Vdocuments - MX - SCT 1466 Vol G Techno Commercial Bid Technical For Electrical Vol G PDF

TENDER SPECIFICATION
BHEL: PSSR: SCT: 1466
FOR
Pre-bid tie up on back to back basis for

Civil, Structural & Balance of Plant for 1x
700 MW Combined Cycle Power Plant of
Andhra Pradesh Power Development
Company Limited
at
Nedunoor, Karimnagar Dist, AP
TECHNOCOMMERCIAL BID-
VOLUME-G –TECHNICAL
REQUIREMENTS FOR GENERAL
ELECTRICAL
BHARAT HEAVY ELECTRICALS LIMITED

(A Government of India Undertaking)
Power Sector – Southern Region
690, Anna Salai, Nandanam, Chennai – 600 035.
(A Government of India Undertaking)
Power Sector, Southern Region
690, Anna Salai, Nandanam, Chennai – 35
Tender Specification No. BHEL: PSSR: SCT: 1466
For
Pre-bid tie up on back to back basis for Civil, Structural & Balance of
Plant for 1x700 MW Combined Cycle Power Plant of Andhra Pradesh
Power Development Company Limited (APPDCL) at Nedunoor,
Karimnagar Dist, AP
One set of Tender documents consisting of Volume - A to Volume- L (details as below)

BOOK SLNO_________________
Issued to
M/s
Refer NIT for Last date of submission
Please note this tender document is not transferable
For and on behalf of

ADDL GENERAL MANAGER / CONTRACTS
Place: Chennai -35

Tender Specification BHEL PSSR SCT 1466 comprise of Volume-A to Volume -L as below:
No. of pages
Sl no of
Description (including Remarks
Volumes
drawings)
BHEL NIT
Vol -A
Project information, schedules, QA, Other
requirements
Scope TP, Exclusions
BHEL
Proposed scope split of Electrical between BHEL &
Vol -B
EPC contractor
Scope split BHEL & EPC contractor dt 29-06-2011
Scope of lifting equipments
BHEL SCC- BHEL
Vol -C
BHEL Consolidated GCC- BHEL-PEM
Vol -D APPDCL Volume -1,SECTION A1 TO A4
Geo tech investigations
BHEL
Tech requirements for General Civil works
Vol -E
Additional civil drgs
BHEL Scope of Cooling tower
Vol -F
BHEL Tech requirements for General Electrical works
Vol -G
BHEL Technical spec for Mechanical packages- Bought
Vol -H out packages
BHEL NOT APPLICABLE
Vol -I
BHEL Amendments & clarifications
Vol -J
BHEL Schedules
Vol -K
BHEL Price schedule
Vol -L
TECHNICAL
REQUIREMENTS FOR
GENERAL ELECTRICAL
VOLUME -G
Bharat Heavy Electricals Limited

1X700 MW CCPP AT NEDUNOOR, KARIMNAGAR
ANDHRA PRADESH POWER DEVELOPMENT COMPANY

LTD.
TECHNICAL REQUIREMENTS FOR GENERAL ELECTRICAL WORKS
DOCUMENT NO. PE-TS-I59-888-E001 REV 0

POWER SECTOR, PROJECT ENGINEERING MANAGEMENT
NOIDA 201301
Doc. No. PE-TS-I59-888-E001
700MW KARIMNAGAR CCPP
TECHNICAL SPECIFICATION FOR Rev. : 0
GENERAL ELECTRICAL WORKS
Page : of
CONTENTS
SL. NO. DESCRIPTION PAGES

1. INTENT OF SPECIFICATION 1
2. SCOPE OF WORKS 1
3. DOCUMENTS TO BE SUBMITTED BY BIDDER WITH EPC BID 1
4. DOCUMENTS TO BE SUBMITTED BY EPC PARTNER AFTER THE 2

AWARD OF CONTRACT
5. ELECTRICAL TECHNICAL SPECIFICATION:
5.1 GENERAL REQUIREMENT 15

5.2 LT BUS DUCTS 16
5.3 400V SWITCHGEAR & MCC 16
5.4 NEUTRAL EARTHING EQUIPMENT 3
5.5 DC SYSTEM 13
5.6 CABLING SYSTEM 18
5.7 LIGHTING SYSTEM 16
5.8 EARTHING & LIGHTNING PROTECTION SYSTEM 7
5.9 PUBLIC ADDRESS SYSTEM 15
5.10 ELECTRICAL LAB EQUIPMENT 7
5.11 INSULATING MATS 1
5.12 CATHODIC PROTECTION 2
6. CUSTOMER DRGS.-ANNEXURE-II 5
7. BHEL ELECTRICAL SINGLE LINE DIAGRAM- PE-DG-I59-565-E001 1
8. QUALITY ASSURANCE, INSPECTION & TESTING 77
9. BHEL CLARIFICATIONS (ENCLOSED AS ANNEXURE-B) 2
10. SCHEDULE OF TECHNICAL DEVIATION 1
11. SPARES 3
IT IS CONFIRMED THAT OUR TECHNICAL OFFER COMPLIES WITH THE SPECIFICATION IN TOTO.
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BIDDER’S STAMP & SIGNATURE
1
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1. INTENT OF SPECIFICATION
1.1 The owner Andhra Pradesh Power Development Company Ltd has invited bids for the EPC
package of 1X700 MW CCPP at Nedunoor Karimnagar Dist. BHARAT HEAVY ELECTRICALS
LIMITED (BHEL) intends to bid for this project and invites quotations for design and
execution of the work for electrical systems of the project mentioned in relevant clauses.
1.2 At the outset the bidder must understand that this offer is to be submitted on back to back
basis which means that the bidder assumes total and unconditional responsibility for all
electrical works as per owner’s requirements and subject to owner/ owner’s consultant’
approval.
1.3 Timely submission of drawings & documents / obtaining approval of drawings / documents
from owner / owner’s consultant shall be the responsibility of the bidder.
1.4 It is specifically emphasized that the bidder quoting for Electrical Works package shall be
comprehensively responsible for complete scope of work stated or unstated including
preparation of design and drawings, obtaining necessary approvals, materials, execution as
per codes, best engineering practices and to the satisfaction of the owner.
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2. SCOPE OF WORKS
2.1 It shall be Contractor’s responsibility to provide all the equipment / systems / services and
interfacing between various systems for the completeness of the 700 MW Combined Cycle
Power Plant (CCPP). The following configuration shall be considered.
2 GTs + 2 HRSGs + 1 STG in Multishaft configuration.
2.2 The requirements described here are for 700 MW CCPP. All equipment in the plant shall
operate without any limitation upto the full load of Gas Turbine offered. This shall be applicable
to all regimes of GT operation including the temperature range, frequency range, voltage range,
with evaporative cooler etc.
However for the purpose of the PG test, the evaporative cooler shall be switched off.
2.3 The Plant electrical systems for proposed combined cycle power plant shall essentially
comprise but not be limited to the following:
1. HT power cables, LT Power cables, LT Control cables & instrumentation cables
2. Cabling & installation equipment(cable trays & accessories, cable tray support, trefoil clamps,
termination kits, jointing kits cable glands & lugs etc).
3. Earthing & lightning protection(including above & below grade grounding material)
4. Station lighting system.
5. Neutral grounding resistors for Unit auxiliary transformers.
6. 220V DC battery, battery chargers, DC switchboards and their accessories.
7. 400V AC switchgear, LV power distribution boards and accessories.
8. Public address system equipment.
9. Electrical laboratory equipment
10. Insulating mats
11. Cathodic protection
12. Drawing & Document submission for all packages : System design, Design Calculations,
Design Memorandums, Layout drgs., Electrical load list, cable schedules, cable
interconnections, Data sheets, OGA, Quality plans, test certificate etc.
Detailed scope of work shall be as per scope chart enclosed as Annexure-A.
Any deviation to technical specification is to be clearly mentioned in “schedule of technical

deviation” & undeclared technical deviation is not acceptable at any stage of project.
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3. DOCUMENTS TO BE SUBMITTED BY BIDDER WITH EPC BID:
BIDDER TO SUBMIT SIGNED & STAMPED COPY OF FOLLOWING SHEETS:

i) CONTENTS
ii) INTENT OF SPECIFICATION
iii) SCOPE OF WORKS( ALONG WITH SCOPE CHART IN ANNEXURE-A & TABLE-1)
4
4. MASTER LIST OF DRAWINGS/ DOCUMENTS TO BE SUBMITTED BY EPC PARTNER AFTER AWARD OF CONTRACT
(INDICATIVE)
S.No. DEPT_CODE SI_NO SYSTEM BHEL_DRG_NO DRAWING TITLE
DESIGN PHILOSOPHY FOR ELECTRICAL

1 ELE 100 ELE LAYOUT PE-DC-I59-100-E999 EQUIPMENT LAYOUT
2 ELE 100 ELE LAYOUT PE-DG-I59-100-E001 LAYOUT OF TRANSFORMER YARD

LAYOUT OF ELECTRICAL EQUIPMENT IN CW PUMP
3 ELE 100 ELE LAYOUT PE-DG-I59-100-E003 HOUSE
LAYOUT OF ELECTRICAL EQUIPMENT IN RW PUMP
5 ELE 100 ELE LAYOUT PE-DG-I59-100-E006 LAYOUT OF MAIN SWITCHGEAR ROOM

EQUIPMENT LAYOUT IN STATIC EXCITATION
6 ELE 100 ELE LAYOUT PE-DG-I59-100-E007 ROOM(GTG)
EQUIPMENT LAYOUT IN STATIC EXCITATION ROOM
7 ELE 100 ELE LAYOUT PE-DG-I59-100-E008 (STG) (AB BAY 13.5M EL)
8 ELE 100 ELE LAYOUT PE-DG-I59-100-E009 LAYOUT OF DC BATTERY ROOM

CABLING LAYOUT BELOW MAIN SWITCHGEAR
9 ELE 100 ELE LAYOUT PE-DG-I59-100-E013 ROOM
10 ELE 100 ELE LAYOUT PE-DG-I59-100-E016 CABLING LAYOUT BELOW DC BATTERY ROOM
CABLING TRAY LAYOUT AT 9.5M EL. CABLE VAULT-
11 ELE 100 ELE LAYOUT PE-DG-I59-100-E020 BC BAY
CABLE TRAY LAYOUT IN TG HALL IN BELOW 8.5M
12 ELE 100 ELE LAYOUT PE-DG-I59-100-E021 EL
CABLE TRAY LAYOUT IN TG HALL IN ABOVE
13 ELE 100 ELE LAYOUT PE-DG-I59-100-E022 8.5M EL
14 ELE 100 ELE LAYOUT PE-DG-I59-100-E038 CABLE TRAY LAYOUT ON HRSG PLATFORMS
15 ELE 100 ELE LAYOUT PE-DG-I59-100-E050 IPB LAYOUT-GT
16 ELE 100 ELE LAYOUT PE-DG-I59-100-E051 IPB LAYOUT-STEAM TURBINE GENERATOR

CABLE TRAY LAYOUT AT EL 00.0M
0M FLOOR IN BFP
17 ELE 100 ELE LAYOUT PE-DG-I59-100-E060 SH 1 OF 3 BUILDING (SHEET 1 OF 3)
CABLE TRAY LAYOUT AT EL 6.7M & 10.0M FLOOR IN
18 ELE 100 ELE LAYOUT PE-DG-I59-100-E060 SH 2 OF 3 BFP BUILDING (SHEET 2 OF 3)
CABLE TRAY LAYOUT AT EL 14.500M FLOOR IN BFP
19 ELE 100 ELE LAYOUT PE-DG-I59-100-E060 SH 3 OF 3 BUILDING (SHEET 3 OF 3)
20 ELE 100 ELE LAYOUT PE-DG-I59-100-E063 CABLE TRENCH LAYOUT IN GAS TURBINE BUILDING
ELECTRICAL EQUIPMENT LAYOUT OF BFP
21 ELE 100 ELE LAYOUT PE-DG-I59-100-E065 BUILDING
CABLE TRENCH LAYOUT IN STEAM TURBINE
23 ELE 100 ELE LAYOUT PE-DG-I59-100-E071 INTERPLANT CABLING LAYOUT (2 SHEETS)

CABLE TRAY LAYOUT IN AIR WASHER ROOM – STG
CABLE TRAY LAYOUT IN AIR WASHER ROOM - STG
25 ELE 100 ELE LAYOUT PE-DG-I59-100-E073 BUILDING OUTSIDE A ROW
CABLE TRAY LAYOUT ON STORM WATER PUMP
CABLE TRAY LAYOUT ON PORTABLE WATER PUMP
CABLE TRAY LAYOUT IN AC PLANT ROOM
28 ELE 100 ELE LAYOUT PE-DG-I59-100-E076 (FACILITY BUILDING)
CABLE TRAY LAYOUT IN A.H.U ROOM (FACILITY
29 ELE 100 ELE LAYOUT PE-DG-I59-100-E077 BUILDING)
CABLE TRAY LAYOUT IN A.H.U ROOM (STG
30 ELE 100 ELE LAYOUT PE-DG-I59-100-E078 BUILDING)
ELECTRICAL EQUIPMENT AND CABLE TRAY
31 ELE 100 ELE LAYOUT PE-DG-I59-100-E079 LAYOUT IN ETP MCC ROOM
ELECTRICAL EQUIPMENT AND CABLE TRAY
32 ELE 100 ELE LAYOUT PE-DG-I59-100-E080 LAYOUT IN WATER TREATMENT MCC ROOM
33 ELE 100 ELE LAYOUT PE-DG-I59-100-E081 CABLE TRAY LAYOUT IN CW PUMP HOUSE
5
4. MASTER LIST OF DRAWINGS/ DOCUMENTS TO BE SUBMITTED BY EPC PARTNER AFTER AWARD OF CONTRACT
(INDICATIVE)
S.No. DEPT_CODE SI_NO SYSTEM BHEL_DRG_NO DRAWING TITLE
34 ELE 100 ELE LAYOUT PE-DG-I59-100-E082 CABLE TRAY LAYOUT IN RAW WATER PUMP HOUSE
38 ELE 506 LV SWGR PE-DC-I59-506-E004 ELECTRICAL LOAD DATA (BOARD WISE)
39 ELE 506 LV SWGR PE-DG-I59-506-E003 CONTROL LOGIC FOR 415V SWGR

DESIGN CALCULATIONS FOR HT CABLES
40 ELE 507 CABLES & CABLING PE-DC-I59-507-E001 SELECTION & SIZING
DESIGN CALCULATIONS FOR LV CABLES
41 ELE 507 CABLES & CABLING PE-DC-I59-507-E002 SELECTION & SIZING
42 ELE 507 CABLES & CABLING PE-DC-I59-507-E004 CABLING PHILOSOPHY
43 ELE 507 CABLES & CABLING PE-DC-I59-507-E005 CABLE NUMBERING SCHEME

TYPICAL DETAILS OF CABLE TRAYS AND
44 ELE 507 CABLES & CABLING PE-DG-I59-507-E005 ACCESSORIES
TYPICAL INSTALLATION DETAILS FOR CABLE TRAY
45 ELE 507 CABLES & CABLING PE-DG-I59-507-E006 SUPPORT SYSTEM
TYPICAL DETAILS FOR CABLE TRAY SUPPORT
46 ELE 507 CABLES & CABLING PE-DG-I59-507-E007 SYSTEM
47 ELE 507 CABLES & CABLING PE-DG-I59-507-EXXX LAYOUT FOR ALL AREAS
48 ELE 507 CABLES & CABLING PE-DG-I59-507-EXXX CABLE TRAY LAYOUT FOR ALL AREAS
49 ELE 507 CABLES & CABLING PE-DG-I59-507-EXXX CABLE SCHEDULES FOR ALL AREAS
CABLE INTERCONNECTION FOR ALL CABLE
50 ELE 507 CABLES & CABLING PE-DG-I59-507-EXXX SCHEDULES
51 ELE 508 DC SYSTEM PE-DC-I59-508-E001 DESIGN MEMORANDUM FOR 220V DC SYSTEM

LIGHTNING
52 ELE 509 PROTECTION PE-DC-I59-509-E001 DESIGN MEMORANDUM FOR EARTHING SYSTEM
LIGHTNING DESIGN MEMORANDUM FOR LIGHTNING
53 ELE 509 PROTECTION PE-DC-I59-509-E002 PROTECTION SYSTEM
LIGHTNING
54 ELE 509 PROTECTION PE-DG-I59-509-E003 TYPICAL BELOW GROUND EARTHING DETAILS
LIGHTNING
55 ELE 509 PROTECTION PE-DG-I59-509-E004 TYPICAL ABOVE GROUND EARTHING DETAILS
LIGHTNING BELOW GRADE GROUNDING SYSTEM LAYOUT FOR
56 ELE 509 PROTECTION PE-DG-I59-509-E005 MAIN POWER PLANT AREA
LIGHTNING BELOW GRADE EARTHING LAYOUT FOR OFFSITE
57 ELE 509 PROTECTION PE-DG-I59-509-E007 PLANTS
LIGHTNING
58 ELE 509 PROTECTION PE-DG-I59-509-E008 LIGHTNING PROTECTION FOR OFFSITE PLANTS
PUBLIC ADDRESS DESIGN MEMORANDUM FOR PUBLIC ADDRESS
59 ELE 557 SYSTEM PE-DC-I59-557-E001 SYSTEM
LIGHTING & LOW DESIGN MEMORANDUM FOR LIGHTING & LV
60 ELE 558 VOLTAGE SERVICES PE-DC-I59-558-E001 POWER SERVICES
DESIGN CALCULATION FOR EMERGENCY SUPPLY
61 ELE 561 EMERGENCY DG PE-DC-I59-561-E001 DG SIZING
ELECTRICAL SYSTEM
62 ELE 565 DESIGN PE-DC-I59-565-E004 RELAY SETTINGS CHART FOR LV/HV MOTORS
ELECTRICAL SYSTEM DESIGN CALCULATION FOR GENERATOR AND MV
63 ELE 565 DESIGN PE-DC-I59-565-E002 SYSTEM
ELECTRICAL SYSTEM ELECTRICAL SINGLE LINE DIAGRAM FOR
64 ELE 565 DESIGN PE-DG-I59-565-E001 AUXILIARY POWER DISTRIBUTION
DRG./DOC.(I.E. DATA SHEET/ OGA/ SCHEME/ TEST
CERTIFICATES/ QUALITY PLANS ETC.) FOR ALL
65 ELE 565 ELECTRICAL SYSTEM PE-DG-I59-XXX-EXXX ELECTRICAL PACKAGES
6
SPEC.NO.
ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. VOLUME III
TCE.5960A-H-500- TITLE
001 SECTION:
700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. CONTENT SHEET
EPC SPECIFICATION -ELECTRICAL SYSTEMS SHEET 1 OF 2
VOLUME-III – CONTENTS
ELECTRICAL SYSTEM
NO. OF
SECTION NO. SPECIFICATION NO. REV.NO. TITLE
SHEETS
D3.0 TCE-5960A-H-500-01 R0 GENERAL REQUIREMENT 15
D3.1 TCE-5960A-H-500-01 R0 GENERATOR AND ACCESSORIES 39
D3.2 TCE-5960A-H-500-01 R0 GENERATOR CIRCUIT BREAKER 06
D3.3 TCE-5960A-H-500-01 R0 GENERATOR TRANSFORMERS 09
D3.4 TCE-5960A-H-500-01 R0 UNIT AUXILIARY TRANSFORMERS 03
D3.5 TCE-5960A-H-500-01 R0 BUS DUCTS 16
D3.6 TCE-5960A-H-500-01 R0 GENERATOR, GENERATOR, 08

TRANSFORMER AND UAT
PROTECTIONS
D3.7 TCE-5960A-H-500-01 R0 400 kV SWITCHYARD 49
D3.8 TCE-5960A-H-500-01 R0 GENERATOR CONTROL PANEL 09
D3.9 TCE-5960A-H-500-01 R0 6.6 kV SWITCHGEAR 15
D3.10 TCE-5960A-H-500-01 R0 SERVICE TRANSFORMERS 05

D3.11 TCE-5960A-H-500-01 R0 400V SWITCHGEAR & MCC 16
D3.12 TCE-5960A-H-500-01 R0 NEUTRAL EARTHING EQUIPMENT 03
D3.13 TCE-5960A-H-500-01 R0 DC SYSTEM 13

D3.14 TCE-5960A-H-500-01 R0 UNINTERRUPTIBLE POWER SUPPLY 07
SYSTEM
D3.15 TCE-5960A-H-500-01 R0 CABLING SYSTEM 18
D3.16 TCE-5960A-H-500-01 R0 LIGHTING SYSTEM 16

EARTHING & LIGHTNING PROTECTION
D3.17 TCE-5960A-H-500-01 R0 07
SYSTEM
D3.18 TCE-5960A-H-500-01 R0 COMMUNICATION SYSTEM 15
D3.19 TCE-5960A-H-500-01 R0 FIRE DETECTION AND ALARM SYSTEM 05
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TCE FORM NO. 329 R5

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SPEC.NO.
ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. VOLUME III
TCE.5960A-H-500- TITLE
001 SECTION:
700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. CONTENT SHEET
EPC SPECIFICATION -ELECTRICAL SYSTEMS SHEET 2 OF 2
D3.20 TCE-5960A-H-500-01 R0 MOTORS 10
D3.21 TCE-5960A-H-500-01 R0 ELEVATORS 08
D3.22 TCE-5960A-H-500-01 R0 ELECTRICAL LABORATORY EQUIPMENT 07

D3.23 TCE-5960A-H-500-01 R0 MISCELLANEOUS ELECTRICAL 03
EQUIPMENT
D3.24 TCE-5960A-H-500-01 R0 CONSTRUCTION POWER SUPPLY 04
D3.25 TCE-5960A-H-500-01 R0 TRANSDUCERS 02
BID DRAWING
NO. OF
SL NO. DRAWING NO. REV.NO. TITLE
SHEETS
1.0 TCE.5960A-EL-2001 P0 KEY ONE LINE DIAGRAM 01
2.0 TCE.5960A-EL-2003 P0 MAIN ONE LINE DIAGRAM (SH. 1 OF 2) 01
3.0 TCE.5960A-EL-2003 P0 MAIN ONE LINE DIAGRAM (SH. 2 OF 2) 01

SWITCHYARD SCADA ARCHIETCTURE
4.0 TCE.5960A-EL-2004 P0 01
DIAGRAM
PARALLEL REDUNDANT UPS WITH
5.0 TCE.5960A-EL-2005 P0 STATIC BYPASS TO REGULATED 01
SUPPLY
FLOAT CUM BOOST CHARGER WITH
6.0 TCE.5960A-EL-2006 P0 01
2x100% BATTERY
7.0 TCE.5960A-EL-2007 P0 400kV SWITCHYARD PLAN 01
8.0 TCE.5960A-EL-2008 P0 400kV SWITCHYARD SECTIONS 01
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TCE FORM NO. 329 R5

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5.1
ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. SECTION: D3.0
TITLE SHEET 1 OF 17
1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST.
ELECTRICAL SYSTEMS - SPEC. NO.
GENERAL REQUIREMENTS TCE.5960A-H-500-001
1.0 General Requirements
(a) For the purpose of design of equipment / systems, an ambient

temperature of 500C and relative humidity of 95% shall be considered.
The equipment shall operate in a highly polluted and highly corrosive
environment. However, for equipment in air-conditioned areas,
design ambient temperature shall be 350C, if 2x100% air conditioning
system is provided.
(b) All equipments shall be suitable for rated frequency of 50 Hz with a

variation of +3% to -5% and 10% combined variation of voltage and
frequency unless specifically brought out in the specification. The step
up voltage of the project shall be 400 kV as applicable.
(c) Contractor shall provide fully compatible electrical system,

equipments, accessories and services for the entire station/plant in his
scope as well as those specifically required by the Owner.
(d) All the equipment, material and systems shall, in general, conform to
the latest edition of relevant National and International Codes &
Standards, especially the Indian Statutory Regulations. The
accompanying specifications also indicate the applicable codes and
standards. The equipment/material/systems conforming to other
equivalent national and international standards shall also be
considered provided the same ensures equal or better features
compared to standards listed in accompanying specification.
(e) Control supply voltage for all the switchgear for the GTG, HRSG,
Cooling tower & STG shall be 220 V DC & 110 V AC. However the
area where the DC control supply is required shall be finalized during
the detailed engineering.
(f) Fault level shall be limited to 44 kA rms for 6.6 kV systems and 50 kA
rms for 400 V system. However the three phase symmetrical short
circuit fault current value shall be based on load flow and fault
studies, to be carried out as a part of this contract.
(g) The nominal voltage of main DC system shall be 220V and 24V DC
system for I& C application. To cater the 400kV switchyard PLCC
load, separate 48V DC system shall be provided. Any other voltage
required shall be derived from 220V DC or 230V AC UPS distribution
board for catering to the control & instrumentation loads.
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TCE FORM NO. 329 R5
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TITLE SHEET 2 OF 17
(h) The Contractor shall furnish calculations of maximum loading and

fault levels under the most onerous conditions for the various
equipment/systems to prove adequacy of their parameters. In case
any equipment or system is found to be inadequate, it shall be
changed / modified without any additional liability to the Owner.
(i) Transformer voltage ratios, taps, impedances and tolerances thereon,

shall be so optimized so that the auxiliary system voltages (6.6 kV &
400 V) under various grid and loading conditions are always within
permissible limits and equipment are not subjected to unacceptable
voltages during operation and starting of motors. The vector groups
of the transformers shall be so selected that all the buses of particular
voltage level have same vector through out the plant.
(j) The responsibility of coordination with electrical agencies and

obtaining all necessary clearances from all the statutory authorities,
shall be by the Contractor.
(k) All control and protection panels, 6.6 kV switchgear, 400 V

switchgear, MCCs, DC and AC distribution board and battery charger
panels shall be painted by powder coating process. External surfaces
of all equipments shall be painted with Epoxy paint. Paint shade shall
be opaline green (external) & semi-glossy white (internal).
(l) The electrical scheme for the project shall be as per the enclosed
drawings:
Key one line diagram : TCE.5960A-EL-SK-2001
Main one line diagram : TCE.5960A-EL-SK-2003 (Sh. 1 of 2)
Main one line diagram : TCE.5960A-EL-SK-2003 (Sh. 1 of 2)
Switchyard SCADA : TCE.5960A-EL-SK-2004

Architecture diagram
UPS scheme : TCE.5960A-EL-SK-2005
Float cum boost charger : TCE.5960A-EL-SK-2006

with 2 x 100% battery
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TITLE SHEET 3 OF 17
400kV Switchyard plan : TCE.5960A-EL-SK-2007
400kV Switchyard sections : TCE.5960A-EL-SK-2008
1.1 Generator and its auxiliaries
1.1.1 The generator shall be three phase, horizontal, two pole, cylindrical rotor,
Wye connected machine with phase and neutral terminals brought out for
connection to isolated phase bus duct. The Gas turbine generators /steam
turbine generators and their excitation systems shall have a capability at
least matching the declared maximum continuous output of the associated
gas turbine /steam turbine at the outside ambient air temperature ranging
from 00C to 500C, at all power factor between 0.85 lagging and 0.95 leading.
The contractor shall ensure that when the generator is working at this
capability, no part of the generator shall attain a temperature in excess of the
temperature limit specified in IEC 60034. The Insulation class of the machine
shall be Class-F but its temperature rise shall be limited to Class-B.
1.1.2 The Gas Turbine Generator and Steam turbine Generator shall be of
hydrogen & water cooled. The Stator core & Rotor winding shall be hydrogen
cooled. The Stator winding shall be DM water cooled.
1.1.3 The Contractor shall offer 2 nos. Static Frequency Converter (SFC) for
starting of one gas turbine generator at a time. It shall be ensured that either
of SFC can be used for cranking any of the Gas turbines without any
limitation on successive starts of all gas turbines and restarts thereon.
1.2 Generator Circuit Breaker (GCB)
The continuous current rating of the GCB shall be arrived at considering the
maximum output of the generator and at specified minimum voltage. The
voltage class of the Generator circuit breaker shall be same as that of the
generator. The GCB shall be of SF6, metal enclosed, outdoor and
freestanding type.
1.3 Generator Transformers
1.3.1 The continuous rating of the generator transformers shall be such that the
declared maximum continuous output of the respective turbine unit at any
ambient temperature between 00C and 500C can be delivered at the rated
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TITLE SHEET 4 OF 17
power factors and allowable generator voltage variations without exceeding

the permissible temperature rise limits set by the applicable Indian Codes
and Standards for these equipment. Further a margin of 5% on the rating
shall be provided considering the maximum Generator output. The Bidder
shall furnish the rating of the equipments.
1.3.2 The GT shall be with voltage ratio of generator voltage / 420kV, two winding,
50 Hz, ONAN / ONAF / OFAF cooled transformer, with On Load Tap
Changer with +10% to -10% of in steps of 1.25% on the HV side.
1.4 Unit Auxiliary Transformer
2 Nos. Unit auxiliary transformer shall be capable of supplying auxiliary

power requirement of complete station system. UAT shall be a * MVA,
*/6.9kV, three phase, two winding, 50 Hz, ONAN/ONAF cooled transformer
with * % impedance with OLTC +10% in steps of 1.25% on HV side (*By
Bidder). Further a 10 % margin on rating shall be provided after considering
final load requirement. UAT shall be suitable for medium resistance earthing
with earth fault current limited to 300A.
1.5 Bus duct
1.5.1 The continuous current rating of the generator bus duct shall be arrived at
considering the maximum output of the generator and at specified minimum
voltage.
1.5.2 The M.V. / L.V. Bus duct shall be sized based on the transformer rating at
minimum tap.
1.6 Protection
Fully graded protection system with requisite speed, sensitivity and

selectivity shall be provided for the entire plant. Critical equipments/systems
shall be provided with double protection. Contractor shall recommend the
relay settings to be adopted along with back-up calculations.
1.7 400 kV Switchyard
(a) A 400 kV switchyard shall be provided for evacuation of power

generated in the plant through four (4) nos. 400kV transmission lines.
The 400 kV switchyard shall have one and half breaker switching
scheme.
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(b) The layout of the switchyard shall be such that adequate space for
maintenance of prime equipment like circuit breakers and current
transformers is available. Approach road shall be provided. Approach
road all around the switchyard shall also be provided for maintenance
and patrolling.
(c) Earth mat
The earth mat shall be extended 2 m beyond fence for the switchyard.
The earth mat of 400kV switchyard shall be inter connected with main
plant. The earth mat shall be designed for short time rating of 1
second rating and shall be considered for calculation of step & touch
potential. For the Earthing system design System fault current to be
considered is 50 kA.
(d) The EMVT/CVT and LA shall be connected to earth pit through pipe
electrodes.
(e) The Conductor tensions shall be 2 Tonnes per conductor.
(f) All tension insulator strings shall have double tension string
arrangement.
(g) Air conditioned outdoor kiosks will be suitably located in switchyard,

housing various Intelligent Electronic Devices (IEDs) such as Bay
Control Units (BCUs), Protection Panels, Fault Disturbance
Recorders, PLCC Panels, etc. for each dia.
(h) The connections from LA to transformer shall be through shortest

electrical distance.
(i) The coolers shall preferably be arranged on side, other than LA.
(j) The receptacles of 63 A ratings shall be provided on the gantries at

suitable location for connection to welding sets/other emergency
equipments.
(k) The aluminium tubular busbar conductors wherever if used shall have
maximum one joint per span.
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(l) Corona rings & corona bells shall be used wherever required and
same shall be of non-magnetic material. The requirements regarding
RIV and corona extinction voltage shall include terminal fittings.
(m) All equipments shall be suitable for hot line washing.
(n) The connectors for termination of conductor on equipment shall be

either of rigid or expansion type suitable for aluminium tube or Moose
ACSR conductor.
(o) The switchyard shall be provided with suitable phase markers and
danger plates.
(p) Insulation Co-ordination
The Contractor shall be fully responsible for complete insulation co-

ordination of switchyard. Contractor shall carry out detailed
calculations to evolve the required parameters, locations, energy
capability etc. of surge arrestors such that an adequate protective
margin exits between the peak impulse voltage occurring due to other
connected sub stations. Bidder to note that surge arrester parameters
given at D3.7 are indicative and shall be finalised after insulation
coordination studies.
The quantity of surge arresters shown in the drawings are minimum

required. Additional arresters, if required based on the insulation
coordination study, shall be provided by the Contractor.
The Contractor shall provide surge arrestors and other devices as

required to protect all the equipments from fundamental frequency,
harmonics, ferro-resonance, switching surges, and lightning impulse
over voltages under steady state, dynamic & transient conditions.
The Contractor shall furnish the system studies like load flow, short
circuit and transient stability studies of the complete system including
the transmission lines during detail engineering stage for Owner’s
approval. In addition to the above, Contractor shall submit the relay
co-ordination, motor starting studies for the complete plant for
Owner’s approval.
(r) 400 kV System
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(i) Max voltage 420 kV
(ii) Rated frequency 50 Hz
(iii) Rated short time current 50 kA rms for one (1) second
withstand capacity
iv) Rated one minute power 630 kV rms

frequency withstand
voltage
v) Rated lightning impulse 1425 kVp

withstand voltage
vi) Clearance
Phase to phase 4200 mm
Phase to earth 3400 mm
Sectional clearance 6500 mm
Ground clearance 8000 mm
(s) System neutral earthing Effectively earthed
(t) Auxiliary contacts The contacts shall have continuous

rating of 10A and breaking capacity
of 2A with circuit time constant of
minimum 20 ms at 220 V DC.
(u) Type of circuit breaker SF6
(v) Operating mechanism Spring / Spring charge mechanism

Circuit breaker
(w) Type of isolator Horizontal centre break/Pantograph
(x) Instrument transformer Outdoor, Oil filled hermetically

sealed with SS bellow.
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(y) Creepage distance for 31mm/kV

insulators
1.8 Control philosophy of electrical system
(a) Control of L.V. and M.V. auxiliary power system, covered under the
scope of this package shall be provided through the DCS system.
(b) Control, Protection, monitoring, indication, annunciation and metering

of complete 400 kV switchyard under Bidder's scope shall be through
SCADA.
(c) PLCC panels for lines shall be located in the outdoor kiosk panels.
(d) The control, monitoring, measurement, annunciation, synchronizing

and sequential event logging for each generator and its subsystem
shall be provided on the DCS.
e) SCADA shall have communication with plant DCS for providing

measurement, monitoring, annunciation etc of 400kV switchyard.
1.9 6.6kV Switchgear
The 6.6 kV switchgear and its accessories shall conform to all latest editions
of national and international standards. For feeding the plant auxiliaries rated
for 6.6 kV and service transformers, adequately rated switchgears shall be
provided. The fault level for the switchgear, circuit breakers, isolators, earth
switch, bus bars, etc., shall be arrived at, on the basis of short circuit current
contribution from UAT plus short circuit contribution by the motors running on
the bus.
A margin of 5% over higher of the above S.C current, shall be applied and
rounded off to the next higher standard ratings and this value shall be
adopted for the breakers and switchgears. The momentary current ratings
shall be 2.55 times this value.
1.10 Service transformer
Adequate number of 6.6 kV / 420V epoxy cast resin dry type service
transformers shall be provided to meet the demand on 400V systems, with
the criteria that each 400 V switchgear / MCC / DB shall be fed by 2x100%
transformers / feeders, and these shall be rated to carry the maximum load
expected to be imposed with 10% margin at all ambient. Each of the
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switchgear / MCC / DB shall be sectionalised. Highest efficiency operating

point shall be designed near to the normal loading of the transformer i.e.
when the bus coupler is open.
The service transformers shall be two winding, three phase, 50 Hz, 6600 /
420 Volts, Dry type AN cooled with off-circuit taps of ±5% in steps of 2.5%.
1.11 400 V Switchgear
The 400 V switchgear and its accessories shall conform to all latest editions
of national and international standards. For feeding the 400V / 230V AC
loads of the plant, 400V switchgear / motor control centres (MCCs) and AC
distribution boards (ACDBs) shall be provided. The switchgears shown in
Key One Line Diagram drg. No. TCE.5960A-EL-SK-2001 is tentative. Any
additional switchgear / MCCs as required shall also be provided.
1.12 Neutral Earthing Equipment
(a) 400 kV system is solidly earthed. The neutral of GTs are

independently connected to earth.
(b) Generator neutral shall be high resistance earthed. The neutral shall
be connected to a suitably rated neutral earthing transformer with
secondary loading resistor, limiting the earth fault current to about 5-
10 A. The neutral earthing equipment shall be rated to carry this
current for at least 30 seconds considering the generator terminal
voltage under maximum field forcing conditions.
(c) 6.6 kV systems shall be medium resistance earthed. The neutral of

the unit auxiliary transformers shall be independently connected to the
earth through a suitable resistance designed for 30secs. The earth
fault current shall be limited to 300A.
(d) 400V system shall be a solidly earthed system. The neutral of

service transformers shall be independently connected to the earth.
(e) 220 V DC system & UPS system shall be kept ungrounded.
(f) Diesel generator shall be of solidly earthed system.
1.13 DC System
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(a) DC power supply with high discharge Lead acid plante type battery
cells forming bank shall be the source of the power supply for control,
protection, interlock, annunciation of the complete plant including I&C
system during the running of the plant as well as for a safe shutdown
at the time of the total power supply failure.
(b) 220V, DC 2 x 100% battery bank with associated float cum boost-
charger, 1 No. DC switchboard shall be provided for each gas turbine
generator (GTG) unit. The GTG unit DC system with 100% capacity
shall be sized to cater complete unit loads for atleast 10 hrs.
(c) 220V, DC 2 x 100% battery banks with associated float cum boost-
chargers and 1 No. DC switchboard shall be provided for station DC
system. The station DC system shall be sized to cater STG, HRSG
and station loads for at least 10 hrs.
(d) 220V, DC 2 x 100% battery banks with associated float cum boost-
chargers and 1 No. DC switchboard having 2 Incomers & one bus
coupler shall be provided for 400kV system (switchyard) auxiliaries.
The switchyard DC system shall be sized to cater loads for at least 10
hrs.
(e) 48V, DC 2 x 100% battery banks with associated float cum boost-
coupler shall be provided for 400kV switchyard PLCC application.
(f) 24V, DC 2 x 100% battery banks with associated float cum boost-
coupler shall be provided for I& C , DCS system.
(g) The boost charger unit shall be rated such that the battery can be fully
charged from fully discharged condition within 8 hours.
(h) Each battery charger shall be capable of float charging the two
batteries while supplying the normal DC loads.
(i) Sizing criteria shall include design margin of 10%, 25% margin on
ageing and ambient temperature compensation as per IS.
1.14 Uninterruptible Power Supply (UPS)
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Parallel redundant UPS shall be with duplicate charger, inverter & battery
system and standby supply to cater the UPS loads of complete plant
Instrumentation and control system loads such as HMI, SWAS etc. The UPS
shall be sized considering full load plus spare loops plus 20% margin.
1.15 Cabling System
Cables shall be derated for the site ambient and ground temperatures,
grouping and soil resistivity. Contractor shall furnish detailed cable
selection/sizing criteria for Owner’s approval. Cables shall be selected to
limit maximum voltage drop at equipment terminals during normal operation
and starting conditions well within permissible values. Voltage grade of
cables shall be of earthed grade when used in solidly earthed systems, and
unearthed grade when used in non-effectively earthed systems.
1.16 Lighting System
Lighting system shall be provided for the entire plant covering all the
buildings, outdoor areas, roads, yards, boundary, etc. The lighting system
design shall comply with the acceptable norms and the best engineering
practices. The lighting layout shall be designed to provide uniform
illumination with minimum glare. The layout design shall meet all the
statutory requirement, local rules etc.
1.17 Earthing System
The earthing system shall be designed for a life expectancy of at least forty
(40) years, for maximum fault current of 50kA for 1.0 sec. The minimum rate
of corrosion of steel for selection of earthing conductor shall be 0.12mm per
year. Grounding and lightning protection for the entire power plant,
switchyard and other areas or buildings covered in the specification shall be
provided in accordance with IS:3043, IS:2309 & IEEE : 80 and IEEE : 665.
1.18 Motors
(a) Wherever the basis for motor ratings are not specified in the
corresponding mechanical specification sections, maximum
continuous motor ratings shall be at least 10% above the maximum
load demand of the driven equipment under entire operating range
including voltage and frequency variations.
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(b) All M.V. motors shall be suitable for 6.6 kV, 3 phase, 50 Hz and LV
motors shall be suitable for 400 V, 3 Phase, 50 Hz power supply. The
voltage for M.V. and L.V. motors shall be ±10%.
(c) The motors rated 175 kW and above shall be 6.6kV and motors rated
upto 175 kW shall be 400 V.
1.19 Emergency Diesel Generator Set
Each Emergency Diesel Generating set shall be sized at an ambient

temperature of 500C for all essential auxiliaries and emergency loads of all
gas turbines, steam turbines, station service and switchyard loads.
1.20 Islanding Scheme
The plant shall be designed to operate in islanding mode of operation by

tripping all the lines and generators except for one pre-selected unit, which
shall run with the available plant load under such condition.
1.21 Auxiliary System
(a) 6.6 kV incomers and ties from transformers to switchgear shall be

through 6.6 kV segregated phase bus duct (SPBD) only. If adequately
rated cables shall be provided then Owner’s permission shall be
obtained. For 400V system, non-segregated phase bus duct (NSPBT)
assemblies shall be preferred for incoming connection from
transformers to the switchboard.
(b) The 6.6 kV system shall incorporate a microprocessor based

numerical fast auto change over scheme which will restore supplies to
the 6.6kV unit board from other unit board, on loss of supplies from
unit transformer. Manual live changeover and slow changeover shall
also be arranged for all 6.6 kV buses & 400V buses. Automatic
changeover to the reserve supply source shall be arranged for 400V
critical switchgear/MCC sections as necessary to prevent the loss of a
unit or to ensure the equipment safety.
(c) 6.6kV and 400V switchgear, MCCs and DBs shall have positive fool-
proof interlocking to ensure that different supplies and transformers
are never operated in parallel and fault level does not exceed the
switchgear capability. For 400V switchgear, contribution from
emergency DG set shall be considered while designing the fault level.
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(d) During Grid black-out condition, it shall be ensured that only the
essential auxiliaries of all units are fed from emergency Diesel
generator & non- essential loads are automatically tripped.
(e) DC scheme shall provide at least two feeds through diode sharing to
critical consumers e.g. all protection panels / control desks, circuit
breakers, GCB, 6.6 kV / 400 V unit and emergency switchgear panels,
generator excitation system, generator oil seal system, etc. The
details shall be subject to Owner’s approval. For generator protection
and protection panels for all 400 kV switchyard feeders, duplicated
DC feeders shall be provided, one from each battery system.
1.22 The insulation level for the transformer windings and bushings shall be as
follows:
Winding Bushing
Highest System Rated Rated Rated Rated

Voltage Power lightning Power lighting
Freq. impulse freq. impulse
withstand withstand withstand withstand
voltage voltage voltage voltage
(kVrms) (kVp) (kVrms) (kVp)
7.2 kV 20 60 20 60
12 kV 28 75 28 75
17.5 kV 38 95 38 95
34.5 kV 95 250 95 250
420 kV 630 1300 630 1425
Note: for 400kV system switching impulse of 1050 kVp shall be considered.
1.23 Degree of protection
Degree of protection for various enclosures as per IS: 13947 shall be as

follows:
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(a) 6.6 kV switchgear
i) VT/relay compartments - IP 52
ii) Other compartments - IP 42
iii) Switchgear in air-conditioned areas - IP 32

(all compartments)
(b) 400V switchgear / MCC / DBs / Fuse Boards
i) Compartments and busbar chambers - IP 52

upto 1600A
ii) Compartments and busbar chambers - IP 42

above 1600A
iii) All compartments in case switchgear - IP 32

in air-conditioned areas
iv) Switchgear located out door - IP 54
(c) Busduct enclosure / GCB
i) Indoor portion including VT & SP cubicle - IP 52
ii) Outdoor portion - IP 65
iii) GCB - IP 65
(d) Motors
i) Indoor motors - IP 54
ii) Outdoor motors - IP 55
(e) Control and relay panel
i) In air-conditioned areas - IP 32
ii) In other areas - IP 52
(f) Transformers
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i) Indoor Transformers - IP 31
ii) Cable box - indoor area - IP 52
iii) Cable box - outdoor area - IP 55
iv) Indoor kiosks and marshalling boxes - IP 52
v) Outdoor kiosks and marshalling boxes - IP 55
(g) Push button stations and any other kiosk / box / panel / enclosure
i) Indoor - IP 54
ii) Outdoor - IP 55
(h) Junction boxes for cables/wires - IP 55
(i) Outdoor lighting fixtures - IP 55
(j) Gen. Neutral grounding resistor - IP 22
(k) 6.6 kV Neutral grounding resistor - IP 33
1.24 FAULT LEVEL
Equipment through fault withstand capabilities under worst operating

conditions duly taking into account tolerances on transformer, generator &
maximum fault levels of source etc. shall be as follows :
i) All other transformers - 2 seconds
ii) Generator busduct main run, GCB, (higher of - 1 second

generator or EHV system fault contribution)
iii) Tap off run busduct (sum of generator and - 1 second

EHV system fault contribution)
iv) 6.6 kV Busduct - 1 second
v) Switchgears - 1 second
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vi) Cables to the feeders protected by breakers Main protection fault

clearing time with 0.16
seconds minimum
vii) Cables of all other feeders As per fuse operating

time
viii) 6.6 kV cable screen - 2 seconds for the

adopted ground fault
current
ix) EHV systems - 1 second
1.25 Type Test
All equipment / systems to be supplied shall conform to type tests as per

relevant standards / relevant chapters of this specification and shall be of
proven type.
1.26 Communication System

For effective communication in the plant, public address system, private
automatic branch exchange system (EPABX), radio paging system, walkie-
talkie and P&T telephone system with the features described below will be
provided:
a) Public Address System

This system will have paging and party channels comprising handset
stations with amplifiers, transmitters, receivers, and loud speakers. This
system will facilitate paging, communication and also private
conversation as in conventional telephone.
b) EPABX System
This system will have adequate number of push button type handset
stations, central automatic telephone exchange, etc. The handsets in the
control room would be provided with priority service facility to enable
them to have immediate access to any handset even if it is already
engaged.
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c) Landline Telephones, Broadband connectivity

Necessary number of ISDN / PSTN landlines would be provided at
strategic locations within the plant boundary. Broadband connectivity
would be provided at strategic locations for online access of data from
remote station.
d) Wireless System (Walkie-Talkie System)

Walkie-Talkie system will be provided for mobile communications. These
systems will be of particular use during commissioning stage as well as
subsequently during maintenance.
e) GPRS/CDMA mobile system of any reputed service provider can be

provided for wireless system. The mobile system coverage in the power
plant area should be 100%.
f) Interface between the EPABX, PA and Wireless systems shall be

provided to enable communication between these systems.
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SHEET 1 OF 42
GENERATOR AND ACCESSORIES TCE.5960A-H-500-001
1.0 GENERATOR & ACCESSORIES
The generator and its accessories such as the cooling system

excitation system, automatic voltage regulator, static start up
systems for gas turbine generator etc. shall generally comply with
the requirements specified in the national and international
standards indicated as per Data sheet A 3.1 and shall additionally
comply with the specific requirements of Data sheet A 3.1 and as
indicated below:
1.1 Generator
1.1.1 The MW out put of generator of the Gas turbine generator unit and
Steam turbine generator unit shall be sufficient to evacuate the
normal and peak power output of gas turbine power over the
complete range of site ambient conditions specified in Section-B
and at rated casing (Hydrogen) pressure and temperature.
1.1.2 The Maximum Continuous Rating (MCR) of the generator shall

correspond to the maximum MVA, MW and minimum associated
over-excited power factor that it is guaranteed to deliver
continuously (without exceeding its specified temperatures or
temperature rises at rated casing (hydrogen) pressure and
temperature.
1.1.3 The generator shall be three phase, horizontal, two pole, cylindrical
rotor, Wye connected machine with phase and neutral terminals
brought out for connection to isolated phase bus duct. The
generators shall conform to IEC60034-1, IEC60034-3 or other
equivalent international standards. The generator shall be capable
of satisfactory continuous operation at rated MVA and power factor
at any voltage from 95% to 105% of rated voltage and within a
frequency range of 47.5 to 51.5 Hz (and a combined frequency and
voltage variation of 5%) even if frequency and voltage variations
occur simultaneously, without exceeding safe temperature rises, but
not necessarily in accordance with the standards established for
operation at rated voltage and frequency. The generators shall be
provided with Class-F insulation with temperature rise limited to that
of Class-B at full load and at rated voltage & frequency. However,
for abnormal operating conditions of voltage and frequency, the
temperature rise shall in no case exceed that of Class-F when the
machine is operating continuously at full load and at rated power
factor at any working voltage and any frequency in the range
stipulated above.
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1.1.4 The generator unit shall be capable of withstanding 3 phase short

circuit at the generator terminals when operating at rated MVA and
power factor, 5% over voltage and with rated excitation for 3
seconds.
1.1.5 The line charging capability of the generator shall not be less than
30% of its rated MVA at zero power factor.
1.1.6 The generator shall be non-effectively earthed through a single-

phase distribution transformer provided with secondary loading
resistor. The sizing of the transformer and the value of the
resistance shall be such as to restrict the maximum earth fault
current to 1.5 times the capacitive current at normal working
voltage. The generator shall be capable of operating alone or in
parallel with other generators and / or utility grid.
1.1.7 The core of the generator shall be designed such that it permit the
flow of earth fault current of at least 15 amperes for one (1) second
without any core damage.
1.1.8 The generator phase and neutral side terminals shall be brought out
through seal off bushings.
1.1.9 The bearings shall be lubricated by oil from the turbine lube oil
system. Non-hygroscopic insulation shall be provided to prevent
any damage due to the circulation of shaft current to the bearing
surfaces and the lubricating oil.
1.1.10 At least one of the bearings shall be suitably insulated with

arrangements for checking the insulation resistance while the
machine is in operation.
1.1.11 On-line shaft leakage current monitoring system shall be provided to

detect any leakage current through the shaft. Abnormal leakage
current shall trigger an alarm in the control room.
1.1.12 The generator and its components shall be designed to avoid

resonance over the entire range of operating frequency or their
multiples.
1.1.13 The noise (sound) power level emitted by the generator as

measured one (1) metre from the surface of the generator and at
1.5 metre height above floor level shall be limited to 85 dB(A).
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1.1.14 The generator unit shall be capable of withstanding the electrical,

mechanical and thermal stresses developed during fast auto
reclosing of high voltage line, transmission line switching, grid
faults, out of step operation, out of phase synchronisation, etc.
1.1.15 The vibration severity when measured on generator and main

exciter bearings shall not exceed 2.8mm / sec.
1.1.16 When tested on open circuit and at rated speed and voltage, the
telephone influence factor of the turbine generator shall not exceed
1.5 %.
1.1.17 The generator winding shall withstand test voltage of 4 U + 5 (where

U is the rated voltage in kV). Lightning arrestors of suitable rating
shall be provided for the surge protection of generator winding. In
addition to the above if surge capacitors are recommended, the
same shall be included in the offer.
1.1.18 All components of the generator requiring inspection and

maintenance shall be designed for easy access and replacement.
1.1.19 Resistance / thermocouple type temperature detectors shall be

provided where the highest temperatures are expected. The
approximate number and location of temperature detectors shall be
as follows:
(a) Twelve (12) duplex RTDs (Four per phase) distributed equally
around the periphery of the stator winding and also between
three phases shall be provided. The geometry of the detectors
shall be such that hot spots anywhere in the stator winding can
be detected.
(b) Twelve (12) duplex RTDs for stator core out of which six shall
be located in the end zones where maximum temperatures are
expected.
(c) Two (2) duplex RTDs for each hydrogen cooler section at inlet
and outlet (if applicable).
(d) Two (2) thermostats per hydrogen cooler section for gas inlet
and outlet (if applicable).
(e) Two (2) duplex RTDs for hydrogen cooler water inlet and outlet
(if applicable).
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(f) Two (2) duplex thermocouples per bearing.
(g) Two (2) duplex RTDs for cold air temperature and two (2)
duplex RTDs each for air temperature in the exciter air
passage and rectifier wheel along with thermostats for cold and
hot air.
(h) Set of duplex RTDs and thermostats for shaft seal system (if
applicable).
(i) Rotor winding temperature measurement is also to be done

through 2 Nos. of duplex RTDs located at the locations where
the temperature is likely to be maximum.
(j) Additional RTDs / Thermocouples / Thermostats if required or if

required at additional locations shall be provided as found
necessary.
1.1.20 All RTDs shall be of platinum duplex four wire type and shall have a
resistance of 100 Ohms at zero degree centigrade and calibrated
as per DIN standards. Termination of RTD leads shall be at terminal
box after grouping of signals. Terminal box shall be at an easily
accessible position so as to enable maintenance / testing of the
devices when the machine is under operation. Termination box of
the temperature measuring devices shall be of IP-55.
1.1.21 All the above temperature measurement devices shall be hooked to

DCS.
1.1.22 One (1) generator condition monitoring system shall be supplied

along with all piping and accessories to continuously sample the
generator hydrogen for detection of thermally produced particulates
/ aerosols which indicates overheating.
1.1.23 Generator auxiliary system like cooling, excitation, hydrogen gas

handling system, etc., shall be provided with respective local control
panels with required control, indication / annunciation and
necessary main control system interfacings with DCS.
1.1.24 Generator rating shall be on the basis of continuous operation with

guaranteed temperature, or temperature rises, not exceeding those
given in IEC 60034-1.
1.1.25 Insulation and Temperature Limits

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The generator stator and rotor windings inclusive of main and

neutral leads, shall be provided with Class F insulation but
temperature rise shall be limited to class B. The maximum
permissible temperatures of different parts of the generator shall be
as specified in IEC-60034.
1.1.26 Short Circuit Withstand Capability during Unbalanced Faults
The generator shall be capable of withstanding, without injury, any

short circuit at its terminals provided the integrated product of I22t
does not exceed the value stipulated in IEC60034-1, where I2 is per
unit negative sequence current and t is the duration of fault in
seconds.
1.1.27 Overload Capability
With balanced current, the short time thermal capability of the

generator armature shall permit operation at 150% of the rated
armature current for at least 30 seconds, starting from stability
temperature at rated load.
1.1.28 Capacity with one Gas Cooler Out of Service
Hydrogen coolers would be built into the stator frame of the

generator and would be sized to ensure at least 80% of the rated
output continuously with 10% of tubes in each coolers are plugged
and one of the hydrogen cooler is out of service then also the
temperatures rises shall be limited to class B.
1.2 Stator Housing
1.2.1 The stator housing shall be of totally enclosed gas tight

construction, having sufficient mechanical strength and rigidity to
withstand internal gas pressure, 100 percent vacuum and
vibrations and also internal hydrogen explosion without any
damage or permanent deformation.
1.2.2 Suitable numbers of trunions shall be provided for handling the

stator by means of crane. The Bidder to clearly bring out in the
proposal the features provided in the generator body construction
to enable generator stator to be lifted/dragged in case of non-
availability of suitable crane.
1.2.3 The housing shall have suitable provision for handling, lifting and /
or jacking the stator. Manholes with sealing arrangement shall be
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provided at suitable locations to facilitate inspection of terminals,

internals such as back of the core, end winding area, etc.
1.2.4 End plates of the generator frame shall be suitably shielded from
stray flux. Stray current insulation shall be provided so that all
paths of stray current will be broken at two places in series at one
end of the generator with provision made for determining the
insulation resistance at each place of insulation with the unit in
operation.
1.2.5 The frame shall be stress relieved and then subjected to an

extended hydraulic test at a pressure not less than 1.5 times the
maximum design pressure.
1.2.6 All leads, including power, control and instrumentation shall be

suitably supported to contain vibrations and shall be brought out of
the generator housing to terminal boxes through gas tight seals.
The instrumentation terminal box shall have IP55 protection class
and shall be located at an easily accessible position so as to
enable maintenance / testing of the devices when the machine is
under operation. Location may be preferably on the TG Deck. A
drawing indicating the location of the temperature detectors and
the terminal box shall be enclosed with the proposal.
1.2.7 The dimensions of the generator stator body to be within the

maximum permissible rail transportation dimensions within the
country taking into account the special wagons available / being
made available for transporting such heavy over sized
consignment.
1.3 Stator Core
1.3.1 The stator core shall be fabricated out of high permeability best
quality cold rolled silicon steel so that losses are minimum. The
core assembly and mounting arrangement shall be such that the
transmission of the forced vibration of the core to the housing and
foundation is effectively restricted. The end packets shall be
adequately strengthened to minimise the magnetic vibration due to
end leakage flux.
1.3.2 The core assembly shall have adequate ventilation ducts for
cooling by hydrogen. Press plates and fastening elements shall be
made of non-magnetic material and shall be with proper locking
arrangement.
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1.3.3 The stator core mounting arrangement shall be such that radial
and tangential magnetic vibrations of the stator core due to
electromagnetic loading transferred to stator frame are minimised.
The stator core, frame and mounting shall be designed to avoid
resonance at 50, 100 and 200 Hz.
1.4 Stator Winding
1.4.1 The stator winding shall consist of three phase, double layer, short
chorded, bar type lap winding having two parallel paths. The
strands making up the stator bar shall be Roebel transposed to
minimise eddy current losses.
1.4.2 The winding and all connections inclusive of phase and neutral
leads shall be insulated for full voltage to ground.
1.4.3 In order to reduce the corona in the slot and where the stator bar
leaves the stator core, a surface treatment corona grading system
shall be applied which shall be carried into the end turn area.
1.4.4 Firm seating of the stator bar in the slot shall be ensured by proper
wedging and fillers. Ripple springs shall be provided below the slot
wedges to compensate for any future shrinkage and ensure
permanent firm seating of the bars in the slot during operation.
The end turns shall be suitably braced and supported to withstand
forces during normal operation and sudden short circuit at
generator terminals when the machine is operating at rated MVA,
power factor and permissible maximum over voltage.
1.4.5 The stator windings shall be designed for connection in single

/double star with three (3) phase and three (3) / six (6) neutral
terminals brought out.
1.4.6 At least six (6) numbers of vibration pickups at each end of over
hang portion of the winding shall be provided, symmetrically
located around the periphery with connection to Turbine
Supervisory system. Provision shall also be made available to
connect the same to DCS. Bidder shall wire up all the pickups to a
junction box outside the generator casing.
1.5 Terminal Connection
1.5.1 All phase and neutral terminals shall be brought out from the top
of the generator (non-drive end) and located in a non-magnetic
steel terminal box. Phase terminal bushing shall be spaced to
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permit connection to isolated phase bus duct to provide complete

phase isolation directly upto the generator housing. Adequate
spacing shall be provided between phase and neutral bushings to
permit connection of the neutral enclosure.
1.5.2 The bushing shall be preferably of porcelain type or of epoxy

based material with non-hygroscopic property. The terminal
bushing shall be cooled by suitable arrangement with cooling
medium/system envisaged for the generator. Silver coated copper
terminal connectors suitable for connection to the busduct through
flexibles shall be provided for which the operating conductor
temperature shall not exceed 105OC.
1.6 Rotor
1.6.1 The generator rotor shall be machined from a single alloy steel
forging to ensure required mechanical strength and magnetic
properties. Adequate margin shall be provided between critical
speed and the running speed to ensure smooth running. Facilities
shall be provided for inserting at least two radial and one axial
probe into the rotor shaft for carrying out ultrasonic and residual
stress measurements during the life of the rotor.
1.6.2 The forging shall be subjected to elaborate ultrasonic and

mechanical tests to ensure freedom from any internal defect.
1.6.3 After assembly, the rotor shall be dynamically balanced and

subject to 20% over speed for 2 minutes.
1.7 Rotor Winding
1.7.1 Rotor winding shall be made of hard drawn silver bearing solid
copper conductors. Winding insulation shall correspond to Class-F
(i.e. epoxy glass based material) with temperature limited to Class
-B. Rotor winding shall be secured in the slots by suitable slot
wedges and fillers. The overhung portion of rotor winding shall be
held in position against centrifugal force by retaining rings when
the rotor is running at upto 20% above its normal speed.
1.7.2 The retaining rings shall be machined from high strength, non-
magnetic alloy steel forging with the material specification
X8CrMnNi1818 resistant to stress corrosion. The retaining rings
shall be floating type, shrunk on rotor body and prevented from
axial movement by snap rings / locknuts.
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1.7.3 Suitable damper winding shall be provided on the rotor to permit

increased asymmetrical electrical loading.
1.7.4 The rotor shall be suitable for operation without requiring

preheating of the rotor or rotor winding or pre-warming of the rotor
forging.
1.8 Bearing
1.8.1 The generator shall be provided with self-aligning type sleeve

bearings either mounted on separate pedestals or on the end
shields. The bearings shall be of horizontally split construction and
forced lubricated from turbine oil system. The bearing shells shall
be lined with tin based babbitt metal. Oil buffers shall be provided
to prevent leakage of oil and oil vapours along the shaft. All the
intermediate support pieces of the bearing shall have complete
interchange ability with those of similar type and size of TG
bearing.
1.8.2 Non-hygroscopic insulation shall be provided between bearing and

frame to prevent any damage due to circulation of shaft currents to
the bearing surfaces and the lubricating oil. Arrangement shall be
provided to measure the insulation of the generator bearing with
the machine in operation. This shall be achieved by having two
layers of insulation with a metallic plate in between. Build-up of
shaft voltage beyond permissible limits as well as a short in the
bearing insulation shall trigger an alarm.
1.8.3 Each bearing shall be provided with a well for thermometer in the
return line and a sight glass with illumination to observe bearing oil
flow. Redundant vibration pick-ups and transducers for bearing
shall be provided. The vibration sensors shall be installed on X
and Y dimensions. RTDs for measurement of metal temperature
and bearing drain oil temperature shall be provided.
1.8.4 Provision shall be made for hydraulic jacking of the shaft during
start up and turning gear operation.
1.9 Shaft Seals
1.9.1 Labyrinth shaft seals shall be provided. Shaft seals, preferably of

double flow ring type shall be fitted to the end-shields to prevent
hydrogen leakage from generator housing. To ensure effective
sealing, seal oil pressure in the annular gap between the rotating
shaft and seal ring shall be maintained at a higher level than the
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gas pressure in the generator casing. The face of the sealing ring
shall be lined with babbitt metal.
1.9.2 The hydrogen side seal oil housing shall be provided with oil baffle
rings to prevent intrusion of seal oil into the generator along the
rotor shaft. Shaft seals and oil piping shall be suitably insulated to
prevent circulation of shaft current. Arrangement shall be made to
measure the insulation of the shaft seals while the machine is in
operation.
1.10 Fans
Hydrogen shall be circulated in the generator in closed circuit by

the axial fans located on rotor shaft. The fans shall be shrunk on to
their seats on the rotor shaft and locked against tangential or axial
movement.
1.11 Brushes
The rotor winding insulation and shaft voltage shall be monitored

through a brush, suitably mounted and sliding on an oil free
surface. Shaft grounding brushes shall be provided at the turbine
end bearing pedestal. It should be possible to increase the brush
pressure while generator is working. Brush holders shall be of
constant pressure type, which can be adjusted as per requirement.
Suitable insulation shall be provided to prevent passage of current
through pressure device. Carbon brushes for the measurement of
the rotor winding temperature is also to be provided on the oil free
surface similar to the carbon brush used for shaft voltage
measurement
1.12 Excitation System
1.12.1 Type
1.12.1.1 A complete generator excitation and voltage regulating system

shall be provided with the generator. The system shall be a
brushless excitation system. The excitation system offered shall
be of proven design and shall have a satisfactory field service
record on machines of similar size and construction incorporating
the type of excitation.
1.12.1.2 The excitation system shall have matching characteristics suitable

for satisfactory parallel operation with other generators in the plant.
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1.12.1.3 The various change over relays and other equipment, which are
not controlled by the control supply required by AVR shall be such
that the loss of their control supply does not lead to the excitation
system outage.
1.12.1.4 The necessary inputs and interface equipment shall be provided

with Generator Excitation and Automatic Voltage Regulator for
hooking up with Turbine Automatic Run up system and Electro
Hydraulic Governing System.
1.12.1.5 The excitation system shall also meet the performance

requirement specified hereinafter.
1.12.2 Performance Requirements
1.12.2.1 The excitation system shall have two (2) 100% channels including
independent AVR’s, power converters and controls. Each shall be
equipped for auto operation with the facility for selecting either
channel in Auto or Manual mode.
1.12.2.2 The system shall function without hunting and shall be capable of
preventing any abnormal change or oscillation in the generator
voltage.
1.12.2.3 The system shall have high initial response to improve steady state
and dynamic stability of the generator. The excitation system
response time shall be less than 0.5 sec.
1.12.2.4 The excitation system shall be capable of maintaining generator

voltage within + 0.5 % of the preset value over the entire load
range of the machine. When the generator is subjected to a
sudden loss of rated output at rated power factor, the system shall
be capable of restoring the voltage within 2% of the nominal preset
value within negligible time.
1.12.2.5 The reference voltage set point shall be adjustable over a range of
70% of no load to 110% of the nominal rated voltage at MCR.
1.12.2.6 The excitation system shall be rated to continuously carry current

at least 20% above the rated generator field current at MCR
output. The excitation system shall also be capable of supplying
higher current to meet the short time duty mentioned above.
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1.12.2.7 The ceiling voltage shall not be less than 150% of the machine
excitation voltage at MCR condition.
1.12.2.8 The system shall be capable of supplying the field-forcing

requirement for at least 10 seconds even for close-in faults on high
voltage outgoing lines or bolted faults at generator terminals.
1.12.2.9 The nominal exciter response ratio shall not be less than 2.
1.12.2.10 The excitation system shall have proper field suppression

arrangement, so as to limit the voltages across the rotor winding to
a safe value.
1.12.2.11 In excitation system monitoring facilities with self-diagnostic

features to indicate faulty cards and abnormalities shall be
available.
1.12.2.12 In case of failure of the PMG, the field of the main exciter shall be
transferred to the supply derived from the auxiliary 400V station
supply. This changeover shall be such that it does not result into
the tripping of the generator.
1.12.2.13 An alarm shall be generated if the difference in the set point of the
Auto-1 & Auto-2 is more than a ±0.5% with a 1sec time delay. i.e.
failure in the follow-up circuit.
1.12.3 Automatic Voltage Regulator
1.12.3.1 Continuous acting, non dead-band type microprocessor based

digital automatic voltage regulators with accessories mounted in a
suitable panel shall be provided for the generator. The automatic
voltage regulator shall be capable of working over the whole load
and voltage range of the generator. All rectifying elements shall
have over voltage and short circuit protection.
1.12.3.2 The automatic voltage regulating equipment shall control the

generator voltage under steady state load conditions and over the
whole of the operating range of the exciter within ± 0.5 percent of
the setting value without hunting.
1.12.3.3 The voltage regulator shall be automatic, high speed, continuously

acting, high response, digital type and shall be complete with the
following limiters, compensators etc.
a) Maximum Excitation Limiter, adjustable type

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b) Maximum Stator Current Limiter (The stator current limiter shall

act immediately in under-excited range. The time delay in over-
excited range shall enable a temporary overloading of the
machine)
c) Reactive Drop Compensator (Suitable feedback proportional to
transformer drop shall be provided for compensation and the
range of compensation shall be 0-15%)
d) Over Fluxing (volts / hertz) Limiter (To limit the ratio of generator
voltage and frequency at all operating conditions to such a value
that the maximum generator transformer core flux density does
not exceed the value specified.)
e) Load Angle Limiter (This shall enable to keep the angle between
the direct axis of the machine and network vector within the set
reference value as determined by stability, by adjusting the
excitation.)
f) Minimum Excitation Limiter
g) Adaptive Power System Stabiliser (PSS shall be suitable for
damping the various modes of electro-mechanical oscillations at
all frequencies in the range of 0 to 3 Hz under varying generator
loading and power system network configurations. PSS shall
automatically adapt itself to varying operating conditions with
features to compute optimum stabilising signal along with
suitable scheme for identifying external reactance of the
generator. Facility for remote manual switch off-on along with
indication shall be incorporated. Automatic supervision and
Blocking/Switch off facility along with indications, etc. shall also
be provided.)
h) Rotor Current Limiter (The regulator shall act with time delay, so
that the regulation dynamics are not impaired in case of a fault.)
i) Ramp generation circuit to enable gradual rise of reference

signal applied to the comparator circuit to avoid sudden voltage
build up shall be provided.
j) The channel reference control shall be either solid state control

or microprocessor control.
1.12.3.4 All the above conditions of limiter operations shall be annunciated

in local panel as well as in DCS. Local AVR panel shall be
complete with necessary facia windows, sequence logic, power
supplies, accept-reset-test push buttons, indicating lamps, control
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switches, local/remote switches, auxiliary relays and

programmable logic controllers, etc.
1.12.4 Auto / Manual Channels
1.12.4.1 Two fully equipped independent automatic regulators with one

acting as Master and the other as Slave shall be provided. On
failure of the Master control, the Slave control, which follows the
Master control, shall take over automatically. Either channel shall
be capable of being the main or stand-by. Either channel shall be
capable of being selected as manual also.
1.12.4.2 In auto mode, the range of regulation shall be 70% of no-load to

110% full load excitation. In manual mode the range of regulation
shall be 0 to 110% of nominal rated voltage.
1.12.4.3 Automatic change over from Auto-1 to Auto-2 channel or vice

versa shall be possible in case of trouble in the running channel.
Automatic change over shall be possible from ‘Auto’ to ‘Manual’ in
case of:
1. Generator protection circuit operation i. e. after field

forcing and over excitation condition with a time delay
2. Loss of terminal voltage feedback by way of any of the
VT fuse blowing up
3. Faulty over excitation condition
4. Loss of automatic channel reference signal
5. Power supply failure in the automatic channel
6. Manual intervention
7. Any other condition as considered necessary by the
Bidder
1.12.4.4 In order to avoid a sudden change in generator voltage when

voltage regulation is transferred from ‘Main’ to ‘Standby’ or from
‘Auto’ to ‘Manual’, a suitable arrangement shall be provided to
follow up changes in ‘Auto’ mode along with follow up indication in
Unit Control Panel. An alarm and visual indication shall be
provided to indicate change over from Auto channel-1 to Auto
channel-2 or from ‘Auto’ to ‘Manual’.
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1.12.4.5 The maximum change in generator voltage when AVR is

transferred from Auto to Manual under all conditions of excitation
shall be less than 0.5%.
1.12.4.6 A negative sequence component filter to permit response only to

the positive sequence component of the regulated voltage shall be
provided.
1.12.4.7 At least, the following instruments and control devices suitably

clubbed on a plate/console shall be supplied for being mounted on
unit control panel. Further, it shall be possible to exchange
information with DCS through suitable protocol.
1. A center zero balance indicator to indicate the channel

difference signal
2. Generator field current indicator
3. Rotor winding temperature recorder
4. Auto Channel-1 to Auto Channel-2 & Auto/Manual
changeover indications
5. Generator field breaker/exciter field breaker control &
instrumentation
6. PSS control and instrumentation
7. Auto and manual channel control of excitation level
8. Speed set point control
1.12.5 Brushless Excitation System
1.12.5.1 The complete equipment shall be mounted on a bed plate and

enclosed by suitable enclosure. The system shall consist of :
1. Permanent Magnet Generator (PMG) type Pilot Exciter.

2. Rectifier Unit for PMG
3. Brushless Main Exciter
4. Rotating Rectifier Unit
5. Regulator Cubicle
6. Complete instrumentation and protection system.
7. Inter-connecting cables between different components of
the system
1.12.6 Pilot Exciter
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1.12.6.1 The pilot exciter shall be revolving field, salient pole, permanent
magnet high frequency type. The armature shall be stationary 3
phases feeding current to the static rectifier assembly and
excitation control equipment. The rotor shall be magnetized and
stabilised by the Manufacturer to give stable magnetisation
characteristic during operation.
1.12.6.2 The stator winding shall be of class ‘F’ insulation or better but its
temperature rise shall be limited to Class-B, suitable for operation
at 500C ambient temperature. The machine shall be fitted with
fans for self-ventilation.
1.12.7 Rectifier Unit for PMG
1.12.7.1 Fully controlled three phase, full wave bridge type thyristor
converter facilitating fast and high ceiling performance shall be
provided. They shall be suitable to ensure trouble free service of
the cells under all fault conditions. The converter shall have
redundant thyristors for satisfactory operation even in the event of
failure of any of the thyristors. The thyristors shall be selectively
protected against short circuits by ultra high speed fuses. Suitable
lamp indication shall also be provided to indicate the defective
‘thyristor’.
1.12.8 Brushless Main Exciter
1.12.8.1 The rotating armature shall be 3-phase, star connected, feeding

current to the rotating diodes mounted on the exciter shaft. The
armature core shall be made from silicon sheet lamination to
reduce eddy losses and shall be suitably varnished on both sides.
The exciter shall be totally enclosed, self ventilated, frame
supported on the generator foundation having journal bearings.
1.12.8.2 Integrally mounted air fan shall be provided for the cooling of the
exciter.
1.12.8.3 The armature conductor in the overhang portion shall be

adequately held to withstand the electro-dynamic forces during
field forcing condition. Rotor end winding retaining ring shall be
made up of stress corrosion resistant material. The stator and
rotor winding insulation shall be of class ‘F’ with the temperature
rise limited to class B limits of IEC 60034.
1.12.9 Rotating Rectifier Assembly

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1.12.9.1 The rotating rectifier assembly shall have the following essential
features :
1. The rectifier assembly made of silicon diodes shall be

arranged as two distinct rings with opposite polarity
diodes on respective rings.
2. The diodes shall be connected in a conventional three-
arm full wave rectifier bridge. Rectifier assembly shall
have one complete bridge as redundant. Alternatively a
single three phase rectifier bridge having at least one
redundant parallel rectifier branch in each of the six arms
of the bridge may also be considered. Rectifier assembly
shall have same requirements as regards the component
features and rating as detailed out for the thyristor
assembly.
3. Diodes shall be cooled by forced air circulation by means
of fans mounted on the main exciter.
4. Each diode shall be provided with a fuse together with
visual indication in the event of diode failure.
5. The output from the rectifier shall be fed to the generator
field through the bore of the rotor shaft and necessary
plug in type of shaft connection. The axial copper
connector shall be designed such that it shall be possible
to disconnect this connector at the point where the exciter
shaft couples to the generator so that, if necessary, the
generator and exciter can be tested individually.
1.12.10 Regulator Cubicle
Self-supporting, sheet metal enclosed with swing doors and

ventilating louvers with wire gauge shall be furnished for the
excitation and voltage regulating equipment. Natural ventilation
shall be provided for the cooling of excitation cubicles.
1.12.11 Instrumentation
The instrumentation for excitation system shall generally include,

but not be limited to the following:
i) Suitable duplex RTDs for measuring hot and cold air

temperature of exciter with necessary provisions for protection
tripping/interlocks.
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ii) Instruments and devices for the measurement of rotor winding

temperature.
iii) Stroboscope or suitable alternative device for detection of faulty

rotating diode element.
iv) Suitable arrangement for exciter field suppression.
v) A pair of auxiliary slip rings shall be provided to give access to

the rotor circuit allowing an earth fault detector circuit to be
connected.
vi) For all alarms in the system, contacts shall be taken from the
temperature switches, etc. provided at suitable points. The
system shall be provided with transmitters for the above
indicators.
1.13 Hydrogen Cooling System
1.13.1 System Requirements
1.13.1.1 The hydrogen gas cooling system comprises a hydrogen circuit for
cooling the stator core, stator winding, lead terminal bushings and
rotor windings, carbon-dioxide scavenging system and compressed
air supply system.
1.13.1.2 The system is required to fill the generator with hydrogen, maintain
it under pressure, monitor and control gas purity and to empty the
hydrogen from generator. Also the system shall permit emptying of
the generator casing with help of CO2 purging. The design has to be
such as to ensure safe filling / emptying by preventing formation of
explosive H2 – air mixture. For filling, air is first displaced by CO2,
which in turn is replaced by H2. While emptying H2 is first displaced
by CO2 before admission of air in the machine in order to obviate
possibility of any explosion. For removing CO2, instrument quality
air supply shall be used.
1.13.1.3 The major system components are H2 and CO2 gas manifolds, CO2
heating system, hydrogen pressure regulator, H2 gas coolers, H2
drying equipment, inter-connecting pipings, fittings, valves, gauges,
thermometers, pressure transmitters and other instrumentations,
control & monitoring panel. Annunciation and electrical instruments
shall be located in a separate electric panel common with seal oil
system outside the hazardous area.
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1.13.1.4 Hydrogen supply of 97-99% purity shall be obtained from H2

cylinders on rack through H2 distributor. The distributor shall be
capable of connecting H2 cylinders to meet at least one shutdown &
one start up of all the units & 30 days of normal operating
requirement. Intermediate valves shall allow replacement of
individual cylinders during operation. The high pressure H2 gas
from the distribution header shall be provided with 2x100%
pressure reducing valves. This shall be further reduced to
generator pressure requirements by means of 2x100% pressure
reducing circuit.
1.13.1.5 Hydrogen shall be circulated in the generator in closed circuit by fan

fitted on the rotor shaft. H2 gas is cooled by water/gas heat
exchangers located in the generator housing. The coolers shall be
of sectionalised design such that with one cooler section out of
service & 10% of the tubes in other sections are plugged, the unit
can deliver at least 80% of the rated load continuously without
exceeding the permissible temperature limits of class B.
1.13.1.6 The hydrogen coolers shall be provided with 10% excess tubes.
Cooler shall be designed for at least 10 Kg/sq. cm. Gauge pressure
on the gas side irrespective of a lower normal operating casing
pressure.
1.13.1.7 Corrosion resistant tubes with integral fins shall be provided and
arranged in the stator casing so as to avoid the direct fall of water
during leakage, if any, on the winding insulation. It shall be possible
to clean/plug the cooler tubes of a section with the machine under
operation.
1.13.1.8 Water pressure in the coolers shall be maintained below the

operating hydrogen pressure in the generator casing.
1.13.1.9 The generator drying arrangement complete with all

electrical/mechanical drives/equipment, accessories and controls to
enable drying out operation of the generator with hot air circulation
shall be provided. The system shall be complete with necessary
pressure, temperature and flow gauges as well as thermostats as
required.
1.13.1.10 A certain quantity of H2 circulating in the generator shall be

bypassed through gas drier for removing the moisture and
maintaining the gas in dry condition. 2x100% capacity H2 dryers
with in-situ reactivation facility shall be provided to maintain the H2
inside the machine dry with 0O C dew point at operating pressure.
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The arrangement shall be such that one drier can be taken out of
service for reactivation without affecting the system performance in
any way. Glass indicator shall be provided to indicate humidity.
1.13.1.11 To run the gas system for short time during shut down of generator
(at standstill) for which gas circulation arrangement through drier
with blower, piping valves and accessories along with required
control equipment shall be provided. A suitable hot air blowing
system complete with blower, heater and thermostatic control etc.
shall be provided to prevent condensation during long shut down.
1.13.1.12 The design of the drier shall be such that it is possible to reactivate
the drying medium in-situ after isolation from the generator casing
and connecting it to atmosphere. Arrangement for purging out
entrapped air from the drier after regeneration shall also be
provided, as applicable. For controlling the time/regime of
reactivation, suitable thermometers, thermostats, timers etc. with a
local control panel shall be provided.
1.13.1.13 On line dew point monitoring system shall be provided across the
inlet and outlet lines to the drying system along with
alarm/annunciation in case of high moisture content in the
generator casing hydrogen.
1.13.1.14 The cylinders of CO2 shall ensure complete emptying of the

cylinders as well as to avoid evaporation of liquid CO2 to gas in
cylinder itself. The arrangement of CO2 distributor shall correspond
to that of H2 distributor. The CO2 shall leave the cylinder in liquid
state and shall be evaporated and expanded in a vaporiser.
Thermostat controlled electrical heating system shall be provided
for CO2 system so that the freezing of CO2 pipe is prevented.
1.13.1.15 Seamless steel tubes shall be used for valve piping. Valves shall
be glandless diaphragm type, wherever possible. The valves in gas
system shall be of special design to minimise gas leakage. Safety
relief valves shall be furnished at hydrogen manifold both on low
and high pressure sides of the gas system. A manually operated
vent valve shall be provided for discharging casing hydrogen to
atmosphere (outside the TG hall) in case of emergency. The three
way valves used along with the drier for interconnecting the
hydrogen and airline (as applicable) shall preferably have
mechanical interlocking such that closing of the hydrogen side port
is positively ensured before opening of the air side port.
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1.13.2.1 To ensure efficient and reliable operation of the generator gas

system adequate instrumentation shall be provided. This shall
include the following as a minimum:
1.13.2.2 Dial type thermometers for CO2 vaporiser, and gas drier. Pressure
gauges for gas cylinders, gas manifold, fan differential pressure,
generator casings, gas flow meter.
Required number of temperature, pressure and liquid level detector
switches for alarm and interlock. Necessary sensors/transmitters
for remote indication and recording in DCS.
The local H2 panels shall include indicators for H2 gas cylinder

pressure, H2 gas manifold pressure, generator casing pressure, H2
gas purity, H2 gas temperature (for hot and cold H2 inside casing),
CO2 pressure inside generator, CO2 pressure in the manifold, air
pressure in the air supply manifold and dew point level indicator for
casing H2 across drier inlet and outlet lines.
H2 pressure and purity shall be monitored in DCS.
Gas Analyser shall be of thermal conductivity type and shall

continuously analyse the gas discharged from the casing during
purging and shall also analyse samples of the casing hydrogen
during normal operation. The analyser shall measure the gas purity
under the following three conditions: a) Normal % of purity of
Hydrogen in air in the generator casing. Purity range shall include a
low purity alarm. b) % of Hydrogen in CO2 leaving the casing when
Hydrogen is being admitted or expelled. c) % of air in CO2 leaving
the casing when CO2 is being admitted or expelled.
Portable gas analyser as detailed above shall be provided for

supervision of the gas purging operation.
The Contractor shall provide instrument for on line monitoring of

moisture content in hydrogen inside generator casing.
1.13.3 Annunciation
1.13.3.1 The following annunciation shall be provided on the local electric

panel and DCS. The local control and annunciation panel shall be
complete with switches, lamps, indicators, facia annunciation,
power supply, accept-reset-test push buttons, hooter, etc.
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H2 Pressure in Generator Casing : High / Low
H2 Pressure in Cylinders : Low
H2 Pressure in Manifold : Low
Purity of H2 in Generator Casing : Low
Temp of Cold/Hot Gas in the Generator : High
Pressure of Cooling Water of H2 : Low / High

Coolers
Dew Point Level in H2 Gas across the : High

drier inlet & outlet lines
H2 Leakage into Cooling Water : High
Liquid Level in Generator Casing : High
Power / Control Supply : Failure
1.13.3.2 Independent signals, analog and digital, shall be connected to DCS

system. All instruments shall be mounted on a gas control cubicle
to be located near the machine.
1.13.4 H2 and CO2 Cylinders
1.13.4.1 The number of H2 and CO2 cylinders shall be equal to total

requirement for one start up and one shut down of a unit plus those
required to be connected on manifolds of all units plus total
requirements for seven days consumption of all units. The
Contractor shall supply H2 and CO2 gas till completion of trial
operation.
1.13.4.2 Getting necessary approval from chief controller of explosives is in

the scope of the Contractor. The Contractor shall also furnish the
necessary test certificates and filling certificates.
1.13.4.3 The cylinders to be supplied under this specification shall conform

to IS:8198. Each gas cylinder shall be complete with cap and valve
as per IS:3224. Volumetric (water) capacity of each cylinder shall
be 45.0 litres. Each cylinder shall be hydro tested at pressure of
250 kg/cm² (min.).
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1.14 Generator Shaft Seal Oil System
1.14.1.1 A complete seal oil supply and control system including AC and DC
motor operated pump sets, coolers, filters, pressure regulators, oil
tanks, de-gassification tanks, regulating and control valves, gauges,
thermometers and other instruments, interconnecting piping
including hangers and supports, valves and control/annunciation
panel complete with all interlocking relays shall be provided.
1.14.1.2 A shaft seal oil system shall be provided to prevent the leakage of
hydrogen from the generator casing. The seal oil, when maintained
at a pressure suitably in excess of the hydrogen gas pressure in the
generator casing shall provide an effective gas seal and shall
lubricate and cool the seals when the generator is running.
Seamless steel piping shall be used in the system. A diaphragm
operated regulating valve in the seal oil supply line shall control the
seal oil pressure by a constant amount.
1.14.1.3 The differential pressure shall be kept constant once set at the time
of commissioning, at all hydrogen pressures and all regimes of
generator operation. The pressure regulator or the regulating valve
used for the purpose shall be adjustable type.
1.14.1.4 The seal oil system shall be so designed that it is possible to run
the machine at no load in air medium at a slightly positive air
pressure without any modification in the system.
1.14.1.5 The seal oil shall be cooled in two (2) 100% capacity water cooled
heat exchangers along with necessary 3 way valves for isolating or
bringing one cooler in service. These coolers shall be shell and
tube type suitable for using DM water of condensate quality.
1.14.1.6 Seal oil coolers shall be designed to have 15% excess tube surface
area over and above designed tube surface area required for the
rated load conditions while maintaining the design pressure drop on
cooling water side. The oil pressure in the coolers shall be greater
than water pressure under all operating conditions.
1.14.1.7 2x100% capacity filters shall be provided. Piping and valve

arrangement shall be such that any cooler/filter can be taken out for
cleaning and maintenance without affecting the operation of the
system. Seal oil system shall have connection to turbine oil system
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for make up and also excess return and also shall serve as 100%
back up.
1.14.1.8 For the seal oil system, 2x100% capacity motor driven AC pumps
shall be provided of which one pump shall always be in operation.
Upon failure of the normal service pump due to a mechanical or
electrical fault, the standby pump shall automatically take over the
supply. On of the seal oil pumps shall be fed from the emergency
DG bus. Upon the failure of both AC driven pumps, the seal oil
supply shall be taken over by the emergency DC seal oil pump
without any interruption. The seal oil system shall thus be self-
contained. The auto starting of standby seal oil pumps shall be
interlocked with seal oil pressure.
1.14.1.9 During short time emergency, which may arise due to non
availability of both AC & DC pumps, unit may be tripped and seal oil
supply for such coasting down period shall be from a suitable
arrangement from lubrication oil system or a damper tank.
1.14.1.10 The seals shall be designed so that minimum oil enters the
hydrogen side of the machine and the oil drained from this part of
the machine passes to a suitable hydrogen detraining tank. 2 x
100% Blowers for venting out Hydrogen gas liberated from oil shall
be provided suitably mounted at places where such gas
accumulation is likely to occur. Also H2 diffusion loss through seal
oil shall be minimum to maintain H2 purity level inside generator at a
high level.
The hydrogen dilution blower shall have the following features:
HYDROGEN DILUTION BLOWER
Type - Centrifugal/Twin
lobes
Capacity m3/hr By bidder
Air intake filter type - Simplex / Duplex

type
Suction pressure Bar Atmospheric

pressure
Discharge pressure Bar By bidder
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Mounting type - Skid mounted
MATERIAL OF CONSTRUCTION
Impeller/Lobes - AISI Type SS 316
Shaft - AISI Type SS 410

(Duplex SS)
Casing - AISI Type SS 316/

AISI Type SS 304/
2% Nickel Cast Iron.
Base Plate - IS:2062 Gr.B with

epoxy coated.
Prime mover details - 400V, 50 Hz & 3φ
Silencer - Shall be provided (If

applicable)
Noise level dB(A) 85 @ 1.5 meter

distance
Pressure drop across the mmWc By Bidder

lobes
Performance test Shall be conducted

as per standard
1.14.1.11 Necessary hydraulic sealing arrangement shall be provided in H2
side oil discharge line to prevent circulation of gas due to any
possible difference of heads developed by fans mounted at the end
of the generator.
1.14.1.12 A water detector with sight glass and drain valves shall be mounted
adjacent to the gas manifolds at the end of a pipe connected to the
bottom of the generator casing.
1.14.1.13 The oil which is used for the hydrogen sealing shall be same as the
lubricating oil for the turbine & generator bearing & governing
system.
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1.14.2.1 To ensure efficient and reliable operation of the seal oil system
adequate instrumentation shall be provided. This will include the
following as a minimum: -
i) Dial type thermometers for inlet and outlet temperature of the

seal oil and cooling water to each cooler.
ii) Pressure gauges at inlet and outlet of pumps, at outlet of
coolers, at inlet and outlet of pressure regulators and filters,
seal oil inlet to hydrogen and airside seals, hydrogen-casing
pressure, across each strainer and H2 seal oil differential
pressure and at oil supply header.
iii) Seal oil tank level indicator and flow meters for flow through
seals.
iv) Required numbers of temperature, pressure and level gauges
for alarms and interlocks. Necessary sensors / transmitters for
remote indication and recording in DCS.
1.14.2.2 Local seal oil control panels shall be provided with indicators for
pump discharge pressure, seal oil pressure at the seals (for both
hydrogen and air side streams), thrust oil pressure, hydrogen / seal
oil differential pressure, seal oil flow, seal oil temperature at the
seals and status indications for seal oil pumps.
1.14.2.3 The remote instrumentation at Unit Control Room shall include seal
oil temperature recording and seal oil / H2 differential pressure
recording in DCS.
1.14.3 Annunciation
1.14.3.1 The following annunciations shall be provided on the local

electric panel and in DCS system.
Seal Oil Tank Level : High / Low / Very Low
Seal Oil Temperature : High
Pressure of Seal Oil : Low
Pressure of Thrust Oil : Low
Seal Oil H2 Differential : High / Low

Pressure
Oil Level in Damper Tank (if : Low

applicable)
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Oil Level in Damper Tank – : Very Low

Emergency (if applicable)
Oil Level in Hydraulic Seal : High
Oil Level in Hydraulic Seal : Low
Seal Oil Filter : Choked
Seal Oil Pump : Failure
Standby Seal Oil Pump : Running
DC Seal Oil Pump : Running
AC Seal Oil Motor Power : Failure

Supply
DC Seal Oil Motor Power : Failure

Supply
Power / Control Supply : Failure
Seal Oil Cooler Water : High / Low

Pressure
Seal Oil Cooler Water : High / Low

Temperature.
1.14.3.2 All annunciations shall be duplicated in the Unit Control Room. For
this purpose, separate alarm contacts shall be provided.
Independent signals, analog and digital shall be made available for
connection to DCS system.
1.15 Stator Water Cooling System
1.15.1.1 Generator stator winding shall be cooled by water. Water cooling

shall be with a closed loop cooling system. The system shall
generally include but not be limited to the following:
1.15.1.2 One (1) number primary water tank shall be provided and mounted
on the stator frame on anti-vibration pads and covered by the
generator cladding. The empty space in primary water tank may be
filled with Nitrogen to minimise water evaporation. The Bidder shall
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hydrogen that leaks into the stator water cooling system, to a safe
place outside the building through suitable safety valves.
1.15.1.3 The make-up water for primary water system shall be tapped off
from condensate extraction pump discharge header (before and
after the condensate polisher) and from DM water make-up line to
the condenser. The level in the tank shall be maintained by means
of suitable valves in the make up line.
1.15.1.4 Two (2) 100% capacity water to water heat exchangers shall be
provided. The water-to-water heat exchanger shall be designed to
accept secondary DM water (condensate quality). The system shall
be so designed that the pressure of primary DM water inside the
cooler is always greater than that of secondary DM water
(condensate quality). The exchanger shall be designed to have
10% excess tube surface area over and above the designed
surface area required for the rated load condition while maintaining
the design pressure drop on cooling water side.
1.15.1.5 Two (2) 100% capacity fine wire mesh filters with magnet bars of
unlimited life shall be provided for removal of all magnetic particles.
The permanent magnet bars shall be protected by sleeves of
stainless steel. It shall be possible to clean easily the ferromagnetic
particles adhering to the magnet bars during capital maintenance.
1.15.1.6 Two (2) 100% capacity AC motor driven cooling water circulating
pumps shall be provided. Standby pump shall cut in automatically
in case the working pump fails or the pressure of circulating water
drops below a certain preset value.
1.15.1.7 One (1) mixed bed demineraliser (MBD) of adequate capacity shall
be provided to maintain the required quality of water. The MBD
shall remain continuously in service in order to retain high purity of
stator cooling water with its associated electrical resistivity. The
Bidder shall indicate in the proposal the capacity of MBD necessary
to maintain the quality water at the desired level for time duration of
six months or more. The system shall be designed such that the
MBD could be taken out of service for refilling without untoward
effect on the system which could necessitate load
reduction/rejection.
1.15.1.8 Alkaliser unit shall be provided alongwith stator water required for
ensuring a corrosion free operation system.
1.15.2 Control System

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1.15.2.1 The following instruments shall be provided on the local panel :
1. Indicator for primary water flow in the stator winding.

2. Indicators for primary water conductivity at the inlet of
winding and after the demineraliser.
3. Indicator for stator winding differential pressure.
4. Indicators for primary water temperature at the inlet and
outlet of stator winding.
5. Indicator for primary water pressure at the inlet of stator
winding
1.15.3.1 The following minimum instrumentation shall be provided :
1. Set of conductivity meters in the main water circuit and

after the demineraliser.
2. Set of flow switches (at least two nos.) to monitor the low
distillate condition and flow transmitters/meters for
primary water to stator winding and main bushing, make
up water etc.
3. Sets of pressure gauges at the inlet and outlet of stator
water filters, differential pressure switches for the filters,
differential pressure gauge across stator winding and
pressure transmitters as required.
4. Set of resistance temperature detectors/indicators for
primary water before and after the generator winding,
bushing and cooler. Vapour filled temperature detectors
shall also be provided to give signals for high
temperatures.
5. Set of dial type thermometers for cooling water at the inlet
and outlet of the cooler.
6. Water gauge, transmitters, level switches for high and low
level alarms and other accessories for primary water
tank.
1.15.4 Annunciations
The following minimum annunciations along with duplicate contacts

for use in DCS shall be provided:
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1. Water level in the primary water tank - low.

2. Water level in the primary water tank - high
3. Temp. of primary cooling water at outlet of stator wdg. -
high.
4. Temp. of primary cooling water at inlet of stator wdg. -
high.
5. Flow of primary cooling water to the stator winding - low.
6. Conductivity of primary cooling water at the winding inlet -
high.
7. Flow of primary cooling water to the stator winding - very
low.
8. Conductivity of primary cooling water at the winding outlet
- high.
9. Pressure of primary cooling water at the inlet of winding -
low.
10. Differential pressure across the primary water strainer -
high.
11. Stator water cooling pumps - tripped on overload.
12. Reserve control supply for stator water cooling - failed.
13. Differential pressure across stator winding - high.
14. Leakage of hydrogen into primary water - high
15. Primary stator bar water temperature - high.
16. Any other critical parameter to be annunciated
A “summary annunciation” for the above shall be provided on the
unit control panel
1.15.5 On line stator water temperature monitoring system for individual

stator winding bars shall be complete with all software and
hardware required to detect any abnormalities in the temperature at
any given generator operating point and shall be sensitive to
generator loads, header water flows, pressure etc. and shall be
possible to exchange information with DCS through suitable
protocols.
1.15.6 On-line oxygen monitoring system shall be provided, if the

manufacturer recommends continuous monitoring of dissolved
oxygen content in the stator water, to prevent copper corrosion.
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1.15.7 Liquid leakage detector shall be provided at all the low level points
inside the generator casing including end shields along with
provisions of indication and alarm during leakage of liquid in
generator.
1.15.8 Stator coolant flow recorder shall be monitored in DCS.
1.16 Cubicle and Motor Starters
1.16.1 Cubicles shall be furnished as required for (a) Excitation System,

(b) Automatic Voltage Regulator (c) Hydrogen Cooling System (d)
Seal Oil System (e) Stator Water Cooling System, (f) DC Motor
Starters.
1.16.2 The panels shall be of the self-supporting, floor-mounted type. The

panels for DC Motor starters shall house stainless steel starting
resistors.
1.17 Measurement / Alarms in Control Room
1.17.1 Each alarm shall be individually available on the DCS HMI whereas
set of alarms can be grouped into a group alarm on the window of
Local Control Panel. All the required relays / contacts / devices
shall be provided to achieve the same.
1.17.2 All the measurements shown in the protection and metering one
line diagram TCE.5960A-EL-SK-2002 shall be made available in
DCS and also in Local Control Panel.
1.17.3 The continuous measurement of the rotor winding temperature

while the machine is running shall be provided in DCS.
1.17.4 The turbine generator control VDU in the central control room shall
have graphical display of various generator subsystems,
process/flow diagrams such as seal oil, hydrogen, lube oil,
generator stator and rotor parameters along with display of
generator capability curves and operating points, generator
temperatures and vibration parameters, etc. They shall also have
limiting values for alarm/trips, tag numbers, etc. clearly displayed on
DCS. In addition operator help features for control of these systems
and historical and reference data shall also be made available for
efficient operator guidance of these systems. All inputs including
logics for recommended control and instrumentation system
required to integrate with artificial intelligence based software’s
pertaining to generator and its auxiliary system shall be furnished.
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1.17.5 On line partial discharge measurement system.

Permanently connected Independent sensing unit for each
generator shall be provided. However evaluation unit for all
generators shall be common. Latest software shall be provided to
interpret the PD result. It shall also be suitably connected to DCS.
1.18 Gas Turbine Generator Unit Start-Up System
1.18.1 2 nos. Static start-up system for gas turbine unit complete in all
respects shall be offered. Additional thyristors in converter /
inverter units to take care of thyristor failure, redundancy for critical
items and self monitoring features.
1.18.2 The voltage to frequency ratio of the start-up system output shall be
maintained constant throughout the start-up and shall not lead to
overfluxing condition of generator transformer and neutral
grounding transformer. Over fluxing shall be limited to 110%.
1.18.3 The current transformers (CTs) in the busduct and voltage

transformers (VTs) shall not temporarily or permanently saturate
even after successive starts through the start-up system. Also, the
protections shall not mal-operate during gas turbine starting.
1.18.4 The Contractor shall note that all the protection shall be set for
normal operation of the plant and the settings will not be altered
during start-up. To this extent the Contractor shall provide suitable
protections on the start-up system output to protect the generator,
CTs, VTs, etc., and cut off the start-up system in the event of
operation of these protections.
1.18.5 In case any of the protections are to be blocked during start-up

operation due to likelihood of mal-operation, the Contractor shall
provide suitable blocking and de-blocking signals from the start-up
system. Both these signals shall be suitably supervised and
annunciated.
1.18.6 Minimum electrical system requirements in respect of control,

monitoring, measurement, annunciation, synchronising are
indicated in I&C System Section No. D2.4.
1.19 Tests
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1.19.1 Tests on Generator
1.19.1.1 The following Routine Tests shall be carried out at works on each
generator:
i) Measurement of insulation resistance of the following before

and after high voltage test:
a) Stator Winding Insulation
b) Rotor Winding Insulation
c) Embedded Resistance Temperature Detectors
d) Bearing Pedestal Insulation
ii) Polarisation Index for Stator Winding Insulation.
iii) Tan-delta measurement of Stator Winding Insulation.
iv) Measurement of the DC resistance of the following:
a) Stator Winding
b) Rotor Winding
c) Embedded Resistance Temperature Detectors
v) Determination of generator open circuit characteristics, short
circuit characteristics and calculation of short circuit ratio.
vi) Stator Phase Sequence checking.
vii) Measurement of Core Losses
viii) Measurement of Mechanical Losses
ix) Determination of generator efficiency by the separation of
losses at 100%, 80% and 60% load.
x) AC High Voltage Test on Stator and Rotor Winding
xi) Measurement of Rotor Winding Impedance at standstill and at
various speeds upto 3000rpm.
xii) Measurement of phase to neutral and phase to phase
capacitance of all the three phases of the stator and the rotor
and calculation of the equivalent generator capacitance as
viewed from the generator terminals; also the measurement
of the capacitance between the complete winding and the
body.
xiii) Measurement of bearing leakage current / shaft voltage.
xiv) Overspeed Test
xv) Mechanical Run and measurement of Vibrations
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xvi) Retardation test to establish GD2

xvii) Hydrogen leakage test
xviii) Partial discharge tests on stator windings.
1.19.1.2 The field tests to be conducted on each generator at the site shall
include but not be limited to those listed below. Any other test
considered necessary by the bidder shall also be carried out :
i) Measurement of insulation resistance of the stator and the

rotor windings to the frame and between phases, after drying
out the machine, and measurement of polarisation index.
ii) Measurement of the DC resistance of all windings and
embedded temperature detectors.
iii) Measurement of the insulation resistance of bearings
iv) Capacitance measurement and dissipation factor between the
winding and body.
v) Open circuit and short circuit tests.
vi) Measurement of temperature rise at the rated load.
vii) Performance capability of the machine.
viii) Line charging capacity
ix) Short Circuit tests on the generator end and the generator
transformer HV end to check the stability and operation of the
generator and the overall (i.e. generator, generator
transformer and unit auxiliary transformers) differential
protections and negative phase sequence protection. These
tests will be carried out jointly with the commissioning
engineers of other vendors whose equipment are under test.
x) Hydrogen leakage test
xi) Vibration test
xii) Overspeed test
xiii) Hydraulic tests on coolers
xiv) Bearing and shaft current test
1.19.1.3 One generator of each type and rating shall be assembled at works
and shall be tested to verify/ensure design and workmanship in
accordance with IEC-60034/VDE-0539/IEEE-43. The tests shall be
carried out keeping all conditions/parameters as close as possible
to site conditions with all the built in instrumentation (like RTD etc.)
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suitably wired and the readings recorded. During various tests

bearing, shaft overhang vibrations shall also be measured with and
without excitation. Recording of bearing and seal oil running
conditions and environmental conditions (like temperature etc.)
shall also be done. The tests to be carried out under the contract
shall include the following :
i) Instantaneous short circuit test shall be carried out to

determine transient and sub-transient reactance parameters
and to ensure stability of winding during sudden short circuit
condition.
ii) Determination of negative sequence and zero sequence
impedance.
iii) Determination of Telephone Influence Factor and Total
Harmonic Distortion of the voltage waveform.
iv) Short circuit heat run test at rated pressure and cooling
parameters with one cooler out of circuit at two third of rated
stator current.
v) Vibration measurement on all planes on stator overhang
winding at minimum six (6) locations on each end and at other
critical locations for the following conditions :
a) Open circuit operation.
b) Short circuit operation.
c) Sudden short circuit conditions.
d) Stand still condition- with hammer test.
The test results of above shall prove that the values are within the
normal operating limits for long satisfactory performance and that
there are no components or parts, which have natural frequency of
resonance near operating frequencies or 100Hz.
1.19.2 Tests on Exciter and AVR
1.19.2.1 The following Routine Tests shall be carried out at works on each
exciter and AVR:
a) Pilot Exciter (PMG)

i) Measurement of output voltage at rated speed
ii) Checking of phase sequence and measurement of
frequency
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iii) Measurement of load characteristics

iv) Measurement of insulation resistance and high voltage
test on stator winding
v) Measurement of DC resistance of stator winding
b) Main Exciter (Brushless Exciter)

i) Measurement of open circuit characteristics
ii) Load magnetisation characteristics
iii) Measurement of insulation resistance and high voltage
test on armature and field winding
iv) Measurement of DC resistance of armature and field
winding
c) Voltage Regulator
i) Response ratio test
ii) Insulation resistance and high voltage test
iii) Performance test at reduced supply voltage
iv) Auto –1 / Auto –2 channel follow up test
v) Auto – Manual channel follow up test
vi) Thyristor load test (light load test at rated voltage and full
current test)
vii) Functional tests
1.19.2.2 The field tests to be conducted on each AVR at the site shall
include but not be limited to those listed below. Any other test
considered necessary by the bidder shall also be carried out :
i) Accuracy test
ii) Sensitivity test
iii) Performance tests on all limiters
iv) Impulse input response test
v) Auto –1 / Auto –2 channel follow up test
vi) Auto – Manual channel follow up test
vii) Range of voltage adjustment for both auto and manual
channels
viii) Functional tests
1.19.2.3 The following type tests on Brushless excitation system of one

machine of each rating shall be conducted.
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a) Main Exciter : Temperature rise test at peak rating of

excitation system and ceiling duty condition shall also be
demonstrated.
b) PMG : Temperature rise test at peak rating of excitation
system shall be demonstrated.
c) Field Breaker : Type tests on exciter field breaker shall be
conducted as per IEEE/ANSI C 37-18.
d) Converter Assembly (of the exciter field) :
i) Temperature rise test at peak rating of excitation system
and ceiling duty condition shall also be demonstrated.
ii) Input and output surge withstand capability test.
iii) Soak test for electronic modules.
e) Voltage Regulator :
i) Soak test on electronic equipment
ii) Surge withstand capability test on electronic equipment
1.19.3 The following test to be conducted on startup system
a) SFC panels
i) Temperature rise test
ii) Surge withstand capability test
iii) Noise level test
b) SFC Transformer
The following type tests shall be conducted on one transformer
i) Tank Pressure test
ii) Tank vacuum Test
iii) Short circuit test on one transformer to be selected by

Owner.
iv) Noise level
v) Measurement of harmonics of no load current

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vi) PRD operation test
vii) Degree of protection test on marshalling box
viii) Zero sequence Impedance ( not applicable for Delta-

delta transformer)
ix) Temperature rise test
x) Lightning impulse test on one limb
xi) DGA test on oil before and after temperature rise test
1.19.4 All components of the excitation system shall be tested in

accordance with the relevant standards and type and routine test
certificates shall be furnished.
1.19.5 All Type and Routine test certificates shall be furnished to the
Owner for review and approval.
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TCE FORM NO. 329 R5
ANDHRA PRADESH POWER DEVELOPMENT SECTION: D3.1
COMPANY LTD.
DATA SHEET – A3.1 SHEET 39 OF 42
SPEC. NO.
TCE.5960A-H-500-001
SL. NO. DESCRIPTION UNITS VALUES / REQUIREMENTS
1.1 Generator and Excitation System
1.2 Rated Output Ref clause 1.1.1
1.3 Rated terminal voltage By Bidder
1.4 Rated frequency Hz 50
1.5 (a) Rated power factor 0.85 (lagging)

(b) Power factor variation 0.85 (lag) to 0.95(lead)
1.6 No. of phases 3
1.7 Continuous operation under As per IEC: 60034-1

unbalanced load
1.8 Stator winding connections Star
1.9 Speed rpm 3000
1.10 Type of cooling
(a) Stator Winding Water
(b) Rotor Winding and Stator Core Hydrogen
1.11 No. of line terminals to be

brought out Nos. Three (3)
1.12 No. of neutral terminals to be Six (6)-(In case of split

brought out phase winding and
having more than one conductor
per phase or else three (3) )
1.13 Rated short circuit ratio at MCR

not less than 0.5
1.14 Operation under unsymmetrical As per IEC-60034-1

fault
1.15 Class of insulation of generator Class F (temp. rise limited

stator and rotor windings to that of class B)
REV. NO. R0 PPD. BY RKD JOB NO. CLIENT : APPDCL

DATE MAR’ 10 CKD.BY HA 5960A PROJECT : 700MW CCCP AT
NEDUNOOR, KARIMNAGAR
DIST.
REV. BY DATE
TCE FORM NO. 330 R3
TATA CONSULTING ENGINEERS LTD
64
COMPANY LTD.
SPEC. NO.
TCE.5960A-H-500-001
1.16 Degree of protection for generator IP-54
enclosure
1.17 Excitation system response ratio Minimum 2.0
1.18 Excitation system response time sec. <0.5
1.19 Accuracy of Gen. Terminal voltage % <+0.5
1.20 Manual channel shall follow auto % <0.5

channel within
1.21 Telephone harmonic factor % shall not exceed 1.5
1.22 Field forcing capability during

bolted fault on generator terminals % Minimum 150
1.23 Type of voltage regulator Two auto and one manual

channel, Solid state,
continuously adjustable
1.24 Space heaters for generator Required (to be switched on

automatically when turbine is
shut down)
1.25 Maximum amplitude of vibrations As per VDE 2063 and shall meet
(peak to peak) requirements as per respective
gas turbine and steam turbine
sections.
(Bidder shall indicate).
1.26 Noise level from the surface of As per IEC 60034 shall meet the
equipment requirements as per respective
gas turbine and steam turbine
sections
(Bidder shall indicate)
1.27 Limiters, compensators,

monitoring devices for generator
excitation system
1.27.1 Minimum excitation limiter Required

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COMPANY LTD.
SPEC. NO.
TCE.5960A-H-500-001
1.27.2 Maximum excitation limiter Required
1.27.3 Maximum rotor current limiter Required
1.27.4 Under/over excitation limiter Required
1.27.5 Maximum stator current limiter Required
1.27.6 Cross current compensator Required
1.27.7 Overfluxing (V/Hz) limiter Required
1.27.8 Load angle limiter Required
1.27.9 Transformer drop compensation Required (adjustable between 0%

& 15%)
1.27.10 Power system stabiliser Required
1.27.11 Two stage Field suppression

facility Required
1.27.12 Two stage Field earth fault

monitor Required
1.27.13 Automatic power factor controller Required
1.27.14 Motorised manual control for

remote parallel operation Required
1.27.15 Manual control range of AVR 70% of no load to 110% full load of
voltage range
1.28 Number of RTDs/Thermo-couples Ref. clause 1.1.20

required for generator
1.29 Efficiency at 100% load at rated As per IS-4899

power factor
0
1.30 Maximum Inlet Temperature C 350 C
of Cooling Water available
for Hydrogen / Air coolers
1.31 Type of cooling water available DM water

DIST.
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COMPANY LTD.
SPEC. NO.
TCE.5960A-H-500-001
for Hydrogen coolers / Air coolers /
water coolers (ordinary water
/ sea water)
1.32 Codes and Standards
1.32.1 Specification for rotating electrical

machines - rating & performance IS-4722 and IEC-60034-1,3
1.32.2 Guide for testing synchronous IS-7132

machines
1.32.3 Method of determination of

efficiency of rotating electrical
machines IS-4889
1.32.4 Measurement and evaluation of

vibration of rotating electrical
machines IS-12075
1.32.5 Methods for determining IS-7306 and

synchronous machine quantities IEC-60034-4/4A
from tests
1.32.6 Degree of protection provided by
enclosures for rotating electrical
machines IS-4691 and IEC-60034-5
1.32.7 Methods for cooling rotating IS-6362 and IEC-60034-6

machinery
1.32.8 Terminal markings and direction

of rotation of rotating machines IEC-60034-8
1.32.9 Method of measurement of
airborne noise emitted by rotating
electrical machines IS-6098 and IEC-60034-9

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SHEET 1 OF 8
1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. SPEC NO
ELECTRICAL SYSTEMS - TCE.5960A-H-500-001
GENERATOR CIRCUIT BREAKER
2.0 GENERATOR CIRCUIT BREAKER
2.1 Generator circuit breaker shall be provided in single phase

enclosures, all fully assembled on a common frame with operating
mechanisms, supervisory and control equipment.
2.2 The voltage class of the Generator circuit breaker shall be same as
that of the generator.
2.3 The continuous current rating of the Generator circuit breaker shall
be arrived at considering the maximum output of the generator and
at specified minimum voltage.
2.4 The Generator Circuit Breaker (GCB) is installed indoor / outdoor

and connected to Generator busduct (Isolated Phase) on both
sides. Suitable provisions shall be made for connection with
Isolated Phase Busduct (IPB) through flexible connection.
2.5 The GCB movement during short circuit shall be restricted so as to

limit the stresses on GCB support insulators within their
capabilities.
2.6 Support structure shall be designed to withstand the dynamic as

well as static load of the GCB. Design calculations of support
structure shall be furnished for Owner's approval.
2.7 The Generator circuit breaker shall be integrated with series-

disconnector, current and voltage transformers, grounding
switches, surge arrestors and protective capacitors in three single
phase enclosures, as shown in attached Main one line diagram
TCE.5960A-EL-SK-2003.
2.8 The short time and momentary current rating of the Generator
circuit breaker shall be decided as follows:
(a) Short time current rating for 1 second:
(i) Higher of the short circuit current contribution from

generator or the short circuit current contribution from
400 kV system through generator transformer (400 kV
system fault level 50 kA)
Plus (+)
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(ii) Contribution of 6.6 kV auxiliary system through unit

auxiliary transformers.
(b) Momentary current rating:
2.55 times the short time current rating arrived as above.
2.9 The basic switchgear module shall include the following minimum
equipment but shall not be limited to the same.
a) Circuit breaker with disconnector for series isolation on

Generator Transformer side.
b) Grounding switches fitted both sides of unit and to all three
phases.
c) Generator side current transformers with upto two cores per
phase towards GT side.
d) Voltage transformers with two secondary windings; two per
phase on generator side, one per phase on transformer side.
e) Protective capacitors fitted to both sides of the unit and to all
three phases.
f) Surge arrestor with surge counter on generator transformer
side
g) 0.25μF surge capacitor on either side of circuit breaker as shown in
the Main SLD.
h) Supporting structures and suitable platform.
2.10 The system shall be extended by all of the following items:
a) A switched (motor operated) short circuiting connection

between the power circuit breaker and the series
disconnector for maintenance and protection checking.
b) A manually fitted grounding link for the above short circuiting
connection.
c) An isolator for the SFC connections
The accuracies of the CTs & PTs shall be as per the enclosed Main
one line diagram TCE.5960A-EL-SK-2003.
The CTs and VTs shall not temporarily or permanently saturate

even after successive starts through the start up system. Also, the
protections shall not mal-operate during gas turbine starting.
2.11 The GCB shall be of SF6, metal enclosed, indoor / outdoor and free
standing type. It shall be provided with three pole gang operation
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and anti-pumping feature. All the three poles shall operate

simultaneously. If all the poles do not close simultaneously the
breaker shall trip on pole discrepancy. The Generator circuit
breaker shall use SF6 gas both as its arc-extinguishing medium as
well as for internal insulation. It shall be designed with separate
contact systems for the current breaking and current carrying
functions. Semaphore position indicators shall be provided for local
indication of the position of the circuit breaker.
2.12 The GCB enclosure shall be non-magnetic aluminium alloy,

minimum flux, and isolated phase type with degree of protection
IP-65 and canopy shall be provided if installed outdoor.
2.13 Insulators shall be of high strength, fine glazed porcelain or epoxy

resin type.
2.14 SF6 gas monitor for each phase shall be provided. Necessary
interlocks are to be arranged to prevent breaker operation on fall of
SF6 gas density.
2.15 A series disconnector shall be fitted on the outgoing side of the

circuit breaker and within the same enclosure. The disconnector
shall be of a tubular telescopic unit with the moving contact tube
connected on the transformer side, the fixed contact being on the
circuit breaker side of the unit.
2.16 Grounding switches shall be provided on both sides of the

switchgear unit. The connections and the switches shall be rated
for full fault current. The ground connections shall be made via the
switchgear enclosure to the housings of the isolated phase
busbars and then to their grounding connection.
2.17 The short circuiting disconnector and its connections shall be

designed to expedite the testing and adjustment of the power plant
protection system. Closure of the disconnector shall establish a
three phase short circuit on to the generator connections but
without ground to save time, both during initial commissioning, as
well as, when routine testing the protective relaying.
2.18 The Main One Line diagram enclosed indicates the relays and
meters to be connected to the current transformers and voltage
transformers. The VA burden, knee point voltage, secondary
resistance and the exciting currents of CTs and VA burden of the
VTs shall suit the connected metering/protective equipment.
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2.19 Locking bars or effective mechanical arrangement shall be

provided to lock main and auxiliary contact in the open position to
prevent inadvertent closing either in main breaker or on
disconnecting switch.
2.20 Duplicate shunt opening release coils suitable for operation with
voltage upto 60% of rated voltage of coils along with status
monitoring shall be provided.
2.21 If the offered breaker is pneumatic operated then, on loss of

compressed air supply breaker shall get locked in its current state.
2.22 In case of pneumatic operating mechanism compressed air plant

shall be provided with 2x100% compressors. Driers shall also have
same capacity. Capacity of each high pressure receivers shall have
stored energy for 2 close-open operations. Capacity of local air
receivers shall meet one close-open operation.
2.23 In case of hydraulic mechanism, the stored energy shall be suitable

for two close open operations. The breaker shall have 2 x 100%
hydraulic pumps. The bidder shall clearly bring out the details in
respect to this offer.
2.24 The operating mechanisum shall be spring operated both for closing
and tripping operations. The stored energy in the spring shall be
sufficient to permit at least two close-open operations. The spring
charging motor shall be suitable for 220V DC and shall be fed from
respective Unit DCDB. The spring charging motor shall be capable
of charging the spring within 30 secs.
2.25 The minimum number of auxiliary potential free contacts required to

be wired up to the terminal strip for PURCHASER’s use after
BIDDER’s use in all Control and Protection circuits shall be :
12 NC + 12 NO for Circuit Breaker

8 NC + 8 NO for Disconnector
8 NC + * NO for each Earthing Switch
Contact wear monitoring shall also be offered along with the GCB.
2.26 Local control panel shall be provided near GCB to facilitate Local
ON/OFF Control, status indication, alarm and annunciation of the
breaker and all auxiliary equipments shall also be located in local
control panel. Local control panel shall include a Local/Remote
selector switch.
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2.27 The GCB shall be suitable for synchronizing duty and capable of
withstanding out of phase voltage across open contacts. The
breaker shall also be capable of switching on to a fault and out of
phase switching.
2.28 Main contacts shall have ample area and contact pressure for carrying the
rated current and the short time rated current of the breaker without
excessive temperature rise which may cause pitting or welding.
Contacts shall be easily replaceable and shall have a minimum of
movable parts and adjustments to accomplish these results. Main
contacts shall be the first to open and the last to close so that there
will be little contact burning and wear.
2.29 Arcing contacts, if provided, shall be the first to close and the last to
open and shall be easily accessible for inspection and replacement.
Tips of arcing and main contacts shall be silver faced or have
tungsten alloy tipping.
2.30 The operating mechanism and associated accessories shall be

enclosed in weather proof mechanism cabinet of hot dip galvanised
sheet construction, thickness of which shall not be less than 2 mm.
Hinged doors giving access to the mechanism at the front and sides
shall be provided. Suitable gaskets shall be provided to make the
mechanism housing water-proof and dust-proof. The housing latch
shall accommodate padlock requiring a 12 mm diameter hole.
Padlock and duplicate keys shall be included in the BIDDER's scope
of supply.
2.31 Working parts of the mechanism shall be of corrosion resisting

material. Bearings which require grease shall be equipped with
pressure type grease fittings. Bearing pin, bolts, nuts and other parts
shall be adequately pinned or locked to prevent loosening or
changing of adjustment with repeated operation of the breaker.
2.32 Provision shall be made for connecting travel recorder to perform

speed test of breakers at site.
2.33 Motor operated mechanism shall be provided for Disconnectors &

Earth switches with suitable Electrical & Mechanical interlocks.
Normal operating mechanism shall also be provided for emergency
purpose.
2.34 The operating mechanism offered for GCB shall be in service for a
minimum of 2 years in any of the power plant with trouble free
operation.
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2.35 SF6 density monitoring, alarm on low density and close & Trip
blocking on very low density shall be provided.
3.0 Tests
3.1 All acceptable & routine tests as per IEC-60056 and IEEE Std
C37.013a-2007 standards shall be conducted on all the
equipment/components of each of the generator circuit breaker.
a) Power frequency voltage withstand dry tests on the main circuit.
b) Voltage withstand tests on control and auxiliary circuits
c) Measurement of the resistance of the main circuit.
d) Mechanical operating tests.
e) Design and visual checks.
3.2 Following type tests shall be conducted on each type & rating of the
equipment.
a) Rated dielectric strength tests
(i) Rated low frequency withstand voltage dry test.
(ii) Rated full wave impulse withstand voltage test.
b) Short circuit rating and transient recovery voltage tests
(i) Test for rated symmetrical short circuit current

interrupting capability, duty cycle and rated transient
recovery voltage parameters.
(ii) Test for rated closing, latching and short time current
carrying capability.
(iii) Test for rated Generator source asymmetrical short circuit

interrupting capability.
d) Load current switching test
e) Out of phase switching current tests

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f) Rated excitation current switching tests.
g) Type tests and oscillographic test records for closing and

tripping timings for generator circuit breaker of the rating
offered.
3.3 Test reports for the following type tests shall be submitted for each
type & rating of equipment:
a) Rated continuous current carrying tests
b) Mechanical endurance life tests.
c) Noise level tests.
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ELECTRICAL SYSTEMS - SPEC NO
TCE.5960A-H-500-001
Technical Parameters
GCB shall comply with the technical particulars given below and the
Contractor shall furnish the details wherever indicated as ‘*’.
Sl. Description Unit Technical Particulars

No.
(a) Make *
(b) Applicable Standards IEEE(ANSI) std C37.013a-

2007 , IEC60056 (1987), IEC
60694 (1980) & IEC 60298
(1990), IEC-60529, IEC-
60129, BS-5169 & BS-5500
(c) Voltage rating kV Bidder to indicate
(d) Frequency Hz 50
(e) Rated current A Bidder to indicate
(f) Rated short circuit breaking Bidder to indicate
current kA
(g) Rated short time withstand Bidder to indicate
current for 1 sec. kA
(h) Rated short circuit making Bidder to indicate
kAp
current
(i) Degree of protection
• Control cubicles and IP 54
drives
• Enclosure IP 65
(j) Duty CO-30 min-CO
(k) Panel paint shade Opaline Green(external) ,
Semi Glossy white (internal)
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GENERATOR TRANSFORMERS TCE.5960A-H-500-001
3.0 GENERATOR TRANSFORMERs (GTs)
The generator transformer (GT) and its accessories shall conform to

the latest editions of national and international standards indicated
in Data sheet – A 3.3. Also, the GT and its accessories shall
comply with the requirements indicated in Data Sheet – A 3.3 and
specific requirements indicated below.
3.1 The MVA rating of the Generator Transformers (GTs) shall be

sufficient to evacuate power generated by the respective gas
turbine generators and steam turbine generators. The GT shall be
so sized as to be able to evacuate power from the GTG / STG to
which it is connected without exceeding the average winding
temperature of 870C and hot spot temperature of 980C over the
entire range of site ambient temperature as specified in Section - B
of this specification. The GT shall be with voltage ratio of generator
voltage / 420kV, two winding, 3 phase, 50 Hz, ONAN/ONAF/OFAF
cooled transformer, with On Load Tap Changer with +10% to –10%
in steps of 1.25% on the HV side.
3.2 Three (3) of 50% capacity separately mounted radiator banks shall
be provided. Each bank shall be provided with adequate number of
fans and pumps and one oil pump and one fan spare. Each radiator
bank shall be provided with uni-directional bypass valve to permit
oil to bypass the pump in the event of pump failure. It shall be
possible to completely isolate any one of the radiator banks for
maintenance, while the transformer is in service. Flexible
expansion joints, one each, on top and bottom pipe connections for
each radiator shall be provided. Each radiator bank shall have
atleast two (2) extra radiators to facilitate usage of the same in
case of leakage in the other radiators. If radiators are arranged in
groups, each group of radiator shall have upper and lower shut-off
valves with blanking at either ends. Control scheme shall be
suitable for both manual and automatic operation of each group of
fans and oil pumps.
3.3 Electrical Performance
3.3.1 The transformers shall operate without injurious heating at the

rated MVA at any voltage within ±10% of the rated voltage of that
particular tap.
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3.3.2 The transformer shall be designed to deliver rated MVA

continuously even at the lowest tap without exceeding specified
temperature rise.
3.3.3 The transformer shall be capable of remaining in operation without

injurious heating at full load atleast 10 minutes when complete
forced cooling equipment has failed.
3.3.4 The dynamic ability to withstand short circuit shall be demonstrated

by the Contractor by calculations.
3.3.5 Generator transformers shall be suitable for back charging.
3.3.6 It shall also be capable of being charged from HV side through

circuit breakers without pre-insertion resistors and kept charged
continuously with no load on the LV side without any adverse
impact on the transformer life.
3.3.7 Generator transformers shall be suitable for bi-directional power

flow.
3.3.8 Bidder shall furnish the guaranteed loss values of Transformer.
3.4 Constructional Features
3.4.1 Bell type design shall be adopted for transformer tank.
3.4.2 The magnetic circuit shall be constructed from high grade cold
rolled non-ageing grain oriented silicon steel laminations. The flux
density shall not exceed 1.7 Wb/m2 at rated voltage and Current
density shall not exceed 3 A/mm2.
3.4.3 For generator transformers the insulation of core to bolt and core to
clamp plates shall be able to withstand a voltage of 10 kV rms for 1
minute.
3.4.4 The windings shall be made of electrolyte grade copper.
3.4.5 Tank shall be made of good commercial grade low carbon steel
and shall be of welded construction.
3.4.6 The tank of the transformer along with radiators, conservators,

bushings and other fittings shall withstand full vacuum of 760 mm
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of Hg while filling the oil under vacuum and also an excess internal
pressure of 0.35 kg/cm2.
3.4.7 Tank shields shall be such that no magnetic fields shall exist
outside the tank. They shall be of magnetically permeable
material. If required, impermeable shields shall be provided at the
coil ends. Tank shield shall not resonate when excited at the
natural frequency of the equipment. Contractor shall conform use
of tank shields in the additional information scheme.
3.4.8 Bushing shall be of porcelain. No arcing horn to be provided. For

52 kV and above, bushing shall be oil filled porcelain condensor &
non-oil communicating type with following fittings:
i) Oil level gauge
ii) Oil filling plug and drain valve if not hermetically sealed
iii) Tap for capacitance and Tan delta test
3.4.9 Bushing below 52 kV shall be soild porcelain/condensor/oil

communicating type.
3.4.10 Bushing CT’s shall be of adequate rating for protection as required,

WTI etc., These CT’s shall be mounted in the turret of bushing.
3.4.11 Busduct termination shall be suitable for high air temperature inside
the bus duct and shall be provided with draining arrangement as
lowest point for leaked oil / water.
3.4.12 Fire protection system shall be provided for the GTs as per the
requirement specified under relevant fire and safety
codes/standards, TAC guidelines and as specified under section
D1.11 of this specification
3.4.13 Fittings and Accessories
Transformers shall be provided with all accessories like, but not

limited to inspection manholes / handholes, lifting lugs, jacking
pads, bi-directional flanged wheels, haulage lugs, skids, earth
pads, neutral earthing downcomers (2 nos.) supported on pin
insulators, terminal marking, rating and diagram plates, marshalling
boxes, conservators (breatherless) (flexible oil resistant air bag),
valves for various purposes including draining, filtering, filling,
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double float buchholz relay, oil and winding temperature indicators

with high and very high contacts, magnetic (150 mm dia) and
prismatic oil level gauges, anti-earthquake clamping arrangement,
tank mounted radiators with accessories, and pressure relief valve
(Min. 02Nos. & the adequacy of the number of PRDs and their
location shall be established for any location of the fault inside the
tank). 4-20mA signal for remote WTI & OTI. It shall be a repeater
of local WTI & OTI.
3.4.14 On-line Gas Extractor Analyser shall be provided for each

Generator transformer. It shall be hooked up to the plant DCS.
3.4.15 A device for measuring the hot spot temperature of the winding shall be
provided.
3.4.16 For Top oil temperature measurement & Winding temperature

measurement RTDs / transducers shall be provided for remote indication
in SCADA.
3.4.17 A flexible oil resistant air bag shall be provided in the conservator to
prevent the air from coming into contact with the oil.
3.4.18 Suitable shock recorders to record maximum shock forces during

shipment/ transport shall be provided.
3.4.19 A set of hydraulic jacks suitable for the transformers under supply.
3.4.20 Transformer oil shall be supplied in non-returnable oil drums ( with

10% extra oil). 3 Nos., 20 KLitres capacity Transformer oil tank and
1 No. 6 KLitres Transformer oil filter machine of reputed make
approved by Owner shall be supplied.
3.4.21 Impact recorder shall be provided to monitor the impact during

transport on returnable basis.
3.4.22 Transformer shall be transported with tank filled with pure inert gas
at pressure of 2 – 2.5PSI. The temperature and pressure at the
time of gas filling shall be marked. Necessary accessories
including filled replenishment N2 shall be maintained at site also till
the transformer is filled with oil.
3.5 Two auxiliary power supplies, 400 V, 3 phase, 3 wire shall be

drawn from two separate boards for the cooler control cabinet and
OLTC cubicle. Cooler control equipments shall be divided in to
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two halves, each having one power supply incomer with bus
section between two halves. In case of one power supply failure,
loads shall be automatically transferred to other. Indications are to
be provided at cooler control cabinet and at OLTC cubicle along
with remote annunciation in DCS for failure of normal source and
for transfer to standby source, and also for failure to transfer.
3.6 Each cooling fan and pump motor shall be provided with isolating
switch, starter, thermal overload, single phase preventer and short
circuit protection. Separate on/off switch for each incoming power
supply with MCCB shall be provided. All cooling equipment trouble
shall be indicated in local control panel with repeat alarm in main
control room, with remote annunciation in DCS. Status of each
cooler fan/pump shall be available in DCS.
3.7 On Load Tap Changer (OLTC)
3.7.1 The OLTC gear shall be designed to complete successfully tap

changes at 150% of rated current. Devices shall be incorporated
to prevent tap change when the through current is in excess of the
safe current that the tap changer can handle. The OLTC gear shall
withstand through fault current without injury.
3.7.2 The tap range shall be decided based on the voltage profile of the
grid and following shall be complied with / provided. It shall permit
operation of generator at full load and at rated terminal voltage &
p.f. over the entire range of variation of grid voltage:
(a) Complete its operation once commenced, independent of

power supply, relays etc.
(b) Block reverse tap change command during the forward tap
change in progress.
(c) Be such that the oil in the compartment containing making

and breaking contacts does not mix with oil in other
compartment of OLTC or transformer tank.
(d) Be equipped with separate conservator for OLTC oil

temperature and oil surge relay with contacts.
(e) Cut off of power supply when manual handle is inserted.
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(f) Remote and local electrical operation & tap position

indication.
(g) Be equipped with automatic and manual operation facility

including hardware, relays as required.
(h) Be equipped with Digital type tap position indicator with in-
built transducer for repeating the tap position in DCS.
(i) Be provided with necessary initiating contacts for

annunciation of any abnormal condition in DCS and grouped
alarm in control desk.
(j) A sheet steel, dust and vermin proof marshalling box shall
be provided for each transformer and shall be provided with
thermostatically controlled space heaters. The degree of
protection shall be IP 55. All wiring for remote connection for
OLTC control / indication / annunciation from OLTC cabinet
shall be terminated in Marshalling box by providing separate
terminal block.
3.8 Tests
3.8.1 Following type tests and special tests as per IS 2026 (revision as
applicable on date of submitting of offer) shall be conducted on
one transformer :
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(a) Temperature rise test, Dissolved gas analysis of the oil, before
and after the temperature rise test.
(b) Vacuum withstand and deflection measurement on tank and
radiators.
(c) Pressure test on tank with deflection measurement.
(d) Determination of cooler losses.
(e) Partial discharge test.
(f) Radio influence voltage.
(g) Short circuit impedance of each limb with single phase
voltage from each HV & LV sides.
(h) Oil leakage test – 12 hours (this test to be conducted after
heat run test).
(i) Auxiliary power measurement.
3.8.2 All routine tests as per IS : 2026 shall be conducted on each of the
transformer. The following additional routine tests on each of the
transformer shall be conducted.
(a) Impedance voltage shall be measured at principal and at all the

taps
(b) No load loss and exciting current shall be measured at rated

frequency at 90%, 100% and 110% rated voltage
(c) Calibration of temperature indicators and relays
(d) Impulse test on GTs shall include chopped wave test
(e) Sweep Frequency Response Test at factory and at site
(f) Magnetic balance test.
(g) Measurement of tan delta and capacitance of each winding

and bushing.
(h) Pressure test on PRD.
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(i) Measurement of zero sequence impedance.
(j) Core isolation test
(k) Noise level measurement
(l) ACSD & ALD as per standards
3.9 Minimum electrical system requirements in respect of control,

indicated in I&C system Section No. D2.4.
3.10 The following calculation shall be furnished for Owner’s approval:
a) OLTC recovery voltage calculations in case of buck and

boost type of OLTC (wherever applicable)
b) Transfer surge calculations
c) Short circuit withstand calculations
3.11 Evaluation of Bids
3.11.1 Bids will be evaluated based on the formula furnished in Data Sheet-
A3.3
3.11.2 For the purpose of evaluation of Bids, the quoted load losses and
iron losses shall be included to take into consideration tolerance as
permitted by applicable standards.
3.12 Liquidated Damages for Non-Performance
Should the losses as measured on the transformer after

manufacture be found to be in excess of the guaranteed losses
including tolerance, if any, the VENDOR shall pay to the
PURCHASER, liquidated damages based on the charges indicated
in Data Sheet A3.3
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TCE FORM NO. 329 R5
ANDHRA PRADESH POWER DEVELOPMENT COMPANY SECTION: D3.3
LTD.
GENERATOR TRANSFORMER SPEC NO:
TCE.5960A-H-500-001
1.0 Generator Transformers
1.1 Type Outdoor, Two winding, 3 phase
1.1.1 MVA Rating MVA 315MVA for GTG (tentative),

340MVA for STG (tentative)
1.2 Cooling method
1.2.1 ONAN 60%
1.2.2 ONAF 80%
1.2.3 OFAF 100%
1.3 Overfluxing capability 110% for continuous

125% for 1 minute
140% for 5 seconds
1.4 Winding connections
- HV Star
- LV Delta
- Vector Ynd1
1.5 Impulse (1.2 / 50 microsecond) / power

frequency withstand voltage windings
- HV 1425 kVp / 630 kV (rms)
- LV * / *
0
1.6 Maximum temperature rise of oil at 110% of C 50
full load for 24 hrs.
0
1.7 Maximum temperature rise of winding at C 55
110% of full load for 24 hrs.
1.8 Tapping particulars
1.8.1 Type OLTC
1.8.2 Tap range + 10% to – 10%
1.8.3 Tapping step 1.25%
1.8.4 Category of voltage variation CFVV

DATE JUNE’ 10 CKD.BY HA 5960A PROJECT : 700MW CCPP AT NEDUNOOR,
KARIMNAGAR DIST.
REV. BY DATE
TCE FORM NO. 330 R3

84
LTD.
TCE.5960A-H-500-001
1.8.5 Tapping power Full
1.9 Bushing particulars

1.9.1 Voltage class HV / LV / HV (n) 420 kV / --- / 36 kV
1.9.2 Standard applicable IS : 2099
1.9.3 Creepage distance 25 mm / kV
1.9.4 Clearance in air
(a) Phase-phase-HV/LV/HV(n) 4200 mm / -- /
(b) Phase-earth-HV/LV/HV(n) 3400 mm / --- / - mm
1.10 Paint shade Opaline Green
1.11 Noise level Not to exceed values specified in NEMA TR-

1
1.12 Loss evaluation formula
1.12.1 Formula for evaluation of Bids Evaluated price + (A x guaranteed no-load
loss in KW) + (B x guaranteed load loss in
KW) + (C x guaranteed cooler loss in kW)
A = Rs. 3,80,000 / kW
B = Rs. 2,60,000 / kW
C = Rs. 2,32000 / kW
1.12.2 Rates of liquidated damages for exceeding the
guaranteed losses
No load loss Rs/kW A = 3,80,000
Load loss Rs/kW B = 2,60,000
Load loss Rs/kW C = 2,32000
1.13 Applicable codes and standards
1.13.1 Power transformer IS : 2026/IS:6600/IEC:60076
1.13.2 Fittings and accessories IS : 3639
1.13.3 Loading of oil immersed transformers IS : 6600
1.13.4 Oil IS : 335 / IEC:60296
1.13.5 Bushings IS : 2099 / IEC:60185
1.13.6 Degree of protections IS : 2147

KARIMNAGAR DIST.
REV. BY DATE
TCE FORM NO. 330 R3

85
LTD.
TCE.5960A-H-500-001
1.13.7 Tests IS : 2026
1.13.8 Tolerance on guaranteed particulars IS : 2026
1.13.9 Buchholz relay IS : 3637
1.13.10 Electrical insulation classified by thermal IS : 1271

stability

KARIMNAGAR DIST.
REV. BY DATE
TCE FORM NO. 330 R3

86
ANDHRA PRADESH POWER DEVELPOPMENT COMPANY LTD. SECTION: D3.4
SHEET 1 OF 3
1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. SPEC.NO.

ELECTRICAL SYSTEMS - TCE-5960A-H-500-001
UNIT AUXILIARY TRANSFORMERS
4.0 UNIT AUXILIARY TRANSFORMER (UAT)
The Unit Auxiliary Transformer (UAT) and its accessories shall conform to
the latest editions of national and international standards indicated in
Data sheet - A 3.4. Also, the UAT and its accessories shall comply with
the requirements indicated in Data Sheet–A3.4 and specific requirements
indicated below:
4.1 UAT shall be a * MVA, */6.9kV, three phase, two winding, 50 Hz,
ONAN/ONAF cooled transformer with *% impedance with OLTC ±10% in
steps of 1.25% on HV side (*By Bidder). 6.6kV system shall be suitable
for medium resistance earthing with earth fault current limited to 300A.
4.2 Impedance
The impedance of the transformers at taps corresponding to nominal

transformation ratio (primary taps) shall be selected keeping in view the
short circuit level of the 6.6 kV and 400 V switchgear & the voltage dip at
motor terminals not exceeding the limits specified in Section D 3.20
4.3 MVA rating
4.3.1 UAT
Each UAT shall be able to supply (100%) auxiliary running load of 700
MW power plant. It shall be able to start the largest motor at 80% base
load. The Contractor shall provide the design calculations for arriving at
the capacity of UAT during detail engineering stage. Additional margin of
10% shall be kept over & above all the loads due to variation in the loads
i.e. 110% of the complete station load.
4.4 Specific Requirements
4.4.1 The unit auxiliary transformers shall comply with the specific
requirements indicated in Section D-3.3 except for the following
variations.
4.4.1.1 The tank cover for the UAT can be of conventional type.
4.4.1.2 The UAT shall be provided with 2 x 50% detachable built on radiator
banks and if it is not possible to have built on radiator banks, the same
can be separately mounted. Each radiator bank shall have at-least two
extra radiators for use in case of leakage in any other radiator.
4.4.1.3 All tests specified in Section D-3.3 shall be conducted on UAT.

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DATA SHEET – A 3.4 SHEET 2 OF 3
UNIT AUXILIARY TRANSFORMER .
SPEC NO.
TCE-5960A-H-500-001
UAT
1.0 Type Outdoor, two winding
2.0 No load voltage - HV kV *
- LV kV 6.9
2.1 Rating on ONAF MVA 28 ( tentative)
3.0 Cooling method
(a) ONAN % 80%
(b) ONAF % 100%
4.0 Overfluxing capability 110% continuous, 125% for 1 minute, 140%

for 5 seconds
- HV Delta
- LV Star
- Vector group Dynll
6.0 Impulse (1.2 / 50 microsecond) / power

- HV */*
- LV 60 kVP / 20 kV (rms)
- HV (n) ---
0
7.0 Maximum temperature rise of oil C 50
0
8.0 Maximum temperature rise of winding C 55
(a) Tap ON LOAD CIRCUIT TAP CHANGER
(b) Tapping range % ±10%
(c) Tapping step % 1.25
(d) Category of voltage variation -
(e) Tapping power -
(a) Voltage class HV / LV / HV (n) / * / 7.2 kV / -

tertiary
DATE JUNE’ 10 CKD.BY HA 5960A PROJECT : 700MW CCCP AT
NEDUNOOR, KARIMNAGAR DIST.
REV. BY DATE
TCE FORM NO. 330 R3
88
COMPANY LTD.
UNIT AUXILIARY TRANSFORMER .
SPEC NO.
TCE-5960A-H-500-001
(b) Standard applicable IS-2099
(c) Creepage distance 31 mm / kV based on line to line highest

system voltage
(d) Clearance in air
(i) Phase-Phase-HV / LV * / 127
(ii) Phase-Earth-HV/LV/HV(n) * / 127/-
11.0 Paint shade Opaline Green
12.0 Noise level Not to exceed values specified in NEMA TR-1
13.0 Loss evaluation formula
13.1 Formula for evaluation of Bids Evaluated price + (A x guaranteed no-load loss
in KW) + (B x guaranteed load loss in KW) +
(C x guaranteed cooler loss in kW)
A = Rs. 3,80,000 / kW
B = Rs. 2,60,000 / kW
C = Rs. 2,32000 / kW
13.2 Rates of liquidated damages for exceeding the

guaranteed losses
No load loss Rs/kW A = 3,80,000
Load loss Rs/kW B = 2,60,000
Load loss Rs/kW C = 2,32000
Note: - (*) By Bidder

REV. BY DATE
TCE FORM NO. 330 R3
89
SHEET 1 OF 15
ELECTRICAL SYSTEMS - BUS DUCTS SPEC. NO.
TCE.5960A-H-500-001
A) ISOLATED PHASE BUS DUCTS (IPBD)
The Isolated phase bus duct (IPBD) and its accessories shall conform to
the latest editions of national and international standards indicated in
Data sheet – A 3.5 IPBD. Also, the IPBD and its accessories shall
comply with the requirements indicated in Data Sheet–A 3.5 and specific
requirements indicated below:
5.1 Isolated phase bus duct forming the main current carrying leads shall be
used in following circuits:
5.1.1 Generator phase side terminals to respective GCB, GCB to Generator

transformer LV terminals for GTG and generator phase side terminals to
generator transformer LV terminals in the case of STG.
5.1.2 Tap-off bus duct for Unit Auxiliary Transformers in the case of GTG.
5.1.3 Tap-off bus ducts for VT and SP cubicle, static excitation transformer (if
applicable)
5.1.4 Bus duct to generator neutral side terminals to neutral grounding

equipment panel, which shall house a neutral earthing transformer and
neutral earthing resistor.
5.1.5 The CTs etc., to be located in the Isolated phase bus duct shall be as per
the enclosed Main one line diagram – Drg. No. TCE.5960A-EL-SK-2003.
Current transformers as required shall be located in the above bus duct.
5.1.6 If the generator transformer is three numbers single phase units, then the
delta formation of the LV Windings shall be carried out with Isolated Bus
Duct.
5.1.7 The voltage class of the bus duct shall be as follows:
Generator voltage Bus duct voltage class
(a) Upto 12 kV 12 kV
(b) More than 12 kV upto 21 kV 24 kV
5.2 Sizing and Design
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5.2.1 Sizing of the bus duct shall be arrived based on the continuous and short
time rating of the respective circuit.
5.2.2 The continuous current rating of the main (generator) bus duct shall be
arrived at considering the maximum output of the generator and at
specified minimum voltage.
5.2.3 Short time current rating of the main busduct shall be for 1 second and
shall be decided as follows:.
(a) Higher of the short circuit current contribution from generator OR

the short circuit current contribution from 400 kV system through
generator transformer (400 kV system fault level 50 kA)
Plus (+)
Contribution of 6.6kV auxiliary power supply system through

UAT.
(b) Momentary current rating shall be 2.55 times the short time
current rating arrived as above.
5.2.4 The short time and momentary current rating of all tap-off bus ducts (to
VT and SP cubicle) shall be as follows:
(a) Short time current rating for 1 second:
(i) Short circuit current contribution from generator
Plus (+)
(ii) Short circuit current contribution from 400 kV system
NOTE: Negative tolerance allowed in the standards shall be considered

for generator and generator transformer impedance for calculation of
short time ratings in clauses 5.2.3 and 5.2.4 above.
5.2.5 The bus duct shall be designed to withstand the internal or external
forces resulting from the following:
(a) Normal operating conditions
(b) Momentary short circuit currents
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(c) Rigorous / adverse weather conditions as detailed in project

information section B
(d) Seismic forces as detailed in project information section B.
5.2.7 The degree of protection shall meet the requirements of water and air
tightness test specified in IS-8084 and the degree of protection shall be
IP-55 or better. The outside of the busduct shall be painted with 631 of
IS-5.
5.3.1 The bus enclosure shall be of continuous bonded type. The material of
bus conductor & enclosure for main run shall be Al alloy grade 19501
(H2) of IS-5082. The material of bus conductor for tap-off shall be Al
alloy grade 63401 WP (range 2) & for enclosure material shall be Al alloy
grade 19501 (H2).
5.3.2 Inspection covers for periodic inspection of the insulators shall be

provided. There shall be no joints or fixing bolts on top of the enclosure
through which water can seep.
5.3.3 The outdoor portion of the bus duct shall take into account heating effect
due to solar radiation and shall be provided with a continuous rain hood
of non-magnetic material suitably supported from the bus duct support
structure.
5.3.4 The bus conductor shall be given a coat of matt black paint to facilitate
heat dissipation. However, the sizing of the bus conductor shall consider
the conductor as bare.
5.3.5 The process of silver plating shall be approved by the owner.
5.3.6 Each phase shall be enclosed in weatherproof, dust tight, non-magnetic

metal enclosure. The enclosure shall be designed for welded
connections. The enclosure shall be of minimum flux type to permit not
more than five (5) percent of total, magnetic flux outside enclosure.
5.3.7 The enclosure shall be insulated at the connections to various

equipment so that the longitudinal current will not flow through or be
transmitted to any connecting equipment. The insulation shall be non-
deteriorating and shall be clearly indicated on the Contractor’s drawings.
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5.3.8 The Contractor should ensure that no load is transferred on electrical

equipments transformers, generator terminals etc. by the busducts.
5.3.9 The bus conductor shall be designed for welded connections except at
equipment terminations, bolted disconnect links, and bolted flexible.
Detailed welding procedure adopted by the manufacturer should be
furnished along with the offer and approved by the Owner.
5.3.10 Flexible connections shall be provided between bus sections to allow for
expansion and contraction of the conductor. Flexible connections shall
also be provided at all equipment terminations.
5.3.11 The bus support insulators shall be mounted on resilient pads.
5.3.12 The bus support insulator shall be interchangeable, high strength & fine
glazed porcelain manufactured by wet process or high strength epoxy
resin cast. The voltage rating shall depend upon generation voltage.
5.3.13 The spacing of the bus support insulators shall be considered by giving
due factor of safety to withstand the forces due to the momentary short
circuit assigned for the bus duct.
5.3.14 Wall frame assembly and seal-off bushings shall be provided where the
bus duct passes from indoor to outdoor area to prevent condensation
due to air temperature variation between indoor and outdoor portion.
Wall frame assembly shall be fabricated out of aluminium angles and
sheets. It shall be ensured that no load of the bus duct is imparted on
the walls.
5.3.15 The bus duct supports shall be fabricated from standard steel sections.
The support structures shall be hot dip galvanised.
5.3.16 Thermostatically controlled space heaters shall be provided along the

length of the bus duct.
5.3.17 Duplex RTD shall be provided for measurement of ambient air inside the
bus duct. The same shall be hooked upto the DCS.
5.3.18 The equipment terminal connections shall be readily accessible and

shall provide sufficient air gap for safe isolation of requirement during
electrical testing.
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5.3.19 If the material of bus conductor and that of the equipment terminal is
different, then suitable bi-metallic connectors shall be provided by the
Contractor.
5.3.20 The electrically continuous bus enclosure shall be used as the grounding
bus. All parts of the bus enclosure, supporting structure and equipment
frames shall be grounded to earthing mat.
5.3.21 Neoprene Rubber bellows shall be provided at the termination point of

the bus duct at various equipment. Rubber bellows shall also be
provided in the run of the bus duct after gas turbine generator foundation
block to avoid transfer of vibrations of GTG pedestal. In case of rubber
bellows at intermediate locations flexible braids copper connection, shall
be provided across the bellows to establish continuity of bus duct from
end to end.
5.3.22 Provision shall be made in bus duct at an approved location for

installation of shorting bar having rated current carrying capacity same
as that of main bus duct for carrying out generator stator dryout. A set
of shorting bar along with requisite hardware shall be supplied for this
purpose. A set of shorting bars along with requisite hardware shall be
supplied for this purpose. Disconnecting links with rating same as that of
the main bus conductor shall be provided in the run of the bus duct as
required to facilitate disconnection of the bus conductor during testing.
5.3.23 The IPBD shall be of natural air cooled type.
5.3.24 Silica gel filters shall be provided both in indoor and outdoor portions of
the bus duct for absorption of moisture.
5.3.25 Seal off bushings
(a) Seal-off bushings shall be provided at the entry of tap-off bus

duct to the VT and SP cubicle, static start-up, unit auxiliary
transformers, neutral grounding cubicle, etc.
(b) One set of seal-off bushings shall be provided in the bus duct
after the generator bushings to prevent hydrogen leakage into
the bus duct. Arrangement shall be provided to vent the trapped
hydrogen in the portion between generator bushings and these
seal off bushings (applicable for hydrogen cooled generators).
5.3.26 Two numbers earthing terminals with bi-metallic connectors shall be

brought out at termination points of the bus duct, main and cross
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supporting structures, terminal boxes, adapter boxes, unit auxiliary

transformer, VT and SP cubicle, etc., and for further connection to
earthing grid.
5.3.27 All steel supporting structures and hardware shall be hot dip galvanised
after fabrication.
5.4 Pressurisation System
5.4.1 Not used.
5.5 Current Transformer
5.5.1 The current transformers shall be epoxy cast-resin, single core ring type,
mounted within the bus duct enclosure and suitable for operation at an
ambient temperature existing within the bus duct enclosure which may
be in range of 900C to 1000C. Mounting arrangement of CT shall be so
designed so as to avoid equalizing connections between live conductor
and CT inner surface.
5.5.2 CT secondary leads shall be brought out through non-magnetic metallic

conduits to a marshalling box (MB) with degree of protection IP-55
(IS:13947 Pt.1). The MB shall be provided with removable aluminium
gland plate. The facility for shorting and grounding shall be provided at
the terminal blocks.
5.5.3 All CTs shall be tested for partial discharge. The partial discharge at 10
percent over voltage of the highest system voltage shall not exceed 50
pico coulombs. Arrangement shall be made to maintain potential of
inner surface of busduct CTs at the same value as the conductor to
prevent partial discharge.
5.5.4 Protection CTs shall be rated for 5A secondary current and shall be of
Class PS & Class 5P20. Metering CTs shall be rated for 5A secondary
current and shall be of 0.2S accuracy class with instrument security
factor less than 5.
5.6 Voltage Transformer and Surge protection Cubicles
5.6.1 The V.T and S.P cubicles for each phases shall be metal clad, dust and
vermin proof, free standing, dead front assemblies housing VTs, surge
capacitor, lightning arrester, V.T. L.V. side fuses etc.
5.6.2 Lightning arrester shall be Gapless type station class, hermetically

sealed, connected between line and ground, specifically suitable for
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generator protection as per technical parameters given elsewhere in the

specifications.
5.6.3 A discharge counter along with the ampere meter shall be provided for
each lightning arrester. The discharge counter register & leakage
current measurement meter with suitable environmental protection
covering, shall be visible without having to open the compartment door.
5.6.4 Mineral oil filled/Askarel (PCBS) filled surge capacitor shall not be
acceptable.
5.6.5 The voltage transformer shall be epoxy cast-resin type, suitable for
nominal voltage operation, connected from line to ground, and as per
Technical Parameters given in the specifications.
5.6.6 The secondary side of voltage transformer shall be provided with MCB.
Suitable guide slots and stops shall be provided to ensure easy
withdrawal and positioning. The fixed and draw out contacts of voltage
transformer primary shall be tinned or silver plated.
5.6.7 In the disconnected position, the voltage transformer primary and

secondary circuits shall be automatically disconnected. The draw out
frame shall be grounded at all times. A reliable automatically operated
shutter mechanism shall be provided for isolating and shrouding the bus
bar live parts when the VT is in drawn out position.
5.6.8 From phase cabinets the VT secondary leads shall be brought to

marshalling box having sufficient number of terminals with 20% spare, to
accommodate all VT leads. Facility of making star points and undrilled
gland plate for cable connections shall be provided in the marshalling
box.
5.6.9 VT and CT secondary neutral or common lead shall be earthed at one

place only at the terminal blocks, provided in the instrument transformer
marshalling boxes. The facility for connecting with earthing grid, shall be
provided by the Contractor through suitable connectors in the
marshalling box, with isolating links for testing of instrument
transformers.
5.7 Cubicle Construction (V.T. & S.P., N.G. Cubicle etc.)
5.7.1 All cubicle shall be fabricated from cold rolled sheet steel for minimum
2mm thick suitably reinforced to ensure structural rigidly. The degree of
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protection for all indoor cubicle shall be IP:52 except for neutral
grounding resistor enclosure which shall be minimum IP:23.
5.7.2 Space heater, Illumination and Grounding.
5.7.3 Each cubicle shall be equipped with space heater with thermostat,
internal illumination lamp, 230 V AC, 5A receptacle. Ground bus
suitable for receiving two (2) numbers of 50x6mm galvanised steel flats
shall be provided on each cubicle.
5.8 Wiring
5.8.1 All wiring shall be done with insulated stranded copper conductor of not
less than 2.5 mm² cross-section with suitable lugs on both sides.
5.8.2 The wiring inside the bus duct enclosure (i.e. for CT etc.) shall be
suitable for operating in the ambient temperature existing inside the bus
duct.
5.8.3 Not more than two wires shall be connected to a terminal. Spare
terminals equal in number to 20% of active terminals shall be furnished
and these shall be uniformly distributed through out the cubicle CT
terminal blocks shall be of stud type and suitable for round type lugs with
a facility for isolation, shorting and grounding. It shall be Elmex type
CATD or equivalent.
5.9 Name plate
5.9.1 Name plates shall be furnished for each equipment, disconnect link,
voltage transformer compartment, lightning arrester compartment and
fuse block, current transformer TB, etc.
5.9.2 Material for nameplate shall be embossed on SS plate & letters filled
with indelible black ink.
5.10 Hot Air Blowing Equipment
5.10.1 Suitable facility shall be provided to blow hot air into the bus duct to
evacuate moisture inside the bus duct during initial start-up and also
after subsequent shutdowns for maintenance on the bus ducts.
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5.10.2 The hot air blowing system shall be open loop type, capable of blowing
hot air simultaneously in the indoor and outdoor portions of the bus duct.
The system shall be suitable for operation at low voltage 3 phase AC
supply indicated under project information.
5.10.3 Ambient air will be drawn in through inlet dampers and dry air filters and
then forced through thermostat controlled heaters. Hot air shall be
distributed by properly sized ducts and dampers to the indoor and
outdoor portions of the bus duct. Hot air shall be let out through suitably
directed outlets provided at the indoor and outdoor portions of the bus
duct and at each equipment suitably.
5.10.4 The hot air blowing system shall be complete with motor blower unit,
combination starter, washable filters, necessary ducting, piping,
dampers, valves, heaters, thermostats, control, instrumentation and
monitoring system, all mounted on a mobile trolley.
5.10.5 A local control cabinet mounted on the trolley, shall be provided with the
necessary control, indication and monitoring devices.
5.10.6 The system shall be sized to completely dry the entire bus duct
installation within two hours. Suitable provision shall be made to isolate
this system after the drying operation is complete.
5.10.7 The mobile trolley shall be common for the specified number of bus duct
units. The bus duct of each unit shall be provided with suitably supported
inlet ducting with blanking plates.
5.10.8 The tap off air ducting from IPB to mobile trolley delivery flange is
included in Bidder’s scope of supply.
5.11 Tests & Test Reports
The following type and routine tests shall be conducted on representative

section of the bus duct assembly. The bus duct assembly tested shall
include bolted connections, flexible connections and current
transformers.
5.11.1 Type Tests
a) One minute power frequency withstand voltage test.
b) Impulse withstand test
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c) Temperature rise test of black matt painted conductors & enclosures
d) Short time current test
e) Dynamic current withstand test
f) Water-tightness test
g) Air tightness test
h) Milli-volt drop test
5.11.2 Routine Tests
a) One minute power frequency withstand voltage test
b) IR measurement
5.12 Bidder shall furnish the following calculations for main run and tap off
run busduct.
5.12.1 Temperature rise at rated current considering effect of solar radiation.
a) Conductor size
b) Guaranteed kW losses in conductor & enclosure
c) Supporting span
d) Dynamic and static forces transferred to TG foundation.
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B) HV & LV Bus ducts
5.13 Segregated Phase Bus Ducts [SPBD]
5.13.1 7.2 kV class segregated phase bus duct and accessories shall be
provided for connection of the two winding unit auxiliary transformer to
6.6 kV switchgear.
5.13.2 The continuous rating of the bus duct from UAT to 6.6 kV Switchgear
shall be same as the rated current of 6.6 kV switchgear bus.
5.13.3 The short time and momentary current ratings of the bus ducts shall be
same as that of associated 6.6 kV switchgear.
5.14 Non-Segregated Phase Bus Ducts [NSPBD]
5.14.1 1.1 kV class non-segregated phase bus duct and accessories shall be
provided for connection between all service transformers and their
respective 400V switchgear. NSPBD shall also be considered for
connections between other switchgear / MCCs to suit the layout.
5.14.2 The continuous rating of the bus duct shall be same as the rated current
of respective switchgear bus.
5.14.3 The short time and momentary current ratings of the bus ducts shall be
same as that of associated 400V switchgear.
5.14.4 The busbars in the bus-duct shall be sleeved with FRLS heat shrinkable,
colour coded XLPE sleeves.
5.15.1 The bus conductor shall be of Aluminium alloy grade 63401 WP (range
2) as per IS: 5082.
5.15.2 The enclosure shall be rectangular and shall be made of aluminium alloy
sheets for SPBD and for NSPBD the same shall be of mild steel.
5.15.3 In case of segregated phase busduct, the phase segregation shall be of

either aluminium or non-hygroscopic insulating material like fibreglass.
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5.15.4 Flexible expansion joints shall be provided for the conductor and
enclosure along the run of the bus duct length to take care of expansion.
Also flexible joints shall be provided at the termination points.
5.15.5 Inspection covers for periodic inspection of the insulators shall be

provided. There shall be no joints or fixing bolts on top of the enclosure
through which water can seep.
5.15.6 The outdoor portion of the bus duct shall be provided with a continuous
rain hood of non-magnetic material suitably supported from the bus duct
support structure.
5.15.7 The bus conductors shall be given a coat of matt black paint to facilitate
heat dissipation. However the sizing of the bus conductor shall consider
the conductor as bare.
5.15.8 The adjacent sections of the bus conductor shall be welded or bolted.
5.15.9 The joints along the conductors shall be of highest quality and the
temperature rise test shall be conducted including the joints.
5.15.10 The bus support insulators shall be of 7.2 kV class (as required) for
segregated phase bus ducts and 1.1 kV class for non-segregated phase
bus ducts and shall be mounted on resilient pads.
5.15.11 The material of insulator shall be epoxy resin cast.
5.15.12 The spacing of the bus support insulators shall be considered by giving
due factor of safety to withstand the forces due to the momentary short
circuit current assigned for the bus duct.
5.15.13 Wall frame assembly and seal off bushings shall be provided where the
bus duct passes through walls (indoor to indoor). These shall be
fabricated out of aluminium angles and sheets. Wall frame assemblies
with seal off bushing shall be provided where bus ducts pass through
walls (outdoor to indoor).
5.15.14 The bus duct supports shall be fabricated from standard steel sections.
The support structures shall be hot dip galvanised.
5.15.15 Thermostatically controlled space heaters shall be provided along the

run of bus duct.
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5.15.16 At the factory, on one typical section of SPBD containing bends, joints
etc., following type tests shall be conducted
(a) air tightness test

(b) water tightness test
(c) Temperature rise test
(d) Short circuit current withstand
(e) Impulse withstand test
For NSPBD, type test certificates shall be furnished.
5.15.17 On all the pieces of SPBD & NSPBD applicable routine tests shall be
conducted. Also, test certificates shall be furnished for bought out items.
5.15.18 HV voltage test, air tightness test and water tightness tests shall be
conducted at site on fully assembled bus duct.
5.16 Technical Requirements
5.17.1 Segregated/non-segregated phase bus ducts shall comply with the

particulars indicated in the following table.
Sl. Description Requirement for

No.
Segregated Non-segregated
Phase Bus duct Phase Bus duct
(a) Type of cooling Natural air Natural air
(b) Maximum temperature 40oC 40oC
rise of conductor over
50oC ambient
(c) Maximum temperature 30oC 20oC
rise of enclosure over
50oC ambient
5.18 Data to be furnished with the Bid
5.18.1 Technical particulars for the segregated/non-segregated phase bus

ducts as per Table below.
5.18.2 Typical calculation for arriving at the size of the conductor and the
insulator spacing.
5.18.3 Experience list of the make of bus duct proposed.
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5.18.4 Type test report (short circuit, impulse withstand, temperature rise test)
for similar bus duct manufactured by the proposed manufacturer.
5.19 Technical Particulars
(To be separately furnished for each rating of segregated and non-

segregated phase bus ducts.)
Sl.No. Description Unit Technical

Particulars
(a) Designation (from & to)
(b) Manufacturer
(c) Applicable standard
(d) Momentary short circuit kA
withstand current (as per peak
clauses 5.13.3 & 5.14.3)
(e) One second short circuit kA rms
withstand rating (as per
clauses 5.13.3)
(f) Continuous current rating at Amps
50oC design ambient air
temperature (as per clauses
5.13.2 & 5.14.2)
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DATA SHEET – A 3.5 SPEC. NO.
TCE.5960A-H-500-001
Isolated Phase Bus Duct
1.0 Type of bus duct Isolated Phase Bus Duct - Continuous
2.0 Type of cooling Natural air cooled
3.0 Maximum temperature rise of over an ambient

temperature of 500C
0
3.1 Conductor (Hot spot) C 55
0
3.2 Enclosure (Cold spot) C 30
4.0 Applicable codes and standards
4.1 Bus conductor material IS :5082
4.2 Porcelain bushing IS : 2099
4.3 Porcelain post insulators IS : 2544
4.4 Hot dip galvanising IS : 2629
4.5 Interconnecting busbars IS : 8084
5.0 Creepage distance for insulators and bushing 25 mm/kV of rated voltage
6.0 Voltage of :
(i) Acc. class Refer Main Line Dia TCE.5960A-EL-SK-

(ii) Rated voltage factor 2003
1.2 Cont., 1.9 for 30 seconds.
7.0 Type of insulation for current trf. and neutral Cast epoxy resin
grounding transformer
8.0 Duty rating
(i) NGT 30 Secs.

(ii) NGR 30 Secs.

DATE JUNE’ 10 CKD.BY HA 5960A PROJECT : 700 MW CCPP AT
REV. BY DATE
TCE FORM NO. 330 R3
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SHEET 1 OF 8
ELECTRICAL SYSTEMS – GENERATOR, GENERATOR
TRANSFORMER AND UAT PROTECTIONS SPEC. NO.
TCE.5960A-H-500-001
6.0 GENERATOR PROTECTION
6.1 Complete protection system consisting of protective relays, auxiliary

relays, timers, etc., shall be provided to protect the generator, its
subsystems, generator transformer and unit auxiliary transformer.
6.2 Generator Protection
All the protective relays, auxiliary relays, timers, transducers etc., to

protect the complete generator, its subsystems shall be housed in
generator relay panel (GRP). This panel will be located in the Main
control room.
6.3 Protection Philosophy
6.3.1 The protection philosophy of every equipment shall be divided into two
100% groups namely two main protection groups. Complete protection of
the respective equipment shall be fully available even if either of the
group is not available. Hence, both groups shall be mechanically,
physically and electrically separated into two separate and independent
systems. One group shall be receiving all AC and DC signals from one
set of devices and the other from another set of devices. Similarly, these
two groups will derive DC supply from two separate feeders. However,
the relays in each group shall be tripping the circuit breaker through both
trip coils I & II. Monitoring devices such as supervision of DC supplies,
supervision of protective relays, supervision of trip relays, CT and PT
supervision and supervision of both trip circuits shall be provided. Dead
machine protection shall receive their DC power supply from station
DCDB as appropriate.
6.3.2 The generator protection system relays shall be classified into three
categories viz., Class – A trip shall be classified into GCB & field breaker
trips (Class-A1) and GT HV breaker Trip (Class-A2). Class-B shall trip
GCB or GT breaker on reverse power through Class A1 or A2. Class- C
shall trip GT HV circuit breaker. Both groups of protection shall be divided
into these three modes of tripping.
6.4.3 The breaker failure relays connected with 400 kV generator transformer
bay and relays connected with 400 kV bus bar protection shall be housed
in separate relay panels which will form part of 400 kV switchyard
protection system.
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6.4.4 The protections envisaged in GRP are listed below. Also, Main One Line
Diagram drg. No.TCE.5960A-EL-SK-2003 indicates various
protections envisaged. Both the list and the drawing shall be considered
Complementary to each other and all the protections indicated shall be
provided. Contractor shall include any additional protections deemed
necessary by him for the equipment offered even if not indicated in the list
and the drawings.
Numerical relays shall be provided for main protection of Generator, GT

and UAT. However, static relays have to be provided for PT supervision,
dead machine protection and pole slipping protection. Numerical relays
shall have adequate output contacts for tripping, annunciation, etc.,
contact multiplication relays shall be provided if necessary. They should
likewise have adequate number of opto couplers for external trip inputs,
interlocking etc., Two identical numerical relays shall be provided for
generator protection. A dedicated operator station shall be provided in
the Main control room for setting the numerical relays of Generator
protection and 6.6 kV switchgear.
(a) Generator differential protection (87G)
(b) Generator stator 100% earth fault protection (64 G1).
(c) Generator stator 95% earth fault protection (64G2).
(d) Generator stator 95% back-up earth fault protection (64 G3).
(e) Pole slipping relay protection (78G).
(f) Loss of excitation protection (40 G).
Loss of excitation relays shall be with two independent outputs for

conditions with and without under voltage.
(g) Negative phase sequence protection (46 G).
It shall have a definite time stage for alarm and inverse stage for
trip. In addition they shall have an output of 4-20 mA for remote
indication of negative phase sequence current.
(h) Back-up impedance protection (21G).
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(i) Stator over-load alarm relay (50 GS).
It shall be provided with timer to detect actual over load.
(j) Generator VT fuse failure protection (60 G11, 60 G12, 60G13 /

60 G21, 60 G22, 60G23)
(k) Reverse power/ Low forward power protection (32 G/37G).
(l) Under frequency protection (81 G).
4 stage with independent time and frequency adjustment.
(m) Over voltage protection (59 G).
Over voltage protection shall have an instantaneous stage and a

definite time stage with independent voltage settings.
(n) Under voltage protection (27G)
(o) Dead machine relay (61 B).
(p) Islanding protection schemes to isolate power plant from grid for
disturbances in the grid.
(q) Generator field over voltage protection (can be a part of excitation

system)
(r) Over fluxing protection (99G) with inverse time characteristics.
(s) Rotor earth fault (64F) 2 stage
(t) Inter turn fault protection through differential current

measurement in case generator has six terminals brought out on
neutral side
Or
Through residual voltage (Vo) with neutral biasing in case three
terminals are brought on the neutral side.
(u) Local breaker back up protection (50 LBB) with it’s own trip relay.
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(v) Generator, generator transformer overall differential protection

(87GTU) for STG and generator, generator transformer, UAT
overall differential protection for GTG (87 G/GT/UAT).
(w) Generator transformer restricted earth fault protection (64 GT)
(x) Generator transformer back-up earth fault protection (51 NGT).
(y) Tripping relays for protection devices of Generator Transformer

(GT) and 63X / 49X for multiplying the contacts of protection.
(aa) For trip function (63X1/49X1)
• GT buchholz II stage (63TX)
• GT OLTC buchholz II stage (63 OLTC TX)
• GT winding temperature very high (49 WTX)
• GT oil temperature very high (49 OTX)
• GT pressure relief device operated (63 PTX)
• GT fire protection trip (63 FRTX)
(bb) For annunciation function (63x2/49x2)
• GT Buchholz I stage (63AX)
• GT OLTC buchholz I stage (63 OLTC AX)
• GT winding temperature high (49 WAX)
• GT oil temperature high (490AX)
• GT oil level low (OLAX)
• GT cooler supply failure
• GT cooler trouble
• GT OLTC trouble
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(z) UAT IDMT overcurrent protection on HV and LV sides (51)
(aa) UAT Instantaneous over current protection on HV side (50)
(bb) UAT – Buchholz (63), winding temperature (49 WT) and oil
temperature (49 OT) protections
(cc) Auxiliary relays for protection devices of UAT 63 x 1/49 x 1 and

63 x 2 / 49 x 2 for multiplying their contacts.
(dd) UAT differential protection (87 UAT).
(ee) UAT restricted earth fault protection (64 UAT).
(ff) UAT instantaneous earth fault relay (51N UAT)
(gg) High speed trip relays (86 G1 to GX): Adequate number of high
speed trip relays for each category tripping and separately for
each group shall be provided for the protection of the unit. The
quantity of the trip relays shall also consider the requirement due
to the following:
(i) Contact requirements from these relays to various

systems covered under the scope of this contract.
(ii) Contacts from each category of tripping relay for

annunciation, data acquisition, and sequential event
recorder and fault disturbance recorder.
(iii) Contacts for control, protection and interlock in system

viz., 400 kV circuit breakers tripping / close permissive,
6.6 kV auxiliary supply breakers trip / close permissive,
transformer cooler circuit interlocks, LBB protection, etc.,
(iv) 10% spare contacts (both N/O and N/C).
(hh) Supervision relays for tripping relays (98 GL1 to GLX).
(ii) Open delta VT for Pre-synchronising Earth fault (59NGT)
(jj) 400 kV generator breaker trip coil supervision relays (98G1 to

G4).
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(kk) Auxiliary relays, timers in adequate number to make the

protection & the scheme complete, relays required for the
discrepancy switch scheme in Generator control panel.
(ll) Auxiliary VTs and Auxiliary CTs required for the protection
systems. The parameters of the same shall be selected to suit
the application and the same is subject to approval of Owner.
6.6 The characteristics and relay setting ranges shall be decided by the
Contractor and shall be such as to provide complete protection for the
generator under normal and all abnormal operating conditions.
6.7 Trip Matrix required for implementing class A/B/C tripping schemes shall
be provided by the Contractor and shall be indicated in block interlock
diagrams to be submitted.
6.8.1 The protection system shall comprise pre-engineered modular or discrete

self-contained systems comprising preferably of static relays. In addition
to the relays/protections mentioned in this specification, any additional
protections/relays considered necessary by the Contractor for his system
shall be included and offered by the Contractor.
6.8.2 Two Nos. DC supplies shall be arranged for the GRP. These supplies
shall be taken through a selector switch with the positions, viz.,
independent, source-1 & source-2. In the Independent position Group-1 &
2 protection system will be fed by source 1 & 2 respectively and the
common services from any one of the sources. In case of failure of any
one source (say source 1) switch shall be changed over to the other
source (source 2) and complete DC supply requirement of GRP will be fed
from the other source.
DC auxiliary supply shall be supervised by supply supervising relays. The

NC contact of the relays shall be delayed on drop off by approximately
100 to 200 m sec. for annunciation in Operator station/Generator control
panel. The relay shall be provided with flag indicators wherever required.
White colour supervision lamps of clustered LED type shall be provided
on GRP to indicate availability of DC supply. All LEDs shall be 22.5 mm
size self coloured.
6.8.3 The relay panels shall be provided with supervisory system facilities to
indicate the location of the failed component when pre-engineered
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protection system is offered. Self checking facility ‘In-Built’ in the relay

panel shall be provided with watch dog contact for remote annunciation
and DCS.
6.8.4 Either hand reset mechanically operated operation indicator or LED with
reset push button shall be provided for protective relays. They shall be
arranged to operate only when tripping current passes through output
circuit of the relay.
6.8.5 One laptop of high configuration shall be provided with necessary

software & hardware (with multiple licences) for setting the parameters &
evaluation of numerical relays.
6.9 In addition to the contacts required as per schemes, Contractor shall wire
out to the terminal block atleast all NO & NC spare contacts of each of the
relays.
6.10 The protection scheme shall include all the necessary contacts to achieve
the schemes required, alarms in Operator Station, annunciation windows,
sequence event recorder and for switchyard control panel annunciation
wherever required. Contact multiplication relays for generator circuit
breaker and associated isolators shall be provided for this purpose.
6.11 Testing Unit
6.11.1 Two Nos. of test kits shall be offered to test all of generator, transformer,
line and motor protection relays, timers by secondary injection. This is in
addition to self monitoring and watch dog facilities that will be built into
these protective relays.
6.12 Control room alarms/indications/SER points
Each of the alarms, trip conditions, abnormal conditions through the

protection relays, shall be individually indicated in Operator station and
also individually or appropriately grouped available in the annunciation
windows in generator control desk / panel. Selected alarm/trip conditions
finalised during the detailed engineering stage shall be used for SER
system. (Further the lockout relay operation and certain grouped alarms
shall be available in the SCADA/400kV-switchyard control system.
Operator station/SER shall have a time resolution of 1 (one) ms.
Minimum electrical system requirements in respect of control, monitoring,
measurement, annunciation, synchronising are indicated in I&C system
section No. D2.4.
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6.13 Fault disturbance recorder
Microprocessor based fault disturbance recorder shall be provided for

each generator to record the graphic form of instantaneous values of
voltage and current in all three phases and neutral, open and close
positions of relay contacts and breaker during disturbance etc., Facility of
fast scan as well as slow scan feature to be provided to record transient
as well as dynamic performance of the system.
6.14 Tests
Tests shall be as mentioned in Section D3.7 for Switchyard Relay Panels.
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ELECTRICAL SYSTEMS - 400 kV SWITCHYARD SPEC. NO.
TCE.5960A-H-500-001
7.0 400 kV SWITCHYARD
7.1 A 400 kV switchyard shall be provided for evacuation of power

generated in the plant through four (4) nos. 400 kV transmission lines.
The necessary line bay equipment, generator transformer bay
equipment with associated equipment, controls, monitoring, protection
and SCADA system shall be provided by the Contractor.
7.2 The 400 kV switchyard shall have one and a half breaker switching
scheme. The Main One Line Diagram sketch no. TCE.5960A-EL-SK-
2003 shows the switchyard scheme and arrangement of major
equipment in the switchyard.
7.3 The 400 kV switchyard shall consists of various bays for different
configuration as follows:
Description No. of Bays

Generator Transformer 3
400 kV Line 4
Bus Reactor 2
Future bay (Spare) 1
Total 10
7.4 The switchyard equipment shall be supplied and installed with all
accessories to make the switchyard complete in all respects. The
switchyard shall include the equipment indicated below but not limited to
the following.
7.4.1 420 kV circuit breakers
7.4.2 420 kV isolators
7.4.3 420 kV current transformers (CTs)
7.4.4 420 kV capacitor voltage transformer (CVTs) and electromagnetic

voltage transformers (EMVTs).
7.4.5 360 kV lightning arresters (LA’s)
7.4.6 Wave traps & Coupling capacitors.
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7.4.7 Power line carrier communication (PLCC) system for 4 lines.
7.4.8 Bus bars, insulators, clamps and connectors.
7.4.9 SCADA (Supervisory Control and Data Acquisition) system for entire
switchyard with bay control units for each bay including event logging.
7.4.10 Protection panels for all bays/equipment, communication and interfacing

panels as required.
7.4.11 Stand alone disturbance recorders with associated network cabling, PC,
HMI, Printer and evaluation software.
7.4.12 ABT (Availability Based Tariff) meters including necessary software &
hardware for monitoring on dedicated PCs with suitable networking.
7.4.13 RTU (Remote Transmission Unit) for transfer of data to SLDC (State
Load Dispatch Centre) and RLDC (Remote Load Dispatch Centre).
7.4.14 Outdoor kiosks housing BCUs, protection panels, PLCC/OLTE panels,

fault disturbance recorders, etc.
7.4.15 Air conditioning and ventilation system for control building and outdoor
kiosks.
7.4.16 Fire alarm, detection & protection system for switchyard.
7.4.17. Switchyard structures, switchyard fences, earthing, trenches and

complete civil works including switchyard floors with RCC blocks.
7.4.18 Bus Reactor
7.5 Design Criteria
7.5.1 The switchyard shall be generally designed based on the following

codes and standards.
(a) IS 10118 – 1982 : Code of practice for selection installation

and maintenance of switchgear and
control gear – part-3 (Installation).
(b) CBIP Technical Manual on layout of substation report No.3
(c) IEC 61850 (universal): Substation automation protocol
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7.5.2 A creepage distance of 31 mm/kV on 400 kV shall be provided for circuit

breakers, isolators, Bus reactor, CTs, CVTs, EMVTs, LA’s, bus post
insulators, string insulators and 420 kV transformer bushings.
7.5.3 The switchyard main buses shall be designed for continuous rating.
Bay buses shall be rated according to the circuit rating. The switchyard
shall be designed for a fault level of 50 kA for 1 sec. and dynamic rating
of 130 kA.
7.5.4 The 400 kV system shall be designed to withstand the power frequency
over voltage to 1.5 p.u and surge over voltage to 2.3 p.u. The busbars
shall be of standard ACSR or tubular aluminium / copper according to
standard metricised iron pipe size (IPS) of suitable size.
7.5.5 The conductor size of tubular bus and stranded conductors shall be
based on the maximum load current, suitability under short circuit
conditions, corona / voltage gradient and effect of solar radiation.
Calculation shall be submitted for Owner’s approval.
7.5.6 The final temperature of the conductor when carrying full load current
shall not exceed 850C with a maximum ambient temperature of 500C.
7.5.7 The size and spacing of strung bus, tubular bus and clamps
connections shall be checked to limit the voltage gradient to 17 kV/cm to
reduce corona effect.
7.5.8 The size of shield wire shall be based on the lightning impulse current
expected and the time duration for which it is likely to flow. Allowance
shall be given in the final size to account for corrosion of the shield wire
during service at rate of 0.03 mm per annum, if galvanised steel wires
are used. However, minimum size of the shield wire shall not be less
than 70mm2.
7.5.9 Insulators
(a) Design of insulator shall avoid stresses due to expansion and

contraction in any part of the insulator leading to deterioration.
(b) All ferrous parts shall be hot dip galvanized. The associated
metal part shall be permanently secured to the insulator, air tight
and shall be designed to withstand all shocks and stresses to
which they may be subjected to during operation and
maintenance.
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(c) The design shall ensure uniform compressive pressure on the

joints.
(d) All insulators shall be of homogeneous glazed porcelain or

composite type with silicon shed profile, free from laminations,
cavities and other flaws or imperfections, and shall be thoroughly
vitrified, tough and impervious to moisture.
(e) Porcelain glazing shall be uniform brown in colour, free from

blisters, burns and other similar defects. Composite insulators can
be of grey in colour.
(f) There shall be no electric discharge between conductor and

insulators, when operating at normal voltage, which would cause
corrosion or injury to any of the material.
(g) Tension and suspension insulator strings shall be anti-fog type

selected based on the voltage, insulation level, pollution level and
electro-mechanical strength. Creepage chosen shall be suitable
for high pollution, i.e., 31 mm / kV. Electro-mechanical strength
shall be selected with factor of safety of 2.5.
(h) Bus post insulators shall be solid / post insulator anti-fog type and
shall be selected based on the system voltage, insulation level
mechanical strength and pollution level requirements.
(i) Insulator hardware shall be corona free upto a falling power

frequency visible discharge test voltage of 1.1 times the maximum
system voltage.
7.5.10 The lightning protection of switchyard shall be provided by lightning

masts and shield wires. The zone of coverage for the shield wire shall
be considered as 60 deg. between the two shield wires and 45 deg. for
the end shield wires.
7.5.11 The criteria for deciding phase to phase clearance in case of strung
conductors shall take into account that the conductor swing of one of
the conductors (say R phase) with maximum wind velocity and the
adjacent conductor (say Y phase) with 80% of maximum wind velocity
at maximum sag conditions.
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7.5.12 For the layout proposed by the Contractor the adequacy of the
cantilever strength specified shall be checked considering the following
factors of safety.
(a) Sum of all permanent normal loads (wind load on tubular bus +
wind load on stack + dead weight of the tubes) x 2.5 (factor of
safety).
(b) Combination of all normal loads plus either maximum short circuit
or earthquake load whichever is higher x 1 (factor of safety).
7.5.13 The switchyard shall be designed for the seismic coefficient and wind
pressure as indicated in Section-B.
7.5.14 All structural steel and steel components in the switchyard equipment
shall be of hop dip galvanised.
7.6 Switchyard Layout Requirements
7.6.1 The Contractor shall adopt bolted type connectors for tubular bus
conductors, fixed type of terminal connectors for isolator terminals,
flexible type of terminal connector for circuit breakers, current
transformers and power transformers and flexible jumper connectors for
connecting lightning arresters and voltage transformers.
7.6.2 The Contractor shall consider suitable bay width, phase spacing,
clearances, etc., depending on the actual dimensions of the equipment
keeping in view the design criteria / requirements and without sacrificing
any maintenance space / conveniences.
7.6.3 In the transformer yard, the power conductor termination shall not be
tapped off directly to the Generator transformer from the strung bus
between the TG building and switchyard. The tap off conductor shall be
routed through a bus post insulator located near the transformer.
7.6.4 The Contractor shall note that the sequence of bays shall be so
arranged that the maximum horizontal angle of deviation of the
incoming power and shielding conductors from Generator transformers
do not exceed 300C. Similarly, the point of anchoring on TG building
shall be such that the vertical angle of deviations is limited to 300C from
horizontal plane.
7.6.5 The switchyard shall be provided with access ways near the current
transformers and circuit breakers.
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7.6.6 The cable trenches for the equipment shall be run as close to their
foundations as possible even preferably touching.
7.6.7 The switchyard shall be enclosed in fence or wall around for safety and
to prohibit unauthorised persons from entering. Lockable gates for
personnel entry and equipment shall be provided at convenient
locations.
7.6.8 The fence provided around switchyard shall be of 2500 mm minimum

height and at a minimum distance such that section clearance is
available from any live part. The fence shall be suitably earthed as per
relevant Indian standards.
7.6.9 Earth mat of suitable size with closely spaced earth conductor shall be
provided below the operating handle of individual switchyard equipment
As per the allowed step & touch potential values in IS.
7.6.10 Design criteria for civil works and structures shall be as specified in
Section-D4.0, civil works.
7.7 Switchyard Equipment
7.7.1 Circuit Breaker
7.7.1.1 (a) The 420 kV circuit breakers shall be of SF6 outdoor type. The
circuit breaker and its accessories viz. marshalling box / junction
box shall be with IP 55 degree of protection.
(b) The SF6 circuit breakers shall be single pressure type and utilise
puffer cylinder for interrupting currents. The breaker shall be so
designed that upon loss of pressure, the gap between open
contacts shall be suitable to withstand at least rated voltage at zero
gauge pressure of gas. Each SF6 circuit breaker pole shall be
provided with its own self-contained gas system.
(c) The circuit breakers shall comprise three identical single phase
units with operating mechanism suitable for single pole operation.
(d) Tie beams between foundations of breakers of different phases are

recommended as during closing / opening operation additional
load in the form of vibrations may be transferred to the
foundations.
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(e) Design of circuit breaker shall be such that contacts shall not close
automatically upon loss of gas / air pressure.
(f) SF6 breakers shall be provided with temperature compensated SF6

density switches for individual poles with separate lockout, alarm
and blocking contacts. Temperature compensated SF6 Density
monitor to be provided for each phase at such a level so as to
enable viewing and reading.
(g) The operating mechanism shall also have pressure switches for
low alarms, high alarm, trip, lock out switches for close, open and
reclose operation.
(h) D.C. circuits for two trip coils shall be separate and each of them
shall be monitored separately.
(i) Manually operated emergency trip push button or any other device,
conveniently located for mechanical tripping of all the three phases
simultaneously shall be provided.
(j) Duty cycle for the breakers shall be O-0.3sec-CO–3min-CO under

all normal and fault conditions.
(k) Circuit breakers shall be suitable for rapid auto re-closing duty.
(l) All the circuit breakers in the switchyard shall be of identical make
and type with interchangeable components to maximum possible.
(m) The middle breakers and the outgoing line breakers shall be
provided with PIR.
7.7.1.2 Operating mechanism
(i) Circuit breakers shall be operated by spring / spring charged

mechanism. It shall be anti-pumping type and trip-free. One
O-C-O operation shall be possible with failure of AC supply.
(ii) Two trip coils shall be provided for greater reliability. The trip
coils shall have sufficient continuous rating to cater to the trip
coil supervision relay current.
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(iii) Separate pole discrepancy circuit with proper relay and other
accessories shall be provided. Disagreement circuit shall be
provided which shall detect pole position discrepancy.
(iv) A closing release shall operate correctly at all values of

voltage between 80% and 110% of the rated voltage. A shunt
trip shall operate correctly under all operating conditions of
the circuit breaker upto the rated breaking capacity of the
circuit breaker and at all value of supply voltage between 50%
and 110% of rated voltage.
(v) Mechanical interlocks shall be provided in the operating

mechanism to prevent discharging of closing springs when
the breaker is already in the closed position. Provision shall
be made to prevent a closing operation to be carried out with
the springs partially charged.
7.7.1.3 One set of SF6 gas filling, evacuation and refilling equipment consisting
of trolley mounted compressed SF6 cylinder, gas regulator with
manometer and necessary coupling for filling gas in the breaker shall be
provided. The equipment shall be trolley mounted. 2 nos. of gas leak
detector shall be included in the scope of supply. Detectors shall be of
reputed make and have Visual as well as Audible sound facility when
leakage is detected. Contractor shall supply spare SF6 gas equal to
20% of the total requirement for the station.
7.7.1.4 All circuit breakers controlling the lines shall be provided with either
closing resistors or proven controlled switching devices to reduce over
voltages and in-rush currents.
7.7.1.5 All routine tests on the circuit breakers shall be carried out as per IEC-
62271-100. Type test certificates for all tests carried out on identical
circuit breaker as per IEC-62271-100 shall be furnished.
7.7.2 Isolators & Earth Switch
(a) Isolators shall be horizontal centre break type suitable for

horizontal upright type of mounting.
(b) Isolators & Earth switch shall be suitable for operation on 400V, 3
phase, AC motor. However, it shall also be possible to operate
them manually in the event of failure of power supply or outage of
the drive motor with proper interlock provision for isolation of motor
in case of manual operation. Earth switches shall be motor
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operated with proper interlock so that it shall not operate in case

respective isolator is ON and other requisite conditions are not
met. Tripping of drive, loss of AC drive supply and DC control
supply shall be wired for giving alarm. The Disconnecting switches
and earth switches shall be independent pole and gang operated.
(c) Isolators shall be electrically interlocked with the circuit breakers in

accordance with the switchyard safety interlocking scheme. The
interlocks shall be effective for all modes of operation i.e. Electrical
remote, Electrical local and Manual local. Bolt type interlock and
any special accessories required on the isolator side for
satisfactory operation of scheme shall be included. Interlocking
scheme shall be so designed as to ensure absolute safety
maximum flexibility and proper switching of CT and PT circuits.
(d) The design of the auxiliary switches for the isolators shall be such
that signalling of the closed position shall not take place unless the
contact system has reached such a position that the rated current
and the rated short time current can be carried safely; signalling of
the open position shall not take place unless the contact system
has reached a position of at least 80 percent of the clearance
distance of the isolating distance. Contacts used for CT switching
shall make before the isolator closed and starts carrying current.
Similarly they shall open after isolator opens and breaks the
primary current.
(e) Base channels and other structural steel members such as

operating pipes, phase coupling rods, operating mechanism boxes,
bolts, pins, etc. shall be hot dip galvanised or metallised. All
castings except current carrying parts shall be made of malleable
cast iron or cast steel. Manual operating handles shall be
galvanised steel.
(f) The isolator and earthing switch shall be provided with high current
carrying contacts on the hinge and jaw ends and all contact
surfaces shall be of silver faced copper.
(g) Each pole of the isolator shall be provided with two earthing pads
of non-corrodible material at opposite ends, brazed to the channel
base. Flexible copper earth connectors shall be provided for
connecting operating handles of isolators and earthing switches to
the earthing system. The poles of the isolators shall be
mechanically ganged.
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(h) Earthing switch shall be provided with some isolators as indicated

in main one line diagram. Two independent earthing pads each
with flexible copper braids (tinned or suitably treated against
corrosion) and suitable connectors for the specified size of earth
conductor lead shall be provided at the hinge end of the switch.
The flexible copper connections between rotating shaft of earth
switch and frame shall have a cross section suitable to withstand
the short time current.
(i) Isolator and earthing switch shall be mechanically interlocked such

that it will not be possible to close the earthing switch when the
isolator is closed and vice-versa.
(j) Isolator shall be provided with electrical interlocking feature in all

modes of operation. This shall be in the form of bolt interlock
comprising an interlock coil of latch in type to lock the isolator
driving shaft and hence prevent isolator operation in the latch-in
condition. It shall be possible to release the latch by energising the
interlock coil when certain pre-set conditions of interlocking
scheme are fulfilled.
(k) Electrical interlocking arrangements shall be fail-safe type.
(l) Isolator shall be provided with mechanical interlocking feature in

addition to electrical interlocking feature described above.
(m) Operating Mechanism and Controls
(i) The manual operating handles shall be mounted on the base

of supporting structure. A weather-proof galvanised sheet
steel cabinet with gasket hinged door and padlocking facility
shall be provided to house the driving mechanism, motor
starters, control valve solenoids, auxiliary switches etc. The
operating mechanism box shall have enclosures conforming
to IP 55.
(ii) Arrangement shall be provided to permit manual operation of

power isolators. The arrangement shall be such that when
manual operating handles is in the engaged position, the
power operation shall be made inoperative. Pad-locking
facility shall be provided for the manual operating handle.
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(n) All routine tests as per IEC 60129 shall be carried out. Type test
certificates for all tests carried out on identical isolators as per IEC-
60129 shall be furnished.
(o) All tests shall be made on completely assembled isolators,

earthing switches, their operating devices and auxiliary equipment.
One assembled isolator shall be subjected to 1000 operations for
checking mechanical endurance.
7.7.3 Current transformers (CTs), capacitor voltage transformers (CVTs)

and Electromagnetic Voltage Transformers (EMVTs)
(a) Electromagnetic VTs shall be provided for tariff metering (if

required by grid) and CVTs for other metering and protection.
Metering cores of CTs and EMVTs/CVTs shall be with accuracy
class 0.2S and 0.2 respectively. Tariff metering CT & PT should
comply with the requirements of CEA regulations on installation
and operation of energy meters & respective grid authorities which
will be intimated to successful bidder during detailed engineering.
(b) A separate 2 core CT (for Main and Check Meters) of accuracy

class 0.2S for tariff metering for each line. The VA burden of the
tariff metering CTs shall be subject to the approval of grid
authorities.
(c) A separate 2 winding EMVT (for Main and Check Meters) of

accuracy class 0.2S for tariff metering for each line. Tariff
metering EMVT terminals shall be housed in separately sealable
terminal boxes.
(d) Separate CT cores for Main-1 and Main-2 Carrier aided Distance
Protection (21) for each line.
(e) The CTs and EMVTs shall be either oil filled hermetically sealed or
SF6 gas filled single phase type. The CVTs shall be oil filled
single phase type.
(f) In case of SF6 filled CTs and EMVTs, gas density monitors with
remote alarm facility shall be provided.
(g) The rated burden for the metering and protection cores shall be
decided considering all the loads/relays connected, future
additions, lead burden etc.
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(h) The knee point voltage for PS class cores shall be decided
considering the total connected burden with adequate margin.
(i) The magnetising current at Vk/2 shall be as minimum as possible

(say 15 mA). Shall have a rated extended primary current of 120%
of rated primary current.
(j) The core lamination shall be of cold rolled grain oriented silicon
steel or other equivalent alloys. The cores shall produce
undistorted secondary current under transient conditions at all
ratios with specified parameters.
(k) Insulator shall be one piece without any metallic flange joint.
(l) Expansion chamber at top shall be provided with oil sight glass.
(m) Shall have provision for taking oil samples from bottom of CT
without exposure to atmosphere to carry out dissolved gas
analysis periodically.
(n) The CVT secondary shall include necessary MCBs with auxiliary
contacts for alarm for protecting the secondary winding. Further,
for the purpose of supervision on remote panel, line terminals of
the CVTs shall be brought out through second set of MCBs. All
the terminal boxes shall be powder coated with IP-55 degree of
protection.
(o) Secondary terminals of CTs shall be brought out in a weather

proof power coated terminal box. Facility shall be provided for
short circuiting and grounding the CT secondary at the terminal
box. All the taps of each core shall be wired to Marshalling Box to
facilitate ratio changing. The box shall have a degree of protection
IP-55. Tariff metering core terminals (for connecting main and
check meters) shall be housed in a separate sealable terminal
box.
(p) CT/CVT/EMVT assembly shall be suitably braced to withstand

stresses induced due to seismic disturbances.
(q) The tank/base and all exposed ferrous parts shall be hot dip
galvanised conforming to applicable standards.
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(r) Each CT shall be equipped with an over voltage protective device

to limit the voltage developed across the secondary terminals to a
safe value not exceeding 3 kV under open circuit condition.
(s) It shall be possible to select the ratio on any core independent of

the setting in the other cores, for which purpose, tappings will
have to be provided on the secondary windings.
(t) Oil filled insulator/bushings shall be hermetically sealed to prevent

ingress of moisture. A cushion of nitrogen gas shall be provided to
allow for expansion.
(u) Each CT/CVT/EMVT shall be supplied with suitable G.I supporting

structure.
(v) All CTs/EMVTs shall be provided with stainless steel bellows.
(w) One MB for each set of 3 CTs/CVTs/EMVTs shall be provided.

The MB shall be fixed to the supporting structure of CT/CVT/
EMVT. The MBs shall be fitted with adequate no. of disconnector
type of test terminal boards suitable for terminating 2 nos. of 2.5
sq mm multi-strand copper wires. At least 20% spare terminals
shall be provided.
(x) The instrument transformers shall be provided with filling and

drain plugs.
(y) Polarity marks shall indelibly be marked on each instrument

transformer and at the secondary terminals at the associated
terminal block.
(z) Neutral of all cores of CTs, CVTs and EMVTs shall be formed in
marshalling box of the respective equipment. Cables with
sufficient number of cores are run from these marshalling boxes to
protection panels. The neutral of CTs, CVTs, and EMVTs shall be
earthed only at protection panels by means of a disconnecting
link.
(w) Tests & Test Reports
All routine tests on the 400 kV voltage and current transformers

shall be carried out as per relevant standards. Type test
certificates for all tests carried out on identical voltage and current
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transformers shall be furnished. If test reports are not in line with

the requirement of IS/IEC then the Contractor shall carry out type
test at no additional cost to the Owner.
7.7.4 BUS REACTORS
a) 400 kV, 50 MVAR Three Phase Oil Filled Bus Reactors are considered in
the switchyard. However, the exact requirement for these Bus reactors will
be confirmed during detailed engineering based on the system study to be
carried out by the bidder. However, at present, the bidder shall consider
these Bus reactors in their offer.
b) Bus reactors shall operate continuously at the highest system voltage

without exceeding the guaranteed temperature rise.
c) The total harmonic content in the phase current of a star connected reactor
and zero sequence components appearing in the neutral shall be below
3% of the crest value of rated current.
d) The impedance of reactor shall have a constant value upto about 1.5 times
rated highest system voltage. Further the impedance shall be accurately
balanced between the three-phase system.
e) The magnetic circuit of reactor shall be so designed that the audio sound
level shall be minimum.
f) The losses of the reactor shall be limited to the values to permit ONAN type
of cooling.
g) Bus reactors shall be designed for 110% continuous over-fluxing withstand

capability.
h) The reactors shall be either gapped core type or coreless type.
i) Special measures shall be taken by providing non-magnetic shielding to

combat the effects of stray/leakage flux.
j) Windings shall be of copper unless specifically approved by the

PURCHASER. The conductors shall be transposed at sufficient intervals in
order to minimise eddy currents and equalise the distribution of currents
and temperatures along the windings.
k) Tank shall be made from good commercial grade low carbon steel and
shall be of welded construction.
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l) Tank shall be provided with a pressure release device which shall operate
at a pressure below the test pressure for the tank and radiators. The device
shall be rain-proof after blowing and shall be provided with a device visible
from ground to indicate operation. An equaliser pipe connecting the
pressure relief device to the conservator shall be supplied.
m) Valves shall be of forged carbon steel upto 50 mm size and of gun-metal or

of cast iron bodies with gun-metal fittings for sizes above 50 mm. They
shall be of full-way type with screwed ends and shall be opened by turning
counter clockwise when facing the hand wheel. There shall be no oil
leakage when the valves are in closed position.
n) The under-carriage of the reactor shall be provided with detachable steel

flanged wheels.
o) Separately mounted radiator banks shall have bolted flanged connections

and pipe extensions to permit withdrawal of reactor tank without disturbing
the radiators.
p) Bushings shall be of the oil-filled condenser type with a central tube and
draw-in conductor, which shall be connected to the connector housed in
the helmet of the bushings. The pull through lead shall be fitted with a gas
bubble deflector. Condenser type bushings shall be equipped The angle of
inclination to vertical shall not exceed 30 deg.
(a) Provision for power factor testing without disconnecting main leads.
(b) Stress rings and lower and shields.
(c) Current transformers shall be provided and the bushing shall be so

arranged that it can be removed without disturbing the current
transformers and secondary terminals.
(d) Bushing turrets shall be provided with vent pipes, which shall be
connected to route any gas collection through the Buchholz relay.
q) The Bushing CT’s for protection shall be provided as per the enclosed Main
One Line Diagram TCE.5960A-EL-SK-2002.It shall be possible to remove
turret mounted Bushing CT's from the reactor tank, without removing the
cover.
7.7.5 Lightning Arrester
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(a) 360 kV, 20 kA nominal discharge current, class – IV pressure relief

class-A, metal oxide, gap less lightning arrester shall be provided
as per the Main one line diagram No. TCE.5960A-EL-SK-2003.
(b) Operational requirements
(i) Shall protect power transformers, circuit breakers,

disconnecting switches, instrument transformers etc. with
insulation levels specified in this specification.
(ii) Shall be suitable for circuit breaker duty cycle in the given
system.
(iii) The reference current shall be high enough to eliminate the

influence of grading and stray capacitance on the measured
reference voltage. Values and calculations shall be furnished
with offer.
(iv) Shall be fully stabilized thermally to give a life expectancy of

one hundred (100) years under site conditions and take care
of effect of direct solar radiation.
(v) Shall be capable of discharging over-voltages occurring due

to switching of unloaded transformers and long lines,
(c) Specific Requirements
Arrester shall be suitable for installation in effectively earthed

system. The Contractor shall carry out the insulation coordination
studies for deciding the exact location and voltage levels of the
LA’s.
(i) Shall be hermetically sealed single phase unit.
(ii) Shall be robust with excellent mechanical and electrical

properties.
(iii) Shall be capable of withstanding meteorological and short

circuit forces under site conditions.
(iv) Each lightning arrestor shall be complete with insulating base

for mounting on structure.
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(v) LAs shall be provided with grading and/or corona rings as

required.
(vi) LA’s shall not fail due to porcelain contamination.
(vii) Porcelain shall be so coordinated that external flashover will

not occur due to application of any impulse or switching surge
voltage upto maximum design value for LA.
(viii) The end fittings shall be non-magnetic and of corrosion proof

material.
(ix) Surge monitor shall be provided for each arrester and the
same shall be mounted at a suitable height to facilitate easy
reading of the counter mechanism and leakage current
detectors.
(x) Insulated copper conductor of adequate size and length shall

be used for connecting discharge counter, terminal and
lightning arrester earth terminal. Insulation level of the same
shall not be less than 3.6 kV.
(xi) Suitably sized bypass copper shunts shall be provided for

bypassing the discharge counter for removal / maintenance of
the counter.
7.7.6 Line Traps
(a) Line trap shall be of pedestal mounted, wound coil, broad band
tuned.
(b) Line trap shall prevent undue loss of carrier signal for all
conditions.
(c) It shall have negligible impedance at power frequency, which shall

be relatively high over the frequency band appropriate to carrier
transmission.
(d) It shall be suitable for outdoor pedestal mounting and mechanically

strong to withstand the stresses due to wind pressure.
(e) It shall be mounted on a tripod structure formed by three solid core

bus post insulators.
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(f) Line trap shall consist of a main coil designed to carry continuously
the rated current without exceeding the limit of temperature rise
limits. It shall be equipped with bird barriers and shall be spray
painted as per IS. It shall be provided with protective device and
tuning device.
(g) Suitable corona rings shall be provided to meet corona and radio
interference performance as specified for 400kV equipment if
required.
(h) Even though the line traps shall be installed in two phases, the
foundation shall be constructed in all the three phases to facilitate
the change of location of line trap between the phases.
(i) Suitable surge arresters shall be provided.
(j) Shall be designed and arranged such that neither significant

alternation in its protective function nor physical damage shall
result from either temperature rise or the magnetic field of the main
coil at continuous rated current or rated short time current.
7.7.7 Clamps and Connectors
(a) Shall be Aluminium alloy casting conforming to designation A6 of

IS:617 for connecting to equipment terminals and conductors of
aluminium. In case the terminals are of copper, the same clamps/
connectors shall be used with 2mm thick bimetallic liner.
(b) Shall be Galvanized mild steel for connecting to shield wire.
(c) Bolts, nuts and plain washers shall be hot dip galvanized mild steel
for sizes M12 and above. For sizes below M12, they shall be
electro-galvanized mild steel.
(d) The spring washers shall be electro-galvanized mild steel.
(e) All castings shall be free from blow holes, surface blisters, cracks
and cavities.
(f) All sharp edges and corners shall be rounded off to meet specified
corona and radio interference requirements.
(g) Shall have same current rating as that of the connected equipment
with temperature rise limited to 350C over 500C.
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(h) All current carrying parts shall be at least 10 mm thick.
(i) Shall be manufactured to have minimum contact resistance.
(j) Flexible connectors, braids or laminated strips shall be made up of

copper/ aluminium.
(k) Current rating and size of terminal/conductor for which connector is

suitable shall be embossed/punched on each component.
7.7.8 Insulator String Hardware
(a) Shall be of bolted type and forged steel except for insulator cap,
which can be of malleable cast iron.
(b) Shall also generally meet the requirements of clamps and

connectors as specified above.
(c) In one span, Tension string assembly at one end shall be supplied
with suitable turn buckle.
(d) Suitable sag compensating spring shall be supplied in case the

design calculations show excessive variation of the sag over the
temperature range of 0 to 80 deg. C.
7.7.9 Spacers
(a) Shall be non-magnetic material except nuts and bolts, which shall
be of hot dip galvanized mild steel.
(b) Shall generally meet the requirement of clamps and connectors

specified above.
(c) Design shall take care of fixing and removing during installation
and maintenance.
7.8 Switchyard Control and Relay Panel
7.8.1 Bidder shall offer air conditioned outdoor kiosks suitably located in
switchyard, housing various IEDs such as Bay Control Units (BCUs),
Protection Panels, Fault Disturbance Recorders, PLCC/OLTE Panels,
etc. However, SCADA servers and associated equipment, SCADA
Operator Station, RTU for SLDC/RLDC, DC battery, battery chargers,
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DCDB, 400 V ACDBs, UPS system, etc. shall be located in the

switchyard control building for overall optimization in respect of cabling
and control room building size. One kiosk shall be considered per
diameter (comprising of two circuits in one and half breaker scheme) of
400kV switchyard. In case of incomplete diameter, the kiosk shall have
necessary space for accommodating the future bay IEDs. One
additional kiosk, if required, shall be provided for housing busbar
protection panels at suitable location in switchyard. The layout of
equipment/panels shall be subject to Purchaser’s approval. The kiosk
shall be provided with fire alarm system with at least two detectors and
shall be wired to fire alarm panel as described elsewhere in the
specification. All CT, PT, control cables, etc. from switchyard
equipment shall be connected to respective IEDs located in kiosks.
Two optical fibre cables (OFC) shall be laid to connect BCUs to SCADA
for data exchange. Different routes shall be adopted for OFC.
Technical requirements of outdoor kiosks are detailed elsewhere in the
specification.
The switchyard protection shall consist of:
(a) One complete set of relay panels for 400 kV switchyard

equipment
(b) System fault locaters – as a part of Main-1 numerical relay

(BCU)
(c) Stand alone Disturbance recorders - as a part of BCU
7.8.2 The control and interlocking scheme suitable for one and a half breaker
switching scheme shall be provided. Contractor shall furnish block
interlock diagrams for the switchyard for Owner’s approval. The
scheme as approved by Owner shall be provided. All the auxiliary
relays, timers, switches, hardware, etc., required for the scheme are
deemed to be included in the Contractor scope.
7.8.3 Line bays shall be provided with single phase and three phase auto
reclosing feature. The auto re-closing scheme shall be available in one
of the numerical line protection relays but shall get independently
actuated by the operation of both the protective relays. All the
necessary relays, trip relays, auxiliary relays shall be provided.
Provisions shall be made to accord higher reclosing priority to main
breakers, or to issue reclosing command to both breakers
simultaneously. Rapid reclosing & delayed reclosing features shall be
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provided. All conditions requiring blocking auto reclosure shall be

considered.
7.8.4 Live line–dead bus closing and dead line-live bus closing facilities shall
be provided using dedicated relays for this purpose. Indicating lamps
for fulfilment of the permissive condition shall be provided.
7.8.5 Synchronizing function shall be through BCU for GTG units and a
separate synchronizing equipment along with check synchronizing
facility to be provided for STG units. Synchronising facility shall be
provided for all lines in DCS. In check synchronising position, the
synchronising criteria shall be fulfilled as indicated by the closing
permissive provided by check synchronising relay. In manual mode,
closure is possible only if either the line or the bus is dead. It shall not
be possible to close in manual mode if both line and bus are live.
7.8.6 Control and indication shall be provided for each of the breaker and
isolator.
7.8.7 The measurement requirements for each of the bays shall be as per
the Main one line drawing TCE.5960A-EL-SK-2003 and Section D2.4 -
I & C requirements.
7.8.8 Monitoring-Indication, abnormal conditions, Measurement required in

DCS shall be as given in Section D2.4
7.8.9 All relay panels shall be located in outdoor kiosk and these kiosks shall
be located in switchyard.
7.8.10 In the event of shortage of contacts in main circuit breakers, isolators

and earth switches, contact multiplying relays shall be used. The same
shall be two coil, latching type with electrical reset and shall be
mounted in switchyard relay panels. At least 2NO + 2NC spare
contacts shall be wired to terminal block after fully utilising for control,
protection, annunciation, etc.,
7.8.11 It shall be possible to control (including synchronising) all the 400 kV

switchyard breakers and isolators from SCADA .
7.8.12 Relay setting calculations shall be furnished by the Contractor to the

Owner for his approval.
7.8.13 All main protections shall be of numerical type. The functional

requirements and characteristics of the relays specified are the
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minimum required. The responsibility of establishing the equivalence or

superiority of relays offered vis-a-vis the stipulation of the specification
rests with the Contractor.
7.8.14 The Contractor shall provide licensed copy of software on CD for relay
setting software and calculations for future use of the Purchaser. Relay
setting calculations shall be furnished by the Contractor to the
Purchaser and the grid authorities for their approvals.
7.8.15 The numerical protection relays shall be able to be configured locally.

For this, Contractor shall provide a laptop and the necessary software
for relay settings, data transfer and parameterization. This laptop shall
be common for SCADA BCU (Bay Control Unit) parameterization and
protective relay parameterization. The configuration/specification of the
laptop shall be the latest as available in the market as on date of supply.
It shall also be possible to configure the SCADA BCUs remotely from
the SCADA Engineering Station.
7.8.16 The relay settings, parameterisation and the retrieval of data from the
relay and relay operations shall be possible from SCADA operator
station in addition to the laptop. The communication between the
numerical relays and SCADA system shall be through serial link with
fibre optic cable connection. The communication protocol between the
numerical relays and SCADA system shall be IEC-61850.
7.8.17 The interlocking scheme shall be hard wired and shall be suitable for
one and a half breaker switching scheme. Contractor shall furnish block
interlock diagrams for the switchyard for Purchaser’s approval. The
scheme as approved by Purchaser shall be provided. All the auxiliary
relays, timers, switches, hardware, etc. required for the scheme are
deemed to be included in the Contractor’s scope.
7.9 Protection Philosophy
The protection philosophy indicated in section D3.6 for Generator

protection shall be followed for switchyard protection as well.
Numerical relays shall be provided for main and secondary protection of

lines, Buses, etc. However, static relays have to be provided for breaker
protection, PT supervision.
(a) The protections envisaged for each 400 kV switchyard bay

are listed below and also in Main one line diagram Drg. No.
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TCE.5960A-EL-SK-2003. It shall be read in conjunction with

the following and all protection indicated shall be provided.
(b) Line Bay Relay panel (Each Line Bay)

(i) Main-1- 3-zone carrier aided distance protection (21-1)
with in-built back-up directional over current and earth
fault protection (67/67N).
(ii) Main-2- 3-zone carrier aided distance protection (21-2)

with in-built back-up directional over current and earth
fault protection (67/67N).
Both main-1 & main-2 protections shall be
mechanically, physically and electrically separated into
two separate and independent systems. Both main-1
and main-2 protections shall work on different
principles/algorithms. 21-1 & 21-2 line protection relays
shall have all the basic protection like SITF, PSB etc.
(iii) Identical distance relays shall be supplied loose for
four (4) 400kV lines
(iv) Fuse fail relay (FFR) for each secondary of CVT /
EMVT
(v) Two stage over voltage relay (instantaneous & time
delayed)
(vi) Stub protection (50STB) as part of main-1 & main-2

protections for 400 kV lines to protect the stub portion
of line bays during line outages
(vii) Distance to fault locator (DFL)

(viii) Fault disturbance recorder (FDR) with 8 analog and 16
digital channels.
(ix) Under voltage relays for live line/dead bus, dead
bus/live line closing and safe grid re-establishment (27-
1, 27-2, 27S)
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(x) Auto reclosing scheme relays with single phase &

three phases reclosing, dead line charging and live line
reclosing.
(c) Busbar Protection Relay Panel

Numerical type, distributed busbar protection scheme based
on”low impedance” principle for selected bus arrangement
shall be provided. It shall have check and discriminating
zones, CT supervision and In-Out switch. Each breaker shall
be provided with its own trip relay. Each trip relay shall be
supervised and contacts shall be made available for
annunciation/SCADA.
(d) Over head line differential protection (between GT HV

bushing & switchyard gantry) (87OH) shall be part of
switchyard relay panel (SRP).
(e) Common Items/protections to be included in all relay

panels
(i) Local breaker back up protection with its own trip relay
(50 LBB for each breaker). LBB in-out switch shall also
be provided.
(ii) Pre and Post close Trip circuit supervision relay for
each trip circuit (98L)
(iii) High speed trip relays (86L).
(iv) Supervision relays for tripping relay (98 LT1 to LTX) to

supervise the coil of each trip relay.
(v) Auxiliary relays and timers in adequate numbers to

make the protection scheme and discrepancy switch
scheme complete.
(vi) Auxiliary CTs and auxiliary VTs with suitable

characteristics and accuracy as required.
f) Reactor Protection
Over Current Protection (50 and 51)
Neutral Over Current Protection (51N)
High Impedance type Differential Protection (87R)
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7.9.1 The functional requirements and characteristics of the relays specified

are the minimum required. Any additional protection considered
necessary by the Contractor shall also be provided by him. The
responsibility of establishing the equivalence or superiority of relays
offered vis-a-vis the stipulation of the specification rests with the
Contractor.
7.9.2 The protective relays shall be of integrated numerical type with serial
interface for communication with SCADA system. The numerical
protective relays shall be based on internationally accepted Open
Protocol IEC-61850. If any of the protections are not covered in the
main numerical relay, separate discrete
numerical/microprocessor/static relays shall be provided. All hardware,
auxiliary relays, timers etc. required for tripping/interlock schemes shall
be provided by the Contractor.
7.9.3 Numerical relays shall have self diagnostics and watch dog feature for
remote annunciation in SCADA. Protective relays shall have adequate
number of site configurable LEDs and output relays. Push buttons for
testing and resetting the LEDs shall also be provided. All protective
relays and meters shall be provided with test terminal blocks for
secondary injection testing of protection relays and meters. In addition
to the contacts required as per the schemes, Contractor shall wire out
to the terminal block at least one NO & one NC spare contacts of each
of the relays.
7.9.4 The protection schemes shall include all the necessary contacts for
interlocks, alarms in SCADA, sequence event recorder wherever
required. Contact multiplication relays for 400kV circuit breakers and
associated isolators shall be provided for this purpose.
7.9.5 All SCADA alarms shall be categorized into different categories

(typically 5). For each category, a different tone shall be sounded on
the hooter and the alarm shall be represented in a different colour on
the screen. All digital inputs shall have a time resolution of 1 (one) ms.
7.9.6 All numerical relays and SCADA clock shall be time synchronised with
the GPS master clock. The contact rating of contactors provided in
SCADA Panels shall be suitable for making/breaking of control circuit
currents of the respective devices being controlled.
7.10 Supervisory Control and Data Acquisition (SCADA) System
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7.10.1 SCADA system comprising of various controls, metering, indication,

annunciation, synchronising, remote control functions, mimic diagram,
sequence of events recording, etc., shall be provided for the
switchyard.
7.10.2 The controller shall be configured with redundant CPU. The redundant
CPU shall be configured to operate as hot standby. The SCADA
system shall be generally in line with the details shown in SCADA
System Configuration Drawing, TCE.5960A-EL-SK-2004. All the
SCADA switches and servers shall be located in switchyard control
room. All SCADA servers & Front End Processor servers (if any) shall
be rack mounted. The Controller shall also be configured with double
redundant power supply units.
7.10.3 The switchyard equipment shall be remote controlled from Central

Control Room (CCR) of the Power Plant through the SCADA HMI in
order to enable the Switchyard Control Room being totally un-attended.
7.10.4 The SCADA system shall be based on a de-centralised concept with

bay oriented distributed intelligence devices, for safety and availability
reasons. The offered SCADA system shall be of latest state of art
design with capability to interface with bay control units (separate for
each bay). The offered SCADA system shall be based on
internationally accepted Open Protocol IEC 61850, Scalability and
Open Architecture.
7.10.5 The communication between the numerical relays and SCADA system
shall be with fibre optic cable.
7.10.6 SCADA system shall be fail safe design. The Contractor shall furnish
documents to establish and prove that the system is highly reliable with
very high MTBF (Mean Time between Failures).
7.10.7 One (1) no. Operator Station(OS) for SCADA (for control and
monitoring of complete 400 kV switchyard equipment) shall be located
in Central Control Room (CCR) of power plant and one (1) no. in
Switchyard Control Room. One (1) no. Engineering Station shall be
provided in the Switchyard control room to make the SCADA
configuration changes and system settings. The Engineering
Station(ES) located in Switchyard control room shall also be configured
as Operator Station to act as standby in case of failure of the Operator
Station in Switchyard control room. The OS and ES display/monitors
shall be dual headed, 24 inches size, LCD type and the make shall be
finalised during detailed engineering so as to match with those
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provided for Main Plant DCS. In the CCR, necessary printers as

shown in SCADA Configuration Drawing shall also be provided for
SCADA system. All printers shall be equipped with USB port and
enough USB cables (minimum 5m length) to enable the printers to be
placed in a convenient location. It shall be possible to configure the
printers to print on demand/online or at specified intervals. Control
room furniture for mounting the operator station along with 3 nos.
chairs shall be provided in the switchyard control room. The console
on which the operator station is mounted shall be properly ventilated
(forced cooled if required).
7.10.8 The control location for the switchyard equipments shall be Switchyard
control room by default. But provision shall be made available in the
SCADA to control the switchyard equipments from Centre control room
(CCR) also. It shall not be possible to control the switchyard
equipments from both the locations simultaneously. The required
selection shall be provided in the operator station of Switchyard control
room.
7.10.9 Information exchange shall be provided from SCADA to plant DCS

through suitable, fast, reliable and redundant serial communication
interface.
7.10.10 Synchronising facility shall be provided for all lines in SCADA. In check
synchronising position, the synchronising criteria shall be fulfilled as
indicated by the closing permissive provided by check synchronising
relays in-built in BCUs (separate sync check relays are not envisaged).
In dead bus/line mode, closure is possible only if either the line or the
bus is dead. The synchronising of the line shall be possible through
both main breaker and the middle breaker. Display of voltages and
frequencies of incoming and running supplies, synchroscope and the
sync. permissive signal shall be simulated in the SCADA operator
station. The synchronism and energizing check functions shall be bay
oriented and distributed to the bay control units and/or protection
devices. All features shall be available viz. a) Setting voltage, phase
angle, and frequency difference b) Energizing for dead line - live bus,
live line - dead bus or dead line – dead bus with no synchro-check
function c) Synchronising between live line and live bus with
synchrocheck function. The correct voltage for synchronizing and
energizing is derived from the auxiliary switches of the circuit breakers
and the isolators and shall be selected automatically by the bay control
and protection IEDs. The closing operation of line breaker shall involve
the following steps, viz. a) selection of the breaker to be closed, b)
mode of closing operation i.e. whether both the line and the bus are
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live or only one of them is dead as sensed by voltage relays connected

to the respective CVTs. In live-bus/live-line case, synchronisation
between the two voltages is checked by the check synchronisation
relay which generates permissive only if the synchronisation criterion is
met. If either the line or the bus is dead, the logic develops using the
contacts of bus voltage and line voltage relays which generates
permissive for closing of the breaker, c) issuing the closing command
after obtaining the synchro permissive or live-bus/dead-line or live-
line/dead-bus permissive as the case may be. This permissive shall be
displayed on the SCADA HMI.
7.10.11 The generator transformer main breaker will be controlled from main
plant DCS. It shall be possible to control the middle breaker from both
DCS (through auto/manual synchronisation) and SCADA with the help
of a selection available in the SCADA software. The selection shall
have two positions i.e. “SCADA” and “DCS”. If “SCADA” is selected, all
the required signals including PT signals for synchronising shall be
transferred to SCADA system. If “DCS” is selected, all the required
signals shall be transferred to DCS/GRP (Generator Relay Panel).
The control of middle breaker from SCADA shall be suitably interlocked
such that its closure is not possible when it is used as generator
synchronising breaker.
7.10.12 Transducers shall be provided, wherever necessary, for the indication

of electrical parameters related to switchyard bays as required.
Transducers shall be used only for monitoring of non electrical
quantities such as Bus reactor oil and winding temperature and for
electrical quantities such as battery charger voltage, battery charger
current, 400 kV bus voltages. For monitoring of all other bay wise
electrical quantities, IEDs such as BCUs shall be used. The exact no.
of analog and digital IO (input/output) points shall be dicided during
detailed engineering.
7.10.13 All the auxiliary contacts of main equipment such as circuit breakers,
isolators, earth switches shall be brought to the protection panels for
indications, interlocks, SER function, etc. In case of shortage of
auxiliary contacts, contact multiplying relays shall be used. The same
shall be two coil, latching type with electrical reset and shall be
mounted in switchyard protection panels. At least 2NO + 2NC spare
contacts shall be wired to terminal block after fully utilising for control,
protection, annunciation, etc.
7.10.14 It shall be possible to control and monitor (including synchronising) all

the 400kV switchyard breakers & isolators from SCADA except main
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circuit breakers of generators. Main circuit breakers of generators are

controlled from Central Control Room through Plant DCS and
monitored both in DCS and SCADA. Earth switches shall be operated
only from local but is monitored in SCADA. Isolators and earth switches
pertaining to generator transformer bay shall be monitored both in DCS
and SCADA.
7.10.15 Monitoring – SCADA
a) Indication – status of all breakers, isolators and earth switches of

all 400 kV bays, local/remote selector switch positions,
synchronising switch positions, voltage selection, Auto re closing
selection, selection of control from SCADA/DCS, etc. shall be
available in SCADA. The selection of control of middle breaker of
generator bay from DCS/SCADA shall be displayed both in DCS
and SCADA.
b) Abnormal conditions to be considered for alarm inputs are
400 kV system operation of each line protection, Busbar

protection, Trip circuit unhealthy of each equipment, protection
unhealthy of each equipment, Trip relay unhealthy of each
equipment, VT circuit unhealthy of each VT, LBB operation of each
breaker, DC supply failure of each protection / control scheme as
appropriate, wrong selection of PT supply, abnormal conditions of
breakers, successful /unsuccessful auto reclosure, DC & UPS
system alarms, etc. The alarm states are not exhaustive. The
Contractor shall include all alarm states deemed necessary for the
safe operation of the system.
c) Event register with time stamping – Opening or closing of all

breakers, isolators and earth switches, opening and closing
commands, change of positions of switches such as Local/Remote
selection, synchronising selection, voltage selection, auto re-
closing selection, selection of control from SCADA/DCS, operation
of all protection and trip relays, VT fuse fail relay operation, auto
re-closing operation, direct trip send and receive, pole discrepancy
relay operation, trip circuit faulty, trip relay faulty, DC supply fail,
SF6 pressure Low, LBB operated, etc. shall be available in
SCADA. As stated at b) above, this list shall include all events and
operation of switchyard equipment that are considered essential
for analysis of faults.
7.10.16 Mimic
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A mimic diagram depicting the entire electrical system being

controlled from the system with different colours for different voltage
levels shall be provided in SCADA operator stations. The colours of
different voltage levels shall be as per relevant IS applicable for mimic
on panels.
7.10.17 Measurement
The measurement requirements for each of the bays shall be as per

the Main one line drawing TCE.5960A-EL-SK-2003 and as given
below:
Feeder Description DCS Operator Station
(a) GT bays V (All phases)

A (All phases)
MW
MVAR
Tap position, Winding
& Oil temperature
TVM
(b) 400 kV line bays V(All phases)
A(All phases)
MW
MVAR
MWH
MVARH
TVM
(c) 400 kV Bus PT V(bus 1&2)
F(bus 1&2)
7.10.18 Event logging and trending facilities shall be provided in SCADA system.
It shall be possible to trend different parameters on the same trend. It
shall be possible to store historical data for a minimum of two years.
SCADA system shall have provision for expansion and shall be capable
of communicating with other systems through open protocol.
7.10.19 The Contractor shall make provision for terminating 4-20 mA analog
signals and potential free digital signals for the following data on a
terminal block in a suitable interface panel located in switchyard control
building for transmission to SLDC (State Load Despatch Centre) and
RLDC (Regional Load Despatch Centre) through RTU (Remote
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Transmission Unit). The energy meters(EM) shall not be connected to

the RTU’s. The specification of RTU provided for this purpose by the
Contractor shall be subject to approval by the SLDC/RLDC authorities.
The actual data to be transmitted to SLDC/RLDC shall be finalised
during detailed engineering and the following is the minimum data to be
transmitted through RTU.
• MW and MVAR of all lines

• MW and MVAR of HV side of all generator transformers
• Voltage and frequency of 400 kV buses
• ON/OFF positions of all breakers and isolators of all line bays,
Generator transformer bays, Bus PT bays.
• Tap positions of GTs & UATs
7.11 Bay Control Unit (BCU)
a) The BCU shall be an intelligent unit and shall be state of the art
technology. It shall perform control functions in accordance with
control commands from SCADA and shall also do monitoring of the
respective bays. The BCUs shall be installed in the respective
protection panels of each circuit breaker in the switchyard relay
room (Outdoor Kiosk). The control voltage for the BCU shall be
220V DC. The degree of protection of the panel shall be IP-52. The
BCU shall comply with relevant IEC/BIS standards.
b) BCU shall have adequate number of ports for communication and

interface with switchyard control system for bay control and
monitoring. The BCU shall provide direct connection to the
switchyard equipment for control (with or without interposing
relays) and shall perform control and monitoring functions,
including live-line/dead-bus, dead-line/live-bus and live-line/live-
bus breaker closing. The communication link between BCU and
SCADA shall be redundant. The BCUs shall be independent of
each other and functioning shall not be affected by any fault
occurring in any of the other BCUs.
c) Protection relays shall be separate and shall not be part of BCU.

Direct hard wiring shall be employed for critical tripping. Numerical
protection relays shall also be connected to the SCADA bus for
retrieval of data.
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d) Atleast one bay control unit (BCU) shall be provided for each
breaker. The analog and digital signals pertaining to a circuit shall
be taken through the BCU provided for that circuit.
e) One no. licensed software for configuration and parameterization

of SCADA shall be delivered on CD along with BCUs. The
configuration shall be carried out from local or from laptop
computer but operation shall be from SCADA operator station.
Configuration of BCUs shall also be possible from remote through
engineering work station. The lap top computer provided for the
switchyard shall be loaded with this software.
f) The BCU shall have at least the following features:
i) Monitoring
The following monitoring functions shall be provided as a
minimum :
• Status monitoring and failure monitoring (in SCADA HMI)
of bay equipment like breaker, isolators, earth switches,
instrument transformers, protection relays and ancillary
equipment metering (measured-value acquisition)
• Signal and command indications
• Switching statistics in BCU (breaker ON/OFF, breaker
auto-reclose, pole discrepancies) and data stored in
SCADA server
• Energy metering values
ii) Control
The following control functions shall be provided as a
minimum:
• Control of circuit breakers and isolators
• Interlocking for isolators and circuit breakers, isolators and
earth switches (The interlocks for earth switches shall be
hard wired)
iii) Recording
The event recording function shall be provided and processed
in the BCU and the record stored in SCADA. Each BCU shall
contain an event recorder capable of storing at least 200 time
tagged events.
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iv) Human Machine Interface (HMI)

Following local human machine interface inbuilt in BCU shall
be provided as a minimum :
• The local HMI is a monitoring and maintenance tool for
bay control unit and data communication unit during
commissioning and/or maintenance.
• Position of switching elements (Feeder control diagram)
shall be shown on the graphic display.
v) Time Synchronizing Feature

• BCU shall be time synchronized with GPS based Master
Clock of the Facility
vi) Self diagnostic and Supervision Features

• BCU shall have self diagnostic and supervision features.
Failure of IEDs connected to the SCADA System such as
BCUs, Numerical Relays and Tariff Meters shall be
indicated in the SCADA HMI
vii) Operating Mode Selection

• Operation mode selection (local or remote) shall be
provided in BCU.
7.12 Bay Marshalling Box(s)
Adequate number of outdoor mounted, free standing type, power

coated bay marshalling boxes shall be provided in switchyard. The pre-
treatment of the sheet steel shall involve degreasing rust/scale removal,
phosphating and oven drying. The phosphate coating shall be sealed
by the application of two coats of ready mixed, stoving type zinc
chromate primer followed by two coats of synthetic enamel paint by
powder coating process. The paint shade of the panels shall be Opaline
Green(external) and semi glossy white(Internal). Bay marshalling box
shall be provided with two subsections namely: Terminal box and
auxiliary supply distribution box.
(a) Terminal box: Providing intermediate termination of all auxiliary

contacts of breaker, isolator and earthing switches (whether
used or not) and preparing interlocking. (CT & PT marshalling
boxes shall be provided with respective CTs & PTs.)
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(b) Auxiliary supply distribution box from where both AC auxiliary

supply, heating/lighting supplies and DC auxiliary control supply
shall be distributed to various motors of all CBs, isolators/
earthing switches local marshalling box/equipment marshalling
box and heating and lighting supply to various bay marshalling
boxes. The marshalling boxes shall be provided with doors on
both sides with key lockable handle for each door. The key
shall be removable only in door locked position.
All auxiliary contacts of the CBs, isolators and earthing switches shall
be terminated in terminal box section of bay marshalling boxes. All
hardwired interlocking shall be wired in the above box. All auxiliary
contacts and interlocked scheme contacts shall be wired to respective
panels in the control room.
Provision for terminating two number of 3 phase, 3 wire AC 50 Hz

power supply called supply I & II, shall be provided in each auxiliary
supply bay marshalling box. The AC distribution scheme shall be wired
to manually select any one of the supplies by manually operated
selector switch. After the manual selector switch, MCB controlled AC
distribution shall be provided in such a way that individual and radial
feeder supplies to driving mechanism/motor of every equipment is
arranged. Contacts for remote alarm for supply fail shall be provided.
Similarly provision for terminating 2 Nos. DC supplies and selection
feature to select any one of the two supplies as supply-I and other as
supply II shall be provided. Either of them shall be used after
distributing it via suitably rated HRC fuses to feed, control supply of all
isolators and earthing switches. Remote independent alarm for failure
of all AC and DC outgoing feeders shall be provided by supply
supervision relays having delayed dropout NC contact.
Single phase 230V heating and lighting supply shall be provided in a

loopin / loopout mode at bay marshalling box. The heating and lighting
supply shall be sub-distributed in radial way to provide heating and
lighting supplies for all HV equipment marshalling boxes and each bay
marshalling box.
The scheme for all protections, controls, indications, interlocking,

metering, AC and DC distribution and all other schemes shall be
prepared in such a way that cables shall be laid in radial pattern. Loop
formulation of cables shall be completely avoided.
Neutral of all cores of CTs, CVTs and EMVTs shall be formed in

marshalling box of the respective equipment. Cables with sufficient
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number of cores are run from these marshalling boxes to control and
relay panels as appropriate. The neutral of CTs, CVTs, EMVTs shall be
earthed only at control/relay panel by means of a disconnecting link.
7.13 DC Distribution Philosophy for Controls, protection, Indication,

Annunciation, Fault-Recording and Event Recording Systems
The DC distribution scheme in various panels shall be prepared based

on following DC distribution philosophy for various functions.
(a) Protective Functions
Two nos. DC supplies shall be arranged from two sections of

switchyard DCDB to each of the protection panels. These
supplies shall be taken through a selector switch with three
positions, viz. independent, source-1 & source-2. In the
independent position main-1 & main-2 protection systems will be
fed by source-1 & source-2 respectively and the common
services from any one of the sources. In case of failure of any
one source (say source-1), the switch shall be changed over to
the other source (source-2) and complete DC supply
requirement of protection panels will be fed from the other
source. DC auxiliary supply shall be supervised by supply
supervising relays. The NC contact of the relays shall be
delayed on drop off by approximately 100 to 200msec for
annunciation in SCADA. The selector switch and the fuses shall
be mounted inside the panel. These DC supplies shall be
separated from DC supplies in the control panel by provision of
interposing relays (IPRS) in protection relay panels.
(b) Similarly, Bus bar protection scheme and indications shall be

provided with two (2) nos. of 220V DC supplier through three (3)
position selector switch fused and supervised by supply
supervision relays having time delayed drop off type NC contact.
Loss of supply shall be wired for annunciation at SCADA
indication and annunciation supplies shall be separately fused.
The selector switch and fuses, etc. shall also be mounted

internally inside the panel.
(c) Control Functions
Control circuit of each breaker circuit will be provided with 2

independent 220V DC control supplies. Each of the above
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feeders shall be fed from separate section of DC board.

Manually operated 8 pole, 3 position selector switch for positions
called source I, independent and source II shall be used to select
any one as closing/synchronizing and trip coil I supplies and
other as trip coil II and auxiliary supply for contact
multiplication/follower relay supplies, etc. Each incoming supply
before select switch and outgoing supply after selector switch
shall be separately fused and supervised by supply supervision
relay having time delayed type “NC” contact. Loss of supply
shall be wired for annunciation at SCADA. The DC supplies shall
be isolated from DC supplies in relay panels as specified in a)
above.
One separate 220V DC annunciation supply for upto half number

of the control panel shall be provided. Remaining half shall be
supplied by separate but similar 220V DC supply. The Contractor
shall tap annunciation supply through fuses and after supervision
relays use it for all annunciation in respective panels. The
supervision relay shall have time delayed drop off type NC
contact for annunciation, failure of annunciation supply shall also
be combined and annunciated on 230V AC operated
annunciation system. In turn the failure of AC annunciation
supply shall be annunciated in normal DC operated annunciate.
It shall all be provided with additional contacts for event
recording and remote annunciation.
d) The RTU’s and the PLCC located in the Switchyard control room
for SLDC/RLDC shall be provided with 48V dual DC supply.

The specific requirements listed in Sec. D3.6 for generator protection
shall apply for switchyard protection system also in addition to the
following:
(a) The panels shall have a degree of protection not less than IP-
52 and shall be fabricated with 3 mm thick cold rolled sheet
steel for front and rear equipment bearing surfaces and
bottom gland plates, and 2.5 mm for sides and top. The doors
and removable covers shall be gasketed. The panels shall be
provided with anti vibration pads. The paint shade of panels
shall be of shade opaline green (External) and semi-glosy
white (Internal).
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(b) The pre-treatment of the sheet steel shall involve degreasing

rust / scale removal, phosphating and oven drying. The
phosphate coating shall be sealed by the application of two
coats of ready mixed, stoving type zinc chromate primer
followed by two coats of synthetic enamel paint by powder
coating process. The paint shade of panels shall be of shade
opaline green (External) and semi-glosy white (Internal).
(c) All relays and measuring instruments shall be flush mounted

type & the equipment on the front of panel shall be flush
mounted.
(d) The centre line of switches, push buttons and indicating lamps
shall be not less than 750 mm and centre lines of relays,
meters and recorders shall not be less than 450 mm from the
bottom of the panel. Control switches / push buttons /
selectors and relay resetting knobs shall be located at a
height between 1.0 m and 1.2 m from the bottom of the panel.
(e) No auxiliary relay shall be mounted on front of the control

panel. They shall be mounted either internally or on the
respective relay panel.
(f) All the internal wiring shall be carried out with 1100V grade
stranded copper conductor wires with PVC insulation. For CT
/ PT circuits the wire size shall be 2.5 mm2 / lead and other
circuits it shall be 1.5 mm2 / lead. All wiring meant for power
supply to transducers, recorders shall be suitably MCBs or
designed to limit short circuit currents. Means for detection of
blown or open circuited fuses shall be provided.
(g) Terminal blocks shall be 650V grade, 10 amps rated, stud

type terminals with terminal marking. The insulation between
any two terminals and terminal to framework shall withstand
2 kV rms for one minute. Terminal blocks for CT & VT
secondary leads shall be disconnecting, stud type. Terminal
blocks for SCADA control commands shall be of
disconnecting type. Terminal blocks for SCADA digital inputs
shall be with knife type isolation. CT secondary leads shall
also be provided with short circulating and earthing facility. A
clearance of 250 mm shall be maintained between terminal
blocks and gland plate and 150 mm between two rows of
terminal blocks. At least 20% spare terminals shall be
provided.
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(h) Provision shall be made to mount Tariff meters supplied by

grid in the switchyard itself in the grid tie lines as per
requirement of grid authorities.
(i) All indicating lamps shall be of self-coloured clustered LED

type of size 22.5mm. Colour of the lamps shall be different for
different purposes.
(j) All the push buttons shall be momentary contact type, the
colour of PBs shall be different for various functions. Push
buttons shall be suitably shrouded to prevent inadvertent
operation. All PBs shall have 2 NO + 2 NC contacts.
(k) Each of the control & relay panels shall be provided with
thermostat-controlled space heaters, CFL type cubicle
illuminating lamps and a 5A, 3 pin receptacle.
(l) Each control & relay panel shall be provided with necessary
arrangement for receiving, distributing, isolating and short
circuit protection by use of MCBs/MCCBs of D.C. and A.C.
supplies for various control, signalling, lighting and space
heater circuits.
(m) If miniature circuit breakers (MCBs) are used in VT secondary

circuits, they shall have adequate auxiliary contacts for
blocking trip circuits of voltage dependent protection and
annunciation. Where high-speed protections are involved, the
speed of operation of MCB shall be less than 5 milli seconds.
(n) All the panels shall be equipped with a continuous earth bus
with connectors and clamps between panels for interpanel
connection of the earth bus. All the metallic cases of relays,
instruments and other panel-mounted equipments shall be
connected to the earth bus by 2.5 mm2 copper wires. CT and
PT secondary neutral or common lead shall be earthed at one
point only at the terminal block and such earthing shall be
made through links. Separate copper earthing flat shall be
provided in the panel for cable screens of static equipment.
(o) All PT circuits shall be provided with HRC fuses having

special holders such that they cannot be interchanged with
other types of fuse holders and other fuse holders cannot be
inserted into them.
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(p) Tests
(i) relay panels shall be subject to the

following tests :
• Mechanical operation test

• High voltage test (2000V for 1 minute)
• Megger test
• Verification of wiring as per approved
drawings
• Electrical control, Interlock and sequential
operation tests
(ii) Type tests and routine tests
Type tests and routine tests shall be carried out on all

associated components / equipment as per relevant
standards and test certificates shall be furnished.
(III) Acceptance Tests

• The equipment shall be demonstrated for proper
operation, including operation of meters, relays,
alarms and indications.
• Certified copies of all type and routine test certificate
shall be submitted for the Owner’s approval before
dispatching the control / relay panel.
7.15 Fault Disturbance Recorder
7.15.1 Stand alone Fault Disturbance Recorder with associated cabling, PC,
HMI, Printer and evaluation software shall be provided for the 400 kV
Switchyard. The HMI and PC loaded with evaluation software shall be
located in Switchyard Control Room/Central Control Room. It shall have
8 analog and 16 digital channels. The equipment shall be complete with
disturbance recorder, control / display unit, junction box and accessories
like auxiliary CTs and shunts.
The FDRs shall be modular and shall be suitable for expansion.

Provision shall be made to synchronise the electronic clock of each
disturbance recorder with external master clock which GPS based.
Also, a number of disturbance recorders in the particular location shall
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be capable of being synchronised with any one of the recorders as

master.
7.15.2 Specific Requirements of the Equipment
(a) The microprocessor based fault recorder shall be designed to

continuously monitor analogue, digital signals and contacts of all
protective / lockout relays. Recording shall be self started or
triggered by dI / dt, dV / dt, or change of state of any of the digital
input signals. The data acquisition unit of the fault recorder shall
be provided with self-test diagnostic feature, which annunciates
and alters the operator to rectify the defect or fault, if any.
(b) The number of channels / recorders offered shall cover the

following:
(i) Analog channels: (a) Currents in 3 phases and neutral

(b) Voltages of 3 phases and their vector sum wherever
VTs are provided.
(ii) Digital channels: Protective relay contacts, lock out relay

contacts, breaker contacts. The total number of channels
offered shall be such that 20% spare channels are
available.
(iii) The fault recorder and all its peripherals shall be designed
for operation on 220V DC. Recorders shall be provided
with pre-history recording feature with pre-history
recording time not less than 0.5 or 1 sec. The sampling
rate of the wave shall be between 1.2kHz to 10kHz.
(iv) Auxiliary CTs while catering for the required VA burdens

shall not saturate under maximum fault current conditions.
Auxiliary multi ratio PTs shall be provided to facilitate tap
selection in voltage signal recording. The accuracy of
analog channel recording shall be less than +3% for
current channels and +1% for voltage channels.
7.16 Synchronising Scheme
The closing schemes of the CB shall be prepared and wired in such a

way that only one CB is selected at a time for synchronising. It shall be
possible to bypass synchronising relay only through a bypass switch
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and under voltage relays to sense dead-line / live-bus and live-line /

dead-bus conditions. While preparing the scheme, it shall be noted that
key operated auto / off / manual selector synchronising switch provides
command from control panel. The synchronising and guard relay
scheme shall be designed in such a way that when closing impulse is
given, the CB can be closed only after the operation of synchronising
check relay. If closing impulse is initiated before synchronising check
relay operates, the CB shall not be closed on operation of the check
relay.
Live line-dead bus and dead line / live bus closing facility shall be
provided using dedicated relays on CVT. The closing shall be possible
only in manual position of synchro selection switch.
Live-line / dead bus and dead-line / live-bus relays shall be one set per
CB.
Isolating transformer shall be provided in each incoming AC and

running AC potential circuit of the synchronising scheme. The technical
details of each isolating transformer shall be 30 VA, 110 / 110V with
accuracy class of 0.5
All AC circuits, DC power supply, synchronising check relay permissive

output contact and synchronising check relay indicating lamp contacts
shall all be switched to respective circuit after synchronising selection
scheme for any equipment is switched on. After synchronising
selection is switched on, all synchronising indicators (e.g., double
voltmeter, double frequency meter, synchroscope, bright lamps, etc.)
synchronising check relay, live line / dead bus, dead line / live bus and
guard relay outputs shall all be started and permissive conditions be
generated for closing the respective circuit breaker.
7.17 Sequence of events recording System (SER)
7.17.1 The SER system shall be a part of SCADA system. SER shall be
designed with 1 ms resolution for digital input events with time stamping
from each phase of all breakers, isolators and earth switches, opening
and closing commands, change of positions of switches such as
Local/Remote selection, synchronising selection, voltage selection,
auto re-closing selection, selection of control from SCADA/DCS,
operation of all protection and trip relays, VT fuse fail relay operation,
direct trip send and receive, pole discrepancy relay operation, trip
circuit faulty, trip relay faulty, DC supply fail, SF6 pressure Low, LBB
operated, etc. shall be available in SCADA. Critical interlocks and
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those SER points which are not covered by numerical relays shall be
hard wired to SCADA. The chronological printout facility shall be
provided for any of the first 100 occurrences. Further occurrences shall
be printed chronologically. This list is only indicative and not
exhaustive. The clock shall have resolution of 1 ms and first up feature.
It shall be possible to synchronise the clock with an external master
clock.
7.17.2 The event recorder shall be suitable for operation on 220V DC supply.
7.18 PLCC System
PLCC system shall be provided for four nos. of 400kV outgoing lines.
100% redundancy shall be provided in hardware for protection
signalling. 1 no. dedicated channel shall be provided for speech/data
necessary hardware & software & accessories shall be included,
however exact requirement of APTRANSCO grid authorities shall be
intimated to successful bidder.
7.19 Control, Indication, Alarm and SER Points

7.19.1 Minimum electrical requirements in respect of control, monitoring
measurement, annunciation, synchronising are indicated in I&C system
section D2.4.
7.20 ABT Metering System
7.20.1 ABT compliant energy meters for main & check with accuracy class of
0.2S shall be provided with suitable communication port for interfacing
the same with SCADA system. In SCADA system separate work station
shall be provided for accessing the Energy Meter readings. Separate
core for main & check tariff metering with 0.2S accuracy class shall be
provided for all the lines. Energy meters must be provided with a pair
of suitably rated potential free contacts to generate signal for
annunciation and SCADA, if voltage supply to the meters are
interrupted. Provision shall be made to amount Tariff meters supplied
by grid in the switchyard itself in the grid tie lines as per requirement of
grid authorities.
7.21 Test & Test Reports
7.21.1 The Contractor shall conduct all the routine, type and acceptance tests
as per the relevant standards and as specified in this specification in
the presence of the Owner. The test certificates shall be furnished for
Owner’s approval.
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If, in case of circuit breaker, isolators, current transformers, voltage

transformers, lighting arresters insulators strings, bus post insulators,
control & relay panels and other components of all the main equipment
type tests are already conducted on identical equipment to the one
offered and found to be acceptable, such tests will normally be waived.
However if due to any reason Owner requires the same to be
conducted again, conducting the tests are included in the scope. In
case of hardware such as clamps the temperature rise test material
composition test and mechanical test shall be conducted on one
sample of each type even if test reports are already available.
Disturbance recorder shall comply with the test requirements as per
IEC-60255-5&6.
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1.0 400 kV SWITCHYARD
1.1 Nominal voltage kV 400 kV
1.2 Highest System voltage kV 420 kV
1.3 Short circuit breaking current kA 50 kA for 1 sec.
1.4 Making current kA 130

(peak)
1.5 Impulse withstand voltage kV 1425

(Peak)
1.6 One minute power frequency kV (rms) 630

withstand voltage
o
1.7 Reference ambient temperature C 50
1.8 Creepage distance mm 31 mm / kV based on highest

system voltage
1.9 Clearances
i) Phase to phase mm 4200
ii) Phase to earth mm 3400
iii) Sectional clearance mm 6500
iv) Ground clearance mm 8000
2.0 400 KV CIRCUIT BREAKERS
2.1 Type SF6
2.2 Execution of poles Nos. 3 nos., single pole
2.3 Rated current A *
2.4 Operating duty O-0.3 sec-CO-3 min-CO

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2.5 Auto Reclosing - Required
2.6 First pole clear factor 1.3
2.7 Breaker opening time m.sec. *

Breaker closing time m.sec. *
2.8 Line charging breaking current A *
2.9 Small inductive current breaking From 0.5A to 10A
2.10 Type of operating mechanism Spring / Spring charged
2.11 Operating mechanism to be 1 Phase operation

suitable for
2.12 (a) Control voltage 220V DC
(b) Spring Charging 220V DC
2.13 No. of trip coils per pole Nos. Two (2)
2.14 Phase to phase spacing 4200 mm
2.15 No. of auxiliary contacts 15 NO + 15 NC (minimum)
2.16 SF6 Gas filling plant Not required
2.17 Gas evacuation and filling unit Required
2.18 Cantilever strength kgs 600
2.19 Out of phase switching Required.
3.0 400 kV ISOLATORS
3.1 Type Horizontal centre break /

Pantograph type
3.2 Reference standard IS 9921

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3.3 Rated current A *
3.3 Insulation Test values
3.4.1 One minute P.F wet withstand

voltage
(a) Between poles and earth kV(rms) 1425
(b) Across isolating distance kV(rms) 1425
3.4.2 Impulse withstand voltage
(a) Between poles and earth kVp 1050
(b) Across isolating distance kVp 1200
3.5 Material of main contact Cu
3.6 Whether contacts are to be silver Yes

faced
3.7 Insulators
3.7.1 Codes and Standards IS 2544
3.8 Operating mechanism (motor/

manual)
3.8.1 Main blade Motor & Manual
3.8.2 Earth blade Motor & Manual
3.9 Insulation Data
3.9.1 Minimum cantilever strength kg 600
3.10 Miscellaneous
3.10.1 Auxiliary supply
(a) Electrical 220V DC for control and interlock;

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400V AC, 3 phase for motor drive
For both Electrical and manual
operation.
3.10.2 Type of interlock Bolt interlock electrically operated
3.11.1 Insulators IS : 2544
3.11.2 Isolators IS : 9921
4.0 400 kV CURRENT TRANSFORMER
4.1 Type Outdoor, SF6/oil filled hermetically

sealed with SS bellow
4.2 No. of cores Refer Main one line
4.3 Primary current ratio diagram Drg. No. TCE.

5960A-EL-SK-2003
4.4 Secondary current A 1
4.5 Class of insulation Oil immersed Class A

0
4.6 Maximum temp. rise of winding C 500 C
above ambient of 50°C
4.7 Cantilever strength of CT at the kg 600

terminal
4.8 Applicable Standards
4.8.1 Current transformers IS 2705
4.8.2 Insulating oil IS 335
4.8.3 Bushings IS 2099
4.8.4 Large hollow porcelains IS 5621

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4.8.5 Insulators IS 2544
4.8.6 Hot dip galvanising IS 2633 and IS 2629
5.0 400 kV CAPACITOR VOLTAGE TRANSFORMERS / EMVT
5.1 Type EMVT: Outdoor, oil filled/ SF6 gas

filled, hermetically sealed
CVT: Oil filled only
5.2 System neutral earthing Solidly earthed
5.3 No. of primary / secondary

windings Refer Main one line
diagram Drg. No. TCE.
5.4 Primary / secondary winding voltage 5960A-EL-SK-2003
5.5 Class of insulation Oil immersed Class A
5.6 Maximum temp. rise of winding 50°C

above ambient of 50°C
5.7 Cantilever strength of CVT at the 600 kg

terminal
5.8 Rated voltage factor 1.2 continuous and 1.5 for 30

seconds
5.9 Rated capacitance Contractor to furnish depending

upon frequency selected for
PLCC
5.10 Tolerance + 10% to – 5%
5.11 High frequency range k.Hz 40 – 500
5.12 High frequency capacitance
- For entire carrier frequency Within 80% to 150% of rated

range capacitance

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- Equivalent series resistance over Less than 40 ohm
the entire carrier frequency
range
5.13 Stray capacitance and conductance

of low voltage terminal
- Stray capacitance of low voltage 300 + 0.05 Cn Pf, Where Cn is

terminal over entire carrier rated capacitance
frequency range
- Stray conductance of the low mho 50
voltage terminal over entire
carrier frequency range
5.14 Corona extinction voltage kV 320
5.15.1 Voltage transformers IS 3156
5.15.2 Insulating oil IS 335
5.15.3 Bushings IS 2099
5.15.4 Large hollow porcelains IS 5621
5.19.5 Insulators IS 2544
5.19.6 Hot dip galvanising IS 2633 and IS 2629
6.0 360 KV LIGHTNING ARRESTORS
6.1 System Earthing Solidly earthed
6.2 Type of arrester Metal Oxide Gapless
6.3 Discharge class 20 kA, Class - IV
6.4 Minimum cantilever strength of kg 600

arrestor assembly
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6.5.1 Lightning arrester for alternating IS - 3070 and IEC - 60099

current systems
6.5.2 Insulators IS - 2544
6.5.3 Large Hollow Porcelain insulators IS – 5621
7.0 INSULATOR
7.1 Type Solid core / post type / string
7.2 Cantilever strength kg 600 kg minimum for bus post

insulator.
7.3 Puncture voltage 1.3 times corresponding flash

over voltage.
7.4 Applicable standard
7.4.1 Post insulators IS 2544
7.4.2 Suspension insulators IS 731
7.4.3 Insulator fittings IS 2486
8.0 BUS CONDUCTORS, CLAMPS & IS 5561

CONNECTORS
AAC, ACSR conductors IS : 398
Copper conductors IS : 282
Galvanisation of steel wires IS : 4826
Copper tubes BS : 159
Aluminium / Aluminium Alloys Bars, IS : 5082

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Rods, Tubes, Sections for Electrical
Purposes
Fittings for Aluminium and steel IS : 2121

cored aluminium conductors for
overhead lines
Electric power connectors IS:5561

Hot dip galvanised process IS : 2629 & 2633
9.0 LINE TRAPS
9.1 Installation Outdoor
9.3 Type of earthing Effectively earthed
9.6 Line trap arrester discharge current kA 20
9.7 Band width kHz 40-500
9.8 Tuning device required Required
9.9 Maximum tapping loss dB 2.6
9.10 Type of tuning Wide band
9.11 Winding material Copper
9.12 Line traps IS : 8792, IEC :60353
9.13 Methods of test for line traps IS : 8793, IEC:60353

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SECTION: D3.8
ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD.
SHEET 1 OF 10
ELECTRICAL SYSTEMS – SPEC. NO.
GENERATOR CONTROL PANEL TCE.5960A-H-500-001
8.0 GENERATOR CONTROL
8.1 The control, monitoring, measurement, annunciation, synchronising and

sequential event logging for each generator and its subsystem shall be
provided on the Operator stations (plant DCS through HMI).
Synchronising, essential controls and annunciation shall also be
available from the Generator control panel (GCP).
8.2 Generator and Auxiliary Power Supply System Control & Monitoring
8.2.1 Provision in the plant control system shall be made for the starting,
bringing upto rated voltage and speed, initiation of synchronising,
operation and annunciation on GCP and monitoring, alarm, data logging,
recording and sequential event recording for generator and its excitation
system from the Operator stations (plant DCS through HMI). The
minimum requirements of the measurements are indicated in the Main
One Line Diagram drg no. TCE.5960A-EL-SK-2003.
8.2.2 In the GCP, the mimic of the generator, its subsystems and 6.6 kV &
400V auxiliary power supply system shall be provided.
8.2.3 Synchronising equipment consisting of Auto synchroniser, double

voltmeter, double frequency meter, synchroscope, check synchronising
relay, synchronising lamp, etc., shall be provided in the hardwired GCP
as follows:
(a) One No. of synchronising panel/trolley shall be provided through

which the synchronising of all the GCB & breakers in 400kV
switchyard can be synchronised (GCB in the case of GTGs and 400
kV GT breakers in the case of STGs) by plugging the control cable
into a socket provided on each Control panel of the respective
breaker. This synchronising trolley shall have all the necessary
equipments & meters for carrying out the manual synchronisation.
The raise/lower commands for the same also be done through the
trolley itself.
(b) Auto synchroniser relay for generator (25A): The Auto

synchronising facility shall be made available to auto synchronise
the above breakers through DCS. Auto synchronisers shall
connect the generators to the 400 kV grid either through generator
circuit breaker or 400kV generator transformer breakers
automatically after synchronising the two systems. The equipment
shall be supplied to control both the voltage and frequency of
turbine generator set to match with those of the grid.
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8.2.4 Manual synchronising facility common to all the units shall be provided
for manual synchronisation of the generators. Remote/Manual selection
shall be provided in DCS. When the “Remote” mode is selected,
synchronising shall be initiated from DCS through auto synchroniser.
When the “Manual” mode is selected, synchronising shall be done from
the stand-alone synchronising panel which houses the required
synchronising gear (consisting of dv & df meters with associated
transducers, synchroscope, check synchronising relay, guard relay,
synchronising lamp, etc.), breaker selector switch, breaker control
switches, etc. The synchronising panel shall be located in the control
equipment room.
8.2.5 Hard wired emergency trip push buttons for tripping of generator circuit
breakers of GTGs shall be mounted on the operator console. The push
buttons shall be suitably protected to prevent inadvertent operation.
8.2.6 The 400kV system controls shall be implemented in an independent

SCADA system. However, the 400kV system SCADA shall be interfaced
with the plant DCS through serial link for monitoring of 400 kV system
from DCS. Further, the status of generator circuit breakers, 400 kV
generator transformer breakers along with grouped alarms of generator
and generator transformer shall be made available for
indication/annunciation in 400kV system SCADA switchyard Control
Room as well as main control room.
8.2.4 The GCP shall be provided with all the synchronising switches, selector
switches, push buttons, indicating lamps as needed for the control of the
systems envisaged.
8.2.5 The interlocks for the auxiliary power supply system shall be hardwired
interlocks.
8.2.6 This shall be read in conjunction requirements with requirements

indicated in I&C Section D2.4.
8.3 CONTROL AND MONITORING IN DCS
8.3.1 Control, monitoring, measurement, annunciation, synchronising of

complete electrical system supplied under this contract shall be possible
from plant DCS system. In case of failure of any OS, it shall be possible
to carry out the necessary operation from one of the healthy OS.
Synchronising, essential controls, metering and annunciation shall also
be available from the Respective control panels for the lines.
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8.3.2 DCS System
Minimum functional requirement of plant DCS system in respect of

electrical system shall be as below:
8.3.2.1 CONTROLS
(i) Control of all the Incomers, bus ties of all the electrical
switchboards except outgoing feeders from the main Lighting
Distribution Board, DCDB & UPS DB, shall be carried out from the
DCS. It shall also have the facility to carryout the live changeovers
at all the switchboards at 6.6kV & 400V. Remote position, service
position, breaker health, permissive for interlock set shall be
considered as input to the DCS system. Synchronising gear shall
be housed in the respective switchboards.
(ii) All transformers with OLTC shall have provision for control viz.
issuing raise / lower command to OLTC from plant DCS system.
(iii) Control of generator excitation and governor system shall be

possible from plant DCS including mode selection and set point
control for various parameters viz. MW, MVAR & P.F. controls.
(iv) Selector switch for the operation of equipment shall be at

respective control panel.
(v) Initiation of auto synchroniser.
(vi) DG start, voltage raise/lower, speed raise/lower, DG breaker

closing shall be possible from DCS. Local / remote and auto /
manual selection will be done at DG set control panel. Selector
switch for the operation of equipment shall be at respective control
panel. All the necessary controls required for synchronising the DG
set & stopping of DG set after resumption of Normal power shall be
included in the DCS.
8.3.2.2 Monitoring
(a) Indication-Status of GCB, other breakers (ON, OFF, service, test)

position of Local/Remote selector switches, spring charged
indication etc.
(b) Abnormal conditions to be considered for alarm inputs to DCS are:
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(i) HV System (Generator CB, 6.6kV and 400kV breaker)
Operation of each of Generator protection, motor

protection. Trip circuit unhealthy of each equipment,
protection unhealthy of each equipment, Trip relay
unhealthy of each equipment, VT circuit unhealthy of each
VT, signals generated in Transformer MB about abnormal
operating conditions of Transformer, LBB operation of
each breaker, DC supply failure of each protection/control
scheme as appropriate, Successful/Unsuccessful
changeover of 6.6 kV supplies. GT and UAT condition
shall be monitored from DCS.
(ii) LV System (400V)
Breaker auto trip, individual protective relay operation, trip

relay failure, DC supply failure, bus under voltage, VT fuse
failure, Trip circuit unhealthy. Successful/Unsuccessful
changeover of 400V supplies.
(iii) Generator, Unit Auxiliary & Service Transformers
All alarm and trip conditions of generator transformers,

unit auxiliary transformers and service transformers.
Monitoring of winding & oil temperature of all the
transformers & of all temperatures & pressure parameters
related to Generator. Tap position of GT & UATs shall also
be monitored from DCS.
(iv) DC System
DC earth fault, DC under voltage, group faults in case of

DC boards, and normal operating parameters of the DC
system etc.
(v) UPS System
All normal & abnormal conditions of UPS system with

details.
(vi) Battery charger
Group trouble alarm for chargers with details as available

from equipment.
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(vii) Excitation System and generator
Each of protection relay alarm and trip conditions,

abnormal conditions in excitation system and generator.
(viii) DG Set
DG operating parameters, alarm and trip conditions.
(ix) Alarm for the running hours of 30KW & above motors shall
be generated after achieving predefined set points.
(x) Monitoring of the complete electrical system during the

normal operation.
(xi) Temperatures of all the >= 100KW motors.
(xii) All the energy parameters of the lines, generator &

auxiliary consumption shall be taken from the ABT
compliant energy meters through communication. Energy
parameters on HV side of GTs & UATs shall also be
monitored.
(c) Single line diagram showing Voltage, frequency, MW and MVAR

flows, breaker and isolator positions shall be available on
DCS/SCADA. SLD shall also show the Generator phase currents,
field current and 400kV bus voltages & frequency. More than one
frame can be used if all the details cannot be represented on a
single frame.
8.3.2.3 Measurement
Feeder Description DCS Control Panel
(a) 400 kV line bays MW

MVAR -
A -
V -
MWH -
MVARH -
Pf -
MVA -
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(b) 400 kV GT bays A(All phases) -A (All phases)

MW -MW
MVAR -
MWh MWh
Tap position -
winding & oil
temperature
(c) Generator V(All phases) - V (All phases)

A(All phases) - A (All phases)
MW - MW
MVAR -MVAR
MVARH* -
Frequency -Frequency
MW trending -
MVAR trending -
pf -pf
MWH * -MWH
(d) 400 kV Bus V(Bus –1& 2) -
Frequency(Bus -
–1& 2)
* By pulse output from TVM /Meters
(e) Unit Auxiliary A(All phases) -A (All phases)

Transformer (HV
side)
MW -MW
MVAR -
MWh MWh
Tap position -
winding & oil
temperature
(f) Incomer, Tie feeders A-All phases for -

& Outgoing feeders I/C & Ties, One
of 6.6kV switchgear phase for others
and Incomer, Bus- MW
coupler & outgoing MVAR
feeders of 400V MWH
switchgear
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SHEET 7 OF 10
(g) 6.6kV & 400V Buses V (All phases) All energy metering
F shall be through
the power meters
provided on the
incomers & tie
feeders on the
DCS. These power
meters shall have
the local display
also. Running
hours of the motors
decided during the
detailed
engineering shall
be calculated or
taken from the
numerical relays.
(h) Emergency DG set Running hours, -
electrical
parameters &
Energy reading
shall also be
measured
through
numerical
protection relay
provided at the
DG set. .
(i) DC and UPS System A -
V & Hz for UPS
(j) Generator stator Temperature -

winding and bearing
NOTE :
DCS Input current and voltage shall be considered for all three (3) phases.
The metering data for the 400kV bays shall be through the ABT
compliant energy meter provided except the tariff meters.
8.3.3.4 Event logging shall be provided for all manual operations and relay
operations as detailed below:
(a) Status of each breaker of all equipment being controlled,

isolators and earth switches.
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SHEET 8 OF 10
(b) Close and open commands.
(c) Selector switch positions.
(d) Each protective relay, trip relay, alarm relay operation. Event
logging for each phase shall be provided wherever applicable
(eg. 3-poles of line circuit breaker, distance relay output contacts,
generator protections, fuse fail alarm, etc.)
(e) Event logger shall be a part of the DCS with first up feature. It
shall have a time resolution of 1 ms.
(f) Trip contacts of the complete electrical installation/equipments in

the station viz. battery charger, UPS, Generator, all transformer,
all electrical switchboards etc. are to be included.
8.3.2.5 Trending of parameters during disturbance shall be with a resolution of

0.5/1.0 sec., and at 15 minutes during normal operation. The change
from normal mode to disturbance mode shall be through
threshold/gradient settings provided in the system for analog quantities
and external binary signals obtained from selected protective relays.
Capturing of momentary values of all these parameters shall also be
possible triggered either by a protective relay or by a manual keyboard
command.
8.3.2.6 Synchronising
(a) Generator (Manual and through Auto synchroniser)
Synchronising facility shall be provided for the generator through

auto synchroniser in auto mode and with the help of double
voltmeter, double frequency meter, synchroscope and check
synchronising relay permissive condition in the manual mode.
(b) 6.6 kV Incomer & tie circuit breakers shall have facility for fast and
slow auto changeover/manual synchronising and dead bus
closing.
(c) 400V switch board / MCC incomer and bus coupler breakers shall
have facility for dead bus auto change over / manual live transfer.
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(d) One (1) set of synchronising equipment consisting of double

voltmeter, double frequency meter, synchroscope, check
synchronising relay, synchronising lamps, synchroniser with
lockable only in ' off ' position, etc., shall be provided for each of
the following:
(1) Generators
(2) Breakers associated with Emergency DG synchronising
8.3.3 The functional requirement indicated above are minimum, the Bidder
shall provide all necessary controls indications, interlocks & devices
required for the system offered by him. Also, any additional requirement
arising during detailed engineering shall be provided by the Bidder
without any additional cost to the Owner.
8.3.4 The time critical controls and interlocks shall be hardwired system only.
8.3.5 The control / selector switches & meters shall be of miniaturised version.
8.3.6 Check & main Meters – ABT compliant Tri-vector energy meters of
Accuracy class 0.2S for lines, UAT & generator metering shall be
provided.
8.4 Transducers
8.4.1 The Contractor shall provide all the transducers for electrical system
either in respective switchgear / control panels. All the transducers shall
be self-powered.
8.4.2 The transducers shall comply with the requirements specified for
transducers in Electrical section D3.25.
8.5 Interposing Relays
8.5.1 The interposing relays required for the switchgear / equipment being
supplied under this contract shall be located in separate IPR panels
located in the control room.
8.5.2 The coupling relays shall be rated for 0.5 Amp breaking at 220V DC and
6 Amp make and continuous current at 220 V DC.
8.5.3 Interposing relays used for 400 kV circuit breaker closing shall be
adequately rated for the making current.
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8.6 Tests
Tests for control desk shall be as indicated in Section D3.7 for

Switchyard relay and control panels.
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ELECTRICAL SYSTEMS - 6.6 kV SWITCHGEAR
SPEC. NO.
TCE.5960A-H-500-001
9.0 6.6 kV SWITCHGEAR
The 6.6 kV switchgear and its accessories shall conform to all latest
editions of national and international standards indicated in Data Sheet –
A 3.9. Also, the switchgear and its accessories shall comply with the
requirements indicated in Data Sheet – A 3.9 and specific requirements
indicated below.
9.1 For feeding the plant auxiliaries rated for 6.6 kV and service
transformers, adequately rated switchgears shall be provided.
9.2 Manual & Automatic Transfer of Loads
9.2.1 The station switchgear shall be provided with manual live changeover
scheme for planned changeover of supply from one incomer to another
and vice versa.
9.2.2 Automatic fast changeover scheme for changeover of supply from one
source to another in the event of supply failure from upstream end shall
be provided. Changeover shall be blocked if incomer has tripped due to
bus fault.
9.2.3 The closure of the unit supply breaker shall be supervised by a synchro-
check relay permanently connected to and energised by the secondary
voltages of the unit bus P.Ts. The high-speed transfer shall be
completed in not more than 40 ms. If fast auto change over fails for
whatever reason, an automatic “slow” transfer shall be initiated. The fast
changeover scheme shall be such that the running motors are not
tripped or there is only allowable inrush current due to motor re-
acceleration.
The FBTS should have following transfer modes:
i) Fast Transfer
The bus voltage and incoming source voltage should be monitored on a

continuous basis for magnitude and phase angle to ensure that transfer
operation is carried out under conditions conducive to fast bus transfer
as per high speed sync-check supervision and ANSI C50.41 (1982)
criterion.
ii) In Phase Transfer
The breaker power contacts shall close when the decaying and drifting
bus voltage synchronizes with the incoming source voltage within
acceptable voltage and frequency parameters. The Bus transfer system
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shall continuously process the bus voltage and the drifting phase angle
dynamics to determine in real-time the exact moment of sending a
command to the breaker-closing coil to achieve the above.
iii) Slow Transfer
The breaker power contacts shall close when the falling bus voltage
shall reach an acceptable safe value. The auxiliary drives are selectively
tripped simultaneously to limit the transformer inrush current.
iv) Momentary Paralleling Transfer
This is a “Make before Break” transfer for a very short duration of the
order of few cycles where, under supervision of the bus voltage and
incoming source voltage for magnitude and phase angle, the new source
breaker is closed before opening the old source breaker. Normally not
recommended for unplanned transfers and auto/protective transfers from
the system safety considerations
9.2.4 The bus transfer scheme shall be totally microprocessor based

numerical system with in-phase transfer facility and communication
facility to DCS.
9.3 Spare Feeders
One motor and one transformer type spare feeder of highest rating shall
be provided on both sections of Bus-A & Bus-B of 6.6kV switchgear.
Additionally One (1) no. transformer feeder on each bus (colony supply)
for Owner’s use shall be provided.
9.4 Short Circuit Current Ratings
9.4.1 The fault level for the switchgear, circuit breakers, isolators, earth switch,
bus bars, etc., shall be arrived at, on the basis of short circuit current
contribution from UAT plus short circuit contribution by the motors
running on the bus.
9.4.2 A margin of 5% over higher of the above S.C current, thus calculated
shall be applied and rounded off to the next higher standard ratings and
this value shall be adopted for the breakers and switchgears. The
momentary current ratings shall be 2.55 times this value.
9.4.3 Asymmetrical S.C current breaking capacity of the breaker shall consider
the higher time constant for decay of current in the vicinity of power
generating stations and the breaker offered shall be suitable for this duty.
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9.4.4 Calculations for arriving at the time constant at this plant shall be
furnished to justify breaker selection in accordance with IEC-62271-100
and contractor shall furnish calculation during detailed engineering stage
to establish the adequacy of support insulators and busbar sizes for the
declared continuous and short time current rating.
9.5 Continuous Current Ratings
9.5.1 The continuous current rating of the 6.6 kV unit switchgear buses,
incomer breaker shall be the rated LV winding current of UAT's
respectively with 20% margin rounded off to the next higher standard
rating.
9.5.2 The continuous current rating of the feeders shall be based on the name
plate current rating of the connected equipment with 20% margin
rounded off as indicated in 9.5.1.
9.6 Constructional Measurements
9.6.1 The switchboard shall be indoor, metal clad having separate metal
enclosed compartments for (a) control, metering and relaying devices,
(b) circuit breakers, (c) phase bus bars, (d) instrument transformers and
(e) power cable terminations and adjacent cubicles (panels) shall have
sheets on either side to ensure complete isolation. The bottom of each
panel shall be covered by sheet steel and necessary glands plates.
Switchgear shall be suitable for extension on both sides. Switchgear
shall be suitable for extension on both sides. The switchgear assembly
shall be rodent and vermin proof.
Conductor shall be of high conductivity aluminium alloy for the horizontal

busbars, vertical droppers and connectors to the fixed end of isolating
contacts.
All circuit breaker compartments shall be provided with separate door so

that circuit breaker front cover shall not be used as front door. All live
parts shall be provided with isolating barriers between phases to avoid
exposure to live parts.
Door enclosing the cable termination shall be with hinge. A fixed type
checkered net shall be provided between cable termination and door to
avoid accidental contact to live termination. This arrangement is required
to take Thermographic measurement using Infrared thermometer.
9.6.2 Required number of high speed trip relays, supervision relays, auxiliary
relays, timers, contact multiplication relays, etc., shall be provided in the
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panels to meet the system requirements and to meet the system

operation philosophy indicated in the specification elsewhere.
9.6.3 The circuit breaker shall be drawout type and it shall have test, service
and isolated positions. In test position the circuit breaker shall be capable
of being tested for operation without energising power circuits. At least
5NO+5NC spare contacts shall be wired to the terminal block after fully
utilising for protection, interlocking, annunciation, etc.
9.6.4 The current transformers shall be mounted in the fixed portion of the
switchgear. Adequate space shall be available for termination using heat
shrinkable type cable termination in cable compartment and for mounting
of zero sequence current transformers (core balance current
transformers).
9.6.5 Withdrawal of circuit breaker shall not be possible unless it is in open

position and operation of circuit breaker shall not be possible unless it is
fully in service position, or is fully in test position and drawn out position.
9.6.6 Automatic safety shutters shall cover live parts when the breaker is
withdrawn and all other standard safety features shall be provided.
9.6.7 Earth bus of size 50x6 mm Cu shall be provided at the bottom and shall
extend throughout the length of the switchboard .All non-current carrying
metal work of the switchgear shall be effectively bonded to the earth bus.
Hinged doors shall be earthed through flexible earthing braid for each
type of breaker.
9.6.8 The circuit and bus bar earthing facility with earthing trucks shall be
provided for each type of breaker. Suitable mechanical interlocks shall
be provided to prevent the closing of earth switch on live circuit.
9.6.9 Switchgear shall be supplied completely wired and inter panel wiring
between cubicles of same switchgear shall be provided.
9.6.10 The sizes of wire in the panel shall be stranded copper conductor,
1.5mm² for all circuit and 2.5 mm² for CT circuits.
9.6.11 Terminal blocks shall be of stud type, 650 volts grade, 10 amps rated
complete with insulated barriers. Terminal blocks for CTs and VTs shall
be provided with test links and isolating faciliting and CT terminals with
short circuiting and earthing facility. All spare contacts and terminals of
cubicle mounted equipment and devices shall be wired to terminal blocks
with 20% spare terminals. Not more than 2 wires shall be connected at a
one terminal.
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9.6.12 All relays protective, auxiliary, and timers shall be in draw out cases with
built in test facilities. Necessary test plugs shall be supplied loose and is
included in the scope of supply. Externally operated hand reset indicators
shall be provided on all relays and timers. Timers shall be of
electromagnetic or electronic type only. Atleast 1NO + 1NC spare
contacts of all relays / timers shall be wired to terminal block. All relays
shall be of self reset type unless otherwise specified. In the event of
shortage of contacts in circuit breakers, trip relays, contact multiplying
relays shall be used. The same shall be two coil, latching type with
electrical reset, contacts shall be gold flashed with 20 micron thick
plating.
9.6.13 Breaker control switches shall be pistol grip black and selector switches
shall be oval or knob, black. Breaker control switches shall be 3 position
spring return to neutral, instrument selector switches shall be of
maintained stay put type.
9.6.14 Push buttons provided shall be shrouded.
9.6.15 Space heaters of adequate capacity shall be provided.
9.6.16 Each switchgear panel shall be provided with 230 Volts, 1 phase, 50 Hz,
5 amps, 3 pin receptacle with switch located in a convenient position.
9.6.17 Provision shall be made for receiving, distribution, isolating and fusing of
auxiliary DC and AC supplies for controls, space heating, etc. Two
numbers DC feeders shall be provided for 6.6kV switchgear with selector
switch for selecting any one supply. DC supply supervision lamps (self
coloured clustered LED type of size 22.5 mm) shall be provided and the
same shall be on AC supply. Single phase loads for motor space heating
etc., shall be distributed between different phases to keep the loading on
all the phases uniform.
9.6.18 The ratings of instrument transformers shall be decided by Bidder based

on connected load, lead burdens, changes during engineering stage and
adequate margin at the time of handing over the plant:
(a) The CTs shall withstand momentary and short time current
ratings of the associated switchgear. CTs and VTs shall be of
the cast resin type and completely encapsulated.
(b) In case of smaller rated CTs (say 200 Amp and less) at the
expected fault level the CT saturation may result in the non
operation of the instantaneous short circuit protection. In such
cases separate protection CT core with higher ratio shall be
selected to avoid saturation at high fault currents.
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(c ) Service transformers and motor feeders shall be provided with

50/1 A core balance CTs for connecting earth fault relays.
9.6.19 VTs shall be single phase, drawout type and housed in a separate sheet
metal enclosure. VTs shall be provided with HRC fuses on both primary
and secondary sides under voltage relays, timers, etc. for motor tripping
and remote annunciation on supply failure. Those terminals required to
be connected to earth shall be earthed by an isolating link without a fuse.
Those terminals required to be connected to earth shall be earthed by an
isolating link without a fuse. Fuses on primary side shall have rupturing
capacity equal to the switchgear rating. Primary fuse replacement shall
be possible with VT in isolated position only.
9.6.20 Switchgear panel shall be suitable for bottom cable entry and provided
with removable gland plates. Adequate space shall be available for the
termination of the heat shrinkable cable termination & mounting of the CT
& CBCT.
9.6.21 Cable lugs for all power, control and instrumentation cables connections
shall be supplied. The lugs shall be tinned copper/Aluminium depending
on cable conductor and of solderless crimping type. The cable glands
shall be of double compression type brass glands.
9.6.22 All breakers of identical ratings shall be interchangeable, suitable

mechanical/ electromechanical interlocks to ensure that earth switch is
not closed/truck is not inserted with the bus live or cable side energised.
9.6.23 Bidder shall supply and mount transducers as per Main One Line
diagram and philosophy of control defined elsewhere in the specification,
in the individual switchgear panels.
9.6.24 For the analog parameters (i.e. A, p.f, KW, running hours etc) required in
DCS, 4-20mA outputs for parameters available in numerical relays shall
be used. Wherever not available, separate transducers shall be
provided. The transducers shall have 4–20 mA dual output and accuracy
class shall be less than 0.5%.
9.6.25 Rubber mats suitable for 7.2kV grade shall be provided at front and rear
of switchgear.
9.6.26 Contractor shall furnish calculation during detailed engineering stage to

establish the adequacy of support insulator and busbar sizes for the
declared continuous & short time current ratings.
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9.6.27 Current ratings of all switchgears, circuit breakers, CTs etc. shall be
sufficient for carrying the connected load currents without exceeding the
permissible temperature limits or reduction in service life. Use of two
breakers in parallel to meet the required rating shall not be acceptable.
9.6.28 The connection between the start up transformer and 6.6kV switchgear
shall preferably be by means of segregated phase bus ducts.
9.6.29 Surge arrestors shall be provided for motor and transformer feeders and
shall be as per manufacturer’s recommended type and generally in
accordance with IEC 99-1. They shall be mounted within the switchgear
cubicle between line and earth preferably in cable compartment and
shall be suitable for indoor duty. Surge arrestors shall be suitable for non
effectively earthed system and the maximum switching overvoltage shall
not be more than 2.5 times the peak line to neutral voltage of the
system. Bidder shall furnish temporary overvoltage capability curve and
pressure relief device shall be provided for relieving internal pressure
and preventing violent shattering of the housing following prolonged
passage of follow current or internal flashover of arrestor.
9.6.28 Cubicle Components
Each circuit breaker cubicle shall be provided with the following minimum
standard accessories:
(a) One control switch `Trip - Neutral - Close' spring return to neutral
position.
(b) One two position control selector switch `Local - Remote' switchgear
control stay put type.
(c) Indicating lamps -
(i) `Red' for breaker ÒN' indication and trip coil supervision.
(ii) `Green' for breaker ÒFF' indication.
(iii) Blue' for breaker in 'Service' position.
(iv) ‘Amber' for breaker in 'Test' position.
(v) ‘Amber’ for breaker auto trip indication
(v) 'White' for breaker closing spring 'Charged'.
(vi) 'White' supervision lamp for lockout relays.
(vii) ‘Red' for breaker ON indication at the back of the switchgear
at cable box door
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The indicating lamps shall be self coloured clustered LED type of

size 22.5mm.They shall be bright and visible from any angle. All
indicating lamps shall be on DC.
(d) Mechanical trip push button to trip the breaker when control
supply is lost. The push button shall be shrouded type.
Mechanical close push button provided shall be accessible only
after opening of the front door.
(e) Castle key interlocks shall be provided to prevent opening of

cable compartment door when breaker is closed and busbar
compartment when any of the incomers to bus are closed.
(f) Closing from local shall be possible only in test position whereas
closing from remote shall be possible in either service or test
position. Tripping from local shall be possible only when
local/remote selector switch is in local position. Tripping from
remote shall be possible only when either breaker in service
position or selector switch being in remote position
(g) One electrical antipumping relay.
(h) One double pole control supply switch and set of fuses.
(i) One breaker operation counter.
(j) Cubicle lamp, heater with thermostat and plug point.
(k) Closing coils shall operate satisfactorily in the control voltage

range of 85-110% and tripping coil shall operate satisfactorily in
the control voltage range of 70-110%.
(l) Suitable labels/Name plates for feeders and cubicle mounted

components..
(m) Mechanical indication for spring charged/discharged status.
9.7 Metering & Protection
Adequate protection / metering shall be provided for the switchgear

panels. Location of relays in the switchgear shall be at convenient height,
such that it can be surfed by standing at ground. All relays except for
LBB, PT fuse failure shall be numerical with RS232/RS485 port.
Separate meters shall be provided for each of the feeders mentioned
below, if the same is not available in the numerical relay. Relay setting
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software for setting all the numerical relays in 6.6 kV switchgear and
generator protection panels shall be loaded in a dedicated operator
station in the main control room. All numerical relays shall be time
synchronized with the GPS master clock. On failure of any of the
numerical relay a contact shall be generated, which shall provide the
annunciation to the DCS. All the protective relays, except for auxiliary
relays shall have – remote/local reset facility, and shall be suitable for
efficient and reliable operation of the protective schemes. A combination
of electromechanical & numerical communicable type relays for main
protections is not acceptable. The Bidder shall include in his bid a list of
installations where the relays offered are in trouble free operation for last
two years. The minimum protections / metering shall be provided
required for various typical feeders shall include, but not be limited to the
following:
9.7.1 Incomers
Protections Metering
Composite numerical feeder Ammeter and voltmeter
protection relay with selector switch
Under voltage relay Wattmeter (or)
Multifunction meter with all
the metering parameters
Local breaker backup Current transducer for
protection each phase
Fuse failure relay 1 no. MW transducer
1 no. MVAR transducer
9.7.2 Tie breakers
Composite numerical feeder Ammeter and voltmeter
protection relay with selector switch
Local breaker backup 1 no. kWh meter
protection
1 no. watt meter (or)
Multifunction meter with all
1 no. current transducer
(Y-Phase)
1 no. MW transducer
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9.7.3 Bus PT Feeders
Under voltage protection Voltmeter with selector
switch
Fuse failure protection Voltage transducers–3
Nos.
9.7.4 Motor feeders
Composite motor protection Ammeter* with selector
relay (99) switch
Differential protection for motor 1 no. kWh meter
feeders (rated 1000kW or
above) 1 no. power factor meter
Local Breaker backup 1 no. watt meter (or)
protection Multifunction meter with all
Time delayed under voltage 1 no. current transducer
trip (Y Phase)
* For motor feeders separate ammeters shall be provided.
9.7.5 Service Transformer Feeders
Composite numerical Ammeter with selector
transformer protection relay switch
Local Breaker backup 1 no. kWh meter
protection
Winding temperature and 1 no. Wattmeter (or)
Buchholtz protection Multifunction meter with all
1 no. current transducer
9.8 The switchgears shall be designed to offer adequate level of safety to

operating/ maintenance personnel. Means shall be provided to prevent
access to the live part to avoid accidents during service as well as
maintenance period. Bidder shall bring out the safety means provided to
achieve above. A detailed instruction plate suitable for wall mounting shall
be provided for each switchgear/MCC room describing various safe
operating procedure/safety precautions for safe operation and maintenance
of the switchgear.
9.9 Tests
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All relevant routine tests and acceptance test shall be conducted as per
applicable standards and typical type test certificates of identical
switchgear shall be furnished.
9.10 Minimum electrical system requirements in respect of control, monitoring,

measurements, annunciation, and synchronization are indicated in I & C
system section no. D2.4.
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ANDHRA PRADESH POWER DEVELPOMENT SECTION: D3.9
COMPANY LTD.
SPEC. NO.
TCE.5960A-H-500-001
6.6 kV SWITCHGEAR
1.0 Switchboard cubicles and Bus bar ratings
1.1 Nominal system voltage, phases and frequency V, ph, Hz 6600 / 3 / 50
1.2 System neutral earthing Non-effectively earthed
1.3 Maximum system voltage V 7200
1.4 One minute power frequency withstand voltage kV(rms) 20
1.5 1.2 / 50 microsecond impulse withstand kV(peak) 60

voltage
0
1.6 Maximum temperature of bus bars, droppers, C As per IEC-60694 , table 3
connectors and contacts at continuous current
rating under site ref. ambient temperature
1.7 Material of bus bars Tin coated Copper
1.8 Material of bus bar insulation Heat shrinkable PVC sleeve. Removable bus
bar joints with shrouds of 7.2kV insulation
1.9 Bus bar support insulator 7.2 kV
1.10 Bus bar joints / connection Silver faced
1.11 Bus bar rating By Bidder
1.12 Short circuit current rating and duration RMS 44 kA* for 1 sec.
1.13 Momentary withstand current Peak 100kA
2.0 Switchboard Constructional Details
2.1 Thickness of sheet steel enclosures, doors and mm Cold rolled - 2

covers mm Hot rolled - 2.5
2.2 Thickness of gland plate for 1 core cable mm 3.0, Non-magnetic material
2.3 Degree of protection VT/relay compartments – IP52

Other compartments – IP42
Air conditioned area – IP32
2.4 Colour finished shade (Enamel / epoxy) Interior: Semi glossy white
Exterior: Opaline Green
2.5 Material of earthing bus Galvanised steel – 50 x 6 mm Copper

KARIMNAGAR DIST.
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2.6 Clearance in air of live parts mm Phase to Phase – 120

mm Phase to Earth – 120
3.0 Breaker details
3.1 Circuit breaker type Vacuum
3.2 Voltage, No. of phases and frequency kV, ph, 7.2 / 3 / 50

Hz
3.3 Rated operating duty O-3 min-CO-3 min-CO
3.4 Total opening time 3 cycles
3.5 Total closing time 5 cycles
3.6 Trip free operating mechanism type Motor charged spring. Manual trip and close
facility to be provided.
3.7 Anti pumping feature To be provided
3.8 Short circuit current rating and duration rms 44 kA* for 1 sec.
3.9 Momentary withstand current kA(peak) 100
3.10 Auxiliary control voltage:
(a) For closing / tripping coil / spring V, DC 220

charging motor
(b) For space heaters and lighting and V, Phase 230 V, 1 phase
plug point
3.11 Pressure switch with two potential free NA

contacts for monitoring SF6 gas.
4.0 Current transformer details
4.1 Type Cast resin bar primary
4.2 System voltage and frequency V, Hz 6600 / 50
4.3 Class of insulation Class ‘B’ or better
4.4 Short circuit withstand current and duration 44 kA* for 1 sec.
4.5 Core balance CT for all outgoing feeders Ratio 50/ 1 (As per consumer rating)
5.0 Voltage transformer details

KARIMNAGAR DIST.
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TCE.5960A-H-500-001
5.1 Type Cast resin
5.2 Rated voltage - Primary V 6600 / 3

- Secondary V 110 / 3 / 110 / 3 , 110/3 for open delta
5.3 Method of connection - Primary Star
- Secondary Star / Open
5.4 Rated voltage factor 1.2 continuous

1.9 for 30 seconds
5.5 Class of insulation Class ‘B’ or better
5.6 One minute power frequency withstand voltage kV(rms) 20
5.7 1.2 / 50 micro second impulse withstand kV(peak) 60

voltage
6.0 Meters
6.1 Accuracy class 0.5S for energy meters (0.2 for energy meters
on the switchgear incomers)
1.0 for others
6.2 Type of meters Digital
7.0 Spring charging motor supply voltage V, DC 220
8.1 Circuit breakers IEC : 62271-100
8.2 Metal enclosed switchgear IS : 3427
8.3 Current transformers IS : 2705
8.4 Potential transformers IS : 3156
8.5 Arrangement for switchgear bus bars, main IS : 5578

connection and auxiliary wiring IS : 11353
8.6 Bus bar support insulators IS : 2544
8.7 Degree of protection IS : 2147
8.8 Electrical relays for power system protection IS : 3231

KARIMNAGAR DIST.
REV. BY DATE
TCE FORM NO. 330 R3
187
COMPANY LTD.
SPEC. NO.
TCE.5960A-H-500-001
8.9 Electrical indicating instruments IS : 1248
8.10 High voltage fuses IS : 5792
8.11 AC electricity meters IS : 722
8.12 Aluminium bus bars IS : 5082
8.13 Code of practice for phosphating iron and steel IS : 6005
8.14 (Off-load) isolators IS : 6005
8.15 HRC fuses IS : 1818

KARIMNAGAR DIST.
REV. BY DATE
TCE FORM NO. 330 R3
188
SHEET 1 OF 4
1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. SPEC. NO.
ELECTRICAL SYSTEMS - SERVICE TRANSFORMERS TCE.5960A-H-500-
001
10.0 SERVICE TRANSFORMER
The service transformer shall conform to the latest editions of national

and international standards indicated in Data Sheet A - 3.10 Service
Transformers. Also, the service transformer shall comply with the
requirements indicated in Data sheet A3.10 and specific requirements
indicated below.
10.1 The number and rating of service transformers shall be decided based
on the geographical location of loads without sacrificing the unit and
common load concept. Adequate number of service transformers shall
be provided as required to meet the demand on 400V system based on
the criteria that each 400 V switchgear / PCC / MCC / Distribution board
shall be fed by 2 x 100% transformer / feeders. Each of the above
boards shall be sectionalised.
10.2 Impedance
The impedance of the transformers shall be selected such that the fault
level on the switchgear do not exceed its short circuit capability including
the motor contributions and also voltage dip while starting any auxiliary
does not exceed the limit acceptable for the equipment concerned but in
no case shall exceed 15%.
11.3 MVA Rating
Each transformer shall be rated to feed of the entire load on the

respective switchgear considering the outage of another transformer.
An appropriate load factor with a minimum of 0.8 for continuously
running loads and 0.2 for intermittent loads like cranes, plug points,
sump pumps, valve actuators etc., shall be considered. An additional
margin of 20% over the rating thus established shall be provided for load
variations during the detail engineering stage.
All service transformers shall be cast resin dry type (indoor). The service
transformers shall be two winding, three phase, 50 Hz, 6600 / 420 Volts,
with off-circuit taps of + 5% in steps of 2.5%.
11.4.1 Dry Type Transformers
11.4.1.1 The cast resin transformers shall be housed in naturally ventilated floor
mounted cubicle with louvers backed by fine brass wire mesh. Degree of
protection of enclosure shall be atleast IP32.
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SHEET 2 OF 4
ELECTRICAL SYSTEMS - SERVICE TRANSFORMERS TCE.5960A-H-500-
001
11.4.1.2 The transformer cubicle shall be located right next to respective 400V
switchgear and LV side shall be connected through cables or bus duct.
The HV connections shall be through cables.
11.4.1.3 The dry type transformers shall be provided with core and winding
temperature detectors, with temperature high alarm and very high trip
contacts.
11.4.1.4 The insulation class for cast resin transformers shall be class-F.
11.4.1.5 The core and windings shall be provided with embedded temperature
detectors for remote indication in DCS.
11.4.1.6 Noise level shall not exceed the values specified in NEMA TR-1.
11.4.1.7 Off-circuit tap changers with lockable operating handle, mechanical tap
position indicator, and with a variation of 2.5% per step and a range of
+ 5% shall be provided.
11.5 Tests and test reports
All routine tests shall be conducted as per relevant IS standards. Type

test certificates carried out on similar transformer shall be submitted for
review.
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COMPANY LIMITED
SPEC. NO.
TCE.5960A-H-500-001
Service Transformers
1.0 Type Cast resin dry type , 3-ph, two winding
2.0 No. load voltage - HV Volts 6600

- LV Volts 420
3.0 Cooling method AN
4.0 Overfluxing capability 110% continuous
5.1 HV Delta
5.2 LV Star
5.3 Vector group Dyn11
6.0 Impulse (1.2 / 50 micro second) / Power

6.1 HV kVp, 60 / 20
kV(rms)
6.2 LV kV(rms) -/3

0
7.0 Maximum temperature rise of winding C
a) Dry type transformer Class-F (155 oC)
8.1 Type Off-load
8.2 Tap range % +5
8.3 Tapping step % 2.5
8.4 Category of voltage variation CFVV
8.5 Tapping power Full
9.1 Voltage class – HV / LV kV 7.2/1.1
10.0 Noise level Not to exceed values specified in NEMA TR-

1
11.0 Paint shade Shade 631 of IS-5/RAL 7032/eqt.

REV. BY DATE
TCE FORM NO. 330 R3
191
COMPANY LIMITED
SPEC. NO.
TCE.5960A-H-500-001
12.1 Service transformer IS : 11171
12.2 Fittings and accessories IS : 3639
12.3 Bushings IS : 2099
12.4 Degree of protection IS : 2147
12.5 Tests IS : 2026/ IS: 11171
12.6 Tolerance on guaranteed particulars IS : 2026
12.7 Buchholz relay IS : 3637
12.8 Electrical insulation classified by thermal IS : 1271

stability

REV. BY DATE
TCE FORM NO. 330 R3
192
5.3
1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. SHEET 1 OF 17

ELECTRICAL SYSTEMS -
SPEC. NO.
400V SWITCHGEAR & MCC TCE.5960A-H-500-001
11.0 400V SWITCHGEAR & MCC
The 400V switchgear and its accessories shall conform to the latest
editions of national and international standards indicated in Data sheet
A 3.11 400 V Switchgear / MCC. Also, the 400 V switchgear / MCC and
its accessories shall comply with the requirements indicated in Data
Sheet – A 3.11 and specific requirements indicated below:
11.1 For feeding the 400V/230V/110V AC loads of the plant, 400V

switchgear / motor control centres (MCCs) and AC distribution boards
(ACDBs) shall be provided. The switchgear shown in Key One Line
Diagram drg. No. TCE.5960A-EL-SK-2001 are tentative. Any additional
switchgear / MCCs as required shall also be provided. All 400 V
switchgear, MCCs & ACDBs shall be procured from the same source in
order to ensure interchangeability of components.
11.2 Power Sources for 400V Switchgear
The switchboard shall derive power from the designated auxiliary

transformers as shown in the Key One Line Diagrams TCE.5960A-EL-
SK-2001. The Bidder shall provide additional switchboards as required
without sacrificing the standby philosophy, reliability and flexibility of
operation and with unit and common loads demarcation.
11.3 Feeder Details
11.3.1 The switchgear / MCC shall be provided with two incomers and a bus
coupler (100% each).
11.3.2 The switchgear / MCC shall be provided with suitable numbers and type
of outgoing feeders as required.
11.3.3 Spare feeders - 20% of each type and each rating with minimum of one
no. feeder. (Above quantity is the minimum requirement at the time of
handing over the plant. Any additional quantity required for any
increase/changes during detailed engineering stage also shall be duly
considered).
11.3.4 Bus VT module - 1 no. on each bus section.
11.3.5 Switchboard 230V, 1 phase space heating - 1 no. on each bus.
11.3.6 230V, 1 phase motor space heating supply module - 1 no. on each bus
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11.3.7 Alarm module for common alarm for out going feeder fault - 1 no.
11.3.8 Any of the system/equipment which requires power supply.
11.3.9 For each auxiliary or load, one feeder shall be provided except for the
following cases:
(a) One feeder for maximum of 2 Nos. 400V, 3 phase plug points.
(b) One feeder for maximum of 3 Nos. 400 kV isolator motorised

operating mechanism.
11.3.10 Control transformer on each bus section: 01Nos
11.4 Construction
11.4.1 Switchgear/MCCs shall be metal enclosed, indoor, floor mounted modular

type of uniform height not more than 2450 mm, dust and vermin proof
construction with IP - 52 degree of protection, easily extensible on both
sides having switchboard designation indicating labels. Proper gasketing
shall be provided all around the perimeter of adjacent panels, panel and
base frame, removable covers and doors. Switchgear shall be designed
for the bottom entry of cables however, the incomers shall be suitable for
NSPBD.
11.4.2 Switchgear / MCCs shall be single or double front as execution needed.

The circuit breaker and feeder modules in switchboard and MCCs shall
be of fully drawout construction. In this type of construction it shall be
possible to drawout the chassis without having to unscrew or unbolt any
connections to the equipment mounted on the withdrawable chassis.
The power and control drawout type connections shall be of sliding type.
All drawout contacts, including for auxiliary and control wiring shall be of
self-aligning type.
11.4.3 Switchgear/MCC shall be divided into distinct vertical sections of:
(a) Completely enclosed busbar compartment running horizontally.
(b) Individual feeder modules in multitier arrangement.
(c) Enclosed vertical busbars serving all modules in vertical section.
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(d) Vertical cable alley covering entire height and minimum 250mm
wide.
(e) A horizontal separate enclosure for all auxiliary power and

control bus, if required.
(f) For cable connection to circuit breaker, a separately enclosed

cable compartment shall also be acceptable.
11.4.4 Each vertical section shall be equipped with space heater and
thermostat.
11.4.5 Cable alley shall be provided with suitable hinged doors.
11.4.6 Rear of single front switchboard shall be provided with removable

panels.
11.4.7 All doors shall be with concealed type hinges and captive screws. Stop
Push buttons shall be of latch type with mushroom knobs.
11.4.8 Switchgear/MCC shall be designed such that all component equipment

and busbars operate satisfactorily without exceeding their respective
maximum permissible temperature limits of 105oC.
11.4.9 Switchgear/MCC busbars shall be of uniform cross section throughout

the length and made of high conductivity, aluminium alloy of E91 grade.
11.4.10 Busbars shall be sleeved, and with proper clearances, adequately

supported to withstand stresses developed due to short circuits. Material
used for sleeving shall be capable of withstanding maximum
temperatures specified in technical requirements table. Supports shall be
of glass reinforced phynolic material or cast resin. Busbar joints shall be
shrouded with moulded epoxy removable shrouds. The busbar rating of
the 400V switchgear / MCC shall be rated for LV (400V) side current of
auxiliary transformer plus 20% margin rounded off to the next standard
rating.
11.4.11 All types of relays and timer shall be flush mounted with connections
from inside, and shall have transparent & dust tight cover, removable
from front, drawout construction for easy replacement and testing facility.
The auxiliary relays and timer may be provided in fixed cases.
11.4.12 The switchgears / MCC shall be designed to offer adequate level of

safety to operating / maintenance personnel. Means shall be provided to
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prevent access to the live part to avoid accidents during service as well
as maintenance period. Bidder shall bring out the safety means provided
to achieve above. A detailed instruction plate suitable for wall mounting
shall be provided for each switchgear / MCC room describing various
safe operating procedure / safety precautions for safe operation and
maintenance of switchgear / MCC. Rubber mats shall be provided in
front & back of each panel.
11.4.13 All switchgears, MCCs, DBs, panels, modules, local starters and push
buttons shall have prominent engraved identification plates.
11.5 Control Supply
Individual two (2) nos. (100%) 400/110V, 1-ph, transformers shall be

provided in each main plant switchgear for deriving control supply.
Rating transformers each transformer shall be adequate to cater both
the bus sections. A changeover switch shall be provided for selection.
Control supply for the SFU operated motor feeders shall be 110V AC
and for all ACB feeders, it shall be 220V DC. Control circuits shall
operate at suitable voltage of 220V DC. The auxiliary bus bars for
control supply shall be segregated from main bus bars. The control
supplies shall be monitored.
Switchgear / MCC shall comply with specification requirements indicated

below:
11.6.1 The breaker / feeder modules shall have service, test and Isolate
positions. Suitable trolley arrangement shall be provided for breaker
modules. Two trolleys in the main switchgear room shall be provided so
that breaker module of all types, sizes and rating can be withdrawn on
trolley and lowered for maintenance purpose. Additionally one such
trolley shall be kept at each switchgear room.
11.6.2 All air circuit breakers (ACBs) shall be of short circuit performance
category P2 as per IS 2516 parts I & II.
11.6.3 Breakers shall have inherent fault making and breaking capacities. They
shall have shunt trip coils. All breakers shall have built in interlocks for
equipment and personnel safety.
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11.6.4 Paralleling of two supplies shall be avoided by interlocking except for

switchgear where auto-changeover or live changeover is provided.
Breaker contact multiplication if required shall be through latch relays.
11.6.5 The cable alleys shall be liberally designed considering the size and
number of cables, future additions of cables, easy and safe
maintenance.
11.6.6 For each vertical section a separate set of vertical bus bars shall be
provided to serve the modules.
11.6.7 The switches, contactors and other power devices shall consider a
margin of about 20% over the nameplate current rating of the respective
load.
11.6.8 For breaker control, 2 nos. 220V DC control supply shall be provided
with a manual selection for changing over to either supply. Necessary
voltage monitoring contactors, indication lamps shall be provided.
11.6.9 Minimum of two NO and two NC spare contacts of all contactors & relay
devices shall be wired to terminal block.
11.6.10 20% spare terminals shall be provided for each module.
11.6.11 For CT & VT circuits disconnecting type of terminals shall be provided.
11.6.12 Space heater with MCB and thermostat shall be provided for each
vertical panel.
11.6.13 Transducers required for remote metering shall be provided.
11.6.14 Interposing relays shall be provided for control from remote.
11.6.15 All protective relays shall be of numerical type.
11.6.16 All indicating lamps shall be self-coloured clustered LED type of size
22.5mm.
11.6.17 Mechanically operated, red 'trip' push button, shrouded to prevent

accidental operation.
11.6.18 Module details
(a) Incomers & bus couplers

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(i) The incomer modules and bus coupler modules of 400V

switchgear/ MCC shall be air circuit breaker controlled from
local and DCS. They shall be provided with:
• One no. CT shall be used for the Numerical protection

relay. However the metering shall be done through the
numerical relay and shall be communicated to the DCS.
• Line VT 400/110V, for checking synchronising during live

manual changeover
• Switch, fuses for 220V DC control supply
• Breaker control switch
• Local remote control switch. Closing from local shall be

possible only in test position whereas closing from
remote shall be possible in either service or test position.
Tripping from local shall be possible only when
local/remote selector switch is in local position. Tripping
from remote shall be possible when either breaker in
service position or selector switch being in remote
position.
• Service & test position limit switches with required no. of

contacts.
• Composite Numerical feeder protection relay shall be

provided for breaker feeders other than motor feeders.
• Incomer from Emergency D.G set shall also be provided

with composite numerical feeder protection relay.
• 3 phase inverse time over current relays & 1 no. E/F relay
• 1 no. E/F relay connected to the bushing CT provided in

transformer neutral circuit
• Lock out relay with supervisory lamp
• Indicating lamps for on, off and fault, spring charged, trip
circuit healthy etc
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• Synchronising switches, a set of double voltmeter, double

frequency meter, synchroscope shall be provided.
• Necessary circuitry and devices for auto trip, fault alarm,

and for control/ alarm of the breaker as required.
• Selector switch for tripping selected breaker after live

changeover (in bus coupler for locally controlled
switchboards)
• All incomers for MCC’s and DB’s rated from 630A shall be
ACB’s and for <630A MCCBs shall be provided. However
for MCC’s with important feeders like LOPs and where
auto change over is required, ACB’s shall be provided for
the incomers & Bus couplers.
• The continuous current rating of the bus bars, incomers,

bus couplers of the switchgear fed from other switchgears
shall be the maximum load on the bus due to all the
running auxiliaries during any operation condition plus
20% margin rounded off to the next higher standard
rating. For the load calculation, load factors to be
considered shall be 0.9 for continuous loads, 0.4 for
intermittent loads.
(ii) The incomer modules shall be interlocked with their upstream

breakers such that they can be closed only when upstream
breaker is closed and trips automatically when upstream
breaker is tripped or faulted.
(iii) Changeover scheme
The switchgear with sectionalised buses will be normally

operated with the bus coupler breaker open. Auto
changeover facility shall be provided for switchgear/MCC,
such that if there is a prolonged under voltage on any one of
the bus sections, the respective incoming breaker shall trip
and the bus coupler breaker shall close, provided voltage is
available on the other bus section. Total changeover time
shall not exceed 1 seconds. This auto changeover shall be
blocked if the incoming breaker had tripped either on a bus
fault or manually. Changeover back to the normal source of
supply shall be effected manually. Manual live changeover
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facility shall be provided for the switchgear/MCC. When

planned outage of one of the normal incoming supplies is
required, the respective incomer shall be tripped
automatically after the bus section breaker has been closed
manually.
After carrying out the changeover within 1sec., all the critical
motors which are identified during the detailed engineering
shall be re-accelerated automatically.
(iv) For this purpose, a selection shall be provided by the

Contractor suitably on the DCS in plant control room for
selecting the incomer to be tripped. Thus, depending on the
selection made, incomer to bus section – A or to bus section
– B will be tripped once bus section breaker has been closed
manually, thus maintaining continuity of supply. A timer with a
time delay on pick up of 0.5 – 5 sec for annunciation of the
running breaker failing to trip within a preset time, (i.e if the
two sources remain paralleled for more than a preset time)
shall be provided. When the normal supply is to be brought
back into operation, the incomer breaker shall be closed
where upon the bus coupler shall trip automatically.
(v) All hardware required for meeting the functional requirements

stated above, whether specifically listed out in the
specification or not, shall be included in the Contractor’s
scope of supply.
(b) VT modules
Each bus section of main switchboard and MCCs shall be provided

with a bus VT module along with one voltmeter with selector switch
and energy meter. The accuracy class of VT shall be 1.0 with
adequate VA burden.
(i) Bus VT modules shall be provided with suitable 400/√3 /

110/√3V VTs with primary and secondary fuses, interposing
VTs for synchronising circuit, etc.
(ii) V.T. modules in 400V main switchboard/MCC shall be

provided with all necessary relay devices for auto changeover
function like under voltage relays (2 nos), voltage available
relays (2 nos.), under voltage timer, fuse failure relay, 220V
DC control supply switch & fuses.
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(iii) Earth fault alarm with voltage relay connected to open delta
formed on secondary side of VTs shall be provided on each
bus.
(iv) In case of fuse failure, the under voltage timer operation shall
be blocked.
(v) In the 400V main switchboard buses an additional timer (with

a higher time delay) shall be provided for sending signal for
AMF start of the DG sets.
(c) Feeders provided for supplying lighting distribution boards, local

control panels, power sockets etc., shall be provided with suitably
rated switch & fuses. The modules rated 200Amp & above shall be
provided with a CT and ammeter.
(d) 230V, 1 phase, space heating module (for motor, panel, space
heating) shall be provided with incoming side switch, fuse, suitably
rated 400/230V cast resin type transformer (expected heating
loads of the switchboard + 30% margin) Secondary fuse, and
supply indicating lamp and connection to the space heating buses
in the particular bus section. The 400V power supply for these
modules shall be obtained from the other bus (i.e the supply for the
module in bus A shall be from bus B and vice versa.)
(e) Suitably rated 400 / 230 V, 1-ph cast resin transformer, incoming
side switch fuse, secondary side fuse, supply indication, 1-ph,
MCB outlets shall be provided for feeding 230 V space heating /
lighting supply required by other panels in the plant.
(f) Suitably rated 400V / 420V, 3 – ph cast resin transformers

incoming side switch fuse, secondary side fuse, supply indication
3 – ph, 4 wire outlets MCBs shall be provided for providing space
heating supply for 400V switchboards.
(g) Motor modules
(i) The motor modules shall be provided with

• Switch, fuses, air break contactors (For motors above
100kW, remote controlled electrical circuit breakers, and
for smaller motors, switch-fuse contactor feeders shall be
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provided. The other outgoing feeders would be switch-

fuse units or moulded case circuit breakers)
• Thermal overload relays with integral single phase
preventors. (Thermal overload relays for all motor feeders
upto 100kW and with integral single phase preventors for
motor feeders >45kW).
• Instantaneous short circuit protection on all phases
through HRC cartridge type fuses rated for 80 kA rms
(prospective breaking capacity at 400V)
• On, Off and fault indicating lamps
• Necessary auxiliary contactors for fault alarm circuit,
230V space heating circuit
• Isolating switches shall be of AC 23A category when
used in motor circuit, and AC 22A category for other
applications.
• Module on, off PBs for non reversible modules and
forward ‘reverse’ and ‘Off’ PBs for reversible modules
• Appropriate circuitry for receiving the on, off and forward-
reverse commands from remote panels/ systems,
interlocks, off command from local push buttons, etc.
• MCB for space heating/winding heating circuit.
• Interposing relays for control from remote.
• Transducers shall be provided for remote metering for all
motors rated18 KW and above. Any additional motor, for
which monitoring is required, shall be added during
detailed engineering.
• Isolating switches and MCCBs shall have door interlocks
and padlocking facility
(ii) The motor modules rated 30 KW and above shall be

provided with 230V, 1 phase space heating arrangement.
(iii) The modules for motors rated 50 KW and above shall

have a CT and an ammeter. The CT connection shall be
so wired to the terminal block so that provision for remote
current indication is available.
(iv) For modules of motor rated 100 kW and above ACB’s

shall be provided.
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(v) For modules of motors rated 100 kW and above shall be

provided with composite numerical motor protection
relay.
(vi) Motor modules – Remote start/Stop and ON/OFF /Trip
indication shall be provided from DDCMS for all motors of
the main plant. All abnormal conditions shall be alarmed
to DDCMS. Motor in other areas shall be controlled from
respective PLCs. Local operations shall be provided for
motors like sump pumps etc which are neither controlled
from DDCMS nor PLCs.
(vii) Essential service modules
During auto changeover of the supply the contactors in the

affected bus would have dropped off. The services which
shall be restarted immediately without time lapse to keep the
unit running are considered essential services. (for eg. seal
oil pumps, lube oil pumps, auxiliary cooling water pumps
etc.). Such auxiliaries shall restart automatically without any
action by the operator after an auto changeover. These
modules shall have additionally hardware like timer, aux
contactors and associated circuitry in the module. Such
essential services shall be identified during the detailed
engineering stage and suitable module/scheme shall be
provided.
(viii) The 400V single phase connection control supply transformer,

space heating, winding heating modules etc., shall be
distributed between different phases to keep the loading on all
phases uniform 400V/230V control transformer.
11.7 The internal wiring shall be with 1.5 mm2 stranded copper conductor for
control wiring and 2.5mm2 for CTs and suitably sized for power wiring
with a minimum of 2.5 mm2 copper.
Outdoor switchgears and switchgears/ panels located in close proximity

to gas turbine shall be provided with HR PVC cables.
11.8 400 V A C Distribution Board / Control Panel
11.8.1 Bidder shall include in his scope required no. of 400V AC power supply
distribution board/control panel for feeding packaged auxiliary load like
centrifuge, etc. Bidder shall provide one or two (depending on the
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criticality of the service) incomer from 400V main switchboard to feed the
distribution board/control panel. All the incoming and outgoing feeders
shall be of switch fuse controlled, if it is <400A other wise ACB shall be
used.
11.8.2 A.C. distribution boards/control panels shall be provided with

thermostatically controlled space heater, cubicle lamp and power plug.
11.8.3 The A.C. distribution board/control panel shall comply with technical
requirements table. Also applicable clauses of 400V switchboard and
MCCs shall be complied with for these boards/panels.
11.8.4 Required ACDB shall be provided to cater to the auxiliary power

requirements of 400kV switchyard. 2x100% capacity feeders shall be
provided in the main switchgear for serving this ACDB.
11.8.5 Separate 400V welding distribution boards along with Isolation

Transformer (2x100%) shall be provided in each area. Each circuit of
welding distribution board shall feed maximum of 2 Nos. welding /
Power receptacles.
11.9 Emergency Power Supply
11.9.1 To enable safe unit shutdown during complete A.C supply failure in the
station, certain important plant auxiliaries (such as the A.C. emergency
bearing lube oil pumps, turning gear motor, battery chargers,
emergency lights, essential instrument power supply feeders, etc.) shall
be provided with a reliable A.C. power supply through a separate
source. For this purpose, 400V, quick starting emergency diesel
generator sets with automatic mains failure (AMF) feature shall be
provided. Each DG set shall cater to the emergency loads of each of
the GTG units (i.e. 100%Unit+ 50% STG + 50% station emergency
loads). These DG sets are provided with one stand-by generator of
same rating as a back up.
11.9.2 The DG sets shall be connected to emergency switchgear with required

interconnections to GTG and STG switchgears. When the normal
station A.C. supply fails, the DG sets will start automatically and feed
the essential loads connected to GTG and STG switchgears. When the
normal A.C supply is restored, these essential loads will be manually
changed over to the normal power supply.
11.9 Tests
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Switchboard/MCCs shall be subjected to routine tests as spelt out in

Indian Standards and typical type test certificates for identical switchgear
/ MCC shall be furnished.
11.10 Minimum electrical system requirements in respect of control,

monitoring, measurement, annunciation, synchronising are indicated in
I&C system section No. D2.4.
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400V SWITCHGEAR / MCC

1.0 Switchboard & Bus bars
1.1 Rated voltage, phases & frequency V/P/Hz 400, 3ph, 50, 3 wire
1.2 System neutral earthing Solidly earthed
1.3 One minute power frequency voltage withstand
1.3.1 Power circuits V 2500
1.3.2 Control circuits V 1500
1.3.3 Auxiliary circuits V 2000

0
1.4 Reference ambient air temperature C 50
1.5 Material of bus bars Aluminium

0
1.6 Maximum temperature of bus bars contacts, C 90
droppers at site reference ambient of 500C
1.7 Short circuit withstand
1.7.1 Short time current (1 sec.) rms 50 kA for 1 Sec.
1.7.2 Momentary current Peak 105kA
1.8 Switchboard / MCC Construction Switchboard / MCC
1.8.1 Fully draw out Yes
1.8.2 Double front / single front Single front / Double front
1.8.3 Cable entry (Power & Control) Cable : Bottom Entry

NSPBD: Top Entry
1.8.4 Modular construction Yes
1.9 Degree of protection for as per IS : 2147 IP 54
1.10 Thickness of sheet steel Frame Door Cover
1.10.1 Cold rolled mm 2.5 1.6 1.6
1.10.2 Hot rolled mm 2.5 2.0 2.0
1.10.3 Gland plate thickness mm 3

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1.11 Clearances in air for live parts
1.11.1 Phase to phase mm 25.4

1.11.2 Phase to earth mm 19.4
1.12 Paint shade External : Opaline Green

Internal : Semi Glossy white.
2.0 Contactors & O/L relay
2.1 Utilisation category for contactors AC3 for non-reversible & AC4 for reversible
2.2 Contactor rated duty Uninterrupted
2.3 Reset feature for thermal O/L relay Hand
2.4 Starter type DOL
3.0 Circuit breakers
3.1 Circuit breaker type Air break with shunt trip
3.2 Rated operated duty B-3min-MB-3min-MB
3.3 Type of operating mechanism Motor wound spring charged
3.4 Short circuit rating 50 kA for 1 sec.
3.5 Control voltage for spring charging motor and V/DC 220
tripping & closing
3.6 Emergency manual operation required in

addition to electrical operating devices
3.6.1 For spring charging & closing Required
3.6.2 For tripping Required
3.6.3 Anti-pumping feature Required
4.0 CTs and VTs
4.1 Short time withstand current and duration for 50 kA for 1 sec.
CT
4.1.1 Breaker controlled Based on breaker short circuit current rating

and duration
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4.1.2 Switchfuse controlled To match with fuse withstand
4.2 Overvoltage withstand capacity for VT
4.2.1 Continuous pu 1.2
4.2.2 30 seconds pu 1.5
5.0 Meters Digital
5.1 Class of accuracy 0.5 for energy meters and 1.0 for others
6.1 Switchboard general requirements IS : 4237
6.2 AC circuit breakers IS : 13118
6.3 Factory built assemblies of switchboard and

control gear for voltages upto & including
1000V AC & 1200 V DC
6.4 Air break switches IS : 4064 & IEC 60947-3
6.5 Miniature circuit breakers IS : 8828
6.6 HRC cartridge fuses IS : 9224
6.7 D type fuses IS : 8187
6.8 Contactors IS : 29259
6.9 Starters IS : 8544
6.10 Control switches / push buttons and IS : 6875

maintenance of switchboard
6.11 Code of practice for phosphating iron and steel IS : 6005
6.12 Wrought aluminium & aluminium alloys for IS : 5082

electrical purposes
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SPEC. NO.
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6.13 Control transformer for switchboard and IS : 12021

control gear for voltages not exceeding 1000V
AC
7.0 Technical requirements Table for 400V AC

Distribution Boards / Control Panels
7.1 Location / mounting Indoor / floor mounted
7.2 Current rating Max. expected load current + 20% margin
7.3 Cable entry Bottom Cable entry
0
7.4 Design ambient temperature C 50
7.5 Codes and standards As indicated for 400V switchboards / MCCs.

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5.4
SHEET 1 OF 3
NEUTRAL EARTHING EQUIPMENT
12.0 METHODS OF EARTHING
The neutral earthing equipment shall conform to the latest editions of

relevant national and international standards. These shall comply with
the specific requirements indicated below.
12.1 400 kV system is solidly earthed. The neutral of GTs are independently
connected to earth.
12.2 Generator neutral shall be high resistance earthed. The neutral shall be
connected to a suitably rated neutral earthing transformer. The neutral
earthing resistor will be connected across the secondary of the neutral
earthing transformer.
12.3 6.6 kV systems shall be medium resistance earthed. The neutral of the
unit auxiliary transformers shall be independently connected to the earth
through a suitable resistance. The earth fault current shall be limited to
300A.
12.4 400V system shall be a solidly earthed system. The neutral of service
transformers shall be independently connected to the earth.
12.5 230V systems for lighting and the space heating shall be solidly earthed
system. The neutral of the transformers shall be connected to the earth
bus through a link in the respective board, which is in turn connected to
the plant earth grid.
12.6 230V AC control supply shall be a solidly earthed system. The mid point
of the secondary winding of the transformers shall be connected solidly
through a link to the earth bus in the respective modules of switchgear /
control panels.
12.7 Sizing of Neutral Earthing Equipment
12.7.1 The neutral grounding resistor ohmic value for generator neutral earthing
shall be so selected that during an earth fault on one of the phases of
the generator, the kW power consumed in the resistor shall be atleast
equal to 1.5 times, the capacitive kVA due to capacitance of generator,
generator bus duct and associated equipment including surge protection
capacitor, generator transformer.
12.7.2 The neutral earthing resistor ohmic value for unit aux. transformer neutral
earthing shall be such that earth fault current is limited to 300A.
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12.8.1 Duty rating of the earthing resistor for generator neutral and UATs shall
be 30 seconds.
12.8.2 Cable boxes shall be provided for receiving the cables from the
transformers.
12.8.3 The resistor cubicle shall be mounted on suitably rated insulators.
12.8.4 The resistor cubicle shall be located in transformer yard at a height of

2.5m. If located at ground level the resistor area shall be fenced
separately, even though located within the fenced transformer yard.
12.8.5 The transformer and resistor shall be located in separate

cubicles/compartment adjacent to each other. The cubicles shall have
hinged access doors capable of being pad locked.
12.8.6 For outdoor cubicle, canopy shall be provided.
12.8.7 Each neutral earthing resistor unit shall be air cooled and self supporting
type. The minimum degree of protection for the resistor element shall be
IP 34.
12.8.8 The transformer cubicle shall be made of angle frame steel construction
with formed sheet sides. The resistor cubicle shall be made of angle
frame steel construction with hot dip galvanised screen sides.
Alternatively it can be painted with heat resistant paint suitable for 2500C
the neutral grounding equipment shall be completely assembled, wired
and connected to the neutral bus tap through seal-off bushing.
12.8.9 The neutral grounding transformer shall be cast epoxy resin type natural
air cooled single phase connected between generator neutral and
ground.
12.8.10 The loading resistor shall be formed of non-aging, corrosion resistant

punched stainless steel grid element provided with necessary insulation
and designed for indoor service for a temperature rise not exceeding
3000C.
12.8.11 All alarm, protection and indication leads shall be wired upto terminal
blocks shall be mounted in a IP:54 enclosure suitable for flush mounting
and having a fully hinged cover with lock.
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12.8.12 Enclosure shall not be earthed, so as to prevent bypassing of resistor in

case of shorting of resistor from inside.
12.9 TESTS
12.9.1 All Acceptance and routine tests as per IS/IEEE shall be conducted on
NGR assembly.
12.9.2 The following tests on resistors shall be performed and test certificate
shall be furnished prior to dispatch:
i) High voltage withstand test
ii) Ohmic value test on off-load on complete resistor
iii) Heat run test on complete assembly
iv) Insulation resistance measurement test
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SHEET 1 OF 14
700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST.
ELECTRICAL SYSTEMS - DC SYSTEM SPEC. NO.
TCE.5960A-H-500-001
13.0 DC SYSTEM
The DC System and its accessories shall conform to the latest editions of
national and international standards indicated in Data sheet – A 3.13
Also, the DC system and its accessories shall comply with the
requirements indicated in Data Sheet – A 3.13 and specific requirements
indicated below:
13.1 DC power supply with high discharge plante lead acid cells forming bank
shall be the source of the power supply for control, protection, interlock,
annunciation of the complete plant including I&C system during the
running of the plant as well as for a safe shutdown at the time of the total
power supply failure. For feeding the DC supply for the above, the
following shall be provided.
13.1.1 220V DC, 2 x 100% battery bank with associated float cum boost-
charger, 1 No. DC switchboard having 2 Incomers & one bus coupler
shall be provided for each gas turbine generator (GTG) unit. The GTG
unit DC system shall be sized to cater complete unit GTG loads. The
scheme shall be as per sketch TCE.5960A-EL-SK-2006.
13.1.2 220V DC, 2 x 100% battery bank with associated float cum boost-
charger, 1 No. DC switchboard having 2 Incomers & one bus coupler
shall be provided for each steam turbine generator (STG) unit loads,
HRSG system loads and common station auxiliaries (excluding 400 kV
system auxiliaries). The scheme shall be as per sketch TCE.5960A-EL-
SK-2006.
(a) Loads of Steam Turbine Generator (STG) unit
(b) Loads of HRSG
(c) UPS loads catering to the I&C requirements
(d) Other DC supply loads as required by I&C system which shall be

derived from 220 V DC through DC/DC converters.
(e) 6.6 kV switchgear and 400 V switchgear.
(f) Common station DC auxiliaries and emergency lighting loads.
13.1.3 220V DC, 2 x 100% battery banks with associated float cum boost-
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coupler shall be provided for 400kV system (switchyard) auxiliaries. The

switchyard DC system shall be sized to cater the following loads:
(a) DC load of 400kV switchyard
(b) Emergency lighting building
The 400 kV system DC battery, battery chargers and DCDB shall be

located in the switchyard control building.
coupler shall be provided for PLCC system of 400kV switchyard.
coupler shall be provided for catering the I& C and DCS system
application.
13.2 Scheme for earth fault detection shall be provided for each DC bus and
feeders.
13.3 Battery shall be sized to cater for the following loads with minimum
duration as indicated. The voltage at the end of duty cycle shall be
1.85 V/cell for lead acid batteries. Detailed sizing / selection calculation
shall be subject to Owner’s approval.
13.3.1 Momentary Load (For duration upto 1 minute).
(a) Tripping / closing load of 400 kV, 6.6 kV & 400V breakers.
(b) Starting current of all automatically started DC drives.
(c) Solenoid valves.
(d) In rush current of excitation system.
13.3.2 Emergency & Continuous Load (For 10 hours duration)
(a) Running currents of essential DC motors.
(b) Emergency lighting
(c) Indicating lamps on switchgears and control panels

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(d) Control room emergency lighting
(e) Auxiliary relays
13.3.3 I & C system loads
13.3.4 UPS requirement for 4 hours.
13.4 Further, for arriving at the battery capacity, the following shall be
considered.
13.4.1 The temperature correction factor as given in IS. For this purpose,
electrolyte temperature shall be considered as 10 deg. C above the
ambient temperature.
13.4.2 25% margin for ageing as per IEEE guidelines.
13.4.3 A design margin of 10% shall be considered for each of the GTG Unit
Batteries & Common Station Batteries and 20% margin shall be
considered for the 400 kV System Batteries.
13.5 Battery Chargers
13.5.1 Float charger will be rated to cater the following:
(a) Trickle charging current of the battery
(b) 10 hours load indicated above.
(c) Standing load due to all units running, starting or tripping

whichever is higher.
(d) 20 % spare capacity over above loads
(e) The float voltage output of the float charger shall be

automatically adjusted depending upon the ambient temperature
such that the batteries remain floating through out the range of
variation of temperature as specified in Section – B.
13.5.2 The boost charger unit shall be rated such that the battery can be fully
charged from fully discharged condition within 8 hours.
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13.6.1 220V Batteries
(a) The battery offered shall be High Discharge plante Lead Acid
batteries confirming to IS: 1652 suitable for indoor application.
(b) The battery shall be of closed top or sealed in type. Open type
cells are not acceptable.
(c) The battery shall be complete with accessories and devices,

including but not limited to the following:
(i) Battery racks

(ii) Porcelain insulators, rubber pads etc.
(iii) Set of lead coated intercell, inter-tier and inter bank
connectors as required for the complete installation.
(iv) Electrolyte (KOH) for first filling +10% extra.
(d) One set of variable resistor load suitable for carrying out
discharge tests at 5 hour discharge rate & suitable shunt for
measuring current on all batteries shall be supplied.
Alternatively, electronic controls for carrying out discharge test of
the batteries at selectable rate can also be provided.
(e) The battery should be periodically charged/discharged to avoid

loss of performance due to memory effect.
13.6.2 220V Battery charger
(a) The float cum boost charger offered shall be static type
composed of silicon controlled rectifiers and diodes (complete
with resistor/capacitor network for surge protection) connected in
three phase wave bridge circuit. It shall be provided with an
adequately rated isolation transformer and filters on input to
minimise harmonics on the output to keep ripple factor within
acceptable limits.
(b) Charger shall have provision for manual control if the automode
fails. Load limiting features shall be provided. The same shall be
designed for adequate short time over load to take care of the
starting of the largest DC motor/testing of lamps, etc. with other
DC loads connected to bus. The rectifier shall utilise power
semiconductors and heat sinks rated to carry 200% of the load
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current continuously. The heat sink temperature shall not be

permitted to exceed 85°C irrespective of the panel temperature.
The chargers shall be suitable for operation from remote.
(c) The chargers shall be provided with automatic voltage regulation

in float mode and automatic constant current regulation in boost
mode.
(d) The charger shall essentially comprise the following items but not
limited to:
(i) One (1) moving coil DC voltmeter of size 96mm x 96 mm

of suitable range with selector switch for float, boost, and
load voltage.
(ii) One (1) moving coil DC ammeter, with shunts, size 96

mm x 96 mm to read output current of float-cum-Boost
charger.
(iii) One (1) moving coil centre zero ammeter, with shunt,
size 96 x 96 mm to read discharge/charge
current of the battery, with suitable range.
(iv) One (1) cubicle space heater suitable for 230V AC,
50Hz, single phase supply.
(v) One (1) 230V AC lamp for cubicle internal lighting.
(vi) Two (2) - On/Off switches with fuses for space heater
and internal lighting.
(vii) One LED lamp on DC load side to indicate DC "On"

condition.
(viii) One (1) set of LED lamps on AC main input to indicate

mains AC "ON" condition. All indicating lamps shall be
self-coloured clustered LED type with less than 0.5 W
burden.
(ix) Indication lamps for battery on boost charge & load

limiter operated.
(e) Fault indicating lamps shall be provided on the charger cubicle

and initiating contacts shall be provided for remote alarm for
each of the following faults:
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(i) Mains AC failure

(ii) Float charger AC input fuse blown
(iii) Charger DC output fuse blown
(iv) Charger U/V and current limit protection
(v) Charger over voltage protection
(vi) Charger overcurrent protection
(vii) Charger filter condenser fuse blown
(viii) Charger rectifier fuse blown
(f) Type of cooling for the charger panel shall be such that no
external fans are required to dissipate the heat developed within
the panel.
(g) The adequate number of dropper diodes shall be used in order

to meet the load voltage & maintaining the battery float charging
voltage as per the battery manufacturer recommendations.
Suitable scheme shall also be made that during the power
failure, the dropper diodes shall be bypassed, thereby giving the
required voltage to the connected load.
(h) One complete set of all accessories and devices required for
maintenance and testing of batteries shall be supplied for each
battery bank. Each set include at least the following:
(i) Hydrometer - 2 nos.
(ii) Set of hydrometer syringes - 2 nos.

suitable for the vent holes
in different cells
(iii) Thermometer for measuring - 5 nos.

electrolyte temperature
(iv) Specific gravity correction chart - 2 nos.
(v) Wall mounting type holder - 2 nos.

for hydrometer thermometer
(vi) Cell testing voltmeter (3-0-3 V). - 2 nos.
(vii) Rubber apron - 2 nos.
(viii) Pair of rubber hand gloves - 2 nos.
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(ix) Set of insulated spanners - 2 nos.
(x) No smoking notice - 2 nos.
(xi) Goggles (industrial) - 2 nos.
(xii) Instruction card - 10 nos.
(xiii) Minimum and maximum - 1 no.

temperature indicator for
each battery room
(xiv) Acid / Alkali mixing jar - 2 nos.
(xv) Battery maintenance record book - 20 Nos.
(xvi) Safety gears - 2 nos
13.7 D.C. Switchboards
13.7.1 For feeding the 220V DC loads 220V DC Switchboard as per clause
13.1.1 to 13.1.3 shall be provided.
13.7.2 The switchboards shall be provided with suitable quantity and type of
outgoing feeders for the auxiliaries, control supplies to various
panels/systems. For each load and auxiliary, one separate feeder shall
be provided. In addition, the following feeders shall be provided in
switchboard.
(a) Spare feeders - 20% of each type and rating with a minimum of
two nos. feeders. This is the minimum quantity at the time of
handing over the plant.
(b) Switchboard 230V 1 phase space heating module - 1 No.
13.7.3 Current ratings
The short circuit current rating of the switchboard shall be arrived

considering the contribution from charger & battery with 5% margin, with
a minimum of 25 kA.
The continuous current rating of the bus bars, incomers, ties for 220V DC
switchboards shall be the maximum D.C. load (excluding the momentary
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load) on the bus plus 20% margin rounded off to the next higher standard
rating.
13.7.4 Specific requirements
(a) DC switchboards shall comply with all the requirements of this

specification and technical requirements table.
(b) Positive and negative bus bars in the DC switchgear shall be

completely segregated from each other by sheet steel partitions.
(c) The DCDB incomers and Buscoupler shall be suitable for

operation from remote.
(d) All the DCDB compartments shall have bottom cable entry
through individual cable gland for each power, control and
instrumentation cables. Metallic enclosure shall be provided
between cable tray & cable entry.
(e) Module details
(i) Incomer
The incomer modules shall be MCCB controlled. Each

incomer shall be provided with
• ammeter & voltmeter

• earth fault relay with potential free contact for
remote annunciation.
• under voltage relay with timer
• indicating lamps for ON, OFF, earth fault, under
voltage conditions (22.5 mm size LED)
• one no. current & voltage transducer for remote
indication
• necessary hardware & circuitry for fault alarm
and for lamp test & reset.
(ii) Outgoing feeders & tie feeders/Bus coupler
• These feeders shall have DC MCB/MCCB,"ON"

& "Fault" indicating lamps, supply supervision
relays, lamp test, accept & reset push button
through common alarm module.
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• The feeders rated 200 Amps & above shall be

provided with a shunt & ammeter.
(iii) Motor modules
• For motors, starters shall be preferably housed

within the DC switchgear module. However the
resistors can be separately located in
boxes/panels within the DC switchgear room.
The starting current of the motor shall be limited
to 200% of full load current.
The motor modules shall be provided with
• Switch (rotary type suitable for DC application),

fuses, air break contactors
• Thermal overload relays
• Starting resistors with associated timers
• ON, OFF, Fault indicating lamps
• Necessary auxiliary contactors for fault alarm
circuit
• 230V space heating circuit
• ON, OFF PBs for testing purposes
• One shunt & ammeter
• Appropriate circuitry for receiving the ON, OFF
commands from remote panels/systems,
interlocks, 'OFF' command from local push
buttons, etc.
• MCB for space heating circuit
(iv) Space heating module
• 230V 1 ph, space heating module shall be

provided with incoming side switch fuse, suitably
rated 400/230V cast resin type transformer
(expected heating loads of the switchgear and
the connected motors + 30% margin) secondary
fuse, and supply indicating lamp and connection
to space heating buses. The 400V power supply
for these modules shall be obtained from the
400V main switchboard.
13.8 Tests for Batteries
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All tests shall be conducted as per the relevant standards. Tests shall
comprise:
13.8.1 Type Tests: Performed at Manufacturer's works or type test report on

identical rating and type of cell issued by an authorised test house shall
be furnished
13.8.2 Acceptance Tests: Acceptance tests as per relevant standards shall be

performed at vendor’s works. Also acceptance tests shall be performed
at site after installation and commissioning of the battery including
capacity test and test for voltage during discharge.
13.8.3 A loading resistor bank which can be automatically controlled using time
and current signals along with the charger shall be supplied to facilitate
discharging of voltages as a part of routine maintenance tests.
13.9 Tests for battery chargers
The following routine tests shall be conducted at works
13.9.1 Visual checks for dimensions and general arrangement.
13.9.2 Wiring checks
13.9.3 Functional checks
13.9.4 Voltage regulation for rated input supply for loads from 0-100%.
13.9.5 Load test to show the charger can deliver the rated duty without the
current limiter device operating.
13.9.6 Ripple measurement by oscilloscope at different loads.
13.9.7 Demonstration of guaranteed efficiency and power factor.
13.9.8 Insulation test (with 500V megger)
13.9.9 High voltage test, excluding electronic controller, at 2kV AC for one
minute.
13.9.10 Heat run test shall be conducted at full load for 24 hours at the vendor
works on charger.
13.10 Tests for DC distribution board
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13.10.1 All routine tests as per applicable standards shall be conducted on the
board.
13.10.2 Type test reports on identical switchgear issued by an authorised test

house shall be furnished.
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1.0 DC SYSTEM
1.1 Type of charger float-cum-boost
1.2 DC system voltage (Nominal) 220 V /48V /24V
1.3 DC system earthing Unearthed

0
1.4 Ambient design temperature C 50
2.0 BATTERY DETAILS
2.1 Maximum time for boost charging of battery Hrs 8
2.2 Battery type High Discharge Plante Lead Acid
2.3 Minimum end cell voltage Nickel / Lead Acid 1.85V per cell
2.4 Battery capacity By Bidder
3.0 BATTERY CHARGER DETAILS
3.1 DC voltage setting adjustment of AVR for + 10% of nominal voltage

float charging
3.2 Voltage stabilisation for constant voltage (i) +1% of set DC voltage for + 10%
regulator voltage and +5% frequency variation in
power supply
(ii) + 5% during transients
3.3 DC current adjustment for boost charging 30% to 100% of maximum boost charging
current
3.4 Current stabilisation for constant current + 2%

regulator for boost charger
3.5 Minimum permissible p.f. at rated continuous 0.8

load
3.6 Permissible ripple content at rated continuous 1% maximum

load
3.7 Degree of protection/paint shade IP 42/ External : Opaline Green

Internal : Semi Glossy White.
4.0 DC BOARD
4.1 Reference ambient air temperature 50 0C

DATE JUNE’ 10 CKD.BY HA 5960A PROJECT: 700MW CCPP AT NEDUNOOR,
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SPEC. NO.
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4.2 Degree of protection for enclosure IP 54
4.3 Type of construction Fully draw-out, compartmentalised
4.4 Paint shade External : Opaline Green

Internal : Semi Glossy White
5.0 APPLICABLE STANDARDS
5.1 Basic climatic and mechanical durability tests IS 9000

for components for electronic and electrical
equipment
5.2 Environmental tests for electronic and IS 9000

electrical equipment
5.3 Metal clad base material for printed circuits for IS 5921
use in electronic and telecommunication
equipment
5.4 Transformers and inductors (power, audio, IS 6297

pulse and switching) for electronic equipment
5.5 Printed wiring boards IS 7405
5.6 Environmental requirements for semi- IS 6553

conductor devices and integrated circuits
5.7 Terminals for electronic equipment IS 4007
5.8 Factory build assemblies of switchgear and IS 8623

control gear for voltages upto and including
1100V AC and 1200V DC
5.9 Air break switches IS 4064
5.10 Miniature circuit breakers IS 8828
5.11 HRC cartridge fuses IS 9224
5.12 Contactors IS 2959
5.13 Control switches / push buttons IS 6875
5.14 Indicating instruments IS 1248
5.15 Degree of protection IS 2147
5.16 Code of practice for phosphating iron and steel IS 6005
5.17 Semi-conductor converters IEC 60146-1-1/2/3

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SPEC. NO.
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5.18 Semi-conductor rectifier equipment safety code IS : 6619
5.19 Stationary cells & batteries
5.20 High Discharge Plante Lead acid IS : 1652
5.21 Water for storage battery IS : 1069
5.22 Pasted +ve plates IS : 6071
5.23 General requirements IS : 8320

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ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. SECTION: D.3.14
SHEET 1 OF 13
ELECTRICAL SYSTEM -
UNINTERRUPTIBLE POWER SUPPLY SYSTEM SPEC. NO.
TCE.5960A-H-500-001
14.0 UNINTERRUPTIBLE POWER SUPPLY SYSTEM
The Uninterruptible power supply system (UPS System) shall cater

to the complete plant instrumentation and control system loads
such as HMI, Large Video Screens, Master clock, DCS & SCADA
panel lighting & other critical loads, except DCS & SCADA panel
loads. The UPS shall be sized considering full load plus spare
loops plus 25% margin. The output shall confirm to stringent
requirements in respect of voltage & frequency regulation,
harmonic content & transient recovery. The UPS and its
accessories shall conform to the latest editions of national and
international standards indicated in Data sheet – A 3.14 Also, the
UPS system and its accessories shall comply with the
requirements indicated in Data Sheet – A 3.14 and specific
requirements indicated below:
14.1 The UPS shall be of “parallel redundant with static bypass to

regulated supply” type with 2 x 100% chargers & inverters and
2X100% battery bank, bypass line transformer and voltage
stabiliser, AC distribution board, other necessary protection devices
& accessories. One set of parallel redundant UPS system shall be
provided for the plant which will cater power to locations as
indicated below:
• UPS system for GTG
• UPS system for STG, HRSG & common station loads
• UPS system catering to the requirements of 400kV SCADA

system.
14.2 System Requirements
UPS shall employ IGBTs as power components. Microprocessor

based controls shall be employed for rectifier, inverter and static
switch. The UPS system shall have static switches for added
protection and transfer of loads with no break during under voltage
condition to the healthy inverter or to standby regulated supply. The
components of UPS shall isolate power line voltage transients,
frequency variations and high/low voltage conditions from the
critical load and act as a line filter and voltage regulator, apart from
providing no-break power at constant frequency during normal
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ELECTRICAL SYSTEM -
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power outages. The UPS shall be sized considering full load plus
spare loops plus 20% margin.
14.3 Static UPS system provided shall be of the type described below:
14.3.1 UPS shall derive power from station service switchgear and
Normal/ Emergency switchgears as shown in the sketch for UPS
scheme Drawing No. TCE.5960A-EL-SK-2005. UPS Battery shall
be High Discharge Lead Acid Plante type with 4 hour duration.
Parallel redundant UPS with static bypass to regulated supply shall
be as per sketch No. TCE.5960A-EL-SK-2005.The system shall
have a combination of two inverters (UPS modules) operating in
synchronism, each having isolating facility from the critical bus by a
static switch. In addition to the two inverter systems, a backup from
a regulated AC supply through transformer and voltage stabilizer
derived from Station service switchgear shall be provided. The
system shall have a selector switch. In the `Normal' position, the
respective UPS loads shall be supplied by its own inverter, sharing
50% load each, with output of both inverters being automatically
synchronized with each other, by using synchronising signal from
the master inverter. If one inverter fails, the healthy inverter shall
supply the full 100% load by the operation of the static switch.
When any one of the UPS is under maintenance, the selector
switch shall be suitably changed and the branch circuit supplying
100% load shall be synchronised with the frequency of the standby
source.
14.3.2 If the frequency of the standby source is beyond the preset limit,
the inverter frequency control shall get disconnected from the
standby synchronising signal. The operating inverter shall
continuously monitor the frequency of standby source and upon
restoration of proper frequency of the standby source, the inverter
shall use the frequency of the standby source as the synchronising
signal. It shall be ensured by the contactor that the bandwidth
selected for the UPS to remain locked with the SCVS frequency
shall be maximum & the downstream instrumentation system
should be capable of accepting the above frequency variations.
14.3.3 When the selector switch is in bypass position the standby source
shall cater 100% load, isolating both inverters from the critical load
bus.
The output of the UPS shall feed all the essential loads through
the ACDB.
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ELECTRICAL SYSTEM -
TCE.5960A-H-500-001
Typical scheme/connections to be adopted for the UPS is shown in

the sketch TCE.5960A-EL-SK-2005.
14.3.4 Rectifier
The rectifier shall essentially be a three phase 6 pulse design with

input isolation transformer. For Redundant UPS design the two
rectifiers input isolation transformers shall have vector grouping and
connections to ensure 12 pulse operation seen from the source
side. The rectifier shall be provided with soft start feature. The
rectifier shall have features for temperature compensation charging
of the batteries.
The rectifier shall be capable of supplying the inverter full load, in

addition to charging the fully discharged batteries in 8 hours or as
recommended by battery manufacturer and then maintain the
battery on trickle charge mode.
14.3.5 Inverter
PWM (Pulse Width Modulation) type, adequately designed to meet

the requirements as specified.
14.3.6 Static Transfer Switch
Inverter output shall be connected to the AC bus through a static

switch and fast acting fuses. The static switch comprises an
interrupter and transfer switch, enabling loads to be connected to
the standby regulated AC supply.
Automatic initiation of the transfer from a faulty branch circuit to the

standby regulated source shall be accomplished during following
conditions:
(a) Loss of inverter square wave/inverter failure
(b) Loss of inverter AC output
(c) Retransfer to the inverter circuit shall be manual.
14.3.7 Battery
The batteries shall be 2 X100% rated with backup time of 10 hours.

The type of batteries shall be High Discharge Lead acid Plante. The
BIDDER shall choose the required voltage of the battery. The AH
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ELECTRICAL SYSTEM -
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backup time / duty cycle, and minimum ambient temperature as

specified in Project Information. The guaranteed DC/AC efficiency of
the UPS system offered shall be mentioned.
BIDDER shall furnish calculation for sizing of the battery based on the
requirements of entire plant UPS loads.
14.3.8 Regulated Stand-by AC Supply
Regulated standby AC supply shall be derived from standby supply

through a step-down transformer of appropriate rating and a servo
controlled voltage stabiliser with isolation transformer and power
conditioning equipment viz., spike arrester, etc.
14.3.9 UPS system shall be connected to the AC switchgear. The AC

switchgear shall comply with the requirements indicated in section
D3.11 - “400V Switchboard / MCC”. Each of the UPS AC
Distribution Boards shall be provided with two bus sections and a
bus coupler as shown in dwg. no. TCE.5960A-EL-SK-005. UPS
load consumers shall be fed with redundant power supply feeders
from each bus section. 20% spare feeders shall be provided in
each of the UPS distribution boards
14.3.10 The UPS system shall be provided with necessary meters

(accuracy class 1.0 or better) mimic diagram, local indication/alarm
conditions and protection as indicated below. Grouped alarms and
analog parameters (4-20 mA) of each branch of parallel redundant
UPS shall be made available in DCS/SCADA as appropriate.
Necessary potential free contacts shall be provided from UPS to
plant DCS/SCADA as appropriate.
14.3.11 Protection
The UPS system components and assemblies shall be provided

with the necessary protection associated with all components.
Necessary logics shall be derived in the controlling microprocessor,
based on the UPS parameters including temperature protection.
14.3.12 Tests
(a) Type and routine tests certificates for all components made
use in the UPS system shall be furnished. Tests for
components shall be as per relevant standards.
(b) Tests on the following equipment shall as per the relevant

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ELECTRICAL SYSTEM -
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(c) System tests shall be performed on the completely assembled

UPS system at vendor’s works. System tests shall include
frequency regulation, voltage regulation, current limiting
feature and harmonic content tests in addition to the tests to
prove the functional requirements such as transfer of static
switch for conditions of loss of square wave, overload and
under voltage conditions, Short circuit conditions etc.
(d) Routine tests covered under clause 7.3 of IEC-60146-4 shall

be conducted on the UPS system in addition to the system
tests. Test certificates of type tests shall be submitted for
review.
(e) Endurance test on static switches shall be performed for not

less than 10 transfer/ retransfer cycles at full load.
(f) The complete assembled UPS system shall be operated at

rated load under relevant ambient conditions for not less than
96 hours continuously prior to release for shipment.
14.3.13 Minimum electrical system requirements in respect of control,

indicated in I&C system section No. D2.4.
Sl. Contractor’s
Description Specification Requirement
No. Unit Details
1. Type Parallel redundant UPS with

static bypass to regulated
supply.
2. Application Uninterruptible Power supply

for loads of HMI, LVS ,
Master clock etc.
3. Number required One parallel redundant UPS.
0
4. Ambient temperature C 50
5 Output Voltage 230V, 1–phase
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Sl. Contractor’s
No. Unit Details
6 Output rating at 0.8 kVA

*
p.f lagging load.
7. Degree of protection IP 32
8. Cable entry Will be decided during detail

engineering stage
9. Input Supply Voltage 400V, 3 Phase, 3 wire, 50Hz

supply from N/E switchgear
and for bypass from station
service switchgear
10. Installation / paint Indoor, natural ventilated,

shade shade Opaline Green
(External), Semi glossy
white (Internal)..
11. Material of Enclosure 2.0mm thick Cold rolled

sheet steel
12.0
Inverters
12.1 Type Static
12.2 Number required Two per unit
12.3 Suitable for parallel Yes

operation
12.4 Service
Indoor
12.5 Output rating of each

*
12.6 Output Voltage 230V A.C. 50 Hz, Single

phase
12.7 Voltage regulation Combined Voltage regula-

tion ± 2% from 0 to 100%
load at 0.8 power factor
within 50 milli seconds
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SHEET 7 OF 13
ELECTRICAL SYSTEM -
TCE.5960A-H-500-001
Sl. Contractor’s
No. Unit Details
12.8 Frequency regulation ± 0.1 Hz for 0 to 100% load

variation (continuous or step
load change) and full range
of input variation
a) Transient voltage
12.9
regulation on ± 8%
application or
removal of 100%
load
50
b) Time to recover ms
from transient- to
normal voltage
12.10 Total harmonic 5% RMS maximum with not

content more than 3% distortion in
any single harmonic
12.11 Duty Continuous
12.12 Overload capacity 125% for 15 minutes at 0.8

p.f, 150% for 10 sec.
12.13 Short time rating 1 second for short circuit at

inverter output terminals
12.14 Short circuit current Shall be capable of

withstandability withstanding short circuit
current for the largest fuse to
clear the fault in less than ¼
cycle
12.15 Efficiency Not less than 80% at rated

load
12.16 Cooling Natural air cooled / forced

cooled
12.17 Synchronization with Yes

alternate source
required
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ELECTRICAL SYSTEM -
TCE.5960A-H-500-001
Sl. Contractor’s
No. Unit Details
13.0 Static Transfer

Switch
13.1 Capacity Continuous Make and carry full load

current of inverter at 0.8 p.f
13.2 Type Make before break
13.3 Voltage 230V, single phase
13.4 Short time rating Short circuit rating of the

inverter for 1 second and
150% of full load current for
2 min.
13.5 Frequency Hz 50
13.6 Transfer time Less than 5 milli sec.
13.7 Retransfer Automatic retransfer shall

occur after approximately 2
sec time delay during which
normal source voltage must
remain at 230V ± 2%
I. Indicating lamp for
13.8 Indication protection /
static switch in normal
Annunciation
position.
II. Indicating lamp for static

switch connected to
alternate source.
III. Protection of all

semiconductor devices
against short circuit and
transients.
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ELECTRICAL SYSTEM -
TCE.5960A-H-500-001
Sl. Contractor’s
No. Unit Details
iv) Annunciations for the

following conditions.
a) Static switch
connected to
alternate source
b) Alternate source
voltage deviation
greater than ± 2%
from nominal.
14.0 Bypass Switch
14.1 Capacity Continuous Make and carry full load

current of inverters at 0.8 p.f
14.2 Type Make before break
14.3 Short time rating Short time rating of the

inverter for 1 second and
150% of full load current for
2 minutes.
15.0 Standby AC supply with isolation transformer and servo controlled

voltage stabilizer
15.1 Number One
15.2 Rating Same as UPS rating
15.3 Single or poly phase *

unit
15.4 Type Dry type double wound
15.5 Voltage ratio at no *

load
15.6 Type of cooling Natural Air cooled
15.7 Winding insulation Class-H

class
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TCE FORM NO. 329 R5
SHEET 10 OF
1X 700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST. 13
ELECTRICAL SYSTEM -
UNINTERRUPTIBLE POWER SUPPLY SYSTEM
SPEC. NO.
TCE.5960A-H-500-001
Sl. Contractor’s
No. Unit Details
15.8 Location Indoor
15.9 Voltage regulation ± 2% from 0 to 100% load at

0.8 p.f
15.10 System fault level on kA 50

400 V side
15.11 Output voltage ± 5% of nominal voltage

setting range
15.12 Synchronising Required Within ± 2.5 Hz

between inverter and
standby supply
16.0 ACDB
16.1 Fully drawout/

**
Semidraw out/ fixed
16.2 Dimensions of the

**
board
16.3 Degree of protection IP52
Note:
‘*’ indicated above shall be filled by the Contractor.
‘**’ Contractor shall furnish the data after placement of order.
7.0 Data to be furnished with the Bid
7.1 Technical particulars as per Data Sheet
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COMPANY LIMITED
DATA SHEET - A3.13 SHEET 11 OF 13
SPEC. NO.
TCE.5960A-H-500-001
SL. NO. DESCRIPTION UNITS REQUIREMENTS
1.0 Type Static

Parallel redundant UPS with static
bypass to regulated supply as per
sketch TCE.5960A-EL-SK-2005
2.0 Power Rating at Load PF 0.8

Lagging By Bidder
3.0 Application For supplying the loads of

HMI, Common station, 400 kV
system SCADA & other critical
loads
4.0 Installation /paint shade Indoor, natural ventilated, shade

Opaline Green (External), Semi
glossy white (Internal).
5.0 Input supply V, Ph, 3-PH, 400V AC (From Normal cum

Emergency board and Station
service switchgear)
6.0 Output Voltage V, Ph 230V, 1 PH
7.0 AC voltage accuracy(steady state)

over entire load, load PF & By Bidder
DC voltage range
8.0 Range of adjustment of AC output ±5% at rated load voltage
9.0 AC harmonic content 5% total, 3% for any single

harmonic
10.0 Design Ref. Ambient Deg.C 50
11.0 Standby AC supply with isolation

transformer and servo controlled
voltage stabilizer
11.1 Rating Same as UPS rating

11.2 Type Dry cast resin type, Two winding
11.3 Ratio & frequency
KARIMNAGAR DIST.
REV. BY DATE
237 TCE FORM NO. 330 R3

COMPANY LIMITED
SPEC. NO.
TCE.5960A-H-500-001
(a) Primary By Bidder
(b) Secondary 230 V, 1 PH, 50 Hz
11.4 Automatic voltage regulator Required (servo-controlled)

• Percentage voltage regulation % ±2
• Transient response % ±10 for bypass
• Output voltage setting range % ±5 of nominal voltage
12.0 Bypass transfer selection Auto/manual switch
13.0 Manual bypass PBs Load to bypass, load to inverter
14.0 Manual bypass switch Required
15.0 Synchronising between inverter Required

and standby supply ±2.5 Hz (47.5Hz to 52.5Hz)
16.0 Static switch
16.1 Type Static
16.2 Maximum transfer time Maximum of 1/4 cycle
17.1 Basic Climatic & Mechanical IS - 589

durability tests for components for
electronic & electrical equipment
17.2 Environmental tests for electronic IS - 2106

and electrical equipment
17.3 Metal clad base material for printed IS - 5291

circuits for use in electronic and
telecommunication equipment
17.4 Transformer and inductors IS - 6297

(power, audio pulse & switching)
for electronic equipment
KARIMNAGAR DIST.
REV. BY DATE

COMPANY LIMITED
SPEC. NO.
TCE.5960A-H-500-001
17.5 Printed wiring boards IS - 7405
17.6 Environmental requirements for IS - 6553

semi-conductor devices and
integrated circuits
17.7 Terminals for electronic equipment IS - 4007
17.8 Factory built assemblies of IS - 8263

switchgear and control gear for
voltages upto and including
1000 V AC and 1200 V DC
17.9 Air break switches IS - 4064
17.10 HRC catridge fuses IS - 2208
17.11 Contactors IS - 2859
17.12 Control switches/ push buttons IS - 6875
17.13 Indicating Instruments IS - 1248
17.14 Degree of protection IS - 2147
17.15 Climatic proofing in electrical IS - 3202

equipment
17.16 Semiconductor converters IEC - 60146
17.17 Semiconductor rectifier equipment IS - 6619

code
17.18 Thyristor converters IS – 5082
17.19 Emergency Standby power IEEE – 446

systems

KARIMNAGAR DIST.
REV. BY DATE

5.6
SHEET 1 OF 19
ELECTRICAL SYSTEMS - CABLING SYSTEM SPEC. NO.
TCE.5960A-H-500-001
15.0 CABLING SYSTEM
15.1 Cable Types
15.1.1 For 6.6 kV services, XLPE cables with following specification shall be
provided.
6600 volts unearthed grade single or multi core, stranded aluminium

conductor, screened by triple extruded semi conducting compound, gas
cured, gas cooled, triple extruded, tree retardant, cross linked
polyethylene insulated, cores screened with triple extruded semi
conducting compound in combination with copper tape, laid up, inner
sheathed with extruded PVC compound type ST2, armoured with
galvanised wire or strips for multicore cables and aluminium wire
armoured for single core cables and overall sheathed with extruded FRLS
PVC type ST2 cable complying with IS : 7098 part-2. XLPE insulation
shall be suitable for continuous conductor temperature of 900C and short
circuit conductor temperature of 2500C. The cable cores shall be laid up
with fillers between the cores wherever necessary. It shall not stick to
insulation and inner sheath.
15.1.2 For 400 V power supply services, space heating, outdoor lighting, lighting
in the hazardous areas, power supplies to lighting panels etc., XLPE
power cables with the following specifications shall be provided:
1100 volt grade, single or multi core, stranded aluminium conductor,

XLPE insulated, cores laid up, inner sheathed with extruded PVC com-
pound type ST2, armoured with galvanised steel wire or strip for multicore
cables and aluminium wire or strip armoured for single core cables, outer
sheathed with extruded FRLS PVC compound type ST2 complying with
IS: 7098, Part-1. The cable cores shall be laid up with fillers between the
cores wherever necessary. It shall not stick to insulation and inner sheath.
15.1.3 For control, protection, CT / PT connections and interlocks, metering,

solenoids, and for digital signals from the field devices/junction
boxes/switchgears to terminal cabinets of the control system etc., with
signal voltages more than 60 volts, PVC control cables with the following
specifications shall be provided:
1100 volt grade, multi core, stranded annealed high conductivity copper
conductor (class 2 as per IS 8130), extruded PVC compound type A
insulated, cores identified by numerals, cores laid up, inner sheathed with
extruded PVC compound type ST1, armoured with galvanised single steel
wire/strip and outer sheathed with extruded FRLS PVC compound type
ST1 cable complying with IS: 1554.
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15.1.4 For low voltage digital signals to instrumentation and control system and
for the analog signals, instrumentation cables with following specification
shall be provided :
Single pair, multi pair or triplets or quadruplets as required, stranded

tinned, annealed, high conductivity copper conductor (class 2 as per IS
8130), extruded PVC compound type-A insulated, cores identified by
colour and coding, individual pair/triplet/quadruplets twisted, cores
wrapped by non hygroscopic material by taping or extrusion, non metallic
rip cord under wrapping, individual pair/triplet/quadruplet screened with
aluminium mylar tape of 0.04 mm thick or copper tape of 0.04 mm thick or
copper laminated plastic tape with 30% overlap, provided with 0.5 mm²
tinned copper drain wire for each cabling element, cabling elements
suitably grouped, colour coded, cables overall screened with tinned
copper wire braids of 0.15 mm dia with minimum coverage of 85% or
aluminium mylar tape of 0.04 mm thick with overlap of 30%, inner
sheathed with extruded PVC compound type ST1, armoured with steel
strips/wires and outer sheathed with extruded FRLS PVC compound type
ST1 complying with IEC 60189 - Part 1&2.
15.1.5 Cables for important auxiliaries such as emergency lube oil pump motors,
jacking oil pump motors, barring gear motors, Trailing power and control
cables for cranes & hoist, DC cables from battery to charger and DCDB
etc. shall be of fire survival type (FRLS cables).
15.2 The HV & LV power cables shall be selected on the basis of current
carrying capacity, short circuit rating and permissible voltage drop.
15.2.1 Current carrying capacity
The cable shall be able to carry the full load current of the circuit
continuously under the specified ambient temperature and other
conditions of installation. For this purpose, suitable derating factors shall
be considered due to:
(a) Thermal resistivity of soil
(b) Ambient ground / Air temperature
(c) Derating factor for grouping of cables over the current ratings at
normal conditions given in standards. The design ambient air
temperature and ground temperature for this plant shall be considered
as 500C and 300C respectively.
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15.2.2 Short circuit rating
The cables for circuit breaker controlled circuits shall withstand the fault
currents for the following fault clearing times.
(a) Motor, service transformer (Protected by - 0.16 sec

instantaneous over current protection)
(b)Tie feeders (with no IDMT relays on downstream) - 0.5 sec
(c) Others - 1 sec
For circuits, which are protected by fuse, short circuit rating capability
need not be checked.
15.2.3 Permissible voltage dip normal running
400V System: Voltage drop in cables between the transformer and the
switchgear (PCC) or between PCC and MCC for full load current shall be
limited to 2%. Further, the voltage drop in cables between PCC/MCC to
the motor terminals for full load motor current shall be limited to 3%.
However, these voltage drops may be adjusted in specific cases so that
total voltage drop is within 5%. The screen of the 6.6kV cable shall be
capable of carrying the earth fault current of 6.6kV system for 2 sec.
15.2.4 Permissible voltage dip during starting
(a) 400V system: The voltage dip during starting of individual 400V
motors shall be limited to less than 15% of the full load voltage.
(b) 6.6kV system: The voltage drop during starting of HRSG cooling
pump motors shall be limited to less than 20% of the full load
voltage, for all other motors it shall be 15%.
15.2.5 Minimum conductors cross-section for the power cables shall be

4.0 mm2 aluminium or 2.5 mm2 copper.
15.2.6 All D.C. power supply cables shall be single core cables.
15.3 Control cables
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15.3.1 Current transformer leads shall be checked for lead burden, VA capacity
and knee point voltage. In case 2.5 mm2 Copper Conductor is not
adequate, 4 mm2 cross-section cables shall be used.
15.4 Instrumentation Cables
15.4.1 The cross sectional area shall be 0.5mm2 based on the requirement of
I&C system employed.
15.4.2 The instrumentation cables carrying digital signals shall have overall
screening along with drain wire and analog signal carrying cables shall
have each pair screening and overall screening along with each pair drain
wire and overall drain wire.
15.5 Specific Requirements of Cables
The following aspects are applicable for all types of cables:
15.5.1 Core Identification
Colour coding shall be acceptable for all cables upto 5 cores. Cables with
more than 5 cores shall have printed numerals on each core. In addition
to manufacturer's identification on cables as per IS, following marking
shall also be provided over outer sheath:
(a) Cable size and voltage grade - To be embossed
(b) Word 'FRLS' at every 5 meter - To be embossed
(c) Sequential marking of length of the cable in meters at every one

meter - To be embossed / printed.
The embossing / printing shall be progressive, automatic, in line and

marking shall be legible and indelible. The name of the project shall be
provided at regular intervals of the outer sheath.
15.5.2 Core numbers with a minimum letter size of 3 mm shall be printed serially
on each core of the control cable at intervals of not more than 200 mm.
15.5.3 Core numbers with a minimum letter size of 2 mm shall be printed serially
on each core of the Instrumentation cable at intervals of not more than
200 mm and each core shall be colour coded as per IEC-60189 Part-2
15.5.4 FRLS PVC compound for outer sheaths of all the cables shall meet the
following performance requirements and cables shall pass these tests.
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The bidder shall furnish the necessary type test certificates.
(a) The critical oxygen index value shall be minimum 29 at room

temperature and the temperature index value shall be minimum
250°C at oxygen index of 21 when tested as per ASTM-D-2863-77.
(b) The maximum total acid gas generation as determined by titration

shall be less than 20% by weight, when tested as per IEC 60754-1.
(c) The maximum smoke density rating expressed in percentage light

absorption at any point on the curve during testing period shall not
exceed 60 % when tested as per ASTM-D-2843-77.
(d) The cables shall pass the hydrolytic stability and ultraviolet test as
per DIN 53387. The measured values of ultimate tensile strength
and elongation after the test shall not be less than 60% of that
measured before the test.
15.5.5 The finished cables shall pass the flammability test as per IEC-60332-1
and IEC-60383. In addition it shall also pass flammability test as per
class F3 of Swedish Standard S5-424-1475.
15.5.6 In plant repairs to the cables shall not be accepted. Pimples, fish eye,
blow holes etc. are not acceptable.
15.5.7 Cables shall be supplied in non returnable wooden or steel drums of

heavy construction. The surface of the drum and the outer most cable
layer shall be covered with water proof cover. Both the ends of the cables
shall be properly sealed with heat shrinkable PVC/ rubber caps secured
by 'U' nails so as to eliminate ingress of water during transportation,
storage and erection. Wood preservative anti-termite treatment shall be
applied to the entire drum. Wooden drums shall comply with IS: 10418.
15.5.8 Each drum shall carry manufacturer's name, Owner's name, address and
contract number, item number and type, size and length of cable and net
gross weight stenciled on both sides of the drum. A tag containing same
information shall be attached to the leading end of the cable. An arrow
and suitable accompanying wording shall be marked on one end of the
reel indicating the direction in which it should be rolled.
15.5.9 The cross-sectional area of the metallic screen strip/tape shall be
considered in design calculations.
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15.6 Tests
15.6.1 The Contractor shall conduct the routine tests on each drum length,
acceptance test on the cables as per applicable standards. Tests
certificates of all type tests as per applicable standards conducted on
similar cables shall be submitted for review. Also special tests for critical
oxygen index, temperature index values, acid gas generation, smoke
generation, flammability test, effects of light and water test as specified
shall be conducted on specimen, from different batches. Routine tests
shall include but not limited to the following for instrumentation cables.
15.6.2 Test for dielectric strength for one minute (as per IEC-60189-1)
15.6.3 Insulation resistance test (as per IEC-60189-1)
15.6.4 The vendor shall carry out all routine tests as per IEC.60189-1 for
instrumentation cables
15.6.5 Cable carrier system
(a) Cables shall be always laid above ground to all locations including
outgoing areas with cable trays supported on overhead steel
structure works. Cable tranches shall be provided in switchyard and
transformer yard. Any deviation may e subjected to Owner’s approval.
Following cable carrier system shall be adopted in various areas as
indicated below.
(i) Control room building :
- Cable vault : Cable trays

(ii) Switchgear room
- Cable vault : Cable trays

(iii) GTG building : Cable trays / conduits
(iv) STG building : Cable trays / conduits
(v) Switchyard and transformer : Cable trench

yard
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(vi) HRSG area : Cable rack
(vii) HRSG platforms : Cable trays
(viii) Road / Rail crossings : Hume or steel pipes
(ix) Cable carrier system : Cable Trays

connecting outlying areas
(x) Off-side buildings and : Cable trays

utilities
(b) Cable tunnels shall have minimum head room of 1.8 m

considering the obstruction due to light fittings, sprinkler piping,
etc.
(c) Cable trench
(i) Cable trenches shall be of different sizes depending on

the number of cables laid in that route.
(ii) Preferred working space between the cable support arms

and the wall are as follows. Contractor shall design the
trenches accordingly.
Trench depth Width of Working

Trays Space
1500 mm (5 tiers) 600 mm 750 mm
1200 mm (4 tiers) 600 mm 750 mm
1000 mm (3 tiers) 600 mm 750 mm
700 mm (2 tiers) 300 mm 500 mm
(iii) PCC flooring of buildup trenches shall be sloped for

effective drainage with sump pits and sump pumps.
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(iv) No sub zero level cable vault / trenches shall be

provided below control building/ switchgears rooms in
main plant.
(d) Cable trays
(i) Cable trays of ladder and perforated types and the

associated accessories such as coupler plates, tees,
elbows, bends, reducers, brackets, crosses etc., and
hardware such as bolts, nuts, washers, G.I. strap, hook
etc., shall be fabricated from 14 gauge (2.0 mm thick)
mild steel sheets. Cable tray covers shall be fabricated
from 16 gauge (1.70 mm thick) MS sheets. The thickness
of side coupler plates shall be minimum 3 mm. Cable tray
shall be ladder type for power & control cables and
perforated for instrumentation cables.
(ii) Cable trays, accessories and covers shall be hot dip

galvanised. Cable trays shall have standard width of 150
mm, 300 mm & 600 mm and standard lengths of 2.5
metre.
(iii) In battery rooms and water treatment plant, the cable

trays, accessories and covers shall be epoxy painted.
(iv) The spacing of rungs for ladder type of trays shall be not
more than 250 mm.
(v) Vertical raceways shall be formed by either structural

members and slotted angles or by running the
prefabricated trays vertically.
(vi) Prefabricated cable trays, accessories and covers shall

be hot dip galvanised. Site fabricated cable trays shall
be painted with cold galvanisation paint at site.
(vii) Cable troughs shall be required for branching out few

cables from main cable route. These shall be U-shaped,
fabricated of mild steel sheets of minimum thickness 2
mm and shall be hot dip galvanised as per relevant IS.
Troughs shall be standard width of 50 mm & 75 mm with
depth of 25 mm.
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(viii) Cable tray support system shall be pre-fabricated similar

or equivalent to "Uninstrut make”.
(ix) Support system for cable trays shall essentially comprise

of the two components i.e. main support channel and
cantilever arms. The main support channel shall be of
two types : (i) C1:- having provision of supporting cable
trays on one side and (ii) C2:-having provision of
supporting cable trays on both sides. The support system
shall be the type described hereunder.
a. Cable supporting steel work for cable racks/cables shall

comprise of various channel sections, cantilever arms,
various brackets, clamps, floor plates, all hard wares
such as lock washers, hexagon nuts, hexagon head bolt,
support hooks, stud nuts, hexagon head screw, channel
nut, channel nut with springs, fixing studs, etc.
b. The system shall be designed such that it allows easy

assembly at site by using bolting. All cable supporting
steel work, hard wares fittings and accessories shall be
prefabricated factory galvanized.
c. The main support and cantilever arms shall be fixed at

site using necessary brackets, clamps, fittings, bolts, nuts
and other hardware etc. to form various arrangements
required to support the cable trays. Welding of the
components shall not be allowed. However, welding of
the bracket (to which the main support channel is bolted)
to the overhead beams, structural steel, insert plates or
reinforcement bars will be permitted. Any cutting or
welding of the galvanized surface shall be brushed and
red lead primer, oil primer & aluminium paint shall be
applied
d. All steel components, accessories, fittings and hardware

shall be hot dip galvanized after completing welding,
cutting, drilling and other machining operation.
e. The typical arrangement of flexible support system is

described briefly below:
The main support channel and cantilever arms shall be

fabricated out of minimum 2.5 thick rolled steel sheet
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conforming to IS.
f. Cantilever arms of 300 mm, 600 mm and 750 mm in

length are required, and shall be as shown in the
enclosed drawing. The arm portion shall be suitable for
assembling the complete arm assembly on to component
constructed of standard channel section. The back plate
shall allow sufficient clearance for fixing bolt to be
tightened with tray in position.
The size of structural steel members or thickness of sheet steel

of main support channel and cantilever arms and other
accessories as indicated above or in the enclosed drawings are
indicative only. Nevertheless, the support system shall be
designed by the bidder to fully meet the requirements of type
tests as specified. In case the system fails in the tests, the
components design modification shall be done by the Contractor
without any additional cost to the Owner. The bidder shall submit
the detailed drawings of the system offered by him along with the
bid.
(e) Conduits & Pipes
(i) The galvanised steel conduits shall be used for sizes

upto 63.5 mm. The conduits shall be manufactured by
electric resistance welding process and shall be hot dip
galvanised. The conduits and fittings shall comply with
IS: 1653, 3837, and 2667.
(ii) Galvanised steel pipes shall be used for sizes from

80mm on wards. They shall be medium duty class-B type
as per IS. The pipes shall be manufactured by electric
resistance welding and hot dip galvanized. The pipes
and fittings shall comply with IS.
(iii) Flexible steel conduits shall be manufactured with electro

galvanising process. The flexible conduits and their
fittings shall comply with IS: 3480, 4649.
(iv) The hume pipes/RCC pipes shall comply with IS: 458.
(f) Cable/Cable tray supports
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(i) Cable tray supports shall be fabricated from standard

steel structures of different sizes. The sizes selected
shall be adequate for the weight of cables/trays
encountered.
(ii) The steel members shall be cleaned thoroughly for rust

and painted as follows:
• For indoor - One shop coat of red oxide zinc

chromate primer and two site coats of aluminium
alkyd paint.
• For outdoor & corrosive areas like battery room,

DM plant - Hot dip galvanised.
(g) Cable Carrier Installation practice
(i) Minimum level difference between two tiers of horizontal

cable trays in building, trenches shall be 300 mm. In
vertical race ways with multi-tiers the tiers shall be
located atleast with 400 mm intervals.
(ii) In trenches & tunnels the width of the cable tray shall be
limited to 600 mm. In case of horizontal trays it shall be
limited to 800 mm.
(iii) Separate cable trays/tiers shall be provided for different

voltage grade cable viz., 6.6 kV power, 400V/230V
power, control cables and instrumentation &
communication cables. Communication links wherever
redundant shall be run in different conduits and in
separate trays.
(iv) Cable trays shall be supported at every 1000 mm

interval. Cable trenches around the transformer shall be
filled with sand.
(v) Cable trays shall be welded to the mounting/carrier

structures.
(vi) Vertical trays (raceways) and all outdoor cable trays shall
be provided with removable 16 guage galvanised MS
sheet covers.
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(vii) Each continuous laid out length of cable tray shall be

earthed at minimum two places by MS flats of minimum
size 25mm x 3mm, the distance between earthing points
shall not exceed 10 metres.
(viii) When cables are taken in vertical raceways / trays and

they pass from one floor & other floor pipe sleeves in
concrete shall be provided.
(ix) At least 300mm clearance shall be maintained between

the top tray and beams, piping or other obstacles to
facilitate installation of cables in the tray. A working space
of not less than 600mm shall be maintained on atleast on
one side of each tray.
(x) No cables shall be mounted near hot zones like hot flue
gas duct, steam pipe, etc.
15.7 Cable Installation
15.7.1 Cables to each circuit shall be laid in one continuous length. Cable
jointing and splicing shall be avoided. Jointing will be allowed only for the
cases where the route length is more than the maximum possible drum
length.
15.7.2 Outdoor cable installation
(a) Where cables cross roads and water, oil, gas or sewage pipes, the
cables shall be laid in hume or steel pipes. For road crossings, the
pipe for the cable shall be buried at not less than 600 mm. Hume
pipes shall be preferred to steel pipes from the point of view of
corrosion.
(b) The cables shall be tied to tray rungs by means of 3mm dia. nylon
cord at an interval of 5000 mm and also at bends.
(c) For good sealing arrangement at entry points, suitable pipe

sleeves, adequate in number and of adequate sizes shall be
provided in building walls/slabs for passage of cables into a
building from cable trays/racks/cable trenches located outside the
building.
15.7.3 Cables in Trays / on Racks
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(a) Different voltage grade cables shall be laid in separate trays. When
trays are arranged in tiers, HV cables shall be laid in top trays and
cables of subsequent voltage grades in lower tiers of trays.
(b) The HV power cables shall be laid in trays/on racks as follows:
i) In single layer only without exception.
ii) 3 core cables to be laid in touching formation.
iii) Single core cables to be laid in trefoil groups.
(c) 1100V grade power cables of 120 mm² size and above shall
normally be laid in single layer in trays/on racks.
(d) Smaller 1100V grade power cables below 120 mm² may be run in
double layers, where required, due to space restrictions.
(e) Control and instrumentation cables can be laid upto a maximum of

three layers in each tray/rack. Approximately 10% space on the
cable trays shall be provided for future.
(f) Single core power cables for 3 phase AC circuits laid in

trays/racks/ trenches in trefoil groups shall be held in trefoil clamps
placed at an interval of 3 m. The trefoil groups of cables shall be
additionally tied by means of 3 mm dia. nylon cord as follows:
(i) At an interval of 1m when laid in cable trays/racks.
(ii) At an interval of 750 mm when laid in trenches without

cable trays.
(g) Control cables and small power cables on racks shall be run in
ladder type cable trays supported on rack carrier arms. The cables
shall be tied to tray rung by means of 3 mm dia. nylon cord at an
interval of 5000 mm and also at bends.
(h) All cables assigned to a particular duct / conduit shall be grouped

and pulled in simultaneously using cable grips and suitable
lubricants. Cables removed from one duct/conduit shall not be
reused without approval of Owner.
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(i) Cables shall be segregated as per IEEE Std.-422. In vertically

stacked trays, the higher voltage cable shall be in higher position
and instrumentation cable shall be in bottom tier of the tray stack.
The distance between instrumentation cables and those of other:
system shall be as follows :
From 6.6 kV tray system - 914 mm
From 400V tray system - 610 mm
From control cable tray system - 305 mm
(j) The cables emanating from redundant equipment / devices shall

be routed through different routes. The above segregation of
cables & wiring for redundant equipments/ devices shall be in
accordance with IEEE-Std-422.
15.7.4 Bending radii for cables
The bending radii for various types of cables shall not be less than those
values specified by the cable manufacturer.
15.7.5 Terminations, clamping and miscellaneous details
(a) Cable entry to motors, push button stations and other electrical
devices shall be from the bottom as far as possible or from the
sides. Top entry of the cables is not acceptable particularly for
outdoor equipments.
(b) All cables shall be identified by tag. Nos. provided in Owner's

approved format at both the ends as well as at an interval of 5
meters. Identification tags made from aluminium sheet shall be
attached to each end of each cable by means of GI binding wire.
Tags shall be additionally put at an interval of 30 metres on long
runs of cables and in pull boxes.
(c) All cable terminations shall be done with solderless crimping type
lug. Cable terminations shall be done with double compression
type brass cable glands.
(d) Saddle type clamps to suit number of cables to be clamped at a

particular location shall be used for clamping cables running along
walls, ceilings, structures, etc. at 750mm interval.
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15.7.6 Termination and jointing kits for 6.6 kV grade XLPE insulated cables shall
be of proven design and make which have already been extensively used
and type tested. Termination kits and jointing kits shall be heat shrinkable
type/push on type. 6.6 kV grade joints and terminations shall be type
tested as per IS:13573. Cable jointing shall be carried out only by
Raychem certified jointers only. Straight through joint and termination
shall be capable of withstanding the fault level for the system. 1.1 kV
grade Straight Through Joint shall be of proven design.
15.7.7 Testing and commissioning of cables
(a) Cables shall be checked for insulation resistance before and after
jointing.
(b) High voltage testing
All cables of 1.1 kV grade 400 mm² and above and all HV cables
shall be subjected to DC or AC (preferably DC) high voltage test
after terminating but before commissioning as per Table 4 in
IS: 1255.
15.7.8 Earthing
(a) Metallic sheaths, screens and armour of all multicore cables shall
be earthed at both equipment and switchgear end.
(b) Sheath and armour of single core power cables shall be earthed at
switchgear end only. For long lengths of cables multiple earthing
may have to be adopted to safeguard against the presence of
standing voltages under normal as well as fault conditions.
15.7.9 Fire proof sealing system (FPS)
(a) Fire proof sealing system shall consist of
(i) Fire-stops/fire-seals for sealing of cable/cable tray and

conduit/pipe penetrations, both horizontal and vertical,
through brick or RCC walls/floors, to prevent the spread
of fire from one area, which is separated from others by
fire-resistant barriers.
(ii) `Fire-breaks' provided on long runs of cable racks/trays

to prevent the propagation of fire along the cable rack,
within a single fire-area or fire- zone.
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(b) The FPS system shall also include all the necessary accessories
and equipment required for supporting, holding in position, fixing
and installation of the fire-stop/fire-break.
(c) The FPS system shall comply in all respects with the
requirements of the codes and standards listed below
IEEE-634
ASTM-E-814
ANSI-IEEE-383
IEC-60331
IEC-60332
(d) Fire Stop/Seal
The FPS system adopted for cables or cable trays penetrating

through walls and floor openings, or cables passing through
embedded conduits/pipes/ pipe-sleeves, constitutes a `fire
stop/seal', which is meant to prevent spreading of fire between
areas separated by fire-resistant barriers.
(e) Fire Break
The fire proofing system, other than fire-stops, adopted to retard

flame propagation along long runs of horizontal or vertical cable
trays in the same fire zone or area, in an event of a fire, shall
constitute a `fire-break' and shall be provided by applying a
suitable fire-resistant coating on cables and cable trays for the
required length, with or without a fire resistant panel, at the point
of the fire break to obtain the fire-rating specified.
(f) Performance Requirements
(i) Requirement of fire stops
• The material, design and construction of the fire

stops shall be such as to provide the fire rating of
120 minutes for a fire on any side and meet all
requirements listed in this specification and the
relevant codes and standards.
• The materials used in the fire stops shall be non-

hygroscopic, compatible with the type of cables.
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• The fire stops shall be suitable for retrofitting of

cables through the penetration seal without
disturbing the sealing of the cables already
existing.
(ii) Requirements of fire breaks
• Each firebreak shall have a fire rating of 30

minutes and shall be capable of withstanding for
the duration specified, a fire on any side of the
fire break.
(g) Application of fire proof sealing system
(i) Fire stops
Fire stops shall be provided for cable penetration

openings listed below
• The passage of cables/cable trays pipe

sleeves/embedded conduits through walls /
floors.
• Vertical raceways, which carry cables between

successive floors, through openings provided in
the RCC floor slab, shall be sealed by fire stops
at each floor level.
• Cable entry through openings in floor slabs

below MV/LV switchgear, MCCs, various control
and relay panels and other bottom entry panels,
shall be effectively sealed by fire stops.
(ii) Location of fire breaks
• Fire breaks shall be provided on both cable rack

and trenches at all cable tray intersections and
tee-offs.
• On linear runs of cable trays between fire stops

or fire breaks, fire breaks shall be provided at
intervals of 15 metres on horizontal cable runs
and 5 m on vertical cable runs.
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• Fire breaks in linear runs of cable trenches

between intersections and tee-offs shall be
provided at intervals of 30 metres.
15.7.10 Contractor shall furnish the test certificates for the fire stops and fire
breaks after award of contract for Owner’s review. If the certificates are
not satisfactory all the tests shall be conducted free of cost. The offered
system i.e. fire stops and fire breaks shall be identical (or better) with the
system which is successfully type tested for the specified rating i.e. the
composition density of the material, thickness of coating in case of fire
breaks and any other properties of the material / system offered shall be
identical or better than the tested system and shall be subject to Owner’s
approval.
15.7.11 Performance Tests: Tests on Fire Stops
(a) The fire stops shall be subjected to the following type tests:
(i) Fire Rating Test

(ii) Hose Stream Test
(b) Type tests shall be conducted on different fire stop test

specimens described above as per IEEE-634. The sizes of the
fire stop test specimens shall be similar to the largest of the sizes
being used in the plant.
(c) Preconditioning of fire stop test specimens

Before conducting the fire rating and hose stream tests, each test
specimen shall be preconditioned for thermal ageing, water
immersion and vibration.
(d) Test on Fire Stops
During the fire rating test, the transmission of heat through the
cable penetration fire stop shall not raise the temperature on its
unexposed surface above the self ignition temperature of the
outer cable covering, the cable penetration fire stop material, or
material in contact with the cable penetration fire stop, with a
maximum temperature limit on the unexposed surface of 200oC.
(e) Tests on fire breaks
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Fire breaks shall undergo the following tests as per ANSI-IEEE-

383:
(i) Ampacity test
(ii) Flame test
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SHEET 1 OF 16
SPEC. NO.
ELECTRICAL SYSTEMS - LIGHTING SYSTEM TCE.5960A-H-500-001
16.0 LIGHTING SYSTEM
Lighting system shall be provided for the proposed plant covering all the
buildings, outdoor areas, roads, yards, boundary, etc. The lighting
system shall be to owner’s approval, having good aesthetics and
designed to provide the required illumination levels in all areas and to
meet the fire and safety codes.
16.1 Categories of Lighting
16.1.1 The plant lighting system shall comprise the following four (4) categories:
(a) Normal 230 V Single phase AC lighting system
(b) Normal-cum-Emergency 230 V Single phase AC lighting system
(c) Emergency 220V DC lighting system
(d) Maintenance 24V AC Lighting System
16.1.2 Normal 230V AC lighting system
In this system, the lighting circuits shall be fed by the 400V, 3 phase, 4
wire, normal AC supply available from the normal lighting distribution
boards. All the lighting fixtures connected to this system shall be
available as long as supply is available from normal source viz., auxiliary
transformer.
16.1.3 Normal cum emergency 230V AC lighting system
Certain lighting fixtures considered essential shall be connected to this

system. In this system the lighting circuits shall be fed from another
lighting distribution board from normal/emergency section of the 400V
main switchboard. The lighting fixtures connected to this system will be
available whenever normal supply is available in the plant and also
whenever emergency DG set supplies the power to this bus section
during blackout conditions. During blackout conditions, the lighting
fixtures connected to this system will go off and shall come back as soon
as the DG set starts feeding power to the 400V normal-emergency bus
section.
16.1.4 Emergency DC lighting system
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(a) During station emergency involving total AC failure, incandescent

lamp DC lighting fixtures shall be provided for movement of
personnel in GTG and STG buildings, Control & Switchgear
Building, Switchyard Relay Building at strategic locations viz.,
near entrance, staircase, landings etc. and for lighting the control
room and DG set area.
(b) These fixtures shall be connected to lighting panels supplied

from 220V DC station battery. These lighting fixtures shall be
normally kept ÒFF'. All the area in the plant shall have the
same philosophy & DC lighting for these areas shall also be from
the station battery.
(c) Lighted exit signs shall be provided and installed in the control &
switchgear room, relay room, maintenance area etc.
(d) Minimum one number of instalite shall be provided in all

switchgear rooms pump houses and control rooms where DC
lighting not envisaged.
16.1.5 Maintenance 24V AC Lighting System
For lighting facilities comprising portable hand lamps and/or connection

of portable hand tools etc., required during the routine maintenance work,
24V single phase 3 pin sockets with switches shall be provided at
selected points such as HRSG area, TG building Hall, Cable galleries
and any other areas considered necessary by CONTRACTOR. Such
sockets for routine maintenance shall be clearly identified by colour
coding in order to distinguish them from the normal 230V power outlets.
Necessary outlets shall be made on the inside walls of the building near
equipments.
16.1.6 The area-wise distribution of lighting fixtures connected to the systems

discussed above shall be as follows:
----------------------------------------------------------------------------------------------------------------
Percentage wise distribution of Lighting
Area /Building -------------------------------------------------------------------
Normal Normal &
Emergency 220 V DC
-----------------------------------------------------------------------------------------------------------------
GTG, STG, buildings 80% 20% *
Switchyard control room 80% 20% *
Switchgear and battery rooms, control
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room in Control & Switchgear building 80% 20%

HRSG area 80% 20% *
Transformer area & 400kV switchyard 100% - -
Pump houses, Admin building
Canteen 100%
Roads & out going areas 100% - -
DG set control room 80% 20% *
----------------------------------------------------------------------------------------------------------------
* Adequate for personnel movement and also located at strategic

locations.
16.2 Lighting Supply Distribution System
16.2.1 Normal and normal emergency AC systems
(a) For these systems, the distribution shall be by 400V, 3 phase, 4

wire, 50 Hz supply with effectively earthed neutral. This supply
shall be derived from 400 V, 3 phase, 3 wire, 50 Hz unit service
switchgear by providing a 400 / 400V delta/star lighting
transformers. The secondaries of lighting transformers shall be
connected to 400 V, 3 phase, 4 wire, AC lighting distribution
boards (LDBs) having 2x100% incomers & a bus-coupler. The
LDBs will be provided with number of outgoing circuits controlled
by MCBs to feed the lighting panels and by MCCB/Contactors to
feed around the plant as well as to directly feed three phase
street lighting and yard lighting supplies.
(b) AC lighting panels shall have 3 phase, 4 wire incomer with ELCB
and number of 1 phase outgoing circuits controlled by MCBs.
Lighting panels feeding the Lighting fixtures in indoor areas shall
be controlled from the respective lighting panels located in
various buildings in the plant. Road, yard lighting and aviation
warning lights also shall be contactor controlled. All outdoor
lighting system and aviation warning lighting system shall be
automatically controlled through photoelectric controllers.
Provision to bypass the timer or photocell shall be provided in the
panel. Also manual switching òn and off' facility shall be
provided. The Infrared sensing system shall be used for the
control of lighting in unmanned substations.
16.2.2 220 V DC lighting system

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Emergency DC lighting supply distribution shall be on 220V DC, 2 wire

unearthed system. Minimum 10% of 220V DC lighting shall be provided.
This power supply shall be obtained from station 220V DC switchboard.
DC lighting panel shall be provided for distribution of lighting supply. This
panel shall have an incoming switch, undervoltage relay and number of
outgoing circuits controlled by switch fuses. No voltage at the normal
emergency switchgear shall be sensed and DC contactor shall be
switched on thus extending DC supply to the lighting circuits.
16.3 Illumination levels and choice of lighting fixtures
The area-wise distribution of average illumination levels and type of

luminaires shall be as given below.
Sl. Area/ Structure Average Type of Fixture Type of Luminaire

No. Illumination
Level in Lux.
1. GTG, STG Building / Control
& Switchgear building
(a) General (auxiliary equipment 200 Medium /low bay fittings / 1 x 70 W / 1 x 150
areas) Industrial well glass vitreous W HPSV lamp
enamel reflector integral
mounted control gear/
industrial bulk head with
integral mounted control gear.
All the lighting fittings shall
have separate control & gear
box arrangement. The control
box shall be fixed on the
wall/column for the easy
maintenance.
(b) Cable vault 150 Industrial type with vitreous 2 x 36W
enamel reflector fluorescent lamp
(F.L)- Trulite
(c) All switchgear room area 250 Industrial type with vitreous 2X36W fluorescent
(including off-site building enamel reflector lamp (F.L)-Trulite
control room)
(d) GTG Building 200 Industrial high bay with 1x400 W, Metal
anodised aluminium reflector Halide Lamp,
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No. Illumination
Level in Lux.
Industrial High with
Anodised
Aluminium
Reflector
(e) Control room 500 Decorative recessed with wide Energy efficient
angle mirror optic anti glare Lamp – T5
type
(f) Battery rooms 250 Vapour proof 2X36W F.L.-Trulite
(g) A/C plant room 200 Totally enclosed vapour proof 2 x 36W F.L
with clear acrylic cover
-Trulite
(h) Unloading and maintenance 250 Industrial high bay 1x400 W, Metal
bay Halide Lamp,
Industrial High with
Anodised Alumi-
nium Reflector
(i) Electrical / Instrument 250 Decorative recessed with wide 2X 36W F.L.
laboratory, chemical laboratory angle mirror optic anti-glare
-Trulite
(air-conditioned) type
(j) Chemical laboratory (non-air 250 Corrosion proof 2 X 36W F.L.
conditioned)
-Trulite
2. HRSG area
(a) HRSG area and platforms
Dust proof / dust tight well
(i) Indoor 150 70W HPSV lamp
glass fixture
(ii) Outdoor 50
3. Transformer Area
(a) General 30-35 Flood light medium beam type 1 x 150W HPSV
lamp
(b) Near equipment 35-50 Dust proof / dust tight well 1 x 70W HPSV
glass on fire partition walls
4. Switchyard Area
(a) General 30-35 Flood light medium beam type 1 x 150W HPSV
lamp
(b) Near equipment 35-50 Post top lantern with HDP 70W HPSV
reflector
(c) Switchyard Control room 500 Decorative recessed with wide Energy efficient
angle mirror optic anti glare Lamp – T5
type
5. Various Off-site building
(a) Switchgear room (All pump 200 Industrial type with vitreous 2 x 36W F.L.
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No. Illumination
Level in Lux.
house) enamel reflector upto
mounting height of 8M
(b) Outside working areas 70 Flood light medium beam
(c) Equipment room (Pump house, 250 Industrial high bay / medium 1x400W / 1x150W
Compressor & DG house) bay depending on height Metal Halide Lamp
(HPMV)
6. DM Plant / Filtration Plant
(a) General 250 Corrosion proof 1 X 70 WHPSV
7. Road and yard lighting
(a) Main roads 20 Street light with clear acrylic 1 x 70W / 150W
cover cut-off type with integral HPSV
Secondary roads 10
mounted control gear or LED
fixtures with control gear.
(b) Perimeter (compound) lighting 20 - do - - do -
(c) Parking area (Indoor / sheds) 70 General purpose flood light, 1 x 250 W HPSV
high/medium beam flood light
8. Workshop building 300 Industrial type with vitreous 2X36W F.L x
enamel reflectors/industrial 250W HPSV
high bay
9. Administration Building
(a) Main office areas cabins (air 200-250 Decorative recessed type with 2 x 36W F.L.
conditioned areas) mirror optic reflector
(b) Main office areas, cabins with 200-250 - do - - do -
false ceiling but non-air-
conditioned
(c) Main office areas, cabin non air- 200-250 Decorative with wide angle - do -
conditioned areas without false mirror optic reflector
ceiling
(d) Warehouse, canteen, medical 150 Industrial type with vitreous 2 x 36W F.L.
centre enameled reflector
10. General
(a) Corridors, walk-ways, staircase, 150 Industrial type with vitreous 2 x 36 W F.L.
etc. enamel reflectors/channel
mounted box type compact
flourescent lamp
(b) Lockers, toilets, wash rooms, 100 Channel mounted box type 2 x 36 W F.L.
etc.
(c) Building periphery lighting - Industrial well glass with 1 x 70 W HPSV
integral mounted control lamp
gear/industrial bulk head with
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No. Illumination
Level in Lux.
integral mounted control gear
(d) Security, Time office, Gate 150 Decorative with louver 2x36W F.L
house, Executive canteen
11. Elevator
(a) Elevator machine room 100 Industrial type vitreous 2 x 36W F.L.
enamelled reflector
(b) Elevator well 20 Industrial bulk head/ industrial 1 x 100 W
bulk head with integral incandescent lamp
mounted control gear / 1 x 70W HPSV
12. DC Light Fitting
(a) Control room - Decorative recessed type with 1 x 100 W
cylindrical reflector incandescent lamp
(b) Other areas - Industrial bulk head or 1 x 100 W
industrial well glass with incandescent lamp
reflector
The illumination levels for areas, which are not specifically covered
above, shall be decided based on illumination levels indicated for similar
areas or in relevant standards.
16.4 Lighting System Design
The lighting system design shall comply with the acceptable norms and
the best engineering practices. The system design shall consider
principles of lighting specified in following paragraphs. The lighting layout
shall be designed to provide uniform illumination with minimum glare.
The layout design shall meet all the statutory requirement, local rules etc.
16.4.1 Indoor lighting
The illumination level for various areas in the plant is indicated in the
table above. Following factors shall be considered while arriving at the
utilisation factor to determine the number of fixtures for each
area/building in the plant.
(a) Maintenance factor
(i) Control room and system cabinet room - 0.8
(ii) All other indoor areas - 0.7
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(iii) Out door areas - 0.6
(b) Reflection factor for wall and ceiling
(i) Control room and system cabinet room - 0.7 ceiling,

0.5 wall
(ii) Other areas - 0.5 ceiling

0.3 wall
(c) The value of the ratio of spacing (S) to mounting height (H) shall
be commensurate with the type of fittings selected, uniformity of
illumination. The suspension height for suspended fixtures shall
not exceed 1 metre.
(d) The control room lighting shall be designed such that no glare
from the lighting appears on the DCS-CRT from any angle.
16.4.2 Roadway lighting
(a) Lighting design for roadways shall consider a maintenance factor

of 0.6 for average conditions.
(b) Ratio of minimum to average illumination shall not be less than

0.3. The road lighting layout shall consider the width of the road
to decide whether the lighting poles shall be located on one side,
on either side or in the central reserve.
(c) The mounting height of the luminaires shall be generally 9

metres.
(d) The control gear for street light shall be of non integral type i.e.,
the control gear of the light fixture shall be mounted at the foot of
the pole.
(e) The lighting poles shall be galvanised steel poles with

reasonably thick layer of galvanising for ensuring long life.
16.4.3 Selection of lighting fixtures and accessories
16.4.3.1 The type of luminaires and accessories like switches, receptacles etc.,
shall be selected based on the plant area in which they are intended to
be used. Lighting fixtures shall be explosion proof in hazardous and fuel
oil areas.
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16.4.3.2 All fluorescent fixtures, shall have electronic chokes with low harmonics &
energy efficient 'T5' type fluorescent lamps except the fluorescent fixtures
used for division 2 hazardous area. The louvers of these fixtures shall be
designed for 'T5' type fluorescent lamps. All fluorescent lamps shall be
have "Cool day light" colour designation. The mirror optics type
fluorescent fixtures shall have no iridescence effect.
16.4.3.3 All HPSV and HPMV lamp fixtures or LED fixtures shall be provided with
wire-wound ballasts. All fluorescent fixtures except for Class-I, Div-II
fittings/ increased safety fittings (Div-II/Hazardous Area) shall be provided
with electronic ballasts.
16.4.3.4 Conduits, Pipes and Accessories Galvanised heavy duty steel conduits
for normal area and galvanised heavy duty steel conduits with an
additional epoxy coating for corrosive area shall be offered.
16.4.3.5 Rigid steel conduits shall be heavy duty type, hot dip galvanised
conforming to IS : 9537 Part-I & II shall be suitable for heavy mechanical
stresses, threaded on both sides and threaded length shall be protected
by zinc rich paint. Conduits shall be smooth from inside and outside.
16.4.3.6 Flexible conduit shall be water proof and rust proof made of heat resistant
lead coated steel.
16.4.3.7 Pull out boxes shall be provided at approximately 4 (four) metre interval in
a conduit run. Boxes shall be suitable for mounting on Walls, Columns,
Structures, etc. Pull-out boxes shall have cover with screw and shall be
provided with good quality gasket lining. Pull out boxes used outdoor
shall be weather proof type suitable for IP :55 degree of protection and
those used indoor shall be suitable for IP :52 degree of protection. Pull
out box & its cover shall be hot dip galvanised.
16.4.3.8 The poles shall be of ERW tubes of specified lengths, swaged tubular and
joined together. The complete pole shall be hot dip galvanised. The
terminal boxes for the lighting pole shall be IP55 protected & of glass
reinforced epoxy type.
16.4.3.9 Lighting Mast shall be of continuously tapered polygonal cross section hot
dip galvanised. The Mast shall be of 30M height with lantern carriage to
enable raising/lowering for ease of maintenance, including the Head
Frame, Double Drum Winch, continuous stainless steel wire rope, in built
power tool, luminaries, suitable aviation warning light, lightning along with
necessary power cables within the mast. The mast shall be delivered only
in three sections & shall be joined together by slip stressed fit method at
site. No site welding or bolted joints shall be done on the mast.
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16.4.3.10 Suitable collapsible / telescopic ladder shall be provided to approach

lighting fixture installed at height.
16.4.4 Switches and receptacles
(a) In the plant areas, the lighting circuits shall be controlled directly
from the MCBs in the lighting panels. Wherever the lighting panel
is not in the same area, separate switches shall be provided. For
cabins, rooms etc., separate switches shall be provided for each
point. Similarly for entrances, building periphery lighting separate
switches shall be provided.
(b) Receptacles with MCB (5A and 15A) shall be provided in all
building/areas of the plant. Also inside a building, receptacles
shall be provided at regular intervals so that any point of the
building is not more than 10 m with a minimum of 2 nos., in an
enclosed area. Inside each cabins atleast two receptacles shall
be provided. The same shall be indoor/outdoor/flameproof as per
the location. Suitable no. of 63A, 3 phase, 400VA.C industrial
heavy duty receptacles shall be provided for outdoor plant for
welding purpose. The industrial receptacle shall be provided at
an average distance of 50 mts. At-least two 63A, 3 phase, 400V
industrial heavy duty type receptacle shall be provided in each
building. It shall be metal enclosed with SFU and housed inside
with suitable connection for cabling and receptacles.
(c) Ceiling fans, to be provided in non air conditioned office/control

room area, shall be suitable for operation on 230 V, 50 Hz, AC
supply comprising of class ‘F’ insulated copper wound single
phase motor, 1200mm sweep, aerodynamically designed well
balanced MS blades (3 Nos.), down rod, die cast aluminium
housing, capacitor, suspension hook, canopies etc. finished in
stove enamelled white. Power factor of fans shall not be less
than 0.9. Each fan shall cover approximately 10m2 area.
16.4.5 Lighting distribution boards (LDB) & lighting panels (LP)
Each of the LDBs shall be provided with voltmeter and ammeter along
with selector switches, `Supply On' indicating lamps, etc. The LDBs and
LPs shall be sheet steel enclosed and shall be fully dust and vermin
proof, with a degree of protection of IP 54. Outdoor panels shall be
weather proof type with IP - 54 degree of protection. LDBs, LPs shall be
explosion proof wherever provided in hazardous and fuel oil areas. The
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switch boxes, receptacle boxes etc., shall be made up of 18 SWG sheet

steel.
16.4.6 The distribution of lighting fixtures/receptacles shall be such that the

loading on each phase of the LDB is approximately equal.
16.4.7 Wiring
(a) 1100 V grade stranded copper conductor, PVC insulated wires to

IS: 694 laid in GI conduits shall be used for lighting in non-
hazardous area. In the hazardous areas cable wiring with 1100 V
grade stranded aluminium conductor, PVC insulated, PVC inner
sheathed, GI wire armoured and overall PVC sheathed cables to
IS: 1554 shall be adopted. For outdoor areas like transformer
yard, switchyard and road lighting also cable wiring as above
shall be adopted.
(b) Minimum size of wires in case of conduit wiring shall be 2.5 mm2
in case of lighting and 4 mm2 in case of receptacle wiring.
Minimum cable size in case of cable wiring shall be 4 mm2 for
lighting and 6 mm2 for receptacles.
(c) Wires of different phases shall be run in separate conduits.

However wires of same phase but having different circuit nos.
can be run in same conduit. Wires of lighting and power
receptacles will be carried out in separate conduits and on
separate circuits. Wires of AC and DC lighting systems shall be
carried out in separate conduits.
(d) For outdoor lighting, the cable shall be buried at a minimum

depth of 750 mm from ground level. The buried cables shall have
suitable bedding, protective covers & markers.
(e) The wiring in the conduit shall be such that 20% space in the
conduit is free.
16.4.8 Lighting circuit design
(a) In an area, the lighting fixtures shall be arranged in different

phases/LPs such that even in case one lighting panel goes faulty
complete lighting is not affected. In case of room the lighting
shall be arranged from two phases.
(b) The circuit loading on each circuit shall be restricted to 80% of

the MCB rating.
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(c) The voltage drop from LDB and any fixture shall not exceed 3%.
(d) The contractor shall submit design calculation for sizing of LDBs
and also provide lumen contour for the main road and other
areas. Contractor shall demonstrate the same at location
decided by Owner.
16.4.9 Earthing
(a) Lighting fixtures, receptacles, switches, conduits and junction

boxes shall be properly earthed using 12 SWG GI wire run along
the entire length of the conduit between the fixture and the
corresponding lighting panel where it will be connected to the
station earth.
(b) For fixtures in hazardous areas, the third core of each single-
phase armoured cable circuit shall be used as earthing
conductor.
(c) For outdoor earthing of lighting poles, junction boxes on the

poles, 25 X 6 GS Flat, shall be run buried in ground at a depth of
600 mm and tapped to each lighting pole. The earth conductor
shall be connected to the nearby main earthing grid at the first
and last poles of each feeder circuit and at some intermediate
poles.
16.5 Tests
16.5.1 Type test reports of the following items as per relevant standards shall be
submitted for approval.
i. Lighting fixtures of each type
ii. Lamps of each type and rating.(life cycle and rating test
only)
iii. Lighting panel of each type (Degree of Protection)
iv. Junction Box of each type
v. Receptacles of each rating
vi. M.C.B. of each rating.
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16.5.2 All acceptance tests & routine tests for the lighting fixtures and
accessories covered in this specification shall be carried out as per the
relevant standards listed under "Codes and Standards” given below for
the respective fixtures/ components. Type test certificates shall be
furnished for review.
16.6.1 Electric Lighting Fittings General and Safety IS:1913

Requirements
16.6.2 Code of Practice for Industrial Lighting IS:6665
16.6.3 Calculation of Co-efficient of Utilisation IS:3646 (Part-III)
16.6.4 Industrial Lighting Fittings with Metal IS:1777

Reflectors
16.6.5 Decorative Lighting Outfits IS:5077
16.6.6 Dust Proof Electric Lighting Fittings IS:4012
16.6.7 Dust Tight Electric Lighting Fittings IS:4013
16.6.8 Electric Lighting Fittings for Division IS:8224

2 Areas as per IS:5572 (P1)
16.6.9 Flame Proof Lighting Fittings IS:4013

Part (I&II)
16.6.10 Flame Proof Enclosure IS:2148
16.6.11 Flood Lights IS:10322

Pt-V SECT-5
16.6.12 Luminaries for Street Lighting IS:10322

Pt-V SECT-3
16.6.13 Waterproof Electric Lighting Fittings IS:3528
16.6.14 Watertight Electric Lighting Fittings IS:3553
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16.6.15 Bayonet Lamp Holders IS:1258
16.6.16 Edison Screw Lamp Holders IS:10276
16.6.17 Bi-Pin Lamp Holders for Tubular Fluorescent IS:3323

Lamps
16.6.18 Starters for Fluorescent Lamp IS:2215
16.6.19 Holders for Starters for Tubular Fluorescent Lamps IS:3324
16.6.20 Ballast for Use in Fluorescent Lighting Fittings IS:1534 (Part 1)
16.6.21 Transistorised Ballast for Fluorescent Lamps IS:7027
16.6.22 Ballast for HP Mercury Vapour Lamp IS:6616
16.6.23 Capacitors for Use in Fluorescent, HPMV & LP IS:1569

Sodium Vapour Discharge Lamp Circuits
16.6.24 Vitreous Enamel Reflector for Tungsten Filament IS:8017

Lamp
16.6.25 Tubular Fluorescent Lamps IS:2418 (Part 1)
16.6.26 High Pressure Mercury Vapour Lamps IS:9900
16.6.27 Tungsten Filament General Electric Lamps IS:418
16.6.28 Cast Acrylic Sheets for Use in Luminaires IS:7569
16.6.29 Screwless Terminal and Electrical Connections for IS:10322 Pt-III

Lighting Fittings
16.6.30 High Pressure Sodium Vapour Lamps IS:9974

16.6.31 Emergency Lighting Units IS:9583
16.6.32 Ignition Proof Enclosures, Dust-Tight for IS:11005
Electrical Equipment
16.6.33 Luminaires (Part 1 to V) IS:10322

16.6.34 Arrangement for Busbars, Main Connections and IS 5578
Auxiliary Wiring and Marking IS 11353
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16.6.35 Enclosed Distribution Fuse Boards and Cut-outs for IS 2675

Voltages not exceeding 1000 V
16.6.36 General Requirements for Switchgear and Control IS 4237

gear for Voltages not exceeding 1000V
16.6.37 Code of Practice – Installation and Maintenance of IS 10118

Switchgear
16.6.38 Factory Built Assemblies of Switchgear and IS 8623

Controlgear for Voltages upto and including 1000 V
AC and 1200 V DC
16.6.39 Degree of Protection of enclosed equipment for IS 13947

Low Voltage Switchgear and Controlgear
16.6.40 Switches, Disconnectors, Switch Disconnectors and IS 13947 Part-3

Fuse Combination Units for Low Voltage
Switchgear and Controlgear
16.6.41 Miniature Air Break Circuit Breakers for AC Circuits IS 8828
16.6.42 HRC Cartridge Fuse Links upto 650 V IS 9224
16.6.43 Current Transformers IS 2705
16.6.44 Voltage Transformers IS 3156
16.6.45 Direct Acting Electrical Indicating Instruments IS 1248
16.6.46 AC Electricity Meters IS 722
16.6.47 Electrical Relays for Power System Protection IS 3231
16.6.48 Flameproof Enclosures of Electrical Apparatus IS 2148
16.6.49 Guide for Selection of Electrical Equipment for IS 5571

Hazardous Areas
16.6.50 Switches for Domestic and Similar Purposes IS 3854
16.6.51 Three-Pin Plugs and Socket Outlets IS 1293
16.6.52 Fans and Regulators, Ceiling Type, Electric IS 374
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16.6.53 Rigid Steel Conduits for Electrical Wiring IS 9537
16.6.54 Accessories for Rigid Steel Conduits for Electrical IS 3837

Wiring
16.6.55 Flexible Steel Conduits for Electrical Wiring IS 3480
16.6.56 Rigid Non-Metallic Conduits for Electrical IS 9537 Part-2

Installations
16.6.57 Fittings for Rigid Non-Metallic Conduits IS 3419 Part-2
16.6.58 PVC Insulated Cables for Working Voltages upto IS 694

and including 1100 V
16.6.59 Tubular Steel Poles IS 2713
16.6.60 Wrought Aluminium and Aluminium Alloys, Bars, IS 5082

Rods, Tubes and Sections for Electrical Purposes
16.6.61 Code of Practice for Phosphating Iron and Steel IS 6005
16.6.62 Fittings for Rigid Steel Conduits for Electrical Wiring IS 2667
16.6.63 Prestressed Concrete Circular Spun Poles for IS 13158

Overhead Power, Traction and Telecommunication
Lines
16.6.64 Methods of Test for Concrete Poles for Overhead IS 2905

Power and Telecommunication Lines
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SHEET 1 OF 7
EARTHING & LIGHTNING PROTECTION SYSTEM TCE.5960A-H-500-001
17.0 EARTHING SYSTEM
Earthing system shall consist of earth grids and electrodes buried in soil
in the plant area, embedded in concrete inside the buildings to which all
the electrical equipment, metallic structures are connected to have earth
continuity for safety reasons.
Earthing system shall be in strict accordance with IS:3043 and Indian

Electricity Rules/Acts.
17.1 Design Criteria

17.1.1 Fault Current & Duration
The earthing conductor shall be designed for 50 kA for duration of 1
second.
17.1.2 Conductor Material

The earthing system conductors and accessories as proposed are to be
as follows :
(a) Conductors above ground level : Galvanised steel

and in trenches
(b) Conductors buried in ground or : Mild Steel

embedded in concrete
(c) Electrodes : GS Pipe / Rod
(d) Lightning protection air termination : GS Flat

and down conductors for buildings
(e) Exposed lightning protection air : Lead coated copper

termination on chimney top
The Contractor shall undertake the soil resistivity measurements at site

and select suitable type and cross section of conductors.
17.1.3 Size of Conductors
(a) Main Earthing Conductors

The earthing conductor sizes shall be calculated as per IS 3043
and shall comply with Indian Electricity rules and IEEE-80.
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The calculated size shall be suitably (depending on the resistivity

of soil) increased as per table below to account for the loss of
material (steel) due to corrosion in soil.
Resistivity of Soil Reduction in

Ohm– Metric thickness/diameter, mm
>0 <10 8.0
>10 <25 7.0
>25 <50 5.5
>50 <75 4.5
>75 <100 3.0
>100 1.5
The minimum steel corrosion shall be 0.12 mm/year.
(b) Rod Electrodes
Galvanised steel rod electrodes of suitable diameter (min dia

40mm) and length shall be used as per the recommendation of
IS-3043. For test pits electrodes shall be heavy duty type (Class
– C) GI pipe of suitable diameter with perforations. Electrodes
installed in the test pits will have disconnecting facilities.
(c) Equipment Earthing Leads
The size of the earthing leads shall be decided based on the

type of equipment and structure to be earthed and shall be
provided generally as per IS-3043. However the min. size of the
of equipment earthing lead shall be 65x10 mm GS flat.
(d) Conductors for lightning protection system
The size of conductors for lightning protection system shall be

decided based on mechanical strength.
17.2 Earthing System Layout
17.2.1 The earthing system design and installation shall generally comply with
IS-3043, IEEE-80 and Indian Electricity Rules.
17.2.2 General
(a) Metallic frames of all current carrying equipment, supporting
structures adjacent to current carrying conductors, lightning
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protection system conductors and neutral points of various

systems shall be connected to a single earthing system. Two
earthing leads shall be used if rated voltage of equipment is
above 250V. If the rated voltage is 250V or below, one earth
lead shall be provided. Metallic structures adjacent to electrical
equipment shall be earthed by one earthing lead. Crane rails,
tracks, metal pipes and conduits shall also be effectively earthed
at two points. Steel RCC columns, metallic stairs, and rails etc.
of the building housing electrical equipment shall be connected
to the nearby earthing grid conductor by one earthing ensured by
bonding the different sections of hand rails and metallic stairs.
Metallic sheaths/screens, and armour of multi-core cables shall
be earthed at both ends. Metallic Sheaths and armour of single
core cables shall be earthed at switchgear end only unless
otherwise instructed by the Owner. Every alternate post of the
switchyard fence shall be connected to earthing grid by one GS
flat and gates by flexible lead to the earthed post. Portable tools,
appliances and welding equipment shall be earthed by flexible
insulated cable
(b) Earthing conductors in outdoor areas shall be installed at a

minimum depth of 600 mm.
(c) All cable trays in the plant buildings as well as inside the
trenches shall be connected to earth grid at an interval of about
10 m.
(d) Each side of the generator neutral earthing resistor shall be

terminated at two nos. treated pipe earth electrodes. The earth
pipe electrodes shall be further interconnected to the buried
earth grid.
(e) Neutral of the auxiliary transformers shall be directly connected

to two nos. treated pipe earth electrodes. The earth pipe
electrodes shall be further interconnected to the buried earth
grid.
17.2.3 Earthing Conductor Layout in Switchyard
(a) Main earthing conductors shall be laid in the form of a grid.

Spacing between conductors, number of parallel conductors,
etc., shall be decided such that step and touch potential are
within safe limits.
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(b) The maximum permissible step and touch potentials shall be

calculated in accordance with the formula, given in IEEE-80.
(c) Earthing conductors shall be provided around the outside edge

of fence at a distance of approximately 6000 mm. This shall be
connected to the switchyard earthing grid.
(d) An earthing mat comprising closely spaced (about 150 mm)

conductors shall be provided below the operating handles of
disconnecting switches and breaker operating kiosk for the
additional safety of the operating personnel.
(e) Each earth leads of transformer neutral, lightning arrester earth

leads, CVT’s earth leads shall be directly connected to two
separate electrodes, with treated earth pits. Lightning protection
down conductor shall be directly connected to a separate earth
electrode. All earth electrodes in turn shall be connected to
station earthing system. The earth grids of different areas of the
plant shall be interconnected through separate conductors & with
2 Nos. test pits, test pits to enable measurement of earth
resistance for each area separately.
(f) Earthing grid design shall be done in such a manner that the grid
resistance is less than 0.5 ohm.
17.2.4 Earthing Conductors Inside Building
(a) Main earthing conductors shall be buried in earth around the

building. Minimum two taps-off from this earthing loop shall be
taken inside the building and connected to the earthing grid
embedded in the floor slab with approximately 50 mm concrete
cover.
(b) In case, the building has more than one floor, each floor shall be
provided with earth grid. Floor earthing grids shall be
interconnected.
(c) Each RCC / Steel column of the building shall be interconnected

to the floor earthing grid in the ground floor.
(d) Cable trays, steel pipes / conduits, steel columns, etc., shall not
be used as earth continuity conductors.
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(e) Instrumentation system and computer system shall be provided

with a dedicated earthing system suitable for the equipment and
shall confirm to DCS manufacturer’s specification.
(f) Earthing grids of all the buildings, outdoor yards shall be

interconnected to form a single grid for the plant.
(g) Earthing grid design shall be done in such a manner that the grid
resistance is less than 0.5 ohm.
17.3 Earthing System Installation
17.3.1 The spacing between two electrodes shall be atleast equivalent to twice
the length of the electrode.
17.3.2 Earthing conductor running exposed on column, walls, etc., shall be

supported by suitable cleating, at intervals of 750 mm.
17.3.3 The earthing conductor crossing the road / track shall be laid in hume
pipe or laid at a greater depth to avoid damage.
17.3.4 When earth conductor passes through floors, walls, etc., suitable pipe
sleeves shall be provided and the same shall sealed after installation.
17.3.5 The connection between earthing pads / terminal to the earth grid shall
be made short and direct and shall be free from kinks & splices.
17.3.6 Metallic conduits and pipes shall not be used as earth continuity
conductor.
17.3.7 Street lightning poles, flood light poles & towers, their junction boxes
shall be connected to the earthing conductor to be run along with supply
cable. This earth conductor shall be in turn connected to earth grid at two
extreme points.
17.3.8 Flexible earth conductors shall be provided at expansion joints for

earthing the gates, operating handles, etc.
17.3.9 Equipment bolted connection after being checked and tested shall be
painted with anti-corrosive paint / compound.
17.3.10 Connection between the equipment earth lead and the grid conductor
shall be welded. For rust protection, the welds shall be treated with zinc
chromate primer and coated with zinc rich paint.
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17.3.11 The cable sheaths, screens armour shall be earthed at both ends for
multi-core cables. For single core cables the same shall be done at one
end (switchgear end) only.
17.3.12 All bimetallic connections shall be treated with suitable compound to

prevent moisture ingression.
17.3.13 Alternate switchyard fence posts shall be connected to the earth grid.
17.3.14 Contractor shall demonstrate the effectiveness of earthing system by

measurement of earth resistance, step and touch potential at different
location.
17.4 Lightning Protection System
Lightning protection system shall consist of vertical air termination rods,

horizontal roof conductors, down comers, test links and pipe electrodes.
17.4.1 Need for Protection
The need for providing the lightning protection system shall be

established by calculating risk index value for each building structure,
etc., as per procedure given in IS-2309 and any building whose over all
risk factor is more than 10-5 (as per IS-2309), shall be provided with
lightning protection.
17.4.2 Lightning Protection System Layout
(a) The lightning systems design and installation shall generally

comply with IS: 2309 code of practice for the protection of
building and allied structure against lightning.
(b) For stack air termination, rods interconnected by circumferential

conductors will be provided at the apex of flue and also upon
outer shell of the stack. The air termination system will be formed
by lead coated copper conductors to prevent corrosion of
conductors due to flue gas.
(c) For cooling towers, air termination system will comprise of

horizontal circumferential conductors at the top.
(d) Lightning masts shall be provided for switchyard. Calculation for

sizing, no. of lightning mast etc shall be furnished for approval of
Owner. Shield wire shall be provided between gantry support &
Power house building wall over phase conductors and shielding
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network shall be connected to switchyard earth mat. For

switchyard down conductors from the shield wires shall be run
along the tower and connected to rod / electrode. The zone of
coverage for the shield wires and 450 on end conductor shall be
considered as 600 between two conductors.
(e) Down conductors shall be as short and straight as practicable

and shall follow a direct path to earth electrode. All joints in the
down conductors shall be welded type. Each down conductor
shall be connected to a rod electrode which in turn shall be
connected to the station earthing system through test links.
17.4.3 Lightning Protection System Installation
(a) Conductors of lightning protection system shall not be connected

with conductors of safety earthing system above ground level.
(b) The down conductors shall be welded to steel structures at 1000

mm interval or cleated to wall at 750 mm interval. Wherever
welded, the weld locations shall be treated to provide rust
protection.
(c) Each down conductor shall be provided with a test link at a

height of about 1000 mm above ground level.
(d) All the metallic structures within a vicinity of 2000 mm shall be

connected to the lightning protection conductors.
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ELECTRICAL SYSTEMS – COMMUNICATION SYSTEM SPEC. NO.
TCE.5960A-H-500-001
18.0 COMMUNICATION SYSTEM
18.1 Intrasite Communication System
18.1.1 Intercom Telephone System (EPABX System)
(a) Micro-processor based, fully integrated, modular construction

type, modularly expandable digital electronics EPABX system
with capacity of 600 ports extendable to 800 ports shall be
supplied. The system shall be based on Pulse Code Modulation
(PCM)/Time Division Multiplexing (TDM), fully non-blocking
principle. The state of the art technology shall be used for
designing the system. The system shall be equipped with
necessary electronic cards for trunk lines and extension lines,
housed in a weatherproof enclosure, suitable for mounting in a
non-air-conditioned area. This EPABX shall be hooked to P&T
system by 40 tie lines, which shall include 20 direct lines. These
direct lines will be for the use of management cadre & control
room staff for direct communication with P&T subscriber without
operator intervention. The cable from P&T exchange to power
plant EPBAX shall be included in the contractor’s scope.
Additionally two cables of 50 pairs each shall be laid from the
plant EPABX system to the colony utility building as mentioned in
the section C2. These cables shall be laid in the suitable
conduits. The entire job shall be the scope of Bidder.
(b) The quantity of the trunk cards and extension cards shall be
selected in such a way so as to provide 10% spare capacity.
Electronic cards with intelligent processors shall be provided.
The system shall have compatibility for analogue telephone
instruments, digital (key) telephone instruments, and the special
feature telephones. The system shall be supplied with the
operator console as an in-built feature. Operator console shall be
equipped with a PC with tracking provision for all calls, call times
etc. and PC shall have provision to come over office automation
LAN. One spare port for operator console shall be provided.
(c) The system shall have 100% non-blocking feature. Redundancy

for control and processor card shall be provided. The system
shall be 100% fault tolerant. It should have computer (PC)
compatibility for data transmission.
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(d) The EPABX system shall have connectivity (hardware, software

and any / all other accessories) for Integrated Digital Network
(ISDN), Dual Tone Multi-Frequency (DTMF) Connectivity,
Computer (Local Area Network) LAN & Wide Area Network
(WAN), FAX as well as connectivity to Wireless System specified
in this section. The system shall be so interconnected that it
shall be possible to access any of the systems (Intercom/
Wireless) from any other system without human intervention in
any way.
(e) EPABX system shall be provided with the following:
(i) One (1) 48V DC High Discharge Plante Lead Acid

battery of adequate AH capacity with 10% margin
suitable for twelve (12) hours uninterrupted service of
exchange working at 100% capacity including its allied
systems.
(ii) One (1) float-cum-boost charger of suitable capacity to

supply power to the exchange. The battery charger
shall be suitable for the High Discharge Plante Lead
Acid battery specified above.
(iii) One (1) operator console.
(iv) Required number of telephone instruments.
(v) Two (2) dial testers for DC pulsing and DTMF telephone
instruments.
(vi) Three (3) line man hand held telephone sets with DC
pulsing and DTMF switchable with built in ringer unit and
crocodile clip.
(f) Call Billing software shall be provided with dedicated personal

computer with SVGA colour monitor, dedicated printer. Using this
software, it shall be possible to read from screen/obtain a print
out of calls made, called station, pager/wireless set with number
called, date of each call, duration of each call, number of
metered calls, extension/wireless/fax set from which call was
made, time at which each call was made. Besides the above,
the EPABX shall be provided with two Combo drives with
provision and facility including software to store/retrieve all the
above parameters to/from a disk. The call billing software shall
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also have facility for printing all / selected parameters listed

above at regular (site adjustable) time intervals as well as facility
to browse on screen/print any of the above parameters in any
desired format eg. Number of calls made from a particular
extension for a given period of time (selectable). Software lock
shall be provided to prevent unauthorised personnel gaining
entry to above. All above parameters shall be capable of being
stored automatically for a minimum period of 3 months. Erasure
of this information shall only be after adequate warning alerting
operator to take back up. None of the stored data shall be lost
for failure of power supply.
(g) EPABX shall have full self-diagnostic feature. All faults, besides
being annunciated by high intensity LED on the EPABX and
audio alarm, shall be displayed on the PC with component level
fault being displayed in English.
(h) The EPABX shall be provided with 120% capacity main power
supply unit with 100% standby power supply unit. On failure of
main unit, standby unit shall automatically cut-in. Annunciation
(audio and visual) shall be provided for each power supply unit
fail and also auto-changeover fail. Changeover time shall not
affect the EPABX/its allied systems in any way.
(i) The EPABX system shall be capable to accommodate the

EPABX system of the colony (which is not in scope of Bidder). It
shall have provision of 100 lines for interfacing with colony.
(j) The Bidder shall provide all the telephone instruments in the
plant areas at each working areas. The locations shall be
decided during detailed engineering. But the Bidder shall supply
at least 200 telephone instruments.
(k) Telephone Instruments
(i) The telephone instruments shall be indoor desk type or

indoor wall mounted type or outdoor wall mounted type
as required. The type of handset shall be selected
based on its location.
(ii) All desk type instruments for all subscribers shall have
keypad with push buttons.
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(iii) The instruments mounted outdoor shall be provided with

weather proof type enclosure.
(iv) Selected instruments shall be provided with additional

features to meet the special facility requirements as
mentioned below.
(v) Telephone instruments located in high ambient noise

level area shall be provided with loud ringing device and
sound proof booths.
(l) The following special features shall be provided on selected

instruments:
(i) Call interruption / priority – the handsets shall be

provided with a priority push button. After dialling from
this handset station, if engaged tone is received, the
caller can cut into the conversation by pressing the
priority service button.
(ii) Emergency alert – Dialling a number shall intimate a

fire or emergency alarm. The caller’s number shall be
stored to reduce / prevent the incidence of mischievous
calls.
(iii) Automatic call back – This shall enable the selected

subscribers, who receive a busy tone when calling
another extension to come on the busy extension. The
call back equipment shall make the connection as soon
as the called extension is free. While waiting for the call
back, calling party can use his telephone for other calls
as usual.
(iv) Automatic call diversion - This feature shall re-route a

call for an extension (A) to extension (B). This
arrangement shall function for all calls till it is reset.
(v) Conference call - This shall enable the subscribers to

set up telephonic conference involving atleast 5 parties.
(m) Cell phones with group arrangement to be provided.
18.1.2 Landline Telephones, Broadband connectivity
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a) Necessary number of ISDN / PSTN landlines would be provided at

strategic locations within the plant boundary. Broadband connectivity
would be provided at strategic locations for online access of data from
remote station.
18.1.3 Walkie Talkie( Wireless system)
18.1.3.1 This system shall include the following:
(a) Base stations with antennae, power supply units, inverters,

voltage stabilisers and all other accessories.
(b) Twenty (20) Nos. hand held two way transmitter receiver sets.
(c) Battery charger for hand-set batteries – 20 Nos.
(d) The system shall be capable of being coupled with the EPABX
and PA systems such that any wireless set can be contacted
from any of the EPABX-intercom extensions or PA system and
from the DTMF keypad of the portable radios it should be
possible to contact any of the EPABX – intercom number
through the EPABX.
(e) The wireless sets shall be addressable type and light weight.
(f) The system shall have a minimum operating range of 15 kms

between one base station to another base station. Range from
base station to handset is about 8 kms. Handset to handset is
about 3 kms.
(g) The power supply to the entire base stations shall be through the
UPS, to allow the radio communications during “Black Out”
conditions also.
(h) The exact details of requirements, installation design and

specifications shall be worked out during detailed engineering.
But the contractor shall consider the modern communications
system with above specifications for the purpose of bidding.
18.1.3.2 GPRS/CDMA mobile system of any reputed service provider can be

provided for wireless system. The mobile system coverage in the power
plant area should be 100%. The mobile system shall be interfaced with
plant EPBX and PA systems.
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18.1.4 Cables
The type of cables and their technical particulars shall be as per the
requirement of the system for giving best performance.
18.1.5 Tests
All the equipment covered in this specification shall be subjected to

routine tests as per relevant standards. Type test certificates shall be
submitted for review.
18.2 Public Address System

18.2.1 General Requirements
This specification covers requirements for selection, design, engineering,

manufacture, shop testing, type testing, erection and commissioning of
Public Address System as described below:
(a) The Public Address System shall consist of zones, sub-zones and
Exchanges to interface all these zones among them selves. The
zones shall also cover all off-site Plant Auxiliary Systems and shall
be finalized during detailed engineering, taking into consideration
the configuration of the combined cycle plant.
(b) All the above-mentioned zones shall be connected with a central

exchange to be located in Control room/ Control Equipment Room.
(c) The Contractor’s scope shall also include successful

demonstration of performance testing specified herein complete in
all respects along with cables, junction boxes, earth wire and
accessories like standard brackets, nut-bolts, glands, lugs, conduit
sleeves, etc., as required, to complete the proper installation
conforming to IS: 1881, IS: 1882 of all the equipments supplied as
covered in this specification. All equipment, accessories and
facilities required for completeness of this system shall be
furnished by the Contractor, whether these are specifically
mentioned herein or not.
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(d) The equipment furnished under this section shall meet the
requirements of all-applicable codes and standards as specified or
their equivalent international codes and standards.
(e) The Public Address System (PAS) offered by the Bidder shall be
from reputed manufacturer who should have designed,
manufactured, tested and commissioned a distributed amplifier
type industrial Public Address systems as specified in power
plants or large industrial installation as on the date of bid opening.
(f) The system shall be adequately protected from signal and power
line noise and meet the Surge Withstand Capability (SWC)
requirements of ANSI C37.90.1/ IEEE standard 472-1989
equivalent.
(g) The Bidder shall guarantee satisfactory performance of the

equipment under stipulated variations of voltage and frequency.
The design and manufacture shall be such that equipments/
components of same type and rating shall be interchangeable.
(h) In addition to the facilities to be provided by the Bidder as

mentioned in relevant clauses of this section the Bidder shall make
his own arrangements for any other requirements that are
necessary to put the system in service.
(i) All the items, including Public Address system erection hardware,
cables, cable erection hardware, telephone cables etc. as may be
required to make the PA system complete and functional are to be
furnished by the Contractor on as required basis.
18.2.2 Power supply arrangement
The Bidder shall provide power to the Public Address System from UPS
system as detailed in Section D3.14 of technical specifications. The
details shall be finalized during detailed engineering stage. In case the
Bidder's offered equipment is operating at any other voltage level, the
Bidder shall provide all required hardware, to make the offered system
compatible with specified power supply arrangement. The system shall
be fully functional during the total power supply failure of the plant.
18.2.3 System description
(a) Communication within a zone
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(i) PAS shall have two modes, i.e., Paging mode and Party
mode. Each of the two modes shall be open line, common
talking type. Paging mode shall be used for locating a
person and for general instructions. Party mode shall be
used for conversation between individuals without
broadcasting the same over the loudspeaker.
(ii) Whenever the 'Press to page' push button is pressed on

any of the handset stations, a pleasant chime shall be
broadcast over all loudspeakers except the one associated
with that handset station to attract attention. Conversation,
in paging mode shall be heard over all loudspeakers except
the loudspeaker associated with the handset station whose
'Press to Page' push button is being held in pressed
condition. When 'Press to Page' push button is released,
the associated handset shall return to party mode. When a
handset station is being used for party mode, its associated
loudspeaker shall be free to receive all paging calls.
However, the operator shall have the option of silencing the
associated loudspeaker by pressing "Loudspeaker mute'
push button, should he find it disturbing his conversation on
party mode. The loudspeaker shall return to normal
operation automatically when the 'loudspeaker mute' push
button is released. Simultaneous operation on both modes,
i.e. some handsets on party channel and some handsets on
paging channel, shall be possible without any crosswalk
between the two channels. During conversation on 'page'
mode within a zone, the centralized equipment/hardware of
the associated zone shall have the feature to monitor and
identify the handset from where conversation is being
continued with the 'page' button depressed and the access
code of the person. Further, suitable indication of 'Power
Supply on' and 'Party channel busy' shall be provided on
hand set stations.
(iii) Portable type handsets with Multipin plugs shall be used at

certain locations where operational personnel are not
present normally. Necessary sockets, wiring, etc., shall be
provided at these locations. The locations (distributed in
each zone) etc. shall be finalized during detailed
engineering.
(iv) Unless requested, announcements/ communication within a

zone shall not be audible in other zones.
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(b) Inter Zone Communication
(i) Each of the zones shall be connected to a Central

exchange to be located in Central Control room/ Control
Equipment Room. All the communication facilities like
paging and party mode communication as described above
between these two zones shall be possible as if they have
now become a single zone.
(ii) The Central Exchange shall have one master control unit
for each of the modules and one more master control unit
for Shift In charge Room. All the master control units shall
be connected in parallel. Any inter-zone communication
shall be possible through this master control unit. The exact
type of the same shall be decided during detailed
engineering. Further, it shall be possible to broadcast
recorded speech, music etc. over the loudspeakers.
(iii) Communication/ announcements within a zone shall not be

heard in loudspeakers of other zones. It shall be possible to
communicate from a station in one zone to another station
in other zone through the master control unit(s) only.
(iv) It shall be possible from a station in one zone to

communicate with another station in a different zone, both
in party/ page mode through the master control units
located on each module control desk at Control room and
Shift Incharge Room.
(v) Suitable built-in interface shall be provided for connection

with Owner's main telephone exchange in the Central
Exchange and/or Master Control Units through which it shall
be possible to communicate with any station in any zone
from any telephone set through Central Exchange and/or
Master Control Unit.
18.2.4 Handset Stations
(a) Handset stations shall be of the following types:
(i) Outdoor Wall/ column mounting type.(Type - A)
(ii) Indoor desk-top mounting type. (Type - B)
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(iii) Indoor control desk flush mounting type. (Type - C)
(iv) Mosaic grid compatible telephone set. (Type - D)
(b) Each handset station shall have following:
(i) One (1) - telephone handset.
(ii) One (1) - Cradle switch for resetting the handset.
(iii) One (1) - "Press to Page" push button.
(iv) One (1) -"Press to Mute Loudspeaker" push button.
(v) Pre-amplifier and Power amplifier.
(vi) Indication for 'POWER SUPPLY ON'.
(vii) Indication for 'PARTY CHANNEL BUSY'.

(c) The outdoor wall/ column mounting type handset stations shall be
dust-tight and weather-proof, with appropriate protection against
direct rain, ingress of dust and moisture conforming to IP-55
degree of protection as per IS: 2147. The indoor desk-top
mounting type handset stations shall have a degree of protection
of at least IP-32. The outdoor wall/ column mounting type handset
stations shall have covers with padlocking facility. All handset
stations and their components shall be capable of continued
satisfactory operation at an ambient temperature at 55°C.
(d) The control-desk mounting type handset stations shall be suitable

for flush mounting on Unit Control desk.
(e) Handset transmitter/ microphone shall be noise canceling type and

all switches and push buttons provided on the handset station
shall be of encapsulated contact type. Handset
transmitter/microphone shall have filters to protect from dust. Each
handset shall be provided with one meter (extended) retractable
coiled type of cable.
(f) All handset stations shall have a compact, robust, rust resistant,
shock-resistant body made of high impact polystyrene or
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equivalent. The Type-A handset shall be inside an enclosure with

transparent glass door, which can be opened through number
padlock only.
(g) The wall/column mounting handset stations shall be tamper-proof,

using internal anchoring bolts and peculiar (e.g. triangular head,
counter-sunk) screws which can be loosened only with special
keys. Constructions where the entire electronic part shall be
modular type and can be removed from the handset station
enclosure for easy maintenance. Terminal connections of different
PCBs should not be interchangeable.
(h) The handset stations in the noisy areas like Turbine Hall, BFPs,
etc., shall be housed in Acoustic hoods. An industrial type free
standing, floor mounted hood shall be used for providing the above
requirements. The design noise level within the hood shall be
limited to a maximum of 60 dB SIL.
18.2.5 Amplifiers
(a) Amplifiers shall be solid state, class-B, Push-pull type, in built with
the handset fully conforming to IS: 1301 & IS: 10426 or equivalent
international standard.
(b) Amplifiers shall have 0-100% volume control setting. with facility
for coarse and fine setting along with following controls which shall
be located inside the Handset Station.
(i) Input sensitivity control
(ii) Receiver volume control
(iii) Bass cut filter
(iv) Anti side tone control feature
18.2.6 Loudspeakers
(a) Indoor loudspeakers shall be cone type housed in sturdy metal

cabinet suitable for wall/ column mounting. The cabinet shall be
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treated with acoustic under-coats to prevent resonance. They shall

have IP-52 degree of protection as per IS: 2147.
(b) Outdoor loudspeakers shall be industrial horn type and of pressure

die cast aluminum construction. The mounting bracket shall be
with adjustable base suitable for vertical and horizontal orientation.
They shall have IP-55 degree of protection as per IS: 2147.
18.2.7 Central exchange & master control unit
(a) Central exchange shall be wide band microprocessor based

having associated circuitry for calling station identification and of
modular design. This exchange shall consist of all the necessary
control hardware, required for operation, monitoring, protection,
indication, switching, testing, measurement of all the voltages and
load conditions of the entire system, facility for checking of the
operation of all the stations and quality of speech from the master
control units etc. All the card etc. shall be plug in type. Solderless
termination shall be provided for every wiring. Systems bandwidth
shall be at least 200-10 kHz (±10 dB) and shall not alter frequency
response of the open line system. All the central exchange shall
be enclosed in a freestanding cabinet to be located in control
equipment room all the cable entries shall be from bottom only.
This shall be able to cater all the specified zones along with the
ability to interconnect at least ten (10) more zones for future
expansion. Suitable hardware for communication between any
handset of the Public Address System with Owner's Telephone
Exchange shall be provided. All the handsets shall have the
necessary arrangement for using it as a intercom telephone
instrument. It shall be possible to call to any of the intercom
number from any handset. Also, it shall be possible to announce
any message from any intercom phone and then communicate
with the handset selected by field user on party line. Further, all
the programming tools that will be required to program/reprogram
the system shall also be provided.
(b) Master Control Units shall be microprocessor based and of

modular design. These units shall be mosaic grid compatible flush
mountable type along with flexible goose neck type microphone,
luminous miniature push buttons for inter-zone communications,
alarm tone generation, fire alarm tone generation etc.
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18.2.8 Cables and junction boxes
The Contractor shall supply the cables required for PA system on as

required basis. The cables shall be of FRLS type. Colour of the outer
sheath shall be YELLOW. Sizes and details of cables are given below :
a. Mains cable : Multicore of minimum 1.5mm² cross-section

Copper conductor cable armoured with atleast
two spare cores.
b. Signal cable : Multicore multistrand with at least two spare

cores, twisted pair, minimum 0.5 mm² cross
section annealed copper (shielded and
armoured)
c. Loud : Multicore multistrand with at least two spare

Speaker cores, twisted pair, minimum 0.5 mm² cross
cable section annealed copper (shielded and
armoured)
18.2.9 Junction boxes

The junction boxes shall be supplied on as required basis.
18.2.10 Technical particulars

Public Address Systems shall conform to the following technical
parameters.
(i) Overall Installation
Band width (± 3 db) 400-6000 Hz
(ii) Amplifiers
(a) Band width (± 3 db) 200-10000 Hz
(b) THD not more than 1 % at 1 kHZ

at rated output
(c) Signal to Noise Ratio 60 dB
(iii) Microphones
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(a) Band width (±3 db) 200-7000 Hz
(b) Type Noise canceling type
(iv) Loudspeakers
(a) Outdoor wall/column

mounted Horn Type
(i) Capacity 15W (RMS)
(ii) Bandwidth(± 3 db) 200-7000 Hz
(b) Indoor wall/column

mounted Cone Type
(i) Capacity 4W (RMS)
(ii) Bandwidth (± 3 dB) 200-7000 Hz
18.2.11 The quantities for PA system mentioned below are minimum required
and will be finalised at the time of detailed engineering.
-----------------------------------------------------------------------------------------------
S.No Item Description PAS For Common Plant
(for each module)
--------------------------------------------------------------------------------------------------
1. Handset Stations
(i) Outdoor wall/column 30 10

mounting type - (nos.)
(ii) Indoor desktop mounting 3
type with extension
amplifier, (nos.)
(iii) Indoor control desk 2 2
mounting type with extension
amplifier.- (nos.)
2. Loudspeakers
(i) Outdoor Industrial 30 10

Horn type - (nos.)
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(ii) Indoor wall mounted 3

Cone type- (nos.)
3. Mosaic grid compatible 2 2

telephone set
4. Portable handset stations with

multi-pin plug and sockets
(i) Sockets-(nos.) 10
(ii) Portable handset stations 2

with plug (nos.)
5. Cables
(i) Mains cable - (km)- As required
(ii) Signal cable - (km) As required
(iii) Loudspeaker Cable-(km),

for interconnection of loud
speaker with handset station.
only. As required
6. G.I. earthling wire-(km) As required
7. Junction boxes – As required
8. G.I. Rigid conduit on as required – As Required

(Sizes to suit the cable)
9. Acoustic hood (nos.) 8
10. Master Control Unit 1
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FIRE DETECTION AND ALARM SYSTEM SPEC. NO.
TCE.5960A-H-500-001
19.0 FIRE DETECTION AND ALARM SYSTEM
19.1 Fire Detection and alarm system shall be redundant Microprocessor

based intelligent, analogue addressable type. Fire detection and alarm
system comprising automatic fire detectors, manual call points, fire alarm
panel, fire warning siren, cables, junction boxes, any other items to
complete the system shall be provided for the power plant.
19.2 The equipment/system supplied shall comply with the standards listed
below:
19.2.1 IS - 2189
19.2.2 NFPA - 72E
19.2.3 IS - 2175
19.3 The system shall be approved by any or all the following bodies besides
Tariff Advisory Committee (TAC) and Local Fire Authorities, National Fire
Protection Association (NFPA), Underwriters Laboratory (UL), Fire
Officer’s Committee (FOC), Factory Mutual (FM), Central Mining
Research Institute (CMRI), Dhanbad.
19.4 Fire alarm system shall be designed to provide continuous surveillance

against fire in the areas covered by the system under all conditions. Fire
detectors shall discriminate between false and real fire. It shall have
automatic calibrating features by decreasing/ increasing sensitivity levels.
It shall give a pre-alarm when it requires maintenance.
19.5 The type of detectors to be provided in the various areas of the plant shall
be as indicated below:
Area Type of Detector
GTG / STG Building Manual call points (MCP) & UV detectors
Switchgear room, Multi sensor detector & MCPs

Battery charger room
Control & electronic
Cubicle rooms
Battery room Rate of rise of temperature detector with fixed

temperature element (corrosion proof) and MCPs
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Below false floor of Photoelectric smoke detector and
Control room linear heat sensor cables
Above false ceiling of Multi sensor detectors

Control room
Cable galleries Photoelectric smoke detectors and liner heat

Sensing cables
Fuel gas pump house Flame proof type MCPs
Transformer yard Pedestal mounted MCPs

& switchyard
19.6 Rate of Rise of Temperature Detector with Fixed Temp. Element
These shall be resettable type i.e., the same detector shall be capable of
being reset after it goes to the alarm state.
19.7 Multi Sensor Detectors
19.7.1 This detector shall be capable of detecting a fire both in its incipient or
smouldering stages as well as visible flames. To meet this requirement
the detector shall respond to visible combustion products in the form of
smoke as well as in visible particles, aerosols and pyrolysis products from
a clear burning fire.
19.8 Optical Smoke Detectors
Optical smoke detectors shall work on light scattering principle.
19.9 Linear Heat Detection System (LHS)
19.9.1 Linear heat detection system shall be provided in area below false floor
& in cable galleries.
19.9.2 Linear heat detection system shall essentially comprise sensor cables,
interface units and necessary hardwares required for installation.
19.9.3 The Sensor cable shall be Optical fibre LHS cables.
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19.9.4 Linear heat sensor cables shall be run on all the trays below the false
floor of the control room. The sensor cables in cable vault end shall be
supported from ceiling to cover the top most tray and from underside of
the cable trays for bottom tiers.
19.10 The quantity of fire detectors and call points to be installed in each of the
areas shall be based on an average coverage area mentioned below.
The zones of individual detectors shall overlap and no blind zone shall be
left. However, the actual quantity of detectors required, taking into
consideration the obstruction due to floor beams, etc., so as to obtain
complete coverage, shall be worked out by the Contractor based on the
final drawings of the various buildings during detailed engineering.
19.10.1 35 to 40 sq.m per smoke detector for general application areas

considering an average room height of 5.5m.
19.10.2 15 to 20 sq.m per detector for I&C panel room, control room, relay room,
etc., in view of value concentration.
19.11 Each detector shall be provided with an indicating lamp glowing steadily
to indicate that it has operated which will otherwise flash intermittently to
indicate the healthy condition of the detector and sensing circuits.
19.12 When the detectors are mounted below the false floor or in inaccessible
position, response indicator for each of the detectors and test switch shall
be mounted on a separate box, which shall be suitable for mounting on
the wall. If the detectors are mounted above the false ceiling, response
indicators with test switch shall be mounted directly below the detector
(on the false roof).
19.13 Manual call points shall be provided as per the guidelines listed in NFPA
72E/IS 2189. Also, they shall generally be located near all the
entrances/exists for all buildings.
19.14 Contractor shall prepare layout drawings indicating the locations of

detectors, manual call points duly taking into account the regulations of
local fire authorities and submit for Owner’s approval.
19.15 Main Fire Alarm Panel
19.15.1 Fire alarm system shall be redundant Microprocessor based intelligent,

analogue addressable type, shall be complete with annunciator (with
windows) provided with necessary input modules, output modules,
external hooter/lamp control, interface units wherever required for
various control functions through relay contacts & communication
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modules, etc. for satisfactory operation of the system. The panel shall
be located in the control room. Necessary interface shall be provided
between the fire alarm panel and plant DCS for monitoring the system.
A dedicated operator station shall provide in the Main control room. The
paint shade of panel shall be shade Opaline green (External) and semi
glossy white (Internal).
19.15.2 The main fire alarm panel will continuously monitor the status of the
detectors and the connecting lines. The annunciation system shall have
visual and audible alarms, with acknowledge, test, reset, lamp test, etc.
push buttons. The panel shall have 'ON / OFF' PBs for operation of fire
siren.
19.15.3 Main fire alarm panel shall be provided with necessary contacts for
performing the following functions.
(a) Tripping of the air conditioning and ventilation system in the
- GTG hall, STG hall, switchgear room, Relay room

- Control room, I&C panel room, battery room&any other area
which is air conditioned /forced ventilated of the affected area.
(b) Contacts for initiating fire protection system.
19.15.4 Necessary grouping of the detectors/call points to actuate the above

shall be done by the contractor and the same shall be subject to Owner’s
approval.
19.15.5 High discharge plante Lead Acid batteries and battery chargers adequate
capacity shall be provided. The battery shall supply the normal power
requirements for a period of 48 hours from the instant of charger AC
supply failure, after which sufficient capacity would still be available to
provide full load operation for atleast 30 minutes. Full load being defined
as the load of all hooters sounding simultaneously along with operation of
all the associated visual signals, interlocks etc.
19.15.6 The detectors proposed to be provided for 400kV switchyard area shall
be connected to an independent fire alarm panel (with battery back-up)
located in Switchyard control room. This panel shall be suitably interfaced
with the main fire alarm panel in power plant control room. All the
constructional/functional features of this panel shall be same as the main
fire alarm panel.
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19.15.7 Visual alarm shall be povided in all the Control rooms, Electronic cubicle
room, Canteen, offices, conference halls and any other place where the
sound of the fire siren is not audible.
19.15.8 Suitable size & number of the sirens shall be used so that is audible in all
the direction & parts of the station.
19.15.9 All the fire alarm panels in the plant shall be of the same make.
19.15.10 The main fire alarm panel in the control room shall communicate with all
the fire alarm provided in the Gas / Steam Turbine area & in any other if
any.
19.16 Repeater Panel
All annunciation / indications in the main fire alarm panel shall be

repeated in the repeater panel to be supplied by Contractor. This shall
include the annunciations/indications of fire alarm panel located in
switchyard control building. The repeater panel shall be located in the fire
station. The cabling upto the repeater panel is included in the
Contractor’s scope. The paint shade of panel shall be shade Opaline
Green (External) and semi glossy white (Internal).
19.17 Junction Boxes (JB)
Junction boxes required for indoor and outdoor installations shall be 2

mm thick sheet steel and shall be hot dip galvanised. Degree of
protection shall be IP-65.
19.18 Cabling
19.18.1 The cables shall conform to specification indicated in Section D3.15
19.19 Tests
19.19.1 Contractor shall furnish test certificates/approval certificates for the

equipment/ system offered from the Regulatory bodies indicated in the
specification after the award of contract for Owner’s approval.
19.19.2 Performance tests shall be conducted at site on the system to prove that
the guarantees indicated for the individual components shall completely
satisfy all specific requirements. All tests required by the relevant
standards shall be conducted.
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1X700 MW CCPP AT NEDUNOOR, KARIMNAGAR DIST.
ELECTRICAL SYSTEMS - MOTORS SPEC. NO.
TCE.5960A-H-500-001
20.0 AC Motors
20.1 The motor and its accessories shall generally comply with the requirements
specified in the national and international standards indicated in Data sheet-
A3.20. Also Motors shall additionally comply with the specific requirements of
data sheet – A3.20 and specific requirements indicated below:
20.1.1 All HT motors shall be suitable for 6.6 kV, 3 phase, 50 Hz and LV motors shall
be suitable for 400 V, 3 Phase, 50 Hz power supply. The supply voltage and
frequency variation for 6.6 kV & 400 V shall be ±10% and +3/-5%
respectively. The combined voltage and frequency variation shall be of 10%.
20.1.2 The motors rated 175 kW and above shall be 6.6kV and motors rated upto
175 kW shall be 400 V. All LT motors shall be energy efficient. Motors shall
be continuously rated (S1). However, crane motors shall be rated for S4 duty,
40% cyclic duration factor. Motors shall be capable of starting and
accelerating the load with the applicable method of starting without exceeding
acceptable winding temperatures when supply voltage is 80% of the rated
voltage for HT motors and 85% for LV motors. HT motors shall also be
capable of satisfactory operation at full load at a supply voltage of 80% of the
rated voltage for 5 min. commencing from hot condition. The motors shall be
suitable for starting at 110% of the rated voltage.
20.1.3 Motors shall be capable of developing the rated full load torque even if the
supply voltage drops to 70% of the rated voltage. If such operation is
envisaged for a period of one second, the pull out torque of the motor shall be
atleast 205% of full load torque.
20.1.4 Motors shall withstand for 1 second the voltage and torque stresses
developed due to the vector difference between the motor residual voltage
and the incoming supply voltage equal to 150% of the rated voltage during
fast change over of buses.
20.1.5 Locked rotor current of motors rated 1500 kW and below shall be limited to
600% inclusive of 20% tolerance of the full load current of the motors and
motor rated above 1500 kW shall be limited to 450% (inclusive of 20%
tolerance) of full load current of the motor.
20.1.6 The locked rotor withstand time under hot condition at 110% rated voltage
shall be more than the starting time at minimum permissible voltage specified
above by atleast three seconds or 15% of the accelerating time whichever is
greater. Provision of speed switch shall be avoided to the extent possible.
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20.1.7 The degree of protection for the motor enclosure shall be IP-55 and IP-54 for
outdoor & indoor respectively and outdoor and indoor cable boxes shall be
provided with IP-55 and IP-54 respectively.
20.1.8 All HT motors shall be provided with vibration pads (in both X & Y directions
and at both DE & NDE) for mounting vibration detectors. Requirements of
vibration monitoring system shall be as specified in relevant I&C section of
specification.
20.1.9 Motors rated 1000 kW and above shall be provided with differential
protection. These motors shall be provided with star connected stator
windings. The 3 nos. current transformers, one for each phase shall be
mounted in a separate compartment in the neutral side terminal box. The
three phases shall be connected to form the star point after they pass
through the CTs. The CTs shall be of relay accuracy and the CT
characteristics shall be compatible with the differential relay. The additional
3 nos. CTs of identical characteristics shall be provided in the 6.6 kV
switchgear panel.
6.6kV & 400V motors wherever their protection is through the numerical
relay then energy meter reading shall be taken through relay itself by
communicating with it.
20.1.10 The ring oiling system shall be adequate for starting and continuous
operation of the motor for atleast one half hour without pressure oiling
system in operation.
20.1.11 For 6.6 kV motors, 6 nos. duplex RTDs for winding shall be provided. Each
bearing shall be provided with duplex thermocouple for bearing temperature
monitoring. These motors shall be designed to withstand atleast 2%
unbalance in supply voltage. In addition to temperature monitoring & alarms
in DCS local temperature indicators shall be provided for motor bearings.
Motor bearing shall not be subjected to external thrust loads.
20.1.12 The maximum double amplitude vibrations for motors upto 1500 rpm shall be
25 microns and 15 microns upto 3000 rpm. For 400 V motors, maximum
double amplitude vibrations upto 1500 rpm shall be 40 microns and 15
microns upto 3000 rpm.
20.1.13 Maximum noise level measured at a distance of 1.5 metre from the outer
surface of the motor shall not exceed 85 db(A).
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20.1.14 Cable boxes of all 6.6 kV motors shall be provided with quick disconnecting
type terminal connectors to facilitate easy disconnection and removal of the
motors without requiring unsealing or otherwise disturbing the external cable
connections and leaving the phase segregated terminal box intact.
20.1.15 Terminal boxes shall have fault withstand capacity equal to at least rated
short circuit level of the system voltage for 0.25 sec. The terminal boxes
shall be reversible to suit cable entry from bottom or top.
20.1.16 Separate terminal boxes to be provided for space heater, RTDs for winding
bearings temperature, vibration monitors etc. All terminal boxes shall be
provided with two earthing studs for termination of protective earth
conductor. Double compression type brass cable glands and crimping type
copper lugs shall be provided for termination.
20.1.17 The insulation system for 6.6 kV AC motors shall withstand the negative or
positive 0.3 / 3.0 microsecond wave (2.7 pu rated peak line to earth
operating voltage) switching surges originating from non-effectively earthed
power system. All 6.6 kV AC motors shall have BIL of 36 kV (Peak) 1.2 / 50
microsecond wave and shall withstand a power frequency voltage of 14.2 kV
(rms) for one minute.
20.1.18 Canopy shall be provided for outdoor motors.
20.1.19 Variable frequency controller shall be provided for motors requiring speed
control.
20.1.20 Torque speed characteristics of motor superimposed on torque speed

characteristics of drive equipment at 100%, 90% and 80% shall be furnished
by the contractor.
20.2 DC Motors
20.2.1 DC motors shall be suitable for the DC system voltage available in the plant.
Motor shall be capable of starting and accelerating the load with the
applicable method of starting, without exceeding acceptable winding
temperatures, when the supply voltage is in the range of 85% to 110% of
rated motor voltage.
20.3 Actuator Motors
20.3.1 The actuator motors shall be designed for short time duty (S2) in accordance
with IEC 60034-1.
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20.3.2 Hand wheel operation shall be provided in addition to motor drive.
20.3.3 The DC and AC actuator shall be provided with accessories viz., torque limit
switch, end of travel switch, adjustable limit switch, hand wheel motor,
thermostat, integral starter, etc. Complete actuator shall be tested at factory
as per IS 9334.
20.3.4 Two normally open and two normally closed or two changeover potential free
contacts corresponding to open and close positions of the valve shall be
provided. Open / Close limit switches used for interlock operation shall be of
proximity type.
20.3.5 Degree of protection for actuator motor enclosure shall be IP-55 and IP-67
for indoor and outdoor respectively.
20.3.6 The remote position of the valve along with its status indication with trip shall
also be shown in the DCS & local.
20.3.7 Remote operation of the valve shall also be possible.
20.3.8 All the valves shall be of Integral type with field bus compatible.
20.4 General Requirements
20.4.1 For small rating motors cooling shall be of TEFC type but for higher rating
motor TETV, CACA & CACW type cooling shall be considered.
20.4.2
All electric motors shall be chosen from the supplier’s standard
manufacturing program and in accordance with the absorbed load of the
driven machine, using the API Recommendation No.610, 617 and 618 for
the overrating ratio.
20.5 Tests
20.5.1 Tests on all types of motors shall be conducted as per relevant standard.
20.5.2 For 6.6 kV, 400 V motors and DC motors, if type test certificates are
available for the same rating of the motors offered, the same shall be
furnished, else it shall be conducted. However, all routine and acceptance
tests shall be conducted on all 6.6 kV, 400V and DC motors as per relevant
standards.
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20.5.3 For 6.6 kV AC motors, in addition to all the tests specified above, partial
discharge, C & Tan delta and polarisation index test shall be carried out as a
routine test on each motor (the minimum value of polarisation index for all
motors shall be 2 when determined according to IS : 7816).
20.5.4 Noise level measurement test shall be conducted on one motor of each type.
20.5.5 Di-electric tests to establish the insulation withstand level of motors as

indicated in Clause 20.1.17 shall be performed on a sample coil (identical to
those to be used in the motor quoted for) for each type of motor. These
tested sample coils shall not be used in the motors to be supplied.
20.5.6 List of tests to be conducted
The following type tests shall be conducted on each type and rating of HT
motor:
(a) No load saturation and loss curves upto approximately 115% of rated
voltage
(b) Measurement of noise at no load.
(c) Momentary overload test (subject to test bed constraint).
(d) Full load test
(e) Temperature rise test at rated conditions. During heat run test,
bearing temp., winding temp., core temp., coolant flow and its temp.
shall also be measured. In case the temperature rise test is carried
at load other than rated load, specific approval for the test method
and procedure is required to be obtained. Wherever ETD's are
provided, the temperature shall be measured by ETD's also for the
record purpose.
(f) Surge withstand test on the sample coil after placing it in stator core
at (4U + 5 KV) and with at least five impulse of 1.2/50 micro sec.
wave, for HV motors only, where U is the line to line voltage in kV.
(g) Surge-withstand test at 20 kV with 0.3/3 micro sec. wave on each
type of motor coils with at least five such impulses, followed by one
minute power frequency high voltage test on turn to turn insulation,
after cutting the coil and bringing out the turns suitably. The power
frequency test voltage shall be decided during detailed engineering.
20.5.7 List of tests for which reports have to be submitted

The following type test reports shall be submitted for each type and rating
of HT motor
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(a) Degree of protection test for the enclosure followed by IR, HV and no
load run test.
(b) Terminal box-fault level withstand test for each type of terminal box
of HT motors only.
(c ) Type test report on Elastimold Termination kit as per relevant

standard.
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1.0 AC Motors
1.1 Type of Motors Squirrel cage except for cranes
1.2 Supply
(a) Rated voltage 6.6 kV for motors above 175 kW &

400V for rating upto 175 kW
(b) Number of phases & 3 Phase, 50 Hz

Frequency
(c) System Neutral Medium resistance earthing

(6.6kV) / Effectively earthed (400V)
1.3 Type of duty (Clause 9.2 of IS:325 Continuous / Intermittent

or equivalent) depending on application.
1.4 Method of starting DOL
1.5 Class of Insulation For 6.6kV&400V-Class F with

temperature limited to Class B
0
1.6 Ref. Ambient temperature C 50
0
1.7 Temperature rise by winding C 70 for class-B
resistance
1.8 Location
(a) Hazardous area division As per classification (for flame

(IS:5572 or equivalent) proof zone – 1)
1.9 Type of cooling (IS : 6362) TEFC/TETV/CACA/CACW
1.10 Designation for degree of protection IP 55

(IS : 4691)
1.11 Colour shades of paint Opaline Green

DATE JUNE’10 CKD.BY HA 5960A PROJECT : 700 MW CCPP AT NEDUNOOR,
KARIMNAGAR DIST.
REV. BY DATE
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SPEC. NO.
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1.12 Space heaters for motors Required for motors rated 30 kW
and above for 400V motors and for
all 6.6 kV motors
2 DC Motors
2.1 Rated voltage V, DC 220
2.2 Class of insulation Class F with temperature limited to

Class B
0
2.3 Temperature rise C -do-
2.4 Method of starting Reduced voltage
All items indicated above under AC

motors are applicable here also
except 1.2, 1.4
3 Motors for Hazardous Area

Application
3.1 Type of construction Flame proof type
3.2 Degree of protection IP-55
All items indicated above under AC

motors are applicable here also.
4 Valve Actuator & its Motor
4.1 Application Valves as per requirement
4.2 Degree of protection IP 55 for Indoor

IP 67 for Outdoor
4.3 Indoor / Outdoor / Explosion proof As per requirement at the location

where it is installed
4.4 Power supply 400V, 3 Phase, 3 Wire

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REV. BY DATE
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SPEC. NO.
TCE.5960A-H-500-001

4.5 Actuator type Bidder to decide
4.6 Typical connection diagram No drawing is enclosed.

applicable Contractor to furnish his proposed
scheme.
4.7 Type of duty & duty designation for Short time (15 minutes) or twice
motor the valve stroking time whichever
is higher
4.8 Supply condition variation As per 400V AC motors

applicable for motor
4.9 Class of insulation for motor Class of insulation for motor Class
F but limited to Class B
5 Codes and Standards
5.1 Induction motors – three phase IS : 325
5.2 Measurement and evaluation of IS : 12075

vibration rotating electrical
machines
5.3 Code of practice for climate BS – CP 1014

proofing
5.4 Degrees of protection provided by IS 4691

enclosures for rotating electrical
machinery
5.5 Classification of hazardous areas IS 5572

for electrical installation
5.6 Terminal marking for rotating IS 4728

electrical machinery
5.7 Designation of methods of cooling IS 6362

for rotating electrical machines
5.8 Guide for testing three phase IS 4029

KARIMNAGAR DIST.
REV. BY DATE
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COMPANY LTD.
SPEC. NO.
TCE.5960A-H-500-001

induction motors
5.9 Dimensions of slide rails for electric IS 2968

motors
5.10 Designations for types of IS 2253

construction & mounting
arrangements of rotating electrical
machines
5.11 Classification of maximum surface IS 8239

temperatures of electrical
equipment for use in explosive
atmospheres
5.12 Flame proof enclosure of electrical IS 2148

apparatus

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ELECTRICAL SYSTEMS - ELEVATORS SPEC. NO.
TCE.5960A-H-500-001
21.0 ELEVATORS
21.1 One (1) no. passenger lift of capacity 600 kg and speed of 0.75 m/sec
shall be provided for proposed Control and Switchgear building.
One (1) passenger-cum-goods lift of capacity 1500 kg and speed of 1.0

m/sec shall be provided in HRSG area.
21.2 The lift for control building shall cater to various floors of the control room
building. Accordingly, Bidder shall decide the number of landings
required and the total rise of the lift for both control building and HRSG
area elevators.
21.3.1 The capacity of the lift shall be 600 kgs (8 passengers) for passenger lift
and 1500 kgs for goods cum passenger lift.
21.3.2 Any code, statutory requirements, specific requirements at the place of

installation shall be complied with in all respects.
21.3.3 An enclosed machine room shall be provided for the control panel of the
lift.
21.3.4 The A.C motors of the lift shall comply with Section D3.20 of this
specification.
21.3.5 The car and counter weights shall be suspended by stainless steel wire
ropes. Chain shall not be used for suspension. Not less than 4 (four)
independent standard steel wire suspension ropes shall be used for car
or counter weight and all these ropes shall be in one piece and without
intermediate joints. The minimum diameter of the standard rope shall not
be less than 12.5 mm and the minimum factor of safety shall not be less
than 12. The suspension ropes shall conform to IS: 2365 latest edition
"Specification for steel wire suspension ropes for lifts and hoists", or
equivalent international standard.
21.3.5 Special care and precaution shall be taken regarding handling of lift
cable loops between the points of suspension as the loops are prone to
twist / distortion.
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21.3.6 The car shall be provided with fittings & accessories. Glass shall not be
used in the roof except to protect electric light, which is to be fitted with
safety glass / plastic transparent cover mounted inside the car. Glass
exceeding 930 cm² in area shall be of laminated type.
21.3.7 The car floor shall be of smooth non-slip surface. The car platform shall
be robust in construction and elegant in appearance. If there is any
change/changes in the elevations of landing, the same shall be informed
to successful Contractor. The successful Contractor shall comply with
the changes in the elevation without claiming extra price.
21.3.8 The car door shall be of hollow metal construction, 16 gauge thick
stainless steel. Sides of the door shall flush with all seams continuously
welded. Guide shoes shall be rubber of roller type designed for operation
on un-lubricated guides. The car entrance shall be able to withstand the
thrust of 35 kg. The entrance shall be securely fitted with car floor and
frame in order to become working loose or becoming displaced during
the service.
21.3.9 The car door shall be provided with locking gear of heavy and robust
construction so arranged mechanically and interlocked that the doors
cannot under any circumstances be opened unless the lift car is within a
particular landing zone.
21.3.10 Conversely the lift will not move until all the landing doors are closed and
interlocked properly. Car doors & landing doors shall be electrically
operated by torque motor.
21.3.11 The car doors shall be so designed that their closing and opening is not
likely to injure a person, with scratch resistant coating. A retractable
safety shoe shall extend to the full height and project beyond the front
edge of each car to open the closing door if and when it touches a
person or object that is Bidder to provide "Electro-Mechanical Pressure
Detection". Besides this Bidder is also to provide "Electronic Door
Detector". In the first method, slight body contact pressure is detected by
sensors incorporated into door drive mechanisms. Actuation will check
and reverse door movement, allowing passengers to pass.
21.3.12 The second method will also take carry by the screen of Infrared beams
as a safety curtain across the door entrance detects an obstacle when
the doors are closing, the doors then revert to an open position.
21.3.13 A load plate displaying the rated load of the lift in terms of persons and
kilograms shall be fitted in the lift car in a conspicuous position.
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21.3.14 All sheaves and pulleys fixed to and revolving with the shaft shall be
fixed by means of sunk keys of sufficient strength and quality. Sheaves
and pulleys shall be made of cast steel to IS:1030 and free from cracks,
sand holes and other injurious defects. They shall have suitable flanges
and smoothly machined rope grooves. The diameter of the sheave of
pulley shall be as specified in the latest edition of Indian Standard of
equivalent International Standard.
21.3.15 Shafts and axles shall be of forged steel. They shall have sufficient
rigidity and bearing surface. Any shaft when stepped, shall be turned to a
reasonable radius at the point of reduction in diameter.
21.3.16 The elevator shall be provided with suitable counter weights located in
the lift shaft. The counter weight shall be designed for smooth and easy
operation of the lift and shall be in accordance with Indian Standards
referred earlier or equivalent. International Standards. The counter
weight shall be provided in the lift shaft. The counter weight shall consist
of cast iron weight contained in structural steel frame. It should
preferably be equal to that of the car weight plus 40% of the rated load.
The traction should be such that no appreciable slip may occur but that
slip shall be free to take place upon the landing of either the car or the
counter weight.
21.3.17 Guide rails for the car and counter weights shall be machined 'T' sections
and continuous throughout the entire length and shall be provided with
adequate steel brackets or equivalent fixing of such design and spacing
that avoid any deflection during the normal operation. Guide rails section
shall be adequate to withstand the forces resulting from the application of
the safety gear when stopping the counter weights or fully loaded car.
The guide shoes or their lining shall be easily renewable, adjustable and
self lubricated guides shall be of such length that it shall not be possible
for any of the car or the counter weights shoes to run off the guides.
21.3.18 Sufficient number of buffers of spring loaded/oil type shall be fitted below
lift car and counter weights. The buffers shall be capable of stopping the
car or counter-weights without permanent damage or deformation to
itself or any part of the lift equipment. The number of buffers shall be so
fixed as to ensure proper sharing of the impact loads by all of them.
21.3.19 The lift shall be provided with safety device attached to the lift car frame
and placed beneath the car. The safety device shall be capable of
stopping and sustaining the lift car up at governor tripping speed with full
rated load in car. The application of safety device shall not cause the lift
platform to become out of level in excess of 3 cm/m measured in any
direction. Slack rope switches if necessary, shall also be provided.
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21.3.20 Contractor to provide a modern Advanced electronic drive system of

''RESCUING passenger Trapped in a ELEVATOR". This system should
be able to rescue during main power failure and elevator control system
failure. The system should be fully microprocessor control with latest
IGBT power device.
21.3.21 Governors shall be located where there is sufficient room for their proper
operation and where they cannot be struck by the lift car or
counterweight in the event of overrun. Each governor shall be marked
with a tripping speed in terms of car speed in m/sec. and the motor
control and brake control circuit shall be opened before or at the time of
governor trips. Governor ropes shall not be less than 8mm in diameter
and shall be of steel or phosphor bronze and of suitable construction.
The ropes shall run clear of the governor jaws during normal operation of
the lift.
21.3.22 The drive system for the elevator should be variable voltage variable
frequency Drive system.
21.3.23 The lift drive controller and all other apparatus and equipment for lift
installation, except such apparatus and equipment which function in the
lift well or other portion shall be placed in the machine room which shall
be located at the top of the lift well. Sound reducing materials shall be
provided under the machine base by the bidder. The maximum load
transmitted by the single heaviest equipment both during erection and
maintenance of the lift to the machine room floor and other structures like
guides etc. shall be furnished by the contractor within 30 days of placing
the award letter.
21.3.24 The lift drive shall be equipped with brakes. The lift shall be driven by a
drive suitable for method of control offered by the bidder. No friction
gearing or clutch mechanism shall be used for connecting the main
driving gear to the sheaves.
21.3.25 The lift shall be provided with upper and lower normal terminal switches
arranged to stop the car automatically within the limit of top car clearance
and bottom run from any speed attained in normal operation. Such limit
switches are to act independently of the operating device, the final limit
switches and buffers.
21.3.26 Final limit switches shall be provided to stop the car automatically within
the top and bottom clearance independently of the normal operating
device and the terminal limit switches. The final limit switch shall not act
to prevent motion of the car under power in both direction of travel and
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shall after operation, remain open until the lift car has been moved by a
hand winding within the limit of safe operation.
21.3.27 Emergency safety device and over speed governor and buffers shall be
provided.
21.3.28 Fireman's switch at ground floor shall be provided.
21.3.29 The lift shall be provided with automatic levelling device to take care of
over run and under run of the car and rope stretch such that any floor is
within 6 mm from the landing level.
21.3.30 To make the equipment/system complete in all respects, any

requirement of supply & fixing of steel sections for door frame, fixtures in
walls for indicators and push buttons etc. are included in the scope of the
bidder.
21.3.31 The scope of the bidder also includes supply of erection consumables,
arranging the materials for scaffolding and for any other functional
requirement of erection.
21.3.32 The elevator is to provide service in power station. It is necessary for the
equipment to be specifically treated. This shall include application of anti-
corrosion paint/zinc plating. The electrical equipment shall have
enclosure meeting IP-54 and other relevant protection.
21.3.33 An electric contact for the car door shall be provided which shall prevent
elevator movement away from the landing unless the door is in the
closed position. The mechanical interlock with auxiliary door closing
device shall be provided so that the elevator can be operated only after
the interlock circuit is established.
21.3.34 The car door shall be provided with a protective device extending to the
full height and shall be so arranged that should it touch a person or any
obstruction in its path while the door is closing, it shall automatically
cause the car door and hoistway door to return to open position.
21.3.35 An emergency switch shall be provided to stop the elevator at a

particular landing, cancelling all the registered calls.
21.3.39 The contractor shall carryout all the tests necessary & take the
clearances / permissions from the Electrical inspector or any other
agencies who certify the operation of lift.
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21.3.40 The following operating devices / indications shall be provided in the car /
on the landing / in the machine room as indicated below:
(a) Operating devices
In the car In the landing In the m/c On top of

room the car
Up push button Up PB Up PB Up
(PB)
Down PB Down PB Down PB Down
Number PBs for Lift PB Hand cranking Stop

each landing device
230V 1φ
receptacle
Non-stop PB Bell PB Stop PB
Door open PB - - -
Door close PB - - -
Alarm PB - - -
Emergency stop - - -
PB
Key operated - - -
selector for
attendant
operation
(b) Indicating devices.

In the car On the landing
Up direction of travel Up direction of travel
Down direction of travel Down direction of travel
Floor position indicator & voice inside Car position indicator with direction
and outside car
(Illuminated numeral for each landing) (Illuminated numeral for each
landing)
Landing car registering unit Call registered ‘Up’ indicator
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In the car On the landing

Load plate in kg & no. of persons Call registered ‘Down’ indicator
Over load indication
(c) Additional requirement
(a) Car ventilation fan with switch
(b) Fire extinguisher
(c) Telephone handset
(d) PB for emergency indication in control room
(e) Ventilation/pressurisation : 2 x 100% capacity blower of

adequate size along with cyclonic filter for pressurising the
machine room to make it dust proof. If AC is required for the lift
control room, then it should be taken through the Main Control
room Air Conditioning System only.
(f) Hoisting beam in machine room roof slab : To be provided by lift

supplier.
(g) Hoist way machine room & pit lighting: To be provided by lift
supplier.
(h) Individual ladder for access to inside pit : To be provided by lift

supplier.
(i) Automatic rescue device including siren etc : To be provided by

bidder as an emergency rescue measure.
(j) The contractor shall carryout all the necessary tests & take the
clearances / permissions from the Lift inspector or any other
agencies who certify the operation of lift.
The material of doors and lift rope shall be stainless steel. The enclosure
for electrical equipment located outside the machine room shall be dust
tight and the car shall be provided with fluoroscent lighting, blow out
panels, etc. Emergency DC light shall be provided in car. Any other
equipment / accessories required for satisfactory operation of the lift shall
be supplied by the Contractor.
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The interior decor of the lift shall be aesthetically pleasing, and the same
shall be subject to approval by Owner.
The contractor shall be responsible for obtaining the necessary License /

Permission from the relevant authorities.
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COMPANY LTD.
SPEC. NO.
TCE.5960A-H-500-001
Passenger Lift
1.0 Installations Indoor
2.0 Capacity kg 600
3.0 Rated speed m/sec 0.75
4.0 Levelling device Two way automatic maintaining
5.0 Operation Automatic microprocessor based
6.0 Automatic operation type Selective & Collective
7.0 Type of door & material Centre opening sliding, steel
8.0 Type of doors in car 1 or 2 depends on layout
8.1 Emergency exit Required
8.2 Speed control VVVF
8.3 Degree of protection for lift motor IP-54
9.0 Codes & standards
9.1 Specification for electric passenger and goods IS:14665 (Latest edition)
lift.
9.2 Specification for steel wire suspension ropes IS:2365-1977

for lifts, elevators & hoists.
9.3 Specification for carbon steel castings for IS:1030-1982

general engg. purpose.
9.4 Specification for lift door locking devices and IS:7759-1975

contracts
9.5 Material specification ISS or approved equal.
Goods Cum Passenger Lift

1.0 Installations Indoor
2.0 Capacity kg 1500
3.0 Rated speed m/sec 1.0
4.0 Levelling device Two way automatic maintaining
5.0 Operation Automatic microprocessor based
REV. NO. R0 PPD. BY JOB NO. CLIENT : APPDCL

DATE MAR’ 10 CKD.BY 5960A PROJECT : 700 MW CCPP AT
REV. BY DATE
TCE FORM NO. 330 R3
320
COMPANY LTD.
SPEC. NO.
TCE.5960A-H-500-001
6.0
SL. NO. Automatic operation type ION
DESCRIPT UNITS Selective & Collective
VALUES / REQUIREMENTS
7.0 Type of door & material Centre opening sliding, steel
8.0 Type of doors in car 1 or 2 depends on layout
8.1 Emergency exit Required
8.2 Speed control VVVF
8.3 Degree of protection for lift motor IP-54
9.0 Codes & standards
9.1 Specification for electric passenger and goods IS:14665 (Latest edition)
lift.
9.2 Specification for steel wire suspension ropes IS:2365-1977

for lifts, elevators & hoists.
9.3 Specification for carbon steel castings for IS:1030-1982

general engg. purpose.
9.4 Specification for lift door locking devices and IS:7759-1975

contracts
9.5 Material specification ISS or approved equal.
REV. NO. R0 PPD. BY JOB NO. CLIENT : APPDCL

DATE MAR’ 10 CKD.BY 5960A PROJECT : 700 MW CCPP AT
REV. BY DATE
TCE FORM NO. 330 R3
321
5.10
SHEET 1 OF 7
ELECTRICAL SYSTEMS –
ELECTRICAL LABORATORY EQUIPMENT SPEC. NO.
TCE.5960A-H-500-001
22.0 EQUIPMENT TO BE SUPPLIED
22.1 The list of items / equipment to be supplied by the Contractor indicated

here is only indicative. Any other equipment considered necessary by
the Contractor for the installation, testing and commissioning of the plant
shall be included in the offer. Also any additional equipment required or
considered necessary during detailed engineering stage, shall form a
part of the scope.
Category – I – High Voltage Test Instruments

Sl. Instrument Range Qty.
No.
(a) High potential test set AC / DC 0 – 50 kV 1 No.
Category – II – Miscellaneous Laboratory Instruments

Sl. No. Instrument Range Qty.
(a) Automated oil BDV test set 0 – 75 kV 1 No.
(b) Rheostats of following ratings 650 Volts 1 Set
(i) 25 Ohms, 10A-2 nos.
(ii) 50 Ohms, 5A-2 nos.
(iii) 100 Ohms, 2.5 A-2nos.
(iv) 250 Ohms, 2.5A-2 nos.
(v) 500 Ohms, 0.5A-2nos.
(c) Portable secondary injection test set 500VA, 1AMP/
5AMPs Normal;
20AMPS /
100AMPS for 30
secs
(d) Digital Earth resistance tester with 0.01 Ohms, 500 1 No.
resistivity test facility Ohms in three
ranges
(e) Digital Insulation resistance tester 0-100, 000 Mega 2

(transistorised) Ohms, 500-1000- Nos.
2500-5000 Volts
(f) Cable fault locator (HV, LV cable) 1 No.

(g) Relay tool kit 2
Nos.
(h) Hot stick with indication & audible alarm Upto 11 kV 1 No.
Upto 400 kV 1 No.
(i) Temperature controlled soldering iron 50W 2
Nos.
(j) Thermovision equipment (INFRA RED 1 No.
CAMERA)
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Category – II – Miscellaneous Laboratory Instruments

Sl. No. Instrument Range Qty.
(k) Primary Injection kit 5000 A, 7.5 kVA 1 No.
(l) Milli volt drop test set 600A DC 1 No.
continuous
variable
(m) Illuminometer 0 to 50,000 Lux. 2 Nos
(n) Circuit breaker analyser 1 ms to 999 secs 1 No.
(o) Turn ratio meter with vector group 1 to 99000 ratio 1 No.
testing facility
(p) Online DC circuit fault locator 1 No.
(q) Tan delta test kit for 1 No.
generator/transformer
(r) Vibrometer 1 No.
(s) Capacitance and tan delta
measurement kit
(u) Partial discharge measurement kit
(v) Earth loop tester
(w) Battery capacity test kit
(x) Battery impedance measurement kit
(y) Motor checker
(z) Capacitor measurement kit
(aa) Live line detector
Category – III – Meters & Accessories

No.
(a) Three Phase sequence testing (100 – 600 V) 3Nos
meter
(b) Clip on Ammeters AC / DC (a) 0-2000-2500- 1 No.
3000A
(b) 0-250-500A 1 No.
(c) 0-100-150-200A 1 No.
(d) 0-5A 2 Nos.
(e) 0-1A 2 Nos.
(c) Auto-transformers – 3 Phase 0-500 Volts, 7KVA 1 No.
(d) Auto-transformer – 1 Phase 0-270 Volts, 2-16KVA 3 Nos.
(e) Digital micro-ohm meter 0.1 micro-ohm-1999 1 No.
Ohm, 100A
(f) Portable power analyser meter Amp-1A/5A, 1 No.
Accuracy=0.2 Volt 600 V, for
measurement of KW,
KVA, KVAr, KWh, PF,
Amp, Volt, in 1 ph & 3
ph, 3 wire & 3ph, 4 wire
system
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(g) LCD type portable scope meter 1 No.

(Wave form analysis with Harmonic
measurement facility)
(h) Analog voltmeter AC/DC 0-5-10-25-50-100-500 1 No.
V
(i) Analog ammeter AC/DC 0-5-10 A 1 No.
Category – IV – Electronic Instruments

No.
(a) Universal microprocessor based relay 1 no
testing kit to test
1) Current relay
2) Voltage relay
3) Frequency relay
4) Differential relay
5) Distance relay
6) Synch. Relay
7) Timer relays
(b) Regulated DC power supply equipment Voltage 0-+300V DC, 2 2 Nos.

Amps, 0 - + 30V, DC, 2
Amps, 0-+5V 10 Amps,
Current 0 – 2 AMPS
DC, 100 VA
(c) Digital tachometer (non-contact type) 0,1500,3000,5000, 2 Nos.

10000 rpm
(d) Digital multimeter (Class 0.5) 3 Nos.
(e) Hydrogen leak detectors 2 Nos.
(f) Naphtha & fuel gas leak detectors 2 Nos.
(g) All the necessary accessories shall also be supplied with the instruments.
These shall include but not be limited to :
(a) Two meter length power supply cord with plug.

(b) All necessary accessories like jacks, probes, connectors, adapters,
clips, rain jackets, protective covers, shields, carrying / transporting
cases, etc., wherever applicable.
(h) Composite universal microprocessor based test kit with 0.02 accuracy for
testing following:
Distance relays, Differential relays, Over current relays, F/V/I relays,
Ground fault relays, Synchronising devices, Transient playback, Harmonics
generation, Transducers, Energy meters testing /calibration.
Requsite software and Laptop shall be included as a part of test kit.
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22.2.1 Category – I – High Voltage Test Instruments
(a) The test transformers shall be supplied with:
(i) A control desk incorporating all necessary indication, annunciation,

protection and control equipment.
(ii) All necessary cooling equipment if required.
(iii) Mobile base with adequate no. of rollers for easy transport of the
testing unit.
(iv) All necessary accessories for erection, commissioning, normal

operational / testing of all types of equipment, whether specified or
not.
(v) Shall incorporate built-in safety features to ensure complete safety

of operating personnel.
(b) The insulating material used for bushings and top covers shall be as per
BS for Class F/A installation.
22.2.2 Category – II
(a) Automatic Oil Test Sets
(i) This equipment shall have an output voltage of 0 – 75 kV variable

AC, continuously rated 1 kVA with class of insulation being ‘A’.
(ii) The test set shall be so designed that the short circuit current drawn
from the system exceeds 8 times the rated current. The transformer
test set impedance shall be such that the input MCCB trips within a
suitable time (0.02 sec.) for a secondary short circuit.
(b) Rheostats and Phantom Loads
The rheostats shall be 650V grade wire wound type of copper nickel alloy
having a low temperature co-efficient, totally enclosed type with louvers.
Solid copper / graphite brushes with pressure springs shall be provided to
ensure low contact resistance.
(c) Portable Secondary Injection Test Set
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This equipment shall be designed to deliver a normal continuously

adjustable current with multirange selector switch for 1, 5, 10, 50 A etc.
The instrument shall have built in ammeter and voltmeter having adequate
range.
(d) Earth Resistance tester with resistivity test facility
This equipment shall be suitable for measuring the ground resistance,

specific soil resistance and ohmic resistances. The equipment shall be
supplied with all necessary accessories and in-built batteries.
(e) Insulation Resistance Tester (Transistorised)
The insulation resistance shall be measurable to a value of 1,00,000 mΩ

in five ranges. The test voltage shall be adjustable at 500V, 1000V,
2500V and 5000V. The tester shall be suitable for an input supply of 230
V, 50 Hz, single phase AC as well as in-built rechargeable batteries. A
guard terminal shall be provided to eliminate error due to surface leakage.
Accuracy shall be 5%, maximum short circuit terminal current 2.5 mA,
nominal S.C current 2 mA. This tester shall also provide Polarisation
Index Measurement.
(f) Cable Fault Locator for LT Cables
Portable cable fault locator which shall identify the fault in a LT cable
distinctly. This kit shall work on in-built batteries. This kit shall include
Time Domain Reflectometer (TDR) and cable identifying kit and all
necessary accessories & transport cases.
(g) Hot Stick
The hot sticks shall be supplied in different ratings viz. For 6.6 kV, 400 kV.
The insulating handle of stick shall be with Class F / H insulation as per
IEC / BS specifications with scaled detector having high quality viewing
windows. The hot stick should be light weight and portable. Should give
audio visual indication of pressure of voltage.
(h) Temperature Controlled Soldering Iron
The soldering iron rated at 50 W having thermostatic temperature control

shall be supplied complete with set of soldering bits of different sizes and
shapes, three spare heating elements & separate stand to rest the
soldering iron while in use.
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(i) Thermovision Equipment (Infra thermographic common)
The system shall be very light weight, and single hand-operated

instrument. This instrument shall have user friendly, broadly compatible
software which is an image processing software to perform post-imaging
analysis.
22.2.3 Category – III
(a) Phase sequence Testing Meter
This shall be suitable for testing 3 phase 400V supply and shall be suitably
marked for clockwise and anti-clockwise directions. Any conducting part
of the meter/ shall withstand 2 kV for 1 minute. The operative range of the
meter shall be 100V to 600V.
(b) Clip on Ammeter
The meter shall have a large digital display unit and the jaws shall open
adequately to facilitate introduction of the conductor having a size
corresponding to the maximum current range.
(c) Digital low resistance ohm-meter

The instrument shall be suitable for measuring the contact resistance of
switch and circuit breaker contacts, winding resistance of transformer &
motor, busbars, etc. They shall also be suitable to be used in finding
ground faults in electrical equipment, determining temperature co-efficient
and temperature rise by resistance methods, etc.
22.2.4 Category – IV
(a) Automatic Composite Relay Test Kit
Relay test set shall be suitable for input voltage 230 V, 1 Phase, 50 Hz.
Output current range shall be 1-5-50-100A. Overload and short circuit
protection shall be provided. Phase angle adjustment shall be 0-360 deg.
The kit shall be computerised, portable unit and used to test various types
of protective relays quickly and more accurately. The software for testing,
measurement and analysis of the different types of the relays shall be
included.
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(b) Regulated DC Power Supply
Voltage range
(continuously controlled) - 0 to + 300 V DC
Current range
(continously variable) - 0 to 2A DC
Indication - Digital voltage/current
meters integral with the unit
Load regulation - 0.1% variation in voltage

- 0.2% variation in current.
(c) Digital Tachometer
Tachometer shall be of the photoelectric type with a digital display, which

does not necessitate mechanical contact with the machine shaft. A “push
to read” push button shall be provided and also an LED to indicate when
the light beam is on the target. Adequate memory shall be built-in to hold
the last reading for atleast 1 minute.
(d) Digital Multimeter
These meters shall have built in overload protection and protection against
HV transients. They shall have an audio alarm for continuity testing, a
peak hold feature on current and voltage ranges, automatic polarity and
over range indications. The instrument shall be complete with
rechargeable batteries and charging equipment, adapters, probes, leads,
padded carrying case, etc. It shall have safety features to prevent damage
to instrument if voltage is applicable inadvertently current or resistance
measuring range.
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SHEET 1 OF 3
MISCELLANEOUS ELECTRICAL EQUIPMENT SPEC. NO.
TCE.5960A-H-500-001
23.0 MISCELLANEOUS ELECTRICAL EQUIPMENT
23.1 Following equipment shall be included in the Contractors’ scope.
23.1.1 Local push button stations
23.1.2 Junction Boxes (JBs)
23.1.3 3 phase power receptacles
23.1.4 Danger boards
23.1.5 Rubber mats
23.1.6 50 nos. first aid charts shall be provided for display in the plant area.
23.1.7 Minimum of fifty (50) nos. First aid boxes shall be provided at various
locations in the plant.
23.1.8 Sufficient quantity of gas masks shall be provided in line with rule no. 43
of IE rules.
23.2 Local Push Button Stations (LPB)
23.2.1 Local push button stations shall be provided for all the drive motors of the
plant.
23.2.2 LPB’s for outdoor installation shall be weather proof type provided with a
GI canopy and those intended to be used in hazardous areas shall be
flameproof type and the degree of protection shall be IP 55 for both out-
door and indoor application. The LPBs shall be power coated with shade
Opaline green (External) & semi glossy white (Internal).
23.2.3 All stop push buttons shall be lockable type (provided with key for
locking)
23.2.4 Following types of LPBs shall be provided for the various drives as
applicable.
(a) Push button station type A - which shall comprise Three, Push
buttons viz., Òpen', `Close' and `Stop' for control of reversible
motors.
(b) Push button station type B - which shall comprise two push
buttons viz., `Start' and `Stop' for control of the rest of the drives
in the plant.
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(c) Type-C push button station: With start, stop & ammeter.
23.3 Junction Boxes (JBs) / Marshalling boxes (MBs)
23.3.1 Junction boxes as required for the power plant shall be supplied as
required for marshalling cables of devices located in an area/equipment.
Junction Boxes with IP:55 degree of protection, shall comprise of a case
with hinged door constructed from cold rolled sheet steel of minimum
thickness 2mm. Top of the boxes shall be arranged to slope towards rear
of the box. Gland plate shall be 3mm thick sheet steel with
neoprene/synthetic rubber gaskets. All junction boxes shall be of
adequate strength and rigidity, hot dip galvanised as per relevant IS, and
suitable for mounting on wall, columns, structures etc. The boxes shall
include brackets, bolts, nuts, screws M8 earthing stud etc. required for
installation.
23.3.2 Terminal blocks shall be 650 volts grade, rated for 10 Amps and in one
piece moulding. The JBs used in outdoor areas shall be weatherproof
type. Sheet steel thickness of the JBs shall be minimum 2 mm. JBs / MBs
shall be hot dip galvanised and shall be powder coated with paint shade
Opaline green (External) & Semi glossy white (Internal).
23.3.3 Cable entry shall be bottom/side entry for indoor as well as outdoor
mounted junction boxes. The junction boxes shall be installed at 1 m
accessible height.
23.4 3 Phase Receptacles
23.5.1 32 A and 63 A, 3 phase, 4 pin heavy duty type power receptacles shall be
provided in proposed building plant areas, transformer yard, 400 kV
switchyard such that distance between any two of each rating in indoor
and outdoor area does not exceed 15 m and 30 m respectively.
23.5.2 Receptacles boxes shall be fabricated out of MS sheet of 2mm thickness

and hot dipped galvanized or of die-cast aluminium alloy of thickness not
less than 2.5 mm. The boxes shall be provided with two nos. earthing
terminals, gasket to achieve IP55 degree of protection, terminal blocks for
loop-in loop-out for cable of specified sizes, mounting brackets suitable
for surface mounting on wall/column/structure, gland plate etc. The ON-
OFF switch shall be rotary type heavy duty, double break, AC23
category, suitable for AC supply. Plug and Socket shall be shrouded Die-
cast aluminium. Socket shall be provided with lid safety cover. Robust
mechanical interlock shall be provided such that the switch can be put
ON only when the plug is fully engaged and plug can be withdrawn only
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when the switch is in OFF position. Also cover can be opened only when
the switch is in OFF position. Wiring shall be carried out with 1100 V
grade PVC insulated stranded aluminium/copper wire of adequate size.
The Terminal blocks shall be of 750 V grade.
23.5 Danger Boards / Rubber Mats
23.5.1 Danger boards and rubber mats shall be provided as required by the
statutory Authorities. The thickness and length of the rubber mats shall
be as per the guidelines of Indian Electricity Rules / local electrical
inspectorate.
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SPEC. NO.
ELECTRICAL SYSTEMS – CONSTRUCTION POWER SUPPLY TCE.5960A-H-500-001
24.0 CONSTRUCTION POWER SUPPLY EQUIPMENT
24.1 Construction power shall be made available at a single point at 11kV inside
the plant premises from nearest substation of APTRANSCO by the Owner.
The power shall be further extended by the Contractor to different users by
armoured cables or overhead lines. All the equipments used in construction
power shall ensure full safety to the working personnel and no live parts
which are accessible shall be exposed. The Contractor shall estimate the
construction power requirement and indicate the same to Owner to enable
them to enter into an agreement with APTRANSCO for its supply. The
Contractor shall obtain all necessary statutory clearance for the purpose. GA
and layout drawings required for getting clearance from local electrical
inspector / Electricity Board shall be prepared by the contractor and it will be
the complete responsibility of the Contractor to obtain the approval for the
installation and all related works in this regard. The Owner will not be
responsible for power cuts, Power failure for whatever reason, fluctuation in
voltage and frequency and consequences thereupon. To take care of failure
of this supply, Contractor shall provide suitable DG sets. Contractor shall
provide necessary protection for the construction power supply arrangement
to ensure that any fault in his system, should not disturb 11kV power supply
arrangement.
24.2 The Contractor shall provide metering arrangement consisting of two CT, PT
units and two trivector meters of suitable accuracy which shall have MD
registering facility. The contractor shall be responsible for periodic payment
of bills for the energy consumed by him.
24.3 The Contractor shall make arrangements to receive power from the Owner
line through DP structures with fuse protection. 2 x 100% suitably rated
11kV / 420V transformers, 400V switchgear with two incomer ACBs, two bus
sections and bus coupler & required number of outgoing 400V, 3φ, 4 wire
distribution lines to distribute power around plant area. Adequate metering
and protection shall be provided for transformers and incomer feeders.
24.4 Capacitor banks of automatic PF adjustment arrangement shall be provided

by the Contractor depending on the actual load to maintain power factor at
0.95 for optimising the power bills. This shall be installed at each LT
distribution board preferably. If APDISCOMS imposes any penalties to
APGENCO , caused by low power factor, the same shall be paid by the
contractor to the Owner.
24.5 Contractor shall supply and install fire fighting equipment as per the
regulations of the local electrical inspectorate / statutory bodies for the
electrical installation.
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SHEET 2 OF 4
SPEC. NO.
24.6 On award of contract, the Contractor shall furnish the electrical scheme, for
Owner’s approval.
24.7 02 Nos. of 400V, 250A feeder of adequate capacity for Administration

building & Colony construction, shall be given by the Contractor at specified
location.
24.8 LT DISTRIBUTION BOARDS
24.8.1 In general, these shall meet the requirements covered in D3.11 section.
However, the board shall be provided with outer enclosure so that access to
individual compartments, busbar and cable alley shall be available only after
the outer door is opened.
24.8.2 The distribution boards shall be provided with the following:
a) Pad locking arrangement with hinged door

b) Sloped canopy to prevent ingress of rain water
c) Caution notice
d) Earthing at two points
24.9 CABLES
24.9.1 Cables shall be armoured and suitable for direct underground buried
installation. Cable armour shall be suitable for carrying system earth fault
current. HT cables shall be XLPE insulated type.
24.10 EARTHING SYSTEM
24.10.1 Earthing of all substation equipment and overhead line shall be carried out
as per IS:3043. Earthing system shall consist of adequate number of earth
electrodes interconnected. Earth electrodes shall be of 40mm dia.
galvanised steel pipe, buried in earth pit.
24.10.2 Number of earth electrodes for LT substation shall be decided considering

soil resistivity. However, each LT substation shall have minimum two earth
electrodes for neutral earthing, two earth electrodes for body earthing and
two earth electrodes for lightning arrestor earthing.
24.10.3 All non-current carrying metal parts shall be connected to earth system at
two points, each of 100% rating. Metallic supports, fencing, etc. shall also be
connected to earth system.
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SHEET 3 OF 4
SPEC. NO.
24.10.4 Size of earthing conductor shall be selected considering fault current,

duration of fault and corrosion rate. Earthing conductor shall be of
galvanised steel strip/wires.
24.10.5 Overhead lines shall be earthed by continuous galvanised steel overhead

earth wire fastened to each pole and connected with earth at minimum three
points in every km length. Cross section of earth wire shall not be less than
25 mm2.
24.11 INSTALLATION
24.11.1 The electrical installation shall generally be carried out as per Indian
electricity rules and acts.
24.11.2 For road crossing, protective guarding shall be provided. The clearance for
the lowest conductor from ground shall be decided keeping in view the
vertical clearance required for movement of vehicles/cranes, etc.
24.11.3 The LT substation area shall be graded and sloped to prevent any stagnation
of rain water. Surface shall be covered with gravel of 15 to 20 mm size.
24.11.4 The LT substation shall be enclosed by barbed wire fencing on mild steel
angle iron posts to a height of not less than 2500mm with suitable gates for
entrance.
24.11.5 All cable connection parts within the switchgear shall be shrouded with
insulating materials.
24.11.6 The extension boards provided for hand held equipments shall have 3 wire
system i.e. phase, neutral & earth as per IE rules. The plug & socket
arrangement provided shall be of industrial type with switch provided for
proper isolation at the time of insertion or withdrawal of plugs.
24.11.7 The flexible cable used shall have heavy duty insulation.
24.11.8 All equipment used for construction activities shall be fed from separate
switching/isolating devices.
24.11.9 All the working areas shall be adequately illuminated for safe working with
proper fittings/fixtures. The wire shall be laid with proper fixing without any
hindrance to personnel or vehicular movement.
24.12 WORKING PROCEDURES
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SHEET 4 OF 4
SPEC. NO.
24.12.1 Adequate safety equipments shall be provided to all the workers, like hand
gloves, head gear, etc. Meggers & testers shall be provided in sufficient
quantity.
24.12.2 Only ITI qualified workers shall be allowed to handle the electrical or
electrically operated equipments.
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SHEET 1 OF 2
SPEC. NO.
ELECTRICAL SYSTEMS - TRANSDUCERS TCE.5960A-H-500-001
25.0 GENERAL REQUIREMENT
25.1 Bidders shall note that each and every device/equipment mounted in panels,
switchgears, MCCs, chargers, distribution boards, etc,, shall be properly
tagged, both inside and outside (if the equipment is mounted on door) for
identification.
25.2 Transducers
The transducers supplied shall meet the following specifications.
(a) Output range : 4-20 mA DC
(b) No. of output channel : Two (2)
(c) Accuracy : 0.5% of full scale
(d) Repeatability : 0.1% of full scale
(e) Linearity : 0.5% of full scale
(f) Residual ripple output

current : 3 to 5%
(g) Over load capacity : 10 times for 0.5 seconds
(i) Current : 120% continuous

(ii) Voltage : 2 times for 0.5 seconds
120% continuous
(h) Out put Isolation : Galvanic Isolation
(i) Power : Self powered
(j) Adjustment : Zero and span
(k) External resistance. : 500 Ohms
(l) Power frequency

withstand capability : 2 kV rms for 1 minute
(m)Open circuit and short circuit protection shall be provided.
(n) All transducers shall have local mA digital display.

ISSUE
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336
TCE FORM NO. 329 R5
SHEET 2 OF 2
SPEC. NO.
ELECTRICAL SYSTEMS - TRANSDUCERS TCE.5960A-H-500-001
25.3 Digital LED displays for the following parameters shall be provided in two (2)
locations in the Main control room and three (3) locations in the
administration building (*)
(a) Total plant load for each block
(b) Frequency
(c) Ambient temperature
25.4 For all outdoor equipment, which are not protected by sun cover, the heating
effect due to solar radiation shall be considered while considering the
temperature rise.
25.5 LEDs shall be provided with Low Voltage Guard protection.
Note:(*) - Administration building not in EPC scope. However the Bidder

shall install the LED display and wire the same. Location of the building
will be intimated later.
25.6 The following IS standards shall be followed:
IS: 12784 : Electrical measuring transducers for converting AC

electrical quantities into DC electrical quantities
IS : 14570 : Electrical measuring transducers for converting AC

electrical quantities to analog or digital signals.
ISSUE
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337
TCE FORM NO. 329 R5
5.11 TECHNICAL SPECIFICATION
FOR SPECIFICATION NO. PE-TS-I59-888-E001
INSULATING MATS
1.0 SCOPE
1.1 The scope includes design, manufacturing, inspection, testing, packing and delivery to
site of protective mats for placing in front of all 6.6kV/400V/220V Switchboards.
2.0 TECHNICAL REQUIREMENTS

2.1 The physical, chemical, mechanical and electrical properties of the insulating mats shall
be as per IS: 15652.
2.2 The mats should have been type tested in accordance with the applicable standards.
2.3 Insulating mats to be supplied shall be BIS approved and the same shall be engraved
on insulating mats also.
2.4 Insulating mat to be supplied shall be type tested at ERDA.
2.5 Mats shall be supplied preferably in units of 2X1 (length X width) metre.
3.0 SPECIFIC QUALITY ASSURANCE REQUIREMENTS
3.1 All type, routine and sampling tests shall be as per IS: 15652.
3.2 Dispatch of materials shall be permitted only after acceptance of type test certificates,
and inspection and testing of materials.
3.3 The successful bidder shall submit the Quality Assurance Plan (QAP) in attached
format for BHEL/ Customer approval after the award of contract.
3.4 Packing and marking shall be as per IS 15652.
4.0 COMPLIANCE TO SPECIFICATION
Bidder shall confirm total compliance to the specification without any deviations from
the technical requirements stipulated. As a mark of technical conformance, all sheets
of the specification shall be furnished by each bidder with the signature and company
seal affixed thereon.
5.0 Wherever required, soft copy of all approved technical/ quality documentation shall be
submitted as specified without any additional commercial implication. Soft copies may
be required both in native file format (e.g. MS Word/ MS Excel) as well as PDF files.
338

CATHODIC PROTECTION
1. CODES & STANDARDS

I. IS: 8062 : Code of practice for cathodic protection of steel structure.
II. IS: 8289 : Construction & testing of electrical apparatus with type of protection ‘n’
2. GENERAL REQUIREMENT:
2.1 All the metallic structures which are in contact with sea water & underground metallics shall be
provided with Cathodic Protection (CP) system irrespective of the material of structures, to
prevent corrosion due to any pin holes / holidays.
2.2 The CP system shall only be of impressed current type. Preferably LIDA type anode shall be
used.
2.3 If the soil is very corrosive, all underground structures shall be protected against corrosion by
providing suitable CP system.
2.4 Bidders shall furnish in their BID a brief write up indicating the type of CP system
envisaged for various metallic structures in contact with sea water & under ground metallics.
2.5 During detailed engineering the Contractor shall furnish the following for Purchaser’s approval :
2.5.1 Calculations for arriving at the number and dimension of anodes.
2.5.2 Calculations for arriving at the rating of transformer–rectifier set.
2.5.3 Layout of CP system.
2.5.4 Mounting arrangement of anode and reference electrode.
The following minimum design documentation [not essentially limited to these only] shall be
furnished by the successful vendor (for review and approval) at contract stage.
1. Corrosion survey report with interpretation.

2. Basic design package and system optimisation studies.
3. Material and equipment specifications, data sheets.
4. Quality plans for all equipment/ items.
5. Field Quality Plan covering site storage, handling, installation and commissioning checks.
6. Detail engineering and final design report.
7. Key diagrams of each discrete systems and complete CP system.
8. Anode installation drawings representing all variations in type, environment, depth,
placement, supports etc. including anode.
9. Cable layout schedules and terminals.
10. Foundation, weather protection cover details and support details for T/R sets, anodes,
Test Station, distribution boxes and cables of all description.
11. Installation details of T/R sets, test stations distribution boxes etc.
12. Design package on T/R sets essentially incorporating circuit diagrams, fabrications
and installation details, parts list, description on operation and maintenance.
13. Design package on anodes essential incorporating composition, fabrication and
installation details.
14. Connection schemes for all applicable type of test stations and their schedules.
15. Fabrication and installation details of test stations.
16. Fabrication and installation details of anode and cathode junction boxes, schedules
and connection schemes.
17. Interconnection, sectionalisation, isolation schemes for all structures to be protected
and those to be isolated but to be checked out for interaction.
18. Power supply arrangement for each T/R set.
19. Safety earthing details.
20. Procedures for testing during installation, commissioning and monitoring of (after
installation) complete CP system & each equipment.
21. Design and drawings that may be required for mitigation purposes.
22. Complete CP system layout drawings for each CP station.
339

CATHODIC PROTECTION
23. Cable to pipe joint arrangement using thermite welding.

24. Material test certificate for the materials purchased by the vendor along with copy
of manuals.
25. Inspection and test certificates for items fabricated and erected.
26. Performance Test Report.
27. Final check list and completion report.
28. Composite Operation and Maintenance Manual.
29. Monitoring formats.
30. Monitoring schedules.
31. List of E&C Spares.
32. Billing break-up
Note : The list of deliverables shall be finalised during kick-off meeting at contract stage.
340
ANNEXURE-II
341
342
343
344
345
346
Page : of
8. QUALITY ASSURANCE, INSPECTION & TESTING:
ALL MATERIALS, COMPONENTS AND EQUIPMENT’S COVERED UNDER THIS SPECIFICATION SHALL BE
PROCURED, MANUFACTURED, INSPECTED AND TESTED AS PER THE BHEL/ CUSTOMER APPROVED
QUALITY PLAN. THERE SHALL BE NO COMMERCIAL IMPLICATION TO BHEL ON ACCOUNT OF QP
APPROVAL. BHEL QPs ARE ENCLOSED FOR REFERENCE.
347
CUSTOMER : PROJECT SPECIFICATION :
TITLE NUMBER :
QUALITY PLAN BIDDER/ : QUALITY PLAN SPECIFICATION :
VENDOR NUMBER PED-506-00-Q-007/2 TITLE
SHEET 1 OF 9 SYSTEM ITEM: AC ELECT. MOTORS 75KW & ABOVE (LV & MV) SECTION VOLUME III
SL. COMPONENT/OPERATION CHARACTERISTIC CAT. TYPE/ EXTENT OF REFERENCE ACCEPTANCE FORMAT AGENCY REMARKS
NO. CHECK METHOD OF CHECK DOCUMENT NORM OF RECORD
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1.0 RAW MATERIAL & BROUGHT
CONTROL
1.1 SHEET STEEL, PLATES, 1.SURFACE MA VISUAL 100% - FREE FROM LOG BOOK 3 - -
SECTION, EYEBOLTS CONDITION BLINKS,
CRACKS,
WAVINESS
ETC
2.DIMENSIONS MA MEASUREMENT SAMPLE MANFR'S MANFR'S -DO- 3 - -

DRG./SPEC DRG./SPEC
3.PROOF LOAD MA MECH. TEST -DO- -DO- -DO- INSPEC. 3 - -

TEST (EYE REPORT
BOLT)
1.2 HARDWARES 1.SURFACE MA VISUAL 100% FREE FROM -DO- 3 - -

CONDITION CRACKS, UN-
EVENNESS
ETC.
2.PROPERTY MA VISUAL SAMPLES MANFR'S RELEVENT SUPPLIERS 3 - 2 PROPERTY CLASS

CLASS DRG./SPEC IS/SPEC. TC & LOG MARKING SHALL BE
BOOK CHECKED BY THE
VENDOR
1.3 CASTING 1.SURFACE MA VISUAL 100% FREE FROM LOG BOOK 3 - -

CONDITION CRACKS,
BLOW HOLES
ETC.
2.CHEM. & MA CHEM & MECH 1/HEAT NO. MANFR'S RELEVENT SUPPLIER'S 3 - 2 HEAT NO. SHALL BE
PHY. PROP. TEST DRG./SPEC IS/ TC VERIFIED
3.DIMENSIONS MA MEASUREMENT 100% MANUFR'S MANUFR'S LOG BOOK 3 - -

DRG. DRG.
1.4 PAINT & VARNISH 1.MAKE, SHADE, MA VISUAL 100% MANFR'S MANFR'S LOG BOOK 3 - -
SHELF LIFE & CONTINUOUS DRG./SPEC DRG./SPEC
TYPE
BHEL PARTICULARS BIDDER/VENDOR

NAME
SIGNATURE
DATE BIDDER'S/VENDORS COMPANY SEAL
348
TITLE NUMBER :
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1.5 SHAFT 1. SURFACE MA VISUAL 100% - FREE FROM -DO- 3 - - VENDOR'S APPROVAL
(FORGED OR ROLLED) COND. VISUAL IDENTIFICATION SHALL BE
DEFECTS MAINTAINED
2. CHEM. & MA CHEM. & 1/HEAT NO. MFG. DRG. RELEVANT SUPPLIER'S 3 - 2
PHYSICAL PHYSICAL OR HEAT SPEC. IS TC
PROPERTIES TESTS TREATMENT
BATCH NO
3. DIMENSIONS MA MEASUREMENT 100% -DO- MANUFR'S LOG BOOK 3 - -

DRG.
4.INTERNAL CR UT -DO- ASTM-A388 MANUFR'S -DO- 3 2 1 FOR DIA OF 55 MM &

FLOWS SPEC. ABOVE
BHEL SPEC.
1.6 SPACE HEATERS, CONNEC- 1. MAKE & MA VISUAL -DO- MANUFR'S MANUFR'S -DO- 3 - -
TORS, TERMINAL BLOCKS, RATING DRG. SPEC. DRG. SPEC.
CABLES, CABLE LUGS,
CARBON BRUSH TEMP.
DETECTORS, RTD, BTD'S
2. PHYSICAL MA -DO- -DO- - NO BREAKAGE -DO- 3 - -

COND. ON OTHER
PHY. DESIGN
3.DIMENSIONS MA MEASUREMENT SAMPLE MANUFR'S MANUFR'S -DO- 3 - -

(WHEREVER DRG./ SPEC. DRG. / SPEC.
APPLICABLE)
4.PERFORMANCE/ MA TEST 100% -DO- -DO- INSP. 3 - -

CALIBRATION REPORT

NAME
SIGNATURE
349
TITLE NUMBER :
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1.7 OTHER INSULATING 1. SURFACE MA VISUAL 100% - NO VISUAL INSPT. 3 - -

MATERIALS LIKE SLEEVES, COND. DEFECTS REPORT
BINDINGS CORDS, PAPERS,
PRESS BOARDS ETC.
2. OTHER
CHARACTERISTICS MA TEST SAMPLE MANUF'S MANUF'S LOG BOOK 3 - 2
SPEC. SPEC. AND OR
SUPPLIER'S
TC
1.8 SHEET STAMPING 1. SURFACE MA VISUAL 100% - NO VISUAL LOG BOOK 3 - -

(PUNCHED) COND. DEFECTS
(FREE FROM
BURS)
2.DIMENSIONS MA MEASUREMENT SAMPLE MANUFR'S MANUFR'S -DO- 3 - 2 FOR MV MOTOR INSULA-

INCLUDING BURS DRG. . DRG. TION/VARNISH THICKNESS
HEIGHT SHALL BE MORE THAN
THE BURS HEIGHT
3. ACCEPTANCE MA ELECT. & MECH -DO- MANUF'S RELEVANT SUPPLIER'S 3 - 2
TESTS TESTS SPEC./ IS TC
RELEVANT
IS
1.9 CONDUCTORS 1. SURFACE MA VISUAL 100% - FREE FROM LOG BOOK 3 - -

FINISH VISUAL
DEFECTS
2.ELECT. PROP, & MA ELECT. & SAMPLES RELEVANT IS/ RELEVANT IS/ SUPPLIERS 3/2 - 2
MECH. PROP MECH.TEST BS OR BS OR TC &
OTHER OTHER VENDOR'S
STANDARDS STANDARDS INSPN.
REPORTS

NAME
SIGNATURE
350
TITLE NUMBER :
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3.DIMENSIONS MA MEASUREMENT -DO- -DO- -DO- Log Book 3 - -
1.10 BEARINGS 1.MAKE & TYPE MA VISUAL 100% MANFR'S DRG. MANFR'S DRG. -DO- 3 - -
2.DIMENSIONS MA MEASUREMENT SAMPLE BHEL DATA BHEL DATA -DO- 3 - -

SHEET SHEET BEARING
MANUF'S
CATALOGUES
3.SURFACE MA VISUAL 100% - FREE FROM -DO- 3 - -

FINISH VISUAL
DEFECTS
1.11 SLIP RING 1.SURFACE MA VISUAL 100% - -DO- -DO- 3 - -

COND.
2.DIMENSIONS MA MEASUREMENT SAMPLE MANUF'S MANUF'S -DO- 3 - -

DRG DRG
3.TEMP.WITH- MA ELECT.TEST -DO- MANUF'S MANUF'S -DO- 3 - -

STAND SPEC. SPEC.
CAPACITY
4.HV/IR MA -DO- 100% -DO- -DO- -DO- 3 - -
1.12 OIL SEALS & GASKETS 1.MATERIAL OF MA VISUAL 100% MANUF'S MANUF'S -DO- 3 - -
GASKET DRG/SPECS DRG./ SPECS.
2.SURFACE MA VISUAL 100% - FREE FROM -DO- 3 - -

COND. VISUAL
DEFECTS
3.DIMENSIONS MA MEASUREMENT SAMPLE MANUF'S MANUF'S -DO- 3 - -

DRG DRG

NAME
SIGNATURE
351
TITLE NUMBER :
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2.0 IN PROCESS
2.1 STATOR FRAME WELDING 1.WORKMANSHIP MA VISUAL 100% -DO- GOOD FINISH LOG BOOK 3 - -
(IN CASE OF FABRICATED & CLEANNESS
STATOR )
2.DIMENSIONS MA MEASUREMENT -DO- MANUF'S MANUF'S -DO- 3 - -

DRG DRG
2.2 MACHINING 1.FINISH MA VISUAL 100% -DO- GOOD FINISH LOG BOOK 3 - -
2.DIMENSIONS MA MEASUREMENT -DO- MANUF'S MANUF'S -DO- 3 - -

DRG DRG
3.SHAFT SURFACE MA PT -DO- RELEVENT MANUFR'S -DO- 3 - 1

FLOWS SPEC./ SPEC./
ASTM-E165 BHEL SPEC./
2.3 PAINTING 1.SURFACE MA VISUAL 100% MANFR'S BHEL LOG BOOK 3 - -

PREPARATION SPEC/BHEL SPEC.
SPEC./ SAME AS
RELEVANT COL.7
STAND
2.PAINT THICKNESS MA MEASUREMENT SAMPLE -DO- -DO- -DO- 3 - 2

(BOTH PRIMER & BY ELCOMETER
FINISH COAT)
3.SHADE MA VISUAL -DO- -DO- -DO- Log Book 3 - -
4.ADHESION MA CROSS -DO- -DO- -DO- Log Book 3 - -

CUTTING &
TAPE TEST

NAME
SIGNATURE
352
TITLE NUMBER :
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2.4 SHEET STACKING 1.COMPLETENESS MA MEASUREMENT SAMPLE MANUFR'S MANUFR'S Log Book 3 - -
SPEC. SPEC.
2.COMPRESSION MA MEASUREMENT 100% -DO- -DO- Log Book 3 - -

& TIGHTENING
3.CORE LOSS & MA ELECT.TEST -DO- -DO- -DO- Log Book 3 - 2 (FOR MOTORS OF 2MW
HOTOPOT AND ABOVE)
2.5 WINDING 1.COMPLETENESS CR VISUAL 100% MANUFR'S MANUFR'S Log Book 3 - -

SPEC./BHEL SPEC./BHEL
SPEC. SPEC.
2.CLEANLINESS CR -DO- -DO- -DO- -DO- Log Book 3 - -
3.IR-HV-IR CR ELECT. TEST -DO- -DO- -DO- Log Book 3 - -
4.RESISTANCE CR -DO- -DO- -DO- -DO- Log Book 3 - 2
5.INTERTURN CR -DO- -DO- -DO- -DO- Log Book 3 2 -

INSULATION
6.SURGE WITH CR -DO- -DO- -DO- -DO- Log Book 3 2 1 FOR MV MOTOR
STAND AND
TAN. DELTA
TEST
2.6 IMPREGNATION 1.VISCOSCITY MA PHY. TEST AT STARTING -DO- -DO- Log Book 3 - -
2.TEMP. MA PROCESS CONTINUOUS -DO- -DO- Log Book 3 - -

PRESSURE CHECK
VACCUM
3.NO. OF DIPS MA -DO- -DO- -DO- -DO- Log Book 3 - 2 THREE DIPS TO BE
GIVEN

NAME
SIGNATURE
353
TITLE NUMBER :
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4.DURATION MA -DO- -DO- -DO- -DO- Log Book 3 - 2
2.7 COMPLETE STATOR 1.COMPACTNESS MA VISUAL 100% -DO- -DO- Log Book 3 - -
ASSEMBLY & CLEANLINESS
2.8 BRAZING/COMPRESSION 1.COMPLETENESS CR -DO- -DO- -DO- -DO- Log Book 3 - -

JOINT
2.SOUNDNESS CR MALLET TEST -DO- -DO- -DO- Log Book 3 - -
& MV TEST
3.HV MA ELECT. TEST -DO- -DO- -DO- Log Book 3 - -
2.9 COMPLETE ROTOR 1.RESIDUAL CR DYN. BALANCE -DO- MFG SPEC./ MFG. DWG. Log Book 3 2 1 VERIFICATION FOR MV
ASSEMBLY UNBALANCE ISO 1940 MOTOR ONLY
2.SOUNDNESS CR ELECT. -DO- MFG. SPEC. MFG. SPEC. Log Book 3 2 -

OF DIE (GROWLER
CASTING TEST)
2.10 ASSEMBLY 1.ALIGNMENT MA MEAS. -DO- -DO- -DO- Log Book 3 - -
2.WORKMANSHIP MA VISUAL -DO- -DO- -DO- Log Book 3 - -
3.AXIAL PLAY MA MEAS. -DO- -DO- -DO- Log Book 3 - 2
4.DIMENSIONS MA -DO- -DO- MFG.DRG./ MFG. DRG/ Log Book 3 - -

MFG SPEC. RELEVANT
IS
5.CORRECTNESS, MA VISUAL 100% MFG SPEC. MFG SPEC. Log Book 3 - -

COMPLETENESS RELEVANT RELEVANT
TERMINATIONS/ IS IS
MARKING/
COLOUR CODE

NAME
SIGNATURE
354
TITLE NUMBER :
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3.0 TESTS 1.TYPE TESTS MA ELECT.TEST 1/TYPE/SIZE IS-325/ IS-325/ TEST 3 1 1,2 NOTE - 1
INCLUDING BHEL SPEC./ BHEL SPEC./ REPORT
SPECIAL DATA SHEET DATA SHEET
TESTS AS PER
BHEL SPEC.
2.ROUTINE MA -DO- 100% -DO- -DO- -DO- 3 1,2 1,2 NOTE - 2

TESTS INCLUDING
SPECIAL TEST
AS PER BHEL
SPEC.
3.VIBRATION MA -DO- 100% IS-12075 IS-12075 -DO- 3 1,2 -
4.OVERALL MA MEASUREMENT 100% APPROVED APPROVED INSPC. 3 2,1 -

DIMENSIONS & VISUAL DRG/DATA DRG/DATA REPORT
AND ORIENTATION SHEET SHEET &
RELEVANT IS
5.DEGREE OF MA ELECT. & 1/TYPE/ RELEVANT IS BHEL SPEC. TC 3 - 2,1 TC FROM AN

PROTECTION MECH. TEST SIZE AND DATA INDEPENDENT
SHEET LABORATORY NOTE-3
6.NAMEPLATE MA VISUAL 100% IS-325 & IS-325 & INSPC. 3 2,1 -

DETAILS DATA SHEET DATA SHEET REPORT
7.EXPLOSION MA EXPLOSION 1/TYPE IS-3682 IS-3682 TC 3 - 2,1 NOTE-3

FLAME PROOF FLAME PROOF IS-8239 IS-8239
NESS (IF TEST IS-8240 IS-8240
SPECIFIED)
8.PAINT SHADE, MA VISUAL & SAMPLE BHEL SPEC. BHEL SPEC. TC 3 2,1 - SAMPLING PLAN TO BE
THICKNESS MEASUREMENT & DATA & DATA DECIDED BY INSPECTION
& FINISH BY ELKOMETER SHEET SHEET AGENCY

NAME
SIGNATURE
355
TITLE NUMBER :
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NOTES:
1 DEPENDING UPON THE SIZE AND CRITICALLY, WITNESSING BY BHEL SHALL BE DECIDED.
2 ROUTINE TESTS ON 100% MOTORS SHALL BE DONE BY THE VENDOR. HOWEVER, BHEL SHALL WITNESS ROUTINE TESTS ON RANDOM SAMPLES.
THE SAMPLING PLAN SHALL BE MUTUALLY AGREED UPON.
3 IN CASE TEST CERTIFICATES FOR THESE TESTS ON SIMILAR TYPE, SIZE AND DESIGN OF MOTOR FROM INDEPENDENT LABORATORY ARE AVAILABLE,
THESE TEST MAY NOT BE REPEATED.
4 WHEREVER CUSTOMER IS INVOLVED IN INSPECTION WITH THE CUSTOMERS, AGENCY (1) SHALL
MEAN BHEL AND CUSTOMERS BOTH TOGETHER.

NAME
SIGNATURE
356
TITLE NUMBER :
QUALITY PLAN BIDDER/ : QUALITY PLAN SPECIFICATION
SHEET 1 OF 2 SYSTEM ITEM AC ELECT. MOTORS BELOW 75KW (LV) SECTION VOLUME III
SL. COMPONENT/OPERATION CHARACTERISTICS CAT. TYPE/ EXTENT OF REFERENCE ACCEPTANCE FORMAT AGENCY REMARKS
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
1.O PAINTING 1.SHADE MA VISUAL SAMPLE MANUFR'S BHEL SPEC. LOG BOOK 3 - -
SPEC/BHEL SAME AS
SPEC./RELEVANT COL.7
STANDARD
2.0 ASSEMBLY 1.WORKMANSHIP MA VISUAL 100% MANUF'S SPEC MANUF'S SPEC -DO- 3 - -
2.DIMENSIONS MA -DO- -DO- MFG. DRG./ MFG. DRG./ -DO- 3 - -

MFG. SPEC. MFG. SPEC.
3.CORRECTNESS MA VISUAL 100% MFG.SPEC./ MFG.SPEC. -DO- 3 - -

COMPLETENESS RELEVANT IS RELEVANT IS
TERMINATIONS/
MARKING/COLOUR
CODE
3.0 TESTS 1.ROUTINE MA -DO- 100% IS-325/ SAME AS TEST 3 2,1 2,1 NOTE -1
TEST INCLUDING BHEL SPEC./ COL.7 REPORT
SPECIAL TEST DATA SHEET
AS PER BHEL
SPEC.
2.OVERALL MA MEASUREMENT 100% APPROVED APPROVED INSPN. 2 1 -

DIMENSIONS & & DRG/DATA DRG/DATA REPORT
ORIENTATION VISUAL SHEET SHEET
& RELEVANT IS

NAME
SIGNATURE
357
QUALITY PLAN TITLE NUMBER :
BIDDER/ : QUALITY PLAN SPECIFICATION :
VENDOR NUMBER PED-506-00-Q-006/0 TITLE :
SHEET 2 OF 2 SYSTEM ITEM AC ELECT. MOTORS BELOW 75KW (LV) SECTION VOLUME III
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
3.NAMEPLATE MA VISUAL 100% IS-325 & IS-325 & INSPN. 3 1 -

DETAILS DATA SHEET DATA SHEET REPORT
NOTES:
1 ROUTINE TESTS ON 100% MOTORS SHALL BE DONE BY THE VENDOR. HOWEVER, BHEL SHALL WITNESS ROUTINE TESTS ON RANDOM SAMPLES. THE
SAMPLING PLAN SHALL BE MUTUALLY AGREED UPON
2 WHERE EVER CUSTOMER IS INVOLVED IN INSPECTION, (1) SHALL MEAN BHEL AND CUSTOMERS BOTH TOGETHER.
3 FOR EXHAUST/VENTILATION FAN MOTORS OF RATING UPTO 1.5KW , ONLY ROUTINE TEST CERTIFICATES SHALL BE FURNISHED FOR SCRUTINY.

NAME
SIGNATURE
358
TITLE NUMBER :
ITEM : CABLE TRAY SUPPORT MATERIAL & ACCESSORIES
SHEET 1 OF2 SYSTEM SECTION VOLUME III
(BOLTABLE)
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
1.0 RAW MATERIAL
1.1 ROLLED SHEET 1.CHEM.& PHY. MA VERIFICATION 100% IS1079 (for hot rolled) IS1079 (for hot rolled) MILL TC 3/2 - - AS PER CONTRACT & AS
PROPERTIES OF TC'S IS-513 (for cold rolled IS-513 (for cold rolled) APPLICABLE IN TECH.
SPECIFICATION
IS-1730/ IS-1730/
2.DIMENSIONS MA MEASUREMENT 100% QC RECORD 3/'2 - -
SPECIFICATION SPECIFICATION
3.SURFACE MA VISUAL 100% IS1079 (for hot rolled) IS1079 (for hot rolled) QC RECORD 3/'2 - -
FINISH IS-513 (for cold rolled IS-513 (for cold rolled)
1.2 ZINC CHEM.COMP. MA CHEM TEST EACH HEAT IS-209 IS-209 QC RECORD 3/2 - 1/2
2.0 IN-PROCESS
2.1 FABRICATION 1.DIMENSIONS MA MEASUREMENT 100% APPD. DRGS. APPD. DRGS. QC RECORD 2 - 1
2.WELDING MA VISUAL 100% GOOD WELDING FREE FROM QC RECORD 2 - 1 WELDING IS TO BE DONE BY
QUALITY PRACTICE DEFECTS & QUALIFIED WELDERS
SLAG
3.SURFACE MA VISUAL 100% SPECIFICATION SPECIFICATION QC RECORD 2 - 1

FINISH
2.2 SURFACE PREPARATION 1.CLEANING, MA MEASUREMENT PERIODIC IS:2629 IS:2629 QC RECORD 2 - -

PICKLING, IN EACH
RINSING & SHIFT
FLUXING
2. SURFACE MA VISUAL 100% IS:2629 IS:2629 QC RECORD 2 - -

QUALITY
2.3 GALVANISING 1.TEMPERATURE MA TEMPERATURE CONTINUOUS IS-2629 IS-2629 QC RECORD 2 - -

OF BATH INDICATOR

NAME
SIGNATURE
359
TITLE NUMBER :
ITEM : CABLE TRAY SUPPORT MATERIAL & ACCESSORIES
SHEET 2 OF 2 SYSTEM SECTION VOLUME III
(BOLTABLE)
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
2. DROSS MA VISUAL CONTINUOUS IS - 2629 IS - 2629 QC RECORD 2 - -
3. RATE OF MA VISUAL / 100% IS - 2629 / IS - 2629 / QC RECORD 3 - 2

IMMERSION MEASUREMENT MFR'S PRACTICE MFR'S PRACTICE
4.SURFACE MA VISUAL 100% IS - 2629 / FREE FROM QC RECORD 2 - -

QUALITY BURRS, SLAG,
ROUGHNESS,
FLUX.
STAIN. ETC.
3.0 FINISHED ITEMS
3.1 SINGLE / DOUBLE CHANNELS, 1.DIMENSIONS MA MEASUREMENT IS-2500 APPD. DRG APPD. DRG INSP. REPORT 3 2, 1 - FASTENERS SHALL BE OF
CANTILEVER ARMS, CLAMPS DISTORTION LEVEL IV REPUTED & APPROVED MAKE
2.SURFACE FINISH MA VISUAL IS-2500 SPECIFICATION FREE FROM INSP. REPORT 3 2, 1 -

LEVEL IV BURRS, SLAG,
ROUGHNESS,
FLUX. STAIN.
ETC.
3.MASS OF MA CHEM. TEST IS-4759 / IS-6745 / SPECIFICATION/ INSP. REPORT 3 2, 1 -

ZINC COATING SPECIFICATION SPECIFICATION
4.UNIFORMITY MA CHEM. TEST IS-4759 / IS-2633 IS-2633 INSP. REPORT 2 1 -

OF ZINC SPECIFICATION
COATING
5.THICKNESS MA ELCOMETER IS-4759 / SPECIFICATION. SPECIFICATION. INSP. REPORT 3 2, 1 -

COATING
6.ADHESION MA MECH.TEST IS-4759 IS-2629 IS-2629 INSP. REPORT 3 2, 1 -
3.1.1 TYPE TESTING CR TEST 1 SAMPLE SPECIFICATION./ SPECIFICATION./ APPD. INSP. REPORT 2 1 -
APPD. TYPE TEST TYPE TEST
PROCEDURE PROCEDURE
3.1.2 WELD INTEGRITY TEST SOUNDNESS CR MPI SAMPLE TESTED SPECIFICATION. NO DEFECT INSP. REPORT 2 1 - AFTER CARRYING OUT TYPE
DURING TYPE TEST, WELD INTEGRITY TEST TO
TESTING CHECK THE WELD SOUNDNESS/
ACCEPTANCE SHALL BE DONE
BY MANUFACTURER
NOTE: INSTRUCTIONS FOR QUALITY PLAN IS ATTACHED AS ANNEXURE-1.
NAME
SIGNATURE
360
ANNEXURE – 1
INSTRUCTIONS FOR QUALITY PLAN
The Quality Plan shall include all the Quality Control Measures and Checks adopted by the Vendor to ensure that the
material/component/assembly/services supplied by him meet/will meet the requirements as per specifications and good practices.
They shall include all stages of operation such as materials, processes, manufacture, assembly, packing and despatch. The following
guide lines may be noted:
Column 1- Serial Number

Column 2- Component/Operation- The component and/or operation being checked shall be given here.
Column 3- Characteristics check- The characteristics being checked shall be given here, e.g., chemical composition, mechanical
properties, leak tightness, surface defects etc..
Column 4- Category -‘CR’ stands for critical characteristic - affecting safety of equipment and personnel
‘MA’ stands for major Characteristic - affecting safety of equipment and personnel
‘MI’ stands for minor characteristic - affecting appearance etc.
Column 5- Type/Method of check e.g. chemical analysis tensile testing, hydraulic test, visual examination radiography etc.
Column 6- Extent of check, such as, 100, 10, 1 percent etc.
Column 7- Reference Documents - Documents, such as technical specification, drawings, standard specifications (IS, BS ETC.)
procedure, etc. according to which check is done.
Column 8- Acceptance Norms - Standards etc. according to which acceptability or otherwise of the characteristics being checked is
decided.
Column 9- Format of Record - Formats, log shets, reports, etc. in which the observations are recorded. Standard log sheets, reports,
formats etc. of the Vendors shall be numbered and such reference numbers shall be included here.
Column 10- Agency - The agency which performs the test/instruction shall be written in sub-column ‘W’
The agency which verifies test certificates/inspection records and carries out audit check of the components/operation shall
be written in sub-column ‘V’
The agencies are codified as 1,2 & 3
‘1’ stands for (BHEL)
‘1’ * means the operation shall be cleared by BHEL before the start of the next operation.
‘2’ Stands for Vendor
‘3’ stands for sub-Vendor of the Vendor and so on.
Example :
Entry ‘3’ in column ‘P’ means test./inspection to be performed by sub-Vendor’s QC
Entry ‘2’ in column ‘W’ means test./inspection to be witnessed by Vendor’s QC
Entry ‘1’ in column ‘V’ means verification shall be done by BHEL and next stage to be started only after the hold point is cleared
by BHEL
Column11I- Remarks - Any special remarks shall be given here.
NOTES :
1. In absence of correlation with the test certificate(s) (e.g. material identification) samples shall be drawn bgy BHEL and all tests as per
relevent specifications shall be carried out in their presence or in recognized Government Laboratory.
2. When materials and components are initially identified and stamped by BHEL QS engineer, the identification marks shall be
presserved till despatch. Wherever this is not possible, the identification mark shall be transferred to the components in the presence
of BHEL QS Engineer unless other wise agreed.
3. For castings and forgings integral test specimens shall be provided, When this is not possible for casting, they shall be poured in the
presence of BHEL QS Engineer unless otherwise, if witnessing of test by BHEL is called for.
4. When welders qualified by reputed inspection agencies or statutory bodies are not available, qualification tests shall be conducted in
the presence of BHEL QS Engineer.
5. This Quality Plan is liable to be modified as per the requirements of approved drawings and changes in technical
specifications/drawings. If there are contradictions in respect of column 7 & 8 between this Quality Plan and the approved drawings
specifications, the latter shall prevail.
6. Wherever inspection by BHELs Purchaser/Third Party/Statutory authorities are mandatory, this shall be compiled with.
7. Inspection reports, log sheets, test reports/certificate. etc. shall be furnished to BHEL at the approproate stages or at the time of final
inspection, as required.
8. This Quality Plan is also applicable to spares, if any, under scope of supply of Vendor.
9. The quality plan shall be submitted in minimum 4 copies with a soft copy of the same or in line with contract requirements.
361
FOREM NO. PEM-6041-0
CUSTOMER : PROJECT SPECIFICATION
TITLE NUMBER
SHEET 1 OF 3 SYSTEM ITEM :BOUGHT OUT ITEMS SECTION VOLUME III
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
1.0 MATERIAL
1.1 SECTIONS, HARDWARES, 1. DIMENSIONS MA MEASUREMENT SAMPLE BHEL TECH. SPEC./ BHEL TECH. SPEC./ TEST 3/2 - 2 NO VISUAL DEFECT
FLATS, ANGLES & CHANNEL DRG. /DATA SHEETS/ DRG. /DATA SHEETS/ CERT. &
RELEVANT. IS RELEVANT. IS INSPN.
REPORT
2. SURFACE MA VISUAL 100% -DO- NO VISUAL -DO- 3/2 - 2 TC FOR PLATING

CONDITION DEFECTS QUALITY TO BE
PROVIDED
3. SURFACE MA VISUAL SAMPLE -DO- BHEL SPEC. -DO- 3/2 - 2

PROTECTION
(HARDWARES)
1.2 SWITCHGEAR COMPONENTS 1. TYPE TESTS MA ELECTRICAL EACH TYPE BHEL SPEC./ BHEL SPEC./ TEST 3/2 - 2,1
SWITCH SFU'S
A) SWITCH, SFU'S. RELEVENT IS RELEVENT IS CERTIFICATE
INSTRUMENT, TRANSF,
FUSES, CONTACTORS AIR 2. ROUTINE TESTS MA ELECTRICAL 100% -DO- -DO- ROUTINE 3/2 - 2 IF THESE ARE TAKEN
CIRCUIT BREAKERS, (FOR METERS TEST FROM BHEL APPROVED
ISOLATORS. BIMETAL CT'S & PT'S) CERTIFICATE SOURCE THEN TC
THERMAL RELAYS, MCB.S NOT REQUIRED
& MCCB.S
3. PHYSICAL MA VISUAL 100% NO BREAKAGES/ NO. BREAKAGES/ INSPN. 2 - -
CONDITION DAMAGES DAMAGES REPORT
4. MAKE TYPE MA VISUAL 100% BHEL SPEC./ BHEL SPEC./ -DO- 2 - - TO BE PROCURED
RATING ETC. APPD. DRGS APPD. DRGS FROM APPROVED
MAKE
5. FUNCTIONAL
TEST MA ELECTRICAL 100% RELEVENT IS RELEVENT IS -DO- 2 - -

NAME
SIGNATURE
DATE BIDDER'S/VENDOR'S COMPANY SEAL
362
CUSTOMER PROJECT SPECIFICATION
TITLE NUMBER
QUALITY PLAN BIDDER/ QUALITY PLAN SPECIFICATION
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
B) INSTRUMENTS, GAUGES,
INSTRUMENTS GAUGES 1. PHYSICAL
1 MA VISUAL 100% NO BREAKAGES/ NO BREAKAGES/ INSPECTIONN 2 - -
CONNECTORS, LUGS, GLANDS CONDITION DAMAGES DAMAGES REPORT
SPACE HEATER,THERMOSTAT,
TERMINAL BLOCKS, LAMPS, 2. MAKE, TYPE, MA VISUAL 100% BHEL SPEC./ BHEL SPEC./ -DO- 2 - - TO BE PROCURED FROM
PUSHBUTTONS, SMALL , RATING ETC APPD. DRGS. APPD. DRGS. APPROVED MAKE
SWITCHES, NAMEPLATES,
FERRULES, LABELS, 3. FUNCTIONAL MA ELECTRICAL 100% RELEVANT IS RELEVANT IS -DO- 2 - -
STICKERS, PVC SLEEVES/
CHANNELS
C) RELAYS & TIMERS 1. PHYSICAL MA VISUAL 100% NO BREAKAGES/ NO BREAKAGES/ INSPECTION 2 - -

CONDITION DAMAGES DAMAGES REPORT
2. MAKE, TYPE, MA VISUAL 100% BHEL SPEC./ BHEL SPEC./ -DO- 2 - - TO BE PROCURED FROM
RATING ETC APPD. DRGS. APPD. DRGS. APPROVED MAKE
3. FUNCTIONAL MA ELECTRICAL 100% RELEVANT IS RELEVANT IS -DO- 2 - -

TEST
D) PCB ASSEMBLY REFER TO QP NO………PED-557-00-Q-002
1.3 INSULATING MATERIALS 1. ELECTRICAL CR ELECT. TEST SAMPLE BHEL SPEC./ BHEL SPEC./ TEST 2 - 1
(FRP,SMC,DMC,ETC.) RELEVANT IS RELEVANT IS CERTIFICATE
MANUFS. STD. MANUFS. STD.
2. MECH. PROPS. MA MECH. TEST SAMPLE -DO- -DO- -DO- 2 - 1
3. TRACKING MA ELECT. TEST SAMPLE -DO- -DO- -DO- 3/2 - 1

INDEX
1.4 WIRES/CABLES 1. SURFACE MA VISUAL 100% NO VISUAL NO VISUAL LOG BOOK/ 2 - -

FINISH DEFECT DEFECT INSP. REPORT
2. DIMENSIONS MA MEASUREMENT SAMPLE BHEL SPECN. BHEL SPECN. -DO- 2 - -
3. HV TEST AT CR ELECT. TEST 100% IS:694 IS:694 -DO- 2 - -

80% OF ORIGINAL HV

NAME
SIGNATURE
363
TITLE NUMBER
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
1.5
15 BUSBARS 1.
1 DIMENSION MA MEASUREMENT SAMPLE BHEL SPEC
SPEC.// BHEL SPEC
SPEC.// LOG BOOK/ 2 - -
APPD. DRGS. APPD. DRGS. INSP. REPORT
2. SURFACE MA VISUAL 100% -DO- -DO- -DO- 2 - -

FINISH
3. MATERIAL MA VERIF. OF TC 1/LOT -DO- -DO- TEST. CERT. 2 - 1

GRADE
4 CONDUCTIVITY
4. CR ELECT TEST
ELECT. -DO-
DO -DO-
DO -DO-
DO -DO-
DO 2 - 1
1.6 SHEET STEEL 1. THICKNESS MA MEASUREMENT SAMPLE -DO- -DO- -DO- 2 - -
2. WAVINESS MA MEASUREMENT 100% -DO- -DO- -DO- 2 - -
3. DUCTILITY CR BEND TEST SAMPLES -DO- -DO- TEST. CERT./ 2 - -

INSP. REPORT
17
1.7 TRANSFORMER & REACTORS 1 ROUTINE TESTS
1. MA ELECT TEST
ELECT. 100% STD &
RELEVANT STD. STD &
RELEVANT STD. CERT
TEST CERT. 3 - 12
1,2
BHEL SPEC. BHEL SPEC.
2. TEMP. RISE MA ELECT. TEST 1/RATING -DO- -DO- -DO- 3 - 1,2

TEST
1.8 PAINTS SHELF LIFE MA VISUAL 100% ….AS PER PAINTS MANUF'S. SPEC……. INSPN 2 - -
REPORT
1.9 GASKETS ((SYN. RUBBER 1. DIMENSION MA MEASUREMENT SAMPLE MANUFACTURER'S MANUFACTURER'S INSPN 2 - -
ONLY) DRGS. DRGS. REPORT
2. SHORE MA TEST -DO- MANUFACTURER'S MANUFACTURER'S INSPN 2 - -

HARDNESS STD. STD. REPORT
3. AGEING MA TEST -DO- IS-3400/ IS-3400/ INSPN 2 - -

BS-2752 BS-2752 REPORT
BHEL PARTICULAR BIDDER / VENDOR

NAME
SIGNATURE
364
CUSTOMER : PROJECT: SPECIFICATION :
TITLE : NUMBER :
QUALITY PLAN
SHEET 1 OF 1 SYSTEM ITEM : GALVANISED RIGID STEEL CONDUITS & PIPES SECTION VOLUME III
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
1.0 CONDUITS 1. MATERIAL MA VISUAL,MECH, IS - 9537 IS:9537 IS:9537 INSPT. REPORT 3 2 1

& CHEMICAL
2. DIMENSIONS MA MEASUREMENT IS - 9537 IS - 9537 IS - 9537 INSPT. REPORT 3 2 1
3. TESTS MA TESTING IS - 9537 IS - 9537 IS - 9537 INSPT. REPORT 3 2 1
2.0 PIPES 1. MATERIAL MA VISUAL,MECH, IS - 1239 IS - 1239 IS - 1239 INSPT. REPORT 3 2 1

& CHEMICAL
2. DIMENSIONS MA MEASUREMENT IS - 1239 IS - 1239 IS - 1239 INSPT. REPORT 3 2 1
3. TESTS MA TESTING IS - 1239 IS - 1239 IS - 1239 INSPT. REPORT 3 2 1
NOTE : INSTRUCTIONS FOR QUALITY PLAN IS ATTACHED AS ANNEXURE - 1.

NAME
SIGNATURE
365
ANNEXURE – 1

decided.
Example :
by BHEL
NOTES :
366
TITLE NUMBER :
VENDOR NUMBER PED 509 00 Q 001/01
PED-509-00-Q-001/01 TITLE
SHEET 1 OF 3 SYSTEM ITEM : EARTHING COND. & ELECTRODES SECTION VOLUME III
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
1.0 RAW MATERIAL
1.1 MILD STEEL & COPPER 1.CHEMICAL & MA CHEM & PHYS 1/ LOT/SIZE APPD. DRGS/ APPD. DRGS/ MILL TEST 2 - -
(AS SPECIFIED) PHYSICAL TESTS DATA SHEETS/ DATA SHEETS/ CERTIFICATE
PROPERTIES TECH. SPEC. TECH. SPEC.
2.SURFACE MA VISUAL 100% -DO- -DO- IR 3/2 - 2

FINISH
3.DIMENSIONS
3 SO S MA MEASUREMENT
SU 1// LOT/SIZE
O /S -DO-
O -DO-
O -DO-
O 2 - -
1.2 HARDWARES 1.DIMENSIONS MA MEASUREMENT 100% TECH. SPEC. TECH. SPEC. -DO- 3/2 - 2
APPD. DRGS/ APPD. DRGS/
DATA SHEETS DATA SHEETS
2.COATING MA VISUAL SAMPLE -DO- -DO- -DO- 3/2 - 2
1.3 ZINC FOR GALVANISATION 1.CHEM.COMP. MA CHEM.TEST SAMPLE RELEVANT IS. RELEVANT IS. TC 3/2 - 2
2.0 IN-PROCESS
2.1 CUTTING, DRILLING 1.WORKMANSHIP MA VISUAL & 100% APPD. DRGS/ APPD. DRGS/ IR 2 - -
DIMENSIONS MEASUREMENT TECH. SPEC. TECH. SPEC.
& DISTORTION
2.2 WELDING 1.WELDING MA VISUAL &

QUALITY MALLET TEST SAMPLE MFR'S. STD MFR'S.STD. IR 2 - -
2.3 SURFACE PREPARATION FOR 1.CLEANING MA CHEM. & PERIODIC IS:2629/ IS:2629/ IR 3/2 - -
GALVANISING PICKLING & MEASUREMENT IN EACH RELEVENT:IS RELEVENT:IS
RINSING, BATH SHIFT
STRENGTH/
PURITY &
TEMPERATURE

NAME
SIGNATURE
367
TITLE NUMBER :
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
2.SURFACE MA VISUAL 100% IS:2629/ IS:2629/ IR 3/2 - -

QUALITY RELEVENT:IS RELEVENT:IS
2.4 GALVANISING 1.TEMPERATURE MA TEMPERATURE CONTINUOUS -DO- -DO- -DO- 3/2 - -

OF BATH INDICATOR
2.DURATION OF MA VISUAL PERIODIC -DO- -DO- -DO- 3/2 - -

DIP
3.ROSS QUANTITY MA TEST PERIODIC RELEVENT:IS RELEVENT:IS -DO- 2 - -

AGITATION
4.BATH MA VISUAL PERIODIC MFR'S STD MFR'S STD -DO- 2 - -

AGITATION
5.SURFACE MA VISUAL 100% -DO- -DO- IR 3/2 - 2

QUALITY
2.5 PAINTING 1.SURFACE MA CHEM. TEST 100% TECH.SPEC. TECH.SPEC. LOG BOOK 2 - -
PREPN.
DEGREASING &
DERUSTING
2.THICKNESS & MA MEASUREMENT SAMPLES -DO- -DO- -DO- 2 - -

ADHESION
3.0 FINAL TESTS 1.APPEARANCE MA VISUAL SAMPLE IS:2629 IS:2629 IR 2 1 -

FREE FROM
ROUGHNESS
LUMPS ETC
2.DIMENSION MA MEASUREMENT -DO- TECH.SPEC./ TECH.SPEC./ IR 2 1 -

APPD.DRG. APPD.DRG.
3.UNIFORMITY MA DIP TEST SAMPLE IS:4759 IS-2633 IR 2 1 -

OF COATING AS PER
IS-2633

NAME
SIGNATURE
368
TITLE NUMBER :
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
4. WEIGHT OF MA PREECE IS-4739 IS-6745 TECH. SPEC. IR 2 1 -

COATING TEST
5.ADHESION MA HAMMER/ -DO- IS-2629 IS-2629 IR 2 1 -

KNIFE
6.THICKNESS MA ELKOMETER SAMPLES TECH. SPEC. TECH. SPEC. IR 2 1 -

AND
IS-2629

NAME
SIGNATURE
369
TITLE NUMBER :
SHEET 1 OF 3 SYSTEM ITEM : EARTHING & LIGHTNING PROTECTION MATERIALS SECTION VOLUME III
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
1.0 RAW MATERIAL
1.1 MILD STEEL (FLATS & RODS) 1.CHEMICAL & MA VERIFICATION, 100% IS:1079 IS:1079 MILL TC 3 - 2 STEEL SHALL BE
AS PER SPECIFICATION PHYSICAL OF TC'S PROCURED FROM SAIL/
PROPERTIES TISCO/ RINL/ AUTHORISED
RE-ROLLERS/
MANUFACTURERS AS PER
BHEL APPROVED
SOURCES.
2.DIMENSIONS MA MEASUREMENT 100% IS - 1730 IS - 1730 QC RECORD 3/2 - -
3.SURFACE MA VISUAL 100% IS : 1079 IS : 1079 QC RECORD 3/2 - -

FINISH
1.2 ZINC 1.CHEM.COMP. MA CHEM.TEST SAMPLE IS - 209 IS - 209 QC RECORD 3/2 - 1/2
2.0 IN-PROCESS
2.1 CUTTING, DRILLING 1.DIMENSIONS MA MEASUREMENT 100% SPECIFICATION SPECIFICATION QC RECORD 2 - 1

FINISH
2.2 SURFACE PREPARATION 1.CLEANING MA MEASUREMENT PERIODIC IN IS:2629 IS:2629 QC RECORD 2 - -

PICKLING, EACH SHIFT
RINSING,
& FLUXING
2.SURFACE MA VISUAL 100% IS:2629 IS:2629 QC RECORD 2 - -

QUALITY

NAME
SIGNATURE
370
TITLE NUMBER :
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
2.3 GALVANISING 1.TEMPERATURE MA TEMPERATURE CONTINUOUS IS - 2629 IS - 2629 QC RECORD 2 - -

OF BATH INDICATOR
3. RATE OF MA VISUAL/ 100% IS - 2629/ IS - 2629/ QC RECORD 3 - 2

IMMERSION MEASUREMENT MFRS PRACTICE MFRS PRACTICE
4.SURFACE MA VISUAL 100% IS - 2629 FREE FROM BURRS, QC RECORD 2 - -

QUALITY ROUGHNESS,
SLAG, FLUX, STAIN
ETC.
3.0 FINISHED ITEMS
1.DIMENSIONS MA MEASUREMENT RANDOM SPECIFICATION SPECIFICATION INSP. REPORT 3 2, 1 -
2.SURFACE FINISH MA VISUAL RANDOM SPECIFICATION FREE FROM INSP. REPORT 3 2, 1 -

BURRS, SLAG,
ROUGHNESS,
FLUX, STAIN,
ETC.
3.MASS OF MA CHEM. TEST IS - 4759 IS-6745 / SPECIFICATION INSP. REPORT 3 2, 1 -

ZINC COATING SPECIFICATION
4.UNIFORMITY MA CHEM. TEST IS - 4759 IS-2633 IS-2633 INSP. REPORT 3 2, 1 -

OF ZINC
COATING
5.THICKNESS MA ELCOMETER IS - 4759 SPECIFICATION SPECIFICATION INSP. REPORT 3 2, 1 -

OF ZINC
COATING

NAME
SIGNATURE
371
ANNEXURE – 1

decided.
Example :
by BHEL
NOTES :
372
FORM NO. PEM-6041-0
TITLE NUMBER
SHEET 1 OF 2 SYSTEM ITEM ELECTRICAL IN-PROCESS SECTION VOLUME III
SL. COMPONENT/OPERATION CHARACTERISTICS CAT. TYPE/ EXTENT OF REFERENCE ACCEPTANCE FORMAT GENCY REMARKS
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
1.0 FABRICATION 1. DIMENSION MA MEASUREMENT 100% APPD. DRG. APPD. DRG. INSP.REPORT 2 - -
2. ALIGNMENT MA MEASUREMENT 100% -DO- -DO- -DO- 2 - -

& VISUAL
3. FINISH/ MA VISUAL 100% -DO- -DO- -DO- 2 - -

SURFACE
DEFECT
2.0 SURFACE PREPARATION 1. PROCESS CR PROCESS PERIODIC MFR. STD./ MFR. STD./ LOG BOOK 2 - -
& PRE-TREATMENT PARAMETERS CHECK BHEL SPEC./ BHEL SPEC./
(SOLUTION RELEVANT IS RELEVANT IS
STRENGTH,
TEMPERATURE
DIPPING TIME ETC.)
2. SURFACE MA VISUAL 100% -DO- -DO- -DO- 2 - -

CONDITION
3.0 PRIMER & PAINTING 1. SURFACE MA VISUAL 100% -DO- -DO- -DO- 2 - -
(SPRAYED & STOVED) FINISH &
COVERAGE
2. FILM MA MEASUREMENT SAMPLE -DO- -DO- -DO- 2 - -

THICKNESS
3. SHADE MA VISUAL -DO- -DO- -DO- -DO- 2 - -
4. ADHESION MA CROSSOUT -DO- -DO- -DO- -DO- 2 - -

TAPE
NAME
SIGNATURE
373
FORM NO. PEM-6041-0
QUALITY PLAN TITLE NUMBER
BIDDER/ QUALITY PLAN SPECIFICATION
SHEET 2 OF 2 SYSTEM ITEM ELECTRICAL IN-PROCESS SECTION VOLUME III
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
4.0 MOUNTING OF VARIOUS 1. RIGIDITY MA VISUAL 100% MANUFACTURER MANUFACTURER LOG BOOK 2 - -
ITEMS DRAWINGS DRAWINGS
2.TIGHTNESS MA VISUAL 100% -DO- -DO- -DO- 2 - -
3. CORRECTNESS MA VISUAL 100% APPD. DRG. APPD. DRG. -DO- 2 - -

& COMPLETENESS
4. ACCESSIBILITY MA VISUAL 100% -DO- -DO- -DO- 2 - -
5.0 MARKING/LABELLING 1. CORRECTNESS MA VISUAL 100% -DO- -DO- INSPN 2

REPORT
2. ADHESION/ MA VISUAL 100% -DO- -DO- -DO- 2 - -

FIXING
6.0 PRE-FINAL INSPECTION 1. ALIGNMENT MA VISUAL 100% BHEL SPEC. BHEL SPEC. TEST 2 - -
& RELEVANT. STD. & RELEVANT. STD. CERTIFICATE.
2. PERFORMANCE CR ELECTRICAL 100% -DO- -DO- -DO- 2 - -
3. IR & HV CR ELECTRICAL 100% -DO- -DO- -DO- 2 - -

NAME
SIGNATURE
374
TITLE NUMBER :
SHEET 1 OF 2 SYSTEM ITEM ELECTRONIC PCB ASSEMBLY SECTION VOLUME III
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
1.0 BOUGHT OUT ITEMS
1.1 ELECTRONIC COMPONENTS 1. MAKE/RATING MA VISUAL SAMPLE BHEL SPEC, BHEL SPEC, INSPC. 2 - 2
ACTIVE, PASSIVE ICS, CMOS LCSO/ BARC LCSO/ BARC REPORT
ETC. COMPONENT TO COMPONENT TO
BE USED BE USED
1.2 POWER DIODES/THYRISTORS/ 1. MAKE/ RATING MA VISUAL 100% BHEL SPEC./DRG. BHEL SPEC./DRG. -DO- 2 - 1
TRANSISTORS 2.ROUTINE MA ELECT. & 100% RELV. IS/ RELV. IS/ -DO- 2 - 1
TEST MECH BS/ BHEL SPEC BS/ BHEL SPEC
1.3 PCB CONNECTORS 1. MAKE/TYPE MA VISUAL SAMPLE BHEL SPEC, BHEL SPEC, -DO- 2 - 2
LCSO/ BARC LCSO/ BARC
COMPONENT TO COMPONENT TO
BE USED BE USED
2.0 PROCESS
2.1 COMPONENTS MOUNTING 1. CORRECTNESS MA VISUAL SAMPLE MANFR. STD MANFR. STD -DO- 2 - -
& SOLDERING OF COMPONENTS
2. MOUNTING & MA VISUAL 100% -DO- -DO- -DO- 2 - -

ORIENTATION
3. SOLDERING CR VISUAL AT 100% -DO- -DO- -DO- 2 - -

DEFECTS & 10%
FINISH

NAME
SIGNATURE
375
SHEET 2 OF 2 SYSTEM ITEM ELECTRONIC PCB ASSEMBLY SECTION VOLUME III
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
2.2 ASSEMBLED PCBS (INTER- 1. FUNCTIONAL CR 1. ELECTRICAL 100% BHEL SPEC./ BHEL SPEC./ TEST 2 - 1 SOAKING AT 700C FOR
CONNECTED TOGETHER CHECK BEFORE MFR. STD. MFR. STD. CERT 72 HRS. AT ENERGISED
AS SYSTEM/ EQUIPMENT) SOAKING CONDITION
2.
2 ELECTRICAL 100% DO
-DO- DO
-DO- DO
-DO- 2 - 1 DO
-DO-
AFTER
SOAKING
OR
3. ELECTRICAL 100% -DO- -DO- -DO- 2 - 1 TEMP. CYCLE: RAPID TEMP.
AFTER CYCLE AT+ 700C-200C FOR
TEMP. CYCLE 30 MINTS. AT EACH TEMP.
TEST FIVE SUCH CYCLE
2. HV/ IR/ HV/ SWC MA ELECT. TESTS 100% RELEVANT IS/ -DO- -DO- 2 1 -
ANSI-C-37-90-
197
3. UNIFORMITY & CR VISUAL 100% BHEL SPEC./ BHEL SPEC./ INSPN. 2 - -

FINISH OF MFR. STD MFR. STD REPORT
CONFORMAL
COATING ON
BOTH SIDES

NAME
SIGNATURE
376
TITLE NUMBER :
VENDOR NUMBER PED
PED-558-00-Q-001/01
558 00 Q 001/01 TITLE
SHEET 1 OF 3 SYSTEM ITEM :ILLUMINATION SECTION VOLUME III
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
1.0 CABLES & WIRES 1.SURFACE MA VISUAL SAMPLE BHEL SPEC. BHEL SPEC. INSPN. 3/2 2 1 TO BE PROCURED FROM
DEFECTS IS:694 IS:694 REPORT APPROVED SOURCE
IS:1554 IS:1554 & TEST
REPORT
FROM
MANUFACTURER
2.DIMENSIONS MA MEASUREMENT SAMPLE -DO- -DO- -DO- 3/2 2 1
3 TYPE TESTS
3.TYPE CR ELEC TESTS
ELEC.TESTS ONE/TYPE BHEL SPEC.
SPEC BHEL SPEC.
SPEC TEST CERT
CERT. 3 2 1
& SIZE IS:694 IS:694
IS:1554 IS:1554
4.ACCEPTANCE MA -DO- SAMPLING -DO- -DO- -DO- 3 2 1

TESTS
5.ROUTINE MA -DO- 100% -DO- -DO- -DO- 3 - 2,1

TESTS
6.FRLS CR FRLS TESTS SAMPLES BHEL SPEC BHEL SPEC -DO- 3 2 1

PROPS.
2.0 JUNCTION BOXES, LIGHTING

PANELS AND DISTRIBUTION
BOARDS
2.1 JUNCTION BOXES 1.DIMENSIONS MA MEASUREMENT 100% BHEL DRG. BHEL DRG. INSP. REPORT 3 - 2 COMPONENTS TO BE OF
APPROVED MAKE
2.PAINT SHADE/ MA VISUAL/MEAS. SAMPLE BHEL SPEC/DRG BHEL SPEC/DRG -DO- 3 - 2
THICKNESS
3.HV/IR/HV MA ELECT.TESTS 100% 2KV AC FOR 2KV AC FOR -DO- 3 - 2

1 MINUTE 1 MINUTE

NAME
SIGNATURE
377
TITLE NUMBER :
SL.
SL COMPONENT/OPERATION CHARACTERISTIC CAT.
CAT TYPE/ EXTENT OF REFERENCE ACCEPTANCE FORMAT AGENCY REMARKS
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
4.DEGREE OF MA TEST 1/SIZE IS:2147 IS:2147 TEST CERT. - - 2,1

PROTECTION
5.SPECIAL TESTS MA TEST 1/SIZE IS:2148 IS:2148 TEST CERT. - - 2,1

IF ANY,EXPLOSION
PROOF ETC.
2.2 LIGHTING PANELS AND 1.DIMENSIONS MA MEASUREMENT SAMPLE BHEL DRG. BHEL DRG. INSPT. REPORT 3 2,1 - COMPONENTS TO BE OF
LIGHTING DISTRIBUTION APPROVED MAKE
BOARDS 2.PAINT SHADE/ MA VISUAL/ -DO- BHEL SPEC/DRG BHEL SPEC/DRG INSPT. REPORT 3 2,1 -
THICKNESS MEASUREMENT
3.DEGREE OF MA TESTS 1/SIZE BHEL SPEC/ BHEL SPEC/ TEST CERT - - 2,1
PROTECTION RELEVANT IS RELEVANT IS
(INCLUDING
EXPLOSION
PROOF IF ANY)
4.PERFORMANCE MA ELECT. 100% BHEL SPEC. BHEL SPEC. INSPT. REPORT 3 2,1 - BHEL SHALL WITNESS ON
TESTS RANDOM ONE SAMPLE,
THOUGH EACH ITEM
SHALL BE CHECKED BY
THE MANUFACTURER
5.HV/IR/HV MA ELECT 100% 2.5KV AC FOR 2.5KV AC FOR INSPT. REPORT 3 2,1 - -DO-
1 MINUTE 1 MINUTE
6.TEMP.RISE MA ELECT 1/RATING BHEL SPEC. BHEL SPEC. -DO- 3 2 1

TEST
S (FOR COM-
( O CO
PLETE ASSEMBLED
LDB)
3.0 TUNGSTEN FILAMENT LAMPS, 1. ACCEPTANCE MA TESTS SAMPLE BHEL SPEC/ BHEL SPEC/ TEST CERT 3/2 - 1
TUBULAR FLUORESCENT TESTS RELEVANT IS RELEVANT IS
LAMPS, HP MERCURY
VAPOUR LAMPS, SODIUM
VAPOUR LAMPS, BALLASTS,
LUMINAIRES

NAME
SIGNATURE
378
TITLE NUMBER :
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
4.0 CONDUITS 1.MATERIAL MA VISUAL,MECH, AS PER IS:9537 IS:9537 INSPT. REPORT 3 2 1

& CHEMICAL SPEC./
IS 9537
2.DIMENSIONS MA MEASUREMENT AS PER IS:9537 IS:9537 INSPT. REPORT 3 2 1

SPEC./
IS 9537
3.OTHER TESTS MA TEST AS PER AS PER IS:9537 INSPT. REPORT 3 2 1

SPEC./ SPEC./
IS 9537 IS 9537
5.0 ELECTRIC POLES
5.1 MATERIAL 1.CHEMICAL MA CHEM. SAMPLE IS-2713 IS-2713 -DO- 3/2 - 2,1
COMP. ANALYSIS IS:228 & IS:228 &
IS:1894 IS:1894
2.PHYSICAL MA PHY.TESTS -DO- -DO- -DO- -DO- 3/2 - 2,1

PROP.
5.2 FINAL INSPECTION 1.WORKMANSHIP MA VISUAL & MEAS SAMPLES BHEL DRG./ BHEL DRG./ -DO- 3/2 2,1 -
AND FINISH IS:2713 IS:2713
2.DIMENSIONS MA -DO- -DO- -DO- -DO- -DO- 3/2 2,1 -
3.WEIGHT MA -DO- -DO- -DO- -DO- -DO- 3/2 2,1 -
4.TESTS AS MA -DO- -DO- IS-2713 IS-2713 -DO- 3/2 2,1 -

IS 2713
PER IS-2713
NOTE:
IN CASE TYPE TEST CERTIFICATE FOR DEGREE OF PROTECTION/EXPLOSION PROOFNESS FROM INDEPENDENT LAB. IS NOT
AVAILABLE, THE ITEM SHALL BE TESTED AT AN INDEPENDENT LAB.

NAME
SIGNATURE
379
TITLE NUMBER :
SHEET 1 OF 5 SYSTEM ITEM :INSTRUMENTATION CABLES SECTION VOLUME III
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
1.0 RAW MATERIAL
1.1 PVC Compound(for insulation 1. Physical properties MA Physical Tests Sample IS-5831/BHEL IS-5831/BHEL Log Book/ 3/2 - 2
and sheath) Specification Specification Test Cert.
2. Elec.Properties MA Electrical Tests Sample -do- -do- -do- 3/2 - 2
3. Make & Type MA Visual 100% Plant Std. Plant Std. -do- 2 - -
1.2 Galvanised steel wire/strip 1. Phy.and Elec. MA Physical & Sample* IS-3975 BHEL IS-3975/BHEL -do- 3/2 - 2 * Sample from each
Properties Electrical Tests Specification Specification Batch/Lot.
2. Dimension MA Measurement -do- -do- -do- -do- 3/2 - 2
3.Galvanization Quality MA Galv.Tests -do- -do- -do- -do- 3/2 - 2
1.3 Copper/Aluminium Rods/ 1. Physical Properties MA Physical Tests -do- IS-613 IS-613 -do- 3/2 - 2
IS-5484 IS-5484
Wires IS-8130 IS-8130
AND BHEL AND BHEL
Specification Specification
2. Chemical
Composition & purity MA Chemical analysis -do- -do- -do- -do- 3/2 - 2
3.Electrical properties MA Electrical Tests -do- -do- -do- -do- 3/2 - 2
4.Dimension MA Measurement -do- -do- -do- -do- 3/2 - 2
1.4 Screen & drain wire 1. Surface MA visual sample BHEL SPEC. BHEL SPEC. TC & IR 3/2 - 2
Finish
2. Dimension MA Measurement -do- Appd. Data Appd. Data TC & IR 3/2 - 2

Sheet ahwwt

NAME
SIGNATURE
380
TITLE NUMBER :
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
3.. Mech. Prop. MA Mech test -do- MFRS. STD. MFRS. STD. TC & IR 3/2 - 2
2.0 IN PROCESS
2.1 Wire Drawing , Tinning and 1. Physical, Electr. CR Phy.&Elect. Tests Sample BHEL Specn. BHEL Specn. Log Book 2 - 1
Annealing Finish & dimension Visual & Meas. IS-8130 IS-8130
2. Chemical test for CR Chemical Test Sample -do- -do- -do- 2 - -

Tinning
2.2 Stranding of wires 1. No.of wires MA Counting Sample Vendors/BHEL Vendors/BHEL -do- 2 - -
Specn. & Apprd. Specn. & Apprd.
Data Sheet & Data Sheet &
Relevant IS Relevant IS
2. Sequence, lay length

& Direction MA Visual, Meas Sample -do- -do- -do- 2 - -
3 Surface Finish MA Visual Sample -do- -do- -do- 2 - -
4.Dimension MA Measurement Sample -do- -do- -do- 2 - -
2.3 Core Insulation 1. Surface finish MA Visual 100% - Free from bulging -do- 2 - 1
(No repair permitted) burnt particles
lumps, cuts &
Scratches.
2 Insulation thickness CR Measurement Sample Appd.data sheet Appd.data sheet -do- 2 - -

IS-1554 IS-1554
PARTICULARS BIDDER/VENDOR
BHEL NAME
SIGNATURE
381
TITLE NUMBER :
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
3. Concentricity # CR Measurement Sample Mfr's Std./Appd. Mfr's Std./Appd. Log Book 2 - 1 # To be checked at
data sheet data sheet starting & finish end of
Extruded Length
4 Dia over insulation MA Measurement Sample -do- -do- -do- 2 - -
5. Spark Test or Water CR Electrical 100% Mfr's Std. Mfr's Std. -do- 2 - 1
Immersion test
6. Core identification MA Visual 100% IS-1554 IS-1554 -do- 2 - -
2.4 Core pairing, screening 1. Pair identification MA Visual 100% BHEL Spec. BHEL Spec. Log Book 2 - -
(provision of drain wire & appd. Data & appd. Data
& laying) sheet sheet
2.Wire size & MA Measurement 100% -do- -do- -do- 2 - -

tape size
3.Test for CR Elect. Test 100% -do- -do- -do- 2 - 1

capacitance
4. Sequence of MA Visual meas Sample BHEL Spec. BHEL Spec. -do- 2 - 1

lay and lay & MFRs. Std. & MFRs. Std.
length
5. Screen overlap MA Measurement Sample -do- -do- -do- 2 - -

& coverage
6. Dia over laid MA Measurement -do- -do- -do- -do- 2 - -

up core
7. Continuity of MA Elect. Test 100% <--------No Discontinuity ----------> -do- 2 - -

drain & drain wire
with alum. Screen
2.5 InnerSheath Extrusion 1. Surface finish MA Visual 100% -- Free from bulging, -do- 2 - -
burnt particles,
lumps cuts &
scratches.
2. Sheath thickness MA Measurement Sample IS-5831, IS-1554 IS-5831, IS-1554 -do- 2 - -

data sheet data sheet
BHEL NAME
SIGNATURE
382
TITLE NUMBER :
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
3.Dia over inner sheath MA Measurement Sample IS-5831, IS-1554 IS-5831, IS-1554 -do- 2 - -
2.6 Armouring 1. No.of wires/Strips MA Counting At the start of BHEL Specn./ Appd. BHEL Specn./ Appd. -do- 2 - -
the process Data sheet Data sheet
IS-3975 & IS-1554 IS-3975 & IS-1554
2. Lay Direction MA Visual -do- -do- -do- -do- 2 - -
3. Lay Length MA Visual, Meas. At the start of BHEL Specn./Appd. BHEL Specn./Appd. Log Book 2 - -
IS-3975 & IS-1554 IS-3975 & IS-1554
4. Coverage MA Measurement -do- -do- -do- -do- 2 - -
5. Dia over armouring MA Measurement -do- -do- -do- -do- 2 - -
2.7 Outer Sheath Extrusion 1. Surface Finish MA Visual 100% - Free from Bulging Log Book 2 - -
Burnt particles,
lumps, cuts &
scratches
2.Sheath thickness MA Measurement Sample IS-5831 & IS-1554 IS-5831 & IS-1554 Log Book 2 - -
Appd. Data Sheet Appd. Data Sheet
3. Dia over outer MA Measurement Sample -do- -do- -do- 2 - -

sheath
4. Marking MA Visual 100% IS-1554 & BHEL IS-1554 & BHEL Test Report 2 - - Sequential marking shall
Specn. Specn. be done by printing
2.8 Finished Cable 1. Routine Test CR Elec. & Meas. 100% IS-1554 & BHEL IS-1554 & BHEL Test Report 2 - 1
Specn Specn
2. Type & FRLS Tests CR Elec., Phy & Meas. Sample * -do-/Apprd.data -do-/Apprd.data Test Report 2 - 1 * One Drum/Size/Lot
sheet sheet
BHEL NAME
SIGNATURE
383
TITLE NUMBER :
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
3.0 Final Inspection 1. Finish & Length MA Visual (See remark) BHEL specn. Free from Bulging Test Report 2 1 - One drum in a Lot
IS-1554 Burnt particles,
lumps, cuts &
scratches
2. Dimension MA Measurement Sample Appd.Data Sheet/ Appd.Data Sheet/ Test Report 2 1 -

Lengths IS-1554 & IS-1554 &
IS-10810 IS-10810
3. Armouring - MA Visual & Meas. Sample -do- -do- -do- 2 1 -

Coverage No
No.of
of
Wires/Strips
4. Marking/Colour/ MA Visual -do- -do- -do- -do- 2 1 -

pair identification
5. Test for CR Elect. Test -do- -do- -do- -do- 2 1 -

screening
6. Acceptance Tests CR Phy & Elect. Tests 20% -do- -do- -do- 2 1
7. Type & FRLS Tests CR Measurement Sample# BHEL Specn. BHEL Specn. -do- 2 1 - #Type Test shall be
Apprd.Data Sheet Apprd.Data Sheet witnessed on one sample
of every lot
NOTES:-
(A) JOINTS IN WIRE SHALL BE AS PERMITTED BY IS / BHEL SPECIFICATION. VENDOR TO CERTIFY THE SAME.
(B) NO REPAIR OF CORE INSULATION PERMITTED
(C) CABLE ENDS SHALL BE SEALED AS PER BHEL SPECIFICATION
(D) PURCHASER SHALL HAVE RIGHT TO WITNESS THE SPARK TEST AT CORE STAGE
(E) RECORD OF RAW MATERIAL, PROCESS & ALL STAGES SHALL BE CERTIFIED BY VENDORS QC. AND ARE LIABLE TO AUDIT CHECK BY PURCHASER.
(F) FILLERS/DUMMY CORES ETC. SHALL BE AS PER BHEL SPECIFICATION
(G) WHEREVER EXTENT OF CHECK FOR STAGE IS MENTIONED AS SAMPLES, THE SAME SHALL BE AS PER VENDORS SAMPLING PLAN
(H) VENDOR SHALL FURNISH COMPLIANCE CERTIFICATE TO THE INSPECTION AGENCY CONFIRMING THE PACKING AS PER BHEL SPECIFICATION.
LEGEND : P : PERFORMER W: WITNESSER V: VERIFIER (1) BHEL/BHEL's CUSTOMER: 2-VENDOR : 3 SUB VENDOR
BHEL NAME
SIGNATURE
384
TITLE NUMBER
SHEET 1 OF 6 SYSTEM ITEM :LCC'S / M. BOXES/ JN. BOXES SECTION VOLUME III
SL. ONENT/OPERATION CHARACTERISTIC CAT. TYPE/ EXTENT OF REFERENCE ACCEPTANCE FORMAT GENCY REMARKS
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
1.0 RAW MATERIAL & BOUGHT

OUT CONTROL
1.1 SHEET STEEL/CHANNELS 1. DUCTILITY CR BEND TEST SAMPLE IS-1079/IS-513/ IS-1079/IS-513/ LOG BOOK 3/2 - 2 FOR SHEET STEEL
IS-226 IS-226
2. SURFACE MA VISUAL 100% FACTORY STD NO RUSTING -DO- 3/2 - -

FINISH
DEFECTS
3. THICKNESS MA MEASUREMENT 100% BHEL SPEC./ BHEL SPEC./ -DO- 3/2 - 2

IS-1730 IS-1730
1.2 WIRES 1. SURFACE MA VISUAL 100% BHEL SPEC./ BHEL SPEC./ -DO- 3/2 - - ONLY APPROVED MAKES
DEFECTS. IS-1554/IS-694/ IS-1554/IS-694/ TO BE USED
RELEVANT. IS RELEVANT. IS
2. IR, HV, IR MA ELECTRICAL SAMPLE -DO- -DO- -DO- 3/2 - -
3. TYPE / MA VERIFICATION 100% -DO- -DO- MFR'S 3 - 1,2

ROUTINE OF TYPE / TEST
TESTS ROUTINE CERT.
TEST CERTI-
FICATE
1.3 ZINC INGOT FOR CHEM. COMP. MA CHEM. TEST EACH IS-209 IS-209 TEST CERT 3/2 - 1,2
GALVANISING

NAME
SIGNATURE
385
FORM NO. PEM-6041-0
TITLE NUMBER
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
1.3 ELECTRICAL COMPONENTS 1. MAKE MA VISUAL SAMPLE BHEL SPEC. BHEL SPEC. LOG BOOK 3/2 - -
LIKE FUSE, SWITCHES, TYPE & BOM & BOM
INDICATING LAMPS, RATING
PUSH BUTTON,
TERMINALS GASKETS
TERMINALS, 2 OPERATION/
2.OPERATION/ CR ELECTRICAL SAMPLE RELEVANT IS AND RELEVANT IS AND DO
-DO- 3/2 21
2,1 2
CABLE GLANDS AND FUNCTIONAL TEST CATALOGUE CATALOGUE
LUGS CHECK
3. IR, HV, IR MA ELECTRICAL 100% -DO- -DO- -DO- 3/2 2,1 2
2.0 IN-PROCESS CONTROL
2.1 NIBBLING/PUNCHING 1. CUTOUT MA MEASUREMENT 100% APPD. DRGS APPD. DRGS LOG BOOK 3/2 - 2,1 STANDARD CUT OUTS
SIZES TO BE DONE WITH DIES &
PUNCHES ONLY
2.DEBURRING MI VISUAL 100% -DO- -DO- -DO- 3/2 - -
2.2 PANEL FABRICATION 1. DIMENSIONS MA MEASUREMENT 100% APPR. DRGS APPR. DRGS LOG BOOK 3/2 2 -
2. ALIGNMENT MA MEASUREMENT 100% MFR'S STD MFR'S STD LOG BOOK 3/2 2 -
3. WELDING MI VISUAL 100% -DO- -DO- -DO- 3/2 2 -

QUALITY
BHEL NAME
SIGNATURE
386
FORM NO. PEM-6041-0
TITLE NUMBER
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
2.3 SURFACE PREPARATION 1. PROCESS MA PROCESS PERIODIC BHEL SPEC., BHEL SPEC., LOG BOOK 3/2 - - IF SAND/SHOT BLASTING,
AND PRE-TREATMENT PARAMETERS CHECK MFR. SPEC., MFR. SPEC., ACID PICKLINGS IS NOT
((7 OR 8 TANK PROCESS)) LIKE BATH TEMP,, IS-6005 IS-6005 REQUIRED.
Q
CONCENTRATION,
DIPPING/
REMOVAL TIME
2. SURFACE MA VISUAL 100% -DO- -DO- -DO- 3/2 - -

QUALITY AFTER
EVERY DIP
2.4 PRIMER APPLICATION 1. SURFACE MA VISUAL 100% MFR. SPEC., MFR. SPEC., LOG BOOK 3/2 - -
& PAINTING FINISH IS-6005 IS-6005
& COVERAGE
2. FILM MA MEASUREMENT 100% -DO- -DO- -DO- 3/2 - 2

THICKNESS
3. SHADE MA VISUAL 100% -DO- -DO- -DO- 3/2 - 2
4. ADHESION MA SCRATCH TEMPLATE -DO- -DO- -DO- 3/2 - 2

TEST / CROSS
OUT TAPE
BHEL NAME
SIGNATURE
387
FORM NO. PEM-6041-0
TITLE NUMBER
QUALITY PLAN BIDDER/ QUALITY PLAN SPECIFICATION :
SL. ONENT/OPERATION CHARACTERISTICS CAT. TYPE/ EXTENT OF REFERENCE ACCEPTANCE FORMAT GENCY REMARKS
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
2.5 WIRING, GASKET, NAME 1. WIRING LAYOUT MA VISUAL 100% APPD . DRGS & APPD . DRGS & LOG BOOK 3/2 - - PVC CHANNELS TO BE
PLATE, COMPONENT SPEC. SPEC. USED
MOUNTING ETC.
2. WORKMANSHIP MA VISUAL 100% -DO- -DO- -DO- 3/2 - -
AND FINISH
CORRECTNESS
COMPLETENESS
2.6 GALVANISATION 1. TEMP OF ZINC MA TEMP. CONTIN- IS-2629 IS-2629 QC RECORD 2 - -

PROCESS BATH INDICATOR UOUS
2. DURATION OF DIP MA VISUAL -DO- MANUFACTURER MANUFACTURER -DO- 2 - -

PRACTICE. PRACTICE.
3. SURFACE MA VISUAL 100% -DO- FREE FROM -DO- 2 - -

QUALITY ROUGHNESS,
FLUX, STAIN ETC.
4. GROSS QUANTITY MA TESTS PERIODIC RELEVANT. IS RELEVANT. IS -DO- 2 - -

& AGITATION
3 FINAL INSPECTION
3.1 COMPLETE JUNCTION 1. WORKMANSHIP MA VISUAL 100% BHEL SPEC. BHEL SPEC. INSPN 3/2 2,1 -
BOX/ LCC'S & FINISH, PAINT APPD. DRG APPD. DRG REPORT
MARSHALLING BOXES SHADE/GALV. RELEVANT. IS RELEVANT. IS
THICKNESS &
ADHESION
BHEL NAME
SIGNATURE
388
FORM NO. PEM-6041-0
TITLE NUMBER :
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
2. UNIFORMITY MA CHEM. TEST IS-5358 IS-2633 IS-2633 INSPN 2 1 -

OF ZINC REPORT
COATING
3. THICKNESS MA ELCOMETER -DO- BHEL SPEC. BHEL SPEC. -DO- 2 1 -

OF ZINC
COATING
4. WIRING LAYOUT MA VISUAL 100% -DO- -DO- -DO- 3/2 2,1 -
5. COMPONENT MA VISUAL 100% -DO- -DO- -DO- 3/2 2,1 -

LAYOUT &
FIXING, ACCESSI-
BILITY AND
SAFETY
6. COMPONENT MA VISUAL 100% APPD. DRG. APPD. DRG. -DO- 3/2 2,1 -
IDENTIFICATION
(MARKING/
NAME PLATES)
7. PROPER WIRE MA PULLING SAMPLE -DO- NO LOOSE -DO- 3/2 2,1 -

TERMINATION CONNECTIONS.
ALL TERMINATION
TO BE LUGGED
8. DOOR LOCK MA OPERATON 100% APPD. DRG NO MISMATCH -DO- 3/2 2,1 -
FUNCTIONING
BHEL NAME
SIGNATURE
389
FORM NO. PEM-6041-0
TITLE NUMBER
NO CHECK METHOD OF CHECK DOCUMENT NORM OF RECORD
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
9.OVERALL MA MEASUREMENT 100% APPD. DRG. APPD. DRG. INSPN. 3/2 2,1 -
DIMENSIONS REPORT
10. CONTINUITY CR ELECTRICAL 100% APPD. DRG., APPD. DRG., -DO- 3/2 2,1 -
BHEL SPEC., BHEL SPEC.,
& RELEVANT IS & RELEVANT IS
11. IR-HV-IR CR ELECTRICAL 100% -DO- -DO- -DO- 3/2 2,1 - IR-HV-IR
TEST TO BE DONE
12.OPERATION CR ELECTRICAL 100% -DO- -DO- -DO- 3/2 2,1 - BEFORE OPERATIONAL TESTS
INTERLOCKS OPERATION
ETC AND FUNCTION
IN ENERGISED
CONDITION
13. TEMP RISE CR ELECTRICAL ONE/ TYPE/ BHEL SPEC. BHEL SPEC. -DO- 3/2 2,1 -
(IF APPLICABLE) SIZE RELEVANT IS RELEVANT IS
14. DEGREE OF CR WATER AND ONE/ TYPE -DO- -DO- -DO- 3/2 2 - FLAME/EXPLOSION PROOF
PROTECTION & DUST TESTS, TEST, IF SPECIFIED IN
FLAME/ FLAME/ BHEL SPEC.
EXPLOSION EXPLOSION
PROOF TESTS
NOTE:
IF TC'S FOR DEGREE OF PROTECTION/EXPLOSION PROOFNESS IS AVAILABLE FROM AN INDEPENDENT LABORATORY FOR IDENTICAL DESIGN (SIZE SHALL BE
SMALLER THAN THAT INDICATED IN THE TC) THESE TESTS NEED NOT BE REPEATED.
BHEL NAME
SIGNATURE
390
VENDOR NUMBER PED-508-00-Q-002 TITLE :
SHEET 1 OF 1 SYSTEM ITEM LEAD ACID BATTERY (DC SYSTEM) SECTION VOLUME III
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
1.0 FINISHED BATTERY / CELL 1.TYPE TEST MA TEST IS:1651 & IS:1651 & IS:1651 & INSPN 3,2 - 2,1
1652/BHEL 1652/BHEL 1652/BHEL REPORT
SPEC SPEC SPEC
BSI:6290 BSI:6290 BSI:6290
Pt-4 Pt-4 Pt-4
2.ACCEPTANCE
2 ACCEPTANCE MA TEST -DO-
DO -DO-
DO -DO-
DO 2 2,1
21 -
TEST
2.0 ACCESSORIES 1.VISUAL AND MA TEST 100% BHEL DRG BHEL DRG INSPECTION 3,2 2,1 -
DIMENSIONS

NAME
SIGNATURE
391
FORM NO. PEM-6041-0
SHEET 1 OF 3 SYSTEM ITEM LT SWGR/CONTROL PNLS/DIST. BD SECTION VOLUME III
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
1.0 BOUGHT OUT ITEMS REF. QUALITY PLAN NO. PED-506-00-Q-002
2.0 IN-PROCESS REF. QUALITY PLAN NO. PED-506-00-Q-003
3.0 FINAL INSPECTION

1. PHYSICAL MA VISUAL 100% BHEL SPEC. BHEL SPEC. INSP. 2 1 -
BLEMISHES REPORT
2. ALIGNMENT MA VISUAL 100% IS-8623 IS-8623 -DO- 2 1 -
3. DIMENSION MA MEASUREMENT 100% IS-3427 IS-3427 -DO- 2 1 - 1. SHIPPING SECTION JOINTS

PLATES TO BE SUPPLIED
4. PAINT SHADE MA VISUAL 100% BHEL SPEC. BHEL SPEC. -DO- 2 1 -
5. PAINT MA MEASUREMENT FEW APPD. DRG/ APPD. DRG/ -DO- 2 1 - 2. GLANDS & LUGS TO BE
THICKNESS PLACES APPD .DATA APPD .DATA SUPPLIED ALONG WITH BOARDS
SHEET.& OTHER SHEET.& OTHER
RELEVANT IS RELEVANT IS
6. PAINT MA MECH. TESTS -DO- APPD. DRG. APPD. DRG. -DO- 2 1 -

ADHESION
7. VERIFICATION MA VISUAL 100% -DO- -DO- -DO- 2 1 -

OF B.O.M.
8. INTER MA MECH. TESTS 10% -DO- -DO- -DO- 2 1 -

CHANGEABILITY

NAME
SIGNATURE
392
FORM NO. PEM-6041-0
SHEET 2 OF 3 SYSTEM ITEM LT SWGR/CONTROL PNLS/DIST. BD SECTION VOLUME III
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
9. ROUTINE CR ELECT . TESTS 100% APPD. DRG. APPD. DRG. -DO- 2 1 -

TESTS
10. FUNCTION CR ELECT. & MECH. 100% -DO- -DO- -DO- 2 1 - SHALL INCLUDE REMOTE
PERFORMANCE TESTS SIMULATION
11. TYPE TESTS CR ELECT. TESTS 1/ITEM -DO- -DO- -DO- 2 - 1 SEE NOTE 'C'
12. INTERLOCKS, CR SECONDARY 100% -DO- -DO- -DO- 2 1 - PHYSICAL VERIFICATION

PROTECTION & INJECTION DURING INSPECTION
METERING
13. EASE OF MA MECH. TESTS 100% -DO- -DO- -DO- 2 1 -

WITHDRAWAL
& INSERTION
14. ACCESSIBILITY MA VISUAL 100% BHEL SPEC./ BHEL SPEC./ -DO- 2 1 -

OF COMPONENT APPD. DRG. APPD.DRG.
& SAFETY
(SHROUDING)
15. WIRING NEAT- CR PULLING SAMPLE -DO- -DO- -DO- 2 1 -

NESS & FIRMNESS
16. BUS BAR MA MECH. TESTS SAMPLE MANUFACTURER'S MANUFACTURER'S -DO- 2 1 -

TIGHTNESS STANDARD STANDARD
BHEL NAME
SIGNATURE
393
FORM NO. PEM-6041-0
TITLE NUMBER
SHEET 3 OF 3 SYSTEM CABLE ITEM LT SWGR/CONTROL PNLS/DIST. BD SECTION VOLUME III
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
NOTE :
A. ONLY APPROVED MAKE OF COMPONENTS ARE TO BE USED.

B. TYPE TESTS WILL INCLUDE (BESIDES OTHERS)
1. TEMPERATURE RISE TEST
2. DEGREE OF PROTECTION TEST AND EXPLOSION PROOF TEST, IF ANY
3. SHORT TIME CURRENT TEST
4. P & Q TEST
C. REGARDING ACCEPTANCE OF AVAILABLE TYPE TCS, REFER CL.NO. 9.4 OF SPECIFICATION NO. PES-506-01.
D. INDIVIDUAL BREAKER SHALL BE TESTED AT VARIOUS POSITIONS AND AT NORMAL +10% AND -10% OF CONTROL SUPPLY.
E. FUNCTIONAL/PERFORMANCE CHECKS TO BE CONDUCTED ON ENTIRE BOARD AND ALL POWER SUPPLIES SWITCHED ON.
BHEL NAME
SIGNATURE
394
TITLE NUMBER :
SHEET 1 OF 6 SYSTEM ITEM :LV & MV BUSDUCT SECTION VOLUME III
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
1.0 MATERIALS/COMPONENTS
1.1 ALUMINIUM AND COPPER 1. DIMENSION MA MEASUREMENT 100% BHEL SPECS./ BHEL SPECS./ TEST CERT 2 - -
BARS & FLEXIBLES IS:5082/IS:736 IS:5082/IS:736
IS:737/IS:1897 IS:737/IS:1897
2.SURFACE FINISH MA VISUAL 100% -DO- -DO- -DO- 2 - -
3.FLATNESS MA VISUAL 100% -DO- -DO- -DO- 2 - -
4.ELECTRICAL MA ELECTRICAL SAMPLE -DO- -DO- -DO- 3,2 - 2,1

CONDUCTIVITY
1.2 ENCLOSURE MATERIALS 1. DIMENSION MA MEASUREMENT 100% IS:513 / BHEL IS:513 / BHEL INSP REPORT 2 - -
SPECS. SPECS.
2.SURFACE FINISH MA VISUAL 100% -DO- -DO- -DO- 2 - -
3.FLATNESS MA VISUAL 100% -DO- -DO- -DO- 2 - -
4.BEND TEST MA VISUAL 1PIECE/LOT -DO- -DO- -DO- 2 - -

(MS ONLY)
1.3 INSULATORS, SEAL OFF 1.ROUTINE TEST MA ELECTRICAL/ 100% BHEL SPECS./ BHEL SPECS./ MRF TEST 3 - 2,1
BUSHING, CABLES, WIRES, MEASUREMENT RELEV IS RELEV. IS CERT./LOG
SPACE HEATERS BOOK
2.TYPE TEST MA ELECTRICAL/ 1/TYPE -DO- -DO- -DO- 3 - 2,1 FOR INSULATOR BUSHING
MEASUREMENT
3.SURFACE MA VISUAL 100% BHEL SPECS./ BHEL SPECS./ -DO- 2 - -

CONDITION RELEV. IS/PHY. RELEV. IS/PHY.
RATING & CONDITION CONDITION
MARKING
4.DIMENSIONS PHY. MA MEASUREMENT SAMPLE BHEL SPECS./ BHEL SPECS./ -DO- 2 - -

CONDITION RELEV. IS/ NO PHY. RELEV. IS/ NO PHY.
DAMAGE DAMAGE

NAME
SIGNATURE
395
TITLE NUMBER :
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
5.TRACKING MA ELECTRICAL SAMPLE BHEL SPECS./ BHEL SPECS./ INSP. 3,2 - 1

INDEX (FOR RELEV. IS RELEV. IS REPORT
INSULATION
MATERIAL)
1.4 BELLEVILLI WASHERS, PLAIN 1.DIMENSION MA MEASUREMENT RANDOM -DO- -DO- LOG BOOK 2 - -
& SPRING
SPRING, WASHERS & CHECK
FASTENERS, DISC WASHERS
2.SURFACE MA VISUAL -DO- -DO- -DO- -DO- 2 - -

FINISH
3.SHORE MA MEASUREMENT SAMPLE MANUFS STD MANUFS STD INSP. 2 - 1

HARDNESS REPORT
1.5 NEOPRENE RUBBER 1.OIL ABSORPTION MA MEASUREMENT 1PIECE/LOT IS-3400/BHEL IS-3400/BHEL TEST 3 - 1,2
BELLOWS & GASKET SPEC./BS-2752 SPEC./BS-2752 REPORT
2.AGEING TEST MA AGEING TEST -DO- -DO- -DO- -DO- 3 - 1,2
1.6 BUS BAR SLEEVES 1. DIMENSION & MA MEAS & TESTS 1/LOT MANUFS STD MANUFS STD INSP. 3,2 - -
MATERIAL RELV. STD RELV. STD REPORT &
CERTIFICATE TC
2.0 IN-PROCESS
2.1 FABRICATION OF DIMENSION MA MEASUREMENT 100% APPD./MFG DRG APPD./MFG DRG INSP REPORT 2 - -
ENCLOSURES
BHEL NAME
SIGNATURE
396
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
2.FINISH MA VISUAL 100% MANUF'S STD MANUF'S STD INSP REPORT 2 - -
3.ALIGNMENT MA VISUAL & 100% -DO- -DO- -DO- 2 - -

MEASUREMENT
4.ORIENTATION MA VISUAL 100% -DO- -DO- -DO- 2 - -
2.2 SURFACE PREPARATION 1.PROCESS MA PROCESS PERIODIC IS-6005 IS-6005 -DO- 2 - -

INCLUDING PHOSPHATING PARAMETERS CHECKS RELV. IS RELV. IS
& PASSIVATION (SOLUTION
STRENGTH TEMP.
TIME ETC.
2.SURFACE MA VISUAL 100% -DO- -DO- -DO- 2 - -

CONDITION
2.3 INITIAL PAINTING (PRIMER) 1.SURFACE FINISH MA VISUAL 100% -DO- -DO- -DO- 2 - -
& COVERAGE
2.FILM MA MEASUREMENT 100% -DO- -DO- -DO- 2 - -

THICKNESS
2.4 FINISHING OF BUSBARS/ 1.TYPE OF MA VISUAL 100% BHEL SPEC/FAB BHEL SPEC/FAB -DO- 2 - -
FLEXIBLES (TINNING/ FINISH DRG/IS SPEC. DRG/IS SPEC.
PLATING,/PAINTING/
SLEEVING)
3.0 ASSEMBLY
3.1 BUSBAR ASSEMBLY 1.PHASE MA VERIFICATION 100% ASSEMBLY DRG/ ASSEMBLY DRG/ -DO- 2 - -
SEQUENCE BHEL SPEC. BHEL SPEC.
BS-159/BS-162 BS-159/BS-162
BHEL NAME
SIGNATURE
397
TITLE NUMBER :
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
2.BUSBAR MARKING MA VISUAL 100% -DO- -DO- -DO- 2 - -
3.TIGHTNESS OF MA MECHANICAL 100% -DO- -DO- -DO- 2 - -

SUPPORTS
4.SURFACE MA VISUAL 100% MANUF'S STD MANUF'S STD INSP REPORT 2 - -

PREPARATION FOR
JT.PREPERATION
& APPLYING
CONDUCTING
MEDIUM
5.TIGHTNESS OF MA MECHANICAL 100% BHEL SPEC. BHEL SPEC. INSP REPORT 2 - 1 ALUMINIUM BUS BARS JOINTS
JOINTS AND MANUFS STD MANUFS STD WILL BE BOLTED WITH BILLET
FLEXIBLE WASHER AND THIGHTENING
SHALL BE DONE BY TORQUE
6.CLEARANCE TO MA MEASUREMENT 100% -DO- -DO- -DO- 2 - 1 WRENCH ALSO THE JOINT
BODY /EARTH SURFACE SHALL HAVE
& PHASE TO SUITABLE COMPOUND
PHASE
3.2 EARTHING 1.SIZE & MA MEASUREMENT 100% BHEL SPEC. BHEL SPEC. -DO- 2 - -
MATERIAL ASSEMBLY DRG. ASSEMBLY DRG.
2.LOCATION MA VISUAL 100% -DO- -DO- - 2 - -
3.MARKINGS MA VISUAL 100% -DO- -DO- - 2 - -
4.TERMINATIONS MA VISUAL 100% -DO- -DO- - 2 - -
5.TIGHTNESS MA MECHANICAL 100% -DO- -DO- - 2 - -

TO SUPPORTS
BHEL NAME
SIGNATURE
398
TITLE NUMBER :
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
3.3 IDENTIFICATION MARKINGS 1.SECTIONAL MA VISUAL 100% -DO- -DO- -DO- 2 - -

& NAME PLATES IDENTIFICATION
2.EARTH MA VISUAL 100% -DO- -DO- -DO- 2 - -

MARKING
3.BUSBAR MA VISUAL 100% -DO- -DO- -DO- 2 - -

MARKING
4.NAME PLATES MA VISUAL 100% -DO- -DO- -DO- 2 - -

AND DANGER
NAME PLATES
4.0 COMPLETE ASSEMBLY
4.1 APPEARANCE AND 1.DIMENSIONS MA MEASUREMENT 100% APPD.DRG. APPD..DRG. INSPN. 2 1 -

CLEANLINESS LOG SHEET REPORT
2.COMPLETE MA VISUAL 100% BHEL SPEC BHEL SPEC 2 1 - ALL HARDWARES WHICH ARE
LAYOUT LAYOUT DRGS/ LAYOUT DRGS/ EXPOSED TO OUTDOOR SHALL
FAB.DRG. FAB.DRG. BE TOUCHED WITH ANTI
CORROSSION RUST PREVENTION
3.GENERAL & MA VISUAL 100% -DO- -DO- -DO- 2 1 - SOLUTION, VARNISH BEFORE
MARKING- PACKING REPORTS TO BE
APPEARANCE SUBMITTED TO BHEL
4.FITTING OF MA VISUAL 100% -DO- -DO- -DO- 2 1 - IT SHALL BE POSSIBLE TO

INSPN.COVERS ADJUST TEMP KNOB
THERMOSTAT FROM
5.ALIGNMENT OF MA VISUAL 100% -DO- -DO- -DO- 2 1 - INSPECTION COVER.
SECTION
6.EARTH BUS MA VISUAL 100% -DO- -DO- -DO- 2 1 -

ALIGNMENTS &
MARKING
BHEL NAME
SIGNATURE
399
TITLE NUMBER :
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
7.MARKINGS ON MA VISUAL 100% -DO- -DO- -DO- 2 1 -

THE SECTIONS
8.PAINT MA VISUAL 100% APPD.DRGS/ APPD.DRGS/ LOG BOOK 3,2 - 2

THICKNESS BHEL SPEC BHEL SPEC
SHADE MFR SPEC MFR SPEC
9.ADHESION MA SCRATCH TEST TEMPLATE -DO- -DO- -DO- 3,2 - 2
4.2 TESTS 1.ROUTINE MA ELECTRICAL 100% IS-8084 IS-8084 TEST CERT/ 2 1 -

TESTS ANSI C37 20/
ANSI-C37-20/ ANSI C37 20/
ANSI-C37-20/ REPORT
BHEL SPEC. BHEL SPEC.
2.TEMPERATURE MA ELECTRICAL SAMPLE -DO- -DO- -DO- 2 1 -

RISE
3.DEGREE OF MA AS PER SPEC SAMPLE -DO- -DO- -DO- 2 1 -

PROTECTION
4.SHORT CKT MA ELECTRICAL SAMPLE -DO- -DO- -DO- 2 1 -

TEST
5.IMPULSE MA ELECTRICAL SAMPLE -DO- -DO- -DO- 2 1 -

TEST
6.OTHER TYPE MA AS PER SPEC SAMPLE -DO- -DO- -DO- 2 1 -

TESTS, IF ANY
5.0 IDENTIFICATION, 1.IDENTIFICATION MA VISUAL 100% PURCHASER'S PURCHASER'S 2 - -

PRESERVATION MARKING ON INSTRUCTION INSTRUCTION
& PACKING PACKING
CASES
BHEL NAME
SIGNATURE
400
FORM NO. PEM-6041-0
CUSTOMER PROJECT SPECIFICATION:
TITLE NUMBER
SHEET 1 OF4 SYSTEM ITEM NEUTRAL GROUNDING RESISTOR SECTION VOLUME III
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
1.0 MATERIALS
1.1 SHEET STEEL AND 1. DIMENSIONS MA MEASUREMENT 10% IS-1079 IS-1079 INSPN. 2 - -
STRUCTURES IS-2026 IS-2026 REPORT
IS-513 IS-513
2 SURFACE FINISH
2. MI VISUAL 100% -DO-
DO -DO-
DO -DO-
DO 2 - -
3. DUCTILITY OF MA BEND TEST SAMPLES

SHEET
1.2 COPPER FLATS 1. DIMENSIONS MA MEASUREMENT 10% IS-1897 IS-1897 -DO- 2 - -
2. SURFACE FINISH MI VISUAL 100% -DO- -DO- -DO- 2 - -
3. CHEMICAL MA CHEM ANALYSIS 1/ MELT -do- -do- TEST CERT. 3/2 - 2

COMPOSITION FROM
SUPPLIER
1.3 RESISTOR GRIDS 1. SURFACE FINISH CR VISUAL 100% BHEL DRG./SPEC. BHEL DRG./SPEC. INSPN. 3/2 - -
MFG. DRAWING MFG. DRAWING REPORT
2. DIMENSIONS MA MEASUREMENT 100% -DO- -DO- -DO- 3/2 - -
3. RESISTANCE MA ELECTRICAL 10% -DO- -DO- -DO- 3/2 - -

VALUE

NAME
SIGNATURE
401
FORM NO. PEM-6041-0
TITLE NUMBER
SHEET 2 OF 4 SYSTEM ITEM NEUTRAL GROUNDING RESISTOR SECTION VOLUME III
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
4. CHEMICAL MA CHEM ANALYSIS 1/ LOT BHEL DRG./SPEC. BHEL DRG./SPEC. TEST 3/2 - 1
COMPOSITION MFG. DRAWING MFG. DRAWING CERTIFICATE
1.4 MICA INSULATED TIE-RODS 1. DIMENSIONS MA MEASUREMENT 100% MFR'S. STD. MFR'S. STD. -DO- 2 - -
MICA WASHERS, STEEL
WASHER 2 SURFACE
2. MA VISUAL INSPN
INSPN. 100% DRAWING DRAWING -DO-
DO 2 - -
1.5 PORCELAIN INSULATORS 1. DIMENSIONS MA MEASUREMENT 10% MFR'S. STD. MFR'S. STD. -DO- 2 - - PORCELAIN INSULATORS
(POST & BUSHING TYPES) SHALL BE OF APPROVED
2. SURFACE MA MEASUREMENT 100% DRAWING DRAWING -DO- 2 - - MAKE
FINISH & DEFECTS
3. DRY P.F. HV MA ELEC. 100% BHEL SPECN. BHEL SPECN TEST CERT. 2 - 1
TEST IS IS
2 FABRICATION
2.1 CUTTING, BENDING, 1. DIMENSIONS MA MEASUREMENT 100% APPD./MFG APPD./MFG. INSPN 2 - -

PUNCHING, DRILLING ETC REPORT
2. FINISH MA VISUAL 100% -DO- -DO- -DO- 2 - -
2.2 SURFACE PREPARATION 1. SURFACE MA VISUAL 100% -DO- -DO- -DO- 2 - -

CONDITION
2.3 PAINTING 1. SURFACE MA VISUAL 100% -DO- -DO- -DO- 2 - -

FINISH
& COVERAGE
BHEL NAME
SIGNATURE
402
FORM NO. PEM-6041-0
TITLE NUMBER
SHEET 3 OF 4 SYSTEM CABLE ITEM NEUTRAL GROUNDING RESISTOR SECTION VOLUME III
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
2. FILM THICKNESS MA MEASUREMENT 100% APPD./MFG APPD./MFG. INSPN 2 - -

REPORT
3 SUB-ASSEMBLY
3.1 RESISTOR UNIT FRAME 1. HV TEST CR ELECTRICAL 100% BHEL SPECN/ BHEL SPECN TEST 2 - -
ASSEMBLED IS-1822/ IS-1822/ REPORT
BS-587 BS-587
2.RESISTANCE CR ELECTRICAL 100% -DO- -DO- -DO- 2 - -

VALUE
3. DIMENSIONS MA MEASUREMENT 100% -DO- -DO- 2 - -
4 FINAL ASSEMBLY
4.1 COMPLETE NGR 1. HV TEST CR ELECTRICAL 100% BHEL SPECN/ BHEL SPECN TEST 2 1 -
IS-1822 IS-1822 REPORT
BS-587 BS-587
2.RESISTANCE CR ELECTRICAL 100% -DO- -DO- 2 1 -

VALUE
3. DIMENSIONS MA MEASUREMENT 100% -DO- -DO- 2 1 -
BHEL NAME
SIGNATURE
403
FORM NO. PEM-6041-0
TITLE NUMBER
SHEET 4 OF 4 SYSTEM ITEM NEUTRAL GROUNDING RESISTOR SECTION VOLUME III
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
4. SHORT TIME MA HEAT RUN 1/TYPE BHEL SPEC./ BHEL SPEC./ 3 1 -

RATING/TEMPER- IS:1822 IS:1822
ATURE RISE TEST BS:587 BS:587
5. DEGREE OF MA AS PER 1/TYPE IS-2147 BHEL SPEC TEST 2 - 1

PROTECTION IS 2147
IS-2147 REPORT
6. PAINT FINISH MA VISUAL 100% BHEL SPEC./ BHEL SPEC./ 2 1 -

IS-5 IS-5
7. PAINT MA GAUGE ALL -DO- -DO- 2 1 -

THICKNESS
8. PAINT SHADE MI VISUAL-SHADE ALL -DO- -DO- 2 1 -

CARD
BHEL NAME
SIGNATURE
404
TITLE NUMBER :
SHEET 1 OF 4 SYSTEM ITEM PUBLIC ADDRESS SYSTEM SECTION VOLUME III
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
1.0 MATERIAL/ AS PER QUALITY PLAN NO. PED-506-00-Q-002

BOUGHT OUT ITEMS
2.0 IN-PROCESS AS PER QUALITY PLAN NO. PED-506-00-Q-003
3.0 PCB ASSEMBLY AS PER QUALITY PLAN NO. PED-557-00-Q-002
4.0 SPEAKERS 1. TYPE TEST MA ELECT. & 1/TYPE BHEL. SPEC. BHEL. SPEC. TEST CERT. 3/2 2 1
MEAS IS7741, IS7527 IS7741, IS7527
2. ACCEPTANCE MA -DO- AS PER IS -DO- -DO- -DO- 3/2 2 1

TEST
3. ROUTINE TEST MA -DO- 100% -DO- -DO- -DO- 3/2 2 -
4. DEGREE OF MA -DO- AS PER IS -DO- -DO- -DO- 3/2 - 1/2

PROTECTION
5.0 HANDSET 1.WORKMANSHIP MA VISUAL 100% BHEL/SPEC BHEL/SPEC -DO- 3 1/2 -

RELV.IS/BS/ RELV.IS/BS/
IEC IEC
2. COLOUR MA VISUAL SAMPLE -DO- -DO- -DO- 3 1/2 -
3.INPUT CHARACT- MA ELECT. MEAS -DO- -DO- -DO- -DO- 3 1/2 -

ERISTICS
4. OUTPUT CHARA- MA -DO- -DO- -DO- -DO- -DO- 3 1/2 -

CTERISTICS
5. SIDE TONE MA -DO- -DO- -DO- -DO- -DO- 3 1/2 -
6.LIMITING MA -DO- -DO- -DO- -DO- -DO- 3 1/2 -

NAME
SIGNATURE
405
TITLE NUMBER :
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
7. OPERATION MA ELECT. MEAS SAMPLE BHEL/SPEC BHEL/SPEC -DO- 3 1,2

RELV.IS/BS/ RELV.IS/BS/
IEC IEC
8. DEGREE OF MA MEASUREMENT -DO- -DO- -DO- -DO- 3 - 1/2

PROTECTION
9. RIGIDITY, SO- MA DROP & -DO- -DO- -DO- -DO- 3 - 1/2

UNDNESS OF VIBRATION
MOUNTING & TEST
CONSTRUCTION
ETC.
6 FINAL ASSEMBLY 1. WORKMANSHIP MA VISUAL 100% BHEL SPEC BHEL SPEC TC 2 1 -

( SYSTEM ) APPD. DRG. APPD. DRG.
DATA SHEETS, DATA SHEETS,
& RELV. IS/ BS & RELV. IS/ BS
2. WIRING LAYOUT MA -DO- -DO- -DO- -DO- -DO- 2 1 -
3.WIRE TERMINA- MA PULL TEST -DO- -DO- -DO- -DO- 2 1 -

TION(SOLDERING
OR CRIMPED
LUGS)
4. FERRULE NUM- MA VISUAL -DO- -DO- -DO- -DO- 2 1 -

BERING
5.TERMINAL MA -DO- -DO- -DO- -DO- -DO- 2 1 -

BLOCK
ARRANGEMENT
BHEL NAME
SIGNATURE
406
TITLE NUMBER :
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
6.PROPER MA VISUAL 100% BHEL SPEC BHEL SPEC -DO- 2 1 -

MOUNTING OF ITEM APPD. DRG. APPD. DRG.
DATA SHEETS, DATA SHEETS,
& RELV. IS/ BS & RELV. IS/ BS
7.CORRECTNESS MA -DO- -DO- -DO- -DO- -DO- 2 1 -

OF ITEM
8.SMOOTH MA -DO- -DO- -DO- -DO- -DO- 2 1 -

OPERATION OF
VARIOUS
CONTROLS
9.COMPONENT MA -DO- -DO- -DO- -DO- -DO- 2 1 -

LAYOUT
10.IDENTIFICA- MA -DO- -DO- -DO- -DO- -DO- 2 1 -

TIONMARKS
11. PAINT SHADE MA -DO- -DO- -DO- -DO- -DO- 2 1 -

& FINISH
12.PAINT THICK- MA MEASUREMENT -DO- -DO- -DO- -DO- 2 1 -

NESS
13.DIMENSION MA MEASUREMENT -DO- -DO- -DO- -DO- 2 1 -
14 SCREENING MA SYSTEM -DO- 48HRS AT MAX NO FAILURE,DRIFT -DO- 2 1 -

SOAKING 45 DEGREE C ETC
SITE TEMP
15.OPERATION/ CR ELECTRICAL -DO- -DO- -DO- -DO- 2 1 -

FUNCTIONAL
CHECK
BHEL NAME
SIGNATURE
407
TITLE NUMBER :
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
16.INTER-CHANGE- CR ELECTRICAL -DO- -DO- -DO- -DO- 2 1 -

ABILITY
17.EFFICIENCY CR -DO- -DO- -DO- -DO- -DO- 2 1 -
18.POWER SUPPLY- CR -DO- -DO- -DO- -DO- -DO- 2 1 -

VARIOUS
CHECKS
19.IR-MV IR CR -DO- -DO- -DO- -DO- -DO- 2 1
7 PACKING 1.WOOD SPECIES MA VISUAL 100% BHEL SPEC/ BHEL SPEC/ -DO- 2 - 1
MFR STD MFR STD
2.WOOD PRESER- MA -DO- -DO- -DO- -DO- -DO- 2 - 1

VATIVE
TREATMENT
3.STURDINESS MA -DO- -DO- -DO- -DO- -DO- 2 - 1
4.WATER PROOF MA -DO- -DO- -DO- -DO- -DO- 2 - 1

COVER FOR
EQUIPMENT
5.SILCAGEL MA -DO- -DO- -DO- -DO- -DO- 2 - 1

PACKETS
6.MARKING MA -DO- -DO- -DO- -DO- -DO- 2 - 1
7.PACKING SLIP MA -DO- -DO- -DO- -DO- -DO- 2 - 1
BHEL NAME
SIGNATURE
408
TITLE NUMBER :
SHEET 1 OF 5 SYSTEM ITEM :PVC POWER & CONTROL CABLE SECTION VOLUME III
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
1.0 RAW MATERIAL
1.1 PVC Compound(for insulation 1. Physical properties MA Physical Tests Sample IS-5831/BHEL IS-5831/BHEL Log Book/ 3/2 - 2
and sheath) Specification Specification Test Cert.
2. Elec.Properties MA Electrical Tests Sample -do- -do- -do- 3/2 - 2
3. Make & Type MA Visual 100% Plant Std. Plant Std. -do- 2 - -
1.2 Galvanised steel wire/strip 1. Phy.and Elec. MA Physical & Sample* IS-3975 BHEL IS-3975/BHEL -do- 3/2 - 2 * Sample from each
Properties Electrical Tests Specification Specification Batch/Lot.
3.Galvanization Quality MA Galv.Tests -do- -do- -do- -do- 3/2 - 2
1.3 Copper/Aluminium Rods/ 1. Physical Properties MA Physical Tests -do- IS-613 IS-613 -do- 3/2 - 2
IS-5484 IS-5484
Wires IS-8130 IS-8130
AND BHEL AND BHEL
Specification Specification
2. Chemical
Composition & purityMA Chemical analysis -do- -do- -do- -do- 3/2 - 2
4.Dimension MA Measurement -do- -do- -do- -do- 3/2 - 2

NAME
SIGNATURE
409
TITLE NUMBER :
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
2.0 IN PROCESS
2.1 Wire Drawing , Tinning and 1. Physical, Electr. CR Phy.&Elect. Tests Sample BHEL Specn. BHEL Specn. Log Book 2 - 1
Annealing Finish & dimension Visual & Meas. IS-8130 IS-8130
2.
2 Chemical test for CR Chemical Test Sample do
-do- do
-do- do
-do- 2 - -
Tinning
2.2 Stranding of wires 1. No.of wires MA Counting Sample Vendors/BHEL Vendors/BHEL -do- 2 - -
Specn. & Apprd. Specn. & Apprd.
2. Sequence, lay length

& Direction MA Visual, Meas Sample -do- -do- -do- 2 - -
3 Surface Finish MA Visual Sample -do- -do- -do- 2 - -
4.Dimension MA Measurement Sample -do- -do- -do- 2 - -
2.3 Core Insulation 1. Surface finish MA Visual 100% - Free from bulging -do- 2 - 1
(No repair permitted) burnt particles
lumps, cuts &
Scratches.
2 Insulation thickness CR Measurement Sample Appd.data sheet Appd.data sheet -do- 2 - -
IS-1554 IS-1554
BHEL NAME
SIGNATURE
410
TITLE NUMBER :
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
Extruded Length
4 Dia over insulation MA Measurement Sample -do- -do- -do- 2 - -
5. Spark Test or Water CR Electrical 100% Mfr's Std. Mfr's Std. -do- 2 - 1
Immersion test
6. Core identification MA Visual 100% IS-1554 IS-1554 -do- 2 - -
2.4 Core Laying 1. Dia over laidup core MA Measurement Sample -do- -do- Log Book 2 - -
2.Sequence of lay, MA Visual & Meas. Sample Mfrs.Std./relevant Mfrs.Std./relevant -do- 2 - -

Lay length & direction IS IS
up core
burnt particles,
lumps cuts &
scratches.
2. Sheath thickness MA Measurement Sample IS-5831, IS-1554 IS-5831, IS-1554 -do- 2 - -

3.Dia over inner sheathMA -do- -do- -do- -do- -do- 2 - -
2.6 Armouring 1. No.of wires/Strips MA Counting At the start of BHEL Specn./ Appd. BHEL Specn./ Appd. -do- 2 - -
IS-3975 & IS-1554 IS-3975 & IS-1554
2. Lay Direction MA Visual -do- -do- -do- -do- 2 - -
BHEL NAME
SIGNATURE
411
TITLE NUMBER :
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
3. Lay Length MA Visual, Meas. At the start of BHEL Specn./ Appd. BHEL Specn./ Appd. Log Book 2 - -
IS-3975 & IS-1554 IS-3975 & IS-1554
4. Coverage MA Measurement -do- -do- -do- -do- 2 - -
2.7 Outer Sheath Extrusion 1. Surface Finish MA Visual 100% - Free from Bulging Log Book 2 - -
Burnt particles,
lumps, cuts &
scratches
2.Sheath thickness MA Measurement Sample IS-5831 & IS-1554 IS-5831 & IS-1554 Log Book 2 - -
Data Sheet Data Sheet
3. Dia over outer MA Measurement Sample -do- -do- -do- 2 - -

sheath
4. Marking MA Visual 100% IS-1554 & BHEL IS-1554 & BHEL Test Report 2 - - Sequential marking shall
Specn. Specn. be done by printing
2.8 Finished Cable 1. Routine Test CR Elec. & Meas. 100% IS-1554 & BHEL IS-1554 & BHEL Test Report 2 - 1
Specn Specn
2. Type & FRLS Tests CR Elec., Phy & Meas. Sample * -do-/Apprd.data -do-/Apprd.data Test Report 2 - 1 * One Drum/Size/Lot
sheet sheet
3.0 Final Inspection 1. Finish & Length MA Visual (See remark) BHEL specn. Free from Bulging Test Report 2 1 - One drum each for
IS-1554 Burnt particles, Power & control
lumps, cuts & cables in a Lot
scratches
BHEL NAME
SIGNATURE
412
TITLE NUMBER :
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
2. Dimension MA Measurement As per IS Appd.Data Sheet/ Appd.Data Sheet/ Test Report 2 1 -

IS-1554 & IS-1554 &
IS-10810 IS-10810
3. Armouring - MA Visual & Meas. As per IS -do- -do- -do- 2 1 -

Coverage No.of
Wires/Strips
4. Marking/Colour MA Visual -do- -do- -do- -do- 2 1 -

Coding
5. Acceptance Tests CR Phy & Elect. Tests -do- -do- -do- -do- 2 1
6. Type & FRLS Tests CR Measurement (SEE REMARK) BHEL Specn. BHEL Specn. -do- 2 1 - Type Test shall be
Apprd.Data Sheet Apprd.Data Sheet witnessed on one sample
per type(Power/control)
NOTES:- of every lot
(A) JOINTS IN WIRE SHALL BE AS PERMITTED BY IS / BHEL SPECIFICATION. VENDOR TO CERTIFY THE SAME.
(G) WHEREVER EXTENT OF CHECK FOR STAGE IS MENTIONED AS SAMPLES, THE SAME SHALL BE AS PER VENDORS SAMPLING PLAN
(H) VENDOR SHALL FURNISH COMPLIANCE CERTIFICATE TO THE INSPECTION AGENCY CONFIRMING THE PACKING AS PER BHEL SPECIFICATION.
LEGEND : P : PERFORMER W: WITNESSER V: VERIFIER (1) BHEL/BHEL's CUSTOMER: 2-VENDOR : 3 SUB VENDOR
BHEL NAME
SIGNATURE
413
TITLE NUMBER :
SHEET 1 OF 1 SYSTEM ITEM RIGID STEEL CONDUITS & PIPES SECTION VOLUME III
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
FINISHED PRODUCT
1. DIMENSIONAL MA MEASUREMENT 5 SAMPLES AS PER IS-9537 AS PER IS-9537 IR 2 1 -
CONFORMITY PER SIZE PT I & II PT I & II
PER LOT AND OTHER IS AND OTHER IS
2.FINISH MI VISUAL -DO- -DO- -DO- -DO- 2 1 -
3. SCREW MI MEASUREMENT -DO- -DO- -DO- -DO- 2 1 -

THREAD
4. BEND TEST MA MECH. 1 SAMPLE -DO- -DO- -DO- 2 1 -

OF EACH
SIZE
5. COMPRESSION MA MECH. TEST -DO- -DO- -DO- -DO- 2 1 -

TEST
6. WT. OF ZINC MA MEASUREMENT ONE SAMPLE IS-6745 IS-4736 -DO- 3 2,1 -

COATING
7.UNIFORMITY MA CHEMICAL -DO- IS-2633 IS-2633 -DO- 3 2,1 -

OF ZINC
8. ADHESION MA PIVOT/HAMMER -DO- IS2629 IS-2629 -DO- 3 2,1 -

TEST TEST

NAME
SIGNATURE
414
TITLE NUMBER :
SHEET 1 OF 2 SYSTEM ITEM : CABLE TRAYS & ACCESSORIES SECTION VOLUME III
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
1.0 RAW MATERIAL
1.1 ROLLED SHEET 1.CHEM.& PHY. MA VERIFICATION 100% IS1079/ IS1079/ MILL TC 3/2 - - STEEL SHALL BE PROCURED
PROPERTIES OF TC'S SPECIFICATION SPECIFICATION FROM SAIL/TISCO/RINL/
AUTHORISED RE-ROLLERS/
MANUFACTURER AS PER
BHEL APPROVED SOURCES.
IS-1730/ IS-1730/
2.DIMENSIONS MA MEASUREMENT 100% QC RECORD 3/2 - -
SPECIFICATION SPECIFICATION
3.SURFACE MA VISUAL 100% IS1079/ IS1079/ QC RECORD 3/2 - -

FINISH SPECIFICATION SPECIFICATION
1.2 ZINC CHEM.COMP. MA CHEM TEST EACH HEAT IS-209 IS-209 QC RECORD 3/2 - 1/2
2.0 IN-PROCESS
2.1 FABRICATION 1.DIMENSIONS MA MEASUREMENT 100% APPD.DRGS. APPD.DRGS. QC RECORD 2 - 1 INSPECTION AT BLACK
STAGE BY BHEL/ BHEL
AUTHORISED INSPECTION
AGENCY
2.WELDING MA VISUAL 100% GOOD WELDING FREE FROM QC RECORD 2 - 1 WELDING IS TO BE DONE
QUALITY PRACTICE DEFECTS & BY QUALIFIED WELDERS
SLAG

FINISH
4.RIGIDITY MA DEFLECTION SAMPLE SPECIFICATION SPECIFICATION QC RECORD 2 - 1 600 MM OR 450 MM WIDE

(CABLE TRAYs) TEST CABLE TRAY SIZE TO BE
TESTED
2.2 SURFACE PREPARATION 1.CLEANING, MA MEASUREMENT PERIODIC IS:2629 IS:2629 QC RECORD 2 - -

PICKLING, IN EACH
RINSING & SHIFT
FLUXING
2. SURFACE MA VISUAL 100% IS:2629 IS:2629 QC RECORD 2 - -

QUALITY

NAME
SIGNATURE
415
TITLE NUMBER :
SHEET 2 OF 2 SYSTEM ITEM : CABLE TRAYS & ACCESSORIES SECTION VOLUME III
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
2.3 GALVANISING 1.TEMPERATURE MA TEMPERATURE CONTINUOUS IS-2629 IS-2629 QC RECORD 2 - -

OF BATH INDICATOR
3. RATE OF MA VISUAL 100% IS - 2629 / IS - 2629 / QC RECORD 3 - 2

IMMERSION MEASUREMENT MFR'S PRACTICE MFR'S PRACTICE
4.SURFACE MA VISUAL 100% IS - 2629 FREE FROM QC RECORD 2 - -

QUALITY BURRS
ROUGHNESS,
SLAG , FLUX.
STAIN. ETC.
3.0 FINISHED ITEMS
3.1 (CABLE TRAY, ACCESSO- 1.DIMENSIONS MA MEASUREMENT IS-2500 APPD. DRGS. APPD. DRGS. INSP. REPORT 3 2, 1 - FASTENERS SHALL BE OF
RIES & HARDWARES) LEVEL IV REPUTED & APPROVED
MAKE.
2.SURFACE FINISH MA VISUAL IS-2500 SPECIFICATION FREE FROM INSP. REPORT 3 2, 1 -

LEVEL IV BURRS, SLAG,
ROUGHNESS,
FLUX., STAIN. .
ETC.
3.RIGIDITY MA DEFLECTION 1/ LOT SPECIFICATION SPECIFICATION INSP. REPORT 2 1 - 600 MM OR 450 MM WIDE
(FOR TRAYS) TEST CABLE TRAY TO BE
TESTED
4.MASS OF MA CHEM. TEST IS-4759 / IS-6745 SPECIFICATION INSP. REPORT 3 2, 1 -

ZINC COATING SPECIFICATION SPECIFICATION
5.UNIFORMITY MA CHEM. TEST IS-4759 / IS-2633 IS-2633 INSP. REPORT 2 1 -

COATING
6.THICKNESS MA ELCOMETER IS-4759 / SPECIFICATION SPECIFICATION INSP. REPORT 3 2, 1 -

COATING

NAME
SIGNATURE
416
TITLE NUMBER :
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
1.0 RAW MATERIAL
1.1 MILD STEEL (FLATS & RODS) 1.CHEMICAL & MA VERIFICATION, 100% IS:1079 IS:1079 MILL TC 3 - 2 STEEL SHALL BE
AS PER SPECIFICATION PHYSICAL OF TC'S PROCURED FROM SAIL/
PROPERTIES TISCO/ RINL/ AUTHORISED
RE-ROLLERS/
MANUFACTURERS AS PER
BHEL APPROVED
SOURCES
SOURCES.
2.DIMENSIONS MA MEASUREMENT 100% IS - 1730 IS - 1730 QC RECORD 3/2 - -
3.SURFACE MA VISUAL 100% IS : 1079 IS : 1079 QC RECORD 3/2 - -

FINISH
1.2 ZINC 1.CHEM.COMP. MA CHEM.TEST SAMPLE IS - 209 IS - 209 QC RECORD 3/2 - 1/2
2.0 IN-PROCESS
2.1 CUTTING, DRILLING 1.DIMENSIONS MA MEASUREMENT 100% SPECIFICATION SPECIFICATION QC RECORD 2 - 1

FINISH
2.2 SURFACE PREPARATION 1.CLEANING MA MEASUREMENT PERIODIC IN IS:2629 IS:2629 QC RECORD 2 - -

PICKLING
PICKLING, EACH SHIFT
RINSING,
& FLUXING
2.SURFACE MA VISUAL 100% IS:2629 IS:2629 QC RECORD 2 - -

QUALITY

NAME
SIGNATURE
417
TITLE NUMBER :
NO.
NO CHECK METHOD OF CHECK DOCUMENT NORM OF RECORD
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
2.3 GALVANISING 1.TEMPERATURE MA TEMPERATURE CONTINUOUS IS - 2629 IS - 2629 QC RECORD 2 - -

OF BATH INDICATOR
3. RATE OF MA VISUAL/ 100% IS - 2629/ IS - 2629/ QC RECORD 3 - 2

IMMERSION MEASUREMENT MFRS PRACTICE MFRS PRACTICE
4.SURFACE MA VISUAL 100% IS - 2629 FREE FROM BURRS, QC RECORD 2 - -

QUALITY ROUGHNESS,
SLAG, FLUX, STAIN
ETC.
3.0 FINISHED ITEMS
1.DIMENSIONS MA MEASUREMENT RANDOM SPECIFICATION SPECIFICATION INSP. REPORT 3 2, 1 -
2.SURFACE FINISH MA VISUAL RANDOM SPECIFICATION FREE FROM INSP. REPORT 3 2, 1 -

BURRS,, SLAG,,
ROUGHNESS,
FLUX, STAIN,
ETC.
3.MASS OF MA CHEM. TEST IS - 4759 IS-6745 / SPECIFICATION INSP. REPORT 3 2, 1 -

ZINC COATING SPECIFICATION
4.UNIFORMITY MA CHEM. TEST IS - 4759 IS-2633 IS-2633 INSP. REPORT 3 2, 1 -

OF ZINC
COATING
5.THICKNESS MA ELCOMETER IS - 4759 SPECIFICATION SPECIFICATION INSP. REPORT 3 2, 1 -

OF ZINC
COATING

NAME
SIGNATURE
418
TITLE NUMBER :
STANDARD QUALITY PLAN
VENDOR NUMBER PED-507-00-Q-001, R-02 TITLE
SHEET 1 OF 5 SYSTEM ITEM : XLPE P
Power C bl
Cables SECTION VOLUME III
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
1.0 RAW MATERIALS
1.1 XLPE Compound 1. Physical properties MA Physical Tests Sample/ Lot IS:7098 & Mfrs Std. IS:7098 & Mfrs Std. Test Report 3/2 - 1,2 Raw material verification
Log Book as per approved sub-
vendor list
2. Elec.Properties MA Electrical Tests -do- -do- -do- -do- 3/2 - 1,2
1.2 Semi Conducting Compound 1. Phy.and Elec. MA Phy.and Elec. -do- Manufacturer's Manufacturer's -do- 3/2 - 1,2
Properties Tests standard standard
1.3 Copper Foil 1. Dimensions MA Measurement -do- Manufacturer's std./ Manufacturer's std./ Log Book 2 - 2
Appd. Data sheet Appd. Data sheet
2. Physical, Chemical MA Phy., Chem. -do- IS:1897 IS:1897 Supplier's 3/2 - 2

& Elect. Properities & Elect. Tests test report
& log book
1.4 PVC Compound (for sheath) 1. Physical properties MA Physical Tests Sample/ lot IS:5831/BHEL IS:5831/BHEL Log Book/ 3/2 - 2
Specification Specification Test Report
2. Elec.Properties MA Electrical Test -do- -do- -do- -do- 3/2 - 2
15
1.5 Galvanised steel wire/strip 1 Phy
1. Phy. and Elec
Elec. MA Physical & Sample from IS:3975/ BHEL IS:3975/ BHEL Log Book/ 3/2 - 2
Properties Electrical Tests each batch/ Specification Specification Test Cert.
lot
3. Galvanization MA Galv. -do- -do- -do- -do- 3/2 - 2

requirement

NAME
SIGNATURE
419
TITLE NUMBER :
SHEET 2 OF 5 SYSTEM ITEM XLPE Power Cables SECTION VOLUME III
SL
SL. COMPONENT/OPERATION CHARACTERISTIC CAT
CAT. TYPE/ EXTENT OF REFERENCE ACCEPTANCE FORMAT AGENCY REMARKS
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
1.6 Copper/Aluminium Rods/ 1. Physical MA Physical Tests -do- IS:613, IS-5484, IS:613, IS-5484, -do- 3/2 - 2
Wires Properties IS:8130 & IS:8130 &
BHEL Specification BHEL Specification
2 Chemical
2.
Composition MA Chemical -do- -do- -do- -do- 3/2 - 2
& purity analysis
4. Dimensions MA Measurement -do- -do- -do- -do- 3/2 - 2
2.0 IN PROCESS
2.1 Wire Drawing , Tinning and 1. Physical, Electrical, CR Phy. & Elect. Tests Sample IS:8130 & IS:8130 & Log Book 2 - 1
Annealing Finish & dimension Visual / Meas. BHEL Specn. BHEL Specn.
2. Chemical test for CR Chemical Test -do- -do- -do- -do- 2 - -

Tinning
2.2 Stranding of wires 1. No. of wires MA Counting -do- BHEL Specn, Apprd. BHEL Specn, Apprd. -do- 2 - -
2. Sequence, lay MA Visual, Meas. -do- -do- -do- -do- 2 - -

length & Direction
3 Surface Finish MA Visual -do-

do -do-
do -do-
do -do-
do 2 - -
4. Dimension MA Measurement -do- -do- -do- -do- 2 - -
2.3 Conductor Screening 1. Radial thickness MA -do- Sample BHEL Specn & Apprd. BHEL Specn & Apprd. Log Book 2 - -

NAME
SIGNATURE
420
TITLE NUMBER :
VENDOR NUMBER PED-507-00-Q-001,
Q , R-02 TITLE
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
2.4 Core Insulation (XLPE) 1. Surface finish MA Visual 100% - -do- Log Book 2 - 1
((No repair
p permitted)
p )
Extruded Length
3. Thickness of CR Measurement -do- BHEL specn./Apprd. BHEL specn./Apprd. Inspection 2 1 -

Insulation
I l i Dats
D Sheet// IS:7098
Sh IS 098 Dats
D Sheet// IS:7098
Sh IS 098 Report
R
4 Dia over insulation MA Measurement -do- -do- -do- -do- 2 1 -
5. Test on XLPE MA Tests -do- -do- -do- -do- 2 1 1

(Tensile &
Elongation, Hot Set
& Aging Test)
2.5 Insulation Screening, 1. Surface finish MA Visual Sample - Free from bulging Log Book 2 - -
(Non Metallic & Metallic ) burnt particles
lumps, cuts &
Scratches.
2. Thickness MA -do- -do- BHEL Spec./ BHEL Spec./ -do- 2 - -

3 Overlap of MA Measurement -do- BHEL Spec./ BHEL Spec./ -do- 2 - -

Tape Band data sheet data sheet
4 Tightness of MA Visual -do- Plant Std. Plant Std. -do- 2 - -

Tape Band

NAME
SIGNATURE
421
TITLE NUMBER :
NO
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
2.6 Core Laying 1. Dia over laid up core MA Measurement Sample Apprd. Data Sheet Apprd. Data Sheet Log Book 2 - -
2.Sequence of lay, MA Visual & Meas. Sample IS 7098/ Mfrs.Std. IS 7098/ Mfrs.Std. -do- 2 - -
& direction
3. Lay Length MA Meas. -do- Mnfrs. Std. Mnfrs. Std. -do- 2 - -
burnt particles,
lumps cuts &
scratches.
2. Sheath thickness MA Measurement Sample Appd. Data Appd. Data do

-do- 2 - -
Sheet, IS:7098 Sheet, IS:7098
3. Dia over inner sheath MA -do- -do- -do- -do- -do- 2 - -
2.8 Armour 1. No.of wires/Strips MA Counting At the start of BHEL Specn./ BHEL Specn./ -do- 2 - -
the process Apprd.Data sheet Apprd.Data sheet
2. Lay Direction MA Visual -do- IS:7098 IS:7098 -do- 2 - -
3. Lay Length MA Meas. -do- Plant Standard Plant Standard Log Book 2 - -
4. Coverage MA Measurement -do- BHEL Specn./ Appd. BHEL Specn./ Appd. -do- 2 - -
29
2.9 Outer Sheath Extrusion 1 Surface Finish
1. MA Visual 100% - Free from Bulging
Bulging, Log Book 2 - -
burnt particles, lumps,
cuts & scratches
2.Sheath thickness MA Measurement Sample Appd. Data Sheet Appd. Data Sheet Log Book 2 - -
3. Dia over outer sheath MA -do- -do- -do- -do- -do- 2 - -
4. Marking MA Visual 100% IS:7098, BHEL Specn. IS:7098, BHEL Specn. Test Report 2 - - Sequential marking shall
& Appd. Data Sheet & Appd. Data Sheet be done by printing
NAME
SIGNATURE
422
TITLE NUMBER :
SL
SL. COMPONENT/OPERATION CHARACTERISTIC CAT
CAT. TYPE/ EXTENT OF REFERENCE ACCEPTANCE FORMAT AGENCY REMARKS
CHECK P W V
1 2 3 4 5 6 7 8 9 10 11
2.10 Finished Cable 1. Routine Test CR Elec. & Meas. 100% IS:7098 & BHEL specnIS:7098 & BHEL specn. Test Report 2 - 1
2 Type Tests *
2. CR Physical & Sample * BHEL Specn
Specn. BHEL Specn
Specn. -do-
do 2 1 * As per specn
specn.
Electrical Tests Apprd. Data Sheet Apprd.Data Sheet
3.0 Final Inspection 1. Finish & Length MA Visual, (See remark) BHEL specn. & BHEL Specn./ -do- 2 1 - One drum in each Lot
Measurement IS:7098 Free from Bulging
Burnt particles,
lumps, cuts &
scratches
2. Dimension MA Measurement As per IS Appd.Data Sheet/ Specn./ Appd. Data -do- 2 1 -

IS:7098, IS:10810 Sheet/ IS:7098, IS:10810
3. Armouring - MA Visual & Meas. -do- -do- -do- -do- 2 1 -

Coverage No.of
Wires/Strips
4. Marking & Colour MA Visual -do- -do- -do- -do- 2 1 -

Coding
5. Acceptance Tests CR Phy, Elect. Tests -do- BHEL Specn -do- -do- 2 1
Apprd. Data Sheet
NOTES:-
(A) JOINTS IN WIRE SHALL BE AS PERMITTED BY IS / BHEL SPECIFICATION, VENDOR TO CERTIFY THE SAME.
(G) WHEREVER EXTENT OF CHECK FOR STAGE IS MENTIONED AS SAMPLES, THE SAME SHALL BE AS PER SAMPLING PLAN AGREED BY PURCHASER.
(H) VENDOR SHALL FURNISH COMPLIANCE CERTIFICATE TO THE INSPECTION AGENCY CONFIRMING THE PACKING AS PER BHEL SPECIFICATION. IN EXPORT ORDE
PACKING SHALL BE AS PER BHEL SPECIFICATION & THE SAME SHALL BE WITNESSED.
LEGEND : P : PERFORMER W: WITNESSER V: VERIFIER (1) BHEL/BHEL's

BHEL/BHEL s CUSTOMER: 2
2-VENDOR
VENDOR : 3 SUB VENDOR
BHEL PARTICULARS BIDDER/ VENDOR

NAME
SIGNATURE
423
700MW CCPP AT NEDUNOOR, KARIMNAGAR (job no. I-59) ANNEXURE-B
BHEL Clarification (ELECTRICAL) submitted to customer
S. No. Volume Section Page No. Clause No. Technical Specification Clarification
1.0(f) &
Electrical key Fault level shall be limited to 44
line diagram kA rms for 6.6 kV systems .... & 6.6 kV system with fault level limited to 40 kA
1 III D3.0 1 OF 17
dwg. No.: as per key SLD, fault level at rms has been offered.
TCE.5960A- 6.6kV system is 40kA.
EL-SK-2001
The motors rated 175 kW and The motors rated above 175 kW shall be
1 III D3.0 12 OF 17 1.18( c) above shall be 6.6kV and motors 6.6kV and motors rated upto 175 kW shall be
rated upto 175 kW shall be 400V. 400 V.
The generator side current transformer is
(c) Generator side current envisaged as a part of the isolated phase
…………………….GT side. busduct.
2 III D 3.2 2 OF 8 2.9 (c & d)
The voltage transformer, lightning arresters &
(d) Voltage transformers with surge capacitors are envisaged as a part of
……………transformer side. SPVT & VT cubicle provided as part of
generator busduct & associated equipement.
(a) A switched
short………..disconnector.
3 III D 3.2 2 OF 8 2.10 (a & b) Manual shorting link has been offered.
(b) A manually fitted
…………..connection.
Two nos. transformer feeders (One (1) no. on
each bus), rated 2000kVA for Colony
9.3 &
supply(in customer scope) are considered in
Electrical key Additionally One (1) no.
BHEL scope as per clause no. 9.3 of section
line diagram transformer feeder on each bus
4 III D3.9 2 OF 15 D3.9 Vol-III of customer specification. Further
dwg. No.: (colony supply) for Owner’s use
HT cable, LT service transformer, LT busduct,
TCE.5960A- shall be provided.
LT power/control cables & LT switchgear for
EL-SK-2001
the same are excluded from BHEL scope of
supply.
424
700MW CCPP AT NEDUNOOR, KARIMNAGAR (job no. I-59)
BHEL deviations (ELECTRICAL) submitted to customer
S. No. Volume Section Page No. Clause No. Technical Specification Deviation
DC battery is sized for Emergency

DC loads for 1hour & continuous
Emergency & Continuous Load
1 III D3.13 2 OF 14 13.3.2 DC loads( ie. Indicating lamps,
(For 10 hours duration)…..
GRP, ECP7 AVR panel etc.) for
10 hours.
425
Page : of
10. SCHEDULE OF TECHNICAL DEVIATION
S.
Page No. Vol/ section/ Clause No. Technical Specification Clarification
No.
426
Page : of
11. SPARES:
BIDDER TO QUOTE FOR MANDATORY SPARES, ERECTION & COMMISSIONING SPARES &
RECOMMENDED O&M SPARES (FOR 3 YEARS OF OPERATION). AN INDICATIVE LIST OF MANDATORY
SPARES IS GIVEN BELOW FOR REFERENCE.
S. No. Description Quantity

1 LT SWITCHGEAR & LT BUSDUCT
1.1 400V Switchgear
1.1.1 Complete pole of breaker 2 Nos. of each rating
1.1.2 Breaker complete with operating mechanism and truck 1 No. of each rating
mounted
1.1.3 Closing & tripping coils 2 sets of each rating
1.1.4 Fixed and moving contact assemblies of each breaker 2Set
1.1.5 Spring charging motors 2No.

1.1.6 Set of gasket 5Set
1.1.7 Bus bar support insulators 10No.
1.1.8 Aux switch assembly, limit position switches, Local/ 5 No.s
Remote selector switch, breaker control switches &
other switches
1.1.9 Relays of each type used 1 No.

1.1.10 Clustered type LED 10 Nos. of each colour
1.1.11 CTs. of each ratio & type 2 Nos.
1.1.12 VTs. of each ratio & type 2 Nos.
1.1.13 Meters. of each type & rating. 1 No.
1.1.14 Fuses of each rating 5 Nos.
1.1.15 Transducers of each type & rating 2 Nos.
1.2 Non-Segregated Phase Busducts

1.2.1 Bus support insulator 1 No. for each rating
1.2.2 Seal-off bushing 2 No. for each rating
1.2.3 Flexible connector (for equipment connection) 1 No. for each rating
1.2.4 Gasket 1 set
2 DC System
( Spares applicable separately for each battery bank)
2.1 Battery
(a) Battery Cell of each type 1No.
(b) Positive Plate of each Type 1No.
(c) Negative Plate of each Type 1No.
(d) Connectors with Nuts & Bolts 1 Set
(e) Vent Plugs 1 Set
427
Page : of
(f) Terminal Post 1 Set

2.2 Battery Chargers
(a) Silicon Diodes 1 no. of each rating
(b) Control Switch 1 no.
(c) Current Regulator 1 no.
(d) Off-Load Tap Changing Device 1 no.
(e) Fuse of each type 2 nos. of each rating
(f) D.C. Ammeter 1 no.
(g) Miniature circuit Breaker 1 no.
(h) Neon Lamps 5 nos.
3 Lighting Fixtures
3.1 Lighting fixtures (along with lamps) 3% of each type
3.2 Lighting Panels 1 No. of each type.
3.3 MCBs 5 No. of 32A & 5 Nos of 63A.
428
700MW KARIMNAGAR CCPP PROJECT ANNEXURE-A
PROPOSED SCOPE SPLIT OF ELECTRICAL SYSTEMS BETWEEN BHEL & EPC PARTNER
SL. NO. ABBREVIATION EXPANSION

A. B BHEL
1 B(BP) BHEL(BHOPAL)
2 B(ED) BHEL(EDN), BANGALORE
3 B(HR) BHEL(HARDWAR)
4 B(HY) BHEL(HYDERABAD)
5 B(IS) BHEL(ISG), BANGALORE
6 B(JH) BHEL(JHANSI)
7 B(PC) BHEL(PIPING CENTRE), CHENNAI
8 B(PE) BHEL(PEM), NOIDA
9 B(RR) BHEL(RUDRAPUR)
10 B(RG) BHEL(REGION)
11 B(TY) BHEL(TRICHY)
B. P EPC-PARTNER
700MW KARIMNAGAR CCPP PROJECT
PROPOSED SCOPE SPLIT BETWEEN BHEL & EPC PARTNER
SCOPE
BASIC ENGINEERING
SUPERVISION OF
COMMISSIONING
COMMISSIONING
ENGINEERING
EXECUTION &
ERECTION &
ERECTION
DETAILED
SUPPLY
Sl. TERMINAL
SYSTEM / EQUIPMENT REMARKS
no. POINT
1 POWER EVACUATION EQUIPMENT / SYSTEM

1.1 Insulated phase busduct / Segregated phase P/B(PE) B(RR) B(RR) P P
busduct Design & Layout by 'P'
1.2 Generator Circuit Breaker B(PE) B(PE) B(PE) B(PE) B(PE) based on inputs by
1.3 Generator Transformer B(PE) B(BP) B(BP) P P respective BHEL units.
1.4 UAT P/B(PE) B(JH) B(JH) P P
1.5 Generator, GT & UAT protection panels B(PE) B(BP) B(BP) P P
1.6 Generator NGT & NGR P/B(PE) B(RR) B(RR) P P
1.7 P/B(PE) P P
Electrical Control Panel(For main plant, located
B(ED) B(ED)
in CCR), DDCMIS for electrical systems
1.8 DCS (station C&I) P/B(PE) B(ED) B(ED) P P
1.9 Diesel Generator P/B(PE) B(IS) B(IS) P P
2 AC/DC POWER- DISTRIBUTION CONTROL

2.1 MV (6.6 kV) Switch gear P/B(PE) B(BP) B(BP) P P
2.2 LT Aux. Transformers ( dry type) P/B(PE) B(JH) B(JH) P P
2.3 LT Switch gear {PMCC, PCC, MCC, ACDB P P P P P
local PB stns for LT / HT Drives}
2.4 LV Bus Duct & Accessories P P P P P
2.5 NGR for MV system P P P P
2.6 DC Power Supply 220 V dc P P P P P
2.7 DC Distribution 220 V dc P P P P P
2.8 DC Starter - for Boiler, Turbine and Generator B(HY/TY) B(HY/TY) B(HY/TY) P P
3 STATION -ELECTRICAL AUXILIARY PKG

3.1 Plant Lighting Equipment (Supply & E &C) P P P P P
3.2 PA System P P P P P For complete plant.
4 POWER / CONTROL /SCREENED CABLES

4.1 HT Power Cables P P P P P * As per Cable Scope
4.2 LT Power Cables P P P P P detailed matrix (Table-
4.3 LT Control Cables P P P P P 1)
4.4 Screen Cables (instrumentation) P P P P P
4.5 Spl. Cables [ for Cranes, Hoists etc.] P P P P P
4.6 Fire Survival Cables P P P P P
5 STATION CABLING, EARTHING & LIGHTING-MATERIAL

5.1 TG Trunk Cabling (Field-UCD) Material P P P P P
5.2 Boiler Trunk Cabling (Field - UCD) Material P P P P P
5.3 P P P P P
Cabling Material (Cable trays & accessories,
cable tray support, trefoil clamps, cable glands
& lugs, jointing kits, Fire sealing material)
5.4 Equipment Earthing Material (Above ground & P P P P P For main plant & BOP
below ground grade) areas.
5.5 Electronic Earthing Material B(ED) P P P P
5.6 Lightning Protection Material P P P P P
5.7 Plant Lighting - erection material P P P P P
6 Main system design , Electrical single line P P NA NA NA Drg./doc. shall be

diagram & Design Memorandum for all prepared by 'P' in
Electrical package consultaion with B(PE)
7 Electrical Layout/ Cable Listing/ cable P P NA NA NA Interface among inputs
routing/ cable interconnection diagram from respective BHEL
units is in 'P' scope.
8 Preparation of Electrical load data P P NA NA NA Load list shall be
prepared by 'P' in
consultaion with B(PE).
9 Submission of drg./doc.(i.e. Data sheet/ P P NA NA NA
OGA/ scheme/ Test certificates/ Quality
Plans etc.) for all electrical packages
10 Submission of drg. & doc./ follow-up with NA NA NA NA NA P' shall provide support
customer/ obtaining approval from to 'B(PE)'.
customer
Note:-Design & engineering of electrical system and equipment including layout / cable routing engineering and furnishing details/BOM/technical
particulars shall be in Partner's scope.
700MW KARIMNAGAR COMBINED CYCLE POWER PROJECT
TABLE-1: CABLE SCOPE DOCUMENT
ELECTRICAL SYSTEMS
SCOPE OF SCOPE OF
SL
ITEM CABLE TYPE CABLE CABLE REMARKS REV
No.
LISTING SUPPLY
A MV SYSTEM
1 SWGR TO OUTGOING FEEDER MV PC P P 00
2 SWGR TO DDCMIS/ UCP G B(PE)-C&I P 00
3 SWGR TO LPBS CC P P 00
INTERCONNECTING CABLES FOR MV
4 LV PC, CC,F,G P P 00
SWGR
B LV SYSTEM (UNDER STATION C & I)

1 SWGR TO DRIVES LV PC P P 00
2 SWGR TO DDCMIS/ UCP G B(PE)-C&I P 00
3 SWGR TO LPBS F,G P P 00
C LV SYSTEM (UNDER B(PE)- BOPs)

1 SWGR TO DRIVES LV PC P P 00
2 SWGR TO PLC/ LCP G P P 00
3 SWGR TO LPBS F,G P P 00
4 LCP TO DRIVES LV PC P P 00
5 PLC/ LCP TO FIELD G P P 00
6 PLC/ LCP TO DDCMIS F, G B(PE)-C&I P 00
D LV SYSTEM (GAS TURBINES)

1 INCOMER CABLES LV PC B(HY) P
ALL OUTGOING CABLES TO DRIVES/
2 PC, CC B(HY) B(HY) 00
MARK-VI PANESL/ FIELD
3 SWGR TO LPBS F,G B(HY) B(HY) 00
E 220 V DC SYSTEM
1 BATTERY/ CHARGER TO DCDB LV PC P P 00
2 DCDB TO STARTER PANEL FOR DC DRIVE LV PC B(HR) B(HR) 00
3 DCDB TO PANEL/ DC LOAD LV PC P P 00
4 STARTER PANEL TO FIELD CC B(HR) B(HR) 00
F 125 V DC SYSTEM
1 BATTERY/ CHARGER TO DCDB LV PC B(HY) B(HY) 00
2 DCDB TO STARTER PANEL FOR DC DRIVE LV PC B(HY) B(HY) 00
3 DCDB TO PANEL/ DC LOAD LV PC B(HY) B(HY) 00
4 STARTER PANEL TO FIELD CC B(HY) B(HY) 00
G 24 V DC SYSTEM
1 415V SWGR TO BATTERY CHARGER LV PC P P 00
1 BATTERY/ CHARGER TO DCDB LV PC B(ED) P 00
ALL OUTGOING POWER CABLES FROM
3 LV PC B(ED) P 00
24V DCDB VARIOUS LOADS
BIANRY & ANOLOG SIGNALS FROM 24V
4 F,G B(PE)-C&I P 00
SYSTEM TO DDCMIS
H UPS
INCOMING POWER CABLE FROM SWGR
1 PC P P
TO UPS
Page 1 of 2
ALL OUTGING POWER CABLE FROM UPS
2 PC B(ED) P 00
ACDB TO VARIOUS LOAD
BIANRY & ANOLOG SIGNALS FROM UPS
3 F, G B(PE)-C&I P 00
TO DDCMIS
ALL INTERCONNECTING POWER CABLES
4 PC B(ED) P 00
BETWEEN UPS, ACDB & BATTERY
I ELECTRONIC EARTHING
1 BETWEEN DDCMIS CABINETS PC B(ED) P
2 DDCMIS CABINETS TO ELECTRONIS PC B(ED) P 00
EARTH PIT
J STATIC EXCITATION EQUIPMENT (SEE)

EXCITATION TRANSFORMER TO
1 PC B(ED) P
THYRISTOR CUBICLES
THYRISTOR CUBICLES TO FF / FB
2 CC B(ED) P 00
CUBICLES
3 FB CUBICLE TO GENERATOR SLIP RINGS CC B(ED) P 00
4 INTERCONNECTING CABLES WITHIN SEE CC B(ED) B(ED) 00
5 AUX AC SUPPLY FROM SWGR TO SEE PC P P 00
6 AUX DC SUPPLY FROM DCDB TO SEE PC P P 00
CONTROL & INSTRUMENTION CABLES
7 CC P P 00
BETWEEN SEE TO GRP, ECP, DDCMIS
K 415V EMERGENCY DG SYSTEM

1 415 DG PCC TO DG TERMINALS LV PC P P 00
2 415 V SWGR TO DG AUX MCC CC P P 00
DG AUX MCC TO DG ROOM (VENTILATION
3 F,G B(IS) B(IS) 00
FAN, LIGHTING ETC)
POWER & CONTROL CABLES WITH IN DG
4 PC/ CC B(IS) B(IS) 00
SYSTEM
CONTROL & INSTT. CABLES BETWEEN
5 CC, F,G P P 00
DG EQPT TO ECP/ DDCMIS/TRANS. & AVT
L SWITCHYARD
1 LT SWGR TO BATTERY CHARGER LV PC P P
2 LT SWGR TO ACDB LV PC P P
3 ALL SAS/ SCADA CABLES CC, F, G, FO
4 ALL OUTGOING CABLES FROM SWYD LV PC SWYD. VENDOR SCOPE
5 DCDB
ALL OUTGOING CABLES FROM SWYD LV PC
ACDB
CONTROL CABLES BETWEEN SWYD
6 CC, F, G P P
EQPT & GT, GRP, ECP, DDCMIS
ALL CONTROL CABLES TWO BETWEEN
7 CC, F, G P P
SWYD EQPT
ALL INTERCONNECTING CABLES FOR

M LV PC, CC,F,G P P
GRP, DCS, ECP, TRANSFORMERS,
MV PC, LV PC,
M ANY OTHER CABLE P P
CC,F,G, FS
MV PC: MV Power cable; LV PC: LV Power cable; CC: LV Control Cable; F: F-Type Instrumentation cable; G:
G-Type Instrumentation cable; FS: Fire Survival cables
Page 2 of 2

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Vdocuments - MX - SCT 1466 Vol G Techno Commercial Bid Technical For Electrical Vol G PDF

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TENDER SPECIFICATION

BHEL: PSSR: SCT: 1466

Pre-bid tie up on back to back basis for

BHARAT HEAVY ELECTRICALS LIMITED

Tender Specification No. BHEL: PSSR: SCT: 1466

One set of Tender documents consisting of Volume - A to Volume- L (details as below)

Refer NIT for Last date of submission

Please note this tender document is not transferable

For and on behalf of

ADDL GENERAL MANAGER / CONTRACTS

Place: Chennai -35

Bharat Heavy Electricals Limited

ANDHRA PRADESH POWER DEVELOPMENT COMPANY

TECHNICAL REQUIREMENTS FOR GENERAL ELECTRICAL WORKS

DOCUMENT NO. PE-TS-I59-888-E001 REV 0

BHARAT HEAVY ELECTRICALS LIMITED

SL. NO. DESCRIPTION PAGES

3. DOCUMENTS TO BE SUBMITTED BY BIDDER WITH EPC BID 1

4. DOCUMENTS TO BE SUBMITTED BY EPC PARTNER AFTER THE 2

5.1 GENERAL REQUIREMENT 15

Detailed scope of work shall be as per scope chart enclosed as Annexure-A.

Any deviation to technical specification is to be clearly mentioned in “schedule of technical

3. DOCUMENTS TO BE SUBMITTED BY BIDDER WITH EPC BID:

BIDDER TO SUBMIT SIGNED & STAMPED COPY OF FOLLOWING SHEETS:

S.No. DEPT_CODE SI_NO SYSTEM BHEL_DRG_NO DRAWING TITLE

DESIGN PHILOSOPHY FOR ELECTRICAL

2 ELE 100 ELE LAYOUT PE-DG-I59-100-E001 LAYOUT OF TRANSFORMER YARD

5 ELE 100 ELE LAYOUT PE-DG-I59-100-E006 LAYOUT OF MAIN SWITCHGEAR ROOM

8 ELE 100 ELE LAYOUT PE-DG-I59-100-E009 LAYOUT OF DC BATTERY ROOM

15 ELE 100 ELE LAYOUT PE-DG-I59-100-E050 IPB LAYOUT-GT

16 ELE 100 ELE LAYOUT PE-DG-I59-100-E051 IPB LAYOUT-STEAM TURBINE GENERATOR

23 ELE 100 ELE LAYOUT PE-DG-I59-100-E071 INTERPLANT CABLING LAYOUT (2 SHEETS)

S.No. DEPT_CODE SI_NO SYSTEM BHEL_DRG_NO DRAWING TITLE

38 ELE 506 LV SWGR PE-DC-I59-506-E004 ELECTRICAL LOAD DATA (BOARD WISE)

39 ELE 506 LV SWGR PE-DG-I59-506-E003 CONTROL LOGIC FOR 415V SWGR

42 ELE 507 CABLES & CABLING PE-DC-I59-507-E004 CABLING PHILOSOPHY

43 ELE 507 CABLES & CABLING PE-DC-I59-507-E005 CABLE NUMBERING SCHEME

51 ELE 508 DC SYSTEM PE-DC-I59-508-E001 DESIGN MEMORANDUM FOR 220V DC SYSTEM

D3.1 TCE-5960A-H-500-01 R0 GENERATOR AND ACCESSORIES 39

D3.2 TCE-5960A-H-500-01 R0 GENERATOR CIRCUIT BREAKER 06

D3.3 TCE-5960A-H-500-01 R0 GENERATOR TRANSFORMERS 09

D3.4 TCE-5960A-H-500-01 R0 UNIT AUXILIARY TRANSFORMERS 03

D3.5 TCE-5960A-H-500-01 R0 BUS DUCTS 16

D3.6 TCE-5960A-H-500-01 R0 GENERATOR, GENERATOR, 08

D3.8 TCE-5960A-H-500-01 R0 GENERATOR CONTROL PANEL 09

D3.9 TCE-5960A-H-500-01 R0 6.6 kV SWITCHGEAR 15

D3.10 TCE-5960A-H-500-01 R0 SERVICE TRANSFORMERS 05

D3.12 TCE-5960A-H-500-01 R0 NEUTRAL EARTHING EQUIPMENT 03

D3.13 TCE-5960A-H-500-01 R0 DC SYSTEM 13

D3.16 TCE-5960A-H-500-01 R0 LIGHTING SYSTEM 16

D3.19 TCE-5960A-H-500-01 R0 FIRE DETECTION AND ALARM SYSTEM 05

TCE FORM NO. 329 R5

D3.20 TCE-5960A-H-500-01 R0 MOTORS 10

D3.21 TCE-5960A-H-500-01 R0 ELEVATORS 08

D3.22 TCE-5960A-H-500-01 R0 ELECTRICAL LABORATORY EQUIPMENT 07

D3.25 TCE-5960A-H-500-01 R0 TRANSDUCERS 02

2.0 TCE.5960A-EL-2003 P0 MAIN ONE LINE DIAGRAM (SH. 1 OF 2) 01

3.0 TCE.5960A-EL-2003 P0 MAIN ONE LINE DIAGRAM (SH. 2 OF 2) 01

8.0 TCE.5960A-EL-2008 P0 400kV SWITCHYARD SECTIONS 01

TCE FORM NO. 329 R5

ANDHRA PRADESH POWER DEVELOPMENT COMPANY LTD. SECTION: D3.0

1.0 General Requirements

(a) For the purpose of design of equipment / systems, an ambient