of main equipment such as circuit breakers, isolators, earth switches shall be brought to the protection panels for indications, interlocks, SER function, etc. In case of shortage of auxiliary contacts, contact multiplying relays shall be used. The same shall be two coil, latching type with electrical reset and shall be mounted in switchyard protection panels. At least 2NO + 2NC spare contacts shall be wired to terminal block after fully utilizing for control, protection, annunciation, etc. It shall be possible to control and monitor (including synchronising) all the 220kV switchyard breakers & isolators from SCADA. Earth switches shall be operated only from local but is monitored in SCADA. 9.1. Monitoring SCADA Indication status of all breakers, isolators and earth switches of all 220kV bays, local/remote selector switch positions, auto re-closing selection, selection of control from
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
CCR-SCADA/SCR-SCADA, etc. shall be available in SCR-SCADA. The selection of control of generator breaker shall be displayed in both the SCADA. Abnormal conditions to be considered for alarm inputs in SCADA are 220kV system operation of each line protection, bus bar protection, trip circuit unhealthy of each equipment, protection unhealthy of each equipment, trip relay unhealthy of each equipment, VT circuit unhealthy of each VT, LBB operation of each breaker, DC supply failure of each protection/control scheme as appropriate, abnormal conditions of breakers, successful/unsuccessful auto re-closure, DC & UPS system alarms, etc. The alarm states are not exhaustive. The BIDDER shall include all alarm states deemed necessary for the safe operation of the system. Event register with time stamping Opening or closing of all breakers, isolators and earth switches, opening and closing commands, change of positions of switches such as Local/Remote selection, synchronizing selection, voltage selection, auto re-closing selection, selection of control from CCR-SCADA/SCR-SCADA, operation of all protection and trip relays, VT fuse fail relay operation, auto re-closing operation, direct trip send and receive, pole discrepancy relay operation, trip circuit faulty, trip relay faulty, DC supply fail, SF6 pressure Low, LBB operated, etc. shall be available in both the SCADA. As stated above, this list shall include all events and operation of switchyard equipment that are considered essential for analysis of faults. 9.2. Mimic A mimic diagram depicting the entire electrical system being controlled from the system with different colours for different voltage levels shall be provided in SCADA operator stations. The colours of different voltage levels shall be as per relevant IS applicable for mimic on panels. 9.3. Measurement The minimum requirement for measurement of switchyard bay parameters shall be as follows:
S.No. 1
Feeder Description GT bays Line bays
SCADA Operator Station Voltage (All Phases), Amps (All Phases), MW, Power factor, MVAR, MWH, Winding & Oil Temperature Voltage (All Phases), Amps (All Phases), MW, MVAR, MWH, MVARH
Page 47 of 69
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
3 4
220kV buses Station Bay
3 Voltage & Frequency Amps (All Phases), MVAR, Winding & Oil Temperature
Event logging and trending facilities shall be provided in SCADA system. It shall be possible to trend different parameters on the same trend. It shall be possible to store historical data for a minimum of two years. SCADA system shall have provision for expansion and shall be capable of communicating with other systems through open protocol. The bidder has to provide the suitable gateway switches as a part of SCADA system to interact with the PLCC system. The actual data to be transmitted to SLDC/RLDC shall be finalized during detailed engineering and the following is the minimum data to be transmitted through PLCC. MW and MVAR of all lines MW and MVAR of HV side of all generator transformers Voltage and frequency of 220 kV buses ON/OFF positions of all breakers and isolators of all line bays, generator transformer bays, Bus PT bays. 9.4. Bay Control Unit (BCU) a) The BCU shall be an intelligent unit and shall be state of the art technology. It shall perform control functions in accordance with control commands from SCADA and shall also do monitoring of the respective bays. The BCUs shall be installed in the respective protection panels of each circuit breaker in the switchyard relay room. The control voltage for the BCU shall be 220V DC. The degree of protection of the panel shall be IP-52. The BCU shall comply with relevant IEC/BIS standards. b) BCU shall have adequate number of ports for communication and interface with switchyard control system for bay control and monitoring. The BCU shall provide direct connection to the switchyard equipment for control (with or without interposing relays) and shall perform control and monitoring functions, including live-line/dead-bus, dead-line/livebus and live-line/live-bus breaker closing. The communication link between BCU and SCADA shall be redundant. The BCUs shall be independent of each other and functioning shall not be affected by any fault occurring in any of the other BCUs.
Page 48 of 69
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
c) Protection relays shall be separate and shall not be part of BCU. Direct hard wiring shall be employed for critical tripping. Numerical protection relays shall also be connected to the SCADA bus for retrieval of data. d) Atleast one bay control unit (BCU) shall be provided for each breaker. The analog and digital signals pertaining to a circuit shall be taken through the BCU provided for that circuit. e) One no. licensed software for configuration and parameterization of SCADA shall be delivered on CD along with BCUs. The configuration shall be carried out from local or from laptop computer but operation shall be from SCADA operator station. Configuration of BCUs shall also be possible from remote through engineering work station. The lap top computer provided for the switchyard shall be loaded with this software. f) The BCU shall have at least the following features: i) Monitoring The following monitoring functions shall be provided as a minimum : Status monitoring and failure monitoring (in SCADA HMI) of bay equipment like breaker, isolators, earth switches, instrument transformers, protection relays and ancillary equipment metering (measured-value acquisition) Signal and command indications Switching statistics in BCU (breaker ON/OFF, breaker autoreclose, pole discrepancies) and data stored in SCADA server Energy metering values ii) Control The following control functions shall be provided as a minimum: Control of circuit breakers and isolators Interlocking for isolators and circuit breakers, isolators and earth switches (The interlocks for earth switches shall be hardwired) iii) Recording The event recording function shall be provided and processed in the BCU and the record stored in SCADA. Each BCU shall contain an event recorder capable of storing at least 200 time tagged events. iv) Human Machine Interface (HMI) Following local human machine interface inbuilt in BCU shall be provided as a minimum : The local HMI is a monitoring and maintenance tool for bay control unit and data communication unit during commissioning and/or maintenance.
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
Position of switching elements (Feeder control diagram) shall be shown on the graphic display. v) Time Synchronizing Feature BCU shall be time synchronized with GPS based Master Clock of the Facility vi) Self diagnostic and Supervision Features BCU shall have self diagnostic and supervision features. Failure of IEDs connected to the SCADA System such as BCUs, Numerical Relays and Tariff Meters shall be indicated in the SCADA HMI vii) Operating Mode Selection Operation mode selection (local or remote) shall be provided in BCU. The BCU DO card shall be able to drive the breaker trip coil, else interposing relays to be used. 9.5. Sequence of Events Recording System (SER) The SER system shall be a part of SCADA system. SER shall be designed with 1 ms resolution for digital input events with time stamping from each phase of all breakers, isolators and earth switches, opening and closing commands, change of positions of switches such as Local/Remote selection, synchronizing selection, voltage selection, auto reclosing selection, selection of control from SCR-SCADA/CCR-SCADA, operation of all protection and trip relays, VT fuse fail relay operation, auto re-closing operation, direct trip send and receive, pole discrepancy relay operation, trip circuit faulty, trip relay faulty, DC supply fail, SF6 pressure Low, LBB operated, etc. shall be available in both the SCADA. Critical interlocks and those SER points which are not covered by numerical relays shall be hard wired to SCADA. The chronological printout facility shall be provided for any of the first 100 occurrences. Further occurrences shall be printed chronologically. This list is only indicative and not exhaustive.
10.
ANNUNCIATORS
Annunciator shall be completely wired for the annunciation scheme and shall include the fascia annunciator, flag relays, alarm buzzer bell and alarm cancellation scheme. Separate audible alarms of dual frequency shall be provided for trip and non-trip alarm annunciation. Fascia annunciations shall have one translucent window of minimum size 35 mm x 50 mm for each alarm point. Each window shall have two lamps and the inscription on the window shall be visible only when the lamps glow. Annunciations shall be suitable for normally open initiating contacts of either hand or self reset type.
Page 50 of 69
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
In case of static annunciation schemes, special care shall be taken to ensure that spurious alarms do not appear on the annunciation wiring due to the influence of external magnetic fields and switching disturbances from neighboring circuits within the panel. Annunciation shall be provided with three push buttons, one each for alarm ACCEPT, RESET and TEST. Operation sequence for the annunciations shall be as follows: Status -------Normal Fault Accept Reset Test Audible Annunciator --------------------------OFF ON OFF OFF ON Visual Annunciator ----------------------OFF Flashing Steady Glow OFF Steady Glow
In case the RESET push button is pressed before the abnormality is cleared, the lamp shall continue to glow steady and shall go out only when normal condition is restored Any new annunciation appearing after the operation of ACCEPT of previous annunciation shall provide a fresh audible alarm accompanied by visual annunciation. This repeat alarm facility shall be functional even if the action of Accepting or Resetting of previous alarm is in progress. The annunciator shall have RS 485 port communication facility. 10.1. Specific Requirements All components of carrier cabinets shall be completely tropicalised and protected against deteriorating effects of humidity, attack from fungus, etc., Terminal strips for all external connections such as AC, DC supply, PAX, etc shall be mounted inside the cabinet at the rear. Adequate protection shall be provided for all important components. Indicating lamps shall also be provided to facilitate detection of faults. A loop test module shall be provided for a complete check of the transmitter and receiver. The system shall work satisfactorily in the ambient temperature range and supply voltage and frequency ranges envisaged. The carrier voice frequency receiver levels of both speech and signals in pairs of transmitting and receiving terminals without commanders shall be automatically maintained with 0.5 +dB for a 40 dB change in carrier frequency signal level. The carrier shall be equipped for operation as IF repeaters in case of panel to panel direct connection. Adequate measures shall be taken to avoid false tripping. The carrier terminal shall be provided with band pass filter at the output with frequency band width of 4 kHz, which shall be capable of adjustment at a later date to 8 kHz. Telephone
Page 51 of 69
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
hand sets and cord and jack shall be provided with the carrier sets. Space shall be provided inside the carrier terminal cabinet for storing the hand set when not in use.
11.
LIGHTING SYSTEM
The lighting circuits will be fed by 3 phase, 4 wire normal AC supply available from the lighting distribution board. Lighting fixture for switchyard will be provided on the lightning masts/lightning masts at suitable height. The fittings will be switched ON automatically through timer. The lightning masts tower will be provided with suitable platform and ladders for accessing the platform at fitting levels for maintenance. In case the required illumination level is not accomplished with fixtures mounted on lightning masts, the same shall be achieved by providing additional lighting masts. If the lightning protection is by shield wires, then all fixtures will be mounted on separate lighting masts and the same will be motor operated for easy maintenance. The average illumination level for switchyard area is 20 lux. Weather proof, flood light medium beam type 250W HPSV/HPMV shall be used.
12.
GALVANISED STEEL STRUCTURES

All steel structures for the switch yard shall be hot double dip galvanised structures with welded / bolted connections at shop and bolted connection at site. All bolts and nuts shall also be galvanised. Minimum zinc consumption shall be 910 Gms per square meters of exposed surface. Major steel structures are towers, beams, lighting masts etc. They shall lightning arresters, etc may be of tubular section or latticed as the case may be. Lighting masts shall be provided with cage ladder. Where platforms are provided on lighting masts for mounting of lighting fixtures, they shall have protection hand rails formed of galvanised sections. Platforms shall be of galvanised gratings. be of latticed
construction using angle sections. Supporting structures for equipment such as isolator,
12.1.
Design All structures shall be designed for the worst combination of dead loads, and live loads, short circuit forces, wind loads, seismic forces and secondary effects, as shrinkage, changes in temperature, etc. Switchyard structures shall be designed as per IS: 802 but for the condition of all three wires on one side being broken. Wind and other parameters shall however be as specified in IS: 802. The structures shall be designed for the stringing tensions at the elevations as shown on enclosed structural arrangement drawing. The sequence of applying tension shall also be specified by the Contractor on the drawings and taken care of in the design of the structure.
Page 52 of 69
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
Steel shall conform to IS: 2062. Where cut pieces out of plates are used by butt welding to form a part of either flange plates or web plates of fabricated columns and main frame beams, the length of such pieces shall not be less than three meters. When cut pieces out of rolled sections are not to be jointed by butt welding splicing for making beam members, truss members, rolled components of columns, the length of such pieces shall not be less than three meters nor shall the total number of pieces in any member exceed three. 12.2. Fabrication All fabrication work shall be done at the project site and no steel once brought to the work site shall be taken out of the project area without written consent of the Engineer-in-Charge, unless the fabrication at Contractors shop either in full or part is accepted as an alternative. The erection clearances for cleated ends of members connecting steel to steel shall not be greater than 2 mm at each end unless specifically approved by the Engineer-in-Charge in which case suitably designed seating shall be provided. Holes through more than one mm thickness of material for members such as compound stanchion and girders, flanges shall where possible be drilled after the members are assembled and tightly clamped or bolted together. Sub-punching may be permitted before assembly, provided the holes are pounched 3 mm less in diameter than the required size and reamed after assembly to the full size. Punching shall not be adopted where the thickness of metal exceeds 16 mm. When the holes are drilled in one operation through two or more separable parts, those parts, when so specified by the Engineer-in-Charge, shall be separated after drilling and burrs removed. Holes in connecting angles and plates, other than splices, also may be punched in full size through material not over 13 mm thick except where required for close tolerance. Matching holes for rivets and black bolts shall register with each other so that a gauge of 1.5 mm or 20 mm (as the case may be, depending on whether the diameter of the bolt is less than or more than 25 mm) less in diameter than the diameter of the hole will pass freely through the assembled members in a direction at right angle to such members. Finished holes shall not be more than 1.5 mm or 2.0 mm (as the case may be) larger in diameter than the diameter of the black bolt passing through them, unless otherwise specified by the Engineer-in-Charge. Holes of bolts shall not be formed by a gas cutting process, except in special cases with specific permission of the Engineer-in-Charge. Wherever a horizontal member is likely to collect water, suitable holes for drainage shall be provided.
Page 53 of 69
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
The ends of all joints, beams and girders shall be cut truly square unless required otherwise and joint flanges shall be neatly cut away or notched where necessary, the notches being kept as same as possible. The component parts shall be assembled in such a manner that they are neither twisted nor otherwise damaged and shall be so prepared that the specified chamber, if any, is provided. In order to minimise distortion in a member the component parts shall be positioned by using clamps, clips, jigs and other suitable means and fasteners (bolts and welds) shall be placed in a balanced pattern. If the individual components are to be bolted, parallel and tapered drifts shall be used to align the parts so that the bolts can be accurately positioned. Towers, beams, etc. shall be trial assembled keeping in view the actual site condition prior to dispatch to site of erection so that they can be conveniently pre-assembled before erection or conveniently pre-assembled during erection. Necessary match marks shall be made on these components before disassembly in the shop and dispatching. 12.3. Bolting Every bolt shall be provided with a steel washer under the nut so that no part of the threaded portion of the bolt is within the thickness of the parts bolted together. Flat washer shall be circular of a diameter 2 times that of bolt and of suitable thickness. Where bolt heads / nuts bear upon the bevelled surfaces they shall be provided with square tapered washer of suitable thickness to afford a seating square with the axis of the bolt. All bolts and nuts shall be of steel with well-formed hexagonal heads unless specified otherwise forged from the solid and shall be dipped in hot boiled linseed oil as soon as they are made. The nuts shall be good fit on the bolts and two clear threads shall show through the nut when it has been finally tightened up. Notwithstanding anything to the contrary contained in IS: 1363, IS: 1364 and IS: 1367 the unthreaded length of the bolt shank shall be equal to total thickness of metal being bolted together plus 2 mm. The threaded length shall be equal to at least the diameter of bolt plus 6 mm. 12.4. Galvanizing All structural steel works and single pipe supports shall be galvanized after fabrication. Zinc required for galvanizing will have to be arranged for by the Fabricator. Purity of zinc to be used shall be Zn 99.5 as per IS-209-1966. All burrs and irregular edges will be ground smooth before galvanizing.
Page 54 of 69
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
After all shop work is complete, all structural material shall be punched with the Erection Mark and be hot-dip galvanized. Members embedded in concrete shall be galvanized from the top to a point at least 300 mm below the proposed elevation of the concrete foundation. Before galvanizing the steel section shall be thoroughly cleaned of nay paint, grease, rust, scale, acid or alkali or such other foreign matters as are likely to interfere with the galvanizing process or with the quality and durability of the zinc coating. Pickling shall be very carefully done and shall be proper. The amount of zinc deposit shall not be less than 900 gm/m and addition the thickness of zinc deposit at any spot shall not less than 100 microns. The Owner / Consultant reserve the right to measure the thickness of zinc deposit by a suitable instrument and reject any material which shows the thickness of zinc at any location to be less than 100 microns. The galvanized surface shall consist of a continuous and uniformly thick coating of zinc, firmly adhering to the surface of steel. The finished surface shall be clean and smooth and shall be free from defects like discolored patches, unevenness of coating, bare spots, splatter which is loosely attached to the steel, globules, spiky deposits, blistered surface flaking or peeling off etc. The presence of any of these defects noticed on visual or microscopic inspection shall render the material liable to rejection. There shall be no flaking or loosening when struck squarely with a chisel faced hammer. The galvanized steel member shall withstand minimum four one minute dips in copper sulphate solution as per IS: 2633. Galvanizing of each member shall be carried out in one complete immersion Double dipping shall not be permitted. When the steel section is removed from the galvanizing kettle, The processes known as wiping or excess splatter shall be removed by bumping. scrapping shall not be used for this purpose. All bolts, nuts, locknuts, washers etc. shall be hot dip galvanized and spring washers shall be electro galvanized. Excess splatter from bolts, nuts, etc. shall be removed by centrifugal spinning of bolts & nuts. Threading after galvanizing, shall not be permitted Nuts however may be tapped, but not to cause appreciable racking of the nuts on the bolts. Defects in certain members indicating presence of impurities in the galvanizing bath in quantities larger than that permitted by the specifications, or lack or quality control in any manner in the galvanizing plant shall render the entire production in the relevant shift liable to rejection. All towers and accessories shall be treated with Sodium Dichromate or an approved equivalent solution after galvanizing, so as to prevent white storage stains. Fabricator shall furnish sufficient quantity of appropriate paint free of cost, for repairing galvanized surfaces, damaged in transit.
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
12.5.
Welding The works shall be done as per approved fabrication drawings, which should clearly indicate various details of joints to be welded, type of weld length and size of weld whether shop weld or site weld. Symbol for welding on erection and shop drawings shall be according to IS: 813. Efforts shall be made to reduce site welding so as to avoid improper welding due to constructional difficulties. Random liquid penetrant test shall be conducted after welding.
12.6.
Erection All steel work shall be efficiently and sufficiently protected against damage in transit to site from any cause whatever. Distorted steel received during the transport from stores to the fabrication yard shall not be used in fabrication. Before erection of columns on their foundations the top surface of base concrete shall be thoroughly cleaned with wire brushes and by chipping to removed all loose material and shall be chipped with a chisel to ensure proper bond between the grout and the foundation concrete. In case of the foundation as cast is lower than the desired level, it should be make up by providing additional shims. No steel structures shall be erected on their foundations unless such foundations have been certified fit for erection of steel. The steel structure should be stable, at all stages of its erection at site and all necessary measures shall be taken by the additions of temporary bracing and guying to ensure adequate resistance to wind and also to loads due to erection equipment and their operation. Guying and bracing shall be done in such a way that it does not interfere with the movement of working of other agencies working in the area.
12.7. 12.7.1.
Tests Tests and Works The steel materials shall be tested as per Standards. Test samples shall be cut out of the materials from the locations indicated by the Engineerin-Charge and samples shall be prepared in accordance with the requirements of Indian Standard Specification for conducting such tests. For each set of test, three samples shall be taken for tensile strength test and bend test. All these tests will be carried out by the Contractor within his quoted price.
Page 56 of 69
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
12.7.2.
Marking All steel shall be tested quality in accordance with the requirements of IS obtained either from the producer or from the open market. Such materials, test certificate, co-related with the materials obtained at site shall be available.
12.7.3.
Standard for Testing For testing of Materials, the following standards shall be adopted : Method of Tensile Testing of Steel products other than sheet, strip, wire and tube, IS: 1608. Method of bend tests for steel products other than sheet, wire and tube IS: 1599. Method of Chemical Analysis of pig iron Cast iron and plain carbon and low alloy steel IS: 228. Code of practice for Radiographic Testing IS: 2595. Recommended practice for Radiographic examination of fusion, welded butt joints in steel plates IS: 1182. Code of practice for Ultrasonic testing by Pulse echo-method IS: 3664. All steel sections shall be straight, sound, free from twists, cracks, flaws, laminations, rough, jagged and imperfect edges and all other defects. All steel sections, including nuts, bolts, etc. shall be as per relevant standards.
12.8.
Design Criteria for Switchyard Structures Loading for the design of switchyard structures shall be considering the following loads: Dead load due to equipment and dead load due to structure Wind load on towers, conductors, ground wires and insulator strings calculated Temperature effects consisting of effect of temperature variation and sag tension Climatic loads Anti concading loads Torsional and longitudinal loads caused by breakage of conductor Construction and maintenance loads Seismic loads Short circuit forces including snap effect in the case of bundled conductors
Page 57 of 69
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
The switchyard structure shall be designed for the worst combination of the above loads. The factor of safety for design of members shall be considered as 2 for normal and broken wire conditions and 1.5 for combined short circuit and broken wire conditions. Short circuit forces and wind forces shall not be considered simultaneously.
Foundations shall be designed considering a factor of safety of 2.2 for normal and broken wire conditions and 1.65 for combined short circuit and broken wire conditions.
13.
SWITCHYARD MARSHALLING BOXES

Adequate number of outdoor mounted, free standing type bay marshalling boxes shall be provided. Each bay marshalling box shall have a terminal box and an auxiliary supply distribution box.
14.
EARTHING SYSTEM
An Earthing system shall be provided with a Mat in the ground at a depth of 600mm and shall be so designed that the Touch and Step potentials are with in the limits as per IS 3043 & IEE 80 of latest standard. All the structures, LAs, Neutrals shall be connected to that earth mat. The earth mat shall be connected to Earth electrodes driven inside the ground below the earth mat up to a depth of 3 Meters. The number of Electrodes to be decided basing on the fault current of highest rating and also to ensure that the Touch and Step potentials are with in the safe limits.
15.
PRECOMMISSIONING WORKS
All Electrical Equipment in Switchyard should be tested by suitable Electrical Testing Kits before Commissioning. The inter wiring for various protection should be checked through secondary & primary injection before commissioning. The relays will be well coordinator with up & down steam relays.
16.
DC SYSTEM
The battery and battery charger will constitute the D.C. Power supply. The batteries and chargers will be installed indoor in a clean but hot, humid and tropical atmosphere. The battery and charger combinations shall be such as to ensure continuity of D.C. supply at load terminals without even momentary interruption. For continuous operation at specified ratings, temperature rise of the various components of battery and charger shall be limited to the permissible values as stipulated in relevant standards. Further the voltage at load terminals
Page 58 of 69
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
shall never exceed the limits of +10% and -15% of the nominal system voltage. The batteries shall be so sized as to meet emergency load duty cycle requirements for one (1) hour. While estimating battery capacities, a design margin of 15% shall be kept. For the purpose of estimating battery capacities, the maximum and minimum temperatures shall be considered as 50 Deg.C and -2 Deg.C respectively. All momentary loads shall be treated as one-minute loads. The procedure for estimating battery capacities shall be as per guidelines stipulated in IEEE-485. The battery will be sized such that the voltage at any time during the duty cycle shall not be less that 1.85 volt per cell. The float-cum-boost charger shall be sized to restore the fully discharged battery to full charge condition in ten (10) hours with 25% margin over maximum charging rate or to operate as a float charger with duty requirement to cater the total continuous load and the trickle charging current of the battery plus a 25% margin. The output voltage shall be adjustable between 230-240 V, whichever is higher. The batteries & chargers shall be so designed that the maximum fault level on DC DB is limited to 15KA. The batteries shall be Valve regulated Lead Acid (VRLA) type and shall be provided for the following applications: Switchyard Loads 1 X 100% rated batteries with 2 X 100% float cum boost chargers shall be provided. Power Line Carrying Communication-1 X 100% rated batteries with 2 X 100% float cum boost chargers shall be provided.
The following DC Distribution Boards shall be provided: DC distribution board shall be provided, separately for power plant loads, switchyard and power line carrying communication set. One set of special tools and tackle. Mandatory spares. All relevant drawings, data and instruction manuals.
Page 59 of 69
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
17.
17.1.
SPECIFICATION FOR POWER AND CONTROL CABLES

Scope The scope intends the supplier to design, engineer, manufacture, test at suppliers works, inspection, packing, forwarding, delivery at project site, unloading, storage at site, erection, testing and commissioning of power and control cables and documentation in accordance with this specifications.
All fittings and accessories or apparatus which may not have been specifically mentioned below, but which are necessary and essential for the efficient working of the equipment shall be deemed to have been included in the contract 17.2. Standards The cables shall comply with the latest edition of the following IS standards and equivalent to the IEC/BS/IEEE standard:
IS : 1554 (Part-I) -
PVC insulated (heavy duty) electric cables - Part-I for working voltages upto and including 1100V.
IS : 7098 (Part-II)-
Cross-linked Polyethylene insulated PVC sheathed cables : Part-II for working voltages from 3.3 kV upto and including 33 kV.
IS : 8130 IS : 5831 IS : 3975 IS : 2633
Conductors for insulated electric cables and flexible cords. PVC insulation and sheath of electric cables. Mild steel wires, strips and tapes for armouring of cables. Methods of testing weight, thickness and uniformity of coating on hot dipped galvanised articles.
IS : 209
Specification for Zinc. Recommended current ratings for cables : Part-II PVC insulated and PVC sheathed heavy duty cables.
IS : 3961(Part-II) -
IS : 1753
Aluminium conductors for insulated cables.
Page 60 of 69
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
IEC : 502
Extruded solid dielectric insulated power cables for rated voltages from 1 kV upto 30 kV.
IEC : 540 & 540A -
Test methods for insulation and sheaths of electric cables and cords.
17.3.
Design Criteria The cables shall be suitable for installation in a tropical monsoon area having a hot humid climate. The reference ambient temperature to be considered for the purpose of this specification is 50C. The derating factor for the various conditions of installation including the following shall be considered while choosing the conductor size and calculations shall be submitted in the bid. Maximum ambient air temperature. Maximum ground temperature. Depth of laying wherever applicable Grouping of cables.
The allowable voltage drop at terminals of the connected equipment shall be maximum 2.5% at full load for choosing the conductor size and calculations shall be submitted for the same. The maximum continuous conductor temperature and the maximum allowable conductor temperature during short circuit are to be taken as 70C and 160C respectively in case of PVC insulated cables and 90C and 250C respectively in case of XLPE insulated cables. The minimum size of 415 V power cables connected to circuit breakers shall be chosen taking into account of full load current of the circuit. The cables shall be capable of continuous satisfactory operation under a power supply system frequency variation from 47.5 Hz to 52.5 Hz., voltage variation of 10% and combined frequency and voltage variation of 10%. The cables shall in general comply with the requirements of the latest revision of IS:7098 (part-I) for the LT XLPE insulated cables and IS-1554 (part-I) for the L.T. PVC insulated power and control cables or the relevant IEC International Standard unless otherwise specified in this specification. The design, manufacture, installation, testing and performance of the cables, shall comply with the latest revisions of IS/IEC/ NEMA/ASTM standard and the most stringent conditions specified in these specification shall be applicable.
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
Power cable shall be of XLPE FRLS and control cables shall be of PVC FRLS type. Constructional Requirements 17.3.1. General Power cables, control cables, HR PVC cables, special cables, are required for the power supply, control, protection and instrumentation connection of various equipments in the power station. 17.3.2. Conductor The cable conductor shall be made from stranded copper/ aluminum to form compact conductor having a resistance within the limits specified in IS:8130. All the cables of size 25 mm2 and above may have sector shaped conductors. Cables with conductors of nominal area less than 25 mm2 shall be circular only. Power cables shall be of stranded aluminum conductor with a minimum size 6 mm2 and the control cables shall be stranded copper (electrolytic) conductor with a minimum size of 2.5 mm2. 17.3.3. Conductor shield
The conductor having a semi-conducting screen shall ensure perfectly smooth profile and avoid stress concentration. The conductor screen shall be extruded in the same operation as the insulation. The semi-conducting polymer shall be cross-linked for XLPE cables. 17.3.4. Insulation The insulation of the cable shall be extruded type and shall be designed and manufactured for the specified system voltage. The manufacturing process shall ensure that insulation shall be free from voids. The insulation shall withstand mechanical and thermal stresses under steady state and transient operating conditions. The extrusion method should give very smooth interface between semi-conducting screen and insulation. The insulation of the cables shall be of high standard quality.
17.3.5.
Insulation shield In XLPE cables, to confine electrical field to the insulation, a non-magnetic semi-conducting shield shall be put over the insulation. The insulation shield shall be extruded in the same operation as the conductor shield and the insulation by triple extrusion process. The XLPE
Page 62 of 69
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
cable insulation shield shall be strippable. Metallic screening as required for the various power and control and special cables shall be provided. 17.3.6. Sheath The sheath shall be suitable to withstand the site conditions and the desired temperature. It shall be of adequate thickness and applied by a continuous process to produce a sheath of consistent quality free from all defects. PVC sheath shall be extruded. 17.3.7. Armour Hard drawn aluminum wire armouring/galvanised steel tape or wire armouring shall be used for single core and multicore cables respectively. Cables should be unarmoured wherever indicated. The hard drawn aluminum wire for armour shall be of H4 grade, as per IS:8130 (having tensile strength above 150 N/mm2). The diameter of the aluminum wire shall be as per the table for the dimensions of the galvanised steel wire armour given in the relevant standard. 17.3.8. Serving/Outer sheath Extruded PVC serving as per IS:5831 or as specified otherwise shall be applied over the armouring with suitable additives to prevent attack by rodent and termites. All serving must be given anti-termite treatment. 17.3.9. Fillers Cables shall have suitable fillers laid up with the conductors to provide a substantially circular cross section wherever necessary before the sheath is applied. Fillers shall be suitable for the operating temperature of the cables and compatible with the insulating material. All materials shall be new, unused and of finest quality. Workmanship shall be neat, clean and of highest grade. Range of Cables 17.3.10. 415 V system
The cable shall be 1.1 kV grade, heavy duty, stranded aluminum conductor, PVC type-A insulated galvanised steel wire/strip armoured, flame retardant low smoke (FRLS) extruded PVC of type ST1 outer sheathed.
Page 63 of 69
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
17.3.11.
Control cables
The cable shall be 1.1 kV grade, heavy duty, stranded copper conductor, PVC type-A insulated galvanised steel wire/strip armoured, flame retardant low smoke (FRLS) extruded PVC of type- ST1 outer sheathed. Cables may be either single or multicore or both. In multi core control cables, the following minimum reserve cores will be kept at the engineering stage: Upto 7 cores 10 Cores 14,19 & 24 Cores 17.3.12. Special cables One reserve core Two reserve cores Three reserve cores
The cables shall be of 1.1 KV grade, heavy duty, annealed high conductivity stranded copper conductor, insulated with a suitable polymeric/elastomeric material, twisted into pair, overall shielded, extruded inner sheathed, armoured with a metal braid of galvanised steel wire, flame retardant low smoke (FRLS) extruded outer sheathed of suitable polymeric/elastomeric material. All control and instrumentation cable and other signal cables terminating in control room, computer room, power supply rooms shall be flame retardant low smoke type. However, all those fire survival cables which are terminating in these rooms shall have the characteristics and test requirements given for fire survival type cables only. (Note: 1. Specific requirement depend upon the type of application and shall have to be dealt with, in detail engineering stage 2. Bidder shall estimate the quantity and size of the cable required and clearly indicate in the bid.) Identification of Cores The insulated cores of LT power cables shall be identified by colour code. The control cables shall have identification by means of indelible printing of numbers on its cores at intervals not more than 75 mm. At least 20% cores shall be kept as spares in the multicore control cables. As far as feasible, separate cables shall be provided for circuit of different plant and auxiliaries, for circuits of different voltages, and for circuits used separately. Power, control and instrumentation circuits shall invariably be taken through different routes, which shall not be laid together on the same cable tray.
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
Packing and Marking Cable shall be despatched in wooden drum of suitable barrel diameter, securely battened, with the take-off end fully protected against mechanical damage. preservatives shall be applied to the entire drum. On flange of the drum necessary information such as manufacturer's name, type, size, voltage grade of cable, length of cable in meters, drum No. Cable code, ISI Certification mark, gross weight etc. shall be printed. An arrow shall be printed on the drum with suitable instruction to show the direction of rotation of the drum. Cable Installation 17.3.13. Installation of cables Cable routing must be above ground level. Cables shall be laid on cable trays and supports, pulled through conduits/GI pipes and on racks in built up cable trenches and vertical race ways and clamped with aluminum clamps on walls, ceiling and structures and may be directly buried in ground. Cable laying shall also include termination of power and control cables (i.e on both ends of the cables), at equipment terminals, switchgear, control panels etc. All electrical equipments after installation shall be completed with cable terminal boxes, cables glands, cable trays, lugs and terminal blocks. All power and control cables shall be provided with aluminum tag of an approved type, bearing cable reference. Cable routing is to be done in such way that cables are accessible for any maintenance and for easy identification. Power and control cables shall be laid in separate cable trays. The trays, in general, shall be supported at a distance of 1500 mm on horizontal and vertical run. Straight through jointing of cables shall be avoided as far as practicable. Terminations shall be done by crimping type joints for cables upto 150 mm2 and welding joints above 150 mm2 cables. Buried cables should be avoided as far as possible but if necessary it shall be covered with alternate layer of bricks and sand for mechanical protection. Steel markers shall be provided at every 20 meters along the cable route. Cables, oil pipes and gas pipe shall be routed separately. All cables laid on trays/racks shall be neatly dressed up and clamped/tied to the tray/rack. Trefoil clamps shall be provided for single core cables.
The wood used for
construction of the drum shall be properly seasoned, sound and free from defects. Wood
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
17.3.14.
Ladder type cable trays
Ladder type cable trays shall consist of side rails and horizontal ladder rungs. Spacing of the ladder rungs shall be 250/300 mm. The straight sections shall be of 14 gauge (2mm thick) MS sheet and 2.5 (meters) in length.
Each 2.5m section of the cable tray shall be provided with the two side coupler plates and associated bolts, nuts and washers. The side coupler shall consist of 14 gauge (2mm thick) sheet steel plates with holes.
17.3.15.
Galvanizing
All cable trays and their fittings shall be hot dip galvanized with minimum 70 microns, after fabrication according to IS:2629 (1968) or relevant IEC. The galvanizing shall be uniform, clean, smooth, continuous and free from acid spots. 17.3.16. Support and supporting structures
The Contractor shall supply and install all angles, flats, channels, hangers, brackets clamps, nuts, bolts and other anchorage material for the installation of cables, cable trays, race ways and conduits. All steel members shall be suitably treated and galvanized or painted with 2 coats of approved paint. 17.3.17. Rigid conduits and fittings
Conduits shall be rigid, heavy duty and shall be supplied of in lengths of nearly 5 meters. Conduits shall be hot dip galvanized inside and outside as per relevant code or IEC. Cable trenches in the switchgear room, surrounding the panel shall be covered with 5 mm thick chequered plate. Testing of Cables 17.3.18. Tests during manufacture
During the manufacture of cables, manufacturer's standard tests shall be performed and copies of test certificates shall be furnished. 17.3.19. Type, routine and acceptance tests
After completion of manufacture of cables, type, routine and acceptance tests shall be performed strictly as per applicable standard specification and copies of test certificates shall
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
be furnished.
The test reports on all cables shall be got approved from the Owner /
Consultant before despatch of the cables. The tests on the cables that will be conducted by the bidder shall be mentioned in the schedule of tests, for each type of cable separately. The Owner / Consultant reserves the right to witness all tests and the bidder shall provide all facilities to the Owner / Consultant in this regard and shall inform the Owner / Consultant sufficiently in advance to enable the Owner / Consultant to depute his representative to witness the same. The high voltage test shall, however, be performed as per the methods (specified under relevant clause for routine test in the relevant IS). Apart from these, conductors examination, check of dimensions etc. shall be carried out as routine tests. Acceptance tests shall be carried out as specified or desired by owner. Routine tests shall be carried out on each drum length as per specification. Test certificates shall have to be approved by the owner before despatch of cables. Documents Six copies of the following documents shall be supplied by bidder. Test certificates Instruction manuals
18.
SPECIFICATION FOR TRAYS AND ACCESSORIES
18.1.
INTRODUCTION This section covers the requirements of cable trays, fittings and accessories for laying of LT Power & Control Cables and Instrumentation Cables.
18.2.
CABLE TRAYS AND FITTINGS Cable trays shall be designed for a uniformly distributed load of 250 Kg per sq. metre plus a concentrated moving load of 100 Kg moving along the tray length. The maximum deflection admissible with this loading is 10 mm. Cable trays and fittings shall be fabricated out of minimum 2.5mm thick MS sheet free from any flaws and conforming to the relevant Indian Standards. Supply of cable trays shall include supply of all the cable tray fittings and accessories as needed for the cable trays installation. Measurement will be made along the centre line of the cable tray. Design of cable trays, fittings and accessories shall strictly adhere with this specification.
Page 67 of 69
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
18.3.
Ladder type cable trays & fittings 1 Ladder type cable trays & fittings shall consist of side rails and horizontal ladder rungs. Side rails shall be formed to channel shape. All corners shall be as smooth as possible with radius not exceeding 6 mm. 2 Spacing between ladder rungs shall be 250 mm. Alternate rung shall be slotted and each rung shall be spot welded to side rail. 3 4 Straight, sections shall be 2.5 m in length. Elbows, reducers, tees, crosses etc shall comprise of MS sheet side rails and ladder rungs. Their various parts shall be spot welded. 5 Side rails shall have two (2) holes of 10 mm diameter at each end of straight sections, elbows, crosses etc for fixing side couplers.
18.4.
Perforated type cable trays and fittings 1 Perforated type cable trays and fittings shall be fabricated out of single 2.5 mm thick MS sheet with perforations at the bottom. All burrs and sharp edges shall be ground and filed after making perforations so that cable trays have a smooth surface for easy cable pulling/laying. 2 All fittings such as elbows, reducers, tees, crosses, etc shall also be made out of MS sheet steel with perforations at the bottom. 3 Straight sections shall be supplied in 2.5 m Lengths. Dimensions of fittings shall be same as for the ladder type tray fittings except that ladder rungs shall be substituted by perforated MS sheet. The side rails shall have two (2) holes of 10 mm diameter at each end of straight sections, elbows, tees, crosses etc for fixing side couplers.
18.5.
Side couplers Each 2.5 m section of the cable tray and each elbow, reducers, tee, cross etc. shall be provided holes. with four side coupler plates and associated bolts, nuts & washers. The side coupler shall consist of 2.5mm thick MS plates with two circular holes and two elliptical
Page 68 of 69
: : :
Project Consultant
Document Number
:
:

400-ENG-9336-003 Rev. No 00
18.6.
Galvanizing All cable trays and their fittings as well as cable tray covers shall be hot dip galvanised after fabrication according to IS:2629. Galvanising shall be uniform, clean smooth, continuous and free from acid spots. Should galvanising of the samples be found defective, the entire batch shall be re-galvanised at no extra cost. The zinc coating shall be uniform, clean and smooth and free from spangle. The zinc coating shall not be less than 90 micron in thickness and shall weigh not less than 600 gm/sq.metre not area covered.
18.7.
Cable Tray Covers Cable tray covers shall be fabricated out of 2.0mm thick mild steel sheet free from any flaws and conforming to relevant Indian standards and enclosed specification drawing. These tray covers shall be hot dip galvanised and as per relevant standards. Adequate number of clamp for fixing these covers on cable trays shall be supplied along with each cover. All punchings, cuttings, drilling, screw tapping and de-burring processes shall be completed prior to commencement of galvanizing.
19.
REFERENCE DRAWING
Plot plan 0-9336-000-001;Rev 02 Key Line Diagram 0-9336-400-001;Rev 00 220kV Switchyard SLD 0-9336-400-002;Rev 01 Switchyard Layout 1-9336-400-026;Rev 00 SCADA-System configuration-2-9336-400-017; Rev 00
Page 69 of 69

400-Eng-9336-003 Rev 00 (Technical Specification For 220KV Switchyard) PDF

Caricato da

Informazioni sul documento

Descrizione originale:

Titolo originale

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

400-Eng-9336-003 Rev 00 (Technical Specification For 220KV Switchyard) PDF

Caricato da

Copyright:

Formati disponibili

PROJECT: 2 X 150 MW COAL BASED TPP, BHADRESHWAR, GUJARAT

SPECIFICATION FOR 220kV GIS CUM AIS SWITCHYARD

Client Project Consultant Project No. Document No.

OPGS POWER GUJARAT PVT LTD.

Aquatherm Engineering Consultants (India) Pvt. Limited 9336 400-ENG-9336-003

Project Client Document Title

Aquatherm Engineering Consultants (India) Pvt. Ltd.,

Aquatherm Engineering Consultants India Pvt Ltd

Project Client Document Title

Aquatherm Engineering Consultants (India) Pvt. Ltd.,

Aquatherm Engineering Consultants India Pvt Ltd

Project Client Document Title

Aquatherm Engineering Consultants (India) Pvt. Ltd.,

SWITCHYARD CIRCUITS AND EQUIPMENT

Project Client Document Title

Aquatherm Engineering Consultants (India) Pvt. Ltd.,

BASIC INSULATION LEVEL

GAS INSULATION SWITCHYARD

Aquatherm Engineering Consultants India Pvt Ltd

Project Client Document Title

Aquatherm Engineering Consultants (India) Pvt. Ltd.,

Aquatherm Engineering Consultants India Pvt Ltd

Project Client Document Title

Aquatherm Engineering Consultants (India) Pvt. Ltd.,

Project Client Document Title

Aquatherm Engineering Consultants (India) Pvt. Ltd.,

Aquatherm Engineering Consultants India Pvt Ltd

Project Client Document Title

Aquatherm Engineering Consultants (India) Pvt. Ltd.,

Project Client Document Title

Aquatherm Engineering Consultants (India) Pvt. Ltd.,

Aquatherm Engineering Consultants India Pvt Ltd

Project Client Document Title

Aquatherm Engineering Consultants (India) Pvt. Ltd.,

Aquatherm Engineering Consultants India Pvt Ltd

Project Client Document Title

Aquatherm Engineering Consultants (India) Pvt. Ltd.,

Aquatherm Engineering Consultants India Pvt Ltd

Project Client Document Title

Aquatherm Engineering Consultants (India) Pvt. Ltd.,

Aquatherm Engineering Consultants India Pvt Ltd

Project Client Document Title

Aquatherm Engineering Consultants (India) Pvt. Ltd.,

Aquatherm Engineering Consultants India Pvt Ltd

Project Client Document Title

Aquatherm Engineering Consultants (India) Pvt. Ltd.,

Aquatherm Engineering Consultants India Pvt Ltd

Project Client Document Title

Aquatherm Engineering Consultants (India) Pvt. Ltd.,

Aquatherm Engineering Consultants India Pvt Ltd

Project Client Document Title

Aquatherm Engineering Consultants (India) Pvt. Ltd.,

Aquatherm Engineering Consultants India Pvt Ltd

Project Client Document Title

Aquatherm Engineering Consultants (India) Pvt. Ltd.,

Aquatherm Engineering Consultants India Pvt Ltd

Project Client Document Title

Aquatherm Engineering Consultants (India) Pvt. Ltd.,

Project Client Document Title

Aquatherm Engineering Consultants (India) Pvt. Ltd.,

Aquatherm Engineering Consultants India Pvt Ltd

Project Client Document Title