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PIONEER GAS POWER LTD.

380-425MW COMBINED CYCLE POWER PLANT



APSIPL-05- EPC-
3-B11
ELECTRICAL SYSTEMS -
DC SYSTEM


Page 1 of 14
11.0 DC System

The DC System and its accessories shall conform to the latest editions of
national and international standards indicated in Data sheet given below
also, the DC system and its accessories shall comply with the
requirements indicated in Data Sheet given below and specific
requirements indicated below.

11.1 DC power supply with Ni-Cd battery cells forming bank shall be the
source of the power supply for control, protection, interlock, annunciation
of the complete plant including I&C system during the running of the plant
as well as for a safe shutdown at the time of the total power supply
failure. For feeding the DC supply for the above, the following shall be
provided.

11.1.1 1 x 100% battery bank with associated float-cum-boost-charger and one
spare float-cumboost charger, 1 No. DC switchboard shall be provided
for each gas turbine generator (GTG) unit. The GTG unit DC system
shall be sized to cater complete unit loads.

11.1.2 1 X 100% battery banks with associated float-cum-boost-charger and
one spare float-cum-boost charger, 1 No. DC switchboard shall be
provided for 220 kV switchyard. The switchyard DC system be sized to
cater complete 220 kV switchyard loads

11.1.3 2 x 100% battery banks with associated float cum boost-chargers and
1 No. DC switchboard shall be provided for station DC system. The
station DC system shall be sized to cater the following loads :

(a) One steam turbine generator (STG) system.

Plus

(b) One gas turbine generator (GTG) system.

Plus

(c) Common station system


PIONEER GAS POWER LTD.
380-425MW COMBINED CYCLE POWER PLANT

APSIPL-05- EPC-
3-B11
ELECTRICAL SYSTEMS -
DC SYSTEM


Page 2 of 14
Plus

(d) 220 kV switchyard system.

11.2 Tie feeders shall be provided between station DCDB, GTG DCDB, STG
DCDB and switchyard DCDB

11.3 Two (2) nos. 100% +/- 24V/+24V batteries and associated float cum
boost chargers and one DCDB shall be provided for each of GTG and
STG set for feeding the 48V/+24V load requirements. Provision in the +/-
24V DCDB for earthing the middle point through cable shall be provided
with links.

11.4 Scheme for earth fault detection shall be provided for each DC bus and
feeders.

11.5 Battery shall be sized to cater for the following loads with minimum
duration as indicated. The voltage at the end of duty cycle shall be
1.1V/cell for Ni-Cd type battery.

11.5.1 Momentary Load (For duration upto 1 minute).

(a) Tripping / closing load of 220 kV, 6.6 kV & 415V breakers.

(b) Starting current of all automatically started DC drives.

(c) Solenoid valves.

(d) In rush current of excitation system.

11.5.2 Emergency Load (For 2 hours duration)

(a) Running currents of essential DC motors.

(b) Emergency lighting

11.5.3 Continuous Load (For 10 hours duration)

(a) Indicating lamps on switchgears and control panels


PIONEER GAS POWER LTD.
380-425MW COMBINED CYCLE POWER PLANT

APSIPL-05- EPC-
3-B11
ELECTRICAL SYSTEMS -
DC SYSTEM


Page 3 of 14
(b) Control room emergency lighting

(c) Auxiliary relays

11.5.4 I & C system loads

11.6 Further, for arriving at the battery capacity, the following shall be
considered.

11.6.1 The temperature correction factor as given in IS. For this purpose,
electrolyte temperature shall be considered as 5 deg. C above the
ambient temperature.

11.6.2 25% margin for ageing as per IEEE guidelines.

11.6.3 A design margin of 20%.

11.7 Battery Chargers

11.7.1 Float charger will be rated to cater the following :
(a) Trickle charging current of the battery
(b) 10 hours load indicated above.
(c) Standing load due to all units running, starting or tripping whichever
is higher.
(d) 20 % spare capacity over above loads
(e) The float voltage output of the float charger shall be automatically
adjusted depending upon the ambient temperature such that the
batteries remain floating throught the range of variation of
temperature as specified in Project information.

11.7.2 The boost charger unit shall be rated such that the battery can be fully
charged from fully discharged condition within 8 hours.

11.8 Specific Requirements

11.8.1 220V Batteries

(a) The battery offered shall be Ni-Cd type confirming to IS:10918
suitable for indoor application.


PIONEER GAS POWER LTD.
380-425MW COMBINED CYCLE POWER PLANT

APSIPL-05- EPC-
3-B11
ELECTRICAL SYSTEMS -
DC SYSTEM


Page 4 of 14
(b) The battery shall be of closed top or sealed in type. Open type cells
are not acceptable.

(c) The battery shall be complete with accessories and devices,
including but not limited to the following :

(i) Battery racks
(ii) Porcelain insulators, rubber pads etc.
(iii) Set of lead coated intercell, inter-tier and inter bank
connectors as required for the complete installation.
(iv) Electrolyte for first filling +10% extra.

(d) One set of variable resistor load suitable for carrying out discharge
tests at 5 hour discharge rate & suitable shunt for measuring current
on all batteries shall be supplied. Alternatively, electronic controls
for carrying out discharge test of the batteries at selectable rate can
also be provided.

11.8.2 220V Battery charger

(a) The float cum boost charger offered shall be static type composed
of silicon controlled rectifiers and diodes (complete with
resistor/capacitor network for surge protection) connected in three
phase wave bridge circuit. It shall be provided with an adequately
rated isolation transformer and filters on input to minimise
harmonics on the output to keep ripple factor within acceptable
limits.

(b) Charger shall have provision for manual control if the automode
fails. Load limiting features shall be provided. The same shall be
designed for adequate short time over load to take care of the
starting of the largest DC motor/testing of lamps, etc. with other DC
loads connected to bus. The rectifier shall utilise power
semiconductors and heat sinks rated to carry 200% of the load
current continuously. The heat sink temperature shall not be
permitted to exceed 85 deg C irrespectivce of the panel
temperature.

(c) The chargers shall be provided with automatic voltage regulation in
float mode and automatic constant current regulation in boost mode.

PIONEER GAS POWER LTD.
380-425MW COMBINED CYCLE POWER PLANT

APSIPL-05- EPC-
3-B11
ELECTRICAL SYSTEMS -
DC SYSTEM


Page 5 of 14

(d) The charger shall essentially comprise the following items but not
limited to :

(i) One (1) moving coil DC voltmeter of size 96mm x 96 mm
of suitable range.

(ii) One (1) moving coil ammeter, with shunts, size 96 mm x
96 mm to read output current of float- cum-Boost charger.

(iii) One (1) moving coil centre zero ammeter, with shunt, size
96 x 96 mm to read discharge/charge current of the
battery, with suitable range.

(iv) One (1) cubicle space heater suitable for 240V AC, 50Hz,
single phase supply.

(v) One (1) 240V AC lamp for cubicle internal lighting.

(vi) Two (2) - On/Off switches with fuses for space heater
and internal lighting.

(vii) One (1) pilot lamp with series resistor on DC load side to
indicate DC "On" condition.

(viii) One (1) set of pilot lamps with series resistors on AC
main input to indicate mains AC "ON" condition.

(e) Fault indicating lamps shall be provided on the charger cubicle
and initiating contacts shall be provided for remote alarm for each
of the following faults :

(i) Mains AC failure
(ii) Float charger AC input fuse blown
(iii) Charger DC output fuse blown
(iv) Charger U/V and current limit protection
(v) Charger over voltage protection
(vi) Charger overcurrent protection
(vii) Charger filter condenser fuse blown
(viii) Charger rectifier fuse blown

PIONEER GAS POWER LTD.
380-425MW COMBINED CYCLE POWER PLANT

APSIPL-05- EPC-
3-B11
ELECTRICAL SYSTEMS -
DC SYSTEM


Page 6 of 14

(f) Type of cooling for the charger panel shall be such that no external
fans are required to dissipate the heat developed within the panel.

(g) Two sets safety gears, hydrometers, voltmeters, spanners, min-max
temperature indicator etc. shall be provided with each battery bank.

11.9 D.C. switchboards

11.9.1 For feeding the 220V DC loads 220V DC Switchboard as per clause 11.1.1
to 11.1.3 shall be provided.

11.9.2 The switchboards shall be provided with suitable quantity and type of
outgoing feeders for the auxiliaries, control supplies to various
panels/systems. For each load and auxiliary, one separate feeder shall be
provided. In addition, the following feeders shall be provided in switchboard.

(a) Spare feeders - 20% of each type and rating with a minimum of two
nos. feeders. This is the minimum quantity at the time of handing
over the plant.

(b) Switchboard 240V 1 phase space heating module - 1 No.

(c) Alarm module for common alarm of out-going feeder fault - 1 No.

11.9.3 Current ratings
The short circuit current rating of the switchboard shall be arrived
considering the contribution from charger & battery with 5% margin, with a
minimum of 15 kA.
The continuous current rating of the bus bars, incomers, ties for 220V DC
switchboards shall be the maximum D.C. load (excluding the momentary
load) on the bus plus 20% margin rounded off to the next higher standard
rating.






PIONEER GAS POWER LTD.
380-425MW COMBINED CYCLE POWER PLANT

APSIPL-05- EPC-
3-B11
ELECTRICAL SYSTEMS -
DC SYSTEM


Page 7 of 14
11.9.4 Specific requirements

(a) DC switchboards shall comply with all the requirements of this
specification and technical requirements table.

(b) Positive and negative bus bars in the DC switchgear shall be
completely segregated from each other by sheet steel partitions.

(c) Module details

(i) Incomer

The incomer modules shall be switch-fuse unit controlled.
Each incomer shall be provided with

Ammeter & voltmeter
Earth fault relay with potential free contact for
remote annunciation.
Ammeter to read Earth fault current
under voltage relay with timer
Indicating lamps for ON, OFF, earth fault, under
voltage conditions
One current and one voltage transducer for
remote indication
Necessary hardware & circuitry for fault alarm and
for lamp test & reset.

(ii) Outgoing switch fuse feeders & tie feeders/Bus coupler

These feeders shall have DC switch, fuses (2 nos.)
"ON" & "Fault" indicating lamps, supply supervision
relays, lamp test, accept & reset push button
through common alarm module.

The feeders rated 200 Amps & above shall be
provided with a shunt & ammeter.





PIONEER GAS POWER LTD.
380-425MW COMBINED CYCLE POWER PLANT

APSIPL-05- EPC-
3-B11
ELECTRICAL SYSTEMS -
DC SYSTEM


Page 8 of 14
(iii) Motor modules

For motors, starters shall be preferably housed
within the DC switchgear module. However the
resistors can be separately located in boxes/panels
within the DC switchgear room. The starting current
of the motor shall be limited to 200% of full load
current.

The motor modules shall be provided with

Switch, fuses, air break contactors
Thermal overload relays
Starting resistors with associated timers
ON, OFF, Fault indicating lamps
Necessary auxiliary contactors for fault alarm circuit
240V space heating circuit
ON, OFF- PBs for testing purposes
One shunt & ammeter
Appropriate circuitry for receiving the ON, OFF
commands from remote panels/systems, interlocks,
'OFF' command from local push buttons, etc.
MCB for space heating circuit

(iv) Space heating module

240V 1 ph, space heating module shall be
provided with incoming side switch fuse, suitably
rated 415/240V cast resin type transformer
(expected heating loads of the switchgear and the
connected motors + 30% margin) secondary fuse,
and supply indicating lamp and connection to space
heating buses. The 415V power supply for these
modules shall be obtained from the 415V main
switchboard.
(v) Alarm module

Alarm module for outgoing feeder faults shall be
provided with switch fuse, alarm accept, reset PBs,

PIONEER GAS POWER LTD.
380-425MW COMBINED CYCLE POWER PLANT

APSIPL-05- EPC-
3-B11
ELECTRICAL SYSTEMS -
DC SYSTEM


Page 9 of 14
supply 'ON' lamp, `fault detected' lamp, hooter,
necessary auxiliary contactors, control circuit for
detecting, annunciating, accepting, resetting the
fault in any module of the particular bus section.
Contacts from this module for common feeder fault
and its own module supply failure shall be provided
and used for annunciation in CRT.

Alarm module for incomer faults shall be similar
to the above except that it shall work on 240V
AC supply.


11.10 Tests for Batteries

All tests shall be conducted as per the relevant standards. Tests shall
comprise:

14.10.1 Type Tests : Performed at Manufacturer's works or type test report on
identical rating and type of cell issued by an authorised test house shall be
furnished

11.10.2 Acceptance Tests : Acceptance tests as per relevant standards shall be
performed at vendors works. Also acceptance tests shall be performed at
site after installation and commissioning of the battery including capacity
test and test for voltage during discharge.

11.10.3 A locking resistor bank which can be automatically controlled using time and
current signals along with the charger shall be supplied to facilitate
discharging of voltages as a part of routine maintenance tests.

11.11 Tests for battery chargers

The following routine tests shall be conducted at works

11.11.1 Visual checks for dimensions and general arrangement.

11.11.2 Wiring checks

11.11.3 Functional checks

PIONEER GAS POWER LTD.
380-425MW COMBINED CYCLE POWER PLANT

APSIPL-05- EPC-
3-B11
ELECTRICAL SYSTEMS -
DC SYSTEM


Page 10 of 14

11.11.4 Voltage regulation for rated input supply for loads from 0-100%.

11.11.5 Load test to show the charger can deliver the rated duty without the current
limiter device operating.

11.11.6 Ripple measurement by oscilloscope at different loads.

11.11.7 Demonstration of guaranteed efficiency and power factor.

11.11.8 Insulation test (with 500V megger)

11.11.9 High voltage test, excluding electronic controller, at 2kV AC for one minute.

11.11.10 Heat run test shall be conducted at full load for 24 hours at the vendor
works on charger.

11.12 Tests for DC distribution board

11.12.1 All routine tests as per applicable standards shall be conducted on the
board.

11.12.2 Type test reports on a identical switchgear issued by an authorised test
house shall be furnished






PIONEER GAS POWER LTD.
380-425MW COMBINED CYCLE POWER PLANT

APSIPL-05- EPC-3-
B14
DC SYSTEM
DATA SHEET
SL. NO. DESCRIPTION UNITS VALUES / REQUIREMENTS



Page 11 of 14






1.0

DC SYSTEM


1.1 Type of charger Combined float-cum-boost

1.2 DC system voltage (Nominal) 220 V , 24V / +24V

1.3 DC system earthing Unearthed for 220 V DC

1.4 Ambient design temperature
0
C 50

2.0 BATTERY DETAILS

2.1 Maximum time for boost charging of
battery
Hrs 8

2.2 Battery type Ni - Cd

2.3 Minimum end cell voltage Min. of 1.1 V per cell for Ni-Cd

2.4 Battery capacity By Bidder

3.0 BATTERY CHARGER DETAILS

3.1 DC voltage setting adjustment of
AVR for float charging
+ 10% of nominal voltage


3.2

Voltage stabilisation for constant
voltage regulator
(i) +1% of set DC voltage for +
10% voltage and +5%
frequency variation in power
supply

(ii) + 5% during transients

3.3 DC current adjustment for boost
charging
30% to 100% of maximum boost
charging current

3.4 Current stabilisation for constant
current regulator for boost charger
+ 2%











PIONEER GAS POWER LTD.
380-425MW COMBINED CYCLE POWER PLANT

APSIPL-05- EPC-3-
B14
DC SYSTEM
DATA SHEET
SL. NO. DESCRIPTION UNITS VALUES / REQUIREMENTS



Page 12 of 14





3.5 Permissible ripple content at rated
continuous load
3% maximum

3.6 Degree of protection IP 42

4.0 DC BOARD

4.1 Reference ambient air temperature 50
0
C

4.2 Degree of protection for enclosure IP 54


4.3

Type of construction

Fully draw-out, compartmentalised

5.0 APPLICABLE STANDARDS

5.1 Basic climatic and mechanical
durability tests for components for
electronic and electrical equipment
IS 9000

5.2 Environmental tests for electronic
and electrical equipment
IS 9000

5.3 Metal clad base material for printed
circuits for use in electronic and
telecommunication equipment
IS 5921

5.4 Transformers and inductors (power,
audio, pulse and switching) for
electronic equipment
IS 6297

5.5 Printed wiring boards IS 7405

5.6 Environmental requirements for
semi-conductor devices and
integrated circuits
IS 6553



5.7


Terminals for electronic equipment


IS 4007


PIONEER GAS POWER LTD.
380-425MW COMBINED CYCLE POWER PLANT

APSIPL-05- EPC-3-
B14
DC SYSTEM
DATA SHEET
SL. NO. DESCRIPTION UNITS VALUES / REQUIREMENTS



Page 13 of 14






5.8


Factory build assemblies of
switchgear and control gear for
voltages upto and including 1100V
AC and 1200V DC
IS 8623

5.9 Air break switches IS 4064

5.10 Miniature circuit breakers IS 8828

5.11 HRC cartridge fuses IS 9224

5.12 Contactors IS 2959

5.13 Control switches / push buttons IS 6875

5.14 Indicating instruments IS 1248

5.15 Degree of protection IS 2147

5.16 Code of practice for phosphating
iron and steel
IS 6005

5.17 Semi-conductor converters IEC 146-1-1/2/3

5.18 Semi-conductor rectifier equipment
safety code
IS 6619

5.19 Stationary cells & batteries

5.20 Ni-Cd battery IS 10918

5.21 Water for storage battery IS : 1069


5.22

Sulphuric acid

IS - 266


PIONEER GAS POWER LTD.
380-425MW COMBINED CYCLE POWER PLANT

APSIPL-05- EPC-3-
B14
DC SYSTEM
DATA SHEET
SL. NO. DESCRIPTION UNITS VALUES / REQUIREMENTS



Page 14 of 14









5.23





Pasted +ve plates





IS : 6071

5.24

General requirements

IS : 8320