This section of the technical specification defines minimum technical
requirements for design, manufacturing, supply, installation, erection,
testing and commissioning of the steam turbo-generator system with all
the accessories and auxiliaries.

Conditions of Service

The steam turbo generator will be installed in a separate powerhouse,
along with the entire auxiliary equipment and systems. The Powerhouse
will be provided with EOT crane for the maintenance purpose of the
turbo generator.

The turbine control shall be located in the control room, located
adjacent to the turbo generator, whereas important indicating
instruments shall be provided near the turbine in the local gauge board.
Emergency stop arrangements shall be provided in the local gauge


Design and Engineering

The SUPPLIER must offer a very reliable and efficient system with
state-of-the-art proven design with good performance over a long
period. The SUPPLIER shall offer the system including (but not limited
to) the following design and engineering features:

Highest possible thermal and energy efficiency.


State-of-the-art technology and well proven in actual operation
over a long period.


Rugged, conservatively designed, proven components and


Minimum outage for field maintenance and routine inspection.


Better operability at various load conditions.


Advanced instrumentation, control systems, shut-down and
protection system, very reliable online supervisory and
surveillance system, with diagnostics.


Minimum requirement of operating and maintenance man-

76 of 373

power and amenability to unattended automatic operation.

Suitability for harsh tropical ambient conditions prevailing at


Simple design and ease of installation.

The SUPPLIER may incorporate additional features and improvements
to enhance the efficiency and reliability of the system.

The turbine shall be horizontal, single cylinder, bleed cum condensing
type. Provision for required numbers of bleed shall be envisaged. The
High Pressure (HP) bleed steam will meet the feed water heating
requirements in HP feed water heaters. Medium Pressure (MP) bleed
steam from the turbine will meet the steam requirements of the deaerator. The LP bleed steam will meet the LP feed water heater steam
requirements. Necessary spray water pressure reducing station and
desuperheater, if required in the bleed steam line, shall be provided by
the SUPPLIER. The requirement and sizing of the Desuperheating
stations in the extraction lines shall be decided based on the possible
operation of the turbogenerator from 30 % to 100 % load.

All casings and stator blade carriers shall be horizontally split or
otherwise and the design shall be such as to permit examination of the
blading without disturbing shaft alignment or causing damage to the
blades. The design of the casing and the supports shall be such as to
permit free thermal expansion in all directions. The casing shall also
permit the inspection of the bearings without dismantling of the casing.
The bleed branches shall be located on the lower half of the casing.
The low pressure casing shall have a bottom exhaust arrangement
configuration and the exhaust casing shall be suitable for connection to
the condenser without air leakage and suitable for maintaining the
condenser vacuum. The turbine exhaust hood shall be provided with
exhaust water spray system to protect the turbine against excessive
temperature due to windage at no load and low load conditions. The
spray system shall be provided with complete spray nozzles, automatic
spray control valve, interconnecting piping, all necessary controls,
instrumentation and fittings.

The turbine shall have solidly forged and machined rotor with integral
disks. The rotor after fully machined and bladed shall be dynamic
balanced accurately in the shop and shall be given a overspeed test
under vacuum. None of the critical speeds of the rotor shall fall within
the range of 20% above and 20% below the normal running speed of
the rotor. The SUPPLIER, shall analyze the complete coupled train for
both lateral and torsional vibrations, and ensure proper separation

77 of 373

margins. The rotor shall be designed to withstand the maximum shock
loading that may occur during any power system disturbance.
Such shock loading values shall be taken for the design of the gear box
and the generator rotor. SUPPLIER shall specify clearly the
construction of the rotor, the heat treatment proposed and the
procedure for inspecting the shaft to ensure soundness and
homogeneity of the material in the QAP. The material of construction
shall be consistent with proven practices and standards.
To bring the turbine rotor from full speed to rest as quickly as possible,
whenever required a vacuum breaker valve capable of being operated
remotely from the control room and capable of operating in conjunction
with the turbine over speed protection system with necessary interlocks
and logics shall be provided. (This valve will be located in the exhaust
duct connecting the turbine and the Air cooled condenser). The valve
shall have the facility for local manual operation.

The blading shall be designed to withstand all vibrations, thermal
shocks, and other loading that may be experienced during service and
system disturbances. The blades shall be machined from forged bars or
die forged and the materials used shall be chromium steels suitable for
the temperatures encountered, resistant against corrosion and erosion
and consistent with proven experience and standards. In the low
pressure stages, if warranted where the moisture percentage is higher,
additional protection against erosion shall be provided.
The blading depending on the staging shall be adequately fastened as
per the standard practice of the SUPPLIER, but such methods of fixing
the blades shall be a proven one by long use in operation. The rotating
blades are either shrouded or tied with lacing wires depending on the
stresses and the excitation frequencies.

Gland Sealing System
The glands shall preferably be of labyrinth type and sealed with steam.
The gland packing shall be of 13% chromium stainless steel. The
labyrinths shall be of multi-section spring backed type which would
allow for any temporary deformation of the rotor shaft without
overheating the rotor due to friction. Any other sealing system
compatible with the operating conditions may also be furnished, but
however the details of the offered system shall be furnished by the
supplier. The complete piping, valves, pressure gauges, regulators etc.
required for the end seals shall be provided by the SUPPLIER. During
the normal operation of the turbine the source of sealing steam will be
from the turbine. If external sealing steam is required also during the
normal running, it should be specified by the supplier. Required gland

78 of 373

wherever provided shall have one 100 % capacity operating fan and one 100 % capacity standby fan. The shell side shall be designed for the maximum steam pressure from gland and for full vacuum.7 Bearings The Turbine shall be provided with liberally rated hydrodynamic radial and thrust bearings. Provision shall be made for measuring the temperature of the oil leaving the bearings. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION steam condenser with 2 x 100 % capacity AC motor driven exhausters shall be provided. The radial bearings shall be split for ease of assembly.III. All piping and components of shaft seal system shall be sized for 150 percent of the calculated new clearance leakages. including the turning gear operation. All bearings shall be accessible without having to remove cylinder covers. The metal temperatures of all the bearings shall be monitored by thermocouples with extension right into the white metal layer.3. 4. with steel shell backed. gear box. Suction fans.1 A pressure lubrication and control oil system shall be furnished for the turbo generator unit to supply oil at the required pressure to the steam turbine. The lubrication oil system shall supply oil to the turbine generator under all the load conditions.3. 4. The gland steam condenser shall be provided with all instruments and accessories including thermal relief valve.2. BIRLA WHITE CEMENT . generator and governing system. babbitted replaceable pads. The tube side shall be designed for the cold shutoff pressure of the condensate extraction pumps. These bearings shall be equipped with anti rotation pins and shall be positively secured in the axial direction. The cooling medium shall be the condensate from Air cooled condenser. Oil in the reservoir shall be maintained at an appropriate temperature when the TG set is idle by providing suitable electric heaters and temperature controls if required. JODHPUR. and of the sleeve or pad type. A liberal flow of lube oil under pressure shall be supplied to all the bearings for lubrication and cooling. For the hottest ambient conditions to be encountered at the site the oil outlet temperature at any bearing shall neither exceed the maximum 79 of 373 .ULTRATECH CEMENT LIMITED. designed for equal thrust capacity in both directions.8. Mitchell tilting pad type. The thrust bearings shall be of. The oil system of the turbo generator shall be designed with adequate redundancy and emergency provisions such that a failure of a single active component will not prevent the safe operation or a safe shutdown of the turbo generator.8 Lubrication and control oil system 4. the steel backed babbitted multiple segment. KHARIA KHANGAR.2.2.3.

2 The oil system shall include the following: - One hundred percent (100 %) capacity centrifugal type AC driven Main oil pump - One (1) No. 4.C motor driven pump(s). etc. JODHPUR. - One (1) D. arranged to cut in automatically if the oil pressure falls to a preset value.C motor driven auxiliary oil pump of centrifugal type. The minimum capacity of this pump shall be to ensure a safe shutdown of the turbogenerator. of one hundred (100 %) capacity A. KHARIA KHANGAR. - Flow and temperature indication for oil from every bearing. upstream of the inlet 80 of 373 . valves. - LVDH for oil purification including interconnecting piping and valves.2.8.C motor driven.ULTRATECH CEMENT LIMITED. The oil from the collecting oil tank will be pumped to the main oil tank. - Two 100 % capacity (one working and one standby) water cooled oil coolers. BIRLA WHITE CEMENT . RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION permissible temperature for the bearing metal nor the maximum safe operational temperature of the oil. - Two 100 % duty oil filters arranged in such a way that it is possible to clean one oil filter while the other is in service. - 2 x 100% (1AC+1DC) Jacking oil pump with all piping. This pump also shall cut in automatically at a pre set value of the oil pressure. - Oil storage and settling tank with adequate reservoir capacity. emergency oil pump of adequate capacity to provide adequate lubrication in the event of a failure of the A. - Oil clarification system (ELC machine of 100 LPH capacity) - Emergency gravity lube system designed for lubrication up to coasting down period of turbine & additional margin in overhead tank to address the emergency in case of delay in EOP start up - Collecting oil tank with oil transfer pump. centrifugal type. The filters and the coolers shall be arranged with continuous flow transfer valves. strainers. vent and oil mist eliminators and 2x100% capacity vapour exhaust fans.3. instruments. level indicators with float switches and alarm contacts. This pump shall also meet the requirements during the start up and shutdown.III.

4. of control oil pumps and 2 x 100 % duplex oil filters for the control oil circuit. The filter grade for the control oil shall be 10 Microns nominal. The minimum design pressure for the filters shall be the maximum discharge pressure of the oil pumps. for the lube oil.8.8.2. Collecting oil tank capacity shall be the same as Main oil tank. The oil cooler shell side shall be designed for cold shut off head of the oil pump and tube side shall be designed for a pressure of 6 kg/cm² (g). downstream of the coolers and shall be piped in a parallel arrangement with a continuous flow transfer valve. The coolers shall be of shell and tube type with removable tube bundle. 4. The filters and the coolers shall be arranged with continuous flow transfer valves. There shall be isolating valves on either side of the oil coolers (Upstream insolating v/v shall gate v/v and down stream v/v shall be glove v/v) in cooling water line. If the system envisages separate control oil circuit from the lube oil system.3. KHARIA KHANGAR. BIRLA WHITE CEMENT . Supply of the flushing oil and the first fill up of lube oil for the turbine and accessories shall be the responsibility of the SUPPLIER and preferably from the Indian market. Filter cartridges shall have a minimum collapsing differential pressure of 3.2.5 kg/cm². there shall be independent two nos.ULTRATECH CEMENT LIMITED. The coolers shall be constructed in accordance with TEMA class C. The Main and Auxiliary oil pumps and the emergency oil pumps shall be arranged to have flooded suction. the filter grade shall be 10 microns nominal. Oil filters shall be arranged in such a way that it is possible to clean one oil filter while the other is in service. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION strainer. JODHPUR. The coolers shall be amenable for easy inspection and maintenance and cleaning of one cooler while the other one is in service shall be possible.4 Filters Full flow twin oil filters shall be used. The provided surface area shall be adequate to cool the oil with inlet cooling water even with the indicated percentage of the tubes plugged (margin specified else where in the tender specification).III. Differential pressure gauge with alarm shall be provided across the filters. The tube material shall be SS304. The filters shall be either common or separate for the lube and control oil circuits. 81 of 373 . Necessary lifting lugs shall be provided.3.3 Oil coolers The oil coolers shall be water cooled with a duplex arrangement and changeover valves. If a common filter is used for lube and control oil.

7 Emergency Oil Tank Emergency gravity lubricating system shall be provided to assure the lubrication at the time of emergency due to the failure of the DC operated lube oil pump. and shall be designed to supply oil for the coasting down period of the machine. KHARIA KHANGAR.6 Oil purifier and ELC Machine A centrifugal type oil purifier shall be provided for the removal of water.2.ULTRATECH CEMENT LIMITED.5 Oil reservoir The interior of oil reservoirs shall be desalted and rust proofed with a permanent coating. Corrosion allowance of 3 mm shall be considered while designing the system. All necessary piping. The cover plate shall be adequately stiffened to carry the load. This system shall draw lube oil from an overhead tank.8. All necessary piping connections.3. In Addition to the above Electrostatic liquid cleaner machine of 100 LPH shall be provided. complete by itself with drive motor. The reservoir shall be of adequate capacity. 82 of 373 . The oil reservoir shall be so located to permit draining of the contents by gravity and shall be equipped with fine and coarse mesh strainers. Feed to the purifier shall be from the drain end of the reservoir and its operation shall be independent of the oil system. valves and fittings. level switches and level gauges shall be provided. valves and fittings. for proper ventilation.3. Reservoirs with top mounted equipment shall have sufficient rigidity. 4.2.2. BIRLA WHITE CEMENT . The reservoir shall be provided with 2x100 % oil vapour extractors. with oil separator.8. The purifier shall be a separate complete package. mounted on a skid. under gravity. All openings for piping shall be made dust and water proof.8. The flanges provided in the stainless steel oil lines downstream of oil filter shall be LJFF type if the flange is of carbon steel material or SORF if the flange is of stainless steel material.III. piping. The oil drained shall be collected in a drain oil tank/collecting tank of suitable capacity located on the ground floor of the TG building and two numbers of drain oil pumps shall be provided to pump the oil back to the oil reservoir (in case of overflow from the oil reservoir) to outside the TG building for disposal. JODHPUR. valves and fittings shall be provided for the complete oil system shall be provided by the SUPPLIER. If stainless steel material is used they shall confirm to SA 182 F 304 specification. 4. sediments and other oxidation products from the Lube oil system on a continuous basis. The complete piping shall meet the requirements of API 614.3. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION 4.

8 Collecting/ Settling oil tank The settling oil tank shall be located on the ground floor for draining the oil from the oil coolers. The electrical/ electronic and hydraulic components of the control system shall be selected on the basis of reliability over a wide range of operating conditions. The governor shall ensure controlled acceleration of the turbo generator and shall prevent over speed without tripping the unit under any operating condition or in the event of maximum load rejection. if a separate tank is provided for collecting the oil overflow from the emergency oil tank. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION The overhead tank shall be SS and the complete piping shall be of SS 304 material. oil filters and generally from the piping and equipment of the oil system. JODHPUR. 4.9 Steam Turbine Governing System The turbine governing system shall be electro-hydraulic designed for high accuracy. The tank elevation shall be finalized based on the oil pressure requirements at the bearings. 4.3.III.ULTRATECH CEMENT LIMITED. There shall be two transfer pump. The governor shall be configurable in the field.2. This is required to ensure that there is no dust ingress into the oil system while the oil is drained from the emergency oil tank.3. The Vent / overflow of the emergency overhead oil tank shall be brought down to the oil reservoir or to the collecting tank. speed and sensitivity of response. The governor shall have linear droop characteristics with a suitable range for stable operation and shall have provision for adjusting the droop in fine steps. All components used shall be well proven to assure overall system reliability and shall be designed for easy and quick replacement when necessary. The tank shall be epoxy coated on the inside. The system shall be designed with continuous overflow circulation of oil to avoid sludge formation in the tank. KHARIA KHANGAR.8. The drain lines shall be of carbon steel and shall be routed from the respective equipment and other draining points to the tank.2. gear or centrifugal type. The governing system shall have the following important functions: - Speed control Over speed control Load control Inlet Steam pressure control The governor shall be configured to incorporate the following controls while operating in parallel with the grid: 83 of 373 . for the transfer of the oil from the settling tank to the main oil tank. BIRLA WHITE CEMENT .

shall be insulated with low conductivity inert material. JODHPUR. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION 4.ULTRATECH CEMENT LIMITED. Load set point shall remain unaffected for the variation of frequency between 47. 4. reinforced by stainless steel wire net between applied layers. with surface cladding with suitable material. including piping supplied.2.3. External Forces and Moments The SUPPLIER shall furnish the allowable forces and moments on the turbine nozzles.11 Thermal Insulation and Lagging The steam turbine and the other high temperature parts.2.III. 4.4. C above the ambient temperature. Pre molded pipe section insulation of glass fiber material shall be considered for turbine Steam pressure cycle with aluminum cladding of material code L 100 & L150 4.5 Hz and 52. where required.2.4 Capacity and Performance Requirement 4. The insulation shall be designed. The insulation shall be so arranged that it can be removed for access to the flange bolting.2.5 Hz b. As a minimum requirement the turbine shall be designed to withstand the external forces and moments calculated in accordance with the requirements of NEMA SM 23.1 Turbine Generator Rating The turbine rating and other performance criteria shall be as specified in the section on Performance Guarantee.10 a.2. For turbine casing only glass fiber insulation removable pads shall be considered.2. as mentioned elsewhere in the specification.2 Bleeds The turbine shall be provided with required number of bleeds.4. BIRLA WHITE CEMENT .4. control valves and other parts that require periodic maintenance. 4. such that the outer surface temperature of the insulation does not exceed 20 Deg.3 Economic Load 84 of 373 . KHARIA KHANGAR. The turbine inlet steam pressure shall be maintained at the set value by controlling the power export to the grid. The SUPPLIER shall also furnish the thermal expansion movements on each of the nozzles in the turbine.3.

JODHPUR.4 Over Loading The system offered shall be suitable for an overload specified in the specification on continuous basis. 4. The minimum load at which the turbine is required to operate continuously shall be 15% of the designed capacity.9 Speed adjustment The turbine speed at no load shall be adjustable between 6% below and 6% above rated speed.III. The device to raise speed at no load must incorporate limiting means to prevent it from reaching a dangerous speed. The speed governor droop.2.4.4. permanent speed variation from no load to rated output etc.4.e. 4.2. 4. shall be within the limits specified in IEC Recommendations Publication 45. the operation of the electronic speed governor shall prevent the speed rising to a value at which the over-speed trip is set to operate. i. 4. Means are to be provided whereby the speed of the turbine at no load can be raised in a controlled manner for the purpose of testing the over speed trip mechanism and provision made to ensure that such means do not interfere with the action of the speed governor in normal operation.2. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION The specific steam consumption shall be the lowest for operating loads between 80 to 100%.8 Parallel operation The characteristics of the turbine shall be such that the turbine generator set can be run in parallel with the State power grid and / or with the machine to be added later on and possess no abnormal features either individually or collectively.6 Specific steam consumption This guaranteed specific steam consumption / heat rate shall be for the economic load and the testing shall be as per IEC Recommendations Publication 46. and the maximum load is thrown of. 85 of 373 .5 No load and Minimum load operation The turbine shall be capable of operating under no load condition during loss of load for a maximum period of 60 minutes.2.ULTRATECH CEMENT LIMITED. BIRLA WHITE CEMENT . 4.. KHARIA KHANGAR.7 Governing Characteristics When the machine is operating with rated steam conditions and at rated speed.2.

4.12 Steam inlet pressure falling below pre-determined level. High temperature trip for LP stage steam flow. High turbine bearing temperature.ULTRATECH CEMENT LIMITED. Axial thrust wear trip.10 Over speed trip In addition to the speed governor and electronic over speed relay with 02 of 03 logic (wood word make Protec 203). In the event of sudden load rejection. The duration of the over speed test shall be less than 2 minutes. KHARIA KHANGAR. Maximum speed An overspeed test of the turbine rotor shall be carried out preferably at the SUPPLIER's works.4. Turbine differential casing expansion. Supplier shall indicate all over speed trip set point. Steam temperature falling below pre-determined level. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION 4. The over speed trip mechanism shall be capable of being reset when the speed of the turbine has decreased to a speed not lower than the rated speed. Low control oil pressure. Essential trip circuits to be provided are: - 4.2.11 Trip system The turbine shall be provided with a trip system for the complete and rapid closure of steam valves effectively preventing all steam admission to the turbine independently of the closure of the governing valves.4. BIRLA WHITE CEMENT . In order to avoid sudden re-admission of steam to the turbine the trip system shall be fitted with interlocking devices so that trip resetting cannot take place until steam admission can only be achieved as per normal starting up procedure. the turbine and generator shall be protected against excessive overspeed by a separately actuated (Mechanical trip device) overspeed device which operates the trip system. Steam temperature raising above pre-determined level. Lubricating oil pressure falling below pre-determined level.III. Condenser vacuum falling below pre-determined level. 86 of 373 . 4. High turbine bearing vibration. Excessive wheel chamber pressure. should the speed governor fail to meet the requirements the overspeed trip shall operate to prevent any damage.2. The overspeed trip setting shall be stated by the SUPPLIER in the operating instructions. Steam inlet pressure raising above pre-determined level. The overspeed shall not be more than 20% of the rated speed. JODHPUR.2. The overspeed tests shall be at a speed exceeding by 2% the maximum calculated overspeed that would occur if the speed governor failed and if the maximum overspeed was limited by the action of the overspeed trip device only.

4. The detailed specification is indicated in Instrumentation section. All the bearings of the turbine. temperature and time the components will not fracture or deform to a greater extent than is permissible.2.4.16 Materials of construction The selection of materials for parts of the machine shall be based on the experience of the SUPPLIER and experimentally determined data and shall conform that under conditions of stress.15 Hydraulic test All parts subjected to steam pressure shall be tested hydraulically for a pressure of 1.ULTRATECH CEMENT LIMITED. Speed and differential Expansions. gear box and generator shall be provided with the probes for measurement. For those parts which are made of materials which may be damaged by such tests the test pressure shall be agreed by the OWNER and the SUPPLIER during tender stage. JODHPUR.2.4.14 Critical speed The critical speed for the combined turbine and generator train shall be sufficiently away from the rated speed to avoid any adverse effect on the operation of the unit over the range of operating speeds.III.13 Vibration The foremost in the Turbine Supervisory Instrumentation system is the vibration measurement which provides the basic protection to the Turbogenerator.2. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION 4. The system of vibration measurement shall include shaft radial vibrations at the radial bearings.2. BIRLA WHITE CEMENT . gearbox and generator. axial displacement and thrust position. 4.4. The materials selected shall be clearly indicated in the turbine and auxiliaries data sheets. The shaft radial vibration measurement shall employ proximity probes in the X-Y configuration in two orthogonal directions in each bearing.5 times the working pressure. The maximum allowable vibration under any specified operating conditions shall be indicated by the SUPPLIER. Vibration measuring and monitoring systems of reputed make (Bently Nevada make of the latest 3500 series system is preferred) shall be provided for measuring the shaft vibration of turbine.4. KHARIA KHANGAR.2.17 Variation of steam pressure and turbine The turbine shall be capable of accepting variations from the rated conditions within the limits specified by IEC Recommendation 87 of 373 . 4. 4. 4. For the measurement of the thrust position two proximity probes shall be employed in a dual voting arrangement.

5.5 Safety 4.5. 4. Acoustic enclosure should include fire protection & fire alarm system with sufficient movable path inside the enclosure.1 All controls shall operate in a fail safe mode. 4.2. The hardness of the teeth shall not be less than 58 in the Rockwell Hardness Scale. which appears to be necessary.5.1 Gear Box The gear and pinion teeth shall be case carburized and ground to an accuracy class of 4 or higher to DIN Standards.19 Noise The turbine and gear box shall be provided with acoustic enclosure to reduce the noise level to the specified limits of 80 dB (A) at 1 m distance from the equipment.6 Gearing 4. Noise measurements shall also be made during running tests in SUPPLIER’s works so that any corrective action. 4.3 Piping shall be arranged in such a manner as to avoid tripping or overhead problems. The gears 88 of 373 .4 Surface temperature on any point shall not exceed 60 Deg C. Piping or tubing of insufficient mechanical strength which is standing or hanging shall be protected from personnel traffic. 1 meter from the periphery and at the heights of the center lines of main and auxiliary machines. BIRLA WHITE CEMENT . Measurement shall be made with the machine running under normal operating conditions at not less than 8 points evenly spaced around the machine and auxiliaries. can be carried out in advance of operation at site.5. approx.2 All coupling and gears shall be provided with adequate guards.5.ULTRATECH CEMENT LIMITED.2. JODHPUR. 4.III. The overlap ratio shall be adequate to ensure a quiet operation.2.5 Very high standard of safety shall be built into the set with high degree of redundancy.18 Limit of lubricating oil temperature The SUPPLIER shall furnish the permissible temperature for the bearing metal.2. 4.2. 4.6. 4. KHARIA KHANGAR. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION Publication 45 except inlet high high pressure trip.2.2.

RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION shall be dynamically balanced before assembly. Couplings shall be designed to allow for removal of any rotor without opening adjacent turbine casings. Easily removable coupling guard shall be placed over each of the exposed coupling. Illuminated sight glasses shall be provided to inspect the lube oil drain from each individual bearing.6. alarms and switches for the operation of the barring gear.C motor. The gear box design shall be as per the requirements of AGMA with service factor of 1. generator and the gear box. The barring gear shall be interlocked with the lubrication system to prevent its operation without lubrication. Provisions shall be made to level each piece of equipment separately. KHARIA KHANGAR. The barring gear shall be capable of starting the rotor from rest and run it continuously at low speeds.7 Base Frame Suitable base frame either common or individual shall be provided for the turbine. The turbine panel shall be provided with necessary push buttons. BIRLA WHITE CEMENT .2.C supply failure.2 Barring Gear The turbine shall be provided with a barring gear of mechanical type driven by an A. All bearings of the gear box shall be readily renewable and shall be possible to inspect the bearings and the gears readily without disturbing the shaft alignment. Easily removable coupling guard shall be placed over each of the exposed coupling. The gear box shall be capable of transmitting the maximum rating of the set and be able to withstand 20% overspeed over a period of minimum five (5) minutes.ULTRATECH CEMENT LIMITED. The flexible couplings between the turbine and the gear box and between the gear box and the generator shall be of reputed make.2. JODHPUR. The system shall be capable of Auto & Manual engagement and automatic disengagement when the turbine speed goes above the normal barring gear speed. 4. 4. The power rating of the coupling shall be at least equal to the turbine rated power times the service factor in accordance with AGMA 514. The gear box shall also be designed for the short circuit condition of the generator.III. The leveling pads shall be accessible for field leveling after installations with the equipment mounted and the base plate on the foundation. 89 of 373 . The system shall also have facility for manual turning in case of A. to rotate the turbine and generator after shutdown to prevent thermal distortion of the rotor. The housing shall be provided with breather.6. A turbine directly driving the alternator with out a gear box in between is also acceptable.

ULTRATECH CEMENT LIMITED. restraints 90 of 373 .10.1 The flow diagrams enclosed in the tender document are only intended to indicate the general scope and nature of work to be carried out and do not indicate the exact quantum of work to be carried out by the SUPPLIER.10. testing. engineering.10. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION 4. Complete assemblies of supports. Returns. Crosses. Flanges. 4. thermal insulation etc. Pipes. Elbows. unloading.8 Turbine Starting Time The turbine shall have the following starting time from stand still to full load: Cold start Hot Start after 8 Hrs Shutdown 4.2 Scope of Supply 4. Bends. erection. Valves d.2.2. anchors. Gaskets and Fasteners. The piping provided shall be complete in all respects including valves. Tees. Laterals. guides.2.2. Headers and Manifolds. Reinforcement pads. Plugs. Threadolets and other similar fittings. JODHPUR. supports. Tubes. e. delivery. Reduces.10 Piping.2. painting and commissioning of all piping system complete with accessories within the terminal points indicated elsewhere in the specification.1 General The scope of work covered by this specification includes design. c.1 For all the piping systems included in SUPPLIER’S scope of supply shall include but not limited to: a. 4.9 90 Minutes 20 Minutes Turbine external piping The turbine external piping shall include the piping and its accessories as indicated in this tender document. specialties. BIRLA WHITE CEMENT .III. Caps and Closures. Full & Half Couplings.2. Sockolets. Unions. Sleeves & Saddles. Stubs & Bosses. Valves and Specialties 4. KHARIA KHANGAR. as required.1. b. Weldolets. cleaning. fabrication. supply. handling at site.

fittings.10. Restraints. h. Indian Boiler Regulations.2 SUPPLIER shall supply all necessary drains and vents including antiflash funnels as required for the safe and effective draining / venting of the piping systems.2. the necessary weather hoods shall be supplied by the SUPPLIER as directed by OWNER. walls.10. SUPPLIER’S scope includes the supply of thermowell stubs with plugs. It must be noted that the flow diagrams may not indicate all the drains and vents that would be required. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION etc. Concrete Foundations. Varnishes.1 The equipment and work under this specification shall conform to the following standards / codes: a. Thinners and other Painting Materials. all as erected by the Supplier.2. for routing the pipes and provide proper finishing after piping is erected. Guides. f. as required for Hangers. k.10. 4.10.3. 4. 4. SUPPLIER shall make openings in floors.2. The drains and vents indicated on the flow diagrams shall however be regarded as minimum requirements. Supports. It is SUPPLIER's responsibility to identify the requirements of drains and vent whether the same have been shown in the flow diagrams or not and supply the necessary pipework. Anchors etc. i.ULTRATECH CEMENT LIMITED. In case of temperature measurement points. Indian Regulations of Inspector of Explosives.3 Design Requirements 4. The drains and vents shall be led upto the nearest floor drain in case of cold water systems and upto the flash tank in case of steam and hot water systems. Pedestals etc. hangers and supports etc. Where required. Crossing Ceilings and Walls. including welded attachments etc.2. g.III. valve All instrument impulse piping and fittings upto the last root j. 91 of 373 . b. All Paints. gratings etc. BIRLA WHITE CEMENT .3 Wherever uninsulated pipes cross walls or roofs. Auxiliary Steel. Weather hoods for Pipes.2. All approach platforms for all valves & instrument shall be provided with proper stair case (Cage ladder shall not be used). Primers.2. KHARIA KHANGAR. JODHPUR.

3.3.3 All piping shall be routed so as to avoid interference with other pipes and their hangers and supports.3. ventilation ducting.2. equipment etc.1 and all other associated ASME Standards. the following requirements shall be taken into account by the SUPPLIER: 4.III. American Petroleum Institute Standards (API). 4.10.3 meters above walkways and working areas and 8 meters above roadways unless otherwise approved by the CONSULTANT. American Society of Mechanical Engineers (ASME) Codes.9 Drains shall be provided at all low points and vent at all high points as per actual layout regardless of whether the same have been shown in the flow diagrams or not. Applicable Standards for Structural Steel. 4. IS:2062: Codes of Practice for use of Structural Steel in general Building Construction.3. 4.2.ULTRATECH CEMENT LIMITED. structural members. JODHPUR. h. Manufacturer's Standardization Society (MSS) USA Standard Practices. Standards.8 Overhead piping shall have a minimum vertical clearance of 2. electrical cable trays.3. Pipe Fabrication Institute (PFI) USA. 4.10. the bends shall be free from wrinkles and bulges. g. Structural Steel (Fusion Welding Quality) d. i. 4. The bends shall be made by cold bending. f.3.2. i.4 All piping shall be grouped where practicable and shall be routed to present a neat appearance.3.5 The piping shall be arranged to provide clearance for the removal of equipment requiring maintenance and for easy access to valves and other piping accessories required for operation and maintenance. Pipes at working temperatures above the ambient shall however not be buried.2 While routing piping.2. Pipelines shall be sloped towards the drain 92 of 373 .2.2.2. 4. Adequate clearances shall be ensured with respect to the above to accommodate insulation and pipe movements. IS:800 : ii.10. the pipes may be arranged in trenches or buried. e. American Society of Testing and Materials (ASTM) Specifications.7 Wherever pipes are to be bent.6 Piping shall generally be routed above ground but where specifically indicated / approved by the CONSULTANT. BIRLA WHITE CEMENT . RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION c. American National Standard ASME code for “Power Piping " ASME B 31. KHARIA KHANGAR.

10. 4. foundations.10 Provision shall be made while preparing piping layout to accept control valves. restraints and anchors as required for the piping systems erected by him.2.2.3. 4. KHARIA KHANGAR. BIRLA WHITE CEMENT .2. 4.3.17 At all intersection joints. Likewise.III. vents etc.12 All local instruments shall be located on pipelines as to render them observable from the nearest available platforms and accessible for maintenance.2. 4. which form a part of hanger / support system.10. it is SUPPLIER's responsibility to design and provide suitable reinforcements as per the applicable codes and standards. guides.3. welded attachments to piping etc.2. shall be suitably located by SUPPLIER to suit the layout evolved by him. This does not however relieve the SUPPLIER of his responsibility for the design and engineering of the support system.13 Piping with operating temperatures above or below the ambient shall be routed so as to provide adequate flexibility for the pipes. control valves.18 SUPPLIER is responsible for the complete design and engineering of all supports. and the design and detailed engineering of individual components of the assemblies as also all associated steel work.2. JODHPUR. desuperheaters and other specialities as required by the Suppliers. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION points. unions shall be provided to facilitate disassembly.3.10.ULTRATECH CEMENT LIMITED. concrete pedestals. restraints etc. if not indicated on OWNER's layout drawings. 93 of 373 . Sufficient upstream and down stream lengths shall be provided for flow measuring devices. 4.15 All steam tracer lines shall be provided with expansion loops to take care of differential expansion between the tracer and main line.3. drains. anchors.10. 4. type and detail etc.10.2. unions shall also be provided at suitable points on straight lengths of screwed pipelines.10.10. 4.10.14 Tap-off on main lines for field routed pipework.3.2. may be used for guidance. flow measuring elements and any other on line speciality or equipment supplied by others. SUPPLIER's scope of work shall include but not be limited to the location of all required hangers.11 At all screwed valves and screwed connections on equipment. supports. Information contained in OWNER's drawings regarding support location. 4.3.16 Stubs for instrumentation. wherever not located on OWNER's piping layout drawings shall be suitably located by SUPPLIER in accordance with the flow diagrams and layouts. While the designs shall conform to applicable codes and standards and shall be consistent with inter national practice.3.

27 Branch connections: Equal Branch: a) b) NB 65 & Above .2. For 50 NB and below shall be socket welded type. 4.2.10. anchor stubs.2.20 Pipelines of NB 40 size and below are regarded as field run piping.19 The design and engineering of all temporary pipe work as required for erection.III.BW equal tee as per ASME B 16.10. 4.10.21 The SUPPLIER shall design and prepare all fabrication isometric drawings for all IBR piping and NB 50 and above Non-IBR piping. The SUPPLIER shall furnish the calculations for reinforcement for nozzle openings and calculations for welded attachments carried out on the piping. equal tees and reducers shall be as given below: a) b) For pipe size 65 NB and above shall be butt welded type. The SUPPLIER shall ensure that the design and reinforcement for branches shall be calculated as per ASME B 31.11 94 of 373 . For class 900 and above the flanges shall be WNRTJ type.2.26 Pipe fittings like elbows. cleaning. it has to be checked for statutory requirement of Indian Boiler Regulations.3.3.23 In case of branch welding for temperature above 250 deg C. SUPPLIER shall also submit orthographic drawing with Bill of Material for Non-IBR piping of size NB 40 and below.25 All flanges of pressure class 300 and less than 900 shall be of weld neck type. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION All pipe to pipe joints shall be by butt welding only and no couplings shall be used.SW equal tee as per ASME B 16.10. etc for external loading shall be included as per ASME/ IBR to be included. no pad shall be used for pressure reinforcement and external reinforcement. flushing. 4. JODHPUR. For piping reinforcement regulation 362 shall be used.3.3. Also the specific local stress calculation for safety valve stubs.2. testing and commissioning of the piping systems installed by the SUPPLIER is the responsibility of the SUPPLIER.ULTRATECH CEMENT LIMITED. 4.3. BIRLA WHITE CEMENT . KHARIA KHANGAR. SUPPLIER shall prepare isometric drawings indicating the layout of field run pipe work.1 and in addition. 4. blowing out.3.3.3. It is SUPPLIER’s responsibility to plan suitable layouts for these systems insite as per the requirements of this specification and in consultation with OWNER and/ or CONSULTANT. 4. 4.9 NB 50 & Below .

3.1 code.9 or ASME B 16.Cm shall be of size NB 25 with two root valves.Cm and less the size shall be NB 15 with one root valve. Equal tee with reducing coupling or reducer to be used for run size NB 50 and below. c.30. 4. For pressures 40 Kg/Sq.11 to be used. For temperature above 400°C irrespective of pressures.28 All pressure tappings for pressure applications above 40 Kg/Sq.10. However. d. b. Suitable expansion loops.3.2.C.C.ULTRATECH CEMENT LIMITED. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION Unequal Branch: a.10.3.30 Pipe Sizing and Layout 4. KHARIA KHANGAR. the piping system may have to be selected even with a lower velocity than the minimum indicated.10. Branch NB 65 and above. In addition the statutory requirements of the IBR shall also be taken care of wherever required.11 to be used. 4. restraints and anchors shall be provided so as to ensure compliance with the applicable codes and to limit the stress and reactions to within the allowable values.2. No branch welding shall be used for equal branch. Flexibility analysis shall be made for all piping systems with operating temperatures above 100 Deg.30. the root valve size shall be NB 25.1 The design of the piping system shall be based on the ASME B31. BIRLA WHITE CEMENT .III. 95 of 373 .3. if the available pressure drop is to be maintained. and only tees as per ASME B 16. 4.2 All piping shall be sized considering the allowable velocity and allowable pressure drop in the system. 4. Branch up to NB 50 SW half coupling as per ASME B 16. The indicative flow velocities in pipes shall be limited to the following values. for run pipe size NB 65 and above.3. The correct locations of hangers and supports.2.10. shall be considered for the flexibility analysis. with as applicable spring stiffnesses. However no reinforcement pads shall be used for applications with design temperature exceeding 300 Deg. branch piping with suitable reinforcement shall be used.29 All thermowell boss shall be one (1) inch NPT.10.2. JODHPUR.2.

61 22 .2.76 7– 0.35 35 . general service Pump discharge.7 kg/sq.3 0. 4. general service under 2.5 .30 15 .25 20 .0.4 1. viscous liquid Pump discharge.33 25 .70 kg/sq.0 - 10 -15 0.0 1. JODHPUR.30. general service 2. 4.(g) Saturated steam over 7 kg/sq.30.(g) Header.3.2 .4 sub - Superheated steam at 7.2 .5 2. viscous liquid Header. boiler feed Pump suction.20 10 .5 0.0.0. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION Allowable velocities for sizing of pipes Nominal pipe size In mm Saturated steam at atmospheric pressure Saturated steam at 0-1 kg/sq.5 1.1.4 2.9 1.1 – 35 kg/sq.35 30 .3 0. boiler feed Pump discharge.9 0. Lower velocities may be selected if found necessary to meet the allowable pressure drop across the pipes.cm.1 .1 1.30 25 .1 1.2.7 .III.4 The above velocity values are indicative and showing the maximum limits of the flow velocity.2 1.6 0.cm.ULTRATECH CEMENT LIMITED.2 2.4 1.3 .15 mm & above 15 .0 kg/sq.4 2.6 0.1.5 1.2.0 - - 0.6 0.10.4 .5 All pipes of size NB 50 & below shall be schedule 80 thickness for all 96 of 373 .cm. condensate Pump discharge.9 0. KHARIA KHANGAR.9 1.3.3 Drains at all low points and vents at all high points shall be provided.cm.4 All local instruments shall be located on pipelines so as to render them observable from the nearest available platform.1.0 0.10.9 1.22 20 .0 kg/sq. 4.1.(g) Saturated steam at 1.40 30 .4 1.6 0. BIRLA WHITE CEMENT .0.cm.(g) Superheated steam at 35.7 0.2.43 35 .50 40 .2.(g) Compressed air Pump suction.33 30 .3 .5 .(g) Superheated steam over 70 kg/sq.(g) Superheated steam at 0 – 7 kg/sq.6 .2.3.cm.2.10.55 22 .61 50 .(g) & up Note : 10 .(g) Average velocity in Meter / Second Below 50 mm 50 to 150mm 200 15 .cm.1 .33 28 .1 . condensate Pump suction.20 17 .30.cm.50 20 .9 .4 2. general service Pump suction.8 1.cm.2 .8 1.4 1.43 15 .2.2.50 20 .30 20 .5 .0 18 0.

4 Materials 4.10. the piping material shall be IS 1239 Black Heavy Class for size upto NB 150 and as per IS 3589 for size NB 200 and above. vents and air services shall be of seamless steel. safety and relief valve exhausts. 4. carbon steel piping as per ASTM A-106 Grade B.10.III. raw water.11. 4. flanges. 4. KHARIA KHANGAR. 4.C and less than 510 Deg.3 Piping for services at temperatures less than 400 Deg.2.6 For the safety valve exhaust piping.8 For Service air applications the piping shall be GI pipes IS 1239.4.4. condensate. For cooling water and raw water applications the piping material shall be IS 1239 Black Heavy Class for size upto NB 150 and as per IS 3589 for size NB 200 and above. boiler feed. JODHPUR.9 and ASME B16.10. 4.C.5 Other Services: Carbon Steel Piping as per ASTM A-106 Grade B.2.4.10 For piping system where IS1239 or 3589 pipes are used.4.C shall conform to the specifications of ASTM A-335 P22 (2 ¼ chromium 1 molybdenum steel) or its equivalent.2. All flanges shall be as per ASME 16.4.4 HP and LP chemical dosing system: Stainless Steel to SA 312 TP 304 specifications. All materials shall be certified by proper material test certificates.10. Piping for services with metal temperatures higher than 510 Deg.9 For instrument air applications: IS 1239 GI pipes.4.2. 4..2. fasteners shall not be inferior to the specifications given below.C for steam.4. for cooling water. drain piping etc.2. All piping except. 4.ULTRATECH CEMENT LIMITED.2. 1/2% molybdenum ferritic alloy steel seamless pipe as per ASTM A335 P-11 or P12. raw water and air services the piping could be of ERW. Piping for services with metal temperatures equal to or greater than 400 Deg.10.C.10.4.10. where the exhaust steam temperature is less than 400 Deg. 1 1/4% chromium.1 Pipe materials for various services and materials for fittings.10. the fittings shall be as per A 234 as per ASME B 16.5. All material test certificates shall carry proper heat number or other acceptable references to enable identification of the certificate with 97 of 373 . For cooling water. BIRLA WHITE CEMENT .10. 4. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION applications.2.

All piping shall be fabricated true to lines and elevations as indicated on the piping drawings. limited by transport considerations and erection constraints. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION the material it purpose to certify. 98 of 373 .10. Further.III.ULTRATECH CEMENT LIMITED.5. JODHPUR.2 Piping NB 50 mm and above size shall be fully fabricated at SUPPLIER's Works which shall be adequately equipped with the required machinery. 4. The heat number shall also be indicated on the material certified. gauges. longitudinal welds in adjoining sections shall be staggered to a minimum of 90 degrees during fabrication.2. 4.5.10. 4.5 The use of companion flanges to connect two pieces of pipe and the use of odd or short pieces of pipe in making up long runs is prohibited except as noted on OWNER's piping drawings. Fabrication and erection of piping systems NB 50 mm and above size shall be as per SUPPLIER’s fabrication drawings.7 Bends in seam welded pipe shall be oriented so that the seam is positioned along the neutral axis.10. SUPPLIER's fabrication drawings including isometrics.1 Pipelines NB 50 mm and above size are deemed prefabricated. SUPPLIER's fabrication drawings shall take into account the requirements of these specifications as also all applicable codes and standards including statutory regulations such as Indian Boiler Regulations. The extent of fabrication at works shall be such as to restrict field welding to circumferential line joints alone.5.10. welding etc.2. 4. only socket weld elbows to be used.2. templates. SUPPLIER shall prepare necessary fabrication isometric drawings.10.2.2. shall carry all details of fabrication.5. 4. as may be required for obtaining the necessary statutory clearances. tools and tackles etc.3 Pipelines having size NB 40 mm and below are deemed field run and are hence fabricated in site. Suppliers shall provide the details of the facilities available at their works for fabrication of pipe work. KHARIA KHANGAR. 4.10. BIRLA WHITE CEMENT .5 Fabrication and erection 4.4 All welded attachments on pipelines shall be of same material as the parent pipeline and shall be subjected to the same fabrication and welding procedures as the associated piping.2.10. if required. fabrication and erection shall commence only after the necessary clearance have been obtained from the statutory authorities. the number of circumferential line joints to be performed in the field shall be held to a minimum.2.6 Where welded pipe or fittings are used.2. In case of systems requiring statutory clearance. For bends.5.

KHARIA KHANGAR.5.15 The first circumferential weld joint after a pipe bend shall be after a minimum straight length of two times the pipe diameter or 500 mm.2. BIRLA WHITE CEMENT .5. 4.5. No external support shall be welded on valves and specialities except as provided by the Manufacturer. Cutting of standard elbows to odd angles as required per layouts.5.18 The SUPPLIER shall check the bench marks provided by the OWNER.10. Only cold bending which does not require stress relieving operation may be carried out at site.III.13 All welded branch connections shall be of suitable structural adequacy by virtue of the intrinsic weld connection.2.2. The nipples shall be fabricated by the SUPPLIER at site as required.14 All threads on piping components shall be taper pipe threads as per applicable standards.10. whichever is less.2.11 Neither butt nor branch joints shall be closer than twice the pipe diameter to any other joint in the same pipe except where "weldolet" type fittings are used in which case the branch weld must be made to the "weldolet".10. Welded branch connections are not an acceptable alternative where tees have been specified. Any bending requiring preheating has to be done only at shop.9 Gas cutting for bolt holes including for U-clamp supports shall be prohibited.2. Crimping of pipes to form bends is not acceptable.12 All pipe bends.5. The pipe bends shall be true to angle and radius and shall maintain a true circular cross section of pipe without deformity or undue stretching. Cold bending shall be done using pipe bending machine (manual or electric).5.10.10. 4. 4. where the pipe diameter is NB 65 and above. 4. Bends shall be free from wrinkles and bulges. It shall be the SUPPLIER's responsibility to establish all 99 of 373 . shall have a radius of five nominal pipe diameters unless otherwise specified on the OWNER's piping drawings. reinforcing plates or rings or material inherent in the branch. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION 4.2. 4. JODHPUR.10.2. 4. It is the SUPPLIER’s responsibility to provide reinforcement wherever necessary for branch connections. 4.10. is included in SUPPLIERS's scope.10.10.17 Welding ends for butt-welding shall be as per Standard V-bevel with an included angle of 75 degrees.8 No welding shall be carried out on lined pipes. 4.ULTRATECH CEMENT LIMITED. 4.

dirt.23 a. All stub and other attachment to be welded on the piping system shall be carried out in the shop or in pre-fabrication yard and only in situ butt welding alone will be carried out. After erection. All flanges and fittings shall be accurately machined and drilled true to the template. b.10. Use may be made of standby pumps wherever available for the purpose. "Welding Specification for Fusion Welded Piping Systems". Before erection all fabricated pipe work.2 to 1.III. All piping including valves and specialities shall be cleaned by the SUPPLIER before and during erection to remove grease. Final welding of joints shall be undertaken only after the set up of piping is fully checked with respect to layout drawings.2.2.10. BIRLA WHITE CEMENT .10.5. scale and welding slag. b.20 No welding / gas cutting shall be done locally to valves with soft seating components in order to prevent distortion of the soft seats. all steam.2. Welding. fittings and components etc.ULTRATECH CEMENT LIMITED. flushing & blow-out a.10.22 Welding and Non-destructive examination 4.4. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION layouts and levels using his own surveying instruments.2. water and condensate lines shall be mass flushed with water.5.10. dust. assemblies. welding shall be carried out after taking into account specific requirement and/or recommendations of the equipment supplier. shall be thoroughly cleaned internally and externally by blast cleaning or by power driven wire brushes.5. 4. c. 4. subassemblies. Cleaning.9. The cleaning velocities in water and condensate lines shall be 1. The brushes shall be of the same or similar material as the metal being cleaned. KHARIA KHANGAR. c.19 All pipe flanges and contact surfaces shall be concentric with the axis of the piping.2. 4. non-destructive examination of welded joints and repair of weld defect areas shall conform to Clause No. 4.2. 100 of 373 . At equipment terminal points. JODHPUR. The SUPPLIER shall protect the bench mark and shall not remove or disturb the bench mark without the approval of the OWNER.5 times the operating velocities in the pipelines.

For purposes of steam blowing. the inside of all pipes.24 d. BIRLA WHITE CEMENT . All compressed air pipework shall be cleaned by blowing compressed air. valves. in the event for any reason steam blow out has to be done after installation of electrical tracing. f. It is SUPPLIER's responsibility to install necessary temporary pipework for blowing and remove the same after blowing and render all other assistance to OWNER for carrying out the blowing operation. OWNER will make available low pressure steam as required. e. d. tight oil and lubricating oil lines shall be cleaned by pickling. On completion of erection. Orifice plates should not be erected until hydrostatic testing and cleaning operations are completed. All auxiliary steamlines shall be steam blown to effectively remove scale and slag. shall be clean and free from loose scale and foreign matter before subjecting the line to any test / inspection.10. e.ULTRATECH CEMENT LIMITED. Mechanical equipment and pressure relieving devices should be blanked-off or removed from the line during pressure testing and control valves should be set in the open position for the duration of the test. at pressures given in the applicable codes listed in data sheet or as given in the line designation schedule. However.5. All fuel oil. then due care must be exercised regarding steam temperature to be used for blow out. b. KHARIA KHANGAR. g. h.III. The test pressures shall be maintained until all welded / flanged joints are inspected for leakage or atleast for ten minutes. Lines having check valves should have the source of test 101 of 373 . fittings etc.2. Alternately. these lines can be cleaned by steam blowing subject to the timely availability of steam for this purpose. Electrical tracers of fuel oil lines shall be installed only after steam blow out and cleaning of the FO lines. All piping systems shall be tested hydrostatically pneumatically by the SUPPLIER after erection. JODHPUR. Inspection and testing a. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION 4. c.

Test pressure readings may be taken at the lowest point of the system being tested provided the effect of static head is taken into consideration. The rate of pressure increase must not exceed 7 bars per minute. Expansion joints. withheld for the hydrostatic tests.ULTRATECH CEMENT LIMITED. h. Clean water at a temperature of not less than dew point or 10°C whichever neither higher. KHARIA KHANGAR. When conditions require a test pressure to be maintained for a period of time. instruments. JODHPUR. SUPPLIER shall replace the gasket or gland packing and retest the system to the satisfaction of OWNER. No one should be allowed near piping/equipment under test when the test pressure is near the yield strength or when test pressure over 35 bars are being applied. shall be removed or blanked off from the line before testing. When draining the fluid. After hydrostatic test any leaky joints shall be cut out and repaired or completely replaced and test repeated until the test has been satisfactorily passed. orifice plates etc. The pressure should be lowered by 10% before inspection for the leaks. k. After completion of hydrostatic test. If any valve is found to be leaking part the bonnet joint or steam gland packing. during which the testing medium in the system might be subject to thermal expansion. nor exceeding 50°C should be used for hydrostatic test. filters and similar equipment for which the maximum permissible cold test pressure is lower than the hydrostatic test pressure applied to the system. safety valves. m. BIRLA WHITE CEMENT . n. A block valve is required on the line from the test pump to the pipeline/equipment under test. shall be installed in an approved manner. l. j. provision may be made for the relief of excess pressure thereto. the pipelines should be vented slowly to avoid excessive vacuum. i.III.. The SUPPLIER shall consult the OWNER / CONSULTANT for specific guidance. f. 102 of 373 . g. o. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION pressure located on the upstream side. Orifice plates shall however be installed after completion of cleaning operations.

4. regulations and safety codes in the locality where the equipment will be installed. stops and supports. Pump discharge gauge must be visible to the pump operator for the duration of the hydro test.4 Constant load hangers / spring hangers shall be provided wherever necessary for critical piping systems such as main steam piping and boiler feed delivery piping.10. Reports on Visual Examination. fabricate and furnish erection drawings for all hangers. Chemical Composition b. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION 4. Heat treatment in the case of pipes used for steam service. shall not exceed ± 25% of the rated load. q.3 It is desirable that supports should as far as practicable. impact etc. if variable spring hangers are used.1 All equipment covered under this specification shall comply with all currently applicable statutes. The variation between hot and cold loads. JODHPUR. BIRLA WHITE CEMENT . KHARIA KHANGAR. as called for in the respective material specification standards. 4. c. Mechanical properties such as tensile.10.2. Hydrostatic Tests.6 Hangers and supports 4. f. etc.2. Dimensions.6. IBR approved Certificates. auxiliary structures. Only calibrated test gauges should be mounted in the upright position. flattening. required for the proper installation and support of the piping.25 p. e.2. be arranged adjacent to the pipe joint.ULTRATECH CEMENT LIMITED.2.2 The SUPPLIER shall design.10. 103 of 373 . bending. The following test certificates shall be submitted to the OWNER / CONSULTANT for review: Material a. NDT Reports. clamps. h.10.2.6. g. guides.2.10. 4. anchors. d.

7.2.6. All valves shall preferably be of outside screw and yoke type. material and type shall be interchangeable with one another.10 Vertical pipes near tanks should be supported from pad plates already provided on the tank shell.10.1 General Technical Requirement • All valves shall be suitable for the service conditions i. 4.9 All components of hangers which move relative to the pipe during expansion shall be connected to the pipe clamps or lugs in such a way that these parts are outside insulation.2.5 Lugs and additional structural members should be suitably welded to the pipes wherever necessary for hangers and restraints.2. 4.10.2. 4. Valves performing similar duties and of same size. 4. JODHPUR. • All gate valves shall be of full-way type. 4. 104 of 373 . when in the full open position.III.2.e. BIRLA WHITE CEMENT . at which they are required to operate.6.10.10. KHARIA KHANGAR.6. 4. the bore of the valve shall not be constricted by any part of the gate. flow.ULTRATECH CEMENT LIMITED.8 All rigid hangers shall provide a means for vertical adjustments after erection. 4. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION 4.11 All vertical lines shall be properly supported on the vertical run and additionally provided with adequate number of lateral restraints where the length of vertical run exceeds 5 M. temperature and pressure. SUPPLIER shall endeavor to layout the work such that pipe load stress imposed on the supporting steel are kept to minimum.10. rating.2.7 Valves All bare pipes on racks and sleepers shall be clamped at intervals of atleast 2 M. 4.12 4. • All globe valves of size NB 50 and below shall be of integral type. pipes should not be supported from brick walls.10.6.2. • All rising stem valves shall be provided with back seat to permit repacking (of glands) with valves in operation. Pipe clamps shall have a minimum thickness of 6 mm.13 In selecting position and type of hangers.2. Except for small bore lines.

• When globe valves are provided as integral bypass valve.B and minimum schedule 80 thickness. The pipe used for mounting the integral bypass valve shall be seamless to SA 106 Gr.III. 400 and 600. The size of the valve shall be minimum NB 25.M. seat shall be inclined at such an angle from the vertical 105 of 373 . RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION • Reconditioning of seating surface shall be possible without removing the valve body from the line. • Bypass valves shall be motor operated.8Kg. The pipe used for mounting the integral bypass valve shall be seamless to A 335 Gr. • Manually operated valves shall be provided with gear operator of proven quality conforming to some Internationally accepted Standard and Make if the torque required to operate the valve exceed 13. • The body. BIRLA WHITE CEMENT . the direction of flow of fluid must be marked on the body of the main valve by stamping or embossing. KHARIA KHANGAR. • Integral bypass valve shall be provided for valves of size NB 100 and above with pressure class rating 900 and above. The material of integral bypass valve shall be SA 105.P22 and minimum schedule 80 thickness. • All valves shall have indicators or direction clearly marked on the hand-wheel so that the valves opening / closing can be readily determined. The material of integral bypass valve shall be A 182 F22. Integral bypass valve shall be forged gate or globe valve socket welded to ASME B 16. The construction of globe valves shall facilitate for easy disassembly of the internals (stem and disc).ULTRATECH CEMENT LIMITED. • Integral bypass valve shall be provided for valves of size NB 250 and above with pressure class rating 300.11. • All globe valves shall be of vertical stem type. Integral bypass valve shall be forged gate or globe valve socket welded to ASME B 16. • All valves shall be closed by rotating the hand wheel in the clockwise direction when looking at the face of the hand wheel. JODHPUR. if the main valve is motor operated. • Integral bypass valve shall be supplied in the condition of “As welded” with the main valve.11.

BIRLA WHITE CEMENT .3 All gate valves with pressure seal bonnet and used for steam application shall be provided with bonnet relief nipples. Generator shall be suitable for over loading of 110% for one hour in every 12 hours and 150% for 30 seconds.11.10. 4. Generator shall be 106 of 373 .2.2.10. 4.11.1 General 4.11 SPECIFICATION FOR GENERATOR 4.10. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION so as to facilitate closing and to prevent chattering for check valves. • Direction of flow shall be marked on the body of globe valve and check valve. KHARIA KHANGAR. All valve end connections shall suitably be protected to prevent damage and entry of dirt till erected.2. The necessary coupling bolts shall also form part of the supply.4 The valves used in the vacuum service shall be gland sealed valves.1.10 or as per respective codes.ULTRATECH CEMENT LIMITED.III. 4. End to end dimensions shall be in accordance to ASME B 16. 4. • Valves to be installed outside shall be required to have the stem properly protected against atmospheric corrosion.2 The nominal output of the unit shall be delivered at power factor from 0. JODHPUR. design and construction of all types of valves shall be subject to the approval of the OWNER. • Y type globe valves are to be provided in drain and vent root valves for more than or equal to class rating 900.8 PF.1. The generator cooler shall be bottom mounted. • • No asbestos or cadmium based material shall be used.1 The generator shall be of closed air circuit water cooled (CACW) type housed in IP 54 enclosure and driven by Steam turbine.2.7. • All valves under the purview of IBR shall be provided with IBR certificate.2 The materials.11. which will be connected to the piping upstream or downstream of the valve depending on the application.2. • The valves as well as all accessories shall be designed for easy disassembly and maintenance. 4. All sampling and root valves furnished shall be of integral body bonnet type.

the ratio of the negative sequence 107 of 373 . 4.2.4 The rating and specification of all the required accessories should be suitable for 11 kV rated voltage.1.III. 4. Y. 4.2 and operate satisfactorily under system conditions stated above.11.2. 4.6 The generator shall be star connected and the main and neutral leads shall be brought out of the stator frame for insertion of current transformer for protection.2.8 The generator shall be capable of withstanding without damage a stator current of 150 % for a period of 30 seconds. KHARIA KHANGAR. The machine shall be capable of operating continuously on an unbalanced system such that.11.11. The SUPPLIER shall submit his proposal scheme to explain housing arrangements of various current transformers.11.11. 4. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION able to operate at full load with a variation of ±10% in voltage and ±5% in frequency. 4. The generator shall withstand on the sudden application of maximum load or sudden loss of maximum load and during momentary short circuits or sustained ground faults.1. 4.1.7 The short circuit ratio (SCR) shall not be less than 0. with a continued voltage and frequency variation of ±10%. The generator shall be suitable for grounding through grounding resistor.9 The generator shall be capable of withstanding without damage a three phase.2.10 The maximum line charging capacity at rated voltage that can be obtained without negative excitation and with stable operation shall not be less than 35% of rated kVA.1.11.5 The generator shall be suitable for operation over a range of voltage variation as mentioned at 4. a line-to-line.ULTRATECH CEMENT LIMITED. 4.2.1. Excitation System shall have a control accuracy of ±0. JODHPUR. B in clockwise rotation.2.5%. with none of the phase current exceeding the rated current. BIRLA WHITE CEMENT . 3 Phase R.11. a line-to-earth or two line-to-earth short circuit for a period of three seconds. 4.5.11 The saturated rated direct axis sub transient reactance of generator should not be less than 14% and not more than 18%.3 Generation voltage of the Unit shall be 11 kV.12 The moment of inertia of the generator shall be so selected that it meets the requirement of over speed.1. when operating at the rated speed and with an excitation corresponding to a 5 % over voltage at no load. 4.2. metering and surge protection apparatus. 4.

KHARIA KHANGAR. the machine should be designed so as to set the negative sequence relay at 10% of the FLC especially while operating in parallel with grid and system harmonics.17 The equipment offered shall be suitable for manual and auto control from the machine control panels located in the control room. BIRLA WHITE CEMENT .1.1. Offered value is I2 = 10%). The SUPPLIER shall indicate maximum allowable duration for clearing fault inside generator under this condition.1 The generator shall be designed so as to be capable of running at over speed of the turbine.2. The rotor shall be tested at 1.2 times the rated speed for two (2) minutes. to ensure that no damage occurs to the stator laminations.11.2. 4.2.2. In other words.15 The design of the generator structure and housing in which resonance might become objectionable shall be so proportioned as to avoid the possibility of resonance with higher rated frequency or multiple and within the frequency variation.1.14 In the design of generator.ULTRATECH CEMENT LIMITED.11. 4.11. 108 of 373 .2.1 and under fault conditions shall be capable of operation with the product of (I2/IN)2 and time (t) in seconds not exceeding 15.18 The machine shall be suitable for low resistance earthing of the neutral through neutral grounding resistor to limit the maximum earth fault current to 100 A.16 The synchronous generator shall be designed and constructed so as to facilitate easy repair / replacement of generator stator bars and rotor pole winding at site without the necessity of going back to works for repairs. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION component of current (I2) to the rated current (IN) does not exceed 0.11. 4.11.2. and all parts of the generator and other equipment shall fully and safely withstand stresses resulting from over speed operation.2.11. 4.11.1.III. each part shall be so proportioned that the maximum unit stresses therein resulting from any continuous operating conditions specified shall not exceed one third of the yield point or one fifth of the ultimate strength of the material whichever is less. 4.1. 4. (As per IEC in case of direct cooled rotor winding maximum value of I2/In shall be 8% for generator capacity less than 350MVA. JODHPUR.2.2 Over Speed 4. Suitable provision shall be made in the base frame of the Generator to facilitate easy removal of the rotor body by sliding it on the bed plate.

11.4 The insulation and taping of the coils shall be such as to prevent permanent injury from exposure to dampness to provide adequate corona shielding.3 Insulation 4. The SUPPLIER shall also furnish sufficient details on replacing. to withstand high temperatures without injury.2. Detailed drawings shall be submitted showing the arrangement of conductors and the thickness and nature of all materials used both for insulation and mechanical protection in the slots of the stator.11.2. servicing / repairing of the generator. etc.11. and of the same construction as the coil insulation in the stator slots.III. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION 4.2 Insulation of minimum `F ' class as specified in IEC specification of the latest issue shall be used. The bearing metal temperatures shall be detected by means of duplex RTDs which shall be hooked upto the temperature scanner of the control panel in the control room.2.2.8 PF at any working voltages (±10%) and any frequency (±5%) in the range stipulated. after completion of winding.4 Temperature Rise 4. shall be VPI treated. BIRLA WHITE CEMENT . for the specified voltage & frequency range.3 The end turns and coil connections shall have not less than full insulation. The SUPPLIER shall furnish temperature limit curve. The quality of the insulation must be such that it is non-hygroscopic and no deterioration will take place when subjected to the maximum. KHARIA KHANGAR. when operating continuously at the maximum continuous rating at its rated 0..1 The offer shall give a full description of the windings offered both as to the conductor and insulation.2. JODHPUR. The coil and end turns shall be impregnated with high grade insulating varnish.11. 4. 109 of 373 .2. 4. 4. equivalent to. 4.3. the temperature rise shall not exceed Class-B limit at full load. The insulation. Care shall be exercised that the blocking of air passages shall not occur.4. in case of damage of the windings for VPI treated windings.11.ULTRATECH CEMENT LIMITED.3.11.3. to prevent the entering of magnetic particles and to prevent formation of zones. specified operating temperatures nor must it be permanently injured when exposed to this feature as the machine is to operate in a most tropical climate. Provision shall be made for tightly wedging the coils in the slots with the wedges which shall not shrink or buckle.2. The SUPPLIER shall furnish detailed write-ups on treatment methods and procedures.1 Even though insulation of ‘Class-F’ must be used. giving time factor involved.3.11.

If the temperatures are not within the specified limits.2.3 Guaranteed maximum temperature rise.III.2. coolers. 4.2. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION 4.5.. C.2 or IS:4889 or equivalent standards. etc. 60034.2. for the stator and rotor windings of the machine.2 The generator shall be guaranteed to be capable of giving its rated output under the conditions described earlier without exceeding the temperature rise as specified and without tolerance. satisfactorily and without undue heating.1 Cooling Generator shall be provided with adequate cooling systems based on air circulation principle.4. A tolerance will be permitted in the determination of efficiencies as per IEC 60034.5. 4.2 Measurement of temperature shall be made as specified in IEC.2.4 The machine shall be capable of generating more kW than the rated kW during operation of the machine from 0. complete with fans etc. 75%. above inlet temperature of the cooling air not exceeding 45 Deg. The air passages in the stator.11. the vendor shall do the necessary modifications to bring the temperature within the prescribed limits before acceptance by the OWNER.6.5 Efficiency And Output Guarantees 4. C winding temperature.2. KHARIA KHANGAR. C.11.2.8 power factor at 11 kV at frequency 5% below normal.2.11. 50% and 25% shall be as furnished. C and the maximum cooling water inlet temperature as 35 Deg.2. 4.2.ULTRATECH CEMENT LIMITED.11.8 lagging power factor to unity PF but within the kVA rating of the machine.1 The guaranteed overall efficiency of the generator at rated terminal voltage and power factor at 75 Deg..4. The maximum temperature of inlet air shall be taken as 43 Deg. when operating under rated load conditions shall be as follows: a) Stator winding by embedded temperature detectors - 85 °C b) Rotor winding by resistance - 90 °C 4. for the percentage rated output of 100%. rotor fans.5. The efficiencies shall be determined by summation of losses method as specified in the latest edition of IEC Publication No. 4.3 The machine shall further be capable of operating continuously at full load at 0. JODHPUR. shall be designed to give a smooth and quick flow of air. 110 of 373 . depending on the capacity of the units.11. BIRLA WHITE CEMENT .4.11.11. 4. Temperature rises shall be within the Class 'B' insulation Temperature rise limits.

4.6. 4. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION The SUPPLIER should submit drawings in detail to show the cooling system he proposes for the generator. 111 of 373 . 4.4 The coolers shall be constructed out of admiralty brass and shall be located clear off the stator on the bottom of the generator.2.2. short circuit conditions. cm(g) and tested for two times the design pressure. The coolers shall be designed for the shutoff head of the cooling water pumps which will be about 5 Kg/Sq. The Cooler shall have isolating valves on either side of the coolers (Upstream insolating v/v shall gate v/v and down stream v/v shall be glove v/v) in cooling water line.11.11. The pedestal of each generator will be supported on the concrete foundation. 4. size of the unit. JODHPUR. KHARIA KHANGAR.2 The SUPPLIER shall submit a detailed description of the cooling system taking note of the class of insulation and maximum permissible temperature. shall be included in the scope. Any leakage from the cooler shall be drained safely and properly and there shall not be any chance of the cooling water finding its way to the stator / rotor windings. Justification for the adequacy shall be given in the description of the cooling system.6. 4.11. The design shall be such that the generator can deliver 100% of rated output with one section out of service.3 Duplex type RTDs of minimum two numbers each shall be provided in the cold and hot air passages.6.2.ULTRATECH CEMENT LIMITED.2 The SUPPLIER shall give full particulars of the extent to which the generator will be assembled for purpose of shipment and the work to be done at site. Suitable moisture detector device shall be used to detect and warn accidental leakage of water into the cooling air stream.11. 4.11.5 The cooler shall have ten percent plugging margin and shall be sectionalised and designed to be suitable for shutting off section by section for cleaning. All necessary accessories like shims.1 All parts of generator shall be designed and constructed to safely withstand maximum stresses during operation.3 Pedestal bearings shall be provided for alternator for ease of maintenance and shall be insulated from ground to prevent shaft currents.7.2.2. out of phase synchronizing.III.7.. over speed.7 Construction 4. BIRLA WHITE CEMENT .11.6.2. dowel etc.2. All sole plates shall be interchangeable and suitably machined and prepared for use at site with minimum amount of work.

Munsell Green.11.5.8 Stator The stator frame shall be a single piece to consist of a cylindrical casing of welded plate construction.2.4 After primer.2. shade RAL 6024.3 The insulation between turns of field winding shall consist of special epoxy impregnated insulation and glass laminates shall be used for the insulation to ground.5 The field poles shall be provided with adequate damper windings to ensure stability under fault conditions and to meet (I22 x t) value of 15.11. 4. the generator enclosure shall be given two coats of epoxy paint. To facilitate synchronization a shorted damper consisting of several round copper bars in each pole head shall be provided.11.1 The rotor construction shall be of cylindrical type.7. JODHPUR. 112 of 373 . The factor of safety on yield point of material shall not be less than 1.11. mounted on the shaft. 4. 4.9.11. BIRLA WHITE CEMENT .2 The design and construction of the rotor shall be in accordance with the best modern practice and shall be fully described in the offer.III. Light non magnetic alloy end shields shall be bolted to the ends of the frame.9.9 Rotor 4.11.2. Rotors of four pole machines shall be made up of stacked laminations.9.2. The stator winding shall be of the double layer lap type with Class 'F' insulation. 4. KHARIA KHANGAR. annealed punchings of high quality silicon steel to give minimum electrical losses. A comprehensive series of ultrasonic examinations on the rotor body shall be done to ensure that absolutely no inadmissible internal failures are present and that the material meets the quality standards.9. 4.7 The assembly shall be dynamically balanced at shop at rated speed and maximum speed. 4.6 The rotor shall have pedestal bearings with oil cooling system so that the end shields could be removed without disturbing the bearings for inspection of the rotor/stator coils. Stator core shall be made up of segmental.4 The rotor spider shall be of steel constructions. reinforced internally in the radial and axial direction by stationary web plates making the entire frame perfectly rigid. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION 4. The generator rotor shall be forged from a single piece ingot of special alloy steel carefully heat treated to obtain excellent mechanical and magnetic properties.ULTRATECH CEMENT LIMITED.

Heaters shall be suitable for operation on a single phase 230 V AC supply. 4. rings or other means.13 Space heaters & RTDs 4. nut and nut guards for coupling shall be included in the scope. The earth terminals shall be designed to terminate Galvanized Iron conductors. The fly wheel effect shall be incorporated in the alternator and turbines as integral part and not added in the shape of separate weights.ULTRATECH CEMENT LIMITED.2. 4.2.2 A complete set of test reports covering metallurgical strength. 4. All coupling bolts.11.2. properly treated. A suitable double pole switch shall be mounted on or adjacent to the stator frame for the manual switching of the heaters.2. heavy momentary overloading and other stresses without damage.1 The generator shaft shall be made of best quality forged alloy steel.11. including maximum over speed without vibration or distortion and shall be able to withstand short circuit. The shaft shall be of ample size to operate at all speed. crystallographic and ultrasonic tests performed in each shaft during various stages of its manufacturing shall be furnished as also the complete specifications of the shaft material forging and its design parameters such as stresses and critical speed.11. suitable shaft earthing shall be provided.11.11.13. To prevent the flow of harmful shaft currents damaging the bearings.10 Earth Terminal Two Nos. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION 4.2.11. KHARIA KHANGAR.12. of Earth terminals shall be provided. BIRLA WHITE CEMENT . The coupling flange shall be forged integral with the shaft and the shaft coupling shall comply with the requirements of IEC for shaft coupling. 4. Location and the maximum temperature of the heaters shall be such that no damage can be caused to any insulation.3 The generator shaft shall have a suitably shaped flange for coupling to the turbine.11 Speed Regulation The moment of inertia of the alternator together with that of the turbine shall be sufficient to ensure stability and the speed regulation specified in the section covering turbine for full load rejection.12. JODHPUR.1 Suitably rated heaters shall be installed within the enclosure of the generator.2.11.III. 4.12 Shaft 4. The alignment limit for the shaft shall be as per the latest NEMA / DIN standards.2. 113 of 373 .11.12.2.

The digital auto excitation regulator shall be fed from Permanent Magnet Generator (PMG) which shall be coupled at the end of the generator shaft.2. It should be complete with necessary cable entries.14. JODHPUR. fully tropicalised. per stream.11. to enable operation of the set even during failure of PMG supply.ULTRATECH CEMENT LIMITED. nos.14 Excitation System 4.2.11. Nos. automatic excitation regulator. The following minimum displays shall be made available in the operator pad / digital display unit: a) b) c) d) 4.III.2 Duplex type RTDs shall be provided in the following locations.11. Nos. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION 4.2. auto / manual control facilities. 4. on / off and raise / lower selector switches.11. Exciter Field Current Exciter Field Voltage Generator Voltage Generator Power Factor The excitation system shall be provided with the following minimum features: a) b) c) d) shutdown e) f) g) h) Generator voltage control Auto power factor control Field current control Excitation buildup during startup and field suppression Limiter for the under excited range & delayed limiter for overexcited range PT fuse failure detection and auto changeover Diode failure supervision Stator current limitation for lagging & leading loads 114 of 373 . which shall be hooked up to the temperature scanners: a) b) c) d) e) Coil sides Stator core Bearings Cold & Hot air circuits Exciter Field 4.3 - 4 4 2 2 2 Nos.2. each for DE and NDE Nos.11. KHARIA KHANGAR.14. Alternative arrangement shall be made available for supply to the excitation regulator.2.14. per phase. BIRLA WHITE CEMENT .13. high speed. A digital excitation regulation system (with twin redundant auto and a manual back-up channel) shall be provided to control the excitation of the synchronous generator by varying the current applied to the field of the main exciter.1 A brushless exciter shall be used and it shall be mounted on the out board end of the generator frame. adjusting rheostats.2 The excitation regulation system shall be of the ‘state-of-the-art’ microprocessor technology. RTDs shall be provided for hooking up to the temperature scanner in the control panel.11.2.15. Back-up manual mode for testing / emergency operations Follow-on mode for each operation to have bumpless transfer between auto channel and manual channel Audible annunciation for internal faults and for channel changeover with accept provisions RS485 Communication port with MODBUS protocol for configuration / setting option from PC / DCS Digital display & keypad. 4. lightning arrestors and surge capacitors in the generator terminal boxes. if available as their standard practice.1 Main power terminal boxes shall be fully phase segregated and suitable for the envisaged type of connection arrangement.4 Terminal cubicles.3 The SUPPLIER may propose to accommodate auxiliary equipment like current transformers.2. potential transformers. 4.15.11. Each channel will have it’s own thyristor / power bridge arrangement. 4. 115 of 373 .2. Space heaters for anticondensation shall also be provided.5 AVR panel shall have a height of 2200 mm. 4. Necessary vibration transducer.ULTRATECH CEMENT LIMITED. Accessory Equipment 4. for front panel operation All necessary software for interfacing the system with PC / h) Self diagnostic facility b) c) d) e) DCS 4. shall be provided with non-magnetic type gland plates.2. Requirements of such equipment shall be in accordance with IS / IEC standards and the specifications furnished elsewhere in this document. KHARIA KHANGAR. BIRLA WHITE CEMENT .2.III.11.15. JODHPUR.14. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION i) j) k) 4.2 The generator shall be provided with stator temperature sensors installed in the stator winding with leads and shall be brought out to the terminal boxes. including base channel of 100 mm.4 Rotor current limiter Load angle limiter Volts / Hz limiter The system offered shall have the following facilities: a) f) g) Two independent auto cum manual channels. if used for single core cable connections. displacement transducers with transmitters shall be provided which shall be hooked up to the control panel in the control room.

2.11.2. 116 of 373 . e) Determination of open-circuit characteristics. KHARIA KHANGAR. frequency variations. 4. g) Over speed at 120% for 2 minutes and vibration there of. f) Determination of short-circuit characteristics. bearings and embedded temperature detectors. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION 4.11.16 Protective Devices 4.2. Tests The following tests shall be carried out on the machine: a) Measurement of DC resistance of stator and rotor windings.17 4. Metering and Control cubicles and the schematic diagram shall be offered. BIRLA WHITE CEMENT .2 Tests The generator shall be completely assembled at works and type tests as specified below shall be conducted on the assembled unit and auxiliaries as per the latest edition of IS / IEC. b) Insulation resistance of stator winding (before and after high voltage tests).III.2 The SUPPLIER shall note the system conditions like voltage.1 The protective devices as listed under the topic Protection.2.1 4. JODHPUR. d) Phase sequence. SC level at the location of the proposed generating units and offer suitable generating equipment with necessary accessories required for satisfactory working of the generating units.17.circuit cooling.2.11. c) High voltage test of stator and rotor windings at industrial frequency.17. 4. h) Pressure test on coolers for close .ULTRATECH CEMENT LIMITED.16. k) Impedance test of the rotor winding.11. i) Determination of efficiency by separation of losses methods. Detailed test reports shall be furnished. rotor winding. j) Vibration.

copper loss with equivalent method including exciter. m) Measurement of Shaft Voltage n) Polarization Index o) Wave form recording.17. b) Temperature rise test of windings. JODHPUR. Tests on Exciters a) High voltage test b) Measurement of resistances c) Measurement of insulation resistance 117 of 373 . if the generator manufacturer had not carried out the type tests on similar machine (kW rating & speed): 4. r) Harmonics s) Voltage balance test t) Air gap u) Noise test v) Temperature rise test at iron loss. KHARIA KHANGAR. the following type tests shall also be carried out. c) Instantaneous Three (3) phase short circuit test at rated speed and 30% voltage. p) Shaft vibration measurement q) Momentary over current test for 150% of rated current for 30 Secs.ULTRATECH CEMENT LIMITED. In addition to the routine test.11. d) Determination of reactances and time constants.III. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION l) Stator winding capacitance and tan delta measurement.3 a) Mechanical run test for temperature rise.2. BIRLA WHITE CEMENT .

PTs.. 118 of 373 . Test reports for all the type tests on the generator.11. Function of RTD and it’s circuits Pressure tests on coolers Tests on other equipment like CTs. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION 4.2. Measurement of stator and rotor winding insulation resistance. as per relevant standards. JODHPUR. LAs. Overall response of machine and excitation system Adjustment of excitation regulator parameters Synchronising test Dynamic checking of all protective functions Checking and commissioning of various other auxiliary equipment. Over speed test Measurement of shaft voltage Measurement of stator and rotor winding resistance Phase sequence test before excitation (with residual voltage) and after excitation Open circuit and short circuit test Load acceptance and rejection test at selected loads from no load to full load. shall comply with the routine tests etc. & LAs carried out on similar equipment already supplied shall be furnished for approval. CTs.III. PTs.ULTRATECH CEMENT LIMITED. KHARIA KHANGAR.17. BIRLA WHITE CEMENT .4 Tests at Site Site tests for generator shall include the following: Mechanical run and vibration measurement.

testing and supply of equipment covered under this specification shall include but not necessarily be limited to the following: 4. Where Indian Standards are not available.12. synchronising and control cubicles and the associated equipment mounted therein. they shall conform to relevant British.12.ULTRATECH CEMENT LIMITED.2.12.12 SPECIFICATION FOR CONTROL CUBICLES. specifications. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION 4.2 Codes and Standards 4.1 The design. IS:3156 - Auxiliary potential transformers. IS:5578 IS:11353 4. manufacture and performance of equipment covered by this specification shall conform to the relevant Indian Standards and Codes. IS:3202 - Code of practice for climate proofing of electrical equipment. This specification covers the requirements of protection. busbars.III. IEC:44 - Instrument Transformers IEC:185 - Current Transformers IEC:186 - Potential Transformers IEC:255 - Electrical Relays IEC:1036 - Static Meters Scope of Work The scope of design.1 Scope PROTECTION. IS:3231 - Electrical relays for power system protection.2. 4. wiring. main connection and aux.12. engineering and fabrication 119 of 373 of cubicles as per the .2. BIRLA WHITE CEMENT .2.2.1 Design. KHARIA KHANGAR.2.3.12. IS:2705 - Auxiliary current transformers.2.12.3 & - Marking and arrangement of switchgear. JODHPUR. metering. METERING. IS:1248 - Direct acting electrical indicating instruments. IEC and American Standards.2. 4. 4. manufacture.2 The equipment shall conform to following standards in particular.2.

4. formed on a framework of standard sections.2.12.5 mm thick for rest.12.4 The cubicles shall be suitable to be installed on a base frame supplied in one piece along with foundation bolts.12. 4.6 The degree of protection of the cubicles shall be IP 42.12. free standing. including 100 mm base channel.4. JODHPUR.5 A suitable removable undrilled gland plate shall be provided for cable entry from bottom.2. test blocks. 4. BIRLA WHITE CEMENT .12.2 Supply and mounting of all the equipment and auxiliary equipment like auxiliary relays.4 All internal wiring between all equipment upto the terminal blocks and the interpanel wiring.2. 4.3 The protection system shall be provided with communication ports / auxiliary contacts to integrate the system with the PURCHASER’s DCS /ECS for the purpose of Data Acquisition.2 Cubicles shall be sheet steel enclosed dust and vermin proof type. plugs.2.2. The enclosure shall be of cold rolled sheet of minimum 3 mm for front and back and 4. etc.4.III.2.2. 120 of 373 . Amply dimensioned oblong holes shall be provided at the bottom of all the cubicles for their installation on base frame.1. 4.3.ULTRATECH CEMENT LIMITED.3 All doors and openings shall be provided with neoprene gaskets. in addition the cubicles shall have an additional base channel at the bottom with smooth surface.5 Preparation and furnishing of all data / drawings / documents as per the requirement and specifications.4.1. 4. test switches.1.4.12. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION 4. 4. with height of 2200 mm.3.6 Testing at works of the cubicles and the mounted equipment.2. necessary for satisfactory functioning of the control and protection system. KHARIA KHANGAR.2.3. The supporting structure shall be so designed to form a rigid structure. Cubicles shall be floor mounting.2.12.4 Design Requirement 4.12.1 The cubicles shall be of 'Simplex' type.12.1 Constructional Features 4.3. Anti vibration type mounting shall be provided.



All instrument and control gears and relays shall be mounted on the
front. All equipment shall be flush or semi-flush type.

Checking and removal of components shall be possible without
disturbing the adjacent equipment. It shall be possible to set all the
measuring relays “insitu”. All mounted equipment inside the cubicles
shall have “identification tags” of self sticking engraved tapes; in
addition identification numbers shall be painted on cubicle wall to give
permanent identification mark. The mounting of terminal blocks and
any other auxiliary equipment such as transducers, interposing CTs
etc. shall be done in such a way so as to be readily accessible but
without impeding the access to internal wiring and components.

The centre line of switches, push buttons and indicating lamps shall
be not less than 750 mm from the bottom of the cubicle. The centre
line of relays and meters shall not be less than 450 mm from bottom
of the cubicle. All switches, push buttons, indicating lamps, relays,
etc. shall be neatly arranged in a matching manner.

The cubicle shall be matched with other cubicles in dimension, colour
and mimic.

All the cubicles shall be of simplex type and shall consist of vertical
front panels with mounted equipment and rear wiring access. Doors
shall have handles with locking facility.


All wiring shall be done with PVC insulated, 1.1 kV grade, single-core
multi strands (minimum 3 strands) annealed copper conductors
suitable for temperature and humidity specified. The cross section of
the wires for voltage, current and control circuits shall be 2.5 Sq. mm
and that for the alarm circuits shall be 1.5 sq. mm. The wires shall be
vermin proof and shall be laid in plastic gutters.

Each wire shall be identified at both ends with wire numbers by
means of PVC ferrules. Colour coding for the wires shall be as per
IS:375. Each cable shall be identified with aluminium tags.

The terminal boards shall be set at 45 Deg. to the side panels for easy
access. Minimum 20% spare terminals shall be provided on the

121 of 373


The terminals shall be suitable to receive crimped wires to give
positive connection. All terminals shall be properly shrouded against
accidental contact. Sufficient terminals shall be provided so that not
more than one wire is connected to each terminal.

The terminal blocks shall 1.1KV, 10 amps rated, one piece moulded
complete with insulated barriers, stud type terminals, washers, nuts
and lock nuts and identification strips.

Terminal blocks for the CT and PT secondary leads shall be provided
with test links and isolation facilities. Also CT secondary leads shall be
provided with short circuiting and earthing links.


All metal surface shall be thoroughly cleaned and degreased to
remove mill scale, rust, grease and dirt. Fabricated structure shall be
pickled and then rinsed to remove any trace of acid. The under
surface shall be prepared by applying a coat of phosphate paint and a
coat of yellow zinc chromate primer. The under surface shall be made
free from all imperfections before undertaking finishing coat.

After preparation of the under surface, the relay and control panel
shall be spray painted with two coats of final paint. Colour shade of
final paint shall be pebble grey, shade RAL 7032 with glossy finish and
shall be duly approved by the PURCHASER before final painting is
done. The finished panel shall be dried in stoving oven in dust free
atmosphere. Panel finish shall be free from imperfections like pin
holes, orange peels, run off paint etc. The vendor shall furnish
painting procedure details for approval by the PURCHASER /

All unpainted steel parts shall be cadmium plated or suitably treated
to prevent rust corrosion. If these parts are moving element then
these shall be greased.

Cubicle Illumination

Compact fluorescent lamps working on 240 V AC, operated by door
switches shall be provided for internal cubicle illumination, in each

A 240V, 1-Phase, 5 Amp., 3 Pin Socket shall be provided in the panel
corridor or interior of each cubicle with on-off switch for connection of
hand lamps. This socket shall be metal clad type with a spring loaded

122 of 373



A continuous 25 mm x 3 mm copper (tinned) or equivalent aluminium
/ GI earth bus shall be provided running along the full lengths of the
cubicles. Suitable arrangement shall be provided at the two ends for
connection to the plant earthing system.

Each cubicle and the equipment mounted on each cubicle shall be
securely connected to the earth bus. For this purpose, the earth wire
shall be looped from equipment to equipment and both ends of the
earth wire shall be connected to the earth bus.

Space Heaters
Panel space heaters shall operate off 240 V AC and shall be supplied
complete with on-off switch, fuse and thermostat. A common
thermostat shall be provided for the entire panel. The thermostat
shall maintain the internal temperature above the ambient
temperature to prevent moisture condensation.


Mimic diagram shall be provided on cubicles. Mimic diagram shall be
screwed on to the cubicles and shall be made of anodised aluminium
or plastic of approved fast colour. The mimic shall be 10 mm wide for
horizontal run and 5 mm wide for vertical run.

Semaphore indicators used for isolator positions, they shall be so
mounted in the mimic that isolator (or breaker) closed position shall
complete the continuity of the mimic. The mimic diagram shall
incorporate red and green lamps for isolator position indication and
controlling switches with indicating lamps for breakers.

Alternatively, automatic semaphore indicators for isolators and built in
hand operated semaphore and position indicating lamps for breaker
control switches may be provided.


The lamps will remain steady where the hand operated
semaphore position correspond with the breaker position.


The lamps shall flicker with a time delayed alarm if the
semaphore position does not correspond with the breaker

The colours for various voltages in the mimic diagram shall be as

123 of 373

4.12. Control Switches 4.2. Transducers for voltage.4. of illuminated push buttons with covers along with master trip relay (86) with a minimum of 2NO + 2NC (Model VAJH13 or equivalent) shall be wired up to TBs for load shedding purpose.2. 4. wherever required. Each switch shall be provided with external red and green indicating lamps. current. heat resistant material and shall be provided with chromium plated bezels.11.12.1 All control switches shall be rotary.11. BIRLA WHITE CEMENT .4. 4. MVA.2.2 Indicating Lamps These shall be switchboard type of low power consumption.12. 4. Megawatt.4. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION Voltage Level Mimic Colour Shade as per IS:5 EHV Signal Red 537 11 kV Canary Yellow 309 back connected type having cam operation contact mechanism. LED cluster type lamps and shall be supplied complete with necessary resistors. Phosphor bronze contacts shall be used on switches.10 Ten (10) nos.3. JODHPUR. of poles in any selector switch shall be restricted to eight (8) numbers. KHARIA KHANGAR.2.2.12. frequency.2.2.11 Equipment Specifications 4.III.4.4 Control MCBs 124 of 373 .4.11.2 The handle of control switches used for circuit breaker operation shall turn clockwise for closing and anti-clockwise for tripping and shall be spring return to neutral from close / trip with lost motion device. moulded.11. The lamp covers shall preferably be unbreakable.4.ULTRATECH CEMENT LIMITED.1 Transducers Transducers with output of (4-20) mA shall be arranged by the BIDDER.12. 4.3 The no.11.4.3. MVAR and power factor as indicated in the tender single line diagram shall also be provided. Lamps shall be provided with screwed translucent covers to diffuse light.12.11.3. by providing multiplication contactors / relays to meet scheme requirement.11.2.

11.5 The detailed list of protective relays for each cubicle is listed elsewhere.11.6.2. 4.11.4.III.2.Alarm Protective relay operated .2.7 Clock.2.1 One No. digital clock with minimum 50 mm height digital display shall be fitted in an attractive position on the complete cubicle assembly. 4.6. with distinct tones shall be provided for a) b) c) Protective relay operated . All relays shall be switchboard pattern.6 Relays 4. The relays shall be supplied with the necessary accessories to make the system complete.4. All MCBs shall be provided with suitable identification labels. JODHPUR.4.11. The clock shall have a hand operated device for adjustment of clock hands from front.4. KHARIA KHANGAR.12.4.2 A set of test block and test lead for necessary secondary injection tests shall be included.12. 4. reset push The annunciator shall have first-in facility. 4. back connected draw out type suitable for flush mounting and fitted with dust tight covers.ULTRATECH CEMENT LIMITED.4.2.3 The rating of the auxiliary contacts shall not be less than 5 amp at 240 V AC and 15 amp for 110 V DC.4.Trip DC failure with AC as auxiliary supply The scheme shall include necessary acknowledge & buttons. Annunciation Following audible alarm / annunciations.4 Relay terminals to be of stud type / self-locking plug-in type.12. 125 of 373 . 4. All relays in draw out cases shall have suitable spring loaded contacts for inserting test block.11. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION Control MCBs shall generally be mounted on the top half of the cubicles.11.11. 4.7.4. BIRLA WHITE CEMENT . Name and Identity Plates 4.

2. 4. at the test blocks.4.12. Similar plates shall be fixed to the exterior of the switchboard in appropriate places to indicate the functions of control switches. The instrument transformers shall have the following accuracy class Potential Transformer Measurement Protection 4.2 Auxiliary CTs required for summation of two or more feeders and auxiliary PTs required for galvanic isolation of different synchronising inputs shall be included. lamp and other equipment not incorporated in the mimic diagram.12.11.12. KHARIA KHANGAR.4 Name plates bearing respective circuit designation of 50 mm width etched in 40 mm high letters shall be mounted on the top of the front side and back side of each cubicles shall be supplied and fixed in such a way that these can be removed and refitted when desired. synchronising check and guard relays. synchronising cut off switch.11. push buttons. ‘no voltage’ relays.1 Necessary auxiliary potential transformers for open delta potential polarisation and auxiliary current transformers.4.12. synchroscope.2 All instruments. 4. serial number and the electrical rating data.8.8.12. breaker selection switches for all the breakers to be synchronised.2.2. 0. at the MCB blocks and at the cable terminals. relays and other electrical devices mounted on the cubicle shall be provided with plates bearing the manufacturer's name. JODHPUR. Reverse engraved name plate at least 10 mm wide bearing suitable identification marks shall be fixed in the interior of the switchboard.5 Each equipment shall have a rust proof metal tag permanently attached to it with the tag number.4. BIRLA WHITE CEMENT . 4.2. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION 4.ULTRATECH CEMENT LIMITED.11.11.12. auto synchroniser with output for governor & 126 of 373 .12.2S 5P20 & PS Synchronization Panel mounted synchronising equipment complete with double voltage & frequency meters.4. lamps. shall be included in supply.2. wherever required. 4.2 3P Current Transformer Auxiliary PT and CTs 4.11.

4 wire 50 Hz circuits with unbalanced loading and with two sets of elements connected to current and potential transformers of specified ratio.11. individually for all channels. Necessary softwares for downloading of stored parameters and analysis shall also be supplied. PLC based synchronization scheme is to be offered.12.1 Protection of the generator shall be achieved through microprocessor based. shall be provided. BIRLA WHITE CEMENT . 4. power factor and MW should be of digital type.4. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION AVR controls etc.2.2. KHARIA KHANGAR. The scanner shall have scrolling display with output relays for High-Alarm and High-Trip signals. 4. The TG shall be considered for 15 nos.1° C with accuracy of better than ±1%.12.4 Meters for frequency. for hooking up to PC and plant DCS.1 Two (2) numbers of integrating meters of the Trivector or equivalent types capable of indicating all phase instantaneous parameters and recording kWH. with one as primary and the other as back-up. 4.ULTRATECH CEMENT LIMITED.2.4.2 or better with communication port. RS485 interface . Resolution for the complete range shall be not less than They shall be capable of record / display of harmonic data upto 51st harmonics.2. The scanner shall be provided with RS 485 communication port. It shall be possible to set the parameters through membrane type keypad.2.4.11. breaker synchronisation including back synchronisation with the grid.12.12.11. Both the relays shall include the following minimum protective functions: 127 of 373 .9 Trivector / power measurement metering 4.4. kVARH and kVAH directly shall be provided. 4. JODHPUR.11. Each of these meter shall be provided with a minimum of three analog out puts in addition to soft signal at modbus. suitable for MODBUS RTU protocol.III.2. 4.12.3 The meters shall be of digital type. Temperature scanners Microprocessor based temperature scanner shall be provided to process the signals from RTDs of the generator windings / bearings / cooling air paths.4. class 0.12.MODBUS RTU protocol. composite protective digital relays.2.2 These should be suitable for 3 phase.12 Details of Protective Relays 4.11.4. 4.

Overall differential protection 4.12. KHARIA KHANGAR.12.12.12. JODHPUR.4.1 Generator - 4.III. Accidental energisation protection Over & Under voltage (1st and 2nd stage) Under & Over frequency(1st . BIRLA WHITE CEMENT . 2nd & 3rd stage) Field failure Reverse Power Low forward power Voltage restrained over current Generator differential Stator standby earth fault protection (95% and 100%) Local breaker back-up / struck-up Negative sequence Voltage balance / PT fuse failure Over fluxing Protection Pole slipping protection IDMT overcurrent (1st and 2nd stage) Instantaneous overcurrent PT fuse supervision Restricted earth fault protection Thermal Overload Rotor earth Fault Differential protection Restricted earth fault protection Directional overcurrent and earth fault Over fluxing Oil and winding temperature Oil Level Buchloz relay Alarm and trip for all above Overall . RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION 4.2 Generator transformer protection - 4.2.2 The SUPPLIER shall make available a set of output contact. duly configured for one stage of the following voltage / frequency function: - Over voltage Over frequency Under voltage Under frequency 128 of 373 .12.12.ULTRATECH CEMENT LIMITED.

2 core CT Additional discrete relays shall also be provided for the following auxiliary functions: - Master trip relays Trip circuit supervision relays for each trip coil of the tandem circuit breaker and all master trip relays DC supply failure relay Auxiliary relays. KHARIA KHANGAR.4. for processing of data. Self diagnostic facility Rotor Earth Fault protection 95% Stator earth fault relay to cover 95% of winding protection with necessary current and voltage operated relays.5 Communication port.4 Additional discrete relays shall be provided for the following main functions. Disturbance recording & analysis facility All the event.III. Event recording facility.2.3 Both the generator and generator transformer protection relays shall have the following minimum features: - - 4.ULTRATECH CEMENT LIMITED. with settable range of 0. RJ45 interface – IEC61850 protocol.4.2. BIRLA WHITE CEMENT . if required Rotor earth fault relay Check synchronization relay Guard relay No volt relay Dead bus relay 129 of 373 .5% connected from Class 0.12. 100% stator earth fault protection with third harmonic over voltage principle may be provided based on the system and generator suitability along with minimum setting available in the relay for the above function Static / microprocessor based reverse power relay.4.12.12. for a minimum of 32 events.12.12. for hooking-up to plant DCS.12. for down loading & parameter settings Necessary software. disturbance and the fault records shall be stored in the internal memory of the generator protection relays and shall be capable of being downloaded when required. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION 4.2. JODHPUR. even if the same is available in the composite relays: - - - 4.

programming with relays and meters. along with A4 LaserJet Colour printer.4. The PC shall also be loaded with complete Software required for interfacing. LAN network interface. FSB 2933 MHz.933 GHz. This shall consist of the following relays: - Vector surge relay Master trip relay Trip circuit supervision relays Generator and generator transformer shall provided with following signal through kWT for plant DCS: - Current Power factor MW MVAR MVA Frequency Voltage In addition. BIRLA WHITE CEMENT .12.12.8 A common PC. following for governor: - MW MVAR 4. Keyboard. 4. 8GB RAM DDR3 / 500 GB SATA @ / 15000 RPM / No-FDD/DVD-RW/ 32 X combo / 21” TFT monitor with 4 USB and 1 serial ports. 130 of 373 . downloading. Discrete relay for overall differential protection shall be envisaged.III.2.2. The PC and Printer shall be supplied with latest configuration as available in the market. uploading.12.4.7 Discrete relay for grid islanding purpose shall be envisaged.4. This relay shall be of numerical type suitable for three winding transformer (three sets of CT inputs).4. loaded with necessary software and interface units to receive signals from RS 485 and RS 232 communication ports shall be supplied. JODHPUR. 4. KHARIA KHANGAR. Cache 18 MB.ULTRATECH CEMENT LIMITED. PC shall be with minimum configuration of Intel I7 processor with CPU speed 2.12. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION 4.2.9 Connection configuration of the protective relays shall be as shown in the enclosed ‘Electrical Schematic Diagram’. 1 parallel port.12. Mouse.2.

1.1 Standards The equipment covered under this specification shall unless otherwise stated be designed. JODHPUR.1.13 SPECIFICATION FOR SEGREGATED PHASE BUSDUCT.2.2. constructed and tested in accordance with latest revisions of relevant Indian Standards. IS:2099 - HV Porcelain Bushing IS:2544 - Porcelain Post Insulator IS:2629 - Hot Dip Galvanising IS:5082 - Bus conductor material IS:6005 - Phosphate treatment of Iron and Steel 4.1 Segregated Phase Bus ducts 4. C Maximum hot spot temperature of : enclosure at rated current 70 Deg. BIRLA WHITE CEMENT .ULTRATECH CEMENT LIMITED.13. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION 4. NGTR / LAVT CUBICLES AND SEALED TVM CUBICLE 4. Resistance Earthed BIL (kV Peak) : 75 dry : 28 Short time rating for 3 sec (kA rms) : 40 Dynamic Rating (kA Peak) : 100 One minute power frequency withstand voltage (kV rms) Maximum hot spot temperature of : busbar at rated current 85 Deg.13. power : frequency) (kV rms) 131 of 373 11 / 22 . KHARIA KHANGAR. C Busbar Material : Copper Enclosure : Aluminium Alloy : Porcelain Insulators : Type Voltage (Rated / One min.2.III.2.2 Design Particulars Continuous Current Rating : 2000Amp Rated Voltage Class : 12 kV System Voltage : 11 kV.13.

2. composition. JODHPUR. 4. Suitable provision for sealing of this chamber and the junction boxes shall be made available. accessories and insulating supports are enclosed in an earthed metal housing with either metal or insulation barrier between the phases.1.13.2. joints. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION Impulse withstand voltage (kV Peak) : 75 kV Earthing : Generator neutral through resistance 4. electrical withstand characteristics and thickness of the insulating material used shall be indicated by the BIDDER in his bid and shall be subject to the PURCHASER's approval. CT for future use as ‘spare’ shall also be envisaged as indicated in the tender single line diagram. The fault level along with the distance of busduct to be considered shall be as follows: Busduct STC Generator to generator transformer 40 kA for 3 Sec Generator Transformer to CB panel Tap Off for LAVT Panel 40 KA for 3 Sec 40 kA for 3 Sec Generator to Star Point formation 40 kA for 3 Sec Star Point to NGTR Panel 40 kA for 3 Sec 4.ULTRATECH CEMENT LIMITED. joints.1. phase cross over chambers.4 Dedicated CTs and PTs of rating furnished in the tender single line diagram shall be provided in the busduct for open access metering.3 earthed Definition A segregated phase busduct is one in which phase conductor with its associated connections. disconnecting links and tap-off busducts.2. The 11 kV busduct shall connect the generator to generator transformer to 11 kV generator tandem circuit breaker panel. wall through busducts.13. the type.13.1. KHARIA KHANGAR.5 General Requirements 132 of 373 . BIRLA WHITE CEMENT .III. If the BIDDER offers insulated barriers. generator & NGTR Cubicle with tap off to LAVT Cubicle with necessary bends.

13.1 Bus Enclosure This enclosure shall be made of aluminium alloy of minimum 3 mm thickness.1. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION 4.2. 133 of 373 .13. KHARIA KHANGAR.5.5. the hot spot temperature of the conductor shall not exceed 80 Deg.13. temperature rise of conductor shall not exceed 35 Deg.13.5.5 Temperature Rise Under normal operating conditions.2.13.ULTRATECH CEMENT LIMITED.C over an ambient temperature specified in the design basis. BIRLA WHITE CEMENT .1.2. preferably black to facilitate efficient heat dissipation.5. The BIDDER shall submit supporting test certificates. Busduct shall have degree of protection better than equal to IP 54 for indoor and IP55 for outdoor. 4. The bus duct shall be of natural cooling type.1.1.4 Painting The inside of the bus enclosure shall be treated with a matt paint of dark colour.2.2. 4.e. and d) Combination of the above. The bare enclosure with above painting shall be designed so as not to exceed the temperature specified elsewhere when the conductor is carrying rated current.1. The housings shall be of sturdy construction to have inherent strength to withstand the above forces. 4. The outside of the enclosure shall be given a finish of epoxy paint with shade flint / pebble grey RAL 7032.3 Construction The entire bus duct shall be designed for indoor installation with a dust and vermin proof construction.III. 4.C i. JODHPUR.2 Mechanical Strength The design of the busduct enclosure shall be such that it will withstand the internal or external pressures resulting from the following: a) Normal operating conditions b) Momentary short circuit current (peak) c) Rigours of adverse weather conditions.5.

2.5.6 Bellow Joints Joints consisting of rubber bellows shall be provided on the bus enclosure at following points: a) At terminations at Generator b) At terminations at switchgear cubicles 4. The flexible joints shall take care of expansion and contraction due to temperature variations and fault conditions. KHARIA KHANGAR. 4. 4.10 Inspection Covers Provision shall be made for periodic inspection of insulators by means of inspection covers.8 Bonding Necessary bonding shall be provided at the above expansion joints if made of insulating material. It shall be the responsibility of the manufacturer of the busduct to coordinate with various equipment (by others) to which his busduct has to be terminated to ensure proper alignment of the busduct with this equipment.7 Flexible Expansion Joints Flexible expansion joints for the enclosure shall be provided wherever deemed necessary by the manufacturer.1. The flanges shall be provided with gaskets.5. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION 4. The filter 134 of 373 .2. nuts. bolts. 4. The inspection covers shall be provided with quick acting stainless steel clamps and shall have gaskets.III.13.5. BIRLA WHITE CEMENT .ULTRATECH CEMENT LIMITED. etc.2.11 Drain Plugs and Vents Filter type drain plugs shall be installed at low points along the run of the busduct to drain out automatically any moisture condensing within the bus enclosure.2.13.9 Terminal Enclosures and Flanges Three-phase terminal enclosures shall be provided with flanged ends with drilling dimensions to suit the flanges at equipment terminals.13.5. JODHPUR.1.2.1. The drain plugs shall be fitted with porous filter elements which will permit the escape of moisture but prevent the ingress of dust.

2. 4.13. KHARIA KHANGAR.5.2 Rating The bus conductor shall be designed to carry the rated current under normal site operating conditions without exceeding a hot spot temperature of 85 Deg.6.5. The material of the gaskets shall preferably be neoprene closed cell sponge rubber or equivalent. All nuts and bolts shall be mild steel hot dip galvanised. Flange gaskets shall be provided at the equipment terminal connections.ULTRATECH CEMENT LIMITED. 135 of 373 . shall be provided wherever necessary. Clamps.6.13 Miscellaneous Hardware The busduct shall not have any through bolts.14 Earthing Necessary earthing arrangement as applicable shall be provided with clamps to receive the station earthing bus.2.2. 4.13.12 Gaskets The gasket material and thickness shall be so selected as to satisfy the operating conditions imposed by temperature. C. that the required compression of the gaskets can be obtained without damage to the inspection covers by bolts and that covers do not bend after this compression has been applied.6 Bus Conductor 4. Also the temperature of the bus shall not be exceed 250 Deg. C while carrying the specified short circuit current for three seconds when a fault occurs at the operating temperature. etc. 4.2. JODHPUR. splice plates.1 Material The material of the conductor shall be of high grade Copper. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION elements shall be easily removable for cleaning purposes.2.5. Care shall be exercised to ensure that covers fit easily. 4. All accessories and hardware required for the earthing arrangement shall be provided.13. 4.13.2. BIRLA WHITE CEMENT .13.13. Over-compression of the gaskets shall be avoided. weathering durability etc. MS spring washers shall be provided for making satisfactory joints.III.

KHARIA KHANGAR.13.13.2. 4. electrically continuous and mechanically strong connection. 4.III.6. BIRLA WHITE CEMENT .5 Painting The bus conductor may be given a coat of matt black paint to facilitate heat dissipation.3 Shape The section of the bus conductors used shall be rectangular. the stresses consistent with the momentary short circuit current. The losses should be such that an optimal operating cost is obtained.6 Losses The losses in the conductor shall be limited to such a value that the temperature rise of the conductor does not exceed the specified values. 4. double channel or hollow hexagonal/octagonal type. hollow rectangular. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION 4.13.6. Welded Rigid Joints Joints shall be highest quality done as per the recognised methods of welding practice.6. The bare conductor with above painting shall be designed to carry the normal rated current without exceeding temperature rise as specified.2.13. JODHPUR.6.6. 136 of 373 .13. The manufacturer shall submit supporting test certificate.2.2. Suitable aluminium or copper connectors shall be provided wherever the bus sections change. hollow square. Welded Expansion Joints Flexible aluminium or copper connectors welded to the main busbars shall be provided wherever deemed necessary.ULTRATECH CEMENT LIMITED.2.7 Joints Adjacent sections of the bus conductors shall be bolted or welded to provide an efficient. deterioration of conductor material and reduction in the BIL value of the busduct.4 Mechanical Strength The bus conductors and insulated supports shall withstand without permanent deformation. 4. tubular.

ULTRATECH CEMENT LIMITED. Bolted Flexible Joints Flexible braided copper connections shall be provided at the equipment terminal connections. BIRLA WHITE CEMENT . Suitable splice plates and bimetallic connectors shall be provided wherever necessary. Bolted Expansion Joints Expansion joints made of aluminium or copper strips shall be provided wherever deemed necessary by the vendor. All bolts.8 Clamps and Hardware The busbar clamps and insulators shall be designed to withstand the forces due to momentary short circuit current. The bolting schedule and contact pressures shall conform to accepted codes of practice.6. 4. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION Bolted Rigid Joints The connectors shall be of the same material as the conductor and these shall be silver plated to ensure an efficient connection. nuts and lock washers used in the bus assembly shall be of high tensile steel. Suitable copper or aluminium spacers shall be provided wherever necessary.13. All the above joints shall be tested for temperature rise to prove the adequacy of the design. The joints shall be suitably designed to take care of the vibration at the terminals as well as the expansion and contraction of the busbars. KHARIA KHANGAR. 137 of 373 . plated for corrosion resistance. to take care of expansion and contraction of the busbars under normal operating conditions. The material of the clamps shall be aluminium alloy. JODHPUR.2.III. The joints shall be capable of 25mm settlement of equipment mounting pads. Bimetallic connectors shall be provided between the busbar and the copper flexible if the bus conductor is of aluminium alloy. They shall permit free longitudinal movement of the busbars during expansion and contraction. The maximum temperature rise at the joints shall be less than the specified temperature rise for the busbars.

6. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION 4.6. 4.13.6. JODHPUR.2.11 Phase Barriers 4.2. The spacing of the bus 138 of 373 . The shorting links shall have drilling dimensions matching those of the main bus disconnecting links. for the purpose of drying out the equipment before commissioning or for carrying out short circuit test on the equipment. shall be made of nonhygroscopic insulating material such as fibre glass.13. KHARIA KHANGAR.13. rated for the main bus current shall be supplied for shorting the busduct at a location. 4. The insulators shall be mounted on resilient pads provided in the bus enclosure.2. Details of disconnecting links shall be furnished by the manufacturer.12 The phase barriers shall be of the material shall be same as that of the busduct enclosure material.6. BIRLA WHITE CEMENT .2.2.13. 4. 4.3 Mechanical Strength The insulators shall possess sufficient mechanical strength to withstand the forces due to momentary short circuit currents of magnitude detailed in this specification. The separation of the busbar sections with the bolted links removed shall be sufficient to withstand the rated voltage of the busduct.ULTRATECH CEMENT LIMITED.6.1 Within the busduct the bus shall be mounted and supported on insulators.13 Insulated phase barriers.2.7 Bus Support Insulators 4.7. The minimum number of disconnecting links shall be provided as shown in the enclosed drawings 4. Suitable supporting structures and support insulators for the shorting links if necessary shall also be offered. when specified.2.III.13.10 Shorting Links Shorting jumpers.7.9 Disconnecting Links Disconnecting links with rating same as that of the main busbars shall be provided in the run of the bus duct to facilitate disconnection of the bus bars during testing and maintenance. adjacent to the disconnecting links. Material The insulators shall be of porcelain. 4. condensation of moisture may take place on the surface of the insulators.13.2 Material The insulator for wall frame assembly and seal off bushings shall be of porcelain.2. JODHPUR. The seal off bushings shall be flanged type. Hence the insulators shall have a high creepage distance and a withstand voltage rating sufficient to provide specified insulation under highly humid conditions.3 Mechanical Strength The insulator shall withstand the maximum short circuit forces under fault conditions specified in this specification.4 Electrical Strength The electrical properties of the insulator shall be in conformity with this specification.7. The insulator material shall not deteriorate under normal operating temperatures or due to temperature rise under fault conditions.2.2. 4.ULTRATECH CEMENT LIMITED.8. Also the bushings shall be designed for thermal expansion / contraction due to temperature differential for outdoor / indoor use. BIRLA WHITE CEMENT . 4. 4.2.5 Phase Clearances The minimum phase to phase and phase to earth clearances of busbars within the enclosures shall be as follows: Phase to Phase Phase to Earth : : 139 of 373 Not Applicable 120 mm . KHARIA KHANGAR.1 Seal off Bushings The busduct shall be equipped wherever necessary with baffle or seal off bushings to prevent interchange of air at different temperatures.13. 4.8. 4. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION insulators shall be decided giving due factor of safety.3 Electrical Strength As a consequence of current loading and variation in external temperatures in the external sections of the busduct.2.III.8 Wall Frame Assembly and Seal-off Bushings 4.13.2.

13.12.13. bolts and tapped holes shall conform to the relevant standards. 4.3 Accessories and Hardware The supporting structures including supporting members. These marks shall be made in a manner as not to be obliterated and erased in transit or to damage the galvanising of the busduct or the supporting structure. such as clamps. 4.2.2. longitudinal beams. nuts.3.13. JODHPUR.9. hangers.9. required for this purpose shall be furnished by the vendor. All necessary hardware.5 Studs.10 Miscellaneous 4.2.4 Earthing Each supporting structure shall be securely connected at two points to the station earthing bus. All the accessories and hardware of ferrous material shall be hot dip galvanised.2. 4.13. brackets.5 Markings All components of the busduct along with the supporting structure shall be distinctly marked for erection in accordance with the erection drawings to be prepared and furnished by the vendor.III.2. insulating pads.13. BIRLA WHITE CEMENT .9. bolts.ULTRATECH CEMENT LIMITED. connectors etc.13. KHARIA KHANGAR. 140 of 373 .2. 4.2.9 Busduct Supports 4. Only hexagonal nuts shall be used.9. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION 4. Calculations shall be furnished to substantiate the above and shall be subject to the PURCHASER / CONSULTANT's approval. channels.13.13. 4.2 Mechanical Strength The supporting structures shall be designed to withstand the dead weight of the busduct and also the short circuit forces under maximum fault conditions and also the wind load and forces due to seismic accelerations as per relevant Indian Standards. All bolt holes shall be spot faced for nuts. nuts.9.2. insulating washers and all other hardware which are necessary for erection and support of the entire busduct installation.1 Material The supporting structure shall be fabricated from standard steel sections and shall be hot dip galvanised after fabrication.

2.2.13. 4. The space heater shall be automatically controlled by differential thermometers.13.3.3. 4. The tests shall be conducted as per standards indicated in this specification. 50 Hz AC supply.3 All threaded pipe connections and fittings. JODHPUR. c) Heat loss and temperature rise calculations for conductor and enclosure. pipe flanges and tube fittings shall comply with relevant standards.2. Welding shall be performed in accordance with relevant standards.2. The busduct shall be provided with space heaters of adequate capacity to maintain the internal temperature above the dew point to prevent moisture condensation within the busduct.2.3 Tests and Test Reports 4.2.12 Space Heaters & Silica gel breathers 4. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION 4. The bus assembly tested shall include bolted connections and flexible connections.1 The following type and routine tests certificates shall be conducted on representative section of the bus assembly. b) Spacing of the insulators vis-a-vis mechanical strength to withstand forces due to momentary short circuit current.12.13. They shall be machined true as per good workshop practice.III. The space heaters shall be rated for 240V single phase.2 Type Tests a) One minute power frequency withstand voltage test. 4.13. KHARIA KHANGAR.13.2 Castings and forgings shall conform to respective material specifications and shall be free from flaws. 141 of 373 .11. 4.11 Design Requirements of Busduct Adequate number of silica gel breathers shall be provided in the busduct.1 The bid shall contain design calculation in support of the following parameters of the busduct design: a) Sizing of the busbars vis-a-vis thermal capability to withstand rated continuous current and three seconds short time current. BIRLA WHITE CEMENT .ULTRATECH CEMENT LIMITED.

5 One minute power frequency withstand voltage test. Test Report for Components Manufacturer's type and routine test certificates shall be submitted for tests conducted as per relevant standards for the following components: a) Insulators b) Seal-off bushings c) Bolted and flexible joints d) Busbars e) Enclosure material f) Galvanising of support structures 4.5 Impulse voltage withstand test.13. JODHPUR.3. Dynamic withstand test.2. Temperature rise test of bare black matt painted conductors and enclosures. Water tightness test. Water tightness test.13. BIRLA WHITE CEMENT . Wherever Indian Standards are not available.13.12. 142 of 373 . they shall conform to relevant British or IEC Standards.13. KHARIA KHANGAR. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION b) c) d) e) f) 4.2. Routine Tests The following routine test shall be conducted at the vendors shop: a) b) c) 4.ULTRATECH CEMENT LIMITED. terminology and testing procedures for Neutral grounding devices.2.13 NGTR Cubicle 4.13.III.12. Air tightness test.2. Air tightness test.1 Standards The transformer and resistors covered by this specification shall conform to the following and other relevant Indian Standards. IS:3043 BS:162 - IEEE-32 - Code practices for earthing.3. Electric power switchgear and associated apparatus (applicable to Class-B apparatus in BS:162) Requirements.

.13. 4.2.13. The resistive component should be at least more than 3 to 5 times of residual capacitance current. The transformer shall be designed with following capabilities: .13. The neutral current shall be limited to 100A during earth fault.2 General Specifications The values and ratings of transformer and resistors shall be designed to limit the earth fault current to 5 to 10 A depending on the capacitance of the system. JODHPUR.13.1 The distribution transformer shall be of dry type and single phase. corrosion proof.3 times of line to line voltage of generator. The duty of the transformer shall be continuous during normal operating condition and for 30 seconds during earth fault condition.13.ULTRATECH CEMENT LIMITED. . RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION IEC 129 - Alternating IEC 185 - Current Dis-connectors Switches Current Transformers IEC 529 - Classification of Degree of Protection and Earthing Wherever the stipulation in this specification are in conflict with any of the above standards. BIRLA WHITE CEMENT .The knee point voltage of the transformer primary shall be at least Transformer and Resistors 4. The BIDDER shall furnish the detailed calculation and basis for the rating selection of transformer and resistor for the specified rating. the requirement under this specification shall be binding.13. 4.III.2.13. KHARIA KHANGAR. 4. 4.To be suitable for withstanding over voltage caused due to sudden load loss.2.13. It shall be suitable for use in monsoon tropical climate. The rating of transformer and resistor shall be designed to ensure the resistive component of fault current should not be lesser than residual capacitance current to avoid transient over voltage during earth fault.3 Resistors shall be designed for continuous duty during normal operating condition and for 30 seconds during earth fault condition with temperature rise not exceeding 325 Deg. jointless grids.13.2 The resistor shall be of stainless steel edge wound type made up of unbreakable.C over 143 of 373 . field forcing condition and flux doubling conditions.No saturation shall occur at all conditions. Grid washers shall be of natural mica.1 The resistors shall be housed in a metal clad enclosure suitable for indoor installation. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION an ambient temperature of 50 Deg. Potential Transformer and It shall be possible to periodically clean the resistors after lifting the top cover.2. It shall be possible to earth the cabinet or enclosure at two places and for this suitable size of studs shall be provided on the sides.2.13. 4.13. depending on the envisaged connection configuration.13.6 Terminals 4.3 These devices shall be rated for voltage class in accordance with the recommendations of IEEE-32.2. KHARIA KHANGAR.6.1 The connection between generator neutral and NGT shall be done by means of bus duct / internal busbar connection.2.13. JODHPUR.III.2. 4.13.2 The enclosure shall have an arrangement for fixing it on concrete foundations / floor and its thickness shall be not less than 3 mm.4 Grids shall be mounted on steel rods insulated by special heat resistant micanite paper tubes. 4.2. Porcelain insulators shall be used to insulate the resistor element from body of the enclosure. BIRLA WHITE CEMENT .3.C when the resistor is housed in a covered space. Current Contactor 4. with sufficient auxiliary contacts shall be provided in the NGTR cubicle.13. 4.5 Enclosure 4.2. 4. as required for ground fault protection shall also be provided.2 Current and potential transformers.13.13. Transformer.1 Manual link or manual isolator with vacuum contactor of adequate rating.13.5.4 Isolator.3 The terminals for neutral and earthing connection shall be housed in a separate vermin proof. weather proof compartment.2.13.13. with minimum IP52 enclosure.4.13.4. 4.2.ULTRATECH CEMENT LIMITED.2. 144 of 373 .

JODHPUR. name of the equipment.1 Suitable space heater along with thermostat shall be provided inside the resistor cabinet to prevent condensation of moisture.9 Name plate Marking The equipment shall have a nameplate located conspicuously giving particulars.13.13.13. made free from rust and given a priming and final coat of the paint. 4. louvers can be provided in the enclosure.13. The entire arrangement shall be complete with double pole switch.2. shade RAL 7032.11 Inspection & Test Inspection shall be carried out by the PURCHASER / PURCHASER’s representative and the following tests shall be conducted: 145 of 373 . 4. 4. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION 4.5mm) to make it vermin proof.13. But wherever the louvers are being offered it shall be completely guarded on inside with a fine wire mesh (holes less than 0.13.2. rating and other relevant details. Bolted type link shall be provided for isolating the resistor. The cable used for space heater shall be aluminium conductor PVC insulated armoured cable. 4.13.2 Suitable washers shall be provided between grid and terminals to maintain good contact. 50 Hz supply.13. 4. The terminals of the space heaters shall be brought out in a separate terminal box. Bushing terminals shall be provided for neutral and earth connections and they shall be housed in a metal clad enclosure.3 The two ends of the resistor shall be brought out to weatherproof bushing type terminals of adequate rating.13. MCBs and thermostat.13. 4.13. 4.7.7 Space Heater 4.6.ULTRATECH CEMENT LIMITED.III.2. KHARIA KHANGAR.2.13.8 Cooling The NGT shall be natural air cooled and any type of forced cooling shall not be used.10 Painting All surfaces to be painted shall be thoroughly cleaned. This shall be rated to operate from 240 V. such as make. descaled. if required.13. BIRLA WHITE CEMENT .2.13. 4.13. However.


Measurement of resistance value at room temperature
by Kelvin
Double Bridge.
One minute power frequency high voltage withstand
test shall be as
per applicable voltage.

Heat Run Test
The test shall be conducted by passing the rated current for
rated time on the complete assembly or by any method
mutually agreed upon.

Test Certificates
Test certificates of the equipments shall be furnished at the
time of inspection.

LAVT Cubicle



Co-ordination of Insulation



Lightning Arrestors



Potential Transformers



Classification of Degree of Protection

Design Requirements

The cubicle shall house Potential transformers required for
metering, protection, synchronisation and excitation system

Surge capacitors and Lighting arrestors required for surge
protection of the generator shall be housed in this cubicle.

The surge capacitors shall conform to the latest IS:2834 and
shall be rated 0.25 µF. The capacitors shall be suitable for
indoor mounting and shall be provided with built in discharge

The lightning arrestors shall be heavy duty indoor station class
gapless metal oxide type suitable for repeated operation to
limit voltage surges on alternating current power circuits and

146 of 373

to interrupt power follow current. The arrestors shall conform
to IEC 99-4. The nominal discharge current of lightning
arrestor shall not be less than 5 kA.

The SUPPLIER to submit design back-up details for selection
of PT, LA and SC ratings.

Construction Features

The cubicle shall be simplex type.

The cubicle shall be sheet steel enclosed dust and vermin proof
type. The cubicle shall be floor mounting, free standing and
suitable for busduct entry. The enclosure shall be of cold sheet
of 3 mm thick for front and back and 2.5 mm thick for rest. Type
of enclosure shall be IP 52.

The doors and openings shall be provided with neoprene gaskets.

Cubicles shall be suitable for top busduct entry.

All mounted equipment inside the cubicle shall have identification
tags of self sticking PVC tapes, in addition identification number
shall be painted on cubicle wall to give permanent identification

All wiring shall be done by PVC insulated 1100 V grade 2.5 mm
stranded copper cable. Each wire shall be identified at both ends
by means of PVC ferrules.

Minimum 20% spare terminals shall be provided more than one
wire shall not be connected in any terminal. All terminals shall be
stud type.

All busbars shall be sleeved type with colour coding at each end.

The PTs shall be of fully drawout type and both the primary and
secondary shall get isolated and earthed through scrapping earth.

PT’s primary shall be with uniform insulation.

The PTs shall be protected with HRC fuses on primary. MCBs
shall be made available on secondary side for circuit protection.


147 of 373


After preparation of the under surfaces, with two coats of primer
suitable for epoxy paint the cubicle shall be spray painted with
two coats of final epoxy paint. Colour shade RAL 7032, with
glossy finish. All unpainted steel parts shall be cadmium plated
or suitably treated to prevent rust corrosion.

A continuous earth bus running along the full length of cubicle
shall be provided. Suitable arrangements shall be provided at
each end for connection to main earthing grid.

Space Heater
Anti condensation space heater shall be provided along with
thermostat to keep the cubicle temperature above ambient.

The PTs shall be fully tested for 35 kV as per IS:3156. Lightning
arrestors and surge capacitors to be tested as per relevant IS
Following tests shall be carried out:

Checking of correctness of wiring of circuit
High voltage test.
I.R value test.
Routine tests.

Sealed TVM Cubicle

The trivector meter shall be of digital type, class 0.2S with ABT
feature. The meter shall be suitable for 3 Phase, 4 wire system.
The meter shall also be provided with RS 485 communication
port with MODBUS RTU protocol and software.

The TVM shall be base mounted type and shall be provided
with the arrangement of sealing. The cubicle shall be provided
with a door and view glass. This cubicle shall also be suitable
for wall mounting.
Current and Potential Transformers

Current and potential transformers, for protection, metering &
controls shall be provided, in generator terminals, NGTR / LAVT

148 of 373

2 and protection 3P.14.16. For class PS core CTs. Panel Construction 4. BIRLA WHITE CEMENT . 11 kV switchgears and busducts.1.Current Transformers IS:3156 & IEC:186 .2.1 The distribution board and starter panel shall generally conform to the following standards: 149 of 373 . The accuracy class for Metering 0.5 As the PTs are intended to be in service in unearthed system and to avoid ferro resonance effect. The accuracy class for the dedicated PT for open access metering shall be 0.3 The current transformer will be epoxy cast.2 and protection shall be 5P20 & PS. Potential transformer will be protected on primary by HRC fuses and secondary side by MCBs.2.2. the knee point voltage shall match with the requirements of the connected relays.13.16. All CTs shall be provided with not more than two cores and shall be suitable for 120% rated current. Voltage factor for the PTs shall be 1.Potential Transformers 4. bar primary. dry type unit confirming to IS / IEC. KHARIA KHANGAR.16.16.2. A detailed write-up on the proposed method shall be furnished for CONSULTANT’s review. the BIDDER shall envisage a suitable method to mitigate the above effect.2 Standards IS:2705 & IEC:185 . JODHPUR.2S. continuously. 4. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION cubicles.13. The accuracy class for the dedicated CT for open access metering shall be 0. The accuracy class for metering shall be 0. dry type units.ULTRATECH CEMENT LIMITED.14 SPECIFICATION FOR DC STARTER PANEL. Care shall be taken to ensure that the matching CTs are properly matched for knee point voltage & magnetising current requirements. 4.2.2 times continuous and 1. The current transformer shall be designed to withstand the thermal and magnetic stresses resulting from the maximum short circuit current.III. epoxy cast.4 The potential transformers will be single phase. depending on the envisaged system.14. DCDB AND ELECTRIC MOTORS 4. 4. and preferably sourced from same manufacturer.2. 4.9 times for 8 hours.2.

14.2.2. phosphating and passivation treatment.14. Terminal blocks shall be `Elmex' type.1. floor mounted. The assembly shall be finished with two coats of epoxy paint in pebble / flint grey shade RAL 7032. Fabricated structures shall be pickled and then rinsed to remove any trace of acid. KHARIA KHANGAR.2. Diazed fuses will not be acceptable. Reverse engraved name plates shall be provided for the panels and all module sections. 4.III. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION IEC-439 & IS:8623 - IEC-947 & IS:13947 - IEC-269 & IS:9224 IEC-144 & IS:2147 - Specifications of Low Voltage Switchgear & Control gear Assemblies Specification of Low-Voltage IS:13947 Switchgear & Control gear Low voltage fuses Degree of protection of enclosure for low voltage switchgears and control gear IE rules. damp & vermin proof construction.1. compartmentalized. The panels shall have bottom entry provisions and shall be natural cooled. regulation of CEIG 4. rust.4 Inter panel sheet steel barriers shall be provided. 150 of 373 .5 mm thick sheet steel and structural steel. BIRLA WHITE CEMENT .0 / 2.2. the surface shall be given two (2) coats of zinc rich epoxy primer.1. JODHPUR. 4.2. The main earth connection shall be brought out to two terminals for connection to station earthing system.14.14.2 The panels shall be dust. degreased and pickled in acid to produce a smooth surface.14. Hinged doors shall be provided at the front and back where required.2. 4.3 The panels shall be fabricated with 2. All fuses shall be link type.1.1.7 All fuses shall be provided inside the panel. 4. guidelines. After cleaning.ULTRATECH CEMENT LIMITED. self standing type with access from front & back by means of hinged doors. 4. free of scale. It shall be free-standing with suitable louvers for ventilation and must be suitable for use in tropical climate.1. grease and rusts. sheet steel clad totally enclosed. The sheet steel used for fabrication shall be thoroughly cleaned and degreased to remove mill scale. 4.5 All metal surfaces shall be chemically cleaned.8 All potential free metallic parts shall be earthed with soft drawn copper conductor.14. grease and dirt.

14. 4.1 DC starter panel for control of EOP & JOP DC motor shall be provided. The DCDB shall be connected to its own dedicated battery bank.14.2.3 DC contactor used in the starter panel shall be provided with adequately rated magnetic blow out coil for effective arc quenching. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION as part of the DC distribution board. 4.2. 4. the following signals shall be hooked-up to a marshalling compartment in the distribution board : - 4. JODHPUR.1 Two (2) numbers of DCDB with each of the DCDB sized to cater 100% of the TG loads shall be provided.1.14.2. BIRLA WHITE CEMENT .4 DC resistance in suitable steps.3. Busbars shall be colour coded. KHARIA KHANGAR. All the equipment inside the panel shall have suitable name plates.2. in addition to the feeders to meet BIDDER’s requirements: a) b) 4.5 For interfacing with PURCHASER’s DCS.14. 4.2.9 All live parts shall be properly shrouded.2 EOP & JOP Starter Panel 4. A spare feeder with complete starter modules shall be provided in the DCDB.14.2 DC starter shall have switch fuse unit for short circuit protection. Bus coupler for interconnection shall also be envisaged.2. Overload relay shall be provided for alarm purpose. shall be provided.2. 4.III.3 EOP & JOP starter ON / OFF status EOP & JOP motor over load relay operated EOP & JOP motor field failure relay operated Start & Stop command from DCS DC Distribution Board The DC distribution boards and for each TG set shall have the following feeders.14.2.3 Two (2) numbers 63A FSU feeders Ten (10) numbers 32A FSU feeders The distribution board shall have the following meters / relays / transducers: 151 of 373 . 4.2. This shall ensure complete safety to personnel intending routine maintenance by opening the panel doors.ULTRATECH CEMENT LIMITED. The starter shall also have field failure protection for the motor. but not less than three (3).2.

without neutral. - All VFD application motors shall be capable of starting with DOL as bypass starting arrangement.ULTRATECH CEMENT LIMITED.14.4.4 System fault levels to be considered for design of the equipment shall be 65 kA for one second at 415V system.3.14. It shall be 230V.37 kW.2.14. 4. The motors shall be of squirrel cage induction machines with a degree of protection IP54 for indoor application and shall conform to IS:325 / IEC-60034.III.14. KHARIA KHANGAR.14.2. 152 of 373 .2. three phase for motors of rating 0.4 AC Electric Motors kW and above.14.5 The Rated voltage shall be 415V. single phase for motors of rating below 0.2 All the motors shall be of squirrel cage type.6 All AC motors driving various auxiliaries of the unit shall be designed to operate in humid atmosphere with a maximum ambient temperature as indicated in project information. 4. 4. BIRLA WHITE CEMENT . JODHPUR.1 All the auxiliaries shall be suitable for 415 V (3 Phase 3 Wire system). 4.14.3 Starting Methods of Motors shall be as below unless otherwise specified elsewhere in this document: - Motors shall be suitable for DOL starting unless otherwise specified elsewhere in this document.4.4 For interfacing with PURCHASER’s DCS.2. the following signals shall be hooked-up to a marshalling compartment in the distribution board - ON and OFF status of incomer and all outgoing feeders Bus under voltage and over voltage signals (4-20) mA signals from all transducers 4. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION Ammeter and Voltmeter at the incomer Ammeter for all outgoing feeders Current and Voltage transducers at the incomer Current transducer for EOP starter Bus under voltage and over voltage relay 4.4.4. 4. Motors for outdoor application shall be IP55 degree of protection with sheet steel canopy.

4.2.mm f.mm e. 4. with efficiency figure at 100% load is not less than the efficiency value as indicated in the ‘Table for Motor Efficiency’. 90-110 kW : 2-3Cx185 Sq. JODHPUR.11 The terminal boxes shall be capable of withstanding the maximum system fault current for a duration of at least 0.14. 4. The motors shall be suitable for ± 10 % voltage variation (on rated voltage) and 50 Hz ± 5% frequency variation (subject to combined variation of 10%) with maximum temperature rise limited to limits of ‘Class-B’ insulation. KHARIA KHANGAR. pull-up torque and pull-out torque shall be properly coordinated with the speed torque characteristics of the driven equipment. 4.8 All the continuous duty motors shall be of ‘energy efficient’ (IE2 range type for motor rating upto 55 kW and IE3 range type for motor rating 75 kW & above). 132-180 kW : 2-3Cx300 Sq. BIRLA WHITE CEMENT . 153 of 373 . Higher rated motors shall be provided with extension terminal box to receive the aluminium cables of following sizes to avoid cramping of the cable in the terminal box: a.7 The motor windings shall be provided with Class F insulation.III.2.e.10 Terminal box to be rotatable by 4 x 90 Deg.14 Motors shall be capable of operating satisfactorily at full load for 5 minutes without injurious heating with 75% of the rated voltage at its terminals. 200-280 kW : 4-3Cx185 Sq.14. Motor efficiency between 60% to 100% load shall be constant.2.9 Motors of rating 30 kW and above shall be provided with space heaters.13 Motors shall be capable to start and run-up at a minimum of 80% of rated voltage at its terminals with the driven mechanism / equipment connected.2. 4. 4.14.4.mm c.14.4.4. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION 4. 4.ULTRATECH CEMENT LIMITED. Terminal boxes mounting shall be tapered and not on top. 300-440 kW : 4-3Cx300 Sq.4.15 Brake away torque. d. 425-600 kW : 6-3Cx300 Sq.4.12 Motors shall be suitable for being switched on to a solid main even at phase opposition at a maximum residual voltage of 50% i. 625-720 kW : 8-3Cx300 Sq.25 second.4.2. and the BIDDER shall submit the characteristic curves interposing motor & driven equipment curves.14.14. the motor shall be capable of withstanding 150% of the rated voltage.mm b. 4.14.mm 4.

2. No forced lubrication acceptable. under rated load conditions. - Should be suitable for the selected IGBT based variable frequency drive.2.14. 4.17 Starting current of the motor shall be less than or equal to 600 % of the rated current. 4. JODHPUR. for the motors where the starting time is more than 30 second. 4. Cooling fans shall be shaft mounted type only (No additional cooling motor shall be provided). BIRLA WHITE CEMENT . 110 kW Above Not Required Two (2) Nos. KHARIA KHANGAR.2.4.III. The starting time of the motors shall be mentioned in the document. 4.18 Continuous duty motors shall be capable of three equally spread starts per hour under normal condition or two starts in quick succession from cold or one hot start. (Drive End – 1 No.2.4.16 Hot withstand time of the motor shall be at least 10 seconds longer than the starting time under rated load conditions.4.2.ULTRATECH CEMENT LIMITED.21 Specific requirements of LV general duty motors - Rated voltage shall be 415V. For motors with lesser starting time.14. Motors shall be provided with RTDs/BTDs as indicated in the table below: SL Motor Rating RTDs BTDs 1.20 Motor to be of Totally Enclosed Fan Cooled (TEFC) design. - The windings shall be VPI treated and two coat enameled.4. 4. 30 – 90 kW One (1) per phase 2.22 and One (1) per phase Specific requirements of motors intended for VFD application: - Rated voltage shall be 415V.19 All bearing to bee of lubricated anti-friction type. Operating speed requirement shall be as below: 154 of 373 .14.14.14. and Non-Drive End – 1 No.4.2. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION 4.14.14. These motors shall be sized to operate satisfactorily under the lowest speed conditions. and shall match with the drive in respects of over voltage / spikes generated by the drives. a margin of 5 seconds shall be ensured.)

speed and to determine no load  losses and efficiency at full load 155 of 373 30 kW to 55 kW 75 kW & above     .III.23 : : : Thermistors RTD BTD One (1) per Not Required Not Required phase One (1) per Not Required Not Required phase Two (2) Nos. 3. - The BIDDER shall submit detailed calculations for checking adequacy of the motor selected under extreme speed conditions.) Inspection & Testing: The following minimum tests shall be carried out on the motor to ensure its Successful operation as per the specification.7 – 22 kW 2.ULTRATECH CEMENT LIMITED. - NDE bearings of motors of rating 110 kW and above shall be insulated to prevent circulation of shaft currents. furnishing the selection chart of the motor manufacturer for VFD application. current.4.14. 30 – 90 kW 3. BIRLA WHITE CEMENT . - All variable frequency drive motors shall be provided with embedded Thermistors / RTDs / BTDs for motors as indicated in the table below: Sl Motor Rating 1.2. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION Fans Pumps Fuel feeders 50% to 100% 50% to 100% 10% to 100% - The motor windings shall be provided with Class H insulation with maximum temperature rise limited to limits of ‘Class-B less 10 Deg C’ insulation. JODHPUR. (Drive End – 1 and One (1) per Not Required No. and Nonphase Drive End – 1 No. Manufacturer shall furnish details of bearing insulation. KHARIA KHANGAR. TESTS Up to 22 kW Measurement of resistance of windings of  stator and rotor No load test to measure input power. 110 kW Above 4.

() – Test report of identical motor (frame.  . 4.2.The tests shall be carried out in the motor. current and power input at a suitable reduced  voltage Reduced voltage running up test to check the ability of the motor to run up to its  rated speed at no load.4. and slip   Over speed test () () Test for degree of protection () () Test on insulation system () () Temperature rise test at limiting values of voltage and frequency variation. BIRLA WHITE CEMENT .III.24 lso the efficiency calculations by using the values of locked rotor test and full load test for all the motors of above 22kW shall be submitted.14.ULTRATECH CEMENT LIMITED.14.25 All the routine and type tests shall witnessed and verified by PURCHASER/CONSULTANT. KHARIA KHANGAR. 4. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION Locked rotor readings of voltage. Open circuit voltage ratio of stator and rotor windings (applicable for slip ring  motors)       High voltage test    Insulation resistance test    () () Vibration test ()  Noise level test ()  Momentary overload test ()  Full load test to determine the efficiency. () power factor. JODHPUR.4.2. 156 of 373 . speed & kW) for having carried out with in five years.

0 82.5 96.1 90.0 96.5 7.5 96.3 91.4 88.4 92.6 94.2 94.7 95.2 96.2 93.5 66.5 95.7 73.3 95.8 92.3 95.0 90.0 69.III.3 89.5 2.8 96.6 93.8 94. the efficiency figure will be interpolated.9 95.1 97.5 83.6 93.8 84.2 96.9 94.55 0.5 96.5 95.5 88.3 95.14.5 91.2 91.9 95.3 96.4 72. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION 4.0 96.7 90.2 74.0 95.2 77.9 94.8 93.8 97.6 96.5 91.6 82.0 78.7 5.8 85.3 11 15 18.1 73.3 89.2 94.4 87.75 1. KHARIA KHANGAR.4 93.0 93.0 77.4.8 92.0 94.8 76. 157 of 373 .7 96.2 95.2 96.26 TABLE FOR MOTOR EFFICIENCY RATING in KW 2 POLE 3000 RPM 4 POLE 1500 RPM 6 POLE 1000 RPM 8 POLE 750 RPM 0.2 95.5 95.3 88.0 96.5 90.6 77.1 86.2 96.6 95.0 97.9 93.6 94.0 74.5 95.8 92.8 94.2 96.3 94.2 96.2 90.8 88.0 91.0 96.37 0.3 79.0 85.0 89.2.5 22 30 37 45 55 75 90 110 125 132 160 200 250 300 350 440 450 500 Above 70.0 96.6 93.1 86.5 83.3 91.1 89. BIRLA WHITE CEMENT .6 89.2 3.0 95.5 96.5 91.5 91.9 80.7 94.0 86.9 92.6 87.1 1.3 93.2 85.2 & NOTE : - All efficiency figures are subject to IS Tolerance Wherever ratings other than those mentioned in the above table are used.2 92.8 71.5 93.0 82.0 95.7 94.1 89.ULTRATECH CEMENT LIMITED.1 85.8 90.2 92.0 96. JODHPUR.5 94.5 9.

shall be equipped with regreasing devices and grease quantity controllers. bearing housing and terminal box shall be IP54.2.2. - Motors with shaft heights 250 mm and above. heavy duty. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION 4. 4. - Machine feet cast integral with the body as integral foot mounting construction. 4. - Shaft forged from special high tensile steel with tapered ends. - Degree of protection for motor. KHARIA KHANGAR.4 Cooling - TEFC 158 of 373 . JODHPUR.ULTRATECH CEMENT LIMITED.III.3 Terminal Box - To be dimensioned adequately for receiving aluminium cable.5. totally enclosed.5.5. continuously rated.5.2.2. - Stator Yoke and Poles as well as armature shall be preferably of fully laminated construction with low loss silicon steel sheet - Frame made of cast steel or thick rolled steel plates. - To be provided on the right hand side as viewed from the drive end. BS:2613.2 Bearings and bearing Lubrication - Motors with shaft heights upto 225 mm. - Brush holder to maintain constant brush pressure regardless of brush wear and to ensure spark less commutation at top speeds and over-load.1 Constructional features - Industrial type.5 DC Motors 4. BIRLA WHITE CEMENT .14. shall be life time greased. generally designed and manufactured as per IEC:60034/1. - Shall be rotatable by 4 x 90 Deg. IS:4722.

5.6 Quality of operation .III.2.1.ULTRATECH CEMENT LIMITED.15.1 Feed water flow (tube side) : As per HMBD 4.15. JODHPUR.1.5.Same as specified for low voltage squirrel cage induction motors Feed water inlet operating pressure Steam Pressure : As per HMBD 4.2.2 Steam Temperature : As per HMBD 159 of 373 (For HP .2 Feed water inlet temperature : As per HMBD 4.C Heater #2) : As per HMBD SPECIFICATION FOR FEED WATER HEATERS HP heater #1 & #2 4.3 Heater Required Feed water outlet temperature : 190 Deg.15.1. - Insulation: Shall be provided with class F insulation throughout the stator and rotor windings but designed for temperature rise (as measured by resistance method) corresponding to that of class B insulation. KHARIA KHANGAR.14.1 Process Parameters 4.2.15 Electrical design - Operation from DC starter panel - Operation shall be unaffected by voltage or current ripples. - Over speed : Capable of withstanding and over speed of 20% above rated maximum field weakening speed.1.5 Extraction Steam Parameters 4.2.14.C ( For HP #1) 235 Deg.15. - Overload Capacity : Minimum 160% frequently repeated momentary load for 15 seconds. BIRLA WHITE CEMENT . RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION 4.

15.3.3 Design temperature for shell side : Supplier to specify 4.8 kg/cm2 160 of 373 . Turbine condensate (tube side) : As per HMBD Turbine condensate outlet temperature : As per HMBD JODHPUR. kg/cm2 LP heater 4.3 Process Parameters 4.15. KHARIA KHANGAR.15. BIRLA WHITE CEMENT .2.15.4 Design Parameters Steam Temperature : As per HMBD Allowable pressure drop on tube side : 0.15.2 Turbine condensate inlet temperature : As per HMBD 4.4 Design temperature for tube side : Supplier to specify Extraction Steam Parameters Shell design pressure : Supplier to specify 4.1 Tube design pressure : cold shut off pressure of CEP Allowable pressure drop on tube side : 0.4 Design temperature for tube side : Supplier to specify Steam Pressure : As per HMBD RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION 4.15.ULTRATECH CEMENT LIMITED.4.3 Design temperature for shell side : Supplier to specify 4.15.2 Design Parameters Turbine condensate inlet operating pressure : As per HMBD Tube side design pressure : The same shall be cold shutoff head of the BFP Shell design pressure : Supplier to specify 4.15.

5.15.TP 304 Shell material : Carbon Steel to ASME SA 516 Gr.TP 304 LP heater : Stainless Steel to ASME SA 688 Gr.III.6 Nozzle material : Carbon Steel to ASME SA 181 Gr.ULTRATECH CEMENT LIMITED. or equivalent 4. BIRLA WHITE CEMENT . or equivalent 4. Location : TG Hall.1 Orientation of feed water Heater : Horizontal 4.15.2 Tube plate material : Carbon Steel to ASME SA 516 Gr.8 Stud and stud bolts/nuts : SA 193 Gr.6. JODHPUR.5 Heat Load (Design) : Shall be designed with 5% margin over and above the maximum expected heat duty or equivalent 4.15. tie rods : Commercial Quality Steel and spacers 4.4 Channel / channel cover : Carbon Steel to ASME SA 516 Gr. Materials of baffles. or equivalent 4.2. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION 4.B7 or equivalent SA 194 Cl.tube support plates. Drain cooler section required : Supplier to specify 4.15. KHARIA KHANGAR.15.2H or equivalent 161 of 373 .4 Maximum tube velocity : 3.6.5 Other Requirements 4. 1 4.0 Mtrs/Sec 4.5.6 Material of Construction Tube material HP heater : Stainless Steel to ASME SA 213 Gr.5 Flange material : Carbon Steel to ASME SA 516 Gr.15.

15.2. Alignment Dowels.8.7 Accessories The Heater shall be supplied with the following minimum accessories.2. shall be socket welded or screwed. 4.15.ULTRATECH CEMENT LIMITED.1.15.15. 4.8. JODHPUR.15.2.2. Also a set of special tools and tackles shall be provided by the EPC contractor. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION 4. Thermal Insulation Clips. Earthing Cleats. size and design conditions for the feed water heater shall be as specified. 162 of 373 . KHARIA KHANGAR.1 General All connections to feed water heater 65 mm NB size and larger.2. Connections 50 mm NB and smaller. on the steam side. Shell Relief Valve.2.2 The design shall have provision for complete drainage of both shell and tube sides. Pneumatically operated level control valve with 100 % bypass same as main valve on the condensate line of both the heaters. Supports / Brackets. The minimum size of nozzle shall be 50mm.1.15.1 The capability.8.15. BIRLA WHITE CEMENT . indication and control of drain level as specified. Name Plate.1. Tube Bundle Shield.15.8.1. 4.2.4 Heaters shall be provided with startup vent connections which will be separate from the vent connections required for continuous operation.6 Heaters shall be provided with name plates which shall include all information required by the applicable regulations and codes. 4.2.1. Adequate drains in size and number on low points of heater shells and water inlet channels for proper drainage and/or supply of solutions during chemical cleaning process shall be included.1. Channel Drain Valve. Channel Vent Valve. shall be welding-nozzle type with ends shop beveled.7 The feed water heater shall be furnished with instrument connections for alarm. The necessary information shall be on a metal name plate permanently affixed to the heater and set off the surface by brackets so as to be readily visible after the equipment is insulated. 4. except where flanged joints are specified for removal of shell connection or removal of tube bundle. Shell Drain Valve. Jack Screws. 4.15.15. 4.8 Design & Construction Requirements Lifting Lugs.5 The heater shall be designed for full vacuum conditions. Shell Vent Valve.2. Channel Relief Valve.III.

carbon steel and low alloy steel parts shall not be less than 3.2.4 Suitable forged bolts or drilled lugs shall be provided for channel cover. external and internal bolting material. 4. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION 4. All bolt holes shall be spot finished for nuts. Where flanges like weld neck flanges are used.1. shell cover.1 The shell shall be of longitudinally welded or seamless type. shutdowns and trip outs.6 One piece.8.2 mm (0.125 in). the corrosion allowance shall be applied to the inside flange diameter and the flange thickness shall be calculated with the inside diameter under corroded conditions. The shell cover shall have a 2:1 elliptical.8.15. baffles and supports. The pass partition plates shall be tightly welded in place and shall be structurally adequate to withstand normal plant operations such as start-up restarts. Channels shall be so constructed that the tube side of the feed water heater shall be self draining through the tubes.15. The channel cover shall be of either rolled plate or of forged construction.2.15. 4. floating head cover for use in assembling and dismantling the unit. The shell cover shall be welded on to the shell in case of Utube bundles.2. 4.2 Heater Shells 4.2.15. 4. A minimum corrosion allowance of 1.8.0625 in) shall be added to the thickness of ferrous tubes.2.2. 4. 4. The jack screws shall have the same material specification as the bolting material.8.2. JODHPUR.2.15. torispherical or spherical head. Mating surfaces shall not be exposed to fluid. metal jacketed or solid metal gaskets shall be used. The shell cover shall be of forged or built-up welded construction. Of the two.3 Jack screws of proper size and number shall be provided for breaking the channel cover joint and shell cover joint. BIRLA WHITE CEMENT .8.III.8.5 Suitable insulation clips shall be welded to the shells in an appropriate manner for the application of insulation at site.8.8 Corrosion allowance on all cast iron.ULTRATECH CEMENT LIMITED. seamless shell is preferred.8. The thickness of the flat channel cover shall be measured at the groove made for receiving the pass partition wall. No corrosion allowance shall be required to be added to the thickness of non-ferrous tubes.9 The feed water heater shall be provided with relief valves on the shell and tube side. 163 of 373 . the minimum wall thickness (nominal wall thickness less the tolerance ) less corrosion allowance shall be considered as available for design.2.1.2. KHARIA KHANGAR.2.6 mm (0. While offering seamless shell.15.15. tube sheets.

4.8. shall conform to the requirements of latest revisions of the codes and standards. a.3. The tube rolling procedure shall be submitted for the OWNER's review and acceptance prior to the use. The stainless steel tubes including bends shall be in the heat treated condition.3.3 All tubes and U-bends.15. In addition the following shall also apply. The minimum wall thickness required at any points. but in no case shall be tube wall be less than 20 BWG average wall before bending. The tube bundle shall be removable.2.15. JODHPUR. shall be in accordance with the specified codes.15.15. KHARIA KHANGAR. Electric resistance heating is acceptable for heat treating the bends.4 Stainless Steel 4. Hot bending to form U tubes shall not be allowed.3 Tubes 4.8.2. U tubes welded at bends shall not be acceptable.2 Tubes shall comply with the requirements of the latest revision of the specification indicated.3.15. including bends. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION 4.1 The stainless steel tubes shall meet the requirements of the following paragraphs: 4. 164 of 373 . The bends shall be solution annealed after bending.8. shall consist of one continuous bent tube.8. 4. Finished tubes shall be annealed and pickled or passivated in a manner acceptable to the codes and standards.1.III.15. Straight tubes may be 22 BWG average wall.15.8. Due allowance shall be made for thinning of tubes during bending.1 Minimum tube wall thickness of stainless steel tubes shall be determined by standards and codes. Tube MOC shall be as mentioned above.15.2. The tube to tubesheet joint shall be seal welded and fully rolled.2. Tubes shall be expanded into the tube sheet for a length of tubesheet thickness minus 1/8 th inch (3. Bends shall not have cracks. b.2 U tubes when used.3. The annular clearances between the tubes and the shell must be kept to a minimum to prevent the shell side fluid bypassing the bundle and to obtain full penetration of steam through the tube bundle for efficient heat transfer. BIRLA WHITE CEMENT . Tube sheet shall be machined with two grooves for additional longitudinal load resistances.ULTRATECH CEMENT LIMITED.3.2 mm). kinks or deformations. 4.8.2. 4.2.

The tube sheet shall have grooves for receiving the pass partition wall and the web of the gasket. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION c. Perforated impingement plates shall not be accepted.2. 4. 4.8.15. Tests Tests performed on stainless steel tubes shall be as follows: 4.) shall be chloride free (5 ppm maximum). Baffles and Support Plates Tube nests shall be suitably baffled to prevent vibration and to obtain uniform distribution of steam and free drainage of the condensate of 165 of 373 .15.2.5 Adequate stainless steel impingement plates of 10mm (3/8") minimum thickness shall be provided at all shell nozzles receiving steam to protect tubes against impingement and erosion attack.8.2.2 Lubricants. Suitable threaded holes for eyebolts shall be provided on the tube sheet to facilitate pulling and removal of the tube bundle. 4.4.4. The tube sheet shall be of rolled plate or forged and faces of the tube sheets shall be true before and after the tubes are rolled in. The flare test shall be in accordance with ASTM Specification A-450 or any approved standard. welding and at completion of fabrication (before testing).8.1 Tube sheets shall be designed for the full design pressure acting independently on either side.4. 4.4. KHARIA KHANGAR. 4. JODHPUR.2.2. completely water soluble and shall be removed entirely before heat treatment.3.8.2. if used during the manufacturing processes (drawing.15.2.4 Tube Sheets.8.15. 4.3. 4.6 The design of the feed water heater shall incorporate necessary vents and baffles to avoid blanketing of the tube surface by stagnant pockets of non-condensible gases.2. BIRLA WHITE CEMENT . Hydrostatic and non-destructive electric tests (eddy current tests) shall be performed on each tube in accordance with ASTM A-450 or approved equivalent standards.2 The feed water heater shall be designed to prevent the superheated steam at entry to the feed water heater from coming into contact with the tube plate and plate joint. The effective tube sheet thickness shall be as measured at the bottom of the pass partition wall groove minus shell side corrosion allowance.III.8.2 Each lot of tubes shall have a flare test with atleast two tests per lot.ULTRATECH CEMENT LIMITED.8.15. The impingement plate shall have double the area of the inlet nozzle and will be located on the tube bundle.15.3. bending etc.2.

dead fluid spaces between adjacent passes. All baffles shall be designed to eliminate.15.15.2. BIRLA WHITE CEMENT .4.8. 4.15. JODHPUR.1 All flanges shall have a minimum thickness as per code specified. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION the tubes.8. shall snugly fit around the tubes and the shell interior to avoid short circuiting of shell fluid and permit unrestricted differential expansion.8.2.6. stiffening sections shall be external to the water box in order to reduce the turbulence in the waterways to a minimum.2. Nozzle openings shall be flanged. All pipes used for nozzles shall be seamless.III.8. The nozzle wall thickness shall be calculated in accordance with codes specified.6 Flanges. Baffles and support plates shall be provided with notches required for shutdown drainage or for removal of condensate where necessary.3 Nozzles shall project a minimum of 150 mm outside the insulation.8.15.2. KHARIA KHANGAR.15. shrouds etc.2. Wherever required. shall be capable of withstanding 166 of 373 .2. Easy access to the interior of water box for inspection and maintenance shall be provided.4. The water boxes shall be sufficiently deep and specially designed for efficient and smooth entry of water into the tubes and uniform distribution of feed water to all the tubes. Alternatively. Spacers may be welded to baffles to stiffen the baffle assembly. tube support plates. 4.15. baffles. Forged and weld neck flanges shall be preferred.4 Baffles and support plates shall be of rolled plates.4 External Forces on Major Pipe Connections The heater including its supports.ULTRATECH CEMENT LIMITED. Bolts. Nozzles and Pipes 4. the tie rods may be secured to end baffles by nuts which will be screwed on to the tie rod ends. The water box shall be fitted with relief valves and vent valves. Main shell and channel flange joints shall be of tongue and groove type. 4.5 Water Boxes The water box or channel section of all heaters shall be of fabricated or forged steel construction. as far as practicable.8. 4. All nozzle flanges shall be capable of withstanding the maximum test pressure and shall have raised face.2 The minimum entrance area shall not be less than the inside area of the inlet nozzle.15. 4.2.5 The complete assembly of tubes.8. The number of tie rods and spacers used to retain the cross baffles and tube support plates shall be as recommended by specified codes.

However. Care shall be exercised to ensure 96% or more of tube holes are within prescribed limits to avoid over or under expansion when mechanical means of expansion of tubes are employed. 167 of 373 . motor operated valves used in the HP heaters isolation shall have a closing time of maximum 12 seconds.III.9 Fabrication Tolerances 4.16 List of Motorized valves The OWNER wishes to go in for automation of the plant operation to the maximum extent possible. RAJASTHAN TENDER DOCUMENT OF 1X21 MW CPP SECTION 4– TECHNICAL SPECIFICATION safely the forces and moments transmitted from any of the interconnecting piping. Feed water heater channel (water or tube side) connecting nozzles to the Feed water piping shall be capable of withstanding the forces and moments transmitted from the piping on the basis that the piping may be fully stressed under the rules of ASME B 31.2 The tolerances for the finished tube holes in tube sheets shall not exceed the limits prescribed by TEMA. Notwithstanding any thing mentioned to the contrary.15. JODHPUR. 4. 4. BIRLA WHITE CEMENT .Vacuum breaker isolation valve (1 no/ TG) . KHARIA KHANGAR. .ULTRATECH CEMENT LIMITED. The shell sections shall be sufficiently true to roundness so that the difference between the maximum and minimum measured inside diameter at any cross section along the length of the shell shall not exceed 3.Upstream isolation valve in pneumatically operated control valve (main line) The motorized valves open / close time shall be suitable for the application.2. elsewhere in these specifications. the following gives the list of minimum number of motor operated valves (For additional scope for Motorized Valve also refer P & IDs).1 Dimensional tolerances shall be as per TEMA standards.LP extraction line (1 no/ TG) with integral bypass (inching type) .2 mm.HP 1 and 2 extraction steam line (2 nos/ TG) with integral bypass (inching type) . This calls for motor operation for a few of the important valves.2. 4.1 Power Piping Code except that the supplier may limit the forces and moments individually or severally.2.9.