1 X 10 MW CAPTIVE POWER PLANT 

CONSULTANT
 
ARK ENGINEERING AND POWER CONSULTANTS (P) Ltd.,
NO.1, RAJA COLONY, COLLECTOR’S OFFICE ROAD,
TIRUCHIRAPALLI - 620 001 TAMILNADU
Tele-Fax: 0431-2401730
E-Mail: info@arkengg.com
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S.No. Description Page No.

1. INTRODUCTION 03

2. PROJECT INFORMATION 04

3. TECHNICAL SPECIFICATION FOR CABLES 06

4. GENERAL CONSTRUCTION 06

5. SPECIFICATION FOR HT XLPE CABLES 07

6. SPECIFICATION FOR LT POWER & CONTROL CABLES 08

7. TESTING 09

8. PACKING AND MARKING 10

 
 
 
 
 
 
 

M/s.BHAGWATI SPONGE PRIVATE LIMITED – 1 x 10 MW CAPTIVE POWER PLANT

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01.INTRODUCTION

BHAGWATI SPONGE PRIVATE LIMITED is an existing sponge iron plant situated at

Jamuria in West Bengal.

Sponge Iron production, by nature of the process has good potential for power
generation because of waste heat in the Kiln gas (Flue gas) and this source has
potential to generate approximately 2.2 MWe of power from each 100 TPD kiln.

BHAGWATI SPONGE PRIVATE LIMITED has decided to go for 10 MW CPP using the
Heat available from the 3 x 100 TPD kiln exhaust and 1 x 18 TPH AFBC Boiler.

ARK Engineering and Power consultants (P) Limited have been retained as the
Project engineering Consultants for the installation and commissioning of this
proposed Power Plant.

This specification covers the requirement of the HT, LT Power, LT control Cables.

M/s.BHAGWATI SPONGE PRIVATE LIMITED – 1 x 10 MW CAPTIVE POWER PLANT

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02.PROJECT INFORMATION

S.NO DESCRIPTION UNIT DETAILS

A CAPACITY DETAILS
1. Power plant capacity MW 10
2. Generation voltage KV 11
3. Voltage required KV 11
4. T.G. set
I. T.G. type Straight condensing
II. No. of T.G. Nos. 1
III. Type of condenser Air Cooled Condenser
5. Boiler
Type of Boiler Waste Heat AFBC
No. of Boilers Nos. 03 01
Fuel NA Indian Coal
Fuel Calorific value
Char 1400
Fuel 2 Kcal/Kg NA 4271
Fuel 3 3870
Fuel 4 3878
Main steam pressure ata 68
Main steam temperature °C 490
6. PROCESS STEAM (If applicable) Not Applicable

7. Availability of water WBIDC Clarified water available

Applicability of MODVAT/
8. Applicable
CENVAT
9. Soil bearing capacity As per the Soil test report

10. Type of soil As per the Soil test report

B GENERAL
1. Plant Location Ikrah, Jamuria
2. Nearest Railway Station Tapsi
3. Nearest Airport Kolkata
4. Nearest Harbor Kolkata
5. Access Road Black Turf & RCC
Vill & Mouza – Ikrah, P.O. Ikrah –
6. Plant Address 713362, Dist: Burdwan (West
Bengal)
25, Ganesh Chandra Avenue,
7. Office Address
Kolkata – 700013, West Bengal
8. Contacting Person at Office
a. Name Mr. Dinesh Adukia
M/s.BHAGWATI SPONGE PRIVATE LIMITED – 1 x 10 MW CAPTIVE POWER PLANT
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b. Designation Director
c. Mobile No
d. Land Line No.
e. FAX
f. E-Mail dineshadukia@aicsteel.in
9. Contacting Person at plant
a. Name Mr. R.K.Naidu
b. Designation General Manager
c. Mobile No 08798287199
d. Land Line No.
e. FAX
f. E-Mail bhagwatisponge@aicsteel.in
C METEROLOGICAL DETAILS
1. Ambient Temperature °C
a. Max day temperature °C 42
b. Min day temperature °C 37
c. Plant Design (Dry Bulb) °C 42
d. Plant Design (Wet Bulb) °C 37
e. Desing temp for electrical °C
50
(For Electrical Equipment) °C
2. Relative Humidity %
a. Maximum 37
b. Minimum 30
c. Design 60
3. Rainfall (Annual Average) As per available Meteorological
4. Altitude
5. Seismic Coefficient As per IS 1893-1894
6. Predominant Wind direction will be furnished later
7. Max Wind speed As per IS 875
  

M/s.BHAGWATI SPONGE PRIVATE LIMITED – 1 x 10 MW CAPTIVE POWER PLANT

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3. TECHNICAL SPECIFICATION FOR CABLES

CODES AND STANDARDS:

3.1. The design, manufacture and testing of Cables covered by this specification shall
comply with the latest issue of the following standards:

CODES DESCRIPTION
IS : 1554 PVC insulated (heavy duty) electric cables for working voltages up
:
(Part-I) to and including 1100V.
IS : 1753 : Aluminium conductors for insulated cables
IS : 3961 Recommended current ratings for cables PVC insulated and PVC
:
(Part-II) sheathed heavy duty cables
IS : 5831 : PVC insulation and sheath of electric cables
PVC insulated cable with copper conductor for voltages up to 1100
IS : 694 :
V
IS : 7098 Cross-linked Polyethylene insulated PVC sheathed cables for
:
(Part-I) Working Voltage up to and including 1100V
IS : 8130 : Conductors for insulated electric cables and flexible cords
IS : 10810 : Method of Test for Cables

SCOPE

3.2. This specification covers the requirement of HT Power, LT Power, control cables to
be used for the plant.

STANDARDS

3.3. The design, manufacture and performance of equipment covered by this

specification shall conform to the relevant Standards, as listed in this document.

4. GENERAL CONSTRUCTION

4.1. The cables shall be brand new and in good condition. These shall be suitable for
laying in trays, trenches, ducts, conduits and underground buried installation with
uncontrolled backfill and possibility of flooding by water. Rubber end caps for
each Cable size shall be supplied.

4.2. The volume resistivity of insulation material at 27ºC shall be 3.5 * 107 Ohm-cm
and at 85ºC shall be 3.5 * 10¹¹ Ohm-Cm.

M/s.BHAGWATI SPONGE PRIVATE LIMITED – 1 x 10 MW CAPTIVE POWER PLANT

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4.3. All cables shall have sequence marking for length. Cables shall also have
embossment at regular intervals for brand, voltage grade and size.

5. SPECIFICATION FOR HT XLPE CABLES

5.1. All cables shall be with metal coated annealed aluminium conductor, XLPE
insulated, screened, sheathed, armored type cables. Insulation of cables shall be
of 11 KV, Unearthed (UE) grade and 33 KV, earthed (E) grade

5.2. The construction of the conductors shall be stranded and compacted circular for
all cables.

5.3. The cables shall be provided with both conductor screening and insulation
screening. The conductors shall be provided with non-metallic extruded semi-
conducting shielding.

5.4. The core insulation shall be with cross-linked polyethylene unfilled insulating
compound. It shall be free from void and shall withstand all mechanical and
thermal stresses under steady state and transient operating conditions and
insulation shall be dry cured.

5.5. The insulation shielding shall consist of non-metallic extruded semi-conducting

compound in combination with a non-magnetic metallic screening of copper. The
insulation screen shall be strippable without application of heat. The copper
screen tape thickness shall be capable of carrying the single line to ground fault
current of 40 kA for duration of (0.5) second for 11/33 KV side, for three cores
together.

5.6. The conductor screen XLPE insulation and insulation screen shall all be extruded
in one operation by ‘Triple Extrusion’ process to ensure perfect bonding between
the layers. The core identification shall be colored strips or by printed numerals.

5.7. The inner sheath shall be applied over the laid up cores by extrusion and shall
conform to the requirement of Type ST2 compound as per IS / IEC standard. The
extruded inner sheath shall be of uniform thickness of size not less than 0.7 mm
for all sizes of cables.

M/s.BHAGWATI SPONGE PRIVATE LIMITED – 1 x 10 MW CAPTIVE POWER PLANT

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6. SPECIFICATION FOR LT POWER & CONTROL CABLES

6.1. All Power Cables for use on medium voltage systems shall be heavy duty type,
600/1100 V grade with metal coated annealed copper/Aluminium conductor (as
applicable) XLPE insulated, multi stranded, inner sheathed, armored type of
cable.

6.2. All Control Cables for use on medium voltage systems shall be heavy duty type,
600/1100 V grade with metal coated annealed copper conductor, XLPE insulated,
inner sheathed, multi stranded, armored type of cable.

6.3. The construction of the conductors shall be ‘stranded’ for all cables. Conductors
of nominal area less than 16 Sq.mm shall be circular only. Conductors of nominal
area 16 Sq.mm and above may be circular or shaped.

6.4. The core insulation for Control Cables shall be with XLPE compound applied over
the conductor by extrusion and shall confirm to the requirement of Type ‘A’
compound as per IS / IEC. Control cables having 5 cores and above shall be
identified with prominent and indelible ‘Arabic Numerals’ on the outer surface of
the insulation. Colour of the numbers shall be white with a spacing of maximum
500 mm between two consecutive numbers.

6.5. The core insulation for Power Cables shall be with cross-linked polyethylene
unfilled insulating compound. It shall be free from void and shall withstand all
mechanical and thermal stresses under steady state and transient operating
conditions.

6.6. The inner sheath shall be applied over the laid-up cores by extrusion and shall be
of PVC confirming to the requirement of Type ST1 PVC compound as per IS / IEC.
The extruded inner sheath shall be of uniform thickness of size not less than
those specified in IS / IEC.

6.7. For multi-core cables, the armoring shall be by single round galvanized steel
wires where the calculated diameter below armoring does not exceed 13 mm and
galvanized steel strips where this dimension is greater than 13 mm.

6.8. The outer sheath for the cables shall be applied by extrusion and shall be PVC
compound conforming to the requirement of type ST1 rodent and termite attack,
suitable chemicals shall be added into the PVC compound of the outer sheath.

M/s.BHAGWATI SPONGE PRIVATE LIMITED – 1 x 10 MW CAPTIVE POWER PLANT

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7. TESTING

7.1. The cables shall be tested and examined at the manufacturer's works. All the
materials employed in the manufacture of the cable shall be subjected, both
before and after manufacture of the cable, to examination, testing and approval
by PURCHASER / CONSULTANT. Manufacturer shall furnish all necessary
information concerning the supply to the PURCHASER.

7.2. After completion of manufacture of cables and prior to dispatch, cables shall be
subjected to type, routine, acceptance and special tests as detailed below. The
test reports for all cables shall be got approved from the PURCHASER /
CONSULTANT before dispatch of the cables.

7.3. All routine tests as listed in IS / IEC shall be carried, respectively for HRPVC
cables and XLPE cables including the following:

• Oxygen Index test

• Temperature index test

• Acid gas generation test

• Heat shock test

• Loss of mass test

• Thermal heat stability test

• Anti-termite test

• Anti-rodent test

7.4. The inner and outer sheath of XLPE cables shall be subjected to all the tests
applicable for PVC cables. The test requirement for insulation and sheath of PVC
cables shall be as per latest revision of IS / IEC.

7.5. The BIDDER shall produce type test certificates as and when demanded by the
PURCHASER / CONSULTANT. These tests shall also be conducted on mutually
agreed terms, if insisted by the PURCHASER / CONSULTANT.

7.6. Test Certificates shall be submitted for the PURCHASER / Consultant’s approval
before dispatch of the cables.

M/s.BHAGWATI SPONGE PRIVATE LIMITED – 1 x 10 MW CAPTIVE POWER PLANT

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8. PACKING AND MARKING

8.1. Cable shall be dispatched in wooden drum of suitable barrel diameter, securely
battened, with the take-off end fully protected against mechanical damage. The
wood used for construction of the drum shall be properly seasoned, sound and
free from defects. Wood preservatives shall be applied to the entire drum.

8.2. On the flange of the drum, necessary information such as manufacturer's name,
type size voltage grade of cable, length of cable in meters, drum No. cable code,
IS / IEC Certification mark, gross weight etc., shall be printed. An arrow shall be
printed on the drum with suitable instruction to show the direction of rotation of
the drum.

M/s.BHAGWATI SPONGE PRIVATE LIMITED – 1 x 10 MW CAPTIVE POWER PLANT