CEA - Construction of Electric Plants - Reg

Central Electricity Authority (Construction of Electrical Plants & Electric Lines) Regulations, 2007 DRAFT
CENTRAL ELECTRICITY AUTHORITY NOTIFICATION

New Delhi, the , 2007
No. -- In exercise of the powers conferred by clause (b) of Section 73 read with sub-section (2) of Section 177 of the Electricity Act 2003, the Central Electricity Authority hereby makes the following regulations namely: 1. (1) (2) Short title and commencement These regulations may be called the Central Electricity Authority (Construction of Electrical Plants & Electric Lines) Regulations, 2007. These regulations shall come into force on the date of their publication in the Gazette of India. Definitions In these regulations, unless the context otherwise requires,-Accuracy Class means a classification assigned to current or voltage transformer the errors of which remain within specified limits under prescribed conditions of use. Act means the Electricity Act, 2003. Authority means the Central Electricity Authority established under subsection (2) of Section 70 of the Act. Automatic Voltage Regulator (AVR) means a continuously acting automatic excitation control system to regulate a generating unit terminal voltage. Base Load Operation means operation at Maximum Continuous Rating (MCR) or its high fraction. Basic Insulation Level (BIL) means the crest value of a standard lightning impulse wave (1.2/50 s) which the insulation provided to an item of electrical equipment/apparatus can withstand. Black Start means the start up of first unit or a gas turbine following Grid failure. Boiler Maximum Continuous Rating (BMCR) means the maximum steam output (tonnes/hour) the steam- generator (boiler) can deliver continuously at rated parameters.
2. (1) (a)
(b) (c) (d) (b) (c)
(d) (e)
(f) Break time means interval of time between the beginning of the opening time of a switching device and the end of the arcing time. (g) Burden in relation to current transformer means the impedance of the secondary circuit expressed in ohms and power-factor and in relation to voltage transformer means the admittance of the secondary circuit expressed in mhos and power-factor (lagging and leading). The burden is usually expressed as the apparent power in voltamperes absorbed at a specified power-factor and at the rated secondary current. (h) Cold start in relation to steam turbine means start up after a shut down period exceeding 72 hours (turbine metal temperatures below approximately 40% of their full load values). Combined Cycle Gas Turbine (CCGT) module means gas turbine generator(s), associated heat recovery steam generator (s) and steam turbine generator. Combined cycle mode in relation to gas turbine based thermal generating station means operation of gas turbine alongwith associated exhaust heat recovery steam generator and steam turbine. Control Load in relation to coal/lignite based thermal generating units means the lowest load at which the rated steam temperature can be maintained under auto control system. Current Transformer means an instrument transformer in which the secondary current, in normal conditions of use, is substantially proportional to the primary current and differs in phase from it by an angle which is approximately zero for an appropriate direction of the connections.
(i)
(j)
(k)
(l)
(m) Design Head means the net head at which peak efficiency of hydraulic turbine is attained while operating at rated head. (n) (o) (p) Extra high Voltage (EHV) means a voltage above 33,000 volts. FRLS Cable means Flame Retardant Low Smoke cable which emit low smoke and is resistant to fire for certain duration of time. Gas Turbine means a machine which converts thermal energy into mechanical work and includes compressor, combustion system and expansion turbine. Generator means an equipment which converts the mechanical power of the prime mover into electrical power.
(q)
(r) (s)
Governor means a device which regulates the speed and output of turbinegenerator units. Gross turbine cycle heat rate in relation to coal/lignite based thermal generating station means the external heat energy input to the turbine cycle required to generate one kWh of electrical energy at generator terminals. Gross heat rate in relation to gas turbine based and diesel engine based thermal generating stations means the external heat energy input required to generate one kWh of electrical energy at generator terminals. High heat value (HHV) means the heat produced by complete combustion of one kilogram of solid fuel/liquid fuel or one standard cubic meter (Sm3) of gaseous fuel as per IS:1350 (Part-II) or IS:1448 (P:6) as the case may be. Highest system voltage means the highest r.m.s line to line value of voltage which can be sustained under normal operating conditions at any time and at any point in the system. It excludes temporary voltage variation due to fault conditions an the sudden disconnection of the large load.
(t)
(u)
(v)
(w) Hot Start in relation to steam turbine means start up after a shut down period of less than 10 hours (turbine metal temperatures approximately 80% of their full load values). (x) (y) (z) House Load means the unit is operating in isolation to the grid and generating electric power to cater to its own auxiliaries. Hydraulic Turbine means a machine which converts the potential energy of water into mechanical power to rotate the generator. Hydro-electric Generating Station means the generating station as defined in the Act for generating electricity by water-power.
(aa) Impedance Earthed Neutral System means a system whose neutral point(s) is(are) earthed through impedances to limit earth fault currents. (bb) Impulse means a unidirectional wave of voltage or current which, without appreciable oscillations, rises rapidly to a maximum value and falls, usually less rapidly, to zero with small, if any, loops of opposite polarity. The parameters which define a voltage or current impulse are polarity, peak value, front time, and time to half value on the tail. (cc) Impulse withstand voltage means peak value of the standard impulse voltage wave which the insulation of the circuit-breaker withstands under specified test conditions.
(dd) Insulation co-ordination means the selection of the dielectric strength of equipment in relation to the voltages which can appear on the system for which the equipment is intended and taking into account the service environment and the characteristics of the available protective devices. (ee) Isolated Neutral System means a system where the neutral point is not intentionally connected to earth, except for high impedance connections for protection or measurement purposes. (ff) Lightning Arrestor (Surge Diverter) means a device designed to protect electrical apparatus from high transient voltage and to limit the duration and frequently the amplitude of follow-current. The term "lightning arrester" includes any external series gap which is essential for the proper functioning of the device as installed for service, regardless of whether or not it is supplied as an integral part of the device.
(gg) Load cycling means operation alternating at high and low level of load on a regular basis. (hh) Maximum Continuous Rating or MCR - in relation to coal/lignite based thermal generating units means the output at the generator terminals (net of any external excitation power) as guaranteed by the manufacturer at the rated parameters. - in relation to gas turbine based thermal generating stations means the output of the Gas Turbine Generator measured at the generator terminals (net of generator excitation power) in case of simple cycle and sum of output of the Gas Turbine Generator(s) and Steam Turbine Generator measured at the generator terminals (net of generator excitation power) in case of combined cycle, as guaranteed by the manufacturer for design fuel and corresponding to site conditions. - in relation to diesel engine based thermal generating units means the output at the generator terminals (net of generator excitation power) as guaranteed by the manufacturer for design fuel and corresponding to site conditions. (ii) (jj) Maximum heat input per burner means the heat generated from fuel firing in one hour divided by the total number of coal burners. Mesh Voltage means the maximum touch voltage within a mesh of a ground grid.
(kk) Minimum tail water level means the water level in the tail race at the exit end of the draft tube corresponding to a discharge required to run one machine at no load. (ll) Motor Control Centre (MCC) means the switchgear which contains modules for motor supply and its control.
(mm) Net Head means the pressure head differential between the entrance to the hydraulic turbine casing and the tail race water surface elevation. (nn) Net heat input (NHI) available in furnace per unit plan area means the net heat input (i.e. heat generated by fuel/s fired in one hour plus the sensible heat of combustion air above 270C minus the radiation loss, unburnt combustibles, moisture in the air, latent heat of moisture in fuel and that formed by combustion of H2 in the fuel) divided by the plan area of the furnace. (oo) On Load Tap Changer (OLTC) means a device provided on high voltage side of transformer, which is used for variation of voltage during charged condition of the transformer. (pp) Off Circuit Tap Changer (OCTC) means a device provided on high voltage side of transformer, which is used for variation of voltage during OFF condition of the transformer. (qq) Overhead Line means any electric supply line which is placed above ground and in the open air, consisting of conductors which are insulated or bare. (rr) Owner means the company or body corporate or association or body of individuals, whether incorporated or not or artificial juridical person which owns or operates or maintains Electric Plants/ Lines.
(ss) Performance coal means the coal quality for which steam-generator performance is guaranteed by the manufacturer. (tt) Power Control Centre (PCC) means the switchgear which contains modules for power supply to other switchboards/ switchgears/ distribution boards and its control.
(uu) Power House means the structure which houses hydraulic turbines, generators, including main inlet valves and/or gates, associated electromechanical and control equipment. (vv) Power System Stabiliser (PSS) means a device for achieving the dynamic stability of the generating unit under most severe conditions of operation in
case of disturbance created by short circuit condition, load rejection, switching ON/ OFF of transmission lines. (ww) Pump Turbine means a hydraulic turbine having a runner capable of running in one direction in generating mode and reverse direction in pumping mode. (xx) Pumped storage plant means a system of generating electricity in which the electricity is generated during the peak hours by using water that has been pumped into upper reservoir during off-peak hours from the lower reservoir. Resonant Earthed Neutral System means a system in which one or more neutral points are connected to earth through reactances which approximately compensate the capacitive component of a single phase to earth fault current. Runaway speed means the speed attained by a hydraulic turbine at full gate opening when the generator is disconnected from the system and the governor is in-operative.
(yy)
(zz)
(aaa) Simple cycle mode in relation to gas turbine based thermal generating station means operation of gas turbine with exhaust gases vented to atmosphere. (bbb) Solidly Earthed Neutral System means a system whose neutral point(s) is (are) earthed directly. (ccc) Specific speed means the speed in rpm at which a given hydraulic turbine would rotate, if reduced homologically in size, so that it would develop 1 metric horse power (i.e. 736 watts) under 1 meter of head at full gate opening. (ddd) Station means either the Thermal Generating Station or Hydro-electric Generating Station depending upon the context. (eee) Steam turbine means a machine which converts thermal energy from steam into mechanical work to drive the electrical generator. (fff) Step Potential means the difference in surface potential experienced by a person bridging a distance of 1 m with the feet without contacting any grounded object when ground currents are flowing.
(ggg) Subcritical unit in relation to coal/lignite based thermal generating unit means a unit designed for main steam pressure less than the critical pressure (221.2 bars).
(hhh) Subcritical unit in relation to coal/lignite based thermal generating unit means a unit designed for main steam pressure more than the critical pressure (221.2 bars). (iii) Substation means any premises or enclosure containing an assemblage of electrical apparatus for conversion, transformation and control of electrical power other than transforming or converting solely for operation of switching or instruments and includes a pole mounted substation. Surface Power House means the Power House in which upper part starting from the generator floor or service bay are above the ground. Switchgear means switching devices and their combination with associated control, measuring, protective and regulating equipment, also assemblies of such devices and equipment with associated interconnections, accessories, enclosures and supporting structures, intended in principle for use in connection with generation, transmission, distribution and conversion of electric power. Switchyard means a sub-station associated with a generating station for transforming electricity for further transmission.
(jjj) (kkk)
(lll)
(mmm) Thermal Generating Station means the generating station as defined in the Act for generating electricity using fossil fuels such as coal, lignite, gas, liquid fuel or combination of these as its primary source of energy. (nnn) Touch Potential is the potential difference between the object touched and the ground point just below the person touching the object when ground currents are flowing. (ooo) Transients means over voltage or over current phenomena prevailing in an electrical system for a transient period of the order of a fraction of a second or a few seconds not exceeding five seconds. (ppp) Turbine setting in relation to hydro-electric generating station means the elevation of distributor centre line or runner centre line. (qqq) Two Shift Operation means operation at MCR or its high fraction for about sixteen hours in a day, unit being shut down for the remaining time. (rrr) (sss) Under Ground Power House means the Power House in which all major components of the turbine-generator sets are underground. Unit in relation to a coal/lignite based thermal generating station means steam generator with interconnected steam turbine-generator and auxiliaries, operated as one single set/system to generate electric power.
(ttt)
Voltage Transformer means an instrument transformer in which the secondary voltage, in normal conditions of use, is substantially proportional to the primary voltage and differs in phase from it by an angle which is approximately zero for an appropriate direction of the connections.
(uuu) Volumetric Heat Liberation Rate is defined as the heat generated from fuel firing in one hour divided by the volume of the furnace. (vvv) Warm Start in relation to steam turbine means start up after a shut down period between 10 hours and 72 hours (turbine metal temperatures between approximately 40% and 80% of their full load values). Words and expressions used but not defined in these Regulations shall have the same meaning respectively assigned to them in the Act. Applicability of Regulations These regulations shall apply to all Electrical Plants and Electric Lines for which order is placed by the Owner after the date of notification of these regulations. 4. Objectives These regulations are intended to specify the Technical Standards for construction of Electrical Plants and Electric Lines with the objective that all Electrical Plants and Electric Lines to be constructed conform to minimum requirements as laid down hereunder to ensure high level of performance in respect of reliability, availability and efficiency over its lifetime. 5. Technical Standards All Electrical Plants and Electric Lines to be constructed shall conform to the General Requirements specified at Regulation (6) below and The Technical Standards for construction of Electrical Plants and Electric Lines as appended with these Regulations at Schedule -I to IV detailed hereunder: a) Schedule I: Technical Standards for Thermal Generating Stations b) Schedule II: Technical Standards for Hydro-electric Generating Stations c) Schedule III: Technical Standards for Sub-stations and Switchyards d) Schedule IV: Technical Standards for Electric Lines
(2)
3.
6. (1)
General Requirements The Electrical Plants and Electric Lines shall be constructed considering prudent engineering practices and optimal utilization of resources. These shall be complete and include all the equipment and systems necessary to ensure high level of safety, maintainability, reliability and availability throughout their life. The Electrical Plants and Electric Lines shall be suitable for full range of ambient and other environmental conditions. The various parts / components / assemblies of equipment and systems shall be of proven materials with well established physical and chemical properties appropriate to the service as intended. All equipment and systems installed shall comply with latest statutes, regulations and safety codes, as applicable in the area. The Electrical Plants and Electric Lines shall be designed to comply with the requirements stipulated in a) Central Electricity Authority (Installation and Operation of Meters) Regulations, 2006 b) Central Electricity Authority (Technical Standards for Connectivity to the Grid) Regulations, 2006 c) Central Electricity Authority (Measures relating to Safety and Electricity Supply), Regulations, 2007 c) Indian Electricity Grid Code issued by Central Electricity Regulatory Commission (CERC) and d) Applicable State Grid Code issued by appropriate Regulatory Commission.
(2) (3)
(4) (5)
(6)
The design, construction and testing of all equipment, facilities, components and systems shall be in accordance with standards/ codes issued by Bureau of Indian Standards (BIS) and/or reputed international standards/ codes. A non-exhaustive list of reputed international standards is given below: a) b) c) d) e) f) g) h) i) American National Standards Institute (ANSI) American Petroleum Institute (API) American Society of Mechanical Engineers (ASME) American Society of Testing and Materials (ASTM) American Water Works Association (AWWA) American Welding Society (AWS) British Standards (BS) Deutsches Institut fur Normung (DIN), Germany Heat Exchange Institute (HEI), USA
j) k) l) m) n) o) p) q) r) s)
Hydraulic Institute Standards (HIS), USA International Electrotechnical Commission (IEC) Institute of Electrical and Electronics Engineers (IEEE) International Organisation for Standardisation (ISO) Japanese Industrial Standards (JIS) National Electric Code (NEC), USA National Electrical Manufacturers Association (NEMA), USA National Fire Protection Association (NFPA), USA Tubular Exchanger Manufacturers Association (TEMA), USA VDE association for Electrical, Electronic and Information Technologies (VDE), Germany
Other International Standards, equivalent or superior to the above Standards can also be adopted. However, in the event of any conflict between the requirements of the International standards/codes and, and the requirements of the BIS standards/codes, the latter shall prevail. (7) All materials, components and equipment shall be tested at all stages of procurement, manufacturing, erection, commissioning as per comprehensive Quality Assurance Programme to be agreed mutually between the owner and the equipment supplier. The SI /MKS system of units shall be used for design, drawings, diagrams, instruments, etc. The Owner shall retain at the site and make available the following documents for inspection, as may be required by a statutory body: a) As-built drawings including, but not limited to the civil and architectural works; b) Copies of the project design memorandum, technical description, data sheets, operating manuals and manufacturers warranties for all major items and / or equipment ; c) Copies of the results of all tests performed on major items and d) Such other technical documents relating to the design, procurement, engineering and construction as may be required for inspection
(8) (9)
10
SCHEDULE I:
TECHNICAL STANDARDS FOR THERMAL GENERATING STATIONS
This Schedule describes the minimum technical requirements for construction of Thermal Generating Stations of various types in following four parts: Part Part Part Part A: B: C: D: Common to all types of Thermal Generating Stations Coal/lignite based Thermal Generating Stations Gas Turbine based Thermal Generating Stations Diesel Engine based Thermal Generating Stations
PART A: COMMON TO ALL TYPES OF THERMAL GENERATING STATIONS 1.0 1.1 GENERAL TECHNICAL REQUIREMENTS: The coal/lignite based thermal generating stations shall be designed to give life not less than twenty five (25) years. Gas turbine based Stations and diesel generator sets based Stations shall be designed for life not less than fifteen (15) years. The Station shall comply with the environmental stipulations (such as ambient air quality, gaseous emissions, liquid effluent discharges and solid waste disposal) of the Ministry of Environment and Forests (MOE&F), Government of India and any other stipulation in this regard of the Central Pollution Control Board (CPCB) and State Pollution Control Board (SPCB). a) Noise level at the Station boundary shall not exceed the Ambient Air Quality Standard in respect of noise as notified by MOE&F and any other stipulation in this regard of the SPCB and CPCB. Noise level for the continuously operating equipment shall not be more than 85 dBA at a distance of 1 meter and at a height of 1.5 meter from any equipment except in case of Turbine Generator for which noise level shall not exceed 90 dBA. For short term exposure, noise levels shall not exceed the limits as stipulated in the Occupational Safety & Health Administration (OSHA) Standard. Equipment/ machines shall be provided with acoustic enclosures, wherever required so as not to exceed the permissible noise limits.
1.2
1.3
b)
c) 1.4
Areas where a potential flammable atmosphere may exist shall be classified in accordance with the provisions of the internationally recognised standard. Certified equipment shall be used in the designated hazardous areas. To the extent practicable, equipment requiring operator attention and/or electrical equipment shall not be installed in hazardous areas.
11
1.5
All the equipments/surfaces (excluding coal/lignite pulverisers and electrical equipment) having skin temperature more than 60 deg.C shall be provided with required insulation along with cladding. The insulating materials, accessories and protective covering shall be non-sulphurous, incombustible, low chloride content, chemically rot proof, non-hygroscopic and shall withstand continuously and without deterioration the maximum temperature to which they will be subjected as per duty conditions. The use of insulation or finishing materials containing asbestos in any form is not permitted. SITE SELECTION AND LAYOUT CONSIDERATIONS: Site selection The following criteria shall be considered in selection of site for thermal generating stations: i) ii) iii) iv) v) vi) Availability of adequate land for the Station Avoidance of proximity to geological faults, high flood zone of rivers or the high tide zones of sea / backwaters Siting criteria prescribed by MOE&F Availability of required water Feasibility of rail, road or other linkages for transportation of fuel and equipment to the site Feasibility of power evacuation Layout considerations General layout of the Station shall be developed considering space optimization, functional requirements, future extensions (if envisaged) and provision of space requirements during construction stage. Following minimum layout requirements shall be complied with as may be applicable for coal/lignite and/or gas turbine based Stations: i) ii) iii) The layout of the Station shall be compact so as to optimise use of land, materials and minimise losses in the system. Adequate provision shall be made in regard to space and access in order to carry out the maintenance of various equipment. Due consideration shall be given for the wind direction while deciding on the relative location of the following:
2.0 2.1
2.2
12
a) cooling tower and switchyard to minimize the moisture drift towards the switchyard. b) chimney and ash disposal area with respect to township and adjoining habitation areas (applicable for coal/lignite based generating stations iv) Adequate space shall be provided for unloading and maintenance purposes in Turbine - Generator (TG) area. In case of coal/lignite based generating stations, two transverse bays shall be provided in TG area, at ground level at one end of the building for unloading and maintenance purposes. For Stations with multiple units, adequate space shall be provided to meet the requirement for simultaneous maintenance of two units. v) Requisite lay down area shall be provided for each unit on TG floor and same shall be approachable with electric overhead travelling (EOT) crane. Coal/lignite bunker bay shall preferably be located away from the TG building to avoid the dust nuisance. In case bunker bay is located adjacent to TG area, suitable isolation arrangement shall be provided. Adequate fire escape staircases shall be provided in TG building with fire doors at each landing. For coal/lignite based generating stations, interconnecting walkways between TG building and steam generator shall be provided at TG operating floor level and at deaerator floor level. Walkways at various levels shall also be provided for interconnection between steam generator and bunker bay. Provision of adequate space, as per stipulation of MOE&F, shall be made for future installation of flue gas desulphurization plant. One (1) no. of staircase, for each unit/ module, and minimum one (1) no. elevator shall be provided in the TG building. In addition, following elevators shall also be provided for coal/lignite based generating stations: a) One passenger-cum goods elevator for each steam-generator b) One passenger cum goods elevator for coal transfer point in bunker area c) One elevator for chimney with suitable landings
vi)
vii) viii)
ix) x)
13
PART B: 1.0 1.1
COAL/LIGNITE BASED THERMAL GENERATING STATIONS
OPERATING CAPABILITIES OF A UNIT IN THE STATION The unit shall give Maximum Continuous Rating (MCR) under the following conditions: Maximum cooling water temperature Worst fuel quality stipulated for the unit Grid frequency variation of -5% to +3% (47.5 Hz to 51.5 Hz)
1.2
The steam flow through steam turbine under valves wide open (VWO) condition shall correspond to 105% of steam flow corresponding to MCR output. The unit shall be capable of base load operation. However, the unit shall also be capable of regular two-shift operation and load cycling. The design shall cover adequate provision for quick start up and loading of the unit to full load at a fast rate. The unit shall have minimum rate of loading/ unloading of 3% per minute above the control load (50% MCR). The unit shall be capable of automatically coming down to house load and continue to operate at this load in the event of sudden external load throw off. The unit shall be designed to give maximum possible efficiency for the fuel stipulated and other site specific conditions. STEAM GENERATOR (BOILER) AND AUXILIARIES The steam generator shall normally be based on pulverized fuel combustion and shall be of sub-critical or super critical type with single /two pass or any other proven flue gas path configuration. However, wherever very low grade fuel or coal/lignite with high sulphur content is stipulated, fluidized bed combustion (FBC) based steam generator may be used. The steam generator and its auxiliaries shall be suitable for outdoor installation. Boiler Maximum Continuous Rating (BMCR) shall correspond to at least 102% of the steam flow at turbine inlet under VWO condition plus continuous steam requirement for auxiliary systems of the unit (e.g. turbine driven boiler feed pumps, fuel oil heating etc.) when unit is operating above control load. The steam generator shall be capable to give BMCR output for the worst fuel quality stipulated.
1.3 1.4
1.5 1. 6 2.0 2.1
2.2 2.3
14
2.4
The steam generator including pressure parts, vessels, piping, valves including safety valves and fittings shall meet the requirements of Indian Boiler Regulations (IBR). All start up vents shall be provided with two valves in series - one motorized isolating and one motorized regulating type. The typical characteristics of indigenous coal (high abrasive ash, slow burning, high ash resistivity etc) should be given due consideration while designing the steam generator and auxiliaries. The following criteria for furnace sizing may be used for typical Indian coal for unit sizes upto 500 MW. :Description Value @ 6 Maximum Net Heat Input (NHI) per unit plan 5x10 kcal/hr/m2 area of furnace ii) Maximum Volumetric Heat Liberation Rate 1.1x105kcal/hr/m3 iii) Maximum Heat input per Burner 55 x106 kcal/hr/burner @ (Not applicable for fluidized bed boilers) S.No. i)
2.5 2.6
2.7
Pressure withstand capability of the furnace shall correspond to minimum +/660 mmwc at 67% yield strength or maximum expected pressure/draft of fans, whichever is higher. The pulverized coal/lignite burners shall be low NOX type with NOX emission (both fuel NOX and thermal NOX) not exceeding 260 gms per gigajoule of heat input. For pulverized coal/lignite based steam-generators, fuel oil firing system shall be provided for start up and low load flame stabilization. Fuel oil system shall comprise of light diesel oil (LDO) for black start condition and heavy fuel oil (HFO/LSHS/HPS) for start-up & low load operation. The steam generator shall not require oil support above 40% unit load. Coal/lignite preparation system for pulverized fuel system shall have sufficient spare mills. (e.g. one spare mill when using worst coal and two spare mills when using performance coal corresponding to BMCR condition in case of medium speed mills). Coal supply to the mills shall be from the individual coal bunkers having storage capacity of about 16 hours. The coal fineness achieved from the pulverisers shall be at least 70% thru 200 mesh (75 microns) and 98% thru 50 mesh (300 microns) at rated capacity of the pulveriser, with an input coal size up to 50 mm.
2.8
2.9
2.10 2.11
2.12
15
2.13
2x60% forced draft (FD) fans and 2x60% induced draft (ID) fans shall be provided to maintain balance draft conditions in the furnace over the entire load range while burning the stipulated range of fuels. Suitable air pre-heating system shall be provided for recovery of useful heat from the exhaust flue gases. Steam coil air pre-heater (SCAPH) may also be provided for maintaining air temperature within safe limits to prevent corrosion during start up or very low ambient air temperature conditions. The soot blowing system shall be provided for the waterwall, superheater, reheater, economizer and air preheater. The dust collecting system (electro static precipitator, bag filter etc.) shall be provided for removing suspended particulate matter (SPM) from the flue gases to meet the statutory stipulations. In case electro static precipitator (ESP) is provided, the following requirements shall be complied with: i) ESP shall be able to meet the stipulated SPM emission requirement even when one electric field in each pass of the ESP is out of service while firing worst fuel. ESP shall be provided with effective ash evacuation system having controls for ash temperature and ash level in the hopper. Each hopper shall have a storage capacity of minimum of eight (8) hours. Specific weight of ash may be considered not more than 650 kg/m for determining hopper storage capacity and not less than 1350 kg/m for ESP structural design. Pressure withstand capability of the ESP casing shall correspond to minimum +/- 660 mmwc at 67% yield strength and flue gas temperature of 200 C.
2.14
2.15 2.16
ii)
iii)
iv)
3.0 3.1 3.2
STEAM TURBINE AND AUXILIARIES The steam turbine shall comply with latest versions of IEC-45 or equivalent. The gross turbine cycle heat rate as guaranteed by the equipment manufacturer shall not exceed the following values: Unit rating (MW) 100 MW 200 MW 250 MW 500 MW to less than 200 MW to less than 250 MW to less than 500 MW to less than 660 MW Gross turbine cycle heat rate* (kcal / kWhr) at 100% MCR 2000@ 1970@ 1950@ 1950$
16
Supercritical units
1890 ( with turbine driven BFP)
* corresponding to reference conditions of 33O C cooling water temperature and 0% de-mineralised water make up
@
corresponding to sub-critical units with motor driven BFP. In case turbine driven BFP is envisaged, the indicated gross heat rate shall be increased by 40 kcal/kWhr corresponding to sub-critical units with turbine driven BFP. In case motor driven BFP is envisaged, the indicated gross heat rate shall be reduced by 40 kcal/kWhr
3.3
The steam turbine shall be of tandem/cross compound construction, reheat type, condensing, single/multi-cylinder design with number of uncontrolled extractions as optimized for regenerative feed heating. Steam turbines of less than 100 MW rating may be non-reheat type. The steam turbine shall be designed for a minimum of 3000 hot starts, 700 warm starts and 100 cold starts during its life. A self-contained lubricating oil system shall be provided for each steam turbine-generator. A main oil pump (MOP) shall be provided which may be either directly driven by turbine shaft or by AC motor. In addition, a minimum of one AC motor driven auxiliary oil pump shall be provided as standby for the main oil pump. Provision shall also be made for one DC motor driven emergency oil pump for meeting lubricating oil requirement during nonavailability of AC motor driven pump. Jacking oil system, with 2x100% jacking oil pumps, shall be provided to supply high pressure oil to each bearing of steam turbine-generator to lift the rotor during starting or turning gear operation. The oil used for turbine governing (control) shall be either from the lubricating oil system or from a separate control oil system. In case of separate control oil system, the pumps provided shall be 2x100%. The steam turbine shall be provided with electro-hydraulic governing system. However, units more than 200 MW shall be provided with back up governing system of mechanical hydraulic or electro hydraulic type. The turbine shall be provided with protective devices as per IEC-45 or equivalent, including the following:
3.4 3.5
3.6
3.7
3.8
3.9
17
i) ii) 3.10 3.11
Separately actuated over-speed trip device. Emergency hand trip devices to facilitate manual tripping of the turbine locally and from control room.
Turbine vibrations shall be minimized and shall be within limits as per ISO 10816 and ISO 7919. Non-return valves shall be provided in the steam extraction lines as required for protection from overspeed that may result from sudden load throw off or turbine trip. Hydraulic/pneumatic/D.C. operated device shall be provided for rapid reduction of vacuum in condenser to bring turbine rotor to rest as quickly as possible under emergency conditions. The start up and drainage system shall comply with ANSI/ASME Standard TDP-1 Recommended practices for the prevention of water damage to steam turbines used for electric power generation. For steam turbines with rating more than 100 MW, turbine by - pass system of adequate capacity shall be provided for fast hot & warm start ups of unit, dumping steam in condenser during sudden turbine trip (without tripping the boiler), unit house load operation etc. Condensate polishing system shall be provided in the steam turbine cycle for the following: a) units with rated pressure 170 kg/cm2 and above at turbine inlet b) units using sea water for condenser cooling
3.12
3.13
3.14
3.15
3.16
Suitable feed water regenerative system consisting of low pressure heaters, deaerator and high pressure heaters shall be provided for optimized cycle efficiency. Condenser The design, manufacturing and testing of condenser shall be as per Heat Exchange Institute (HEI) or equivalent. Condenser tubes shall be of titanium when using sea water and stainless steel for other sources of water. On load condenser tube cleaning system may be provided, as required, depending upon the quality of cooling water.
3.17 i) ii)
18
iii)
Vacuum pumps or steam ejectors shall be provided as per HEI or equivalent for evacuating air steam mixture and non-condensable gases from the condenser. Condensate Extraction Pumps (CEPs) 3x50% or 2x100% condensate extraction pumps shall be provided for each unit. The design shall meet the requirements of Hydraulic Institute Standards (HIS) or equivalent. The required net positive suction head (NPSH) at 3% head drop shall be well below the available NPSH under all operating regimes with lowest hot well level and maximum pressure drop across suction strainer. Boiler Feed Pumps (BFPs) The unit shall be provided with boiler feed pumps of adequate capacity to give rated output. The following configurations may be considered in order to provide redundancy and start up requirements for various unit sizes: a) 500 MW and above: 2x50% or 1x100% turbine driven BFP plus 1x50% or 2x25% motor driven BFP 3x50% motor driven BFP 2x100% or 3x50% motor driven BFP
3.18 i)
ii)
3.19 i)
b) 100 to 300 MW: c) Less than 100 MW ii)
The required net positive suction head required NPSH at 3% head drop shall be one third of available NPSH at design point with lowest deaerator level and maximum pressure drop across the strainer. ELECTRICAL SYSTEM General Requirements
4.0 4.1
4.1.1 For the purpose of design of electrical equipment/systems, an ambient temperature of 50 deg. C and relative humidity of 95% shall be considered. The equipment shall be suitable for operation in a highly polluted environment. However, for equipment in air conditioned areas, design ambient temperature shall be 35 deg.C . 4.1.2 The Owner shall install and maintain the necessary communication equipment to transmit the required data of the Power Station to the procurer of electricity, Regional/State Load Despatch Centre and Transmission Company.
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4.2
Generator
4.2.1 The turbo-generator shall comply with IS-4722/ IEC-60034 or their equivalent. The efficiency of generator shall be more than 98% at rated load. 4.2.2 Insulation shall be thermal class-F for stator and rotor winding as per IEC 60034. However, temperature rise shall be limited corresponding to thermal class-B insulation. Generator shall be either hydrogen cooled, hydrogen & water cooled or air cooled type. The generator shall be capable of delivering at least two third of its rated output with one hydrogen gas cooler out of service. 4.2.3 Generator Instrumentation Resistance temperature detectors (RTDs)/ thermocouples shall be provided at suitable locations for monitoring the temperatures of stator core, stator windings and bearings. Suitable arrangements shall also be made for monitoring the temperature of the rotor winding in case static excitation system is provided. 4.2.4 Hydrogen gas system Hydrogen gas system shall be provided with driers of 2x100% duty to maintain dryness of hydrogen inside the machine. Suitable system shall be provided to prevent condensation during long shut down. The system shall have the provision of on-line dew point measurement as well as gas analyser. 4.2.5 Water system Stator water cooling system shall be closed loop type with 2x100% AC motor driven circulating water pumps, 2x100% de-mineralised (DM) water heat exchangers, 2x100% filters, one mixed bed de-mineraliser and one alkalizer unit (as applicable). 4.2.6 Seal oil system In case of hydrogen cooled machines, the seal oil system provided shall be equipped with 2x100% AC motor driven pumps and 1x 100% DC motor driven pump. The system shall be provided with coolers and filters having 2x100% duty . 4.2.7 Excitation System 4.2.7.1 Suitable generator excitation system as well as automatic voltage regulator (AVR) shall be provided with the generator as per regulations of
20
the Authority on Grid Connectivity. Power system stabilizer (PSS) shall be provided in AVR for generator of 100MW and above. 4.2.7.2 The rated current of the excitation system shall be at least 110% of the machine excitation current at the rated output of the machine. The rated voltage shall be at least 110% of the machine excitation voltage. Generators of 100 MW and above rating shall be provided with AVR having 2x100% auto channels and automatic changeover. In the event of failure of auto channels, manual control shall be possible. At least 100% redundancy shall be provided for the converters. In case of brushless excitation system, rectifier assembly shall be provided with either complete bridge as redundant or at least one redundant parallel branch in each of the six arms of the bridge. Instrument Transformers
4.2.7.3
4.2.8
4.2.8.1 Current Transformers Current Transformers shall comply with IS: 2705/IEC: 60044-1 in general. The accuracy class shall be as under: a) b) not less than 0.2 for low forward power relay, acceptance testing, energy accounting and audit meters. not less than 0.5 for reverse power relay, generator AVR, Electro Hydraulic governor (EHG) and other measurements.
4.2.8.2 Voltage Transformers Voltage transformers shall comply with IS:3156/IEC: 60044-2 in general. The accuracy class shall be as under: a) b) 4.3 not less than 0.2 for acceptance testing, energy accounting and audit meters. not less than 0.5 for generator AVR, Electro Hydraulic governor (EHG) and other measurements .
Power Transformers
4.3.1 The power transformers (Generator/ Unit Auxiliary /Station Transformers) shall comply with latest versions of BIS: 2026 or relevant IEC. 4.3.2. The generator transformer shall be provided to step up generating voltage for connection to the grid. It shall also be used to provide start-up power from
21
the grid in case circuit breaker is provided between the generator and generator-transformer in generator circuit breaker (GCB) scheme. It shall be mineral oil filled with oil forced air forced (OFAF) (100% rating)/ oil natural air forced (ONAF) (80% rating)/ oil natural air natural (ONAN) (60% rating) cooling. It shall be provided with 2x50% cooling radiator banks. Each radiator bank shall be provided with suitable number of working fans plus one (1) stand-by fan and 2x100% oil pumps. It shall be provided with on-load tap changer (OLTC) or off-circuit tap changer (OCTC) type depending upon system requirements. 4.3.3 The unit auxiliary transformer(s) (UAT) shall be used to meet the unit load requirement during normal running of the unit. However, in case of GCB scheme, it shall provide power requirement of the unit and station auxiliaries during start-up and normal running of the unit. It shall be mineral oil filled with ONAF (100% rating)/ ONAN (80% rating) cooling. It shall be provided with minimum 2x50% detachable cooling radiator banks. Each bank shall be provided with suitable no. of working fans plus one (1) stand-by fan. UAT, in case of GCB scheme, may be provided with OFAF/ONAF/ONAN cooling. The tap changer for UAT shall be of OCTC type in case generator transformer is provided with OLTC and vice versa. 4.3.4 The station transformer (s) shall provide the start-up power requirement and station auxiliary load requirement during normal operation of the unit(s). This may not be applicable in case of GCB scheme. It shall be mineral oil filled with OFAF (100% rating)/ ONAF (80% rating)/ ONAN (60% rating) cooling. It shall be provided with 2x50% cooling radiator banks. Each radiator bank shall be provided with suitable number of working fans plus one (1) stand-by fan and 2x100% oil pumps. It shall be provided with OLTC. 4.3.5 The transformers shall be suitable for continuous operation at rated MVA on any taps with voltage variation of +10% in accordance with IS: 6600. 4.3.6 The insulation levels for the transformer windings and bushings shall be as per Schedule III (Table-5).
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4.4
HT Switchgear SF6 or vacuum type of circuit breakers shall be provided in HT Switchgear (11/6.6/3.3 kV) which shall be of draw out type, re-strike free, trip free, stored energy operated and with electrical anti-pumping features. The protective relays shall be preferably of numerical type with self monitoring and diagnostic features.
4.5
LT Switchgear Air break type of circuit breakers shall be provided for LT switchgear (415 V) which shall be of draw out type, trip free, stored energy operated and with electrical anti-pumping features. The protective relays shall be preferably of numerical type with self monitoring and diagnostic features.
4.6
Generator Busducts
4.6.1 The busducts shall be of standard size as per BIS and designed to carry maximum continuous current under normal site conditions without exceeding temperature rise limits. 4.6.2 The busducts shall be segregated or isolated phase type. The busduct rated more than 3150 A shall be isolated phase type. Busduct rated more than 6000 A shall be continuous isolated phase type. A hot air blowing system or air pressurization system shall be provided to prevent moisture deposition in case of isolated phase ducts while space heaters may be provided in case of other busducts. 4.6.3 The bus assembly shall be designed mechanically to withstand rated continuous current as well as the specified shortcircuit current without damage or permanent deformation of any part of the bus structure. 4.6.4 Lightning arresters and voltage transformers connected to generator busducts shall be located in separate cubicles for each of the three phases. Voltage transformers shall be accommodated in draw-out type compartments in phase-isolated manner in a cubicle. The lightning arrestors and voltage transformers cubicles shall comply with relevant BIS / IEC or equivalent. 4.7 Power Supply System
4.7.1 All auxiliaries dedicated to the unit shall be fed from unit bus connected to UAT(s). During start -up and shut - down of units, the unit auxiliaries shall be supplied power from the station bus connected to station transformer(s). However, in case of GCB scheme, the same shall be provided by the unit bus.
23
4.7.2 All the loads pertaining to balance of plant facilities shall be fed from station bus connected to Station Transformer (s). Station bus shall also be capable of supplying power to largest unit in the Station during start-up and shutdown. However, in case of GCB scheme, the loads pertaining to balance of plant facilities shall be fed from unit bus. 4.7.3 Power supplies, buses, switchgear, interlocks and standby supply systems to station and unit auxiliaries shall be designed in such a way that the main equipment and auxiliaries are not endangered under all conditions. Transformer voltage ratios, type of tap changers and tap ranges, impedances and tolerances thereon, shall be so optimized that the auxiliary system voltages under various grid and loading conditions are always within permissible limits and equipments are not subjected to unacceptable voltages during operation and starting of motors. The vector groups of the generator transformers, unit auxiliary transformers and station transformers shall be so selected that the paralleling at 11/ 6.6/ 3.3KV buses shall be possible. Further, the vector group of other auxiliary transformers shall have identical vector groups. 4.7.4 In thermal power stations with unit sizes more than 100 MW, automatic bus transfer system (consisting of fast, slow, etc. transfer in auto mode ) shall be provided to minimise time for transfer from unit to station bus and vice versa at 11/ 6.6 kV levels. Bus transfer scheme shall also have manual mode to initiate transfer command manually. The 11/6.6/3.3 kV switchgear buses for balance of plant facilities shall be provided with auto reserve closure (ARC) facility between main incomer and reserve breakers. Critical 415 V switchgear buses shall also have ARC feature. 4.7.5 Auxiliary transformers, as required, shall be provided to meet the demand at various voltage levels of auxiliary power systems, with the criteria that each switchgear, motor control centre (MCC), distribution board (DB) shall be fed by 2x100% transformers/ feeders. The auxiliary transformers shall be designed to carry the maximum expected load. 4.8 Neutral Earthing Generator neutral earthing equipment shall be designed duly taking into account the normal rise of the generated voltage above the rated value due to load throw off and field forcing, ferro - resonance, etc. Generator neutral shall be earthed through dry type distribution transformer with secondary loaded with a resistor.
24
Neutral earthing of other systems shall be such that it is possible to provide earth fault protection with proper discrimination. 4.9 Earthing System The earthing system shall be designed for a life expectancy of at least forty (40) years, for maximum fault current or EHV system fault current of 40kA, whichever is higher for 1.0 sec. The minimum rate of corrosion of earthing conductor shall be considered as 0.12 mm per year while determining the conductor size. Grounding and lightning protection for the entire Station shall be provided in accordance with IS: 3043, IEEE : 80 and IEEE : 665. 4.10 Protection Fully graded protection system with requisite speed, sensitivity and selectivity shall be provided for the entire Station. Generator, generator transformer, unit auxiliary transformers (UATs) shall be provided with protections connected to two independent channels/ groups, such that one protection system shall always be available for any type of fault in the generator/ generator transformer/ UAT(s). The protections for the generator/ generator transformer/ UAT(s) shall be provided as under: SN 1 2 3 4 5 Protection Function Remarks Generator differential protection, (87G) Overall differential protection (87OA). Generator transformer differential protection (87GT) for single phase bank Restricted Earth Fault protection for Generator transformer (87NGT) Over head line connection To be provided, if differential protection (87 L) distance between Generator Transformer and Switchyard is about 200 mtrs and above. 100% stator earth fault protection For units of 100 MW and (64G1). above 95% stator earth fault protection For units less than 100 (64G1). MW Standby stator earth fault protection (64G2) Inter-turn fault protection (87TG) Applicable where split
6 7 8 9
25
10 11 12 13 14
Loss of field protection (40G). Back up impedance protection, 3 pole (21G) Backup earth fault protection on generator transformer HV neutral (51NGT) Negative sequence current protection, (46G) Low-forward power and Reverse power interlock for steam turbine generator (37/ 32G) Rotor earth fault protection - two stages (64F1/F2). Definite time over-voltage protection (59G) Generator under frequency protection (81G) Over-fluxing protection for generator (99G)
winding in Stator is provided and if six terminals are available. To be duplicated for units of 500 MW and above.
Preferably 3-ph power relays shall be provided. Both the relays shall be duplicated for units of 500 MW and above.
15 16 17 18 19 20 21 22 23
24 25
To be provided for units of 500 MW and above in duplicate. Over-fluxing protection for generator To be duplicated for transformer (99GT) units of 500 MW and above. Accidental back energisation protection (50GDM) Overload protection for generator (51G) Overheating (winding and/ or Alarm only bearing) (49G) Time graded IDMT type back nondirectional over-current protection in all phases on HV side of generator transformer (51GT) Instantaneous and time delayed Over Current protection to be used on HV side of excitation transformer Generator pole slipping protection (98G)
26
26 27 28 29 30 31 32 33 34 35 4.11
UAT differential protection, (87UAT) UAT LV back-up earth fault protection (51NUAT) UAT LV restricted earth fault (87NUAT) UAT back-up over-current protection (51UAT). Generator transformer OTI (49Q) and WTI (49T) trip Generator transformer Buchholtz (63), PRV / other mechanical protections UAT OTI(49Q) and WTI (49 T) trip UAT Buchholtz (63) , PRV/ other mechanical protections Pole discrepancy protection of generator transformer breaker (162) Breaker failure protection of generator transformer breaker (50Z) . To be provided if single pole breakers are used
Synchronization Automatic as well as manual facility alongwith check synchronizing and guard relay features shall be provided for closing of generator transformer/generator circuit breaker for synchronization of generator with the grid.
4.12
Cables and cabling Cables shall be flame retardant low smoke (FRLS) type. Cables to be directly buried shall be essentially armoured type. Derating factors for site ambient and ground temperatures, grouping and soil resistivity shall be considered while determining the size of cables. Fire protection barriers shall be provided for cable galleries, cable shafts etc. at various suitable locations. Fire resistant penetration seals shall be provided for all openings in floors, ceilings, walls etc.
4.13
Diesel Generator Set Automatic mains failure (AMF) Diesel generators (DG) shall be installed for feeding emergency loads in the event of failure of station supply. One DG set shall be provided for each unit of 200 MW and above. In addition there shall be one common standby DG set of same rating to serve a block of two units.
27
For unit sizes less than 200 MW, one DG set may be provided for every two units. 4.14 D C System Standard levels of DC system shall be 220 volts, 48 volts and 24 volts for control and protection of various equipment. Two sets of batteries shall be provided for each DC system each catering to 100% load. One float -cumboost chargers shall be provided for each battery. 4.15 Illumination System Adequate illumination shall be provided in accordance with IS: 3646. Emergency AC and DC illumination shall also be provided at important places. Energy conservation measures shall be adopted while designing the lighting system. 4.16 Motors AC motors shall be squirrel cage type induction motors suitable for direct online starting. Crane duty motors shall be slip ring/ squirrel cage type induction motor. DC motors shall be shunt wound type. All motors shall be either totally enclosed fan cooled (TEFC) or totally enclosed tube ventilated (TETV) or closed air circuit air cooled (CACA) or closed air water cooled (CACW) type. Temperature rise shall be limited to 70 deg C by resistance method for both class B and F insulation. Enclosures of the motors located in hazardous areas shall be flame proof type conforming to IS:2148 as per details given below: a) Fuel oil area b) Hydrogen generation plant area 5.0 5.1 Group II B Group-IIC
CONTROL & INSTRUMENTATION SYSTEM General
5.1.1 Control & Instrumentation system provided for the Station shall be consistent with modern power station practices and in compliance with all applicable codes, standards, guidelines and safety requirements in force. 5.1.2 The complete thermal, mechanical and electrical functions of the Station shall be remotely controlled from the central control room/ respective local control room of various auxiliary systems, as provided, during normal as well
28
as emergency conditions. The number of control areas shall be kept to minimum with a view to optimize manpower. 5.1.3 All stand-by auxiliaries shall be designed to start automatically as quickly as possible on failure of running auxiliaries. 5.2 Control System for Steam Generator and Turbine Generator
5.2.1 The state of art microprocessor based digital control system (DCS) shall be provided for monitoring and control of steam generator, turbine generator and auxiliaries and shall include monitoring & information, sequential control for drives, closed loop control for regulating drives, interlocking & protection, historical data storage, alarm annunciation system, sequence of event (SOE) recording system etc. DCS system shall be independent for each unit. 5.2.2 Control systems integral to steam- generator and turbine- generator shall preferably be implemented as part of DCS system. Control systems integral to steam-generator shall include burner management system (BMS)/ furnace safeguard supervisory system (FSSS) which shall comply with latest version of NFPA 85. The Master Fuel Trip (MFT) system shall comply with VDE0116, VDE 0160 etc. Control systems integral to turbine -generator shall include turbine protection system, electro-hydraulic governing (EHG) system, turbine stress management system, turbine supervisory system, automatic turbine run up system (ATRS). 5.2.3 Human machine interface system (HMIS) configured around latest state-ofthe art redundant workstations with open architecture shall be provided to operate the unit under all operating conditions. Minimum number of hardwired devices shall also be provided for safe shutdown of unit. 5.2.4. DCS system shall be provided with 100% redundancy for processors, control & input/output bus and network components. 5.2.5 All input modules for control, interlocking and protection shall be redundant. Output modules for all HT drives and critical LT drives shall also be redundant. Redundant inputs/outputs shall be connected to different input/output cards of DCS i.e. triple redundant inputs shall be connected to three separate input cards. The logics for redundant drives shall not be in the same processor. 5.2.6 The design of the control systems and related equipments shall adhere to the principle of fail safe operation wherever the safety of personnel / plant equipment is involved. fail safe operation signifies that the loss of signal, loss of power or failure of any component shall not cause a hazardous condition. However, it shall also be ensured that occurrence of false trips are 29
minimized. No single failure either of component or power source of DCS shall cause loss of generation. 5.2.7 The control system shall include on-line self-surveillance, monitoring and diagnostic facility giving the details of the fault on the human machine interface system (HMIS). 5.2.8 It shall be possible to remove and replace various modules (like any controller, input/output module, interface module, etc.) on-line from its slot for maintenance purpose without switching off power supply to the corresponding rack and without jeopardizing safety of the Station equipment and personnel.
5.2.9
The historical storage & retrieval system shall store and process system data for future analysis. The data shall be transferred to removable storage media for long term storage and retrieval. The binary data to be stored shall include status of SOE (1millisecond resolution), alarm and other binary inputs. All important analog data shall be stored at one second interval. Selected logs viz. start up log, trip analysis log shall also be stored. Control system for Balance of Plant Programmable logic controller/ PLC based control system with independent HMIS shall be provided for all the balance of plant facilities like coal/lignite handling plant, ash handling plant, water treatment plant etc. PLCs shall be latest state of the art system with redundant processors.
5.3
5.4
Local Area Network (LAN) A redundant station-wide LAN shall be provided for information exchange between DCS of each generating unit, PLCs for balance of plant as well as gateway for connecting to the other off-line services of the Station (inventory management, maintenance management etc.).
5.5
Measuring Instruments
5.5.1 Primary instruments like transmitters, thermocouples, resistance resistance temperature detectors (RTDs), local gauges, flow elements, transducers etc. shall be provided as required for comprehensive monitoring of various parameters of the Station. 5.5.2 Microprocessor based vibration monitoring and analysis system shall be provided for monitoring and analysis of vibration of critical rotating equipment (i.e. turbine-generator, boiler feed pumps, ID/FD/PA fans etc.) 5.5.3 Flue gas analysis instruments including sulphur-di-oxide (SO2), nitrogen oxides (NOx), oxygen, carbon mono-oxide (CO) and dust emission monitoring systems shall be provided.
30
5.5.4 The triple sensors shall be provided for critical binary and analog inputs required for protection of steam generator and steam turbine as well as for critical control loops (e.g. furnace draft, drum level, condenser vacuum). Redundant sensors shall be provided for other important applications. 5.5.5 All electrical instruments and devices like switches, transmitters, controllers, analyzers, solenoid valves which are located in the hazardous locations like hydrogen generation plant shall be provided with explosion proof enclosure suitable for hazardous areas as per NFPA/NEC. 5.6 Power supply system Independent, redundant and reliable 230 V AC through uninterrupted power supply system (UPS) and/or DC power supply at standard voltage levels (e.g.220V/48V/24V) shall be used for control & instrumentation systems. 5.7 Control Valves The control valves and accessories shall be designed, constructed and tested as per IBR, ASME code for power piping (B 31.1) and ASME Boiler & pressure vessel code or equivalent. 5.8 Steam & Water Analysis System (SWAS) An online analysis system shall be provided for continuously monitoring the purity of condensate, feed water, steam etc. The on-line chemical analysis shall be carried out in the plant cycle at strategic points as per the recommendation of manufacturers of steam-generator and steam turbine. The system shall be generally designed as per ASME PTC 19.11. 6.0 6.1 BALANCE OF PLANT Coal/lignite handling system The arrangement for transportation of coal/lignite from supply source to the Station may be by rail or other captive systems such as merry go round (MGR), belt conveyor system, ropeway system etc. Further handling shall comply with the following requirements: 6.1.1 The coal/lignite handling plant capacity shall be such as to meet the days fuel requirement by its operation in 14 hours. Days fuel requirement shall be worked out at 100% BMCR using worst coal/lignite and a margin of 10%. 6.1.2 Coal/lignite handling plant shall be provided with 100% standby streams. Each coal/lignite stream shall be provided with 2x75% or 3x50% paddle feeders (in case of track hoppers) or vibro feeders (in case of wagon tippler) and 2x50% crushers with belt feeders. Single set of coal/lignite conveyers from the stockyard to the bunkers shall not cater to more than three units.
31
6.1.3 In case of rail based transportation, marshalling yard for handling of wagons and unloading system shall be designed to facilitate return of empty wagons within the prescribed time by the Indian Railways. 6.1.4 The minimum storage capacity of coal/ lignite stockyard shall be as under: Non-pit head stations: Coastal stations: Pit-head stations 30 days 30 days 15 days
6.1.5 Provision of proper dust suppression facility shall be made for coal at various locations i.e. receiving point, stockyard and discharge points of conveyors, to avoid dust nuisance and spontaneous fire. 6.1.6 The provision for measurement of weight of coal/lignite shall be made through weighbridges at the receiving point. The weight of coal/lignite shall also be measured through belt-weighers. 6.1.7 The arrangement shall be made for sampling of coal/lignite alongwith associated instruments/equipment to monitor quality of coal/lignite on asreceived basis as well as as-fired basis before the bunkers. 6.2 Fuel Oil System
6.2.1 Necessary arrangement shall be provided for unloading and storage of heavy fuel oil (HFO) and light diesel oil (LDO). 6.2.2 The capacity of fuel oil storage facilities shall be adequate for the requirement of fuel oil for at least 30 days operation of the Station. 6.2.3 Suitable heating arrangement shall be made for heating the HFO by steam to maintain its flowability. 6.2.4 The aspects regarding proper storage and handling of fuel oil shall be as per statutory requirements of Chief Controller of Explosives. 6.3 Ash Handling System
6.3.1 For pulverised fuel based steam-generator i) ii) Arrangement shall be provided for extraction and transportation to silos in dry form for 100% of fly ash produced Dry fly ash storage silos of adequate capacity (about 16 hours of ash generation) to collect dry fly ash shall be provided in a separate area near the Station boundary with provision for independent access.
32
iii)
In addition to fly ash disposal in dry form, the provision shall also be made for 100% ash disposal through slurry system. Ash slurry concentration shall be minimum 25%. Suitable ash water recirculation system shall be provided to recycle and reuse water. Furnace bottom ash alongwith economizer ash shall be extracted and disposed in wet/semi-wet form. The capacity of ash handling systems, as a percentage of maximum ash generated corresponding to firing of worst coal/lignite at BMCR, shall not be less than the following: a) Fly Ash System ESP fly ash & chimney ash Air preheater ash b) Bottom Ash System Furnace bottom ash Economiser ash 25% 5% 90% 5%
iv) v)
vi)
Ash removal rate shall meet the following criteria: a) Fly Ash System b) Bottom Ash System Furnace bottom ash Economiser ash 8 hour collection in 90 minutes Continuous 8 hour collection in 6 hours
vii)
Ash handling system shall have the provision for following standby arrangement : Bottom Ash System 100% standby for jet pumps with 2x100 % pipelines for each jet pump outlet or 100 % standby for submerged scrapper conveyor (SSC) Fly Ash System Ash slurry disposal 100% standby for vacuum pumps, collector tanks, wetting heads 100% standby blowers for intermediate and storage silos 50% standby for air compressors to be used for transporting ash One pump stream as operating standby and one pump stream as maintenance standby
33
6.3.2 For fluidized bed type steam-generator i) ii) Dry fly ash extraction, transportation and storage system shall meet the requirements as stipulated above for pulverized fuel based system In addition to fly ash disposal in dry form, the provision shall also be made for wet ash disposal through slurry system. Ash slurry concentration shall be minimum 16%. Suitable ash water recirculation system shall be provided to recycle and reuse water. Furnace bottom ash shall be extracted in dry form by means of drag link chain conveyor and further disposed in wet/semi-wet form. The capacity of ash handling systems, as a percentage of maximum ash generated corresponding to firing of worst fuel at BMCR, shall not be less than the following: a) Fly Ash System ESP fly ash & chimney ash Air preheater ash Economiser ash b) Bottom Ash System Furnace bottom ash v) a) Fly Ash System b) Bottom Ash System vi) 30% 8 hour collection in 6 hours Continuous Ash removal rate shall meet the following criteria: 80% 5% 5%
iii) iv)
Ash handling system shall have the provision for following standby arrangement : Bottom Ash System Fly Ash System Ash slurry disposal 100% standby for drag link chain conveyor 100% standby for compressors an blowers One pump stream as operating standby and one pump stream as maintenance standby
6.3.3. Ash pond management shall be judiciously planned to optimize the area and facilitate use of pond ash. It shall also conform to MOE&F requirements. 6.4 Station Water System
6.4.1. Station Water scheme i) The Station water scheme shall be designed to meet the total clarified water requirement of the Station consisting of cooling tower make up (for non-
34
coastal stations), de-mineralisation system, equipment cooling system, service water, potable water and miscellaneous requirements. ii) For coastal Stations, sea water shall be used for condenser cooling. In case where source of non-saline (sweet) water is not available, sea water shall be used for production of demineralised water, potable water and service water through desalination plant. Raw water for production of clarified water shall be drawn from identified source of water and supplied to the Station site by raw water pumps with adequate standby provision and 2x50% capacity pipelines. Provision for desilting and traveling water screens shall be made at the raw water intake point. Adequate storage of raw water/sweet water shall be provided at the Station site considering the period of non-availability of input water from the source. In case of sea water, de-silting arrangement and traveling water screen shall be provided at the sea water intake. Further, debris filter shall also be provided at condenser inlet
iii)
iv)
6.4.2 Pre-Treatment System The raw water shall be treated in pre-treatment plant to produce clarified water for meeting the requirement of clarified water of the Station. Adequate provisions for raw water chlorination, chemical dosing and sludge handling shall also be made. 6.4.3 Cooling Water System i) The cooling water (CW) system for condenser and secondary cooling system for Station equipment shall be of closed cycle type using cooling towers. However, for coastal Stations using sea water, once through condenser cooling system may be used which shall conform to MOE&F requirements of temperature rise. The cooling tower shall be of mechanical induced draft type or natural draft type depending upon site specific techno-economics. The design wet bulb temperature of the cooling tower shall correspond to the ambient wet bulb temperature which is not exceeded by more than 5% duration over one year period. Adequate recirculation allowance shall be considered for arriving at design wet bulb temperature for induced draft cooling tower. The relative humidity, to be adopted for design of natural draft cooling tower, shall be appropriately selected considering annual variation of relative humidity in combination with annual variation of wet bulb temperature.
ii)
35
iii) iv)
The design of CW system shall be based on model studies and hydraulic transient analysis. CW pumps shall be provided on unit basis for supply of cooling water. The standby pump (s) may be on unit basis or common to the Station. The CW pumps shall be normally of vertical wet pit type. However, concrete volute pumps may also be used particularly for sea water applications. Chemicals such as chlorine, acid, anti-scalant, biocide shall be dosed in the CW system for improving quality of circulating water and reducing its scaling and corrosive tendency.
v)
6.4.4 De-mineralisation System i) The capacity of de-mineralised (DM) Plant shall be based on the requirement of de-mineralised water for heat cycle make-up corresponding to 3% of BMCR, equipment cooling system make-up, regeneration of DM plant and condensate polishing plant, if envisaged. The DM plant shall be designed to produce the daily requirement of de-mineralised water of the Station in twenty (20) hours of operation of the DM plant. 3 x 50 % or 2x100% demineralising streams shall be provided. The demineralized water shall be stored in minimum 2 no. DM water storage tanks of total storage capacity equal to 24 hour Station requirement.
ii)
6.4.5 Waste Water Treatment System The waste water generated at various facilities will be segregated at the source of generation according to their type. Similar type of waste water shall be collected at one point and treated. The treated water shall be collected in central monitoring basin and recycled for plant use or disposed off to meet the requirements of state Pollution Control Board/MOEF. 6.5 i) Fire detection and Protection System: A comprehensive fire detection and protection system shall be provided for the Station. Fire protection system shall be designed as per the guidelines of Tariff Advisory Committee (TAC). Dedicated fire water storage and pumping facilities shall be provided for the fire fighting system. Hydrant system, complying with TAC guidelines, shall be provided at various locations to cover the entire Station.
ii) iii)
36
iv)
All major and minor fire risks in the Station such as transformers, cable galleries/shafts, fuel oil storage & handling, coal/lignite handling plant, coal/lignite conveyors/galleries, control rooms etc. should be protected against fire by suitable automatic fire protection systems. Automatic fire detection and alarm system shall be provided to facilitate detection of fire at the incipient stage and give warning to the fire fighting staff. Portable and mobile fire extinguishers shall be envisaged to extinguish fire in its early phase to prevent its spread. Fire station/fire tenders shall also be provided for the Station. Passive fire protection such as fire barriers, fire retardant coatings, penetrating sealing systems, fire proof doors etc. shall be envisaged to prevent spreading and containment of fire. Compressed Air System Compressed air system comprising of instrument air and service air shall be provided to cater to the requirement for operation of various pneumatically operated valves/dampers and general purpose cleaning & maintenance services. At least one no. service air compressor and two nos. instrument air compressors shall be provided as standby. Air dryers shall be provided for instrument air to achieve desired dryness. Ventilation & Air-conditioning System Suitable ventilation and air-conditioning system shall be provided to achieve proper working environment in the Station. Normally central control room, switchyard control room, local control rooms and service building for O&M personnel shall be air conditioned. Airconditioned areas shall be maintained at about 25 and 50 % relative C humidity for comfort conditions. Water chilling unit or condensing units shall have 100% standby equipment. Package type air-conditioners shall have 2x100% capacity or 3x50% capacity equipment. For window/ split air conditioners, if used for small control rooms, at least one unit shall be kept as standby.
v)
vi) vii) viii)
6.6 i)
ii)
6.7 i) ii)
iii)
The type of ventilation systems to be provided for non-air conditioned areas shall be as under:
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All floors of TG building, switchgear rooms and cable gallery: Other buildings 6.8 Mill Reject System
Evaporating cooling system Mechanical ventilation
The mill reject system shall be provided to collect reject from coal mills. The system shall be mechanized i.e. drag chain conveyor or pneumatically pressurized conveying system. The system shall consist of collection of rejects from each coal mill and transport to silos for final disposal. 6.9 i) Electric Overhead Travelling (EOT) Crane The EOT cranes shall be provided for maintenance and general station services of various TG cycle equipment. These shall comply with the requirements and standards of latest versions of relevant BIS / IEC. The category of cranes shall be M 5 as per IS 3177. Two identical capacity EOT cranes shall be installed in a T-G hall over operating floor. The crane capacity shall be taken as 10% more than the single heaviest equipment to be lifted. Workshop Equipment and Laboratories
ii)
6.10
6.10.1 Mechanical workshop equipment shall be provided for maintenance work and on-site repairs. The standard workshop equipment like centre lathe, universal milling machine, pedestal drilling machine, pedestal grinding machine, hacksaw machine, cutter, grinder, tool grinder, hydraulic press, oxy-acetylene cutter and welding, fitters, benches/ racks, miscellaneous measuring & cutting tools etc. shall normally be provided. 6.10.2 Station shall be provided with following laboratories: i) ii) Electrical laboratory with necessary equipment/instruments for testing and maintenance of electrical equipment. Control & Instrumentation laboratory with necessary equipment/ instruments for testing, calibration and maintenance of control & instrumentation systems. Chemical laboratory with necessary equipment/instruments/reagents for chemical analysis, steam & water analysis and coal/ash/flue gas analysis.
iii)
38
7.0
CIVIL WORKS Civil aspects are site specific and depend upon topographical, geo-technical and other studies. The design philosophy needs to be based on technoeconomics of various alternatives of the construction techniques.
7.1
Geotechnical Investigations Geo-technical investigations are required for elastic assessment of foundation geology and needs to be carried out during investigation stage prior to taking up construction activity. The geotechnical investigations shall include determination of the sub soil type, ground water table etc. Based on above, the type of foundation system, the bearing capacity, the pile parameters, requirement of soil stabilization/ compaction etc., shall be established.
7.2
Site Levelling: The formation level of the Station shall be kept minimum 1.0 m above the High Flood Level (HFL) of the site. It is preferable to keep the entire Station at the same level. However, to keep the leveling cost to minimum, different levels may be adopted for various blocks. The optimization of excavation and filling quantities may be done while fixing the levels of different blocks. The whole area of plant should not be raised at the initial stage itself to avoid double handling of the earth work.
7.3
Foundations: Open foundations or pile foundations or a combination of two keeping in view the lightly/heavily loaded foundations may be suitably adopted. In certain cases, ground improvement/stabilization methods may also be considered. The foundations for turbines, boiler feed pumps and other rotating equipment shall be suitably designed and the amplitude of vibrations shall be within the limits recommended by the equipment supplier. To optimize the foundation system of rotating equipment, 3-D finite element analysis may be carried out. Following loads shall be considered for the design of foundations: a) b) c) d) Weight of equipment Load of other accessories Dead load of foundation structure Vacuum load
39
e) f) g) h) i) j) k) l) 7.4
Un balance forces Loss of blade force Short circuit force Temperature forces Torque loads Frictional and other longitudinal forces Live loads Wind and Siesmic Loads
TG and other buildings: All buildings shall be designed as RCC or steel framed super structures with masonry or steel cladding. TG building shall have structural steel framework for super structure with metal cladding on exterior face. Other buildings may have RCC or steel framework with masonry cladding of minimum one masonry unit thickness on exterior face. The design of steel structures shall be as per provisions of BIS.800 and other relevant standards. Considering the size, loadings and requirements of construction schedule, composite construction with steel supporting structures and RCC floors is preferred for the TG and other buildings.
7.5
Structure System: TG building shall preferably be moment resisting structures in transverse direction and braced in longitudinal direction. Mill and bunker building shall be provided with moment resisting frame having adequate bracings in the transverse direction and braced in longitudinal direction. The structures shall be designed considering worst load combination of dead loads, super imposed dead loads, imposed loads, earthquake loads, wind loads etc. The superimposed dead loads shall include the loads due to equipment and associated auxiliaries and accessories, duct loads as well as crane loads with impact etc. Seismic forces shall be considered as per site specific seismic parameters.
7.6
Architectural Requirements: Over all architectural character of Station building should be in harmony with natural character of environment, climatic conditions and local landscape. Interior design should be given due consideration. The finishing works shall meet the requirements of aesthetics, durability and functional aspects. Adequate glazing shall be provided for natural light. Adequate ventilation shall be provided in all the buildings.
40
7.7
Chimney: Chimney may be single flue unitized or multiflue for two or more units. The height of chimney shall be decided based on MOE&F guidelines and shall also be got cleared by Airport Authority of India. The size of liner shall be decided based on the exit velocity and temperature of flue gases. Chimney windshield shall be of RCC construction. The flue liners shall be of structural steel or brick construction provided with suitable thermal insulation. The portion of liner above chimney shall be of acid resisting bricks protected by RCC minishell. Internal platform and internal ladder shall be provided with the chimney. The top external portion of windshield shall be provided with alternate bands of red and white colours to meet aviation safety. Chimney shall be provided with liner test port for continuous emission monitoring, lightning protection and grounding system, aviation obstruction lighting and an elevator. Wind tunnel testing for chimney shall be carried out to optimize the design. The windshield shall be designed for vertical loading, wind loading, cross wind loading, seismic loading, circumferential wind loading and thermal gradients across the shell.
7.8
Corrosion Protection Suitable measures shall be provided against corrosion for Stations located in coastal areas. Use of special cements, corrosion resistant steel, protective coatings to both concrete and steel are some of the options which can be explored in such conditions. Steel structures may be provided with epoxy or polyurethane based painting systems designed for minimum maintenance free life of ten (10 ) years.
7.9
Roads and drainage: The entire area within the Station boundary should be well connected with network of roads. The drains in the Station area shall be designed for maximum rainfall intensity of 50 years frequency.
7.10
Safety Provisions The safety provisions shall be in conformity with the provisions laid down by National Building Code and other international codes.
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PART-C: 1.0 1.1 1.2 1.3 1.4
GAS TURBINE BASED THERMAL GENERATING STATIONS
OPERATING CAPABILITIES OF THE GAS TURBINE/ COMBINED CYCLE GAS TURBINE (CCGT) MODULE The gas turbine/ CCGT module shall give its MCR output at the specified site conditions and the design fuel. The gas turbine and steam turbine shall be capable of base load operation. However, these shall also be capable of two-shift operation and load cycling. The gas turbine, steam turbine and all rotating auxiliaries shall be suitable for continuous operation within the frequency range of 47.5 Hz to 51.5 Hz. The design of the equipment and control system shall be suitable for operation of the gas turbine / CCGT module in automatic load frequency control. Gas turbine rating (ISO) upto 100 MW shall be provided with black start capability. CCGT module with gas turbine rating (ISO) upto 100 MW shall be provided with facility for simple cycle mode of operation. Design of the gas turbine / CCGT module shall be so optimised as to obtain maximum possible efficiency. The gross heat rate as guaranteed by the equipment manufacturer shall not exceed the following values: (A) Operation in combined cycle mode
Gross Heat Rate (HHV basis) in kcal/kWh at ISO conditions with natural gas as fuel at 100% load Gas Turbine rating (ISO )
1.5 1.6 1.7
20 MW to 30 MW > 30 to200 MW > 200MW (B) Operation in simple cycle mode
2250 1825 1700
Gas Turbine rating (ISO)
Gross Heat Rate (HHV basis) in kcal/kWh at ISO conditions with natural gas as fuel at 100% load
20 to 30 MW > 30 to 200 MW >200 MW
3400 2850 2600
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2.0 2.1 2.2
GAS TURBINE AND AUXILIARIES The gas turbine and auxiliaries shall comply with latest versions of applicable ISO/ASME codes. The gas turbine compressor shall have a stable aerodynamic characteristic throughout its operating regime. The operating point in the entire frequency range of 47.5 51.5 Hz shall be sufficiently away from surge line so that it is stable at all conditions of load, ambient temperature and blade fouling. The compressor shall be provided with variable type inlet guide vanes to meet start up/ shutdown requirements, improved part load performance in combined cycle mode of operation and exhaust gas temperature control over a wide range. Combustion chamber arrangement shall be such as to allow maintenance without dismantling of compressor or turbine section and with minimum dismantling of piping / electrical connections. NOx control shall be either through dry low NOx combustor or through steam/water injection and shall be able to achieve the desired NOx level. Combustion system shall be provided with flame detection system for monitoring and protection. Gas turbine shall be provided with self contained lubrication oil system and control oil system with adequate redundancy for pumps and coolers. Gas turbine shall be provided with an air intake filtration system along with on line cleaning system to deliver filtered air of quality acceptable to the gas turbine. Gas turbine generating unit shall be controlled by an electro-hydraulic governing system with 100% back up. All necessary protective devices required for safe operation shall be provided. Further, control system of the gas turbines shall include necessary features to check healthiness of protective devices. The gas turbine shall be capable of withstanding momentary speed rises to the over-speed trip limit under transient conditions. For gas turbines operating on naphtha, mandatory purging/ flushing of liquid fuel delivery system (downstream of injection pump) shall be provided to ensure safety of the plant and personnel. A less combustible/ volatile liquid fuel (distillate 2 or HSD) shall be used during start-up and shutdown. Gas turbines envisaged for dual fuel operation (natural gas as primary fuel and liquid fuel as back-up fuel) shall be capable of on load fuel changeover 43
2.3
2.4
2.5 2.6 2.7 2.8
2.9
2.10 2.11
2.12
from natural gas to liquid fuel automatically (on loss of gas pressure) and from liquid fuel to natural gas on manual initiation. 2.13 All piping, valves and fittings downstream of liquid fuel delivery system and NOx water injection system shall be made of stainless steel of suitable grade to prevent corrosion and entry of rust into the combustion chamber and maloperation of stop/control valves. Each gas turbine shall be provided with on-line fuel flow metering device to monitor fuel consumption. Gaseous Fuel Conditioning System Fuel gas conditioning system of the plant shall be designed to provide required quantity of clean, dry gas at required pressure, temperature and quality suitable for the gas turbine. The temperature of the gas delivered to the gas turbine shall be at least 200C higher than hydrate forming temperature or gas dew point whichever is higher. A chromatograph and analyzer shall be provided for determining the composition and heating value of the fuel gas. Design of fuel gas system shall be as per the provisions of the latest editions of ANSI B31.1/ B31.3 and ANSI B 31.8. The gas leak detection and protection system shall necessarily be provided in enclosed areas. Liquid Fuel Storage and Conditioning System Liquid fuel storage capacity shall be provided corresponding to 15 days requirement, if liquid fuel is used as a primary fuel. Liquid fuel conditioning system shall be designed to provide required quality suitable for the gas turbine. Liquid fuel storage area shall be at least 90 meters away from the gas turbine. Liquid fuel unloading, storage and forwarding system shall be designed to comply with all applicable statutory requirements.
2.14 2.15 i)
ii)
iii) iv) v) 2.16 i) ii) iii) iv)
44
3.0 3.1
HEAT RECOVERY STEAM GENERATOR (HRSG) AND AUXILIARIES Gas turbine exhaust plenum shall be designed for proper gas velocity and temperature distribution and effective pressure recovery. The exhaust system design shall take into account very rapid start-up and shutdown rate of the gas turbine. Arrangement for mandatory purging of gas turbine exhaust system and HRSG shall be provided in order to eliminate chances of explosion (puffing) for combined cycle plants envisaged for operation on liquid fuel during. The design of HRSG shall be based on finned tube heat transfer banks of superheaters, evaporators, economisers etc. The fin density shall not be higher than 200fins/ m. The design of HRSG shall be suitable for direct on line starting along with the gas turbine. The HRSG shall be designed for single pressure/two pressure/three pressure steam generation based on gas turbine rating and techno-economics. In the event of loss of feed water, it shall be possible to continue HRSG operation for a short duration till the gas turbine is tripped and coasted down or mode of operation of gas turbine is changed to simple cycle. HRSG shall be suitable for outdoor installation and shall be constructed to form a gas tight envelope to prevent gas leakage. HRSG shall meet IBR requirements. The gas temperature at HRSG exit, condensate temperature entering condensate pre-heater and feed water temperature entering economiser shall be such as to avoid acid dew point corrosion. STEAM TURBINE & AUXILIARIES Steam turbine shall be single or multi pressure, condensing, single/multi cylinder type complying with IEC-45 or equivalent. Steam turbine of rating more than 200 MW may be of reheat type. Other requirements stipulated for coal/lignite based thermal generating stations in Part-B shall be complied with as applicable.
3.2
3.3
3.4 3.5 3.6
3.7 3.8 3.9
4.0
5.0
ELECTRICAL SYSTEM Electrical Systems shall generally meet the requirements stipulated for coal/lignite based thermal generating stations in Part-B, as applicable.
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6.0
CONTROL & INSTRUMENTATION SYSTEM Control and Instrumentation Systems shall generally meet the requirements stipulated for coal/lignite based thermal generating stations in Part-B, as applicable.
7.0
STATION WATER SYSTEM Station water system which includes clarified water system, cooling water system, de-mineralisation system, waste water treatment system, shall meet the requirements as stipulated in Part-B.
8.0
FIRE DETECTION AND PROTECTION SYSTEM Fire detection and Protection System shall meet the requirements as stipulated for coal/lignite based thermal generating stations in Part-B.
9.0
CIVIL WORKS Civil works shall meet the requirements as stipulated for coal/lignite based thermal generating stations in Part-B. However, stack shall be of steel construction and its height shall meet the requirements of MOE&F.
46
PART-D: DIESEL ENGINE BASED THERMAL GENERATING STATIONS 1.0 1.1 1.2 1.3 1.4 OPERATING CAPABILITIES OF DIESEL GENERATING (DG) SETS The DG sets shall be capable of base load operation. However, these shall also be capable of two-shift operation and load cycling. The Diesel engine and all rotating auxiliaries shall be suitable for continuous operation within the frequency range of 47.5 Hz to 51.5 Hz. The design of the equipment and control system shall be suitable for operation of the DG set in automatic load frequency control. The DG set shall be a self contained unit and skid mounted. These shall be suitable for indoor installations either on pads or on reinforced concrete foundations. All the facilities required for receiving and feeding the inputs such as fuel, lubricants, water, air etc. including control panel and synchronizing panel shall be provided. The DG set shall have auto start, auto loading, auto stop features and capable of parallel operation in the power distribution system. Design of the DG set shall be so optimised as to obtain maximum possible efficiency. The gross heat rate as guaranteed by the manufacturer shall not exceed the following values. Diesel Engine Generators ( Four stroke) DG set rating 100 kW to 1 MW >1 MW to 3 MW > 3 MW to 10 MW >10 MW Gross Heat Rate (on HHV) in kcal/kWh at 100% load 2350 2250 2100 2000
1.5 1.6
Diesel Engine Generators (Two stroke) DG set rating 3 MW to 10 MW > 10 MW Gross Heat Rate (on HHV) in kcal/kWh at 100% load 2000 1950
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2.0 2.1 2.2
DIESEL ENGINE AND AUXILIARIES The Diesel engine and auxiliaries shall comply with latest versions of applicable IS/ ISO/BS or equivalent codes. Turbo charger, if applicable, shall be of robust construction, suitable of being driven by engine exhaust. It shall draw air through air filter and have adequate capacity to suit engine requirements. The engine shall be capable of satisfactorily driving the generator at 10% over load at rated speed for one hour in any period of 12 hours of continuous running. The Diesel engine shall be provided with suitable self-starting device The Diesel engine shall be provided with an air intake filtration system to deliver filtered air of quality suitable for diesel engine. An engine driven booster pump shall be provided to deliver the fuel oil from the supply tank through the filters. In addition an AC motor driven fuel oil priming pump shall be provided to keep the high-pressure system primed for remote and quick starting at any instant. The DG sets shall be cooled by engine mounted radiators/remote radiators using closed cycle cooling system. In case of remote radiators, low speed axial fans shall be provided to keep the noise level well within acceptable limits. Diesel engine shall be provided with micro-processor based control system. The governor shall be electronic type of class A-2 as per BS : 5514. An over speed trip mechanism shall be provided to automatically shut off fuel in case the set reaches above 10% of rated speed. An engine mounted emergency stop push button shall be provided to stop the engine during emergencies. Diesel engine shall be provided with self contained lubricating oil system. Crankcase gases shall be piped outside the engine room so that oil fumes don't accumulate on the engine/ radiator. The Diesel engine shall be furnished with efficient exhaust silencers complete with interconnecting pipes and fittings expansion bellows, chimney etc. NOx level, stack height and noise level shall comply with the guidelines laid down by MOE&F/ State Pollution Control Board.
2.3
2.4 2.5 2.6
2.7
2.8
2. 9 2.10 2.11
2.12
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2.13 i) ii) iii) iv) 2.14 2.15
Liquid Fuel Storage and Conditioning System Liquid fuel storage capacity shall be provided corresponding to 15 days requirement. Liquid fuel conditioning system shall be designed to provide required quality suitable for the Diesel engine. Liquid fuel unloading, storage and forwarding system shall be designed to comply with all applicable statutory requirements. Each diesel engine shall be provided with on-line fuel flow metering device to monitor fuel consumption. Electrical requirements stipulated in Part- B shall be complied with for switchgear, transformers, cables, protections etc. as applicable. Suitable fire detection and fighting system shall be provided for the DG set.
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SCHEDULE II TECHNICAL STANDARDS FOR HYDRO- ELECTRIC GENERATING STATIONS

1.0 This Schedule describes the minimum technical requirements for construction of Hydro- Electric Generating Stations on various types of schemes i.e Run-of-river scheme, Storage scheme, Pumped storage scheme, Canal head schemes etc. with installed capacity of 25 MW and above. For hydro-electric generating Stations having installed capacity less then 25 MW, the stipulation as appropriate, shall apply. GENERAL REQUIREMENTS The salient features of the project, installed capacity, unit size, project siting and layout, power evacuation arrangement, etc shall be decided considering the best engineering practices and optimum utilisation of resources. The Generating Station shall be complete with all infrastructure works, civil works, hydraulic works and electromechanical works. All the equipment and systems required for safe, reliable and prudent construction, operation and maintenance of the Station shall be included. Additional equipment and systems, as required, for the multi-purpose schemes/projects shall be provided. The life of the civil structures shall not be less than one hundred (100) years, while that of equipments supplied shall not be less than thirty five (35) years. The Station shall be designed for unconstrained operation over maximum net head and minimum net head, specified silt conditions wherever applicable, and full range of ambient and other environmental conditions. The dimensions of the power house, turbine settings, speed rise, pressure rise, run-away speed, etc. shall be governed by the limits specified in relevant BIS. The chemical analysis of water and silt data including the petrographic analysis shall be considered while designing the turbine, spherical valve and other auxiliary equipment susceptible to abrasive effects of silt. All necessary specific provisions such as selection of materials, protective coatings and paintings shall be made to resist silt abrasion.
2.0 2.1
2.2
2.3 2.4
2.5
2.6
50
2.7
The generating units shall also be designed and constructed to operate in synchronous condenser mode for operational flexibility, as per the requirements of system. The operation of the unit shall be smooth and quiet. The noise level shall not be more than 90 dB at a distance of 1 meter from any equipment. The areas where a potential corrosive or flammable atmosphere exists shall be classified in accordance with the provisions of the internationally recognised standards. Suitably certified equipment shall be used in the designated hazardous areas where a potential corrosive or flammable atmosphere exists. The various equipments including the electrical equipment requiring operator attention shall not be installed in hazardous areas as far as practicable. LAYOUT CONSIDERATIONS: General layout of the Station shall be developed considering space optimization, functional requirements, future extensions (if envisaged) and provision of space requirements during construction stage. The layout of the Station shall be compact so as to economise the use of materials. Adequate maintenance facilities shall be provided as required, for assembly, disassembly, handling during maintenance of all important equipments and auxiliaries. Adequate fire escape staircases / galleries shall be provided in main Station building/Cavern. Each equipment room shall be provided with alternate exits in case of fire / accidents as per requirements of factory act and other statutory requirements. The dimensioning and layout of the Station shall be as per BIS 12800, BIS 5496 and other relevant standards. OPERATING CAPABILITY OF THE GENERATING UNIT The unit shall be capable of giving the rated output continuously guaranteed by the manufacturer at the rated design head and rated discharge without any restriction over the complete range of operating conditions and ambient temperature at site as specified. The maximum continuous overload capacity of the unit at the generator terminals during the high head conditions or high discharge conditions or both as guaranteed by the manufacturer shall be based on hydraulic parameters of the Station but shall normally not be more than 10% above the rated output of machine.
2.8 2.9
3.0 3.1
3.2
3.3
3.4 4.0 4.1
4.2
51
4.3
The unit and all the associated auxiliaries shall be suitable for continuous operation without any restriction within a frequency range of 5% to +3% (47.5 Hz to 51.5 Hz). All the equipment driven by the electric motors shall give their rated performance even at a power supply frequency of 47.5 Hz. The design shall incorporate adequate provision for auto start upto sunchronisation by single command. and loading of the unit to full load quickly. The design of the equipments and control system shall permit participation of the unit in automatic frequency control mode. The unit and all its associated auxiliaries shall be designed for trouble free operation upto maximum rating of the unit for the complete range of operation. The unit and its auxiliaries shall be designed to operate satisfactorily for the periods during which high silt content in the river water is observed. Adequate margins and redundancies shall be provided in unit auxiliaries and station equipment so that the generating unit continues to operate even in the event of outage of a part of the auxiliary system. HYDRAULIC TURBINES AND AUXILIARIES The hydraulic turbine shall comply with of latest versions relevant BIS / IEC or other equivalent standards. Turbine shall have smooth and quiet operation. The vibrations, pressure pulsations and power fluctuations shall be minimum. The amplitude of the vibrations at the shaft shall not exceed the limits specified in ISO-7919 and ISO-3945. The type and rotational speed of the turbine shall be selected based on range of head, specific speed, head variation etc. In case two different types of turbines are found suitable for the range of head envisaged (overlapping zone of net head) at a particular site, the selection of turbine shall be based on the techno economic considerations taking into account the aspects like head variation, civil costs, part load operation, operation & maintenance, efficiency etc. The rated speed resulting in even number of pair of poles shall be preferred. In case of high silt content, at least one step lower synchronous speed shall be selected. Before the manufacture of the prototype turbine is taken up, homologous scale model of the prototype turbine shall be made if not already available
4.4
4.5
4.6 4.7
5.0 5.1 5.2
5.3
5.4
5.5
52
and tested to demonstrate that the prototype turbine will meet the guaranteed performance in respect of efficiency, output, smooth operation, pressure pulsations, and other guarantees as stipulated in the specifications. 5.6 The weighted average efficiency shall be computed based on the efficiencies at various outputs. The weightage factors shall be selected corresponding to the average duration or period (in percentage) in a year, for which the units are expected to be operated at a particular output. The weighted average efficiency obtainable shall not be less than 94% for Francis, Kaplan & Bulb turbines and 92% for Pelton, Deriaz & Propeller turbines. The weighted average efficiency of the turbine shall be determined after the installation and commissioning of the generating units on the basis of field acceptance tests as per IEC 41 on one of the units. 5.7 The minimum load for continuous operation for various types of turbines, except for operation in spinning reserve mode, shall be as under: Type of turbine Pelton/Kaplan / Bulb Deriaz Francis Propeller 5.8 Minimum load for continuous operation (percent) 30 40 50 85
The pressure rise and speed rise of turbine shall be within the range specified by BIS. For a unit, which is one of the several units on a common penstock header system, the permissible percentage of speed rise shall be computed on the basis of one unit operating alone. The turbine shall be designed to withstand runaway speed of 1.8 times the rated speed for 30 minutes without causing any residual detrimental affect on future operation of the machine. However, critical speed of the machine shall be around 25% higher than maximum runaway speed. Provision of runner removal from bottom for maintenance shall be made, where ever feasible. The setting of reaction turbine, i.e. centreline of runner, with reference to minimum tail water level shall be governed by cavitation considerations. Based on the calculations, the centerline of the runner may work out to be either above or below the minimum tail water level. Pelton turbine shall be installed at a height of minimum 3 m above the maximum tail water level or as per the recommendation of maufacturer.
5.9
5.10 5.11
53
5.12
Special care shall be taken to select the material of the under water parts. The materials selected for runner, guide vanes, etc. shall have high hardness, strength and toughness as well as have high wear resistance, corrosion and cavitation resistance. Besides, the material shall have good weldability so that parts can be fabricated and the eroded parts can be repaired easily at site. As most of the rivers in the Himalayan region carry high silt which erodes the runner and under water parts of the turbine at a faster rate, appropriate protective coatings shall be provided for these parts of the turbine in order to minimize silt erosion wherever necessary. The guide-vanes, runner, discharge ring and other hydraulic passage shall be designed for a life of 8000 hours against excessive pitting caused by cavitations. In case of power failure of pump turbines/ reversible turbines, maximum torque shall occur upon flow reversal followed by speed reversal. Although this torque is transient and can be reduced for a pump turbine with a governor by closing the wicked gates, this torque should be considered in the design of shaft and couplings. Since in case of pump turbine, substantially more submergence is required for pump operation than for turbine operation, the submergence for pumping operation shall be adequate for turbine operation as well. GOVERNING SYSTEM Microprocessor based digital governing system shall be used for regulating the flow of water to the turbines for the control of active power(MW) thus providing the requisite speed/frequency control and load control. The speed sensing device shall be redundant. The performance requirements of the governing system shall be governed by IEC 61362. High pressure oil system shall be provided for each turbine for the operation of wicket gates/nozzle/deflector servomotors through governors and for the control of main inlet valve (MIV). Piston type accumulator with nitrogen bottles shall be used for pressures higher than 60 kg / cm2. A separate pressure oil system shall preferably be used for the control of turbines and that for control of the MIVs. The sizes of various components of oil sump tank and pressure receiver shall be calculated as per the relevant IS / IEEE.
5.13
5.14
5.15
5.16
6.0 6.1
6.2
6.3 6.4
54
7.0 7.1 7.2 7.3 7.4
SPHERICAL VALVE AND BUTTERFLY VALVE The spherical valve and butterfly valve shall comply with the requirements and standards of latest versions of relevant BIS / IEC. The spherical valve shall be provided for safe emergency closure in case of turbine going to runaway speed. The valves shall have both service seal on downstream side as well as maintenance seal on upstream side. The opening and closing of butterfly valves shall normally be done under balanced water condition. Suitable number of air release valves shall be provided at the appropriate location on the downstream side to allow the air trapped in the penstock to escape when it is filled with water through the bypass valve and for supplying / admitting the air when the valve is suddenly closed. MECHANICAL AUXILIARIES Electric Overhead Travelling (EOT) Cranes
8.0 8.1
8.1.1 The EOT cranes shall comply with the requirements and standards of latest versions of relevant BIS / IEC. The category of cranes shall be M 5 as per IS 3177. The span of the crane shall be fixed in such a way that the travel and lift of the main and auxiliary crane hooks of the crane as well as the hook limits shall be adequate for the assembly and disassembly of the main equipment in the power house. The lift above the service bay (upper limit) shall be adequate to hoist & carry the rotor of the generator and to assemble the transformer. The lift below the service bay (lower limit) shall be fixed in such a way as necessary for assembly and disassembly of the turbine. 8.1.2 The hook capacity shall be taken as 10% more than the maximum weight to be lifted inclusive of the weight of the lifting beam, in case it is provided. If the maximum weight to be lifted is more than around 300 T, two cranes each of equal capacity shall be deployed to lift the heaviest package in tandem operation. 8.1.3 The provision of radio remote control and variable voltage variable frequency (VVVF) drive for various crane motions for the purpose of precision speed control shall normally be made for cranes having capacity 100T and above. 8.1.4 The radio remote control equipment, wherever provided shall conform to all applicable Government rules and regulations. The frequency of operation shall be in the requisite frequency band as per relevant standards.
55
8.2
Cooling Water System
8.2.1 The cooling water requirements of generator air coolers, shaft seal, turbine and generator bearings of each unit and generator transformer shall be met through either by providing pumping the water drawn from the tail pool / draft tube water pumping or providing a penstock tapping for the same. The penstock tapping in case of high head installations i.e. where the penstock pressure is more than 10 kgf/cm2 shall not be provided. If the penstock tapping results in a pressure of upto 10 kgf/cm2, a suitable pressure reducer depending on the requirement of net cooling water pressure (usually 3 to 5 kgf/cm2) may be provided. 8.2.2 In the projects where rivers have silt laden water, closed circuit cooling water system shall be provided. 8.3 8..1 Dewatering & Drainage System The water trapped between the penstock gate/main inlet valve and draft tube gate in case of Francis and Kaplan turbines shall be drained out to the dewatering sump when maintenance on the turbine of any unit is required to be carried out. Suitable dewatering submersible pumps shall be provided to pump out this water to the tail race. The capacity of the pump shall be chosen in such a way that a single unit can be dewatered within 8 hours operation without raising the level in the sump. All the drainage water within the power house shall be collected inside the drainage sump constructed near the dewatering sump. The drainage water shall be pumped out to the tail race. The drainage and dewatering sumps shall be inter-connected by means of gate valve and non return valve which allows the flow of water from drainage sump to dewatering sump only. The spindle of gate valve shall be extended up to turbine floor so that it is possible to operate it from turbine floor. A suitable pressure hatch shall be provided to prevent any flow of water from dewatering sump into the power house. Drainage sump shall not have any pressure hatch. The control panels for dewatering & drainage pumps shall be located at a floor higher than that of turbine floor. Ventilation & Air-Conditioning System
8..2
8..3
8..4
8..5 8.4
8.4.1 A ventilation and air-conditioning system shall be provided to achieve proper working conditions inside the power house complex, to serve the purposes like prevention of temperature stratification, removal of contaminated air,
56
removal of waste heat from equipment as well as provide fresh air necessary for human comfort with regard to temperature, humidity & oxygen content, and to extract/force out smoke and other toxic gases during fire. 8.4.2 Suitable system for circulation of natural air and exhaust shall be provided as a minimum requirement. Cooling of air wherever required may be provided by evaporating, water cooled cooling tubes or chiller units. 8.4.3 Normally control room, relay room, PLCC room, offices, reception, conference room, etc. are recommended to be air-conditioned. The conditioned air shall be around 250 C at around 50% relative humidity for comfort conditions. A choice of installation out of 3 different types of installations i.e. window type, package type or centralized air conditioning plants shall be made on the basis of the required tonnage and suitability of the installation at that particular location. 8.5 HP and LP Compressed Air System
8.5.1 The high pressure (HP) compressed air system shall be provided to meet the compressed air requirement of turbine governing system and MIV. The pressure of HP air compressor shall be 1.1 times the governor working pressure. 8.5.2 Low-pressure (LP) compressed air system shall generally be rated at 7.0 kg/cm2 to meet requirements like inflatable rubber seal of shaft glands, operation of pneumatic tools, cleaning, generator braking and jacking, boosting pressure in the fire protection hydro-pneumatic tank, pneumatic detection line for the operation of deluge valve provided for the generator transformer, etc. 8.6 Power House Lift The lift and its associated equipment shall comply with the requirements and standards of latest versions of IS 14665 & other relevant standards. Minimum one lift shall be provided in the power house besides two sets of staircases for the movement of persons/goods. A lift having a capacity of 816 passengers shall be provided. 8.7 Oil Handling and Purification System
8.7.1 The insulating oil required in the generator transformers for the hydro Station shall conform to IS: 335. The type of turbine oil used as a working fluid in speed regulation system and as a lubricant and a coolant for thrust and guide bearings shall be normally ISO VG-68 conforming to IS: 1012.
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8.7.2 The oil handling system for each grade of oil shall incorporate two tanks (one for pure oil and another for used oil), associated piping and control equipment. 8.7.3 The oil handling facilities shall be located within the power house or in an isolated building outdoors. To convey the oil to the generators and transformers, suitable oil pipes shall be laid within the power house. The portable type pumps & purifiers and standard oil drums shall be used For small hydro-electric stations, 8.8 8.8.1 Fire Fighting System General i) A comprehensive fire detection and protection system shall be provided for the Station. The fire protection system as well as hydrant system shall be designed complying with the guidelines of Tariff Advisory Committee (TAC) and approved by the accredited agencies of Tariff Advisory Committee (TAC). All major and minor fire risks in the Station such as transformers, cable galleries/shafts, control rooms etc. shall be protected against the fire by suitable automatic fire protection systems. The state of art automatic fire detection and alarm system shall be provided to facilitate detection of fire at the incipient stage and giving warning to fire fighting staff. Portable and mobile fire extinguishers shall be provided to extinguish the fire in the initial stage to prevent its spread.
ii)
iii)
8.8.2 The provision shall be made for emulsifier protection for oil filled transformers and water sprinkler system for oil plant rooms, specially in an underground power houses. In addition, the provision shall also be made for fire hose cabinets/hydrants for power house indoor as well as transformer floor. The capacity of overhead / pressurised water tank shall be adequate to meet the emulsifier water requirement for one generator transformer for 40 minutes, plus operation of one hydrant for 60 minutes. Two nos. of fire pumps, each capable of pumping water to fill the overhead / pressurised water tank in reasonable time shall be provided. 8.9 Equipment for Mechanical Workshop Mechanical workshop equipment shall be provided for essential maintenance work and on-site repairs. The standard workshop equipment like Centre Lathe, Universal Milling Machine, Pedestal Drilling Machine, Pedestal Grinding Machine, Hacksaw Machine, Fitters, Benches / Racks, miscellaneous measuring & cutting tools, etc. shall normally be provided.
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9.0 9.1
ELECTRICAL SYSTEM General Requirements
9.1.1 For the purpose of design of equipment/systems, an ambient temperature of 40 deg. centigrade or higher as applicable to Station site and relative humidity of 95% shall be considered. However, for equipment in air conditioned areas, design ambient temperature shall be 35 deg.C. 9.1.2 All equipments shall be suitable for rated frequency of 50Hz with a variation of -5% and +3%. The overall system shall be designed considering maximum voltage variation and combined variation of voltage and frequency as specified in grid connectivity standards. 9.1.3 The Owner shall install and maintain all the necessary communication equipment to transmit the required data of the Power Station to the procurer of electricity, Regional/State Load Despatch Centre and Transmission Company. 9.2 9.2.1 9.2.1.1 9.2.1.2 Generator / Generator-Motor General The generator shall comply with the general requirements and the latest versions of IS: 4722 / IEC:60034 or other equivalent or better standards. Insulation shall be of thermal class F for the stator and the rotor windings with temperature rises limited to that of thermal Class B as per IEC 60034. The generators shall be capable to safely with stand maximum stresses during normal operation, run-away speed conditions, two phase and three phase short circuit conditions, single phase earth fault, 180 deg and 120 deg out of phase synchronization, magnetic unbalance with 50% of the poles short circuited within the speed range of 1.3 times the rated speed, brake application, etc. The construction of the generator shall be such that the rotor poles and stator coils can be handled out or in without removal of the rotor and without disturbing the upper bearing bracket. The rotor poles shall be interchangeable. In case of pump storage plants, the generator-motor shall be specified with an additional motor shaft output corresponding to the pump input at minimum rated head and the pump overload capacity at minimum head.
9.2.1.3
9.2.1.4
9.2.1.5
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9.2.1.6
The generator rated speed shall match the rated speed of the turbine or the pump-turbine. A rated speed resulting in even number of pair of poles shall be normally preferred. The current flowing in stator slot shall be limited to 3000-6000 Amperes with current through individual coil being limited to approximately 3000 Amperes to optimize the generator cost. The power factor and the requirements of reactive power capability shall be specified as per requirement of grid connectivity standards. Lightening Arrestors of suitable rating shall be provided for surge protection of generators.
9.2.1.7
9.2.1.8 9.2.1.9
9.2.1.10 Resistance temperature detectors (RTD) / thermocouples or any other type of temperature sensors at suitable locations for temperature monitoring of stator core, stator winding and bearings shall be provided. Suitable arrangement for rotor winding temperature monitoring shall also be provided. 9.2.1.11 The inertia of the machine shall be adequate to meet the transient stability requirements imposed by the interconnected electrical power system, to limit speed rise and shall have such a value which will not cause the machine natural frequency to be in resonance with the expected frequency of draft-tube hydraulic surges. A margin of approx. 25% shall be provided. 9.2.1.12 Weighted average efficiency based on the computed efficiencies at various outputs for which the generator is expected to operate shall be more than 98%. 9.2.2 9.2.2.1 Bearing Arrangements Combined thrust &upper guide bearing mounted on a top bearing bracket above the rotor and lower guide bearing below the rotor shall generally be used for small diameter, long core, high speed machines. As regards the medium to high capacity machines having low speed combined thrust & guide bearing mounted on a separate bearing bracket located below the rotor and an upper guide bearing installed above the rotor on a separate, light-weight bracket mounted on the top of the stator frame. However, the arrangement of combined thrust & guide bearing mounted on a separate bearing bracket located below the rotor shall be used for low to medium capacity machines having low speed.
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9.2.2.2
The horizontal mounted hydro-electric machines shall be provided with the journal type bearings. The number of journal bearings shall vary depending upon the machine output, speed, diameter, core length, etc. The limiting temperature of the thrust bearing metal on large hydro-electric machines shall be 80 C. The guide bearing temperature limit shall be specified as 70 C. Fire Protection System for Generator Either water based or CO2 type of fire suppression system shall be specified. The water based system shall be adopted in underground power stations because release of CO2 gas in underground installation will be hazardous.
9.2.2.3
9.2.3
9.2.4 9.2.4.1
Generator Busduct The generator busduct shall comply with the general requirements and the standards of latest versions of BIS:8084 / relevant IEC. Generator busduct shall be segregated or isolated phase type. Busduct rated more than 3150 Amps. shall be isolated phase type. The isolated phase ducts shall be preferred over the segregated phase bus ducts. Generator Busduct rated more than 6000 A shall be continuous isolated phase type. A hot air blowing system or air pressurization system shall be provided to prevent moisture deposition in case of isolated phase ducts while space heaters may be provided in case of other busducts. The busduct shall be designed to carry maximum continuous current under normal site conditions without exceeding temperature rise limits. Based on these requirements standard size of busduct as per BIS shall be used. The bus assembly shall be designed mechanically to withstand a rated continuous current as well as the specified shortcircuit current without injury or permanent deformation of any part of the bus structure. The lightening arrestor and voltage transformer (LAVT) cubicle shall meet the requirements of relevant BIS / IEC. Neutral Grounding Terminal Equipment Neutral grounding equipment shall be designed duly taking into account the maximum permissible operating voltage of the generator, voltage rise on load throw off (subsequent to detection of earth fault) field suppression time, ferro-resonance, etc. System earthing shall
9.2.4.2
9.2.4.3
9.2.4.4 9.2.5 9.2.5.1
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be such that it shall be possible to provide earth fault protection with proper discrimination. 9.2.5.2 All large hydro-electric machines having a wye-connected stator winding with the neutral brought out of the machine housing shall be grounded via a high-resistance circuit consisting of a single-phase distribution type transformer connected between the generator neutral and ground having a approximately equal to 1.5 times the maximum machine phase-to-ground terminal voltage rating. A resistor shall be connected across the secondary terminals of the distribution transformer. Instrument Transformers The current transformers shall preferably be of single phase window type fitted around the bus conductors for meeting the protection & measuring requirements. The voltage transformers shall be located in separate cubicle for each of the three phases & mounted in withdrawable drawers. The surge diverters and/or the surge capacitors shall be provided in the same cubicle as that of the voltage transformers with suitable barriers. Continuous On Line Machine Condition Monitoring Systems The following monitoring equipments/systems for prediction of abnormality and preventive action shall be provided for the generating units having rating 100 MW and above : 9.2.7.1 Partial Discharge Monitoring (PDM) A partial discharge analyzer (PDA) shall monitor the partial discharge activity (damage to insulation) of the machine winding, indicating the condition of winding insulation systems. The system shall consist of permanently mounted partial discharge sensors (capacitive couplers) on the line & neutral windings and portable or permanently installed test equipment. 9.2.7.2 Air Gap Monitoring In order to provide high degree of dimensional stability, online air gap monitoring system shall be provided. A uniform air gap under all the conditions of operation below the 10% shall be maintained.
9.2.6 9.2.6.1
9.2.6.2 9.2.6.3
9.2.7
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9.2.7.3
Vibration Monitoring The displacement of the bearings during the running of the units shall be monitored by using on-line vibration monitoring equipment for replicating the forces acting on the rotor.
9.3 9.3.1
Excitation System Static high initial response rectifier excitation system shall generally be used. Static rectifier excitation system shall obtain the necessary electrical power directly from the terminals of the generator. The system shall consist of a power transformer, control element, electronic regulator and deexcitation unit. The capacity of the excitation system shall be adequate to supply continuously 1.1 times the excitation current and voltage required by the generator at 100% rated kVA and 100% rated voltage & for supplying twice the excitation current required by the machine at 100 % rated kVA and 110% rated voltage for a duration of one minute without damage. The excitation system while operating at maximum kVA, terminal voltage, power factor & speed shall be capable of changing from rated field voltage to 90 percent of ceiling voltage within 25 ms for a sustained drop in generator terminal voltage of 5 percent. All the performance requirements such as automatic voltage regulation (AVR), power system stabilizer (PSS) in accordance with the Authoritys connectivity regulations and standards, grid standards, regulations on grid standards shall be complied. The number of bridges shall be such that one bridge is always available as redundant. With the failure of two bridges it shall be possible to continue operation at reduced load. The rectifier PIV (peak inverse voltage) rating shall not be less than four times the maximum RMS voltage of the input. Generator Step-up Transformers
9.3.2
9.3.3
9.3.4
9.3.5
9.4
9.4.1 The generator transformers shall comply with the general requirements and the standards of latest versions of BIS:2026 / relevant IEC. 9.4.2 Water Cooled transformers, wherever feasible, shall be preferred for hydro power Stations, the type of cooling shall be generally OFWF/ODWF. In case, provision of water cooling being not feasible, OFAF type generator transformers shall be provided.
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9.4.3 Selection of single phase or three phase transformers for hydro power Stations shall be governed by the transportation limitations and shall be finalised considering the status of load carrying capabilities of bridges, etc. 9.4.4 Generator Transformer shall be suitable for continuous operation at rated MVA on any taps with voltage variation of in accordance with IS: 6600. 9.4.5 The generator transformers shall be provided with two complete independent sets of cooling equipment each with 100% capacity. 9.4.5 Provision of Off-circuit tap changer shall be made for generatortransformers of conventional generating units. On load tap changer shall be provided for pumped storage schemes having installation of reversible units. The range of operation for the tap changer shall be governed by the system requirements. 9.4.6 Surge diverter shall be provided on the high voltage side of transformers. The surge diverter characteristics, their numbers and exact locations shall be decided based on the insulation co-ordination studies. 9.4.7 Insulation levels for the transformer windings and bushings shall comply with the requirements indicated in Schedule-III. 9.4.8 Emulsifier type fire protection system for generator-transformer shall be provided. This system shall be normally put in auto mode. Fire walls shall be provided wherever required as per the guidelines of BIS. 9.4.9 The following on line monitoring system for large power transformers having three phase rating of 120MVA and above shall be provided: Dissolved / Evolved Gas Analyser: To monitor hydrogen and carbon monoxide. On Line Spectroscopy: To monitor methane / ethylene / ethane. Electrical Auxiliaries Unit Auxiliary & Station Auxiliary A.C. supply Systems To feed the unit auxiliaries and the station auxiliaries, unit station auxiliary supply systems shall be provided. .1 Unit Auxiliary A.C. Supply System The auxiliary supply system of each generating unit shall be provided with unit auxiliary transformer to feed the loads of the unit. The unit auxiliary auxiliary/
9.5 9.5.1 9.5.1.1
64
transformers, one for each unit, shall be supplied power from the units own generation. The essential load consists of mainly of the unit, cooling water pump motors, excitation and AVR cooling fans, space heaters and OPU, etc. The capacity of UATs shall be selected based on the consideration that it is able to continuously cater to the requirement of all auxiliaries of the respective unit. During starting and stopping of units these unit auxiliaries shall be supplied power from the station auxiliary A.C. supply system. 2 a) Station Auxiliary A.C. supply system The station auxiliary A.C. supply system shall be designed to provide a high degree of reliability, continuity of service and primarily to supply uninterrupted AC supply to station auxiliaries during normal operation and unit auxiliaries during starting and stopping of the unit. The station supply loads for various equipments shall be determined and maximum demand shall be calculated at a diversity factor of 0.75. The availability of input supply shall be ensured from the sources independent of station generation. In addition, adequate provision for meeting load of auxiliaries for one unit during starting/stopping of unit shall also be kept and for this purpose the UABs shall be connected to station auxiliary A.C. supply system through tie breakers. Two nos. of Station Service Transformer of equal capacity; one main and other as standby shall be provided for supplying power to the station service board feeding power to the station auxiliaries. In the event of A.C. supply failure, the station load shall be supplied by Diesel Generating set(s) of suitable capacity connected to the station service board. The station service transformers, DG sets and DCDBs shall be located at higher level. The different auxiliary systems shall incorporate a auto transfer scheme/manual changeover to bring in the reserve supply source as required to prevent the loss of unit/s & to ensure the equipment safety.
b)
c)
d)
9.5.1.2
Each switchgear, motor control centres (MCCs), distribution boards (DBs) shall be fed by 2x100% transformers/feeders and these shall be rated to carry the maximum load expected to be imposed. D.C. Supply System
9.5.2
65
9.5.2.1
The D.C. Supply Systems for hydro power stations comprise of Batteries, Battery Chargers & DC Distribution Boards. The standard voltage rating for the DC system shall be 24V / 48V for computerized control system and 220V /110V for control & protection etc. The battery capacity shall be decided with 10% design margin and ageing factor as applicable. The battery shall have sufficient capacity to provide 3 hours uninterrupted emergency illumination independently. Two DC battery sets (one battery of full required capacity & another battery of same capacity as a standby) each with one float and/cum boost charger shall be provided. The float cum boost battery chargers as well as their automatic regulators shall be of static type. It shall have a facility of both auto as well as manual control in both the float and boost modes. D.C. distribution boards shall be designed to supply the various station loads like normal continuous load, emergency lighting load, excitation current for field flashing of generators and indicating lamp loads. The DC batteries, battery chargers, and DCDB shall be placed at a floor higher than that of machine hall. Grounding System The grounding system shall be designed for a life expectancy of at least fifty (50) years, for maximum fault current of the system. MS Flat / rods shall generally be used as main ground mat. The touch and step potentials limit shall be maintained within acceptable limits. Grounding and lightning protection for the entire power Station and other areas or buildings shall be provided in accordance with IS 3043, IEEE : 80 and IEEE : 665. For most of hydro-electric projects, separate, distinct grounding system, if feasible, shall be provided for power house, switchyard & remote structures such as control buildings, communication buildings, spillway gate structures, storage buildings, etc. & other civil/ hydraulic structures inter-connected, if system design so dictates. Special attention shall be made for grounding of HV-GIS equipment, computer networks and communication equipment as per the manufacturers recommendations. All equipment shall be grounded at two points for reliability.
9.5.2.2
9.5.2.3
9.5.2.4
9.5.2.5
9.5.2.6 9.5.3 9.5.3.1
9.5.3.2
9.5.3.3
9.5.3.4
9.5.3.5
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9.5.4 9.5.4.1
Illumination Adequate illumination shall be provided as per BIS standards. Apart from normal AC illumination system, emergency AC and DC illumination at strategic locations shall also be provided. DC illumination shall be provided to enable safe movement of personnel and access to important control points during an emergency. Energy conservation measures shall be adopted, while designing the lighting system. Sodium vapour lighting fixtures shall be preferred for outdoor lighting such as switchyards, spillways and dams, parking areas etc. Automatic switching via photo electric cells can be adopted for outdoor lighting to optimise power consumption. Metal halide fixtures shall be used for certain indoor areas such as erection bay, generator hall, machine hall, turbine pit and other high bay areas where proper colour rendition is needed and long-life is essential. Incandescent lamps shall be used only for battery powered emergency lights and for certain places where lights shall not be turned on continuously or where fluorescent fixtures are impractical. Power and Control Cables Cables shall be flame retardant, low smoke (FRLS) type. Directly buried cables shall be essentially armoured type. Cables shall be derated for the site ambient and ground temperatures, grouping and soil resistivity as per BIS.
9.5.4.2
9.5.4.3
9.5.4.4
9.5.5
9.5.6 9.5.6.1
Cable Trenches / Cable Racks A comprehensive philosophy of segregation/ separation shall be adopted for cable installation. For laying of cables in a power house, a broad based system involving cable gallery, trenches, cable racks, shafts etc. shall be provided. In outdoor switchyards, a cable trench system shall be provided. The main considerations/ practices shall be: Segregation & proper spacing shall be maintained
- Control, auxiliary LV power and MV power cables shall be laid in separate trays. Proper attention shall be given to ventilation / heat dissipation aspects particularly in case of HV cables.
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9.5.7 9.5.7.1 9.5.7.2
Protection Fully graded protection system with requisite speed, sensitivity and selectivity shall be provided for the entire Station. Protective relays shall be used to detect electrical faults and to activate the alarms, disconnect or shut down the faulted apparatus to provide for safety of personnel, equipment and system. Electrical faults shall be detected by the protective relays arranged in overlapping zones of protection. All generating units shall have standard protections to protect the units not only from faults within the units and within the station but also from faults in transmission lines. For generating units greater than 100MW, protections shall be configured into two independent sets of protections (Group A & B) acting on two independent sets of trip coil fed from independent D.C. supplies, using separate set of instrument transformers, and segregated cables of CTs/VTs. The main protection relays for the generators, motors, transformers and the transmission lines shall generally be of numerical type. All relays used shall be suitable for operation with CTs secondary rated for 1 Amp or 5 Amps as per BIS/IEC/IEEE standards. The protections to be provided for the generating units as a minimum are shown below: a) Generator Protection Functions Small (< 10 MVA) Y Y N Y N Y Y Y Y N Y Size of Generating Units Medium (10-100 Large (> 100 MVA) MVA) Y Y Y Y Y Y Y Y Y Y N N Y Y Y Y N Y Y Y Y Y
9.5.7.3 9.5.7.4
9.5.7.5 9.5.7.6
Differential 95 % Stator E / F 100 % Stator E / F Interturn Faults Backup Impedance Voltage Controlled O / C Negative Phase Sequence Field Failure Reverse Power Pole Slipping Overload
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Over voltage Under frequency Dead Machine Rotor Earth Fault Overfluxing b) Generator Transformer
Y Y N Y N
Y Y N Y Y
Y Y Y Y Y
Generator Transformer Differential REF Protection IDMT O/C Protection Neutral Grounding Back-Up Protection (IDMT O/C relay)
Overfluxing Monitoring of Insulation of L.V. bushing Buchholtz Relay Winding Temperature Protection
Oil Temperature Protection Oil level low Pressure Relief Valve
Cooling system failure c) Generator & Generator Transformer Overall Differential Protection d) Unit Auxiliary Transformer Restricted E/F Protection Instantaneous and IDMT O/C Protection O/C & E/F / Neutral Backup Winding Temperature Protection e) Station Auxiliary Transformer Restricted E/F Protection Instantaneous & IDMT O/C Protection O/C & E/F /Neutral Backup Protection Winding Temperature Protection
69
f) Excitation Transformer Restricted E/F Protection Instantaneous & IDMT O/C Protection. O/C & E/F / Neutral Backup Protection Winding Temperature Protection 9.5.7.7 9.5.8 IEEE C37 (102,101,97,91,96) standards shall be generally applied for protection of generators, transformers and motors. Synchronization Synchronization of generator breakers shall be provided through automatic system with check synchronizing feature as well as through manual system with check synchronizing and guard relay. 9.5.9 Motors A.C Motors shall be Squirrel cage induction motor suitable for direct on line starting while Crane duty motors shall be slip ring /squirrel cage type induction motor with Variable Frequency Drive as applicable. DC Motors shall be Shunt wound. Temperature rise for Air cooled motors shall be limited to 70 deg.C by resistance method for both class B&F insulation. All motors shall be either Totally enclosed fan cooled (TEFC) or Totally enclosed tube ventilated (TETV) or Closed air circuit air cooled (CACA) or closed air water cooled(CACW) type. 9.5.10 Diesel Generator The diesel generators shall be installed to provide emergency power supply to essential station services and starting up of one generating unit at a time. In the event of normal station service power disruption and for standby supply during grid black-out condition, it shall be ensured that the essential auxiliaries of all the units are fed from diesel generator & non-essential loads are automatically tripped. 9.6 9.6.1 Control, Protection & Instrumentation General The control & instrumentation system provided for the Station shall be consistent with modern power Station practices and in compliance with all applicable codes, standards, guidelines and safety requirements.
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9.6.2 9.6.2.1
Control System for Main Plant Unit and station control system shall be microprocessor / computer based distributed digital control system interconnected through fibre optic cables or copper cables (for distances less than 100 meters) having hundred percent redundancy. Each generating unit shall have independent redundant programmable logic controller. The control of each unit from unit control board shall be independent of each other. The following control operation and monitoring points shall be provided for units: i) ii) iii) iv) Manual control of individual equipment from control cubicle / control boxes located near the equipment. Manual and automatic control from unit control board (UCB) located near the unit at machine hall Automatic operation from station control center located in the power house control room. Provision shall be made for automatic operation of plant from remote despatch center. It shall be compatible with the station control centre and shall ensure transfer of data / communication.
9.6.2.2
9.6.2.3
The control system shall be divided in the following groups with independent controls: i) ii) iii) iv) v) Generating unit controls Common controls (for control of common auxiliaries) Station controls (for station auxiliaries) Switchyard controls Dam gate controls (wherever applicable)
The above groups shall be interconnected and also controlled from control room through Computerised Control System (CCS). The type of interconnection with remote equipment shall be with reliable communication mode. 9.6.2.4 The following modes of unit start / stop controls shall be provided: i) ii) iii) 9.6.2.5 Automatic start/stop Auto inactive Step by step starting
As a backup to the microprocessor based controls, a relay based back up shut down may also be provided for parallel shut down in case of emergency / protection master trip relay operation. 71
9.6.2.6
A centralized control center for the control of complete power Station shall be installed in power house control room. Computer based Man Machine Interface (MMI) shall be installed with operation control stations having video display units, key board, printers, etc. for operation of Station. For complete overview of complete Station, a passive mimic board or interconnected large video screen (LVS) shall be provided in control room. The emergency stop push button for each unit for unit shut down shall be provided in control room. The emergency push button shall be hard wired from unit control board. An automatic synchronizer with double channel design having frequency and voltage matching including one set of synchronizing equipment for manual synchronizing shall be provided in each UCB. A common manual synchronizing set shall be provided for smaller sets. Provisions for the historical storage / long term storage and retrieval of the data shall be provided.
9.6.2.7
9.6.2.8
9.6.2.9
9.6.2.10 The Computerised Control System shall be compatible with standard IEC-60870 (for protection only) for communication with protection panel, LDC and other PLCs. 9.6.2.11 Independent, redundant and reliable 230 V AC UPS with 30 minutes backup shall be provided for Computerised Control System equipment located in control room and DC power supply system with 2 hours battery backup for controllers, input/ output cards, control network etc. shall be provided. 9.6.3 9.6.3.1 Instrumentation Primary instruments like transmitters, thermocouples, RTDs or other type of sensors, gauges, impact load flow elements, transducers etc. shall be provided. Use of process actuated switches shall be kept to a bare minimum. Microprocessor based vibration monitoring and analysis system shall be provided for critical rotating equipments.
All electrical instruments /devices like switches/ transmitters/ controllers/ analyzers/ solenoid valves which are located in the fields/hazardous locations shall be provided with explosion proof enclosures suitable for hazardous areas as per NFPA/NEC. All the field wiring shall be laid in the conduits.
9.6.3.2
9.6.3.3
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10.0
PROVISIONS REQUIRED FOR PROTECTION POWER HOUSE AGAINST FLOODING Following provisions shall be made for protection of Power House against flooding: i) ii) Installation of submersible type dewatering pumps of sufficient capacity in the dewatering sump. In addition to drainage and dewatering pumps, suitable number of submersible pumps with provision for automatic starting by means of level switches shall be provided at main inlet valve (MIV) floor. The control panels for dewatering and drainage pumps shall be located at a floor higher than that of turbine floor. Suitable float switches shall be provided in power house building to give closing signal to the MIV in the event of inundation of power house due to penstock rupture or leakage in penstock or for some other reasons. The station service transformers and station service boards shall be located at higher level. The excitation cubicles, unit control panels, unit protection panels etc. shall be located in the machine hall to the extent possible. The DC batteries, battery chargers and DCDBs shall be placed at a floor higher than that of machine hall. Provision for operation and control of surge shaft gates from remote for quick isolation of water conductor system in case of failure of other line of defence/protection. Provision of individual hoisting mechanism for draft tube gates of each unit may be considered for quick closing. The draft tube gates shall be capable of closing under unbalanced condition of water pressure.
iii) iv)
v) vi) vii) viii)
ix)
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SCHEDULE III TECHNICAL STANDARD SWITCHYARDS FOR SUB-STATIONS AND
This Schedule describes the minimum technical requirements for construction of Substations and Switchyards in following three parts: Part - A: Sub-Stations and Switchyards (66kV and above) Part - B: Substations (33 kV and below) Part - C: 33/0.4 kV, 11/0.4 kV Distribution Sub-Station (DSS) PART-A: SUB-STATIONS AND SWITCHYARDS (66KV AND ABOVE) 1.0 1.1 GENERAL The maximum fault level on any new substation / switchyard bus should not exceed 80% of the rated rupturing capacity of the circuit breaker. The 20% margin is intended to take care of the increase in short circuit levels as the system grows. The rated breaking current capability of switchgear at different voltage levels may be taken as: Table -1 66 kV 132 kV 220 kV 400 kV 765 kV 25/31.5kA (for 1 sec.) 25/31.5kA (for 1 sec.) 31.5/40 kA (for 1 sec.) 40/50 kA (for 1 sec.) 40/63 kA (for 1 sec.)
If fault level at 400kV sub-station exceeds or likely to exceed permissible limit of 40kA, with the addition of more generators and termination of new transmission lines, adequate measures to limit the fault level like installation of series reactors on line / bus at the respective substations need to be considered for future transmission development.
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1.2
The capacity of any single substation / switchyard at different voltage levels shall not normally exceed: Table -2 765 kV 400 kV 220 kV/230 kV 132 kV/110 kV/100 kV 66 kV 4500 MVA 1500 MVA 500 MVA 150 MVA 75 MVA
1.3
Size and number of interconnecting transformers (ICTs) shall be planned in such a way that the outage of any single unit would not over load the remaining ICT(s) or the underlying system. The design and construction of the proposed installation shall facilitate future expansion and system upgradation including automation and computerized coordinated operation such as Supervisory Control and Data Acquisition System (SCADA) and Energy Management System. DESIGN CONSIDERATIONS SWITCHING STATIONS FOR EHV SUB-STATIONS AND
1.4
2.0 2.1
The EHV substations and switching stations could be conventional Air Insulated Substation (AIS) / Gas Insulated Substation (GIS). The factors to be taken into accounts for designing EHV substations shall be as per Cl. No. 4.1.1 to 4.1.6 The choice of site for a substation / switchyard is a compromise between technical, economic, environmental and administrative factors. The approximate location is determined on grid considerations. The new substation shall enhance the operational flexibility, system reliability and transmission capacity after becoming a part of the network. Land area available shall be considered based on the present and the future expansion on a 10-15 year scenario. Reactive compensation as indicated by system studies of the network is to be provided. The series compensation could be fixed / variable / combination of both (partly fixed and partly variable). Similarly some compensation could be either switched or non-switched type. The selection of switching schemes depends on operational flexibility, system safety, reliability and availability, ability to facilitate system control
2.1.1
2.1.2 2.1.3
2.1.4
75
and costs. The following switching schemes shall generally be adopted at different voltage levels in AIS depending on importance of installation. Table-3 Main and transfer Bus or Double Bus scheme Double Main and transfer Bus scheme or Double Bus scheme Breaker and a Half scheme or Double Main and Transfer Bus scheme Breaker and a Half scheme or Double bus and Double Breaker scheme 2.1.5 66 kV, 132kV 220kV 400 kV 765 kV
In case of AIS, bus-bars shall be either of the rigid type with tubular aluminium bus conductor or flexible stranded conductor with ACSR / AAAC / any other suitable conductors. The conductor of appropriate rating and number of conductors in case of bundle conductors shall be selected considering power flow requirements and other system considerations. For the rigid bus-bar arrangement, aluminium pipes of grade 63401 WP range 2 conforming to IS:5082 shall be to be used. Outdoor Air Insulated Substation / switchyard has to be shielded against Direct Lightning stroke either by provision of overhead shieldwire /earthwire or spikes(masts) or combination of both. Gas Insulated Substations SF6 Gas insulated Metal Enclosed switchgear shall be totally safe against inadvertent touch of any of its live parts. Gas Insulated Switchgear (GIS) installations shall generally be preferred to conventional AIS as a technoeconomic solution for locations where space is major constraint and also for seismic prone areas and coastal areas. However, a techno-economic analysis has to be done in case of each GIS installation. The metal enclosed Gas Insulated Switchgear (GIS) shall comply with IEC 62271203 and IEC-62271-200. The GIS installations could be outdoor / indoor type. The switching scheme has a great impact on the total cost of the GIS and will have to be properly evaluated for a particular project. Generally single bus with / without sectionalization and double main bus switching schemes shall be used depending on voltage level and importance of installation. However, other type of switching schemes can also be considered based on techno-economic analysis.
2.1.6
2.1.7 2.1.7.1
2.1.7.2
76
2.1.7.3
GIS could be isolated phase / three phase non-magnetic enclosure type. For voltage level upto 220kV it could be three phase enclosure type and for 400kV and above voltage level, it could be single phase enclosure type. The arrangement of gas sections or compartments shall be such as to facilitate future extension of any make on either end without any drilling, cutting or welding on existing equipment and without the necessity of moving or dislocating the existing switchgear bays. The design should be such that all parts subjected to wear and tear are easily accessible for maintenance purposes. The equipment offered shall be protected against all types of voltage surges and any equipment necessary to satisfy this requirement shall be deemed to be included. The grounding system shall be designed for expected life of the substation for rated fault current as indicated in Table-1. Earthing system for the entire switchyard, equipment and buildings shall be provided in accordance with IEEE:80, IEEE: 665, IS 3043. The touch and step potentials limit shall be maintained within acceptable limits. The switchyard/ substation layout shall be decided with due consideration to statutory safety requirement, ease of erection and maintenance etc. Safety clearances shall be maintained in accordance with the Authoritys Safety Regulations and Standards. The clearances shall be adequate for moving portable equipment for maintenance and manoeuvring personnel for carrying out maintenance (clearances from adjacent live parts shall be maintained for safety) SALIENT TECHNICAL PARTICULARS / REQUIREMENTS OF SUBSTATIONS System design parameters Table-4 Parameter 1. 2. 3. Highest System Voltage (kV) Rated frequency No.of phases 66 kV 72.5 50 Hz 3 132 kV 145 50 Hz 3 220 kV 245 50 Hz 3 400 kV 420 50 Hz 3 765 kV 800 50 Hz 3
2.1.7.4
2.1.7.5
2.1.8
2.1.9
3.0 3.1
77
4.
i)
Rated Insulation levels Full wave impulse withstand voltage (1.2/50 micro sec.) (kVpeak)
325
650
1050
1425 (1300kVp for transformer/ reactor as mentioned in Table-5) 1050
2100
ii)
Switching impulse withstand Voltage (250/2500 micro sec.) dry & wet (kVp) iii) One minute Power Frequency Withstand Voltage dry & wet (kVrms) 5. Minimum Corona Extinction Voltage (kVrms phase to earth) 6. Max. Radio Interference Voltage for frequency between 0.5 MHz and 2 MHz (microvolts) 7. System neutral earthing
1550
140
275
460
630
830
105
156
320
508
500 (at 1000 (at 92kVrms) 156kVrm s)
1000 (at 320kVrms)
2500 (at 508 kVrms)
Effectivel y earthed
Effectively earthed
Effectively earthed
The above parameters are for installations at altitudes upto 1000m above Mean Sea Level (MSL). For higher altitudes, Insulation level requirements shall be kept higher as per relevant standards/practices. 3.2 3.2.1 Main equipment Power transformers (Other than generating transformer)
78
3.2.1.1
The transformers shall comply with IEC:60076/IS:2026 in general. The transformers shall be usually of two winding type / autotransformer. The transformers above 100 MVA rating shall be provided with tertiary winding. Interconnecting transformers shall be provided with On Load Tap changer(OLTC) as per system requirement. The maximum flux density in any part of the core and yoke at the rated MVA, voltage and frequency shall be such that under 10% continuous over voltage condition it does not exceed 1.9 Tesla. Transformers shall withstand, without injurious heating, combined voltage and frequency fluctuations which produce the following over fluxing conditions - 125% for 1 minute and 140% for 5 seconds. For the purpose of standardization, maximum temperature rise of oil and winding may be specified as 50oC and 55oC respectively over an ambient temperature of 50oC. At existing sub-stations, the impedance, vector groups, OLTC connection and range etc. of the new transformer is to be matched with that of the existing transformer. Interconnecting transformers shall be suitable for bi-directional flow of power. Noise level of transformer, when energized at normal voltage and frequency with fans and pumps running and measured under standard condition, shall not exceed the values specified in NEMA standard publication TR-1. In order to reduce the risk of fire, EHV transformers shall be provided with gravels / pebbles filled soaking pits for each transformer with voids of capacity adequate to contain the total quantity of oil. Otherwise, common soak pit of adequate capacity may be provided for a group of transformers. Besides, separation walls are to be provided in-between the transformers and also between transformer and reactors, if required, as per Tariff Advisory Committee (TAC) guidelines. The transformers may be single phase or three-phase type depending upon transportation constraints. In case single phase transformers are provided, then one single phase unit shall be kept as spare in the substation/switchyard so that it can replace any of the units, whenever required. Shunt Reactors Shunt Reactors, wherever provided, shall comply with IEC:60289/IS:5553/IEC-60076 in general. Shunt reactors upto 420 kV rated voltage shall have linear V/I characteristics upto 1.5 p.u. voltage. 800 kV Shunt reactors shall have linear voltage vs. current (V/I) characteristics upto 1.25 p.u. voltage. If required, the neutral of the line reactors shall be grounded through adequately rated neutral grounding reactors to facilitate single phase auto-reclosure. The neutral of shunt reactors shall be insulated to 550 kV peak for lightning impulse and shall
3.2.1.2
3.2.1.3
3.2.1.4
3.2.2 3.2.2.1
79
be protected by means of 145 kV class surge diverters in case of line reactors. 3.2.2.2 The insulation level for the transformer / reactor windings and bushings shall be as follows: Table-5 WINDING Rated Rated Rated voltag power switching e freq. impulse withstan withstan d voltage d voltage (kVrms) (kVp) 800kV 1550 420kV 1050 245kV 395 145kV 230 52kV 95 36kV 70 24 kV 50 17.5kV 38 12 kV 28 BUSHING Rated Rated Rated lightning power switching impulse freq. impulse withstan withstan withstan d voltage d voltage d voltage (kVp) (kVrms) (kVp) 1950 830 1550 1300 630 1050 950 460 550 275 250 95 170 70 125 50 95 38 75 28 -
Rated lightning impulse withstan d voltage (kVp) 2100 1425 1050 650 250 170 125 95 75
3.2.3 3.2.3.1
Circuit Breakers Circuit Breakers shall comply with IEC 62271-100 & IEC-60694. The interrupting medium of circuit breakers shall in general be SF6. Circuit breakers of 220kV and above voltage class shall be suitable for single phase and three phase auto-reclosing. Circuit breakers of 132kV and below voltage class shall be suitable for three-phase auto-reclosing. Each Breaker of 132kV and above rating shall be provided with 2 nos. of trip coils. Two sets of trip circuits shall be connected to separately fused /MCB controlled DC supplies for greater reliability. Rated break time for circuit breakers shall be as given below.` 765kV 400kV 220kV 132kV 66kV 40ms 40ms 60ms 100ms 100ms
80
3.2.3.2
In accordance with system requirement, the circuit breakers of 400kV and above class shall be provided with Pre-insertion resistors (PIR) for controlling switching over voltage of lines of length more than 200km. Disconnectors & Earthing Switches The disconnectors shall comply with IEC 62271-102 & IEC-60694. Earth switches shall be provided at various locations to facilitate maintenance. Main blades and earth blades shall be interlocked with both electrical and mechanical means, which shall be, fail-safe. Earth switches for 132kV and above shall be suitable for induced current switching duty as per IEC. Isolators of 220 kV and above rating shall have provision for remote and manual operation. Isolators of 132kV and below rating shall have provision for manual and / or remote operation. Earth switches shall be suitable for electrical and manual operation. Only local operation is recommended for earth switches. The earth switches for AIS shall not be suitable for fault making duty. However, high speed earth switches for GIS installation shall have rated fault making capability. In case of GIS installations, high speed earth switches shall be provided for grounding purpose at over head line terminations and where cable length is long.
3.2.4
3.2.5
Current Transformers Current Transformers shall comply to IEC:60044-1 in general. The rated currents and ratio, the number of secondary cores (protection / metering), accuracy class, burden, secondary winding resistance, knee point voltage and excitation current shall be in accordance with the requirements of the protection system. The accuracy class for metering core shall be as per requirements of tariff agreement. Digital Optical Current transformers may also be acceptable in place of conventional Current transformers.
3.2.6
Voltage Transformers Voltage transformers shall comply to IEC:60044-2 in general. The number of secondary cores (protection / metering), accuracy class and burden shall be in accordance with the requirements of the protection system. The accuracy class for metering core shall be as per requirements of tariff agreement. Voltage transformers can be either electromagnetic type or capacitive type. Wherever PLCC is required, Capacitor type voltage transformers complying to IEC:60044-5 shall be used as the same are suitable for carrier coupling. The capacitance of CVT shall be decided depending on PLCC requirements. Digital Optical Voltage transformers may also be acceptable in place of conventional Voltage transformers. In
81
case of GIS installations, SF6 filled voltage transformers shall be electromagnetic type. 3.2.7 Surge Diverter Station class, heavy duty, gapless metal oxide (Zno) type Surge diverters conforming to IEC 60099-4 in general shall be provided. The rated voltage, Continuous Operating Voltage, energy handling capability, nominal discharge current and other characteristics of surge diverter shall be chosen in accordance with system requirements. Surge diverters shall be provided at locations as per insulation coordination studies. These shall be fitted with pressure relief devices and diverting ports suitable for preventing shattering of porcelain housing providing path for the flow of rated currents in the event of arresters failure. Leakage current monitor with surge counter shall be provided with each surge diverter. 3.2.8 Line / Wave Trap A line/wave trap, intended for insertion in a high voltage power transmission line between the point of connection of carrier frequency signals and adjacent power system elements such as bus bars, transformers etc., shall consist of a main coil in the form of an inductor, a tuning device and a protective device. The tuning device shall be so arranged as to permit interchange without removing the line trap. It shall be so designed that neither significant alteration in the line trap blocking requirements nor physical damage shall result from either temperature rise or magnetic field of the main coil at rated continuous current or rated short time current. The protective device shall be so designed and arranged that neither a significant alteration in its protective function nor physical damage shall result either from temperature rise or the magnetic field of the main coil at rated continuous current or rated short time current. 3.2.9 Post Insulators The minimum creepage distances for different pollution levels shall be as per the following: Table-6 Pollution level Creepage distance (mm/kV of line-to-line voltage) 16
Light
82
Medium Heavy Very heavy 3.3 3.3.1 SUBSTATION SUPPORT FACILITIES AC & DC system:
20 25 31
AC & DC supplies shall be provided as per requirements given in Regulations on Grid Connectivity. For computation of capacity of battery in attended substation, in general following durations shall be assumed. Table-7 Where standby battery is Where standby provided battery is not provided Steady and 3 Hours 6 Hours continuous load Emergency light 1 Hours (3 hours in case 2 Hours loads of Hydro / Thermal Power Station) AC and DC distribution system shall be designed to meet the requirement of substation. 3.3.2 Fire fighting system for substation / switchyard A comprehensive fire detection and protection system shall be provided for substation / switchyard. Fire fighting system in general shall conform to Fire protection system guidelines issued by Tariff Advisory Committee (TAC) of India. 3.3.2.1 Automatic High Velocity Water (HVW) spray system / emulsifier system shall be provided for transformers & reactors of voltage rating 400kV and above. Fire detection and alarm system based on heat /smoke detectors shall be installed in control room building in substations / switchyards of 400kV and above. The fire alarm system shall conform to IS:2189. Further, water hydrant system shall be provided for the following area in substation / switchyards of 400kV and above: i) ii) iii) iv) DG set Auxiliary power supply station area Control room building Fire fighting pump house
83
v) vi)
Stores Transformer/Reactor
Portable fire extinguishers shall be provided in substation / switchyards of 400kV and above in Control room building, Fire fighting pump house and stores. 3.3.2.2 3.3.2.3 3.3.2.4 For 220kV sub-stations, water hydrant system and trolley mounted / portable fire extinguishers shall be provided. For 132kV and below sub-stations, portable and portable fire extinguishers shall be provided. trolley mounted /
In case of switchyard associated with generating stations, water supply system can be extended from the fire pump house provided for the generating station. Lighting Adequate indoor and outdoor lighting including street lighting shall be provided for the substation / switchyard. Adequate normal and emergency AC & DC lighting shall also be provided in the control room and other identified locations of the substation / switchyard. Energy conservation measures shall be adopted, while designing the lighting system. The battery shall have sufficient capacity to provide uninterrupted emergency illumination as per Table -7.
Average illumination levels shall be maintained as per IS:3646
3.3.3 3.3.3.1
3.3.3.2
3.3.4
Control room Substation / switchyard control room shall be provided to house the control and relay panels, PLCC equipments, telemetry equipments and recording equipments, AC & DC distribution boards, DC batteries etc. Air conditioning shall be provided in the building as functional requirement. In case of substation / switchyard with automation system with distributed architecture, Intelligent Electronic Devices (IEDs) including protective relays, PLCC panels may be provided in air conditioned kiosks located in the switchyard.
3.3.5
Oil evacuating, filtering, testing & filling apparatus To monitor the quality of the oil for satisfactory performance of transformers, shunt reactors and for periodical maintenance necessary oil evacuating, filtering, testing and filling apparatus shall be provided at new substation for a cluster of substation / switchyards. Oil tanks of
84
adequate capacities for storage of pure and impure transformer oil shall be provided. 3.3.6 SF6 filling, evacuation, filtering, drying & recycling plant SF6 filling, evacuation, filtering, drying & recycling plant with adequate storage capacity shall be provided at new substation / for a cluster of substation / switchyards along with trolley for filling or evacuation of SF6 Circuit Breaker or Gas Insulated Switchgear (in case of GIS installation) and to monitor the purity, moisture content, decomposition product etc of SF6 gas . 3.4 3.4.1 Protection & Control Protective Relaying System The protective relaying system shall be provided for transmission lines, auto-transformers and bus bars so as to minimize the damage to the equipments in the events of faults and abnormal conditions. 3.4.2 3.4.2.1 Grouping of Protection The protection functions shall be subdivided into two groups each having independent and capable of providing uninterrupted protection even in the event of one of the protection groups failing. Wherever two sets of DC sources are available, to obtain redundancy and to be able to take protection out for maintenance, while equipment is in service, the relays could be electrically and physically segregated into two groups (Gr. A and Gr. B). Grouping can be done to the extent possible in such a way that each group can independently carry out protective functions with near equal redundancy. Interconnection between these two groups shall not generally be attempted. However, if found absolutely necessary such interconnection shall be kept to the bare minimum. Even in cases when only one set of battery source is available segregation of protections and trip circuits in two groups may be considered by giving DC supplies through separate fuses. The protection in respect of transmission lines, transformer, reactor, bus bars and other provisions shall be as follows.
3.4.2.2
3.4.3
85
3.4.3.1
Transmission Lines Protection Table-8
Protection
765 kV
400 kV
220 kV
Main I -Distance Protection Main II- Distance protection / Directional Comparison Protection / Phase segregated line differential protection Directional IDMT type E/F relay
Y Y
Y Y
Y Y/N
132 kV / 110kV / 66 kV Y N
Directional IDMT over current and earth fault back up protection
Y (if both MI & M-II are distance protection) Y (if Main-II is not provided) N Y (Single phase/ three phase)
Two stage over Protection Auto reclosing
voltage
Y Y (Single phase / three phase)
Y Y (Single phase / three phase)
N Y (Three phase)
Transmission lines with distance protection shall in general have carrier aided inter-tripping or blocking feature. Separate cores of Current Transformer & Voltage Transformer shall be used for Main-I and Main-II.
86
3.4.3.2
Transformer Protection Table-9
Protection
765 kV 400 kV Y Y Y Y Y Y Y Y Y Y
Differential Protection Over fluxing Protection REF Protection Backup directional O/C and E/F Protection(HV and LV side) / Impedance Buchholz, WTI and OTI (for 1 MVA and above), MOG with low oil level alarm, OSR for OLTC, PRD, SA on both primary and secondary sides of transformers located outdoors and connected to over head lines Tertiary winding Protection
220 kV / 132 kV / 110kV Y Y Y Y Y
66 kV
33kV/0.4kV 11kV/0.4kV Y* N N Y* Y Except PRD & SA which are optional; Plain oil gauge in lieu of MOG is also acceptable;
Y N N Y Y
Over load alarm
Y N N (above 100MVA rating) Y Y N N * If HV is controlled by Circuit Breaker
3.4.3.3
Reactor protection Table-10 Protection 765 kV Differential Protection Y REF Protection Y Reactor backup protection Y (Impedance type or definite time O/C and E/F Protection) Buchholz, WTI, OTI,MOG Y with low oil level alarm, LA(if required) 400 kV Y Y Y Y
Note: (1) Y Required, N Not Required, Y/N - Optional
87
(2)WTI: Winding Temperature Indicator, OTI: Oil Temperature Indicator, PRD: Pressure Relieve Device, OSR: Oil Surge Relay, MOG: Magnetic Oil Gauge, LA: Lightning Arrester 3.4.3.4 Bus bar protection and Local Breaker Backup Protection (Breaker failure protection) Bus bar protection and local breaker backup protection shall be provided in 132kV and above interconnecting substations as well as in all generating station switchyards. The bus bar protection scheme shall have the provision for future expansion. 3.4.3.5 Disturbance Recorders, Event Loggers and Time synchronisation equipment Each 765kV, 400 kV and 220 kV line shall be provided with facility for disturbance recording, distance to fault locator and Time Synchronising Equipment (TSE). Event logger either stand alone or as part of substation / switchyard automation system shall be provided for 220kV and above voltage class substation / switchyard. Time Synchronisation Equipment (TSE)complete with antenna, all cables processing equipment etc., shall be provided to receive synchronizing pulse through a Geo Positioning Satellite System (GPS) compatible for synchronization of Event logger, disturbance recorder and SCADA/automation system of the substation / switchyard. 3.4.3.6 Power Line Carrier Communication (PLCC) Power Line Carrier Communication (PLCC) equipment complete for speech transmission line protections, and data channels shall be provided on each transmission line of voltage rating 132kV and above. The protections for 400kV and above transmission line and the line compensating equipment shall have hundred percent back up communication channels. Each 765kV/400kV/220kV line shall be provided with two protection/speech channels in addition to one speech + data channel for each direction. In case of 220kV/132kV lines, speech and data channel can also be used for protection wherever possible. Optionally, the above functionality may be achieved using wide band communication based on OPGW or any other technology. 3.4.3.7 Control Concept All the EHV breakers in substation/switching stations shall be controlled and synchronized from the switchyard control room / control room of Generating station. Isolators of 220kV and above rating shall have control from remote/local whereas the earth switches shall have local control
88
only. Isolators and associated earth switches are provided with electrical as well as constructional mechanical interlocks. Provision for operation of EHV Circuit breaker & Isolators from remote control stations may also be provided wherever required. 3.5 Cables and Cabling Cables shall be Flame Retardant and Low Smoke (FRLS) type. For laying of cables a broad based system involving cable galleries, trenches, cable racks, shafts etc. shall be provided. In outdoor switchyards, a cable trench system shall be provided. The main considerations/ practices shall be: A comprehensive philosophy of segregation and proper spacing shall be maintained - control, and power cables shall be laid in separate trays. Proper attention shall be given to ventilation / heat dissipation aspects particularly in case of HV cables.
No sub zero level cable vault / trenches are advisable below control building/switchgear rooms. Due to economic and technical reasons, philosophy of direct buried cable may be employed. The Cable shall be armoured type. Cables shall be derated for the site ambient and ground temperatures, grouping and soil resistivity. 4.0 SALIENT TECHNICAL PARTICULARS / REQUIREMENTS OF HIGH VOLTAGE DIRECT CURRENT (HVDC) TERMINALS/ STATIONS The design parameters given in Clause no.-3 shall be applicable for the AC switch yard equipment in the HVDC terminal station to be developed for bulk power transfer for long distances or asynchronous connections between areas operating at different frequencies. The system parameters given for 400 /220 / 132 kV AC system shall be applicable for the commutation voltage for both HVDC back to back and HVDC long distance transmission system. 4.1 HVDC Equipment Description A typical HVDC station for shall consist of the following main equipments: i) ii) iii) iv) v) Thyristor valves Converter Transformers AC harmonic filters Smoothing reactors DC filters*
89
vi) vii) viii) ix) x) xi)
AC PLC filter Control & Protection Electrical & Mechanical Auxiliaries Ground electrode station* AC switchyard equipment DC switchyard equipment*
* Not applicable for back to back schemes 4.1.1 4.1.1.1 The converter station AC yard AC commutating bus equipment The 400 kV AC Circuit Breakers, Isolators, Instrument Transformers and other switchyard equipment shall be similar to that of the 400 kV equipment specified under Clause 3. Continuous current carrying capacity of 400 kV switchgear and the filter banks will be of 3150 Amp., 4000Amp. and 2000 Amp. ratings respectively. The bus rating has to be adopted accordingly. The switching duties of the AC circuit breakers will be decided based on transient over voltage study, insulation coordination, AC filters and protection studies. 4.1.1.2 Surge Diverter The requirements of surge diverters shall be based on the Insulation Coordination study in line with IEC-60071-5. The arrestors used shall be metal oxide (ZnO) type conforming to IEC99-4. 4.1.1.3 Dynamic over Voltage limiter devices: Converters connected to relatively weak AC systems may cause Dynamic Over Voltages (DOV) during load rejection. The DOV limiter shall consist of parallel varistor elements connected phase to phase or phase to ground and designed to absorb the desired amount of energy during a system disturbance. The DOV requirements shall be coordinated with recovery of DC system following a disturbance. 4.1.1.4 AC harmonic filters and shunt compensation a) The HVDC converter generates harmonics during the conversion process and AC harmonic filters shall be used to limit ac voltage distortion due to harmonics to acceptable levels and also to meet the reactive power requirements of the HVDC station. b) The AC harmonic filters shall be switched in and out by circuit breakers. Based on the studies, the reactive power requirement for the terminal and bank / sub bank size shall be determined with no 90
reactive power support being envisaged from the grid. Suitable redundancy shall be provided in the sub-bank filters to avoid reduction of transmission capacity of the station due to outage of any particular sub-bank for maintenance. c) The main filter equipments namely capacitors & reactors shall comply to the requirements of IEC standards as follows: Capacitors Reactors : : IEC 60871-3 IEC-60289
d) Dynamic compensation: If required, dynamic compensation in the form of STATCOM, SVC etc may be used to improve stability during AC system transient faults. The requirement of dynamic compensation and the rating shall be derived from the studies. e) Shunt Reactor Banks: Shunt Reactors of suitable size shall be provided to prevent steady-state AC over voltage during low order dc power transfer. f) This shunt reactor shall be oil filled and can be switched in or out by Circuit breaker. The requirement of reactor shall be in line with the IEC 60289. 4.1.1.5 Power Line Carrier (PLC) filtering: PLC filters shall be installed close to converter transformer to mitigate high frequency harmonic currents generated during thyristor turn on and turn off. Converter transformers a) The converter Transformers shall be single phase two winding or three winding units which shall mainly be decided by size and transportation limitations. The transformers shall have secondary bushings projecting into the valve hall. The transformers shall comply with the requirements of IEC 61378-2.The maximum flux density in any part of the core and yoke at the rated MVA, voltage and frequency shall be such that under 10% continuous over voltage condition it does not exceed 1.9 Tesla. The maximum temperature rises of oil and winding may be specified as 50oC and 55oC respectively over an ambient temperature of 50oC.
4.1.1.6
91
b)
The insulation level for the transformer AC (line side) windings and bushings shall be as given in Clause 3 and insulation levels of the valve side windings shall be determined by the bidder. The impedance of the transformer shall be determined by the bidder and variations in impedance shall be as per requirements of IEC 61378. Converter transformers must also be equipped with On Load Tap Changer (OLTC) mechanism and Metal Oxide Varistor (MOV) devices shall be provided between tap leads of the OLTC. The requirements of soak pits and firewalls shall be in line with Clause no.- 4.
c)
d) 4.1.1.7
Thyristor valves a) The thyristor valves shall be supplied with associated auxiliaries and cooling system. A twelve pulse scheme shall be used and each twelve pulse thyristor valve shall comprise of many thyristor valve assemblies in series. Each assembly shall consist of microprocessor based firing system complete with individual thyristor over voltage protection, thyristor monitoring and damping circuit. The thyristor valve assembly shall be tested as per IEC 60700-1 The thyristor valves shall be water cooled, air insulated and indoor type. The valves shall be either of suspended type or floor mounted type. The Thyristor Valve Cooling System shall use de-ionized water circulated in a closed cycle. The cooling unit shall comprise of a deionizer, expansion vessel, conductivity sensors, mechanical filters, etc. Necessary control and monitoring including tripping of the HVDC system in case of cooling system failure shall be provided. The valves shall be placed in the valve hall which shall have a pressure of 7 mm of WC over atmospheric pressure. The pressurization will be with clean air.
b)
c)
d)
4.1.2 4.1.2.1
The Converter Station DC yard : The DC yard comprises equipments like HVDC bushings, smoothing reactors, DC filters, DC instrument transformers and switchgear all of which are located in the DC yard. The creepage distance for DC yard shall be maintained as indicated below:
4.1.2.2
92
Table-11 Insulator Type Indoor Porcelain/Composite for Valve Hall and indoor smoothing reactor area Indoor DC yard (other than smoothing reactor) Outdoor Porcelain Insulators/Bushings Outdoor Composite Insulators/Bushings 4.1.2.3 4.1.2.4 Under Light Pollution 20mm/KV Under heavy pollution zone 20mm/KV
NA 50mm/kV 50mm/kV
43mm/KV 60mm/kV 50mm/kV
DC Wall bushing: The bushings shall be of polymer housing as per IEC 61462 and filled with SF6 gas along with monitoring devices. Smoothing reactor The Smoothing reactor will be of oil filled /air core type depending upon the requirement. The reactors shall generally comply with IEC 60289 and shall also be subject to DC tests as per their application.
4.1.2.5
DC voltage and current measuring devices The measuring equipment for DC voltage is located on each high voltage DC pole and on the neutral bus. DC current measuring devices are usually located on the neutral bus and the pole bus. The rated DC voltage (pole bus equipment) shall be the same for rated DC transmission voltage.
4.1.2.6
DC filter DC harmonic filters shall be provided in DC yard to limit harmonic currents flowing in DC lines (pole lines and electrode lines).
4.2 4.2.1
Control and Protection The HVDC Bipole shall have many control features like i) ii) iii) iv) v) The reactive power controller Active power controller Frequency controller Power modulator Sub synchronous resonance damping controller
93
vi) The Load Frequency Controller (LFC). 4.2.2 Micro-processor based controls shall be used to enable flexibility in effecting modifications at a later date. Important controls shall be duplicated for increased reliability. Protection shall be provided by Numerical Relays to suit the requirements of high reliability and fast controllability of the HVDC system. It should be possible to operate HVDC system in the following modes: a) b) c) d) 4.2.3 Balanced bipolar operation Monopolar operation with metallic return Monopolar operation with ground operation Reduced voltage operation
The sequence of event recorder, transient fault recorder, on-line fault locator, GPS system, operator control and monitoring system shall be a part of HVDC system with required size of Video Projection system. Telecommunication For smooth operation of the HVDC system, communication network with high reliability and availability shall be provided for transmission of control and protection signals between the two HVDC terminals. The communication system shall be through optical fibers, PLCC or VSAT.
4.3
4.4 4.4.1
Electrode The earth electrode station would be connected to the terminal by means of overhead transmission line. The Earth electrode will be located approximately 20-30 Km (radial distance) away from the converter station. The maximum anodic current density at the sub-electrode surface, i.e., the boundary between backfill (coke) and soil shall not exceed 0.5 A/m2 in clay soils. Each ground electrode station shall ideally have a resistance of less than or equal to 0.3 ohm (both as an anode and cathode) at 50 C ambient temperature. Touch Voltage (Vt):The touch voltage between any grounded metallic object in the electrode station (including the connection to the overhead electrode line) and at any point in the soil which can be touched by a person simultaneously shall not exceed 40 V when the electrode is operating at the 5 sec overload rating.
4.4.2
4.4.3
4.4.4
94
4.4.5
Step Voltage (Vs):The step voltage at ground level above the ground electrode when the electrode is operating at the Temporary Overload (TO) rating shall not exceed (Vs) = 5.0 + 0.03s, where s is the minimum local soil surface resistivity in ohm-m. The above values of resistance, touch and step voltages would depend on the actual geophysical characteristics of the soil at the place where the electrode station is located. Suitable mitigation measures may have to be adopted in case the site has high resistivity.
5.0
ELECTRICAL & MECHANICAL AUXILIARIES The auxiliary power requirement shall be met through two independent feeders. The loads shall be fed through a 415V distribution board using auxiliary transformers. One DG set per pole shall be provided as emergency backup. Batteries and battery chargers would be provided for DC power supplies. Other electrical auxiliaries provided shall include Illumination, PA & Telephone system, UPS, etc. The mechanical auxiliaries shall include Air conditioning, Fire fighting including VESDA system for Valve hall, water supplies, Building Management System (BMS), etc. The BMS shall cover the following services. Air conditioning Fire fighting Station water supply and storage Illumination system Access control & Security
All auxiliaries shall give full output at voltage variation of 10% and frequency variation of -5% to +3%. 6.0 CONDITION MONITORING OF SUBSTATION EQUIPMENT For condition assessment of various substation equipment (e.g. Power transformer/Reactor, Circuit Breaker, Isolator, CT, PT/CVT, Surge Diverter etc.), suitable on-line/off-line diagnostic tools and other related provision shall be provided.
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PART B: SUB- STATIONS (33 kV AND BELOW) 1.0 SYSTEM PARAMETERS The system should conform to the following parameters: Nominal system voltage Highest system voltage System earthing kV kV 33 36 Solidly system 50 170 70 11 12 earthed Solidly system 50 75 28
earthed
Frequency Hz Lightning Impulse kV (Peak) withstand Voltage Power Frequency kV (rms) withstand Voltage
2.0
CONSTRUCTION STATIONS
OF
33/11
kV
SUB-STATIONS
AND
SWITCHING
2.1
The Sub-station shall be designed and constructed complying with the requirements mentioned in this standard, applicable Indian Standards as well as other rules and regulations as per latest amendments. The design and construction of the Sub-stations shall be such that they perform their intended functions. The substation shall be indoor or outdoor. The sub-station shall be either air insulated (AIS) or gas insulated (GIS). Underground substations may also be constructed. The 33/11 kV Sub-stations shall have adequate capacity to cater to the load growth for 5 years. Sub-station shall have adequate land keeping possible future expansion in view. The maximum capacity of any 33/11 kV Sub-station shall be 60 MVA. Each 33/11 kV sub-station shall normally not have less than two transformers. Each 33/11 kV sub-station shall normally have at least two incoming feeders preferably from two different sources. In case both the 33 kV incoming feeders are from the same source (substation), each feeder shall supply independent sections of the 33/11 kV Substation, two sections being isolated from each other by bus coupler or isolators.
2.2
2.3
2.4 2.5
2.6
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2.7 3.0 3.1
All Sub-stations shall have independent circuit breaker control of 33 kV incoming feeders, transformers and 11 kV feeders. SELECTION OF SITE The selection of site for33/11 kV Substation shall be made after taking into consideration the capacity and location of the feeding Grid Sub-station, load in the area, spatial load forecast, demographic factors, the existing network configuration, etc. and the economic, environmental and administrative considerations. The selection of the site of sub-station shall be done keeping following points in view:
3.2
3.2.1 The site shall be near to the load center 3.2.2 The site shall be such that it is convenient for terminating HV lines. 3.2.3 The site shall not be in a low-lying area to prevent flooding during the rains. 3.2.4 The site shall be near to the main road and easily approachable in all the seasons. 3.2.5 3.2.6 3.2.7 The site shall be away from garbage dumping ground to avoid vulture faults. The site shall not be within 3 km from aerodrome. It shall not be near military or police shooting ranges. The land shall be level and shall not have any open drain/nallah or road crossing it. SUB-STATION LAYOUT The layout of the Sub-station shall be such that 4.1 4.2 4.3 5.0 5.1 The incoming and outgoing feeders are easily taken to and from the Substation structures. It shall be possible to carry out equipment maintenance without interrupting the entire supply. The layout shall be economical and shall not hinder future expansion. SWITCHING ARRANGEMENTS Switching arrangements shall ensure operational flexibility, system safety, reliability and have ability to facilitate system control.
4.0
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5.2
Single bus, single bus with bus sectionalizer, main and transfer bus, double bus, double bus with double breaker or mesh arrangement shall be adopted as per requirement. SYSTEM CONFIGURATION The system configuration shall be radial, ring or combination of both as per requirements. The radial configuration shall be minimized to improve reliability. In very densely loaded city centers, VIP areas, essential services and installations, the system shall be of closed ring type
6.0
7.0 7.1 7.2 7.3 7.4 7.5 7.6
SUB-STATION MAIN EQUIPMENT After deciding the layout and orientation marking for the pits for various structures shall be carried out. The depth of pit shall be decided on the basis of type of soil, size and weight of structures it has to support. Concrete padding of thickness depending upon the weight of the structures shall be provided in the switchyard. The control room building can be single storey or double storey or underground depending upon availability of space. The construction activities for the control room and switchyard shall be synchronized to avoid delays in completion. The equipment shall be erected, tested and commissioned as per the relevant Bureau of Indian standards code of practice/ manufacturers instructions. In case of conflict the more stringent instructions shall prevail. POWER TRANSFORMER The transformers shall comply with IS:2026 and fittings and accessories shall comply with IS 3639. The 33/11 kV transformer shall have delta star winding connection. At existing sub-stations, the impedance, vector groups, on load tap changer connection and range etc. of the new transformer shall be matched with that of the existing transformer. The preferred ratings for 33/11 kV transformers shall be 6.3, 8, 10, 16, 20 MVA for urban areas and 1, 1.6, 3.15, 5, 6.3 MVA for rural areas. Any standard ratings other than above may also be chosen depending upon technical and economic consideration.
8.0 8.1 8.2
8.3
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8.4 8.5 8.6 8.7 8.8
The transformers shall be three-phase type. The transformer can be oil filled, epoxy cast dry type or ventilated dry type depending on whether it is installed indoor or outdoor. The cooling shall be ONAN or ONAF. The core shall be made of high grade cold rolled grain oriented steel . The maximum flux density in any part of the core and yoke at the rated MVA, voltage and frequency shall be such that under 10% continuous over voltage condition it does not exceed 1.69 Tesla. Transformers shall withstand, without injurious heating, combined voltage and frequency fluctuations which produce the following over fluxing conditions - 125% for 1 minute and 140% for 5 seconds. The maximum temperature rise of oil and winding shall be 35oC and 40oC respectively over an ambient temperature of 50oC. Each transformer shall be provided with gas and oil actuated relay fitted with alarm and trip contacts, if applicable. Transformers with off-circuit tap changer shall have taps ranging from (+) 2.5% to (-) 10% in steps of 2.5% each on the 33 kV winding for variation in the voltage. The tap changing switch shall be located in a convenient position so that it can be operated from ground level. The switch handle will be provided with a locking arrangement along-with tap position indication, for locking the switch. On load tap changing device shall be provided with transformers of 3.15 MVA and above by the utility for better voltage control. Transformers with on-load tap changer shall have taps ranging from (+) 5% to (-) 15% in steps of 2.5% each on 33 kV winding for voltage variation. The transformer shall be placed in position either directly on plinth or with rollers as per foundation drawing. Wherever required transformer shall be moved by rolling over greased pipes/ rails or on the trolley provided by the manufacturer so that the transformer is not subjected to undue stress. Where rollers are fitted, the wheels shall be suitably locked to prevent accidental movement of the transformer. It shall be ensured that while lifting the transformer, the lifting ropes/wires do not come in contact with the bushings.
8.9 8.10 8.11
8.12 8.13 8.14
8.15 8.16
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8.17 8.18 8.19
Assembly of fittings and accessories shall be carried out as per the manufacturers instructions. Adequate electrical clearances shall be provided from various live points on the transformer to earthed parts. Transformers shall be separated from one another and from all walls and partitions to permit free circulation of air complying with requirements of IS 10028. Space shall be provided in front and rear side of the transformer conforming to safety regulations. For indoor installation, the room shall be well ventilated for escape of heated air. Air inlets shall be provided near the floor and outlet near the ceiling. Transformer shall be physically checked and tested for its electrical properties and mechanical performance characteristics before commissioning. Transformer shall be provided with two separate earths which in turn shall be connected to two separate earth points. BUS-BARS Bus bars shall be of Rigid type or Strain type. The bus bar shall be able to carry the expected maximum load current continuously without exceeding the temperature limit. The capacity of bus shall also be checked for maximum temperature of the conductor under short circuit conditions. The bus bar connections and insulator supports shall be mechanically strong and bus bars supported so as to withstand the stresses generated by vibrations and short circuits. Conductor conforming to IS 398 having the requisite capacity shall be used. Aluminum used for the tubes of rigid type bus bar shall confirm to IS5082. STRUCTURES The structures shall be provided for: (i) Incoming and outgoing gantries (ii) Breaker, isolators, fuses, insulators, CTs and PT,s
8.20 8.21 8.22
8.23 9.0 9.1 9.2
9.3
9.4 9.5 10.0 10.1
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(iii) Bus-bar Switchyard structures to support buses, electrical equipment and termination of line conductors shall be made of fabricated steel, RCC or PSC, Rail or RS Joist depending on technical and economical considerations. 10.2 10.3 10.4 11.0 11.1 The structures shall be able to withstand tension of conductors and load of the equipment and accessories without guys or stays. The steel structures shall be hot dip galvanised or painted. In highly polluted areas painted structures shall be used. Adequate muffing above the ground level shall be provided to avoid water accumulation near the structures. INSULATORS Adequate insulation is of prime importance for ensuring reliability of supply, safety of personnel and equipment, etc. The station design shall be such that number of insulators is minimum but at the same time ensuring security of supply. The insulators shall be porcelain or polymer type. Suitable means shall be provided to accommodate conductor expansion and there shall not be any undue stress on any part or equipment due to temperature change.
11.2 11.3
12.0 Post insulators 12.1 12.2 The post insulators shall be of pedestal type and shall conform to IS 2544 & IS 5350. In the areas where problem of insulator pollution is expected (such as near sea or thermal station, railway station, industrial area, etc.) special insulators viz semi conducting porcelain or polymer insulators with higher leakage resistance shall be used. The minimum creepage distances for different pollution levels shall be as per the following: Pollution level Light Medium Heavy Very heavy Creepage distance (mm/kV of line-to-line voltage) 16 20 25 31
12.3
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13.0 CIRCUIT BREAKERS 13.1 Circuit Breakers shall comply with IS 12729 and IS 13118. The circuit breakers shall be either air blast, minimum oil, SF6 or vacuum type. The rated voltage for the circuit breakers shall be 36 kV or 12 kV as the case may be. Rated short time current rating shall normally not be less than 25 kA for 1 second. The operating mechanism shall be motor operated spring charged type, anti pumping and trip free. The breaker shall be designed to withstand the rated terminal load, wind load and short circuit & seismic forces. The 11kV switchgear shall be metal enclosed indoor type. The switchgear may be fixed type or draw out type or truck type. The rated short time current rating shall normally not be less than 16KA for 1 second for urban areas and 12.5 KA for 1 second for rural areas. The circuit breakers shall be mounted on individual structures in a fixed position in such a way that adequate sectional clearances are always available from its live parts. The maximum fault level on any new substation bus shall not exceed 80% of the rated rupturing capacity of the circuit breaker to take care of the increase in short circuit levels as the system grows. 33 KV AND 11 KV ISOLATORS AND EARTHING SWITCHES The isolators shall comply with IS 9920. For 33 kV horizontal types isolating switches shall be used. The rated current shall be 630 A at 36 kV. For 11 kV both horizontal and vertical mounting isolating switches of 400 Amps at 12 kV shall be used. The isolator shall be gang operated type. The frame of each isolator switch shall be provided with a separate earthing terminal for each phase for connection to an earthing conductor. The operating mechanism for the isolators and the controlling circuit breaker shall be interlocked so that the isolators cannot be operated unless the corresponding breaker are in open position. Earth switches shall be provided at various locations to facilitate maintenance. Main blades and earth blades shall be interlocked both electrically and mechanically. 102
13.2 13.3 13.4 13.5 13.6 13.7
13.8
14.0 14.1
14.2 14.3
14.4
14.5
The earthing switch shall be capable of withstanding short circuit current for short duration as applicable to the isolator. Earth switches shall be suitable for manual operation. Earth switches shall be operated locally only and not remotely. CONTROL AND RELAY PANELS The control and relay panels shall contain control and metering equipment for incoming feeders, outgoing feeders, bus bars, transformers and capacitors with provision for accommodating circuit breakers, relays etc.
14.6 15.0 15.1
15.2 The control and relay panel shall consist of separate cubicle with side covers made of sheet steel and shall be complete with internal wiring, terminals, ferrules and illumination operated with door off and on switch. 15.3 The panel shall be suitable for floor mounting and shall be completely dust and vermin proof. 15.4 The panel shall be provided with: i) Suitable over current and earth fault relays to protect the equipment against short current and earth fault. The relays shall conform to IS 3231. ii) All relays used shall be suitable for operation with CTs secondary rated for 1 Amp or 5 Amps. iii) Measuring instruments such as ammeter, voltmeter and energy meter for 33 kV and 11 kV systems. iv) Mimic diagrams v) Annunciation, Alarms and trip facilities 15.5 Panels shall have degree of protection conforming to IP- 53 or better. 16.0 16.1 33 KV AND 11 KV LIGHTNING PROTECTION The lightening arrestor (LA) which respond to over-voltages without any time delay shall be installed for protection of 33 kV switchgear, transformers, associated equipment and 33 kV lines. Station class, heavy duty, gapless metal oxide (Zno) type Surge diverters in general shall be provided on the buses, high voltage and low voltage side of all transformers and on the incoming terminations of 33 kV lines. The arrestors shall conform to IS 3070.
16.2
103
16.3 16.4
The lightning arrestors shall have corona free operation and wherever required necessary electrostatic screen or grading rings shall be provided. Line type lightning arrestors shall be provided on, at the junction of overhead line and under ground cable. These shall also be installed on 11 kV overhead lines at both sending terminating ends. The rated voltage, Continuous Operating Voltage, energy handling capability, nominal discharge current and other characteristics of lightning arrester shall be chosen in accordance with system requirements. Lightning arrestors shall be single-phase units suitable for outdoor duty. These arresters shall draw negligible current at operating voltage and at the same time offer least resistance during the flow of surge current. The rated voltage of arresters for 33 kV shall be 30 kV for use on 33 kV systems and with nominal discharge current rating of 10 kA. The rated voltage of lightning arresters shall be 9 kV (rms) for effectively earthed 11 kV system (co-efficient of earth not exceeding 80 per cent as per IS: 4004) with all the transformer neutrals directly earthed. The nominal discharge current rating shall be 5 kA. Lightning Arrestors for transformers shall be mounted as near to the transformers as possible and the star point is to be connected to the independent earth.
16.5
16.6
16.7 16.8
16.9
16.10 Lightning arrestors shall have two independent earths. 16.11 The earthing lead for lightning arrestor shall not pass through any iron or steel pipe, but shall be taken as directly as possible from the lightning arrestor to a separate earth electrode or junction of the earth mat already provided for the sub-station. Bends shall be avoided. 16.12 The porcelain of LAs shall not be damaged during erection. 17.0 17.1 17.2 INSTRUMENT TRANSFORMERS (POTENTIAL) TRANSFORMERS) (CURRENT AND VOLTAGE
Current Transformers shall comply to IS 2705. The rated currents and ratio, the number of secondary cores (protection / metering), accuracy class, burden, secondary winding resistance, Knee point voltage, Instrument security factor and excitation current shall be as per the requirements of the protection and metering system.
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17.3
The primary side rating shall depend on the rating of the power transformer of the Sub-station. Current transformers with secondary side rating of 5 Amps or 1 Amps shall be provided. Where the distance between the primary equipment and relay panel is long, CT of 1 Amp secondary current may be used to avoid large VA burden of CT. The CT may be oil filled or resin type for outdoor use and shall be cast resin type for indoor use. Voltage/ potential transformers shall conform to IS 3156. The number of secondary cores (protection / metering), accuracy class and burden shall be as per the requirements of the protection system. The rating of the voltage transformer shall be (11000/ 3)/ (1103) volts and shall be star connected. Voltage transformers shall be of electromagnetic type. The voltage transformer shall be of oil filled or cast resin type for outdoor use. The indoor VT shall be cast resin type only.
17.4 17.5 17.6 17.7 17.8 17.9
17.10 The neutral point of star connected secondary windings of instrument transformers shall be earthed. There shall be no multiple earthing of instrument transformers. 18.0 18.1 CONTROL ROOM Control room shall be provided to house the control and relay panels and all other indoor equipment, measuring and recording instruments required for control and operation of the sub-station. Adequate space shall be provided for the operating staff. Provision of space for future expansion shall also be kept. EARTHING ARRANGEMENT Earthing shall be provided for: a) b) c) 19.2 Safety of personnel Preventing and minimizing damage to the equipment as a result of flow of heavy fault currents. Improving reliability of power supply. IS 3043 and safety
18.2 18.3 19.0 19.1
Earthing shall be carried out in accordance with regulations. 105
19.3 19.4
The basic grounding system shall be in the form of an earth mat. Earth mat shall be provided within the substation area. MS flats shall be used for the earth mat. The earth mat shall be laid minimum 600 mm below the ground level. Risers of MS flats shall be provided near the equipment foundations for providing earth connections to equipment, steel structures etc. Size of the grounding conductor should be such that (i) it has thermal stability to flow the ground fault current (ii) it lasts at least for 50 years without causing break in the ground circuit due to corrosion and (iii) it is mechanically strong. Earth rods shall be uniformly distributed within the sub-station area and also located on the fence around the sub-station. The grounding rods shall be connected to the station earth mat. The earth rods shall be of mild steel of same diameter as earth conductor The maximum and minimum spacing requirements as per design shall be maintained. The earthing must be designed so as to keep the earth resistance as low as possible and must not exceed the following limits: 33 kV Sub-stations Distribution Transformer Structure Tower footing resistance 1.0 5.0 10.0
19.5
19.6
19.7 19.8 19.9
19.10 The resistance of the earth connection shall be maintained to such a value as to make the operation of the protective devices effective. 19.11 The step and touch potentials shall be within safe limits. 19.12 The ground potential rise shall be limited to tolerable values. 19.13 A surface layer of crushed stone shall be provided in the sub-station upto a depth of 75 cm. 19.14 Welding of ground connections may be done with extreme care. 19.15 Neutral points of systems of different voltages, metallic enclosures, frameworks associated with current carrying equipment shall be connected to
106
the single earthing system. All non current carrying parts shall be effectively earthed to the ground mat. 19.16 Metallic pipes, cable tray sections, metallic stairs shall be bonded to ensure electrical continuity and connected to the earthing conductor at regular intervals. 20.0 20.1 20.2 20.3 REACTIVE POWER COMPENSATION Shunt capacitors shall be connected on secondary side of 33/11 kV transformers. The capacitors shall conform to IS 2834 and the residual voltage transformer to IS 3156. The capacitors shall be of automatic switched type for Sub-stations of 5MVA and above.
20.4 Where un switched capacitors are provided, the rating shall be chosen so as to prevent over compensation during off peak periods. 20.5 Each capacitor unit shall be provided with a built in discharge resistor of adequate rating to discharge the residual voltage to less than 50 volts within 5 minutes. The capacitors shall be fixed firmly to the supporting structure to make them immovable.
20.6
20.7 The capacitor shall be earthed appropriately to avoid accidental leakage of charge. 21.0 21.1 21.2 CABLES Power and control cables of adequate current carrying capacity and voltage rating shall be provided. Power cables shall be XLPE insulated PVC sheathed type conforming to IS 7098. . Cables shall be flame retardant, low smoke (FRLS) type. Cables shall be derated for the site ambient and ground temperature, grouping and soil resistivity as per BIS. Proper attention shall be given to ventilation/heat dissipation as pects particularly in case of HV cables. The control cables shall be of copper and conform to IS1554
21.3
107
21.4 21.5 21.6 21.7 21.8 21.9
Cables shall not be laid directly on trench floor. The cables shall be segregated by running in separate trenches or on separate racks. The cable trenches shall be properly sloped so as to drain freely any water, which may enter. Cable trenches shall not be run through oil rooms. Care shall be taken in substation design to permit easy entry of cable into switchgear and convenience of handling even afterwards. Segregation of AC and DC control cables shall be done.
21.10 Separate control cables shall be used for each CT and PT. 21.11 Sufficient extra length of cable should be provided for repair of faults in terminations. 21.12 Cable laying shall be done as per manufacturers recommendation. The relevant drawings of this should be available at work site and should be preserved for future use and reference in the substation. 21.13 All cable ends shall be suitably labeled to facilitate easy identification. 21.14 Adequate number of spare cores shall be included in all control cables. 22.0 22.1 22.2 22.3 23.0 COMMUNICATION SYSTEM The communication system shall be reliable. A dedicated communication system i.e. Power line carrier communication, radio, mobile telephone, satellite or a combination of these shall be provided. The radio communication network shall be in the VHF/UHF frequencies. AUTOMATION SYSTEM State of art systems such as SCADA and DAS shall preferably be provided in the 33/11 kV sub-stations, associated feeders and distribution transformers for improving the operational flexibility, minimizing restoration time of power supply and preventing overloading of lines and transformers in real time mode.
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24.0 24.1
SUB-STATION SUPPORT FACILITIES DC Supply Arrangement The battery charger, battery and load shall be connected in parallel and work as a system.
24.2
Battery i) The 24V/30V DC batteries shall be stationary lead acid or nickel cadmium type. These batteries shall be suitable for a long life under continuous float operations at 2.00 to 2.25 volts per cell. The capacity and discharge rate shall be as per the load requirement. ii) The batteries shall conform to IS 266.
24.3
Battery charger The battery chargers shall be of static type. The battery charger shall be capable of continuous operation at the rated load in float charging mode. The charger in boost charging mode shall be capable of boost charging the associated DC battery at the desired rate.
24.4
Auxiliary Supply Transformer An auxiliary supply transformer of adequate capacity connected to the 33 or 11 kV bus shall be provided to meet the auxiliary and lighting loads of the sub-station.
24.5
Oil and SF6 Evacuating, Filtering, Testing, & Filling Apparatus Oil and SF6 filling, evacuation, filtering, testing plants with adequate storage facilities shall be provided for a cluster of substations as per requirement.
25.0
FENCING AND APPROACH ARRANGEMENT Fencing will be provided around the Substation. A metalled approach road to transport the equipment should be provided leading from the main road.
26.0
LIGHTING SYSTEM Energy efficient lighting system shall be provided at the Sub-station. The lighting system shall comprise of the following:
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26.1 AC Normal Lighting AC lights will be connected to AC lighting panels. All the lights connected to the AC lighting system in different areas shall be connected to the main lighting distribution boards. 26.2 DC Emergency Lighting Emergency lighting operated on the DC system shall be provided in strategic locations viz control room, battery room etc. 27.0 27.1 FIRE FIGHTING SYSTEM Proper attention shall be given to isolation, limiting and extinguishing of fire so as to prevent damage to costly equipments, reduce chances of serious interruption of power supply and ensure safety of personnel. The layout of the substation itself shall be such that the fire shall not spread to other equipment as far as possible. Carbon dioxide (CO2, type) extinguisher or dry chemical powder type extinguisher conforming to IS: 2878 and IS:2171 respectively shall be provided.
27.2
110
PART C: 33/0.4 kV, 11/0.4 kV DISTRIBUTION SUB-STATION (DSS) 1.0 1.1 1.2 GENERAL The DSS shall normally be located near to load centre. The DSS can be indoor or outdoor type. The sub-station can be constructed underground where there is paucity of space or for supply to underground installations. The DSS can also be placed on rooftop. It shall be ensured that the building is suitable for bearing the load of the DSS. Adequate fencing or isolation arrangements shall be ensured. Only dry type transformer shall be used for rooftop and underground installation. The DSS can be conventional, package type or completely self protected type. The capacity of DSS shall be as per the load requirement keeping in view the future load growth for 2 to 3 years. DISTRIBUTION TRANSFORMERS The transformer shall be in conformance with IS-1180 ,IS 2026 and IS-11171 The transformer can be oil filled or dry type depending on requirements. In indoor installations, installations under stilts and underground installations the transformer shall be only dry type. Energy efficient transformers made of high grade cold rolled grain oriented (CRGO) steel or amorphous material shall be used. Transformers made out of scrap CRGO material shall not be used. The efficiency of 11/0.4 kV Distribution transformers of 100 kVA and below shall not be less than 98% at both 50% and 100% loading. The efficiency of 11/0.4 kV Distribution transformers above 100 kVA shall not be less than 98.8% at both 50% and 100% loading. The efficiency of 33/0.4 kV Distribution transformers shall not be less than 99% at both 50% and 100% loading. 2.4 2.5 The transformer may be single phase or three phase. The cooling shall be ONAN for oil filled transformers. Distribution transformers can be either 33/0.4 kV or 11/ 0.4 kV.
1.3
1.4 1.5 2.0 2.1 2.2
2.3
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2.6
The 33/0.4 kV distribution transformers shall normally have standard rating of 500 kVA, 630 kVA, 1000 kVA, 1250 kVA, 1600 kVA or 2000 kVA depending on requirement. Lower ratings can also be used for rural and lightly populated urban areas. The 11/0.4 kV distribution transformers shall normally have standard rating of 6.3, 16, 25, 50, 63, 100, 250, 315, 400, 500, 630 and 1000 kVA. Any standard rating other than above could also be chosen based upon technical and economic considerations. Lower capacity transformers (100 kVA and less) shall normally be used. The higher capacity (larger than 100 kVA) shall be used for concentrated loads or areas with high load density where there are space constraints. TRANSFORMER MOUNTING STRUCTURE The transformer shall be mounted on a single pole, H pole structure or on a plinth. Direct single pole mounting shall be used for transformers upto 25kVA only. The transformers of more than 25 kVA and upto 250 kVA can be mounted on H pole structure or on plinth. The structures shall be provided with anti-climbing devices and danger board. Transformers above 250 kVA shall be mounted on plinth only. The plinth shall be higher than the surroundings. The plinth foundation shall be of concrete. Plinth mounted distribution sub-stations shall be adequately protected by fencing so as to prevent access to the equipment by unauthorized persons. The enclosure shall permit free circulation of air on all sides. LIGHTNING ARRESTERS Lightning arrester shall normally be installed on the High voltage side of the transformer. Lightning arrestor shall also be provided on the low voltage side in areas of high isoceraunic activity. Lightning arresters 9 (kV) outdoor type shall be used for diverting the lightning surges to earth.
2.7 2.8 2.9
3.0 3.1 3.2 3.3
3.4 3.5 3.6 3.7
4.0 4.1
4.2
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5.0 5.1
LT DISTRIBUTION BOX For transformers of 100 KVA and above, sheet metal LT distribution box consisting of breaker & fuse cut outs shall be provided from where distribution feeders shall be taken out. The size of the box shall be suitable for accommodating MCCB, fuse cutouts, cable connectors, bus bars etc. The distribution box shall be mounted at a height of 1.5 to 2 meters for pole mounted distribution transformers while the feeder pillar box can be installed at ground level . The capacity of lugs for cables, connecting strips, bus bars shall be as per requirement. The outgoing cable shall be taken out in a manner so that there are no joints PROTECTION SYSTEM 33/O.4 kV DSS
5.2 5.3
5.4 5.5 6.0 6.1
6.1.1 Suitable high rupturing capacity cartridge fuse or moulded case circuit breaker (MCCB) or miniature circuit breaker (MCB) or air break switch shall be provided on low voltage side. 6.1.2 The high voltage side of these transformers shall be protected by circuit breaker 6.2 6.2.1 11/0.4 kV DSS Suitable high rupturing capacity cartridge fuse or moulded case circuit breaker (MCCB) or miniature circuit breaker (MCB)or air break switch shall be provided on low voltage side for transformers of 100 KVA and above. The high voltage side of these transformers shall be protected by drop out expulsion type fuse or circuit breaker.
6.2.2 Horn gap fuse with air break switch shall be provided on high voltage side and side switch fuse unit or wire fuse on Low voltage side shall be provided for transformers below 100 KVA. 7.0 7.1 EARTHING Pipe earthings or rod earthing shall be provided for the distribution substation. 3 Nos. earth pits with three grounding electrodes shall be
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provided. Each electrode shall be GI pipe at least 2 inches in thickness and 8 feet long and buried vertically so as to leave about 4 inch pipe length above ground level. Earth connections shall be made as under : i) One direct connection from the 11kV lightning arrester and another direct and separate connection from LT lightning arrester if LT LA is provided. ii) Transformer neutral earthing 2 Nos. iii) Transformer body earthing 1 no., one connection from the handle of the 11 kV Air Break switch, and channel earthing iv) One separate connection from the earthing terminal of pole. The transformer neutral earth pit shall be independent just opposite the LA earth pit. Adequate quantity of charcoal and salt shall be used to keep the earth sensitive. In rocky area black cotton soil shall be used to fill the earth pit. The value of combined earth resistance should not be more than 2 ohms. LT CABLES The LT cables shall be used for connecting LT supply from transformer bushings to the LT circuit breaker in the Distribution box and for taking out outgoing feeders from the fuse units to the overhead lines. The LT cables shall be in conformance to IS: 1554 and IS:4288 The LT cables may be armoured or unarmoured for transformers upto 100 KVA and armored for 100 KVA and above. The cables shall be properly clamped to the support without damaging the insulation. A loop arrangement shall be made at the connecting end keeping the cables in such a way that rain water may not enter from the cutout point. METERS Meters shall be provided on the Distribution transformer for energy Audit purposes. The meters shall be in conformance to the Regulations on Operation and Installation of Meters notified by the Authority.
7.2
7.3 7.4 8.0 8.1
8.2 8.3 8.4 8.5 9.0 9.1 9.2
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10.0 10.1 10.2 10.3
REACTIVE COMPENSATION Where the power factor is low reactive compensation may be provided on the distribution transformers. Fixed or automatic switched type capacitors of adequate rating may be provided on the LT bus of the distribution transformers. In case of fixed capacitors it shall be ensured that the rating of the capacitors is such as to prevent over compensation during off peak period.
115
SCHEDULE - IV TECHNICAL STANDARDS FOR ELECTRIC LINES

This Schedule describes the minimum technical requirements for construction of Electric Lines in following two parts: Part - A : Electric Lines (66kV and above) Part B: Electric Lines (33 kV and below) PART-A : ELECTRIC LINES (66KV and ABOVE) 1.0 1.1 GENERAL Whenever a new transmission line is planned and constructed, the Licensee shall ensure that the proposed new installation is compatible with the existing power system and is suitable to become on commissioning, natural & integral part of the power system. The overall performance and output as well as detailed operating characteristics and specifications of the installation shall conform to the rest of power system i.e. the design and construction features shall be compatible with the system to which the new station/installation will be connected. The new installation shall fulfill the connectivity regulations and other applicable standards & regulations issued by the Authority. The owner shall ensure tie-up arrangements which are necessitated by the proposed installation and which must be carried out simultaneously by other entities before the new installation is commissioned and connected to the power system. EHV TRANSMISSION SYSTEM The objective of system planning is to evolve a power system with a level of performance characterized by an acceptable degree of adequacy and security. The salient features for the EHV transmission system in the context of these standards are as summarized below: i) ii) The transmission system should be planned in an integrated manner and optimized considering the total network under CTU and STU. The adequacy of transmission system to be tested for one or more load generation scenarios comprising of peak and off peak conditions in summer, winter and monsoon season.
1.2
2.0
116
iii) 3.0
Size and number of ICTs to be planned in such a way that outage of any single unit does not overload the remaining ICTs or underlying system. ROUTING OF TRANSMISSION LINE The transmission line route shall be selected keeping in view the following:-
3.1
Routing of transmission line through protected/reserved forest shall be avoided. In case it is not possible to avoid the forests or areas having large trees completely, keeping in view of the overall economy, the route shall be aligned in such a way that cutting of trees is minimum. Routing of transmission line through National Parks / Wild life sanctuaries shall also be avoided to the extent possible. Restricted areas such as civil and military airfield shall be avoided. Care shall also be taken to avoid aircraft landing approaches. The line routing should avoid large habitations, densely populated areas to the extent possible. It shall be ensured that all statutory requirements stipulated under Forest Conservation Act, Wild Life Protection Act, Archeological Survey Act & other Acts/Rules/Laws, as may be applicable, are complied with. Licensee shall arrange all required consents/approvals including Power and Telecommunication Co-ordination Committee (PTCC), Civil aviation, road/river/rail/canal/power line crossings, way leaves and environmental & forest clearances etc. from the concerned authorities/agencies. Right of way and way leaves clearance shall be arranged by the Licensee in accordance with the requirements of construction. Compensation for right of way & way leaves shall be given as per applicable Law, rules & regulations, guidelines/directives of local administrative/revenue authorities. DESIGN & CONSTRUCTION OF TRANSMISSION LINES General The transmission lines will be designed & constructed meeting the requirements mentioned in this standard, requirements of applicable Indian Standards as well as other rules & regulations as per latest amendments. The Licensee shall follow all the Prudent Utility Practices in the design, construction and maintenance of the transmission lines. Also, the design & construction of the transmission lines shall be such that they perform their intended functions under the License. Any changes in the standard requirements, if considered necessary or desirable to improve the quality,
3.2 3.3 3.4
3.5
3.6
4.0 4.1
117
efficiency or safety, may be proposed by the Licensee for consideration of the authority. Further, internationally acceptable standards which ensure equal or higher performance than those specified shall also be acceptable. 4.2 Salient Technical Particulars / Requirements of Transmission Lines
4.2.1 Electrical design parameters of the transmission lines Table-1 Parameter 66 kV AC 66 72 325 132 kV AC 132 145 650 220 kV AC 220 245 1050 400 kV AC 400 420 1550 765 kV AC 765 800 2400 500 kV DC
a . b . c .
Nominal Voltage (kV) Maximum System Voltage (kV) Full wave Impulse withstand voltage (1.2/50 microsec.) (kVpeak) Power Frequency Withstand Voltage under Wet condition (kVrms) Switching Surge Withstand Voltage under Wet condition (kVrms) Minimum Corona Extinction Voltage under Dry condition (kVrms phase to earth) Maximum Radio Interference Voltage at 1 MHz (microvolts) for phase to earth voltage of kV under Dry condition
500 525 1800
d . d . e .
140
275
460
680
830
700
1050
1550
1000
156
320
510
550
f.
1000
1000
1000
1000
At At At 550 156kV 320kV 510kV (22 kV/cm conducto r surface gradient)
The above parameters are for transmission lines constructed at altitudes upto 1000m above MSL. For the transmission line at higher altitudes, BIL 118
impulse & switching surge withstand voltage requirements shall be kept higher as per relevant standards/practices. The AC transmission lines shall be transposed, if required depending upon length of line, in approximately three equal parts. 4.2.2 Conductor The conductor of appropriate size shall be selected considering power flow requirements and other system considerations in consultation with other concerned entities. For transmission lines of 400 kV or higher voltage class, bundle conductors (minimum two conductors per phase for 400 kV AC and four conductors per phase for 500 kV DC & 765 kV AC) shall be used for satisfactory performance of transmission lines from corona & interference aspects. Typically, conductors of size & configuration, generally similar to one already used in other existing transmission line(s)/ network in the country/ concerned State/Region, shall be preferred to ensure compatibility. The conductors may be of type ACSR, AAAC or others and shall generally conform to IS:398 / IEC-61089. Other new technology conductors conforming to International standards/specifications may also be used depending on system requirements.
4.2.3 Earthwire
The earthwire of appropriate size to take care of predicted/design fault currents and lightning shall be used. The earthwire shall be either of galvanized stranded steel (GSS) or alternatively ACSR/AACSR conductor type. Optical Fibre Ground Wires may also be used as earthwire. Other new technology earthwires conforming to International standards/specifications may also be used. Generally, one earthwire shall be used for transmission lines upto 220 kV and two earthwires shall be used for transmission lines of 400 kV and above voltage class.
4.2.4 Towers
The towers shall be self-supporting lattice steel type and shall be fully galvanised structure. Alternatively, guyed or pole structure towers may also be used. Type of towers, design/ruling span, wind & weight spans, extension/ truncation provisions etc. may be selected by the Licensee as per prudent utility practices. Live-metal clearances, mid-span clearance, shielding angle etc. shall be decided as per prudent utility practices following applicable standards/codes
119
and keeping in view electrical system parameters/ requirements, line altitude & other service conditions/ factors. Ground clearance shall be as per requirements of Safety Regulations, under Section-53 of Electricity Act, issued by the Authority. 4.2.4.1 Design of Towers The following specify the minimum requirements for design of towers. The Licensee may adopt any additional loading/design criteria for ensuring reliability of the line, if so desired and/or deemed necessary. The towers shall be designed to meet all design requirements & design criteria stipulated in latest revision of IS: 802/IEC:60826, considering wind loading corresponding to applicable wind zone for the transmission line as per IS:875. The towers shall also be designed for appropriate snow / ice loads, if applicable . The loads at conductor & earthwire points under different loading conditions viz. Reliability Conditions (Normal Condition), Security Conditions (Broken Wire Condition), Safety Conditions, Anti-cascading condition etc. (as per IS802/IEC:60826 or equivalent) considering various combinations of design temperatures, wind & snow loads shall be calculated and tower designs developed accordingly. Reliability level 1 corresponding to 50 year return period design loads due to wind as per IS:802 shall be considered for design of towers for transmission lines upto 400 kV. For higher voltage level transmission lines, reliability level 2 corresponding to 150 year return period wind loads shall be considered. Normal Towers shall also be prototype tested as per IS:802(Part-3) unless additional safety factors have been considered in the design. 4.2.4.2 Materials Steel Sections of tested quality in conformity with IS:2062 (Designated Y.S. 250 MPa) or/and IS:8500 grade 490 (designated Yield Strength 350 MPa) shall be generally used in towers & its extensions. Other equivalent grade of structural steel angle sections and plates conforming to International Standards may also be used. Fasteners/ bolts & nuts shall be generally as per IS:12427 / IS:1367 / IS:6639.
120
4.2.4.3 Tower Fabrication Towers fabrication shall generally conform to IS:802 (Part-II). Tower parts shall be galvanized as per IS:2629 & IS:4759. 4.2.4.4 Tower Accessories Various tower accessories viz. danger plates, number plates, phase plates, circuit plates, anti-climbing devices, bird guards etc. shall be provided conforming to IS:5613. 4.2.4.5 Earthing Each tower shall be earthed such that tower footing resistance do not exceed 10 ohms. Pipe type or Counterpoise type earthing shall be provided in accordance with IS:3043 & IS:5613. 4.2.4.6 Aviation Requirements/Warning Signals Day and/or night visual aids/markers for denoting transmission line/structures as per requirements of Directorate of Flight Safety / IS:5613 / ICAO shall be provided. 4.2.5 Foundations 4.2.5.1 Depending upon soil/site conditions, economy and feasibility of construction at site, appropriate type of foundations (viz. open cast, pile, well or other alternative types) shall be considered for transmission line towers. 4.2.5.2 Design of foundations The design of foundations shall be as per applicable Indian Standards/Codes viz. IS:456, IS:4091, IS:2911 etc. Structural design of foundations shall be done by limit state method with minimum overload factor as 1.1. The minimum factor of safety for design of pile/well foundations shall be 2.5. 4.2.5.3 The cement concrete used for the foundations shall be generally as per IS:456.
121
4.2.6 Insulators, Insulator Strings & Hardware Fittings 4.2.6.1 Requisite type of suspension and tension insulator strings with disc insulators or long rod insulators offering equivalent performance shall be used. Number of insulators, creepage distance shall be selected based on electrical system parameters/requirements taking into account other factors/conditions viz. line altitude, expected environmental & pollution conditions etc. Insulators shall generally conform to IS:731/IEC-60383. Polymer/composite insulators conforming to relevant IEC/other International standards may also be used. DC insulators shall be of antifog type having sacrificial zinc sleeve. These shall generally conform to IEC-61325. Insulator & insulator string rating shall be selected such that i) Under ultimate design wind loading conditions, the load on insulator string shall not exceed 70 % of its selected rating ii) Under everyday temperature and no wind conditions, the load on insulator string shall not exceed 25% of its selected rating. 4.2.6.4 Insulator strings shall be complete with all required hardware fittings. The fittings shall generally conform to IS:2486.
4.2.6.2
4.2.6.3
4.2.7 Accessories for Conductor and Earthwire The accessories required for the conductor & earthwire viz. mid-span compression joints, repair sleeve, T-connector, flexible copper bond, vibration dampers, spacer/spacer-dampers, earthwire clamps etc. shall be used suitable for type & size of conductor & earthwire used for the transmission line. The accessories shall generally conform to IS:2121. The vibration dampers shall generally conform to IS:9708 and spacers/spacer dampers (for bundle conductors) shall be generally as per IS:10162. 4.3 Transmission Line Construction:
4.3.1 Construction of transmission line shall be carried out generally as per IS:5613 meeting stipulated requirements under other latest applicable standards and prudent utility practices.
122
4.3.2 Crossing of transmission line with roads / railway / river / power line/ telecommunication lines shall be finalized as per applicable rules & regulations laid by the concerned authorities. 4.3.3 Clearances from ground, buildings, road, power lines, telecommunication lines shall be provided in conformity with Safety Rules, under Section-53 of Electricity Act, issued by the authority. 4.3.4 Clearances from trees, forest clearance etc shall be provided in accordance with Forest Conservation Act and guidelines issued by Ministry of Environment & Forests. 4.4 Service Conditions: Equipment/material to be used in the transmission line shall be suitable for satisfactory continuous operation under tropical conditions as specified below: Maximum ambient temperature (Degree Celcius) Minimum ambient temperature (Degree Celsius) Relative humidity (% range) Maximum annual rainfall/snowfall (Cm) Wind zone Maximum wind velocity (m/sec. as per IS: 875) Altitude above mean sea level (Metres) 5.5 5.6 : As per published : meteorological/ : climatological : data by Indian Meteorological Department : As per IS-875 : As per IS-875 : As per actual
Statutory Clearances: As per Safety Regulations issued by the Authority under Section 53 of the Act. Applicable Standards: BIS/IEC/Equivalent
123
PART B: ELECTRIC LINES (33 kV and below) 1.0 1.1 1.2 GENERAL The lines shall be constructed keeping in view the prime factors of safety as well as electrical and mechanical design considerations. The owner shall ensure tie-up arrangements which are necessitated by the proposed installation and which shall be carried out simultaneously by other entities before the new installation is commissioned and connected to the existing power system network. CONSTRUCTION OF ELECTRIC LINES AND ASSOCIATED EQUIPMENT The system shall be constructed so as to ensure: a) Voltage conditions to be within permissible levels. b) Improvement of reliability and security of power supply c) Improvement in quality of supply 2.2 Independent feeders shall be provided for essential loads of 5 MVA and above such as water works, hospitals, defense and other sensitive installations. Separate rural feeders for feeding irrigation load and domestic load shall normally be provided. Composite lines shall be adopted by the licensees as per requirement. ROUTING OF ELECTRIC LINES The route of the electric line shall be as short as possible. The routing of electric line through protected and reserved forest shall be avoided. In case it is not possible to completely avoid the forests or areas having large trees, keeping in view of the overall economy, the route shall be aligned in such a way that cutting of trees is minimized. The routing of electric line through National Parks and Wild life sanctuaries shall also be avoided. Restricted areas such as civil and military airfield shall be avoided. Care shall also be taken to avoid aircraft landing approaches. The 33 kV line route shall be such as to avoid large habitations, densely populated areas. The line shall avoid rough and difficult country side, natural obstructions, fruit gardens, lakes, rivers etc.
2.0 2.1
2.3 2.4 3.0 3.1 3.2
3.3 3.4 3.5 3.6
124
3.7 3.8 3.9 3.10 3.11
The electric line shall normally not cross educational institutes and cremation grounds. The electric line shall be far off from slaughterhouses to prevent interruptions by bird hits. The electric line shall be close to the road for approach during construction and ease of maintenance. Abrupt turning in line routes shall be avoided. Angle points in the route shall be minimized. Railway and road crossings shall be minimum on the line route and in case it is not possible to avoid the same the crossings shall be at right angles but not less than 60 degrees in any case. Distribution licensee shall arrange all required consents/approvals including civil aviation, road, river, rail, canal, power line crossings and environmental and forest clearances etc. from the concerned authorities. The distribution licensee in accordance with the requirements of construction shall arrange right of way and way leave clearance. Compensation for right of way and way leaves shall be given as per applicable law, rules and regulations, guidelines/directives of local administrative/revenue authorities. DESIGN AND CONSTRUCTION OF ELECTRIC LINES The electric lines shall be designed and constructed complying with the requirements mentioned in this standard, applicable Indian Standards as well as other rules and regulations as per latest amendments. The design and construction of the electric lines shall be such that they perform their intended functions. Extension of existing lines shall be carried out after ensuring that the limits of voltage variations in the lines are not exceeded. The reliability and security of supply shall be improved by use of sectionalisers, auto reclosers, ring main units and fault passage indicators as per techno economic considerations. Nominal system 33 kV voltage Highest system 36 kV voltage System earthing Solidly system Frequency (Hz) 50 Lightning Impulse 170 withstand 125 11 kV 12 kV 400 V 440 V
3.12
3.13
4.0 4.1
4.2 4.3
4.4 Electrical Design Parameters of the Electric Lines
earthed Solidly earthed Solidly earthed system system 50 75 50 60
Voltage(kV Peak) Power frequency 80 withstand Voltage (kV rms) in wet condition
28
10
The above parameters are for electric lines constructed at altitudes upto 1000m above MSL. For the electric line at higher altitudes, Basic Insulation Level, impulse and switching surge withstand voltage requirements shall be kept higher as per relevant standards/practices. 5.0 5.1 5.2 SUPPORTS (Poles and Towers) The supports may be Poles or Narrow based lattice towers with fully galvanised structure as per requirement. Poles may be used for 33 kV, 11 kV and LT lines (lines below 500V) as per requirement. The poles shall be Pre-cast Concrete (PCC) pole, Pre-Stressed Cement Concrete (PSCC) pole, Rolled Steel joist, Rail pole or Steel Tubular pole as required. Poles shall conform to IS 785, IS 1322, IS 1678, IS 2713 as the case may be. Cement poles shall be preferred in plain areas. In hilly areas appropriate snow or ice loading shall be considered for design of poles and towers. For locations involving long spans or higher clearances on account of crossing of power or communication lines or railway line crossings specially designed poles /lattice towers may be used. For angles of deviations of more than 10 double poles structure shall be used The height of the pole above the ground level, length of pole below ground and working load shall be decided taking into consideration wind zone, terrain, topography, and the statutory clearances required to be maintained and these shall conform to relevant IS. LINE SPAN The following general principles shall be observed: 6.1 Line span shall be decided taking into consideration topography, wind pressure, type of support, conductor configuration and ultimate tensile strength. The span shall be within the range specified by IS-5613. Uniform span shall be maintained as far as possible between two consecutive pole structures.
5.3 5.4 5.5 5.6
5.7 5.8
6.0
6.2 6.3
126
6.4 6.5 6.6 6.7 7.0
While constructing a line, if a road is crossings at mid spans then a pole shall be placed on one side of the road. While crossing another power line, the lower voltage line shall be underneath. The lower line shall cross at mid span of the upper line. While placing poles on high places, use of shorter poles can be made to maintain proper ground clearance at the middle of the span. Poles shall normally not be placed along the edges or cuts or embankment of creeks and streams. ERECTION OF POLES Erection of poles shall be carried out in accordance with the provisions of IS 4091 and IS 5613. Following shall also be taken care of:
7.1 7.2 7.3 7.4
It shall be ensured that the poles are held in vertical position (by spirit level); All the steel supports shall be painted with one coat of red oxide primer, above ground level; The embedded portion including plinth shall be well painted with coal-tar of good quality; All type of supports along the roads shall be painted with black and yellow strips of 30 cm width up to 1.80 meter, to protect them against possible danger during night by fast moving vehicles on the road and to be visible to running animals. Fluorescent paint may be considered on roads with fast moving traffic. FACTOR OF SAFETY The supports shall be suitable for the wind loads as per IS-875. The minimum factor of safety for supports shall be as per Safety regulations notified by the Authority.
8.0
9.0 9.1
EARTHING OF POLES All metallic supports shall be permanently and effectively earthed. For this a continuous wire may be run at the top or below the conductors and securely fastened to each pole and connected with earth normally at three points in every km. The earthing arrangement shall conform to IS 3043. Earthing arrangements for PSCC/ PCC Poles used for 33 kV lines, shall be provided by having a length of 8 S.W.G galvanized iron wire embedded in concrete during manufacturing. The ends of earth wire shall be left projected from the pole to a length of 100 mm from top and 150 mm. below ground level. The earth wire shall not come in contact with re-inforcement bars used in the poles. Earthing arrangement for PSCC/ PCC poles used for 11 kV lines, shall be provided with projected length of 50 mm at both ends of pole, using 8 S.W.G. galvanized iron wire embedded in concrete.
9.2
9.3
127
9.4
Metal cross arms and insulator pins for PCC and PSCC poles shall be bonded together and normally earthed at every pole for 33 and 11 kV lines and at every 5th pole for lines below 500 volts. The support on either side of a road crossing, railway crossing or river crossing shall be earthed. Normally coil earthing shall be provided except for locations involving railways, telegraph line, power line crossings and special structures where pipe rod type earthing shall be provided. Whenever the electric lines pass close to a well or a permanently moist place, an earth should be provided in the well or the marshy place and connected to electric line pole. All steel poles on which switches, transformers, fuses etc. are mounted shall be earthed. All poles of 33 kV, 11 kV and lines below 650 volts passing through inhabited areas shall be earthed. The ohmic value of the resistance of the earth should be as low as possible and should not exceed 10 ohms. STAY ARRANGEMENTS
9.5 9.6
9.7 9.8 9.9 10.0
10.1 To prevent tilting of pole from its normal position due to abnormal wind pressure and deviation of alignment, the pole shall be kept in position by stays. The stays shall be provided at: a) b) c) d) 10.2 Angle locations Dead end locations Tee off points Steep gradient locations
Galvanized iron stay wires and stay rods of adequate size shall be used. The individual wire used to form stranded stay-wire shall have a minimum tensile strength of 700 N/mm2 as per IS: 2141, IS 4826 and IS 6594. For double pole structure (DP), four stays along the line, two in each direction and two stays along the bisection of the angle of deviation or as required depending on the angle of deviation are to be provided. When two or more stays are provided on the same pole, each stay shall be grouted entirely separate from the other. The angle between the pole and stay wire shall be about 45 degrees and in no case it shall be less than 30 degrees. Stays shall be anchored either by providing base plates, angle iron or rail. Stay wires shall be connected to the pole with a Porcelain guy strain insulator. The standard Guy Strain insulators shall be of as per IS 5300. Porcelain insulation shall be inserted in the stay wire at a height of 3 m
10.3
10.4 10.5 10.6 10.7
128
vertically above the ground level. The insulators shall be from defects, thoroughly vitrified and smoothly glazed. 10.8 11.0 Wooden insulators shall not be used. PROTECTIVE GUARD Guard wire shall be used where an overhead line crosses or is in proximity to any telecommunication line or any other overhead line and in populated localities. Every guard wire shall be connected to earth wherever its electrical continuity is broken. The minimum factor of safety for stay wires, guard and bearer wires shall not be less than 2.5 based on ultimate strength of the wire. 12.0 ANTI CLIMBING DEVICES Anti climbing devices shall be provided on the supports. For this purpose barbed wire conforming to IS-278 and IS-1340 for a vertical distance of 30 to 40 cm. at a height of 3.5 to 4 meters from ground level or clamps with protruding spikes at a height of 3 to 4 meter shall be used. 13.0 DANGER PLATES Danger Plates shall be provided on electric lines in accordance with Safety Rules. 14.0 14.1 INSULATORS, INSULATOR STRINGS AND HARDWARE FITTINGS Pin insulators should generally be used on straight stretch of the lines. The pin insulators shall conform to IS 731 and IS 1445. The pin insulators may be used on lines up to 33 kV voltage level. The pin insulator shall consist of a single piece of porcelain mounted rigidly on a supporting structure on a pin. Shackle insulators shall be used in lines below 500 volts and these shall conform to IS 1445. Strap type fittings shall be used for dead end location, while U-clamp fittings shall be used at tangent locations. Requisite type of suspension and tension insulator strings with disc insulators or long rod insulators offering equivalent performance shall be used on 33 and 11 kV lines. Number of insulators, creepage distance shall be selected based on electrical system parameters taking into account line altitude, expected environmental and pollution conditions etc. Disc Insulators shall conform to IS 731 and IS 3188. Polymer/composite insulators conforming to relevant IEC/other International standards may also be used.
14.2
14.3
14.4
129
14.5 14.6 14.7
Disc (strain) string insulators can be of ball and socket type or Tongue and Clevis type. Insulator strings shall be complete with all required hardware fittings. The fittings shall conform to IS 2486. Insulator and insulator string rating shall be selected such that a) Under ultimate design wind loading conditions, the load on insulator string shall not exceed 70% of its selected rating b) Under everyday temperature and no wind conditions, the load on insulator string shall not exceed 25% of its selected rating.
14.8 15.0
The insulation shall be designed to avoid excessive concentration of electrical stresses in any section or across leakage surfaces. CROSS-ARMS Cross arms shall be made of mild steel channel. The cross-arm should not be welded/ jointed at any place other than as specified. The cross-arms and the clamps shall be hot dipped galvanized conforming to IS 2633.
16.0 16.1
CONDUCTOR The size of conductor shall depend upon the voltage regulation, factor of safety, power to be transmitted, length of line, line voltage and mechanical strength desired. Steel Reinforced Aluminum Conductors (ACSR) or equivalent All Aluminum Alloy Conductors (AAAC), AAC (All Aluminum alloy), AACSR (Aluminum alloy conductor steel reinforced) shall be used according to requirement. Required accessories for conductor and earth-wire viz: mid-span compression joints, repair sleeve, T-connector, flexible copper bond, vibration dampers, spacer/spacer-dampers, earth wire clamps etc. shall be used suitable for type and size of conductor and earth wire used for the lines. The accessories shall conform to IS 2121. Factor of safety for the conductor shall not be less than two. The configuration of conductors on the line can be triangular, horizontal or vertical depending upon the voltage level of the lines, terrain, right of way and clearances to be maintained. In case clearance from building is difficult to secure, vertical arrangements of the conductor shall be adopted. The installation of conductor on the poles shall be carried out in accordance with the methodology given in IS 5613. Suitable insulating paint shall be provided on conductors in coastal areas to prevent corrosion as well as in theft prone areas. LT SPACERS To avoid clashing and accidental mutual touching of bare overhead conductors on LT lines, spacers shall be provided in between conductors at 130
16.2
16.3
16.4 16.5
16.6 16.7 17.0
appropriate locations in different spans (particularly for lines having longer spans or lines having large sags encountering high winds), which can be either spiral or composite. 18.0 18.1 18.2 18.3 18.4 18.5 18.6 18.7 18.8 18.9 19.0 19.1 CABLES Underground cables or aerial bunched cables of adequate rating can also be used for supplying power. Cables shall conform to relevant Indian Standards. PVC cables shall not be used in systems other than LT system. Aerial bunched cables shall be used in the theft and accident-prone areas. Direct burying of underground cables shall not be adopted except where cables enter and take off from trench. The underground cables shall be segregated by running in separate trenches or on separate racks. The cable trenches shall be properly sloped so as to drain freely any water, which may enter. Cable trenches shall not be run through oil rooms. Cables shall not be laid directly on trench floor. Adequate number of spare cores shall be included in all control cables. SERVICE LINE The service line shall be provided with insulated conductor, armoured cable or under ground cable. The service line shall have adequate margin to take care of load growth for at least five years. Service connection shall be provided either through independent service connection or through LV box. No tapping of service line shall be permitted for supplying power to any other consumer. Feeder pillar-box shall be used for providing under ground service connection through cable to more than three or four consumers. The meters for the consumer connections shall be provided in accordance with the Regulations on Installation and Operation of Meters notified by Authority. LIGHTNING PROTECTION The lightning Arrester (LAs) shall be placed at the terminal points of the lines and also at the junction points of cables and bare overhead conductor lines. For 33 kV and 11 kV lightning arrestors having rated voltage of 30 kV (rms) and 9 kV (rms) having discharge current rating of 10 kA and 5 kA complying with IS 3070 shall be used respectively.
19.2
19.3
20.0 20.1 20.2
131
20.3
The earth wire of appropriate size to take care of predicted/design fault currents and lightning shall be used. The earth wire shall be either of galvanized stranded steel (GSS) or alternatively ACSR/AACSR conductor. The earthing lead for the lightning arrestor shall not pass through any iron or steel pipe, but shall be taken directly to a separate earth electrode. PROTECTION OF 33 KV, 11 KV AND LT SYSTEM The protection scheme shall be finalized by the distribution licensee based on prudent utility practice. An earth leakage protective device shall be provided at consumer premises as per requirement of Safety regulations of the Authority.
20.4
21.0 21.1 21.2
132
Glossary
AC AAAC AAC AC-PLC AACSR ACSR AIS AMF ANSI API ARC ASME ASTM ATRS AVR AWS AWWA BFP BIS BMCR BMS BMS BS CACA CACW CCGT CCS CEP CERC CRGO CPCB CT CTU CVT CW DAS DB DC DCDB Alternating Current All Aluminium Alloy Conductor All Aluminium Conductor AC Power Line Carrier Communication Aluminium Alloy Conductor Steel Reinforced Aluminium Conductor Steel Reinforced Air Insulated Switchgear Automatic Mains Failure American National Standards Institute American Petroleum Institute Auto Reserve Closure American Society of Mechanical Engineers American Society of Testing and Materials Automatic Turbine Run up System Automatic Voltage Regulation American Welding Society American Water Works Association Boiler Feed Pump Bureau of Indian standards Boiler Maximum Continuous Rating Burner Management System Building Management System British Standard Closed Air Circuit Air Cooled Closed Air Water Cooled Combined Cycle Gas Turbine Computerised Control System Condensate Extraction Pump Central Electricity Regulatory Commission Cold Rolled Grain Oriented Central Pollution Control Board Current Transformer Central Transmission Utility Capacitance Voltage Transformer Cooling Water Data Acquisition System Distribution Board Direct Current DC Distribution Board 133
DCS DG DIN DM DOV DP DSS E/F EHG EHV EOT ESP FBD FD FRLS FSSS GCB GIS GPS GSS HEI HHV HFL HFO HIS HMIS HP HPS HRSG HSD HT HV HVDC HVW IBR ACAO ICT ID IDMT IEC
Digital Control System Diesel Generator Deutsches Institut for Normung Demineralisation Dynamic Over Voltages Double Pole Distribution Sub Station Earth Fault Electro-hydraulic Governing Extra High Voltage Electric Overhead Travelling Electro Static Precipitator Fluidized Bed Combustion Forced Draft Flame Retardant Low Smoke Furnace Safeguard Supervisory System Generator Circuit Breaker Gas Insulated Switchgear Geo Positioning Satellite System Galvanized Stranded Steel Heat Exchanger Institute High Heat Value High Flood Level Heavy Fuel Oil Hydraulic Institute Standard Human Machine Interface System High Pressure Heavy Petroleum Stock Heat Recovery Steam Generator High Speed Diesel High Tension High Voltage High Voltage Direct Current High Velocity Water Indian Boiler Regulations International Civil Aviation Organisation Interconnecting Transformer Induced Draft Inverse Definite Minimum Time International Electro-technical Commission 134
IED IEEE IS ISO JIS LA LAN LAVT LDC LDO LFC LP LSHS LT LV LVS MCC MCB MCCB MCR MFT MGR MIV MMI MOE&F MOG MOP MOV MS MSL NEC NEMA NFPA NPSH O/C OCTC ODWF OFAF OFWF OLTC
Intelligent Electronic Device Institute of Electrical and Electronics Engineers Indian Standard International Organisation for Standardisation Japanese Industrial Standards Lightening Arrester Local Area Network Lightening Arrester and Voltage Transformer Load Dispatch Centre Light Diesel Oil Load Frequency Controller Low Pressure Low Sulphur High Speed Low Tension Low Voltage Large Video Screen Motor Control Centre Miniature Circuit Breaker Moulded Case Circuit Breaker Maximum Continuous Rating Master Fuel Trip Merry-Go-Round Main Inlet Valve Man Machine Interface Ministry of Environment and Forest Magnetic Oil Gauge Main Oil Pump Metal Oxide Varistor Mild Steel Mean Sea Level National Electric Code National Electrical Manufacturers Association National Fire Protection Association Net Positive Suction Head Over Current Off Circuit Tap Changer Oil Draft Water Forced Oil Forced Air Forced Oil Forced Water Forced On Load Tap Changer 135
O&M ONAF ONAN OPU OSHA OSR OTI PA PCC PCC PDA PDM PIV PIR PLC PLCC PRD PRV PSCC PSS PTCC PVC RCC REF RMS RTD SCADA SCAPH SOE SPCB SPM STATCOM STU SVC SWAS TAC TEFC TEMA TETV TG TSE
Operation & Maintenance Oil Natural Air Forced Oil Natural Air Natural Oil Pressure Unit Occupational Safety and Health Administration Oil Surge Relay, Oil Temperature Indicator Primary Air Power Control Center Pre Cast Concrete Partial Discharge Analyzer Partial Discharge Monitoring Peak Inverse Voltage Pre-insertion Resistor Programmable Logic Controller Power Line Carrier Communication Pressure Relief Device Pressure Relief Valve Pre Stressed Cement Concrete Power System Stabilizer Power and Telecommunication Co-ordination Committee Poly Vinyl Chloride Reinforced Concrete Cement Restricted Earth Fault Root Mean Square Resistance Temperature Detector Supervisory Control and Data Acquisition System Steam coil Air Pre-heater Sequence of Event State Pollution Control Board Suspended Particulate Matter Static Compensator State transmission utility Static Valve Compensator Steam and Water Analysis System Tariff Advisory Committee Totally Enclosed Fan Cooled Tubular Exchanger Manufacturers Association Totally Enclosed Tube Ventilated Turbo Generator Time Synchronising Equipment 136
UAB UAT UCB UPS
Unit Auxiliary Board Unit Auxiliary Transformers Unit Control Board Un-interrupted Power Supply
VDE VESDA VT VVVF VWO WTI XLPE
VDE association for Electrical, Electronic and Information Technologies Very Early Smoke Detector Acquisation Voltage Transformer Variable Voltage Variable Frequency Valves Wide Open Winding Temperature Indicator Cross Linked Poly Ethylene
137

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Central Electricity Authority (Construction of Electrical Plants & Electric Lines) Regulations, 2007 DRAFT

CENTRAL ELECTRICITY AUTHORITY NOTIFICATION

(b) (c) (d) (b) (c)

TECHNICAL STANDARDS FOR THERMAL GENERATING STATIONS

PART B: 1.0 1.1

COAL/LIGNITE BASED THERMAL GENERATING STATIONS

1.5 1. 6 2.0 2.1

3.0 3.1 3.2

1890 ( with turbine driven BFP)

i) ii) 3.10 3.11

b) 100 to 300 MW: c) Less than 100 MW ii)

CONTROL & INSTRUMENTATION SYSTEM General

vi) vii) viii)

Evaporating cooling system Mechanical ventilation

PART-C: 1.0 1.1 1.2 1.3 1.4

GAS TURBINE BASED THERMAL GENERATING STATIONS

1.5 1.6 1.7

20 MW to 30 MW > 30 to200 MW > 200MW (B) Operation in simple cycle mode

2250 1825 1700

Gas Turbine rating (ISO)

20 to 30 MW > 30 to 200 MW >200 MW

3400 2850 2600

2.0 2.1 2.2

2.5 2.6 2.7 2.8

iii) iv) v) 2.16 i) ii) iii) iv)

3.4 3.5 3.6

3.7 3.8 3.9

2.0 2.1 2.2

2.4 2.5 2.6

2.13 i) ii) iii) iv) 2.14 2.15

SCHEDULE II TECHNICAL STANDARDS FOR HYDRO- ELECTRIC GENERATING STATIONS

3.4 4.0 4.1

5.0 5.1 5.2

7.0 7.1 7.2 7.3 7.4

Cooling Water System

ELECTRICAL SYSTEM General Requirements

9.2.4.4 9.2.5 9.2.5.1

9.5 9.5.1 9.5.1.1

9.5.2.6 9.5.3 9.5.3.1

9.5.7 9.5.7.1 9.5.7.2

Oil Temperature Protection Oil level low Pressure Relief Valve

v) vi) vii) viii)

SCHEDULE III TECHNICAL STANDARD SWITCHYARDS FOR SUB-STATIONS AND

1425 (1300kVp for transformer/ reactor as mentioned in Table-5) 1050

500 (at 1000 (at 92kVrms) 156kVrm s)

1000 (at 320kVrms)

2500 (at 508 kVrms)

Transmission Lines Protection Table-8

Directional IDMT over current and earth fault back up protection

Two stage over Protection Auto reclosing

Y Y (Single phase / three phase)

Y Y (Single phase / three phase)

Transformer Protection Table-9

220 kV / 132 kV / 110kV Y Y Y Y Y

Over load alarm

Y N N (above 100MVA rating) Y Y N N * If HV is controlled by Circuit Breaker

Note: (1) Y Required, N Not Required, Y/N - Optional

vi) vii) viii) ix) x) xi)

43mm/KV 60mm/kV 50mm/kV

2.7 3.0 3.1

7.0 7.1 7.2 7.3 7.4 7.5 7.6

8.0 8.1 8.2