DESIGN BASIS REPORT Alumina Unloading and

ELECTRICAL SYSTEM Transportation System

DOC. NO.14L08-000-DBR-E-001

DESIGN BASIS REPORT

FOR

ALUMINA UNLOADING AND TRANSPORTATION SYSTEM

ELECTRICAL

NATIONAL ALUMINIUM COMPANY LTD.

(A Govt. of India Enterprise)
Nalco Bhavan, P/1, Nayapalli
Bhubaneswar-751013,Odisha 3

Phone: 91-674- 2301988 to 2301999

Fax: 91-674-2300550/2300470/2300521/2300640

DOC. NO.14L08-000-DBR-E-001

JULY, 2015

DEVELOPMENT CONSULTANTS PRIVATE LIMITED

CONSULTING ENGINEERS
DEVELOPMENT CONSULTANTS HOUSE, BLOCK DG-4,SECTOR-II
SALTLAKE CITY, KOLKATA-700091, INDIA
 DESIGN BASIS REPORT Alumina Unloading and
ELECTRICAL SYSTEM Transportation System
DOC. NO.14L08-000-DBR-E-001
 DESIGN BASIS REPORT Alumina Unloading and
ELECTRICAL SYSTEM Transportation System
DOC. NO.14L08-000-DBR-E-001

CONTENTS

CL. NO DESCRIPTION PAGE NO

1.0 INTRODUCTION………………………………………………… 1

2.0 CODES AND STANDARDS…………………………………….. 1

3.0 PROPOSED POWER SYSTEM………………………………….. 1

4.0 MAJOR ELECTRICAL EQUIPMENT………………………....... 2

5.0 ELECTRICAL SYSTEM………………………….......................... 6

6.0 PROTECTION SYSTEM………………………………………….. 10

7.0 SYSTEM CONTROL………………………………………………. 14

8.0 LAYOUT CRITERIA……………………………………………….. 14

ATTACHMENTS

ANNEXURE-A TECHNICAL PARTICULARS OF ELECTRICAL EQUIPMENT 16

2 DRAWING KEY SINGLE LINE DIAGRAM: 14L08-DWG-E-0101, Rev.5

 DESIGN BASIS REPORT Alumina Unloading and
ELECTRICAL SYSTEM Transportation System
DOC. NO.14L08-000-DBR-E-001

1.0 INTRODUCTION

National Aluminium Company Limited (NALCO) intends to set up additional alumina handling&
transportation systemfor existing smelter plant. The purpose of this project is to enhance its existing
capacity of Alumina unloading & Transportation system by introducing a new wagon unloading
system along with transportation system to existing Silo.

2.0 CODES AND STANDARDS

All equipment and materials shall be designed, manufactured and tested in accordance with the latest
applicable Indian Standards (IS) and IEC or equivalent standards published by the Bureau of Indian
Standards (BIS). In case of a conflict between IEC and other standards, the requirement of IEC shall
govern.

Equipment and material conforming to any other standards, which ensure equal or better quality,
may be accepted. In such case, copies of the English version of the standard adopted shall be
submitted along with the bid.

The electrical installation shall meet the requirements of Indian Electricity Rules as amended upto
date and relevant IS Code of Practice. In addition, other rules and regulations applicable to the work
shall be followed.

3.0 PROPOSED POWER SYSTEM

The power supply for the proposed augmentation system shall be received at 11kV level through two
no. HT cable at 11kV switchgear of new substation. This 11kV switchgear shall be used to receive
power from existing substations 710.37 and 11kV switchgear at switchgear room-3 near 220kV
switchyard and to feed HT motors of the proposed system & LT transformers. 11kV shall be further
stepped down to 415V by two no (2X100% capacity) 1.6MVA*, 11/0.433kV oil filled transformer to
feed LT auxiliary loads of the new system. The transformer capacity shall be selected in such a way
that in case of outage of one transformer, the other transformer will take care of total loads. In order
to meet the requirement of emergency power for emergency lighting power shall be received from
existing substation 710.37 through Al. XLPE cable.

1 *Minimum and Indicative. Exact Rating shall be decided during detailed engineering.

For Electrical Power Distribution system, please refer Key Single Line Diagram, Dwg. No. 14L08-
2 DWG-E-0101, Rev.5 attached with this design basis report. The electrical system parameters as
envisaged are given below.

Voltage Level Description Utilization

11 kV 11 kV 10%, 3 ph, 3 wire, 50 Power Source from existing system.

Hz,3%Non-effectively earthed, Power feeding to Motors above 200kW
40kA* for 1 sec. and LV transformer.

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Voltage Level Description Utilization

690V 690V 10%, 3 ph, 4 wire, 50 Power distribution to VFD driven

3 Hz3%, effectively earthed;
Fault level : 50 kA* for 1 Sec
415V 415V 10%, 3 ph, 4 wire, 50
Hz3%, effectively earthed;
Fault level : 50 kA* for 1 Sec
1
DC 110V DC,(+) 10% to (-) 15%, 2
wire, ungrounded, 25kA* for
1Sec.
240V/110V AC 240V/110V AC, 2 Wire supply to
1 UPS
* Indicative only. Shall be decided during detail engineering.
Motor.
Power distribution to LT motors above
200W and up to 200kW, Other LT
loads.
Switchgear control, indication,
protective relay circuits etc.
Motors 200W and below.
Other loadsand module control supply
etc.

Brief description of the new electrical equipment and system are described in following clauses.

4.0 MAJOR ELECTRICAL EQUIPMENT

4.1 HV Switchgear

The11kV switchgear shall be used to receive power from existing 11kV HT switchgear and feed
power feed power to HT drives and LT transformers.
The switchgear shall be indoor, metal-clad, floor mounted, self-standing, dust proof construction,
draw out type with Vacuum circuit breaker. Design and construction shall be such as to allow
extension at either end. All HT drive shall be vacuum breaker operated. Circuit breaker shall not
produce any harmful over-voltage during switching off induction motors, unloaded lines and
1 unloaded transformers. If required, surge protective device shall be provided to limit over-voltage to
2.2 times the peak value of rated phase to neutral voltage.

All Switchgear shall be provided with double bus bar and isolators and shall have bottom cable entry.
The main buses (front and rear bus) and connections shall be of high conductivity copper or
1 aluminum alloy. Insulating sleeves for bus bars and cast-resin shrouds for joints shall be provided.
The switchgear enclosure shall conform to the degree of protection IP-4X.Voltage Transformer (VT)
shall be cast-resin, draw out type and shall have an accuracy class of 1.0. Voltage transformer shall
be mounted in a separate vertical panel.

Each switchgear shall be provided with 20% spare feeders with minimum one no of each type and
rating.

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4.2 LV switchgear

415 V Power cum Motor Control Centers (PMCC) shall be used to feed LT auxiliary loads of the
proposed system. This switchgear shall receive power from 11kV switchgear through two no.
11/0.433kV transformer.
PMCC shall be sized for maximum 100% connected load plus 20% margin.

PMCC/MCCs/DBs shall be indoor, air insulated, and metal-clad type. PMCC/MCCs shall be
2 drawout type & DB shall be fixed type. The design construction shall be such as to permit extension
at either end. All PMCC shall be provided with three phase busbars and neutral busbar. All bus bar
compartments shall be fully enclosed. Main and vertical busbar of PMCC/MCC shall be made of
Aluminium. Earth bus bar shall be of copper. All bus bars of PMCC shall be capable of withstanding
the mechanical forces and thermal stresses due to 50 kA short circuit current for 1 sec. Degree of
protection for LV switchgear shall be IP-52.

For feeder ratings of 800 A and above ACB shall be provided. For feeders less than 800A, MCCB
shall be provided depending on the application. All the breakers are EDO type. All the breaker
feeders shall have micro processor based external relay with communication protocol to link with
SCADA, EMS system. All the ACB incomer breakers from transformer and B/C ACB shall be of
50kA breaking capacity.

All motors rated 110kW & upto 200kW shall be air circuit breaker controlled with external numeric
1
motor protection relay. All the motor up to 30 kW shall be provided with MPCB.

Motors rated above 30kW and below 110 kW shall be Contactor operated by numeric motor protection
1 relay with RS485 communication. For motors between 30kW to 110kW, MCCB with E/F protection
shall be provided.

1 Motors rated below 110 kW shall have DOL starter.

3 phase energy meters with communication facility shall be provided for motor size more than 30KW.
1
Working height shall be limited between 450mm and 1800mm from floor level.

4.3 LT Non-Segregated Phase Busduct

The 415V non-segregated phase bus duct will serve as interconnection between the 415V Indoor
Switchgear and outdoor/Indoor transformer terminals.

The 415V bus duct shall be non-segregated phase enclosure, natural air cooled type. The bus
conductor shall be of high conductivity electrolytic grade copper or aluminum alloy, supported on
fine glazed porcelain / cast resin / FRP insulators fixed to enclosure. Bus duct enclosure shall be made
of Aluminum alloy. The thickness of enclosure material shall not be less than 3mm.

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Phases shall be enclosed in a weather-proof, dust-tight enclosure without any barrier between phases.
Enclosure for indoor run shall be IP52 protected. Outdoor enclosure shall have IP 55 degree of
protection.

4.4 Auxiliary Transformer

The auxiliary transformers shall be used to provide 415V power supply to plant auxiliaries. In order to
1 meet the above requirement two no. 1600kVA*, 11/0.433kV transformer has been envisaged. The
transformer shall be Oil Natural Air Natural cooled. Vector group shall be Dyn11. The transformer
shall be provided with Off Circuit Tap changer with tapping range +/-5 @ 2.5%.
The transformer HV terminal shall be connected to HV switchgear through Al XLPE cable and LV
terminal shall be connected to 415V switchgear through non segregated phase busduct.

The transformer capacity shall be selected in such a way that in case of outage of one transformer,
1 the other transformer will take care of total LT loads. The transformer shall be outdoor type but to be
located indoor.
1 *Minimum and indicative. Exact Rating shall be decided during detailed engineering.

4.5 AC & DC Motor

Motors shall be general purpose, constant speed, squirrel cage, three/single phase, induction type.
Enclosures for the motor and the cable box shall conform to the degree of protection IP-55

Motors rated above 200W and upto 200kW shall be fed from 415V system and motors rated above
200kW shall be fed from 11kV system.

LT motors upto 200kW output rating at 50 ºC and of continuous duty shall be energy efficient type –
efficiency class Eff1 conforming to IS: 12615 or high efficiency class IE2 as per IEC:60034-30.

All motors shall be either totally enclosed fan cooled (TEFC) or totally enclosed tube ventilated
1 (TETV) or closed air circuit air cooled (CACA) type.

The motor shall be capable of operating satisfactorily at full load for 5 minutes without injurious
heating with 75% rated voltage at motor terminals. The mill motors shall be suitable for operating at
75% of rated voltage for one (1) minute.

1 The terminal box shall be capable of withstanding maximum system fault current for a duration of 0.25
sec.
All insulated winding shall be of copper.

HT motors shall have Class F insulation with winding temperature rise limited to 120ºC. Windings
shall be impregnated to make them non-hygroscopic and oil resistant. The lightning impulse and coil
inter-turn insulation surge withstand level shall be as per IEC-60034 – Part 15.

1 LT motors shall have Class F insulation with temperature rise limited to 120ºC.

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Motor of rating 30 kW and above shall be provided with space heaters, suitably located for easy
removal or replacement.

All HT motors shall be provided with minimum four (4) numbers simplex or two (2) numbers duplex
1 platinum resistance type winding temperature detectors per phase.For Bearing Temperature detection, 2
nos of platinum resistance type detectors shall be provided each at NDE &DE.

4.6 Battery and Battery Charger

DC system shall provide reliable sources of DC power supply for control, indication, protection and
1 annunciation of the plant. In order to provide reliable DC supply Lead Acid Plante type battery of
required capacity shall be used. The DC system shall be 110V.

The batteries shall be so sized as to meet emergency load duty cycle requirements for one (1) hour.
While estimating battery capacities, a design margin of 15% shall be kept. An ageing compensation
factor of 1.25 shall be applied. The battery shall be provided with battery charger and DCDB.

Battery charging equipment shall consist of dual float cum boost charger. The battery charging
equipment will be digital microprocessor based controlled and will be designed to supply the
1 continuous DC load in addition to float/trickle/boost charging of the battery.

4.7 VVVF Drives

The system shall be energy efficient, designed as standard product and shall provide very high
reliability, high power factor, low harmonic distortion and low vibration/ wear/ noise. VFD shall
1
comply with major standards IEC 60146, IEC 60289, IS 5553, IEEE 519, IEC 61800 etc.

Each VFD will be of sufficient capacity and will produce a quality output waveform for stepless motor
control from 10 to 100 percent of base speed. Each VFD will be suitable for either constant torque (CT)
or variable torque (VT) loads as required by the driven equipment. To facilitate checkout and
maintenance, each VFD will be capable of sustained operation at the minimum speed (10 percent of base
1
speed). In addition, each VFD system will be capable of operation while disconnected from the
associated motor.

The drive shall trip in case the speed exceeds 105% of the maximum operational speed or reduces to
1 95% of the minimum operational speed for more than 10 second.

For CT loads (conveyors), each VFD will be capable of a momentary overload of 150 percent of rated
motor current for 1 minute out of any 10 minute period. When the load type dictates, each VFD will be
capable of producing full rated torque at any speed in the operating range. VFD system shall be
equipped with following minimum components.

a) Isolation/converter transformer.

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b) Converter (at least 12 pulse).

c) Inverter.
d) Harmonic filters, if reqd.
e) All associated controls and protective devices.
f) Enclosure for rectifier/inverter and associated controls.

Each VFD system will be supplied with a suitably rated drive isolation/converter transformer. The
transformer shall receive power from 11kV switchgear and step down the voltage at 690V to feed the
VFD driven motor. Rating of each transformer shall be decided by the Bidder during detail
3 engineering based on the requirement.

The transformer shall be Oil Natural Air Natural cooled. Vector group shall be Dyn11. The transformer
shall be provided with Off Circuit Tap changer with tapping range +/-5 @ 2.5%.

The transformer will be designed for a maximum temperature rise of 55° C (top oil and average
winding) over an ambient temperature of 50° C.

The transformer HV terminal shall be connected to HV switchgear through Al XLPE cable and LV
terminal shall be connected to VFD panel through Al XLPE cable.

4.8 Power and Control Cables

The HV power cable will generally be XLPE insulated & LT power cable shall also be XLPE
insulated, extruded PVC inner sheath, armoured and overall extruded FRLS grade PVC sheathed
with stranded aluminium conductor. HV power cable shall be Un-earthed.

The control cables will be PVC insulated, extruded PVC inner sheathed, unarmoured/ armoured
1 and overall extruded FRLS grade PVC sheathed with stranded copper conductor.

The cable sizes will be standardized to minimize too many sizes. The minimum cross section of
power cables will be 6 mm 2 for aluminium& 2.5 mm 2 for copper conductor, of control cable
2.5 mm 2 copper and instrument cable 1.5 mm 2 copper.

The actual size of all HT and LT cables will be calculated on the following basis.

a) Continuous Current Rating.

b) Capability to withstand fault current.
c) Voltage drop at normal load as well as during starting of motor.

5.0 ELECTRICAL SYSTEMS

5.1 Illumination system

Suitable illumination system will be provided to have efficient lighting. All the lighting fixture shall be
energy efficient fixture.Generally the following illumination level will be provided:

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a) Transfer Point, Conveyor Gallery : 70 Lux

b) Switch gear Room : 300 Lux

c) Corridors, Walkways, Staircase : 70 Lux

d) Control Room with false cealing : 300 Lux

e) Transformer Room : 200 Lux

f) Toilets/ passage : 50 Lux

g) Battery Room : 200 Lux

h) Unloading Area : 50 Lux

i) Street Lighting : 20 Lux

j) office area : 300 Lux

k) Cable spreader room : 70 Lux

l) Compressor room : 150 Lux

m) Control room/swgr. Room (emergency : 50 Lux

lighting)

k) Emergency Lighting : Beside the above , at least One no. (1) emergency
fixture shall be provided at entry, exit and each landing of stair cases,
platforms of Electrical Substation Buildings, Control Rooms, TPs,
maintenance area , unloading area, etc.

The lighting system shall be designed with following concepts:-

Normal A.C. Lighting

This will be provided by A.C. energy efficient lighting fixtures distributed throughout the
plant. These lights will be ON as long as the plant A.C. supply is available.

Normal lighting fixtures will be fed from respective area lighting panels, which in turn will be
connected to main lighting distribution board. The main lighting distribution boards will be fed
through respective 1:1 ratio lighting transformer, which forms a part of the MLDB. Normal

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A.C. supply thus made available by the MLDB is 415V, 3ph, 4Wire , 50Hz effectively
grounded.

Emergency A.C. Lighting

On failure of normal A.C. supply, emergency A.C. lighting will be provided in selected areas
for general visibility, safe movements and operation of important auxiliaries.

Emergency lighting distribution board shall be fed through 1:1 ratio lighting transformer,
which form a part of ELDB. The power for A.C. emergency lighting shall be arranged from
emergency power distribution board. The power supply for emergency lighting shall be
415V, 3ph, 4Wire, 50HZ, effectively grounded. Emergency power for lighting shall be
1 arranged by contactor from existing substation 710.37. Supply, laying, termination of the
above cable shall be under the scope of this package.

5.2 Grounding System

The system shall (a) provide safety to personnel from contact of dangerous potential caused by
ground fault, (b) ensure sufficient grounding current for effective relaying and (c) stabilize circuit
potential with respect to ground.

Ground grid conductor of mild steel rod shall be used.The minimum conductor section is determined
on the basis of ground fault current. This section is then increased by an allowance to account for the
soil corrosion loss of 0.3 mm per year over the design life of 30 years. However, the minimum size
shall be 1x40 mm dia mild steel conductor.

The ground grid conductors will be buried in earth at a minimum depth of 1000 mm. The length of
1 ground conductors below earth will be sufficient to ensure a ground resistance less than 1 ohm.All
ground grid conductor connections will be welded type.Earth test pit with chamber to measure
individual and grid resistance separately shall be provided.

Galvanized steel flats shall be used for all connections above earth.

Inside building, ground conductors will be run for each floor supported on building steel and/or cable
trays. These ground conductors in turn will be connected to the station ground grid through riser (at
least two) coming up along building columns/cable shafts.

Two separate and distinct ground connections will be provided for each electrical equipment in
compliance with I.E. Rules.

Equipment ground connections will be sized to carry the available ground fault current.
1 Considerations shall also be given to mechanical ruggedness of the connections and to limit the

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number of sizes.Substation earth grid is to be connected with the existing plant grid at least at 2
points.
Electronic equipments and systems, metal enclosures of all electronic panels shall be connected to a
grounding system with which is isolated and separate from the electrical equipment grounding
system.

Following minimum sizes of earth continuity conductors will generally be used for grounding of
equipment:-

a) 40 mm. dia. MS Rod as ground electrode and ground grid

b) 75 x 10 mm GS or 50 x 6 mm GS strip as main risers depending on system

fault current for switch yard equipment & structure, rail, fence
riser
c) 75 x 10 or 50 x 6 mm GS strip for all switchgears, transformers and motor
control centers
d) 50 x 6 mm GS flat for motor above 90 KW
e) 35 x 6 mm GS strip for rotor starters and motors rated between 30 KW and 90
KW
f) 25 x 3 mm GS strip for control desk, small distribution board and
motor rated between 5 KW and 30 KW
g) 8 SWG GI wire for local push button stations, junction boxes and
motors below 5 KW

5.3 Cabling System

Cabling work shall be carried out in such a way as to provide a reliable and assured electric power
supply system to all auxiliaries.

Cables will generally be laid on cable trays, cable trench, cable rack, overhead supported from building
steel/structures or cable bridge/cable trestle. Cable trench shall be avoided as far as possible in
outdoor areas. Cables shall not be buried directly in ground unless explicitly permitted in some areas.

Cable trays shall be of pre-fabricated GI ladder/perforated type sheet steel complete with matching
fittings like brackets, elbows, bends, reducers, Tees, crosses, tray cover etc. and hardwares like bolts,
nuts, washers, GI straps, hook etc.as required. Cable trays shall be ladder type for power and control
1
cables, and perforated type for instrumentation cables. Separate trays shall be used for control &
power cable. Punched identification tags made of 2 mm aluminium plates shall be fixed on each
cable at both the ends and few other locations on the tray.

Cable trays, fittings and accessories shall be factory-fabricated out of rolled mild steel sheets and hot
dip galvanized as per relevant IS.

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Cable trays shall be supplied in standard length of 2.5 meters and in standard width of 150mm,
300mm, 450mm and 600mm.

Mild steel sheets used for fabrication of cable trays and all fittings except the side coupler plates shall
be of 2mm thickness. 3mm sheet shall be used for side coupler plates.

5.4 Lightning Protection System

The main purposes of the lightning protection system shall be (a) to provide protection to structures
from lightning strokes and (b) to provide a low resistance-conducting path to lightning discharge.

Lightning protection shall be provided for switchgear room, other auxiliary building, and other
structures. Lightning protection will also be provided for building/ structures where the overall rise
factor exceeds 10-6 as per IS: 2309.

Vertical air terminals shall be of 20mm dia galvanized steel rod on the structure/building.Horizontal
air termination of 75x10 mm GS flat conductor on the roof of the installation shall be so laid out that
no part of the roof will be more than 9 meters from the nearest conductor.

Down conductors of 75x10 mm GS Flat for all installations except for conveyor gallery will run along
the outer surfaces of the building and shall have a test joint about 1500 mm above ground. It shall be
25x3 mm GS flat for conveyor gallery.

An earth electrode of size 40 mm. diameter 3 metre long MS will be provided at the connection point
of the down conductor with the station ground. All connections will be of welded type.

6.0 EQUIPMENT PROTECTION

The primary objective is to mitigate the damage of the plant and equipment during fault or system
disturbances.

Automatic trip functions will be initiated for isolation of fault, which could cause immediate and
1 severe damage. Protection relays shall be microprocessor based numerical relay with communication
facility. Communication protocol shall be compliant with IEC 61850.

Every effort will be made to avoid unnecessary trip. Whenever possible, therewill be annunciation to
alert the operator to take corrective action in time.

The major protections envisaged for the various equipment are listed under individual headings. All
associated relays for completeness of scheme, auxiliary relay, lockout relay, check synchronizing
relays, auto synchronizer etc. will be provided as required.

6.1 HV Switchgear

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Minimum protections to be provided for different type of circuits are listed below -

A. Incomer : a. IDMTL over current (51) for phase fault

b. IDMTL over current (51N) for earth fault

c. IDMTL over current (51SN) for stand by earth fault (for

incomer from transformer only).

d. Restricted E/F (64) (for incomer from transformer only)

e. Differential Relay (87T) (for incomer from transformer rated

5 MVA & above)

f. Under voltage with time delay (27)

g. VT fuse failure

h. Circuit breaker failure

i. Auxiliary relays for Transformer Protection like Buchholz Relay Alarm &
Trip, Oil Temperature Alarm & Trip, Winding Temperature Alarm &
Trip, OLTC Buchholz Alarm & Trip, Oil Pressure level and Pressure
relief device operated Alarm.

B.Tie : a. IDMTL over current (51) for phase fault

feeder
b. IDMTL over current (51N) for earth fault

c. Under voltage with time delay (27).

d. VT fuse failure

e. Circuit breaker failure

f. Synchronizing check relay, if applicable, complete with

guard relay

C. Motor : a. Thermal overload (49)

feeder
b. Phase fault (50)

c. Unbalance (-Ve seq.) (46)

d. Locked rotor (50 LR)

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e. Definite time O/C (50G) for earth fault (through CBCT)

f. Differential (87) protection for motor above 1000 KW rating.

g. Vibration Monitor (39) (optional)

h. Starts per Hour (66).

g. Circuit breaker failure

h. Winding temperature

i. Bearing temperature

D. Auxiliary/VFD : a.IDMTL over current (50/51) with high set instantaneous units for
Transformer phase faults
3

b. Definite time O/C (50G) for earth fault (through CBCT)

c. Differential protection (for transformers rated 5MVA and above)

d. Auxiliary relays for Transformer Protection like Buchholz Relay Alarm &
Trip, Oil Temperature Alarm & Trip, Winding Temperature Alarm & Trip,
OLTC Buchholz Alarm & Trip, Oil Pressure level and Pressure relief device
operated Alarm.

e. Circuit breaker failure.

6.2 LV Switchgear

The minimum protections to be provided for circuit breaker controlled feeders are listed below:

A. Incoming Feeders a) 3-Inverse time O/C relays (51) for Phase faults
b) 1-Inverse time O/C relay (51N) for Earth faults
c) IDMTL Over Current (51 SN) for stand by earth fault (for incomer
from transformer only)
d) Restricted E/F (64)
(for incomer from transformer only).
1 e) VT Fuse failure.
f) Circuit Breaker failure.

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g) Sensitive earth fault detectors shall be provided in DC system to

annunciate earth faults

B. i) Motor feeders rated above 110 kW and up to 200 kW shall be breaker controlled with
Microprocessor based Numerical motor protection relays having the following
protection features.

a) Thermal model with negative sequence current.

b) Voltage compensated acceleration.
c) Under voltage, over voltage protection.(SR Type)
d) Overload protection.
e) Short circuit & SC back-up.
f) Current unbalance.
g) Locked rotor protection
h) Ground fault.
i) Temperate monitoring (stator, bearing etc.).
j) Phase reversal.
k) VT fuse failure at bus VT and secondary fuse detection scheme.

ii) Motor Feeders rated up to and including 110 kW shall be MCCB and Contactor
operated with the following protection features.

a) Bimetallic thermal overload relay(hand reset Contactor operated type) with

in built single phasing preventor.

b) Short circuit protection by MCCB.

c) Locked rotor protection

d) Earth fault protection

e) Under voltage protection (SR type)

The relay shall have facility for user interface capability, character display, keypad, LED indicator
and communication port along with licensed version software.

C) Outgoing feeder : a. IDMTL over current relay (51) for phase fault – 3 Phase

b. IDMTL over current relay (51N) for

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earth fault.

D) Bus-coupler : Check Synchronization relay (25).

7.0 SYSTEM CONTROL

There shall be one main control room for complete Process Plant located at new substation. Control
Philosophy of the Plant Equipment shall be such that each equipment shall have three modes of
operation selectively through respective Local-Remote selector switch preferably at control room.
Plant on operation shall have only emergency stop facility.

Auto mode
In this mode the equipment shall be operated from the Central Control Room with DCS/PLC fulfilling
all sequence and process interlocks.
Manual mode
In this mode the equipment shall be operated manually from the Central Control Room by individual
start/stop device after fulfilling all sequence and process interlocks.
Local mode
In this mode individual drive shall be started and stopped from the local push button station in de-
interlock mode. However safety interlock, if any, for the drive shall be fulfilled.
Incomer & Bus coupler of 11kV system shall be controlled from existing 220kV SCADA as well as
1
proposed SCADA at newsubstation.

8.0 LAYOUT CRITERIA

Layout of switchgear room shall be liberally designed with adequate clearances. Switchgear/ control
room shall have clear head room of 3.5 M (minimum) and cable cellar room clear head room 3.00M (
Minimum)

Switchgear room shall be located in the first floor of the substation building and ground floor of the
same building shall be used for cable cellar. Separate battery room shall be provided in substation
building.

Following factors shall be considered while finalizing the room size:-

i. Minimum clearance between two switchgear panels, facing each other shall be maintained
as 3000 mm. These distances shall be maintained for all other panels located inside the
room.
ii. Clearance from any obstruction like column, wall, and vertical raceway on back side of
switchgears shall be maintained as 1000mm (minimum) and shall also comply with
manufacture’s standard.
iii) Minimum Space between the sides of two switchgears, between any two panels or between
switchgear and the wall shall be 1000 mm. Where access is not envisaged, clearance shall
be 200 mm.

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iv) Clearance between front face of SWGR and any obstruction like column, wall, vertical
1 raceway, etc. shall be maintained as 1500 mm (minimum) and shall also comply with
manufacture’s standard. All clearances shall be as per relevant standards.
v) Clearance between switchgear panels and any other panels, facing each other shall be
maintained as 3000 mm.

vi) Minimum Clearance from top of bus duct to nearest obstruction shall be at least 1000 mm.

vii) Access to Rooms, Doors, etc. to be provided in various floors shall consider movement of
the panels during erection and later during maintenance.

viii) Switchgear shall be arranged to minimize interference with floor beams. Where interference
is unavoidable dummy panel shall be provided.

ix) Switchgear room/MCC and cable spreader room shall be pressurized above the
atmospheric pressure to prevent ingress of dust.

x) Adequate space and provision for handling of equipment shall be provided.

xi) Control room and battery room shall be Air conditioned.

xii) Layout shall have due provision for maintenance area, shift room and all equipment (e.g.
Crane, Hoist etc.) for handling of heavy equipments shall be provided.

xiii) Adequate clearance shall be provided at both end of PMCC/MCC panel for future
1
extension of at least one vertical module.

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ANNEXURE-A

TECHNICAL PARTICULARS OF MAJOR ELECTRICAL EQUIPMENT

1.0 11kV SWITCHGEAR

Type : Metal-clad, draw out

Service : Indoor

Rated Voltage KV rms : 11 kV 10%

Phase : Three

Rated Frequency : 50 Hz + 3% to -3% 1

System grounding : Resistance

Earthed

Bus bar Material and Rating : Double Busbar, 800A

Rated short time withstand current : 40 kA for 1 Sec

Type of Breaker : VCB

2.0 415V SWITCHGEAR

Type : Metal-clad, horizontal draw

out horizontal isolation ACB and
MCCB Module Fixed type

Service : Indoor

Rated Voltage (Ue) : 415 ± 10% V

Phase : Three Phase, Four Wire

Rated Frequency : 50 Hz ±3 % 1

System grounding : Effectively earthed through resistance.

Bus bar Material and Rating : 3000A 1

Rated short time withstand current : 50 kA for 1 Sec.

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3.0 415V NON-PHASESEGREGATED BUSDUCT

Type : Non-segregated phase, self-cooled.

Service : Indoor 1

Rated Continuous Current : 2500Amps

Material

a. Bus conductor : Aluminum alloy Grade 63401

(56.5% IACS)
IACS: International Annealed Copper
Standard

b. Bus enclosure

> 2000A : Aluminum alloy Grade 31000

(56% IACS).

Rated short time withstand current : 50 kA for 1 Sec.

4.0 AUXILIARY TRANSFORMER

Type : Oil filled, Two winding transformer

Rated power : 1600 kVA**

Rated voltage ratio (line to line) : 11/0.433 kV

No. of phases : 3

Rated frequency : 50 Hz

Type of Cooling & Respective : ONAN (100%)

Power

Insulation level (SI: Switching Impulse Voltage,

LI: Lightning Impulse Voltage, AC: Short duration
induced& separate source AC withstand Voltage)

.HV- (SI/Li/AC) : 75 kVp / 28 kV rms

L.V- (LI/AC) :- kVp / 3 kV rms

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L.V Neutral – (LI/AC) : - kVp / 3 kV rms

Vector group :Dyn11

Short-circuit impedance at 75oC :6.25%**

at principal tap

Type of taps provided :Off load full capacity

** Minimum and Indicative. Impedance value shall be with IS tolerance. 1

5.0 BATTERY

Type :Lead Acid PLANTE

Application :D.C. Closing/Tripping, indicating of

SWGR/PMCC, Critical Lighting.
Battery nominal voltage :110 V

Mounting : Wooden Rack

6.0 BATTERY CHARGER

Charger :Dual float cum boost charger

Type : Solid-state, full wave, fully controlled

with Micro-processor based AVR,
three-phasebridge, suitable for
continuous duty application.

7.0 VVVF DRIVES

Application : Variable / constant torque as

required by the driven equipment.
Nominal input voltage, volts : 690V
2
Nominal frequency, hertz : 50
Speed range : 10 to 100 percent
Minimum continuous speed : 10 percent
Overload capability : >150% for 1 min in 10 min interval

8.0 CABLES

HV Power Cable : Al., XLPE insulated, extruded PVC

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inner heath (for multicore cable),

strip/round wired armoured, Extruded
FRLS PVC outer sheath.

1 LV Power Cable : :Al/Cu conductor, XLPE insulated,

extruded PVC inner sheath (for multicore
cable), strip/round wired armoured,
Extruded FRLS PVC outer sheath.

Control cables :Stranded and non-compacted Cu

conductor,PVC insulated, , round
wiredarmoured,Extruded FRLS PVC
outer sheath.

9.0 CABLE TRAY

i) Type : Galvanized, pre fabricated cable tray

of 300, 450 & 600 mm

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