P.S NO.

: PS/441/316

PURCHASE SPECIFICATION
REV. NO : 00

GROUP : DRIVES & POWER SUPPLIES A4 12

PAGE 00 OF 14

REVISION HISTORY SHEET

COPYRIGHT AND CONFIDENTIAL The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED. It must not be used directly or indirectly in anyway detrimental to the interest of the company.

REV. NO.

DATE

NATURE OF CHANGE

REASONS

PREPARED BY

APPROVED BY

00

FIRST ISSUE

------

REVISIONS

00

APPROVED BY

S.K.Iyengar

PREPARED BY Prachi Rao.V

ISSUED BY D & PS

DATE 16-12-06

P.S NO. : PS/441/316

PURCHASE SPECIFICATION
REV. NO : 00

GROUP : DRIVES & POWER SUPPLIES A4 10

PAGE 01 OF 14

TECHNICAL SPECIFICATION OF VFD FOR 850 kW SQUIRREL CAGE INDUCTION MOTOR

1. Application 2. Quantity
COPYRIGHT AND CONFIDENTIAL The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED. It must not be used directly or indirectly in anyway detrimental to the interest of the company.

: :

ID Fan Drive (Squirrel Cage Induction Motor ) 4 Nos . Fully Assembled Units (CBU) CBU Units Completely Assembled & Tested Panel

3. Input voltage 4. Input phases 5. Input frequency 6. Ambient temperature 7. Motor data

: : : :

690 V +10 %,-15% (From a 6.6 KV / 690V ,3 , 50Hz Transformer) 3 50 Hz 5 % 50C Necessary derating in VFD Rating shall be done to account fo r the above. Rated Power : 850 KW Rated Voltage : 690V Rated Speed : 750 rpm Power factor : 0.85 Sine wave Efficiency(%): 94 Motor is designed for operation with IGBT PWM Inverter Torque Speed2 , Power Speed3 < 95% (non condensing) Max 1000mts above mean sea level

8. Power/Torque vs Speed: 9. Relative Humidity : 10. Altitude :

11. Location of VFD Panels : Indoor, Air-Conditioned Room 12. Output voltage of VFD 13. Output Current of VFD 14. Output Frequency : a) Resolution : b) Accuracy :
REVISIONS 00

: :

0 to Vin 980 Amps at 50 deg C

0 to 50Hz 0.001 Hz 0.01%

APPROVED BY S.K.Iyengar

PREPARED BY Prachi Rao.V

ISSUED BY D & PS

DATE 16-12-06

P.S NO. : PS/441/316

PURCHASE SPECIFICATION
REV. NO : 00

GROUP : DRIVES & POWER SUPPLIES A4 11

15. VFD Panel Construction a) Protection Class : IP42 b) Panel : Free standing, floor mounting type, comprising of rigid welded structural frames with Cold Rolled Sheet Steel enclosure of minimum thickness 2 mm for load bearing and 1.6 mm for other members. All doors & removable covers shall have neoprene gaskets. Ventilating louvers shall have easily removable and washable dust filters : Air Cooled (Natural or Forced Air Cooled) lf forced air cooling is adopted, same shall be with low noise ventilation fans at the top of the cubicle, which shall suck air through the Power modules.The arrangement shall preferably be such that ventilation air passes only through Power modules heat sinks in a separate duct to prevent dust deposition. Suitable thermal relays for exit air temperature monitoring and control shall also be incorporated.
PAGE 02 OF 14

COPYRIGHT AND CONFIDENTIAL The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED. It must not be used directly or indirectly in anyway detrimental to the interest of the company.

c) Cooling

d) Door Interlock: The VFD shall have a door-interlocked input AC line disconnect switch with fuses. The fuses should be of semiconductor type and have as asymmetrical short circuit interrupting capability of 200 kA e) Painting : All exterior surfaces of panels shall be given one primer coat, one filler coat and finished with two coats of lacquer Paint. Interior surfaces shall be primed and finished with one coat of Paint. Exterior and Colour as per shall be as per Shade to be finalised at the time of final drawing approval.

f) Limiting Dimensions: Height of Panels from finished floor level shall be 2400mm g) Cables : Unarmoured Type, Stranded Aluminium Conductor Details of Cable Size, Outside Diameter of Cable, No. of Cables etc shall be given by BHEL during drawing approval stage.

Cable Gland Plates shall be blank (undrilled) to be drilled at site. Gland Plates shall be 4mm thk Aluminium (steel not allowed) 16. Noise Level : Less than 80 dB at a distance of 3 ft.

17. Storage temperature : -40C to +60 C 18. Vibration 19. Interference Immunity : According to IEC68 - 2-6 : According to IEC801 parts 2,3,4 The panels shall be designed so as to have low Radio Frequency Interference (RFl) and Electromagnetic Interference (EMl).

P.S NO. : PS/441/316

PURCHASE SPECIFICATION
REV. NO : 00

GROUP : DRIVES & POWER SUPPLIES A4 11

20. VFD Efficiency 21. Overload Duty 22. VFD Requirements : a) Analog Input
COPYRIGHT AND CONFIDENTIAL The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED. It must not be used directly or indirectly in anyway detrimental to the interest of the company.

PAGE

03

OF

14

: Shall be > 96% : Class II Duty Overload as per IEC 146-1 (150% of Motor Rated Current for 60 secs at 50 deg C)

: 2 nos. User programmable. : 2 nos. 4 20 mA (Isolated)

:

b) Analog Outputs c) Digital Inputs d) Digital Outputs e) Varistors f) Input Choke g) Local/Remote Switch (Door Mounted)

8 nos. optocoupled. User programmable

: 4 nos. user programmable relay outputs for VFD ON, VFD Ready, VFD Fault and VFD Alarm.

: Metal Oxide Varistors (MOVs) shall be provided for transient voltage suppression on the 3-phase AC incoming power line. : Input chokes to be provided if necessary. : Selector switch shall be provided for operator to select Local - Operation from VFD Panel for Speed Control or Remote - Operation from DCS Panel

If VFD is set for speed reference from Remote, it shall be pos sible to program the VFD to either shutdown, go to minimum speed or continue operation at its last known speed reference point whenever a loss of speed reference is detected. h) Door Mounted Local Start/Stop Pushbutton : To be provided i) Door Mounted Emergency Stop j) Anticondensation Heater : Lockable Push-Button to be provided. :One heater to be provided inside the Inverter.

k) Motor Space Heater Feeder: One 230 V, 1200 W (Approx.)feeder to be provided on terminals for Motor Space heater. Final rating shall be provided during drawing stage l) PLC : PLC shall be provided for Interlocking and Protection : For 850 KW Motor

23. Braking Unit: Braking unit

6.0 Ohms 150 KW 104 KW 17.3 KW 100 secs ON 500 secs OFF Number of Braking Units used in the Inverter to be specified.

Resistor value Peak Power Average Power Nominal Power Cycle Time

P.S NO. : PS/441/316

PURCHASE SPECIFICATION
REV. NO : 00

GROUP : DRIVES & POWER SUPPLIES A4 11

24. Input transformer BHEL shall provide the Input Transformer. 25. Input Breaker, Output Breaker & Bypass Breaker: BHEL shall provide the Input Breaker, Output Breaker & Bypass Breaker:
COPYRIGHT AND CONFIDENTIAL The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED. It must not be used directly or indirectly in anyway detrimental to the interest of the company.

PAGE

04

OF

14

26. VFD Features : b) Soft Start & Auto Restart c) Auto Speed Search Facility (Catch on Fly) shall be available for starting into rotating loads. d) Power loss ride through (Kinetic Buffering) for minimum 2 secs time e) Automatic VFD tuning during start-up. f) Flux optimisation function shall be provided to reduced the total energy consumption and noise level in case drive is operated below nominal load. g) DC magnetising features shall be provided to automatically magnetise the motor before start to ensure the highest possible break away torque. h) Selectable reverse run prohibition i) j) Adjustable motor overload feature Settable minimum and maximum operating frequency

k) VFD shall produce not greater than 1 % torque pulsation to the shaft of driven equipment. l) m) Field adjustable Torque limits and acceleration & deceleration ramps. Eight (8) user programmable preset speeds.

P.S NO. : PS/441/316

PURCHASE SPECIFICATION
REV. NO : 00

GROUP : DRIVES & POWER SUPPLIES A4 11

27. Controls And Monitoring a) VFD shall be with an interactive and user-friendly door mounted digital operator interface with LCD display and sealed membrane type keypad. b) The operator interface shall be used for drive programming, drive monitoring and drive trouble shooting. The operator interface must also be able to start and stop the drive, reset VFD faults and manually adjust the VFD's speed reference.
COPYRIGHT AND CONFIDENTIAL The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED. It must not be used directly or indirectly in anyway detrimental to the interest of the company.

PAGE

05

OF

14

c) The operator interface shall have LED indicators for drive fault, drive run, drive in current limit and forward direction of rotation. d) The digital operator shall allow simple monitoring of inverter operating conditions including speed, current, voltage, torque, power etc. e) Messages shall be Alpha numeric in nature. All the fault messages shall be in clear English language. f) The operator interface shall be removable and remote mountable. g) The operator interface shall be able to display all real time operating variables and all drive programming parameters. h) The operator interface shall be capable of displaying a specific user selected parameter on power-up. This power-up parameter would typically be a parameter that is important to the operator such as motor speed or motor load. i) All VFD operating parameter shall be stored in nonvolatile memory (EEPROM).

j) The drive shall have built in monitoring of following parameters as minimum on its digital operator interface and these parameter shall also be displayed at plant DCS : Output Frequency Output Current Motor Speed Output Voltage DC Bus Voltage Output Power (lt shall be possible to display power output of the drive in KW and the accumulated power output over the time (kWHr) Torque Digital Input Status Digital Output Status Analog Input Status k) Necessary transducer shall be provided with 4-20 mA output for indicating motor speed and current in the DCS. Transducer shall be capable of driving 500 ohms load.

P.S NO. : PS/441/316

PURCHASE SPECIFICATION
REV. NO : 00

GROUP : DRIVES & POWER SUPPLIES A4 11

PAGE 06 OF 14

l) The following indications shall be provided on the Panel Door: - Motor Running - Motor Stopped/Tripped - AC Mains "On" - System "Ready to Start" - VFD System Fault
COPYRIGHT AND CONFIDENTIAL The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED. It must not be used directly or indirectly in anyway detrimental to the interest of the company.

m) The VFD shall store fault logs of minimum last 10 faults in memory. n) The interface details of VFD shall be incorporated as required for data communication with DCS system with serial interfaces with RS485 & RS 422 data links. Necessary hardware shall be included in the scope and the interface protocol (i.e. modbus or profibus) shall be defined. 28. Protection : Following protections shall be built in within the inverter and any other protection as required: a) Motor Overload / Over Torque b) Instantaneous Over current (This device shall monitor the peak output current continuously and shall provide instantaneous shutdown without component failure whenever its trip point is surpassed. The trip point must be greater than or equal to 250 % of the VFD's rated full load output current) c) Ground Fault d) Over Voltage/Under Voltage VFD shall be able to withstand 30% dip in supply voltage for 3 cycles without damage to semiconductors or fuses. e) Output Short Circuit f) Output Phase Loss/Fuse Failure g) Phase Sequence Protection h) Input Phase Loss/Single Phasing Preventer i) Over Speed j) Heat sink over temperature/VFD Panel Temperature High Stall prevention (During acceleratio n, deceleration and constant speed operation) k) Loss of Cooling Fans

P.S NO. : PS/441/316

PURCHASE SPECIFICATION
REV. NO : 00

GROUP : DRIVES & POWER SUPPLIES A4 11

29.Type of control:Completely programmable by the user as :a. Flux vector control with speed feedback b. Flux vector control without speed feedback c. Scalar v/f.
COPYRIGHT AND CONFIDENTIAL The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED. It must not be used directly or indirectly in anyway detrimental to the interest of the company.

PAGE

07

OF

14

VFD shall be capable of maintaining motor speed within 6 0.5% of maximum speed without the use of a motor mounted encoder or tachometer. The drive shall have programmable V/F patterns along with a user definable custom V/F patterns. 30. Harmonic limitations Shall be as per IEEE 519 Refer Pg. 14 of 14 of this specification for Single Line Diagram l) Voltage harmonics Maximum individual voltage harmonics to be limited to 3% and Total Harmonic Distortion of System to be limited to 5% as per IEEE 519. ll) Current Harmonics a) Source side i) 5th harmonic Maximum 30 % ii) 7th harmonic Maximum 20 % iii) 11th harmonic Maximum 10 % 31. Switching frequency :Shall not be less than 2 kHz. 32. Auxiliary Supply: 110V AC, 1 KVA, 1Ph, 50 Hz UPS feeder shall be made available. Load requirement to be indicated by vendor. All other supplies required to be derived from input feeder to VFD.

P.S NO. : PS/441/316

PURCHASE SPECIFICATION
REV. NO : 00

GROUP : DRIVES & POWER SUPPLIES A4 11

33. Spares Supplier should quote item wise price for the following spares: MANDATORY SPARES: Unpriced List of Spares quoted for shall be provided in the Technical Offer. BHEL reserves the option of deleting or changing the quantities of the items listed below. Unit Prices shall remain firm irrespective of any change.
COPYRIGHT AND CONFIDENTIAL The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED. It must not be used directly or indirectly in anyway detrimental to the interest of the company.

PAGE

08

OF

14

a) Electronic Cards b) Power Supply c) Door Interface Module d) Relays & Contactors e) Semi-conductor fuses f) Other fuses g) Converter Power Stack: h) Inverter IGBT Stack i) Braking Unit j) Limit Switch k) Pushbuttons and lamps l) Cooling Fan m) PLC n) Tools & Tackles

: : : : : :

2 No. of each type and rating 2 No. of each type 2 No. with necessary connecting cables and fixing hardwares. 2 no. of each type 6 nos. AC Fuses 4 nos. DC Fuses 2 sets (1 set refers to the total qty required for one Drive) 2 No. with Control Card

: : : : : : :

4 Nos. with Control Card 2 Unit 2 No. 2 set 2 no. of each type 2 no. Any special tools & tackles required for commissioning and troubleshooting shall be provided. 1 No. This Inverter is to be used for training and simulation purpose.

o) Small Rating IGBT Inverter : 0.75KW or higher, 690V,3Ph, 50Hz using the same electronic controller

RECOMMENDED/COMMISSIONING SPARES: Besides these spares Supplier will provide the list of recommended spares during commissioning and for five(5) years trouble free operation with item -wise price.

P.S NO. : PS/441/316

PURCHASE SPECIFICATION
REV. NO : 00

GROUP : DRIVES & POWER SUPPLIES A4 11

34. Maintenance : The procedure for maintenance of VFD panels, and the schedule thereof shall be mentioned in the offer. 35. Inspection, Training & Commissioning Support:
COPYRIGHT AND CONFIDENTIAL The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED. It must not be used directly or indirectly in anyway detrimental to the interest of the company.

PAGE

09

OF

14

a) Customer and BHEL representative will be present at msnufacturers works for witnessing of final testing. This is to be incorporated in the Quality Plan. No charges are applicable for this. b) Training for two persons from BHEL/customer for a period of 2 weeks at manufacturers works free of cost. c) Two (2) visits of experts to site during commissioning free of cost for a period of 10 days per visit free of cost. 36. Software for computer interface : This software should be an easy to use commissioning tool for drives and shall be provided along with the system. The interface details of VFD shall be incorporated as required for data communication with DCS system with serial interfaces with RS485 & RS 422 data links. Necessary hardware shall be included in the scope and the interface protocol (i.e. modbus or profibus) shall be defined. 37. Testing & Quality Plan : a) Routine tests shall be carried out on all Panels as per relevant standards. b) Type test certificates for similar equipment supplied by the Bidder shall be submitted along with offer. c) Test Protocol and Quality Plan for approval shall be submitted by supplier along with offer. These documents shall explicitly list out all final tests done on the Fully Assembled Unit. d) Sl.Nos.18, 19 & 20 of Data Sheet to be demonstrated by manufacturers works. 38. Information required along with offer : a) b) c) d) e) f) g) h) i) Dimensional Drg of Panels along with minimum clearance to be mantained for effective cooling Tentative Scheme Weight Losses at Rated Load (Total including Cooling Fans) Quantity and Rating of Cooling Fans provided Experience list of similar rating Catalog User Manual Confirmation to all pts in Sl.39 (a) to (f)

P.S NO. : PS/441/316

PURCHASE SPECIFICATION
REV. NO : 00

GROUP : DRIVES & POWER SUPPLIES A4 11

39. Confirmations required from Supplier : a) After Sales Service & Support shall be given by vendor along with of for a minimum period of 10 (ten) years. Address of the after sales and service representative in India to be given. The same shall be binding on the Principals irrespective ofany change in the Indian Representative. Annual Maintenance Contract (AMC) for the above period to be provided for the system if the same is required by customer. Price for the same shall be indicated in the offer as an optional price.
COPYRIGHT AND CONFIDENTIAL The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED. It must not be used directly or indirectly in anyway detrimental to the interest of the company.

PAGE

10

OF 14

b) The availability of VFD shall be greater than 99.90% for a period of 10 years after commissioning. Further supplier shall give extended warranty of five years. Price for the period of Extended Warranty shall be indicated separately. c) Mean Time Between failures (MTBF) shall be greater than 40000 running hours. All components of VFD shall be considered for MTBF calculations d) The vendor shall confirm that supply of spares and services shall be rendered for a period of 10 years after commissioning. A Revolving Bank Guarantee for a period of 2 years (with a claim period of 6 months) equal to 10% of the value of Purchase Order shall be furnished as a guarantee towards the supply of spares and services. The same shall be renewable for the above stipulated period of 10 years. In case of breach of such an agreement for the supply of spares and services, this guarantee shall be invoked by BHEL. The prices of any spares and services during this period shall be decided keeping the quoted prices with this bid as base and applying increase/decrease after mutual discussions and acceptance as and when such a requirement arises. e) Bank Guarantee Charges shall be borne by vendor. 40. Confirmations/Deviations to Specification : Point-wise confirmation to this specification to be given along with offer. Deviations if any, shall be indicated separately. If there are no deviations to the specifications, supplier shall mention the same explicitly. A reply from vendor stating that Equipment will generally meet the specifications will not be accepted by BHEL. 41. Maintenance manuals/Documentation to be given after Order Placement: a. b. c. d. e. Erection, Commissioning and Maintenance manuals - 10 Copies All drawings for approval 1 no. CD ROM consisting of final drawings and documentation as mentioned above. Test and guarantee certificates. Complete Bill of Material (itemwise) for the equipment supplied.

P.S NO. : PS/441/316

PURCHASE SPECIFICATION
REV. NO : 00

GROUP : DRIVES & POWER SUPPLIES A4 11

PAGE 11 OF 14

Sl.No 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0

DATA SHEET (To be filled in by supplier and attached along with offer) Description Unit Specification requirement Type of Drive Manufacturer Application Type of Motor Rating of Motor Quantity Rated Power Factor Efficiency Ambient Temperature Power Supply System a) Input Supply to VFD b) Variation in Voltage c) Variation in Frequency d) Combined Voltage & Frequency variation VFD Location VFD Offered : a) VFD Type No b) Rated Output Power c) Rated Output Voltage d) Rated Continuous Current at 50 deg C temperature VFD suitable for Duty Class II Overload a) VFD suitable for site ambient temperature b) Derating provided Type of Cooling Dimensions Deg C KW Inverter (IGBT Based PWM Controlled) * ID Fan Squirrel Cage Induction Motor 850 KW 4 0.85 0.94 50 deg C 690V, 3 Ph, 50 Hz +10%, -15% +/- 5% +/- 10% Indoor * * * 980 Yes Yes Yes Air Cooled *

Vendors Details

COPYRIGHT AND CONFIDENTIAL The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED. It must not be used directly or indirectly in anyway detrimental to the interest of the company.

11.0 12.0

KW Volts Amps

13.0 14.0

Yes/No Yes/No Yes/No Yes/No

15.0 16.0

P.S NO. : PS/441/316

PURCHASE SPECIFICATION
REV. NO : 00

GROUP : DRIVES & POWER SUPPLIES A4 11

Sl.No 17.0 18.0 19.0
COPYRIGHT AND CONFIDENTIAL The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED. It must not be used directly or indirectly in anyway detrimental to the interest of the company.

PAGE

12

OF

14

Description Degree of Protection Power Loss Ride Through Time Auto restart after power loss Kinetic Buffering Soft Start Catch on Fly Accelerate/Decelerate time Harmonic Limitation 1) Voltage Harmonics a) Source side b) Load side 2) Current Harmonics a) Source side (i) 5th (ii) 7th (iii) 11th Switching Frequency No. of Braking Units in Inverter Address of Sales & Service Respresentative in Indi a Quality Plan submitted Test Protocol submitted Type test certificate submitted Reference List Max.cable length without output choke Confirmation/Deviations attached

Unit

Specification requirement IP 42

Vendors Details Yes/No

Secs

2 Yes Yes/No Yes/No Yes/No Yes/No

20.0 21.0 22.0 23.0 24.0

Secs

2 Yes Yes * As per IEEE 519

Maximum 30% Maximum 20% Maximum 10% > 2 KHz *

25.0 26.0 27.0

28.0 29.0 30.0 31.0 32.0

Yes/No Yes/No Yes/No Yes/No

33.0

Yes/No

P.S NO. : PS/441/316

PURCHASE SPECIFICATION
REV. NO : 00

GROUP : DRIVES & POWER SUPPLIES A4 11

Sl.No 34.0 35.0 36.0
COPYRIGHT AND CONFIDENTIAL The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED. It must not be used directly or indirectly in anyway detrimental to the interest of the company.

PAGE

13

OF

14

Description Extended Warranty for 5 years Annual Maintenance Contract Bank Guarantee for Spares & Services for 10 yrs as per Sl.39. Information reqd.with offer as per Sl.38(a) (i) Protections offered : To be filled in by vendor

Unit

Specification requirement Required Supplier to quote. Optional to BHEL. Required.

Vendors Details

37.0 38.0

Documents and confirmation required.

P.S NO. : PS/441/316

PURCHASE SPECIFICATION
REV. NO : 00

GROUP : DRIVES & POWER SUPPLIES A4 11

PAGE 14 OF 14

6.6 KV, 3 Ph, 50 Hz Short-Circuit Level = 360MVA

COPYRIGHT AND CONFIDENTIAL The information on this document is the property of BHARAT HEAVY ELECTRICALS LIMITED. It must not be used directly or indirectly in anyway detrimental to the interest of the company.

6.6KV / 690 V Dd0 Transformer 1800 KVA, 6.25% Impedance

I G B T

M
INDUCTION MOTOR 850KW, 690V, 980 Amps

SINGLE-LINE DIAGRAM