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NMDC LIMITED HYDERABAD KUMARASWAMY IRON ORE PROJECT BELLARY DIST - KARNATAKA TENDER DOCUMENT FOR PACKAGE
NMDC LIMITED
HYDERABAD
KUMARASWAMY IRON ORE PROJECT
BELLARY DIST - KARNATAKA
TENDER DOCUMENT
FOR
PACKAGE - II
DOWNHILL CONVEYOR SYSTEM
VOLUME – IV OF V MECON LIMITED BANGALORE MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD REV. 0 JANUARY 2010
VOLUME – IV OF V
MECON LIMITED
BANGALORE
MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD
REV. 0
JANUARY 2010
NMDC LIMITED MECON LIMITED KUMARASWAMY IRON ORE PROJECT PACKAGE NO – II DOWN HILL CONVEYOR
NMDC LIMITED MECON LIMITED KUMARASWAMY IRON ORE PROJECT PACKAGE NO – II DOWN HILL CONVEYOR

NMDC LIMITED

MECON

LIMITED

KUMARASWAMY IRON ORE PROJECT

PACKAGE NO – II

DOWN HILL CONVEYOR SYSTEM

CONTENTS

Chapter

No

Description

1.

Check list

2.

Notice Inviting Tender (NIT)

3.

Instructions to Tenderers (ITT)

4.

General Conditions of Contract (GCC)

5.

Special Conditions of Contract (SCC)

6.

Erection Conditions Of Contract (ECC)

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V

1.

Preamble, Summary of Prices, Price for exemptions / variations and Price Format

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V

Chapter

Description

No

A

Brief on the Project and Intent Of Tender

B

General technical conditions

C

General site information

D

Scope of work and battery limit

E

Performance guarantee and warranty

F

Surface preparation and painting

G

Quality assurance, inspection and testing

H

Construction, erection, testing and commissioning

I

Engineering services

J

Project management services

K

Site services

L

List of Tender Drawings

M

Part/1 - Documents/ drawings to be submitted along with the tender

Part/2 – Questionnaire and design data sheets to be filled and submitted along with the tender

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NMDC LIMITED MECON LIMITED KUMARASWAMY IRON ORE PROJECT PACKAGE NO – II DOWN HILL CONVEYOR
NMDC LIMITED MECON LIMITED KUMARASWAMY IRON ORE PROJECT PACKAGE NO – II DOWN HILL CONVEYOR

NMDC LIMITED

MECON

LIMITED

KUMARASWAMY IRON ORE PROJECT

PACKAGE NO – II

DOWN HILL CONVEYOR SYSTEM

N

Documents /drawings to be submitted by successful Tenderer

O

Spares, Special tools & Tackles

P

List of Preferred makes of equipment

Q1

Technical specification – Mechanical

Q2

Technical specification – Environmental

Enclosures: -

1. Tender drawings as per the list under chapter-L

2. Specimen QAP format for Structural & Mechanical equipment

3. Specimen QAP format for Electrical equipment

4. Specimen Inspection call format.

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V

Chapter

No

Q3

Q4

Q5

Description

Description

Technical specification – Electrical

Technical specification – Automation and Control

Technical specification – Plant Communication System

Chapter

No

Description

Q6

Technical specification – Civil

Q7

Technical specification – Structural

Q8

Technical specification – Hydro Engineering

Q9

Technical specification –Fire Detection and Suppression System for Down Hill Conveyor

Q10

Technical specification – General Layout, Roads and Fire Fighting

Enclosures:- One Compact disc containing soft copy of the following:

1. Soft copy of Questionnaire and design data sheet – Chapter-M (Part-2 of 2)

2. Soil investigation report (for reference only)

3. Waste Dump Locations - Sketch dated 14.09.07

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MECON

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CHAPTER NO. Q3

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CHAPTER-Q3

ELECTRICAL

INDEX

Sl. No.

Description

1.0

SCOPE OF WORK

2.0

EQUIPMENT SPECIFICATION

2.1

11kV & 6.6kV HT SWITCHGEAR & 11kV CICO OUTDOOR PANEL

2.2

11kV & 6.6kV HT CAPACITOR WITH SERIES REACTORS

2.3

BATTERY, BATTERY CHARGER & D.C. DISTRIBUTION BOARD

2.4

TRANSFORMERS

2.5

VARIABLE VOLTAGE VARIABLE FREQUENCY DRIVES

2.6

LT MOTORS

2.7

LT SWITCHGEAR PANEL /LT PMCC /MCC

2.8

CABLES (HT, LT & CONTROL)

2.9

POWER DISTRIBUTION BOARDS / MAIN LIGHTING DISTRIBUTION BOARD AND SUB DISTRIBUTION BOARDS

2.10

ILLUMINATION EQUIPMENT SPECIFICATION

2.11

MISCELLANEOUS ELECTRICAL ITEMS

2.12

EARTHING AND LIGHTNING PROTECTION

2.13

OVERHEAD LINES (11kV )

2.14

EQUIPMENT SIZING & SELECTION

2.15

APPLICABLE STANDARDS AND CODES

3.0

ERECTION, TESTING & COMMISSIONING

4.0

DRAWINGS AND DOCUMENTATION

5.0

MAJOR EQUIPMENT LIST (INDICATIVE)

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1.0 SCOPE OF WORK

1.1 GENERAL

The scope of work includes but not limited to Design, Basic and detailed Engineering, Manufacture, Shop Testing, Inspection, Supply, Transportation to site, Unloading, Storage and Stores Management at site, Shifting of equipment / materials to erection site, erection, testing during erection, preliminary acceptance tests, liquidating defects after preliminary acceptance tests and commissioning, final acceptance tests, liquidating defects after final acceptance tests, performance guarantee tests, obtaining all permissions and approvals from statutory bodies (CEA, DGMS etc.), handing over of Power distribution , electrics, and illumination required for Down Hill Conveyor System.

Battery Limits for Power supply

Power supply shall be made available at the following two points:

i. At DHC Tail End: Client's 6.6kV switchgear at 33/6.6kV substation near the Crushing Plant building. The Tenderer shall supply, lay & terminate 2 runs of 6.6 kV cables (Each rated for the full load of the plant, approximately 450 meters per run) directly in prepared cable trench and through Hume pipes at road crossings/ wherever required up to Tenderer’s 6.6kV switchgear inside the electrical building and terminate the cables at both ends. Further distribution of power to all the equipment in scope of this package, at all voltage levels, is also included in the scope.

ii. At DHC Head End: Tenderer scope shall starts from outgoing terminals of 11kV Outdoor Cable In Cable Out (CICO) panel at Donimalai 11kV switchyard. The tenderer scope also included the supply of 11kV CICO panel. From out going of CICO panel power supply shall be fed to 11kV DP structure-1 through cable which is nearer/ adjacent to the CICO panel. However, Incoming 11kV power supply and 110v DC

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MECON

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NMDC LIMITED

LIMITED

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to the CICO panel shall be provided by client form existing substation. From the DP structure-1, 11 KV OH line will start which is 3 kilometer length. Double pole structures with all accessories shall be provided at both ends of the Overhead line. From the DP structure-2 (at TH3) power shall be fed to the tenderer’s 11kV switchgear through cable. The 11kV switchgear shall cater power to all motors, lighting loads, belt feeder, reversible conveyor, various facilities at Transfer House TH-3, and all downstream equipment covered under this package.

The following substations shall be foreseen by the tenderer:

i. At tail end of the DHC, tenderer shall plan a substation to accommodate 6.6kV HT switchgear, Distribution transformer, lighting transformers, VFDs, and other electrical equipment.

ii. At head end of the DHC two numbers of substation buildings (ie. One near TH5 and another near TH3) shall be provided. At substation near TH5,, 11kV HT switchgear, Distribution transformer, lighting transformers, VFD drive for reversible conveyor, etc shall be located. At substation near TH3, VFD panel for belt feeder (725) shall be provided in a separate AC room with other electrical equipment as per requirement.

1.2

The major equipment / services covered in this tender shall include but not limited to the following:

Equipment at Downhill conveyor system tail end:

1.2.1

One number single incomer 6.6 kV Switchboard to cater to the 6.6 kV loads, 690V loads, 415V LT & Lighting loads (230V phase to phase) of the Down hill conveyor system tail end comprising of required feeders and spare feeders of minimum of one number for each type as per enclosed typical drawing.

For protections of each feeders refer tender drawing no.

MEC/01/Q6DH/KIOP/II/214/TS

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LIMITED

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1.2.2 HT capacitor banks with current limiting reactor, RVT, to ensure a power factor of not less than 0.95 at the tenderer’s 6.6kV incomer. SICAP construction (In a closed container) shall be considered.

1.2.3 110 VDC, 200AH (Minimum),, ‘Plante’' type Lead Acid battery bank, dual redundant Float Cum Boost Charger, DCDB for control supply to HT switchboard

1.2.4 Transformers:

6.6/0.433

kV,

required

kVAR,

3

phase,

ONAN,

Distribution Transformer

 

6.6/0.72 kV, required kVAR, 3 phase, ONAN, converter duty transformer for Down hill regenerative conveyor.

6.6/0.230 kV, required kVAR, 3 phase ONAN transformer for lighting

Dry type Booster transformers to cater to welding power receptacles and lighting loads as required.

1.2.5 690V VVVF Drive (with Active Front end) for the downhill

conveyor (723), &

(720)

415V VVVF Drive for the Belt feeder

1.2.6 415 V, TPN, PMCC with bus sectionaliser to feed repair loads one side and all process related loads on other side, with required feeders including capacitor bank feeder.

1.2.7 Rotor resistance boxes / control panel for Slip ring motors as required.

1.2.8 HT, LT (energy efficient-eff2) motors & 690V Inverter duty motors

1.2.9 Electrics for Belt feeders, EOT cranes, Hoists, magnetic separators and other equipment covered under this package.

1.2.10 Local Control stations for drives and equipment for local control with indications, Junction boxes of different sizes (For Power, control, instrument, Lighting).

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MECON

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1.2.11 In-line Magnet separator, Metal detector and control panel etc as required.

Equipment at Head end side of Downhill conveyor:

1.2.12 One Number 11kV Outdoor CICO VCB panel (at Donimalai 11kV switchyard)

1.2.13 One number 11 kV Switchboard (with single incomer) to cater to loads of the Down hill conveyor system head end, comprising of required feeders and spare feeders of minimum of one number for each type as per enclosed typical drawing.

For

MEC/01/Q6DH/KIOP/II/214/TS.

protections

refer

tender

drawing

no.

1.2.14 HT capacitor banks with current limiting reactor, RVT, to ensure a power factor of not less than 0.95 at tenderer’s 11kV incomer. SICAP construction (In a closed container) shall be considered.

1.2.15 110 VDC, 200AH (Minimum), ‘Plante’' type Lead Acid battery bank, dual redundant Float Cum Boost Charger, DCDB for control supply to 11kV HT switchboard .

1.2.16 Transformers:

11/0.433

kV,

required

Distribution Transformer

kVAR,

3

phase,

ONAN,

11/0.72 kV, required kVAR, 3 phase, ONAN, converter duty transformer for downhill regenerative conveyor.

11/0.230 kV, required kVAR, 3 phase ONAN transformer for lighting

Dry type Booster transformers to cater to welding power receptacles and lighting loads as required.

1.2.17 690V reversible regenerative VVVF Drive for the reversible conveyor (727) system & 415V VVVF Drive for the Belt feeder (725)

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1.2.18

11 kV over-head line with Squirrel ASCR conductors from Donimalai 11kV switchyard Double pole structure to Downhill conveyor head end near TH3. (Line length is 3.0 Kilometers). OH line shall include one number DP structure at both ends and minimum 2nos. cut off points shall be provided. DP structure-1 & 2 shall have horizontal GOS switch with earth-switch, Dropout fuses, Lightning arrestors, stay sets, earthing, earth pits, fencing etc as per specification. Secondhand rail poles (9 Meter long, 90lb/yard) shall be used for 11 kV OH lines. Minimum 13Mtrs long rail poles shall be used for DP structures & OH line road crossings. Earth conductor shall be run along with OH line. Earth conductor shall be provided on the top of the phase conductors (ie. “Y” type conductor spacing shall be planned for phase conductors) . Rail poles and bracings for OH line and DP structures shall be de-rusted and painted with two coats of red oxide followed by two coats of epoxy silver paint

1.2.19

415

V, TPN, PMCC with bus sectionaliser to feed repair

loads one side and all process related loads on other side, with required feeders including capacitor bank feeder.

1.2.20

Rotor resistance boxes / control panel for Slip ring motors as required.

1.2.21

LT (energy efficient-eff2) motors and 690V Inverter duty Motors.

1.2.22

Electrics for Belt feeders, EOT cranes, Hoists and other equipment covered under this package.

1.2.23

Local Control stations for drives and equipment for local control with indications, Junction boxes of different

Other Items:

1.2.24 Modifications to the existing tripper conveyor equipment

122 developing and hooking up all hardware /software at

owner’s existing system / power & control cabling from/to owner’s existing system and at the system being provided under this package for smooth operation, effective control

and monitoring of both systems in an integrated manner.

MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD

© 2010, MECON Limited. All rights reserved.

Rev. 0

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MECON

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NMDC LIMITED

LIMITED

KUMARASWAMY IRON ORE PROJECT

 

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1.2.25 MCCB in shop floor for cranes / hoists and power supply arrangement (Shrouded Bus Bar Power supply system) to cranes / hoists. Complete mounted Electrics for cranes, hoists, etc.

1.2.26 Main lighting distribution boards, Lighting distribution boards, Sub-distribution boards, etc. with suitable provision for switching ON/OFF from PLC in control room including necessary control wiring, push button station, indicating lamps etc.

1.2.27 Lighting for 200 meters of every approach road to buildings and to conveyor Gallery coming under this package.

1.2.28 Light fixtures, lamps, switches, sockets, ceiling fan, and sirens etc. Industrial type (for plant buildings) & Decorative type (Control room, VVVF drives rooms, non-plant buildings etc.).

1.2.29 Portable, rechargeable emergency lights with converter/inverter to be considered for control rooms, transfer houses etc.,

1.2.30 Light fixtures as required for equipment lighting, focus/flood lighting for chutes, external lighting around the buildings, approach roads.

1.2.31 Neon type Aviation obstruction lamps with photocell control for buildings more than 30m height, to cover the profile of the building.

1.2.32 Monorail with manual hoist for panel lifting (If required)

1.2.33 The following additional information may be noted and taken care about lighting.

i. Lighting shall be carried out using High Pressure Sodium Vapor (HPSV) lamps, Metal Halide (MH) lamps, fluorescent tube light and compact fluorescent lamps depending on the mounting height / aesthetics

ii. Integral type control gearbox shall be considered for well glass fittings, High bay, Medium bay, Streetlight etc.

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NMDC LIMITED

LIMITED

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iii. Timer and contactor control for streetlights, outdoor lights, and other area lights with suitable provision for switching ON/OFF from PLC in control room / PLC

room

along with provision to switch ON/OFF locally.

iv. spare feeders / starters with at least one of

20%

each

type and rating shall also be provided in PMCC /

MCC

/ PDB / MLDB / LDB / SLDB / DCDB / other

distribution boards

v. Galvanized Flood light poles / street light poles

including foundations and earthwork for buried pipes,

cable trenches, earth pits etc.

vi. Surface wiring in GI conduits in Transfer Houses, Conveyor galleries, etc., and concealed PVC conduit wiring for office buildings, Electrical switchgear, control room etc. (civil buildings).

1.2.34 63A TPNE, 32A TPN & 20A 1 phase power socket outlets as

required.

1.2.35 All required sizes of cable trays with cable tray supports, HT termination kits, cable accessories, cable duct, structural supports, road crossing pipes1000mm below road, lugs, glands, clamps, tags, route marker etc. Cable trays shall be laid horizontally only. Conveyor structural supports should not be used as cable tray supports.

1.2.36 All interface hardware, software, power monitors / multifunction meters, control, communication & signaling cables etc., required for connecting I/Os from relevant incoming, power feeders, motor feeders of HT, MT & LT, LT switchgear/ MCCs, PDBs, LDBs field devices (whether explicitly specified in detail or not) required for:

i. Control and operation of plant including illumination in a safe manner in automated and other modes.

ii. Monitoring the status and parameters (ON, OFF, trip, voltage, current, frequency, MD, power, power factor etc), from the PLC in the central control room.

1.2.37 Addressable type Pull cord switches, Addressable type Belt sway switches, zero speed switches with contacts for

MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD

© 2010, MECON Limited. All rights reserved.

Rev. 0

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connections to PLC and for interlocking with drive with status display of each switch for conveyors at local and remote in PLC monitors. Pull cord switches shall be hardwired to switchgear also.

1.2.38 Limit switches, proximity switches, level switches / transmitters, pressure switches / transmitters, DP switches, speed sensors, encoders, Hooter’s / Bells etc. as required for the various equipment operation and safety.

1.2.39 All Cables (HT, LT, power, control, Optical fiber cable, illumination, and other special cables, wires for illumination) supply laying and termination including accessories and consumables accessories (Viz HT Cable termination kits, Terminal / Junction boxes, double compression brass cable glands, crimping type lugs etc. as required for laying and termination of cable.

1.2.40 Complete Earthing & Lightning protection system for the plant, buildings, equipment and electrical works carried out under the scope of this tender including.

1.2.41 Air-lock room with airtight door arrangement shall be provided for control room & Air-condition rooms. Minimum 2 entry / exits should be provided for all Electrical / Switchgear rooms & control rooms.

1.2.42 Ventilation systems for HT & LT switchgear rooms, Battery room, MCC room, Electrical rooms & cable cellars etc. with Pressurized ventilation system with Multiple TA Fans without duct. Exhaust fans ventilation for Battery room shall be provided.

1.2.43 Air conditioning system for Control rooms and rooms where PLC, VVVF drive rooms & Shift in-charge room are installed. Wall mounted / pedestal fan shall also be provided for PLC control rooms / office rooms.

1.2.44 Detailed specification for A/C and ventilation system are covered in chapter Q2 of this tender document

1.2.45 Battery room shall be provided with acid resistant flooring, wall tiles and acid proof lighting fixtures/exhaust fans. Wash facility shall also be provided in battery room

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1.2.46 GI cable trays (ladder and perforated type) with coupler plates and electro-galvanised hardware etc. with painted supporting brackets and cable structures nylon cable ties, saddles, aluminium clamps, punched aluminium cable tags, route markers, cable tray separators, ferrules insulating tapes, sealing compound, etc., Mainly overhead cable laying shall be considered.

1.2.47 GI pipes of different sizes as per site requirement for cable protection, for cable laying in ground / floor / through concrete etc. and cable entering / leaving buildings / rooms/ walls / floors, cable duct / structural supports / pipes 1000mm below road for road crossing.

1.2.48 Fabricated steel structures, checkered plates, MS plates and Anchor fasteners for supporting/ mounting of electrical equipment viz. Cable trays, Panels / boards, light fixtures, local control stations etc. All structures shall be de-rusted and two coats of epoxy-based paint over one coat of primer shall be applied.

1.2.49 Chequered plates of 6mm thick with stiffeners and collapsible handles shall be provided for closing floor cutouts after fixing the panels. Checkered plates shall be provided with one coat of primer and one coat of epoxy based paint of black colour.

1.2.50 All accessories like branch/pull/junction boxes, cross arms brackets for supporting light fixtures, distribution board etc., saddle / clamps, single core cable and other miscellaneous items required for the completeness and efficient working of the system whether explicitly specified or not in this specification.

1.2.51 RCC cable trenches / ducts with removable RCC cover wherever approved by the owner/consultant. Excavations of earth trenches and back filling (with bricks / concrete slabs over sand above and below cables, soil over bricks / concrete slabs etc.) only in special locations, as approved during detail engineering.

1.2.52 Fire barriers / fire partition & pressure seals wherever cables enter /exit pressurized areas.

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1.2.53 Safety items for electrical systems such as fire extinguishers, safety charts, first aid box, hand gloves, fire buckets with stand, danger boards, rubber mats, Key boxes, Digital clock etc.

1.2.54 Switchgear rooms & Control room furniture.

1.2.55 Tools and Tackles.

1.2.56 First fill of grease, lubricant, insulating oil, electrolyte etc. and other consumables necessary for commissioning and operation of the equipment.

1.2.57 Any other requirement, whether specifically mentioned herein or not but required for completion of works and satisfactory performance of the plant is included in the scope

1.2.58 The scope mentioned for instrumentation and automation and Plant communication system under different Chapters shall also be complementary to the scope mentioned herein

1.2.59 Commissioning spares.

1.2.60 2 years operational spares as specified.

1.2.61 Successful Tenderer shall have to arrange his own arrangement for construction power supply.

SERVICES

1.2.62 Soil resistivity test shall be conducted by the successful tenderer.

1.2.63 Co-ordination with all agencies for inspection of work / installation, pre-commissioning (no load / load) tests, integrated (no load /load) testing & commissioning, handing over, conducting PAT / FAT and liquidating defects etc. till handing over of the installations and performance guarantee.

1.2.64 Documentation (preparation and submission in requisite copies of all drawings, test certificates, O & M manuals and any other drawings/documents required for the erection of the plant and installation).

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1.2.65

Liaison with statutory bodies on behalf of the Owner and obtaining all necessary clearances / approvals including modifications to be carried out, if any, as per their specific requirement without commercial/contractual implications to the owner.

1.2.66

Submission of all necessary documents and drawings, paying the required inspection fees (fees to be reimbursed by owner on production of receipts) and liaisoning with the statutory bodies for inspection of installation as and when required and make all arrangements for the same. Obtaining of approvals for drawings, prior permission to energize, all HT and other electrical installations from DGMS.

1.3

STANDARDS, CODES AND REGULATIONS

1.3.1

Design supply and installation of electrical system & equipment under this package shall conform to the requirements of latest revisions of IEC, Indian Standards, DGMS standards IE Rules, local rules and regulations. IE rules.

1.3.2

IE Rule No.45, clause 1. No electrical installation work including additions, alterations, repairs and adjustments to existing installations, except such replacement of lamps, fans, fuses, switches, low voltage domestic appliances and fittings as in no way alters its capacity or character, shall be carried out upon the premises of or on behalf of any consumer/owner/ or occupier for the purpose of supply to such consumer, owner, except by an electrical contractor licensed in this behalf by the state government and under the direct supervision of a person holding a certificate of competency and by a person holding a permit | issued or recognized by the state government.

1.3.3

IE Rule No.45, clause 2.No electrical installation work which has been carried out in contravention of clause (1.3.2) shall either be energized or connected to the works of any supplier.

1.3.4

IE Rule No.63, clause 1.Before making an application to the inspector for permission to commence or re-commence supply after an installation has been disconnected for one

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year and above at high or extra high voltage to any person, the supplier shall ensure that the high or extra high voltage electric supply lines or apparatus belonging to him are placed in position properly joined and duly completed and examined. The supply of energy shall not be commenced by the suppliers unless and until the inspector is satisfied that the provisions of rules 65 and 69 (both inclusive) have been complied with and approval in writing of the inspector has been obtained by him.

1.3.5

All linemen, wiremen, electricians, supervisors and engineers engaged by the contractor or his sub-contractor shall posses valid license & the same shall be submitted for verification if called for.

1.3.6

In view of the above, along with bid, the Tenderer shall furnish, the list of sub-contractors having valid electrical contractor’s license of appropriate category in Karnataka whom he proposes to engage for electrical erection / testing & commissioning and for obtaining statutory approval.

1.4

VOLTAGE LEVELS

 

1

VVVF Drives controlled motors

:

415 /690 Volts, 3 Ph (as per requirement)

2

Motors (DOL start up to and including 160 kW)

:

415V

+/-

10%,

50Hz +/-

5%, 3Ph, 4 wire AC

3

Control voltage

:

110V AC obtained through control transformers & protection device.

4

Control voltage (for HT switchboard)

:

110V DC obtained by providing suitable batteries and battery charger

5

Lighting fixtures

:

230V AC (phase to phase)

6

Small Power sockets

:

230V AC

 

7

Welding

switch

:

TPNE, 415V AC, 50 Hz

socket outlets

1.4.1

DC control, if required during detailed engineering, due to longer control cable lengths provided in place of AC controls. In this case provision of suitable control gear and rectifier units with protections / annunciations etc. in Switchgear / PMCC / MCC panel is also included in the

MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD

© 2010, MECON Limited. All rights reserved.

Rev. 0

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MECON

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NMDC LIMITED

LIMITED

KUMARASWAMY IRON ORE PROJECT

 

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scope. This aspect shall be kept in view while submitting the offer.

1.5 SUPPLY VOLTAGE VARIATIONS AND FAULT LEVEL

a) POWER SUPPLY VARIATIONS

Voltage level

Voltage Variation

Frequency

Variation

230

V

± 10

%

± 5%

415

V

± 10

%

± 5%

6.6

kV

± 10

%

± 5%

11kV

± 10

%

± 5%

Combined voltage and frequency variation

± 10 %

b) FAULT LEVELS

Voltage level

In KA

230

V

25

415

V

40

6.6

kV

25

11 kV

25

System earthing

Resistance earthing on 6.6kV side Solid earthing on 11kV & 415V

1.6 CLIMATE CONDITIONS

The climate of area is mild and pleasant during summer months and moderately cold during winter.

Max. Ambient

:

45 0 C

Temperature

Min. Ambient

:

15 0 C to 8 0 C

 

temperature

 

Rain fall

:

600mm

to

800mm

per

annum

during monsoon

 

Relative humidity

:

100%

not

Simultaneously

occurring with maximum

temperature

 

Height above Mean sea level

:

More than 1000M above MSL

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1.7

NOISE POLLUTION CONTROL

 

1.7.1

Noise control measures shall be adopted to restrict noise levels in and around the plant. Maximum noise level tolerable in rooms & offices, work areas and within the plant boundary, have been specified herein. The equipment and the services shall be designed such that these levels are not exceeded.

1.7.2

The maximum noise level guaranteed for each equipment and system with detailed description of noise control measures adopted.

1.7.3

The maximum noise levels for rooms and offices must permit a good understanding of speech. Limiting exposure values of sound pressure levels for different areas are given below:

Office/conference rooms

 

: 65

dB (A)

 

Control rooms, Computer rooms

 

: 55

dB (A)

Factory and shop area

   

- General

 

: 85

dB (A)

Where telephone conversation is Required

 

: 65

dB (A)

-

Plant boundary

 

: 65

dB (A)

1.7.4

The plant and machinery shall be designed such that the continuous exposure noise level of 85 dB (A) is not exceeded. Adequate numbers of suitable earplugs shall be supplied for operating people to approach the areas with higher noise levels.

1.8

MAKE AND INTERCHANGEABILITY

 

1.8.1

The makes of equipment shall be limited to preferred makes indicated in technical specification and such of those equipment for which preferred makes are not indicated, makes of such equipment shall be subject to prior approval by Owner / Consultant.

1.8.2

Similar equipment and components shall be of same make.

Equipment of same interchangeable.

type

and

rating

shall

be

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1.8.3

All materials used and all equipment supplied shall be new and the best of their respective kinds and shall be of the class most suitable for the purpose for which they are intended.

1.8.4

The quality of material and installations shall be to the highest standard of Indian and international practices. The decision of owner/consultant with in this regard is final and binding. When quality of work is not satisfactory in the opinion of consultant/owner, and when so directed the work shall be redone including supply of required equipment and material at no extra cost to the owner and without affecting the agreed milestones.

1.9

MODE OF CONTROL FOR ILLUMINATION

1.9.1

Conveyor gallery illumination (especially of long conveyors) is designed to provide graded levels of illumination so that either one in every three luminaries OR two in every three luminaries can be switched “ON” based on requirement. If required all the lights in the conveyor gallery can be made “ON”. For achieving this 2 Nos. four core power cables shall be laid from junction houses where corresponding LDB’s are located and terminated / looped in junction boxes. For conveyor gallery lighting / Outdoor area and street lighting the LDB's, DB’s and Feeder pillars shall have contactors for each of the incoming /outgoing circuits. Number of contactors shall be decided as per requirement of owner / consultant and shall also include internal wiring. However any other specific requirements will be finalized during detailed engineering / approval of drawings and the same shall be provided without any cost implications. The control from PLC shall also be done apart from local (panel / DB).

1.9.2

Contactors on the incoming side of each LDB's / Feeder pillars shall be provided for switching ON / OFF the whole board and also for few feeders on outgoing side of the LDB's / SDI’s, as desired by owner/consultant, to control the lighting of limited areas. Contactor coil shall be rated for 230V, tapped from the main busbars of LDB for switching ON from remote. ON /OFF controls from PLC shall also be done apart from local DB. Exact requirement shall be indicated at the time of approval of the drawings. ON

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/OFF switches or pushbutton stations shall be located in the plant control rooms (if required).

1.9.3

Outdoor lighting (i.e. Street lighting, area lighting, peripheral lighting etc.) shall have provision for control of fitting in auto and manual modes. In auto mode the lights shall be switched ON by sensing natural light by adjustable photo cells with relay unit (Timers with relay are not acceptable) and the manual mode of operation shall be from near the board or from PLC monitor.

1.10

INSCRIPTION

1.10.1

All equipment shall be provided with indelible / permanent type inscription plates identifying the equipment as per approved drawing. All components, terminal blocks, relays, indicating lamps, control switches shall be provided with permanent inscription plates with inscriptions as per approved drawings.

1.10.2

Identification plates of the equipment shall have letters of 15-mm size. 5 mm characters shall be used for panel- mounted components.

1.11

PAINTING

1.11.1

Metal parts of all equipment shall be protected against corrosion. The sheet steel parts shall be cleaned by sand blasting (wherever required) and shall undergo rust removal by seven-tank process consisting of alkaline, degreasing, de-scaling, pickling and phosphating.

1.11.2

Two final coats of epoxy spray painting shall be applied over two coats of primer. The colour of finished painting shall be as per the approval of owner/ consultant

1.12

TYPES OF STARTER/ CONTROLS FOR DRIVES

1.12.1

The braking system and controls of the downhill conveyor shall be latest state of art technology so that the braking system takes care of all safety requirements and ensures no undue tension, lifting & slackening in the belt under varying conditions (normal / emergency) of loading pattern on the belt. This shall also ensure material stability on the belt (i.e. if the braking or starting is too rapid the material

MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD

© 2010, MECON Limited. All rights reserved.

Rev. 0

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doesn’t avalanche “Down the hill”). The requirements specified in detail in mechanical equipment specification shall be considered.

1.12.2

Mechanical brakes shall also be provided for conveyors /crane / hoists, as required.

1.12.3

DOL / RDOL starters shall be adopted for all other motors in the project as per the requirement. The motors envisaged are mainly squirrel cage motors. Energy efficient motors shall be used preferably for continuous running applications.

1.12.4

Dust suppression system pump and the solenoids shall also be fed from the MCC. The solenoids shall be suitable for 240V DC. Pump shall be continuously working when the plant is in operation but when plant is not operating for some time the pump shall continue to run and re-circulate in tank automatically. If plant is stopped for long time then the system can be switched off. Atomized water spray shall work till the material presence is sensed by switch to be provided below the conveyor for that purpose or equipment is in operation.

2.0

EQUIPMENT SPECIFICATION

 

2.1

11kV & 6.6kV HT switchgear & 11kV CICO Outdoor Panel

2.1.1

DESIGN CRITERIA

I) Cubicle

 
   

11 & 6.6kV HT switchgears (Indoor)

11kV

CICO

(Outdoor)

1. Type

:

Fully compartmentalized metal clad horizontal draw out sheet steel enclosed conforming to IP4X (for indoor panel) & IP 55 with canopy (for Outdoor panel). Fully type tested as per IEC 62271.Inter compartmental partitions as per IP 2X or as per manufacturer’s standard practice

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2.

Thickness of sheet steel

 

(Minimum thickness)

 

a) Sides/bottom/partition between panels

:

2.5 mm hot rolled sheet steel or as per manufacturer’s standard practice

b)

Front & rear hinged door &

:

2

mm cold rolled sheet

steel as

covers

 

per

manufacturer’s standard

 

practice

 

3.

Rated voltage

:

6.6kV & 11kV,

11kV, 3 phase, 3

 

3

phase, 50 Hz,

wire, 50Hz

3

Wire

4.

Continuous rated current at 45 0 C

:

As per Requirement

 

5.

Short circuit withstand capability of switchboard including busbars

   

a) Short time rating

:

25 KA (RMS), 1 sec

 
 

b) Dynamic rating

:

63 KA peak

 

6.

Insulation level

   
 

a) Impulse withstand value

:

60

KVP

for

75

kVP

 

6.6kV & 75 kVP for 11kV

 
 

b) 1 min. PF withstand value

:

20 KV

(RMS)

28

kV (RMS)

 

for

6.6kV &

28

 

kVP for 11kV

7.

Busbars

     
 

a) Material of busbars

:

Aluminium Alloy

 
 

b) Temperature rise of busbars at rated current over

:

As per IEC

 
 

45

0 Cambient

 
 

c) Inter panel busbar chamber partition

:

Not applicable

 
 

d) Busbar joints

:

Zinc passivated bolts

 
 

e) Insulation

:

Encapsulation of Main & feeder Busbars joints to full insulation

 

f) Phase identification

:

Colour tapes

 
 

g)

Support insulators

:

Non-hygroscopic, non-tracking, resin cast insulator.

8.

Auxiliary connections

:

Silver-plated, 16A plug and socket with necessary interlocks.

9.

Safety shutters

:

Automatically operated shutters with facility to lock the busbar and cable side shutters independently.

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10. Locking facility

:

Special door locking with key Integral locking facility for carriage position lock

11. Accessories with each cubicle

   

a)

Panel illumination lamp with switch

:

CFL To be provided in metering compartment

b)

Space heater

:

240V,

AC,

50

Hz

heater

with

 

thermostat & control switch

c)

3 pin power socket with switch

:

To be provided

 

d)

Base channel

:

Base channels as required shall be supplied as part of cubicle

e)

Termination accessories

:

HT cable sealing kit, compression type brass cable glands and tinned copper lugs for HT power, LT power and control cables to be terminated in the panels.

f)

Name plates, inscription plates for components, switches, feeder identification.

:

As Specified

 

g)

Flexible copper connections between hinged doors and cubicle for earthing

:

To be provided

 

h)

Breaker accessories visible and accessible from outside, with the cubicle door closed.

:

Breaker position TEST/ SERVICE Breaker ON/OFF, spring charged Mechanical trip push button accessible from outside with panel door closed Mechanical close push button accessible only after opening the door

i)

Removable welded wire mesh behind the panel

:

To

be

provided

as

per

manufacturer’s standard practice

j)

Danger notice boards and instruction plates

:

To be provided on front and rear

k)

Breaker operation counter

:

To be provided

 
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l)

Components to be mounted on the front door of cubicle

:

Push buttons, control & selector switches (operating height shall not exceed 1800 mm), lamps, meters, relays

m) Outgoing Entry for power and control cable

:

Bottom

 

n) Terminals

:

LT power, control, CT, D.C, A.C terminals shall be segregated and identified. CT terminal shall be CATD-m4 type

o) Earthing trucks

:

Earthing trucks for bus earthing and cable earthing for each panel type with safety interlocks and audiovisual indication.

p) Enclosure

:

IP4X

q) Indicating lamps

:

Front “ON/OFF/TRIP/Trip circuit Healthy, breaker test position, breaker service condition & Spring charged “.All lamps to be LED type.

r) Annunciator

:

Annunciation windows shall be considered for all feeders

s)

Master trip relay

:

VAJHM23

 

12. Operational clearances

   

a) In front for withdrawal of truck

:

To be indicated by Tenderer

b) At the back of the panel

:

To be indicated by Tenderer

13. Minimum safety clearances in air

:

 

a) Between phases in mm

:

as per IEC

as per IEC

b) Between phase & earth in

:

as per IEC

as per IEC

 

mm

14. Control Schemes

:

As per approved drawings

II) Breaker for I/C, Transformers & capacitor feeders/Vacuum contactor with fuse for 6.6kV motor feeders (if required)

1. System

:

6.6

kV & 11kV

50 Hz, 3 phase 3

wire

2. Highest system voltage

:

7.2

KV for 6.6kV & 12kV for 11kV

3. Design ambient

:

45

0 C

MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD

© 2010, MECON Limited. All rights reserved.

Rev. 0

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MECON

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4.

Ratings

   

a) Rated current in IP4X enclosure at 45 0 C ambient

:

As per Requirement

b) Symmetrical breaking capacity

:

25

KA (RMS) for VCBs

c) Making capacity & dynamic stability rating

:

63

KA peak for VCBs

d) Short time current rating

:

25

KA (RMS), 1 sec for VCBs

5. Insulation level

   

a)

One min. P.F withstand value KV RMS

:

20

KV

(RMS)

28kV (RMS)

for 6.6kV & 28 kVP for 11kV

b)

1.2/50 microsecond impulse withstand value KV (peak)

:

60

KVP

for

75 kVP

6.6kV & 75 kVP

 

for

11kV

6. Operating duty

:

Auto re-closure duty not required

7. Total break time

:

Less than 5 cycles

 

8. Critical current

:

Shall be re-strike free

9. Arc extinction medium

:

Vacuum

 

10. First pole to clear factor

:

1.3

11. Operating mechanism

   

a) Type of closing

:

Spring charged stored energy- manual independent closing

b) Method of closing

:

Manual and motor drive

c) Spring charging motor 1) Rated voltage 2) Operating voltage range

:

110

V DC

 

:

80-110% of rated voltage

d) Closing Coil 1) Rated voltage 2) Operating voltage range

:

110

V DC

 

:

80-110% of rated voltage

e) Shunt trip coil

 

Both AC and DC to be provided

DC

trip coil

AC trip coil

 

1) Rated voltage 2) Operating voltage range

:

110

V DC

 

240 V AC

:

70-110% of rated voltage

12. No. of poles/ phase

:

One

 

13. No. of breaks / pole

:

One

 

14. Auxiliary contacts

:

8 No

+ 8 NC

 

(Silver plated contacts)

15. Rating of auxiliary contacts

:

10A at 240 V AC

 

4A

at 110 / 220 V DC

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16. Wiring of auxiliary contacts

:

All auxiliary contacts shall be wired contacts to terminal block, external to draw out truck

17. Test, service position of breaker

:

Without opening the door

 

18. Material of fixed & moving contacts

:

Silver plated copper moving contacts, contacts with self- aligning feature having sufficient contact pressure.

19. Breaker fully type tested as per.

:

IEC- 62271

 

20. Surge diverters in case of VCBs / Vacuum Contactors

:

To be provided for Motor feeders, capacitor feeders & dry type transformer feeders to suit the insulation level of connected equipment.

III) Current transformer

 

1.

Type

:

Resin cast, bar primary

 

2.

Ratio, burden, accuracy class cores

:

As

per requirement (sizing

calculations shall be submitted for approval)

3.

a)

Short time rating

:

Same as for switchboard

 
 

b) Dynamic stability current

:

Same as for switchboard

 

4.

Insulation level

   
 

a) Impulse withstand voltage

:

Same as for switchboard

 
 

b) PF withstand voltage

:

Same as for switchboard

 

5.

Applicable standard

:

IS 2705, 1992

 

IV) Potential transformers

 

1. Type

 

:

Resin cast, natural air cooled, enclosed in cubicle

2. Ratio

 

:

6.6KV/11kV/0.110 KV / 0.110KV

 

3

3

3

3. Connection

:

1 phase, star/ star/ star

 

4. Rated burden

:

50VA

each

Class

1.0

core

for

metering

and

class

3P

for

protection

 
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5. Voltage factor

:

1.1 Continuous

1.2

Continuous

 

&

&

1.9 for 8 hours

1.5

for

30

for

non-

seconds

for

effectively

effectively earthed system

earthed system

6. Neutrals

:

Neutrals to be brought out for earthing on HV & LV side

7. Insulation level

   
 

a) Impulse withstand voltage & peak

:

Same as switchboard

 
 

b) PF withstand voltage KV (RMS)

:

Same as switchboard

 

8.

Protection

   
 

a) HV side

:

HRC fuse for each phase

 
 

b) LV side

:

MCB with auxiliary contact

 

9.

Mounting of BUS PT

:

N.A.

 

N.A.

 

Line PT

 

part of incomer

Separate

side

 

draw

out

cubicle

10. Applicable standard

:

IS: 3156 1992

 

V) Metering System

   

A) Indicating Meters

   

1. Type of meters

:

Ammeters, voltmeters, PF meter, frequency meter, watt meter with

MDI

2. Type of movement

:

Taut band

 

3. Size

:

144

sq for I/C,

144 sq. mm

 

96

sq

for O/G

 

feeders

4. Dial finish

:

White painted dial with pointer type needle

5. Mounting

:

Flush mounting

 

6. Accuracy class

:

1.0

7. Voltage / current

:

110

V PT, 1A CT sec. current

 

8. Range

:

As specified

 

9.

Applicable standard

:

IS: 1248-2003

 
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B) Integrating meters

   

1. Type

:

Microprocessor based metering

system

to

read

phase

&

line

voltages, line currents, 3 phase

MW, MVAR, MVA, MWH, MVARH,

MVAH, Max. demand in MW, MVA

&

MVAR

with adjustable

integrating period

 

2. Features

:

Metering system shall also have Max. demand controller, a serial port (RS 485) for connecting the metering to PLC system. The system shall be supplied with interconnecting cable, terminal accessories, software for data logging & management.

3. Accuracy class

:

0.5

4. Coil rating

   

a) Current

:

1A CT sec

 

b) Voltage

:

110 V AC, PT sec.

 

5. Mounting

:

Flush mounting

 

VI) Auxiliary equipment

   

1. Protection relays

:

Numerical protection relays with adequate binary I/Os.

2. Control switches

:

16A, 440 V AC 10A, 110 V DC Quick make, quick break, flush mounted, stay-put/ spring return, IS: 13947

3. Push buttons

:

2A, 110 V DC 10A, 440 V AC 1 No +1 NC Flush mounted, IS: 13947

 

4. Indicating lamps

:

LED type suitable for flush mounting. Assembly for bulb is from the front.

 

5. Control circuit protection

:

By MCBs

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2.1.2

TECHNICAL SPECIFICATION for both 11kV, 6.6kV boards & Outdoor CICO panel

2.1.2.1

GENERAL

The switchgear shall comply with list of applicable codes and standards and enclosed specification and drawings. The switchgear shall be factory assembled and fully type tested as per IEC .

2.1.2.2

TYPE OF GEAR

2.1.2.2.1

The switchgear shall be metal clad, dead front, air insulated, natural air cooled, fully compartmentalized, fully draw-out, self standing indoor cubicle conforming to IP4X for 6.6kV & 11kV panels and IP 55 with canopy for 11kV CICO panel. Each cubicle shall be constructed on unit principle. Each switchboard shall comprise of number of cubicles forming a single continuous board.

2.1.2.2.2

It shall be possible to perform all switching operations with door closed. Interlocks required for safe switching, operation and maintenance shall be provided. Wherever possible, mechanical interlocks shall be provided in addition to electrical interlocks.

2.1.2.3

CUBICLE

2.1.2.3.1

Each cubicle shall be fully compartmentalized with metallic partitions having separate chambers for main busbars, CTs and cable terminations, switching device, LV chamber for metering, protection and control equipment. The metallic partitions shall be earthed and compartments thus formed shall be dust and vermin proof. This state of the compartments shall be maintained while switching device is in service position.

2.1.2.3.2

Pressure relief flaps, which cannot be opened from outside shall be provided to vent upwards in case of arcing faults inside the cubicle. To ensure personnel safety, the following conditions shall be met for internal arcing faults:

i. Correctly secured doors, covers etc., must not open.

ii. Parts, which may cause hazard to personnel, must not fly-off.

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