Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

Specification G3IR105065SP9044 Date 18-Jul-12 Page 1 of 14

66 KV CONTROL & RELAY PANEL

Project Document No: G3IR000065SP9044

Unit: Discipline: Document Type:

General Electrical Specification

Document Title: SPECIFICATION FOR 66KV CONTROL & RELAY PANEL

ISSUED FOR DESIGN

08 Aug 2012
DISCLAIMER THIS DOCUMENT DEVELOPED BY FLUOR DANIEL INDIA PRIVATE LIMITED, IS THE PROPERTY OF BASF INDIA LIMITED AND THIS DOCUMENT CANNOT BE REPRODUCED, COPIED, DISTRIBUTED DIRECTLY OR INDIRECTLY OR OTHERWISE USED WITHOUT EXPRESS WRITTEN PERMISSION OF BASF INDIA LIMITED FOR ANY PURPOSE OTHER THAN FOR THE PROJECT FOR WHICH IT IS FURNISHED.

1 0 Revision

30-Jul-12 18-Jul-12 Date

Issued for Design Issued for RFQ Purpose

RR RR Prepared By

NG NG Checked By

VP VP Fluor BASF

Approved By

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Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

Specification G3IR105065SP9044 Date 18-Jul-12 Page 2 of 14

66 KV CONTROL & RELAY PANEL Record of Revisions

This specification has been revised as indicated below and described in the revision record on the following page. Please destroy all previous revisions. Revision No. 0 Date Description

18-Jul-12

Issued for RFQ

30-Jul-12

Issued for Design

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Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

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66 KV CONTROL & RELAY PANEL

TABLE OF CONTENTS

1.0 1.1 1.2 1.3 2.0 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13 2.14 2.15 3.0 4.0 5.0

GENERAL............................................................................................................................................... 4 Scope ..................................................................................................................................................... 4 References............................................................................................................................................. 4 Service Conditions................................................................................................................................ 5 TECHNICAL / CONSTRUCTIONAL REQUIREMENT .......................................................................... 6 General................................................................................................................................................... 6 AUXILIARY SUPPLY ............................................................................................................................. 6 Mimic Diagram....................................................................................................................................... 6 Control Scheme..................................................................................................................................... 7 Protection scheme ................................................................................................................................ 7 Annunciation ......................................................................................................................................... 8 Enclosure............................................................................................................................................... 8 Instrument / Meters ............................................................................................................................... 9 Protection Relays................................................................................................................................ 10 Wiring & Terminal Blocks .................................................................................................................. 10 Name Plates & Markings .................................................................................................................... 11 Earthing................................................................................................................................................ 12 Indicating Lamps................................................................................................................................. 12 Control and Selector Switches.......................................................................................................... 13 Accessories ......................................................................................................................................... 13 INSPECTION, TESTING AND ACCEPTANCE ................................................................................... 14 DRAWINGS & DOCUMENTS .............................................................................................................. 14 SPARE PARTS..................................................................................................................................... 14

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Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

Specification G3IR105065SP9044 Date 18-Jul-12 Page 4 of 14

66 KV CONTROL & RELAY PANEL 1.0 GENERAL 1.1 Scope 1.1.1 The Intent of this specification is to define the requirements detailed installation, design engineering, manufacturing & testing of equipments at works, supply, erection, testing and commissioning of all the required equipments and accessories at site for control and relay panel for 66 kV supply & associated equipments. 1.1.2 1.1.3 1.1.4 Seller shall furnish any special tools and tackles for installation and maintenance. The make of all accessories and hardware shall be subject to purchasers approval. Such of the parts that may have not been specifically included, but otherwise form part of the CRP as per standard trade and/or professional practice and/or are necessary for proper operation of control and relay panel, will be deemed to be also included in this specification whether explicitly mentioned or not. 1.1.5 The basic design shall include, but not limited to, the following: a) Protection and control philosophy (selection of protection, control and annunciation schemes). b) 1.2 References 1.2.1 The Design, manufacture, testing & installation of Control & Relay panel shall conform to the latest editions of following standards issued by BIS (Bureau of Indian Standards) and IEC unless otherwise specified. Each publication shall be the latest revision and addendum in effect on the date this specification is issued for Purchase, unless noted otherwise. Except as modified by the requirements specified herein or the details of the drawings, as a minimum, work included in this specification shall conform to the applicable provisions of these publications. S.No. 1 2 Description Direct acting indicating analogue electrical measuring instruments and their accessories Basic and safety principles for man-machine interface, marking and identification-Coding principles for indication devices and actuators Current transformers Voltage transformers 2705 3156 IS 1248 IEC 60051 60073 Development of interlocking schemes.

3 4

60185 60186

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Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

Specification G3IR105065SP9044 Date 18-Jul-12 Page 5 of 14

66 KV CONTROL & RELAY PANEL 5 6 7 8 9 Electrical relays for power system protection Low-voltage fuses for voltages not exceeding 1000V AC or 1500 V DC Switchgear and control-gear for voltages exceeding 1000V General requirements Code for Practice for selection, installation and maintenance of switchgear and control gear Guide for uniform system of marking and identification of conductors and apparatus terminals. A.C. Electric Meters Guide for Marking of insulated conductors Degrees of protection provided by enclosures. (IP Code) 3231 13703 12729 10118 11353 60715 60445 60255 60269

10 11 12

722 5578 60529 60529

1.2.2

In case of any contradiction between various referred standards/specification/data sheets and statutory regulations, it shall be brought to the notice of Client for resolution, before taking a decision. Generally the following order of priority shall govern, Statutory regulations BASF Guidelines Data Sheets This specification Codes and standards

1.3

Service Conditions 1.3.1 The expected lifetime of the equipments to be supplied shall be 25 years. All individual components/materials forming part of the system shall be suitable for continuous operation for periods of up to minimal 5 year without maintenance, 1.3.2 The equipment shall be designed for a design ambient temperature of +45oC and an altitude not exceeding 1000 meters above mean sea level. Relative humidity of 92% shall be considered for design. 1.3.3 The equipment shall be suitable for operating satisfactorily indoor in substation building.

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Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

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66 KV CONTROL & RELAY PANEL 2.0 TECHNICAL / CONSTRUCTIONAL REQUIREMENT 2.1 General 2.1.1 The panels shall be of `simplex' type of standard dimensions. Equipment shall be mounted on the front of the panel and doors for wiring access shall be at the back of panels. 2.1.2 The center lines of switches, push buttons and indicating lamps shall not be less than 750mm and that for relays, meters and recorders shall be not less than 450 mm from the bottom of the panel. The center lines of switches, push buttons and indicating lamps shall be matched to give a neat and uniform appearance. Like wise the top lines of all meters, relays and recorders etc, shall be matched. 2.1.3 All live parts shall be adequately protected to prevent inadvertent or accidental contact. 2.2 AUXILIARY SUPPLY 2.2.1 Supplier shall provide adequate rated switch / MCB to receive these supplies, and suitable switch and fuse or MCB in each sub-circuit as per requirement. 2.2.2 AC auxiliary supply for control, indication etc. shall be received via control transformer and it shall be sized for the entire board. 2.2.3 DC auxiliary supply for control, indication etc. shall be received directly through MCB in switchboard with monitoring facility (DC fail Relay and alarm/indication). 2.3 Mimic Diagram 2.3.1 System Representation: Colored mimic diagram and symbols showing the exact representation of the system shall be provided in the front of control panels. 2.3.2 Material: Mimic diagram shall be made preferably of painted aluminum or plastic of approved fast color material, which shall be screwed on to the panel and can be easily cleaned. Painted overlaid mimic is also acceptable. The mimic bus shall be 2-3 mm thick. The width of the mimic bus shall be 12mm for bus bars and 10 mm for other connections. 2.3.3 Mimic Indications: Discrepancy type switches are to be used for breaker and isolator control indication and semaphore indicators shall be used for earth switch position.

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Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

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66 KV CONTROL & RELAY PANEL 2.4 Control Scheme 2.4.1 Control switch for circuit breaker It shall be possible to close circuit breaker from the control room. For this purpose, control switches having pistol grip type and of the spring return to neutral position type non lockable handles with alarm cancellation contacts shall be provided for operation of circuit breaker. These shall be so designed that after being operated to `close' a circuit breaker, the operation cannot be repeated until the switch has been turned to a `trip' position making it impossible to perform two `closing' operations consecutively. The rating of the control switch contacts shall be suitable for the duty imposed by the closing & opening mechanism of circuit breakers and shall conform to the recommendations which may be made by the suppliers of circuit breakers. The moving & fixed contacts shall be of such a form & material as will ensure good contact and long service under severe operation duty. All contacts shall be readily renewable. The number of contacts in the control switches shall be decided by the Bidder in view of various requirements of this specification. Two pairs of contacts one normally open and one normally closed shall be kept spare. The total number of contacts proposed to be provided shall be stated in the data sheet. Safety against inadvertent operation due to light touch in the control switches shall be ensured. 2.4.2 Control Switch for Isolator It shall be possible to close the 66 kV Isolators from the control room. For this purpose control switches with pistol grip handles & having no provision for locks shall be mounted on the 66 kV C&R panels specified herein. The size/ color of the control switch handle meant for isolator will be different so as to be easily distinguishable from those meant for circuit breaker controls. 2.5 Protection scheme 2.5.1 For details of protection scheme, refer 66 kV protection Single line diagram (Doc. No. G3IR-1050-65-DW-3001).

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Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

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66 KV CONTROL & RELAY PANEL 2.6 Annunciation 2.6.1 Annunciation shall be Static type along with alarm. Annunciations shall be repetitive type and shall be capable of registering the fleeting signal. Facia test facility shall also be provided. 2.6.2 2.6.3 It shall be flush mounted having 12 facia along with appropriate labels on each facia. Sequence of operation of the annunciator shall be as follows: Sr. No. Alarm Condition Normal Abnormal Accept Return to normal Reset Reset before Return to normal 2.6.4 D.C. Fail alarm scheme: A relay for monitoring the Trip Circuit D.C. wiring of the control and relay panels shall be provided. The operation of the DC fail scheme shall be accompanied by visual (indicating lamp of amber color on the concerned panel) and audio (ringing of common buzzer) annunciation. It shall be possible to silence the buzzer by pressing the 'accept' push button while the lamp shall continue to glow till the fault is attended to & D.C. supply restored. A 'DC fail test' push button will be provided to test the lamp circuit of the scheme. 2.7 Enclosure 2.7.1 The control & relay boards shall be completely dust & vermin proof. The enclosure shall provide degree of protection not less than IP-42 in accordance with IS:2147 and shall be suitable for tropical use. Fault Contact Open Close Close Open Open Close Visual Annunciation Off Flashing Steady On Steady On Off Flashing Audible Annunciation Off On Off Off Off On

1 2 3 4 5 6

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Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

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66 KV CONTROL & RELAY PANEL 2.7.2 The C & R panel body shall made by Cold-rolled sheet steel of suitable thickness. Stiffeners shall be provided wherever necessary. 2.7.3 Doors shall be at the rear. For panels having width more than or equal to 800 mm, double leaf doors shall be provided. Doors shall have handles with either built-in locking facility or be provided with padlock. 2.7.4 The cubicle shall be suitable for floor mounting with its bottom open. Each cubicle shall be fitted with flush mounted steel hinged door & lock at the back. All holes and extension windows shall be blanked and access doors shall be provided with compressible liners at the edges. 2.7.5 Ventilating louvers, if provided shall have screens and filters. The screens shall be made of either brass or GI wires mesh. 2.7.6 All doors, removable covers and panels shall be gasketed all around with neoprene gaskets. 2.7.7 The panels shall be fixed on the embedded foundation channels with intervening layers anti vibration strips made of shock absorbing materials. Base frames shall be supplied along with panels. 2.7.8 2 Nos. earthing terminals complete with sockets and identification marks shall be provided on the enclosure of panel. 2.8 Instrument / Meters 2.8.1 2.8.2 Meters shall be flush mounting and fitted on the front of the C&R panel. Ammeters shall be scaled such that full load corresponds to between 50 and 80% of the angular deflection. 2.8.3 Meters and relays shall be capable of withstanding without damage the secondary currents associated with the switchyard component rated fault current flowing in the primary of current transformers taking into account current limiting effects of protective devices. 2.8.4 Unless indicated otherwise, low voltage equipment voltmeters and voltage coils shall generally be direct connected. Ammeters and voltmeters shall be class 1.5. Watthour meters and maximum demand meters shall be class 2.5. 2.8.5 In analogue meters, Zero adjusters shall be provided for operation from the front of the cases. Dials shall be parallax free with scale marked in black on white background and shall be suitable for direct reading.

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Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

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66 KV CONTROL & RELAY PANEL 2.9 Protection Relays 2.9.1 Relays shall be numerical type having dust proof covers. Relay bases shall be keyed to ensure correct contact alignment and shall include retaining clips for the relay. 2.9.2 Where similar relays and timers are used for different coil operating voltages they shall be non interchangeable. 2.9.3 Relays shall have a means of visually indicating they are energised. Timers shall have indication that they are energised and that the timing is in progress. 2.9.4 The coil voltage shall be as specified with the minimum voltage to pull in and maintain no lower than 85% of the nominal control voltage. The relay shall not drop out at any voltage above 60% of the nominal control voltage. 2.9.5 Protection relays shall have hand-reset facilities and clear operating indication, e.g. light emitting diodes. Non-tripping relays may be self-resetting if an indication of operation remains until hand reset. 2.9.6 Relay shall integrate all necessary protections for different applications in accordance with IS and IEC. Relay shall provide wide setting ranges and choice of all IEC, IEEE and other tripping curves through a minimum of two setting groups. 2.9.7 All numerical relay shall have key pad / keys to allow relay settings from relay front. All hand reset relays shall have reset button on the relay front. 2.9.8 Relays with multiple trip and alarm functions shall have separate operating contacts for each function wired out to separate terminals. 2.9.9 Test blocks for injection testing of relays and measuring devices shall be provided on each panel. Current injection test blocks shall be provided with short circuiting links. 2.9.10 All the numerical relays shall have at least a rear port supporting IEC 103 protocol and a local front port for communication with a laptop. 2.9.11 Relays shall have self diagnostic feature with self check for power failure, programmable routines, memory and main CPU failures. 2.9.12 Design of the relay must be immune to any kind of electromagnetic interference. Vendor to submit all related type test reports for the offered model along with the offer.

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Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

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66 KV CONTROL & RELAY PANEL 2.10 Wiring & Terminal Blocks 2.10.1 Terminal block shall be of 1100 V grade, minimum 10 amps continuous rating, Nylon 66, moulded piece, complete with insulated barriers, stud type terminals, washers, nuts and lock nuts. 2.10.2 White fibre markings strip with clear plastic, slip-on / clipon terminal covers shall be provided. 2.10.3 Internal wiring shall be done by.1100V grade, single core, stranded copper conductor wires with PVC insulation. The size shall be 4 sqmm for CT circuits, 2.5 sqmm for PT and 1.5 mm for control circuits. 2.10.4 Ferrules marked to correspond with panel wiring diagram shall be fitted at both ends of each wire. Ferrules shall fit tightly on the wire. Wires directly connected to trip circuit shall be distinguished by the addition of red colored unlettered ferrule. 2.10.5 Fork type, pin type and ring type (as applicable) tinned copper lugs to be used. Insulated sleeves shall be provided at all the wire terminations. 2.10.6 Spare contacts of relays and contactors etc. shall be wired out upto the terminal block. 2.10.7 Auxiliary bus wiring for AC and DC supplies, voltage transformer circuits, annunciation circuits and other common services shall be provided on the same set of terminals in panel with proper segregation. 2.10.8 20 % spare terminal in each TB row shall have to be provided. 2.10.9 Arrangement of the terminal block assemblies and the wiring channel within the enclosure shall be such that a row of terminal block runs in parallel and close proximity to each side of the wiring duct. The side of the terminal block opposite the wiring duct shall be reserved for the external cable connection. 2.10.10 Terminal blocks for current transformer and voltage transformer secondary leads shall be provided with test links and isolating facilities. Also, current transformer secondary leads shall be provided with short-circuiting and earthing facilities. 2.11 Name Plates & Markings 2.11.1 All equipment mounted on front side as well as equipment mounted inside the panels shall be provided with individual name plates with equipment designation engraved. Also, large and bold name plate carrying the feeder identification numbers shall be

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Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

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66 KV CONTROL & RELAY PANEL provided for circuit / feeder designation on the top of each panel on front as well as rear side. All front mounted equipment shall be also provided at the rear with individual name plates engraved with tag numbers corresponding to the one shown in the panel internal wiring to facilitate easy tracing of the wiring. 2.11.2 Nameplates shall be black with white engraving lettering on Non-rusting metal or 3 ply lamicoid. Stickers are not allowed. 2.11.3 Each switch shall bear clear inscription identifying its function. Similar inscription shall also be provided on each device whose function is not other wise identified. If any switch or device does not bear this inscription separate nameplate giving its function shall be provided for it. Switch shall also have clear inscription for each position indicating e.g. Trip-Neutral close, ON-OFF, R-Y-B, OFF etc. 2.12 Earthing 2.12.1 All panels shall be equipped with an earth bus securely fixed. The material and the sizes of the bus bar shall be 25 x 6 mm copper flat as a minimum, unless specified otherwise. 2.12.2 All metallic cases of relays, instruments and other panel mounted equipment including gland plate, shall be connected to the earth bus by copper wires of size not less than 2.5 mm2. The color code of earthing wires shall be green. 2.12.3 VT and CT secondary neutral shall be earthed at one place only at the terminal blocks through links. 2.12.4 All hinged doors shall be earthed through flexible earthing braid. 2.13 Indicating Lamps 2.13.1 Indicating lamps shall be low burden type with series resistor. Lamps shall be LED type except where neon lamps are specifically called for. Lamp covers shall be provided with interchangeable colored lenses of perspex or equivalent unbreakable material. It should be noted that lenses should not get discolored in course of time, due to the heat generated by the lamps. 2.13.2 When neon lamps are used on D.C. circuits, they shall be tested for operation at specified D.C. voltage without any ripple content. 2.13.3 The color of indicating lamp shall normally be the following, unless otherwise specified :Red
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C.B. 'ON'
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Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

Specification G3IR105065SP9044 Date 18-Jul-12 Page 13 of 14

66 KV CONTROL & RELAY PANEL Green White Blue Amber C.B. 'OFF' Auto Trip 'Spring Charged' DC fail

2.13.4 Glass/Plastic lens of appropriate color shall be screwed into the front of the lamp body. The design of indication lamps shall be such as to facilitate replacement of fused lamps. 2.13.5 An engraved label indicating the purpose of the lamp shall also be provided with each lamp. 2.14 Control and Selector Switches 2.14.1 Control and selector switches shall be of rotary type, provided with nameplate engraved with switch operating positions /switch description. 2.14.2 Breaker control switch shall be of pistol grip type spring return, with position indicator sequence interlock and normal after closing (NAC) contact (when specifically called for). 2.14.3 Selector switches shall have stay put positions with oval handle. The number of contacts and their operation in each switch shall be as per the requirement specified during drawing approval. 2.14.4 The switches and push buttons shall conform to utilization category AC11/DC11 as per IS: 13947. 2.14.5 Emergency stop push buttons, if specified, shall be lockable in pushed position. 2.15 Accessories 2.15.1 Space heater: Adequately rated anti-condensation space heaters shall be provided to maintain panel inside temperature. Space heater shall be strip type, rated for operation on 240 V, single phase, 50 Hz. A.C. supply unless otherwise specified. Each heater shall be complete with a rotary type ON/OFF switch, HRC fuse in the phase, neutral link in neutral and a control thermostat.

2.15.2 Socket and Switch: 240V, 5A socket to be provided in each panel with on-off switch.

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Client Name : BASF India Limited Project Name : Project GIR Project Number: G3IR

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66 KV CONTROL & RELAY PANEL 2.15.3 MCBs and Fuses: Provision for receiving, distribution, isolation and fusing of DC and AC supplies to various control circuits should be made using MCBs and Fuses of appropriate ratings. 2.15.4 Panel illumination: 240V AC illumination lamp controlled by panel door switch to be provided in panel. 3.0 INSPECTION, TESTING AND ACCEPTANCE a) The routine tests shall include: b) Visual check- measurement of overall dimension, location, number and type of devices, location and connection of terminals Functional Test Interchangeability Test Contactor pull-in and drop-out voltage A general check shall be carried out. Relays shall be checked under the worst conditions of auxiliary supply voltage. Dry insulation test with power frequency voltage shall be conducted for the main and auxiliary circuits.

Type tests reports shall be submitted which shall comprise (not limited to), the verification of Constructional requirements; Temperature-rise; Operating limits; Operational performance; Degree of protection of enclosed equipment;

4.0

DRAWINGS & DOCUMENTS The Vendor shall furnish drawings in accordance with SDDC form, enclosed with the Bid.

5.0

SPARE PARTS Bidder shall submit list of spares recommended by him for satisfactory operation of the C & R panel for first two (2) years and rate for each spare shall also be quoted. The purchaser will decide the actual quantity of spare parts to be ordered on the basis of the prices of the spare parts, quoted by the bidder.

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