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FOR AUTHORISED USE ONLY

GOVERNMENT OF MAHARASHTRA WATER RESOURCES DEPARTMENT KAL HYDRO ELECTRIC PROJECT (1 X 15 MW)

BIDDING DOCUMENT NO. SEGEMC/KAL/E&M/1


FOR SUPPLY, ERECTION, TESTING AND COMMISSIONING OF TURBINE, GENERATOR AND ASSOCIATED EQUIPMENT . VOLUME-I COMMERCIAL TERMS AND CONDITIONS OF CONTRACT VOLUME-II TECHNICAL SPECIFICATIONS OF TURBINE, GENERATOR & ASSOCIATED EQUIPMENTS

VOLUME-II

OFFICE OF THE CHIEF ENGINEER (ELECTRICAL) HYDRO PROJECTS, HSBC BANK BUILDING, 4TH FLOOR, M.G.ROAD, FORT, MUMBAI-400 001. TEL. (022) 22670074, 22674867 FAX. (022) 22674996

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INDEX Sr.No. SECTION I SECTION - II SECTION III SECTION IV SECTION V Description INTENT OF SPECIFICATION GENERAL REQUIREMENT SCHEDULE OF REQUIREMENT MATERIAL OF MAJOR COMPONENT TECHNICAL SPECIFICATION OF TURBINE SECTION VI SECTION VII SECTION VIII SECTION IX TECHNICAL SPECIFICATION OF MAIN INLET VALVES TECHNICAL SPECIFICATIONS OF STATION AUXILIARIES TECHNICAL SPECIFICATIONS OF GENERATOR TECHNICAL SPECIFICATIONS OF SUPERVISORY CONTROL AND DATA ACQUISITION SYSTEM SECTION X TECHNICAL SPECIFICATION OF FOR LAVT CUBICLE, NG CUBICLE, BUSDUCT, AND ISOLATOR. SECTION XI SECTION XII PROTECTIVE GEAR DRAWINGS 325-331 332 312-324 292-311 209-291 184-208 163-183 Page No 3-14 15-60 61-76 77-82 83-162

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SECTION I INTENT OF SPECIFICATIONS

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SECTION I INTENT OF SPECIFICATION INDEX Sr.No. 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 Description Scope of work Hydraulic Data Rating Requirements Design Requirements Layout Constraints Design study/ calculation Model test of Turbine Data Sheets Drawings and Data to be submitted with Bid. ANNEXURES-1-1 List of Drawings and Data to be submitted with Bid. 13 Page No 5 6 7 7 9 10 12 12 12

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SECTION- I INTENT OF SPECIFICATION


1.1. SCOPE OF WORK:The scope of work comprise of the following: To undertake the complete engineering, design, manufacture, assembly, testing at manufacturers works before dispatch, proper packing, loading at works, transport, delivery to site, unloading at site and stacking, handling, loading at site store, transport at site of erection, onsite erection, testing and commissioning and trial run of following plant and equipment with spares, tools and tackles including composite insurance upto taking over. The brief details of the plant equipment are as below:

Mechanical Lot :One number of Vertical shaft single stage turbine of Francis type. Turbine shall be capable of developing Rated output of at least 15625 kW at 106m rated net head complete with governing equipment and all auxiliaries. One Number: Butterfly valve (2000 mm diameter approx) suitable for connection with spiral inlet of turbine. Valve shall be designed for a pressure of 175m of water column. Penstock pipes. Matching pipes between penstock and Butterfly valve, between Butterfly valve and spiral case of the turbine, between draft tube liner and tail race joint. Further lot shall comprise of stiffeners, supports and anchors for proper embedment. Lot: Common auxiliary station equipment consisting of cooling water system, the power station drainage water system and draft tube/tail race dewatering system.

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Lot: Turbine junction boxes, switches etc. complete. The above work shall be carried out on totality basis including the incidental services mentioned in this document. Further the said work shall be carried out in cooperation with the purchaser, and suppliers of other equipment in a business like manner with utmost speed so as to achieve overall economy and efficiency.

1.2.

HYDRAULIC DATA The hydraulic data and the other data regarding water conveyance system is as follows: A) LEVELS : a) Minimum Draw Down level b) Full Reservoir water level c) Maximum tail water level d) Minimum tail water level 140.50 m 170.00 m 35.00 m 32.00 m

B) OPERATION HEADS 1. Maximum net head 2. Minimum net head 3. Rated net head 4) Head variation 5) Design Discharge 117.00 m 84.00 m 106.00 m 79.24 to 110.37% 17.69 m3/s

The turbine shall be designed based on the hydraulic data mentioned above.

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1.3.

RATING REQUIREMENTS: 1) Output in turbine mode The Turbine shall be so designed that Rated output of at least 15.625MW is developed at the coupling with generating under the rated net head of 106 m The bidder shall furnish information about maximum continuous output at maximum net head of 117 m, at rated net head of 106 m and at the minimum net head of 84.0 m in Annexure-V-5 and data sheets of section V. 2) Turbine setting: The Purchaser has tentatively chosen that the turbine setting should be 0.63 m above the minimum tail water level. Further, the key dimensions / levels of the power house are tentatively fixed based on the dimension of turbine and generator. For example the levels such as the bottom of the draft tube, turbine level, service bay level etc. The bidder shall examine this aspect and give his recommendations about the precise requirements. The proposed setting shall be such that adequate allowance is provided rupture etc. 3) Moment of inertia (GD2) The moment of inertia shall be calculated and furnished. It shall be by considering the maximum momentary speed rise, and maximum momentary pressure rise under swing, shaft tube pressure pulsation, cavitationless performance, vibration and draft tube column

1.4

DESIGN REQUIREMENTS i) The whole of the plant including all auxiliaries shall be designed to give satisfactory service with designed availability for a period of 50 years.

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ii) iii) iv)

Number of tripping Number of turbine runaway condition Closing of Butterfly inlet valve

:Ten (10) nos. per year : One (1) no. in five years life on an average. : Every time the unit is stopped and brought to standstill position.

v)

The rotating parts of the unit shall be mechanically designed so as to allow the continuous operation and the stresses included in any part at maximum runway condition shall not exceed 67% of the yield point of the material of that part or 30% of the ultimate strength.

vi)

The pressure containing parts of the unit for example the Butterfly valve, the pipes and specials, the stay ring/spiral case assembly and the guide vanes, shall be designed from consideration of fatigue stresses induced due to cyclic changes in pressure conditions. The guide vane regulating mechanism shall be designed to have closing tendency and minimum of lost motion and friction.

vii)

The pulsation in power output in turbine operation shall not exceed 1.5% at full load output and 5% at partial loads of actual rated power output.

viii) ix)

The maximum momentary speed rise as per IEC-41 clause 2.3.4.14 shall not exceed 1.5 times the rated speed. Maximum momentary pressure under most unfavorable transient conditions accordingly to Clause 2.3.5.7 of IEC 4 1 shall not exceed permissible limit.

x)

Whole of plant and equipment including the control and protective equipment shall remain operative when maximum credible earthquake occurs at site. Further, the plant should trip and safely come to standstill when earthquake of large magnitude occurs.

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xi)

The plant and auxiliaries shall be designed to operate continuously for 12 months period without any offload maintenance and to achieve high start-up reliability.

xii)

The control scheme shall be so designed that in the event of a collapse of the state grid system KAL HEP is disconnected automatically.

xiii)

When unit is in operation, the noise level in the turbine pit liner 1 m away from shaft measured on any turbine floor shall not exceed 90 dB (A) .

xiv)

The generator and turbine bearing shall be so designed to allow the unit to be frequently and quickly started. Besides, the bearing shall be liberally designed such that full power output is available even if one of oil coolers of any bearing is blocked continuously. In addition, the volume of oil provided and circulating system shall be such that none of the bearing would suffer any damage during shutdown process in the event the unit is tripped due to stoppage of cooling water / oil supply.

1.5

LAYOUT CONSTRAINTS : The layout of power station is prepared with a view achieving over all economy. The major dimensions and floor levels and the space provided is given below i) ii) iii) iv) Width of the power station Overall length of power station Length of the service bay Vertical distance between service bay Level and the top of gantry rails. 11.6 m 15m 32m 10m

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v)

One no. of electrically operated overhead traveling crane of 75/15 T capacity will be provided in power house machine hall for handling the parts of the turbine and generator and other equipment such as Butterfly valve etc.

1.6

DESIGNS STUDIES/CALCULATIONS: The bidder and eventually the supplier shall have to undertake/conduct special studies and calculation in order to establish that the design requirements are achieved. The cost of such studies and calculations shall be deemed to be included in the price. The following studies and/or calculations are required to be completed.

A)

Studies prior to bid submission. 1) Study of hydraulic Transients. The study must be conducted considering worst operating conditions and the results thereof must be submitted in the form of graphs, tables etc. giving the values of maximum momentary pressure, maximum momentary speed, water levels in the approach channel and tail race. The bidder must establish that the draft tube column is not ruptured. The purchaser desires that the following conditions are studied by the bidder. i) Unit generating maximum power is tripped on mechanical fault. ii) Unit generating maximum power is tripped and then attempt is made to restart the unit in emergency. iii) Unit generating maximum power and generator circuit breaker is tripped due to electric fault. The bidder may consider any other condition which may induce/provoke more dangerous situation. In addition, the bidder should provide specific comments regarding settings of intake and outfall structures. 2) Studies regarding critical speed of the shaft system.

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B.

After award of Contract:The Successful bidder (Supplier) shall be required to undertake the following studies and / or calculations: 1. Optimisation of the turbine runner and the hydraulic passages. 2. Review studies and/or calculation mentioned above on the basis of data obtained on completion of detailed design and supply the result. 3. Conduct FEM study to determine the stresses induced and the pattern of concentration of stresses in major components of the unit such as turbine runner, guide vanes, head cover, generator stator frame and the bearing brackets. 4. Computations of forces on overhangs, generator lower bracket foundations, stator foundations etc. under most unfavorable conditions. 5. Dynamic analysis: Studies to determine the dynamic behavior of the unit rotating parts, bearing brackets and the forces which would be induced and transferred to civil foundations shall be undertaken by computer simulations. The studies should demonstrate the unit and the foundations are capable of withstanding without damage the abnormal conditions during trip outs and during runaway conditions. Dynamic analysis by computer simulation of the unit vibratory characteristics should be carried out to determine the amplitude and frequency of the hydraulically and mechanically excited vibrations originating within turbine, generator and entire water passage system. The frequency of these vibrations should be compared with each other and the natural frequency of related components to determine whether or not there would be resonance. The comparison should include critical speeds, major machinery components, draft tube pressure pulsations, frequency and magnitude of vortex shedding from runner, stay vanes and guide vanes, the unit dynamic imbalance, runner hydraulic imbalance earthquake etc. All these natural frequencies shall be checked

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for adequate margin against predominant frequencies to avoid resonance. Studies carried out in this regard shall be furnished. The supplier shall duly analyse all cases of possible interferences of different resonance frequencies and must ensure that abnormal vibration shall not occur when the unit operating at any load from 60% to 100% load turbine. Besides, such an operation shall not provoke power pulsations at generator terminals. 1.7 Model Test of Turbine:-The performance guarantees i.e. output and efficiency figures for turbine equipment being supplied under this contract shall be on the basis of report of turbine model test already carried out by the supplier for similar profile. The contractor shall submit the test report along with calculations to prove the efficiency and output of the turbine. If the calculation are agreeable to the purchaser the model test will not be insisted and the turbine on the basis of data furnish by the contractor will be accepted. If model test reports of similar profile is not available with the supplier then model test shall be carried out by supplier without extra cost to purchaser. In this case it is assumed that price of mechanical lot is inclusive of price of model test. 1.8 DATA SHEETS All data sheets appended to bidding documents must be completely filled in by the bidder. The bidder shall specifically note incomplete information or non supply of important information may result in rejection of his bid. 1.9 DRAWINGS AND DATA TO BE SUBMITTED WITH BID All drawings and data as per enclosed Annexure1.1 shall be submitted alongwith the bid. The drawing and data shall be sufficient enough to prove technical compatibility of the bid and shall not be limited to the list of Annexure 1.

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ANNEXURE 1-1
LIST OF DRAWING AND DATA TO BE SUBMITTED WITH BID I- DRAWINGS A) LAYOUT DRAWINGS 1. Plan and Cross section of Power house. The drawing must show size of power House required, the turbine Setting, the excavation level below the draft tube liner; turbine floor level and generator floor level, Butterfly Valve gallery level, the hook lift requirement above the service bay floor level and the required capacity of the power station crane, Drawing must indicate distance between Butterfly valve center and spiral case centre 2. Plan of the station at Butterfly Valve gallery level showing the equipment proposed and their .1: 100 PREFERRED SCALE

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location. 3. Plan of power station at turbine floor level 4. Plan of power station at generator floor level. 5. Plan of power station at operating Level. 6. Power station Control room Layout 7. Draft tube Hydraulic Design of the draft tube and Elevation & plan of the Draft tube showing the exact provision of steel liner 8. BAR CHART

.1:100

.1:100

.1:100

.1:100

.1:100

..1:20

The bidder shall furnish bar chart showing supply, erection testing and commissioning activities of major equipments of power plant. The overall schedule shall suite the completion period of 22 months.

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SECTION - II GENERAL REQUIREMENT

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SECTION - II GENERAL REQUIREMENT INDEX Clause No. 2.1. 2.2. 2.3. 2.4. 2.5. 2.6. 2.7. 2.8. 2.9. 2.10. 2.11. 2.12. 2.13. 2.14. 2.15. 2.16. 2.17. 2.18. 2.19 General Requirements Limits of contract Interchangeabiltiy Engineering data Drawings Supply of Oils, grease/lubricants and other consumables. Manufacturing schedule and the progress reports. Design improvements. Erection - Tools and Tackles and Spanners Foundations and fixtures Materials and workmanship. Electrical Equipment. Earthing. Units. Protective Guards Storage at site. Rating Plates, name plates and labels Tests Applicable standards 20 21 21 21 39 47 48 48 48 48 49 56 20 17 17 17 17 18 20 Description Page No.

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SECTION - II 2.1 GENERAL REQUIREMENTS: The general requirements explained hereafter should be applicable to the equipments to be supplied.

2.2

LIMITS OF CONTRACT: Equipments furnished shall be complete in every respect with all mountings, fittings, fixtures provided with such equipments and/or needed for erection, completion and safe operation of the equipments and are deemed to have been included. Further, these fittings, fixtures and accessories shall be of the best standards and proven for use.

2.3

INTERCHANGEABILITY: All parts shall be made to standard gauge in accordance with the normal practice for the class of equipment concerned. All corresponding parts of similar apparatus including spare parts shall be interchangeable.

2.4

ENGINEERING DATA: The furnishing of engineering data by bidder shall be in accordance with the provisions mentioned in the Technical specifications and the Data Sheets annexed thereto. The review of these data by the purchaser and his consultant will cover only general conformity of the data to the specifications and documents interfaces with the equipments provided under the specifications, external connections and of the dimensions which might affect plant layout. This review by the purchaser shall not be construed by the supplier, as limiting any of his responsibilities and liabilities for mistakes, omissions and deviations from the requirements, specified under these specifications documents. All engineering data submitted by the supplier after final design including review shall form part of the contract documents and the entire work covered under these specifications shall be performed in strict conformity.

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2.5

DRAWINGS:

2.5.1 DRAWINGS AND DATA TO BE SUBMITTED WITH BID Drawings and other data which is required to be submitted with the bid is stated in the Annexure 1-1 of section I of this Volume. These drawings shall include sufficient details to demonstrate fully that the apparatus furnished shall conform to the provision and intent of these specifications. Detail drawings or design data for the purpose of checking the adequacy of the suppliers design by calculations shall not ordinarily be required but the purchaser reserves the right to call for these in certain cases at his discretion. These drawing shall show sufficient overall dimensions, clearance etc. required for assembling and dismantling and furnishing the space requirements of all apparatus to enable the purchaser to determine the design and layout of the installation and to decide the compatibility of the bid.

2.5.2 DRAWINGS AND DATA TO BE SUBMITTED AFTER AWARD OF CONTRACT: A) Drawings for approval: The supplier shall furnish eight (8) copies of each of the drawings, the list of which is given in respective specifications, for approval of the purchaser. The methodology of submitting these drawings to the officers of purchaser and/or to consultant etc. shall be mutually agreed after award of contract. The purchaser as far as possible will review the drawings submitted by the supplier practicable within eight (8) weeks of their receipt. During the process the purchaser shall have the right to call for additional clarification or to suggest changes, which in the purchasers opinion, are required to conform the equipment to the provision of the specification. The drawings shall then be returned to the supplier along with comments and/or Signature of Bidder
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modified drawing. The supplier shall account for the comments and the suggested modifications and submit the revised drawings for approval. The delay arising out of revision of drawings by the supplier shall not cause any hold-ups related to site work or the manufacturing schedule and eventually the completion of contract. B) Revised drawings: When revised drawings are submitted for approval, the changes for the previous submissions shall be clearly identified on the drawings including changes affected by supplier on his own from previous experience. Revision number and the date and the brief description of the revision shall identify every revision made. The drawings shall be clear and legible in all respects. The revised drawings shall be again examined and if all the comments are accounted, the drawing shall be Approved and copy will be returned to supplier. Further work by the supplier shall be in strict accordance with such approved drawings and no deviation shall be permitted without the written approval of the purchaser. All manufacturing and fabrication works in connection with the equipment prior to the approval of the drawings shall be at the suppliers risk and cost. Approval of suppliers drawing or work by the purchaser shall not relieve the supplier of any of his responsibilities and liabilities under the contract.

C)

As Built Drawings: After the completion of the onsite erection work, the supplier shall furnish ten (10) sets (including one copy on tracing cloth or in velograph i.e. reproducible film) of the As Built drawings showing changes, if made, during erection, for reference and record of the purchaser.

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2.6

SUPPLY

OF

OIL,

GREASE/LUBRICANTS

AND

OTHER

CONSUMABLE: Sufficient quantity of oil, grease, lubricants and other consumable required to put the whole of the plant including auxiliaries into successful operation shall be supplied (i.e. deemed to be included in scope) without extra charges. The quality and the grade of the oil, grease and/or lubricants and other consumable to be used shall be from the locally available suppliers.

2.7

MANUFACTURING REPORTS:

SCHEDULE

AND

THE

PROGRESS

The supplier shall submit to the purchaser his confirmed manufacturing and delivery schedules for all equipments within thirty (30) days from the date of notification of award of contract. This schedule will not relieve the supplier of the delivery and work completion obligations as offered by him with the bid. The schedule shall be such as to meet the requirement of onsite construction. This schedule may be updated, if required, and the changes, if any, must be informed to the purchaser every quarter. The schedules shall also include the materials and equipments purchased from outside. Every quarter a report highlighting the delays, if any, and the actual progress achieved shall be submitted. For substantiating the progress report, video films and copies of the photographs (in duplicate) shall be supplied.

2.8

DESIGN IMPROVEMENTS: The purchaser or the supplier may propose changes in the specifications of the equipment or the quality thereof and if the parties agree upon any such changes, the specification shall be modified accordingly.

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2.9

ERECTION-TOOLS AND TACKLES AND SPANNERS: A complete outfit of erection tools and tackles, gauges, slings, other lifting devices, instruments and all other appliances required for the assembly, erection, dismantling and maintenance of the plant should be supplied. Spanners and wrenches shall fit the nuts and bolts used in the plant.

2.10

FOUNDATION AND FIXTURES: Foundations related to various equipments shall be prepared by the purchaser on the basis of design data furnished by the supplier in line with civil construction schedule. However, the supplier shall supply all fixtures necessary for proper erection of embedded parts. If requested by the purchaser, the supplier shall assist the purchaser in evolving special designs and criteria for civil foundation works of the pump-turbine and generator-motor unit. All supports, fixtures etc. needed for assembly, erection, testing and commissioning including that for field tests shall be prepared by supplier at his cost.

2.11

MATERIAL AND WORKMANSHIP:

2.11.1 GENERAL All parts shall be manufactured true to drawing dimensions. All tolerances shall be defined on the suppliers drawings for both manufacturing and installation purposes. Holes shall be drilled full size or under size and reamed during shop assembly. Punched holes will only be permitted in plates 20 mm or less in thickness provided all such holes are subsequently reamed full size during shop assembly. The materials used in the construction of the plant shall be new of high quality and selected particularly to meet the duties required of them. The material specification shall be indicated in suppliers detailed drawings. Signature of Bidder
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The use of materials liable to be attacked by termites or other insects shall not be allowed. All workmanship shall be of the highest quality throughout to ensure smooth running without vibration and noise under all possible operating conditions. The design, dimensions and materials of all parts, shall be so chosen that the stresses to which they may be subjected shall not render them liable to distortion or damage under the most severe conditions encountered in actual services. Materials and workmanship shall conform to the latest editions of the relevant standards.

2.11.2 PIPING: All pipes and fittings (adequate number to be approved by the purchaser), valves, drain plugs/cocks, test plugs, sight flow indicators, meters etc. shall be provided so as to allow the operation and maintenance of the system with ease. All piping shall be clean inside and where ending in open connections for other works, the piping shall have the ends capped for protection. Valves shall be easily accessible and gauges and other operating or indicating devices shall be located so that they can be conveniently operated or read from the floor walkways. Valves shall be suitable for the services intended. Either a blind end flange or a pipe shall be provided wherever necessary to protect valves. Where piping systems must be disconnected for servicing, flanges or unions shall be provided and the piping, valves and joints shall be arranged for minimum disturbance or interference with other parts during operation. As far as possible, the pipes shall not be embedded but shall run in trenches or shall be suitably supported by hangers, brackets, hooks, pedestals, or any other support suited to the requirements, care being taken to avoid vibration at the supports. An adequate allowance for the expansion of pipes under service conditions shall be made. Each drain Signature of Bidder
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pipe shall be laid with suitable slope to facilitate drainage. End pipe shall be suitably tagged or painted with anti-condensation paints where necessary. The material of piping for different services shall be stated in the bid. Flexible pipe connections to apparatus shall be provided wherever necessary. For ready identification of different piping systems and their functions, each piping system shall be painted in code colour (to be provided by the supplier and approved by the purchaser). All operating points and also each separate section shall be painted with two bands of approved code colours, the wide band twice the width of the narrow one. An arrow showing the direction of flow shall also be marked. All operating valves on a piping shall also be painted with the same code colour. Each valve shall have, fitted to it, a suitable name plate indicating the function of the valve.

2.11.3 FASTENINGS: Nuts, bolts, studs and washers for incorporation of plant shall conform to the requirements of the appropriate standards. Where the contract includes nuts and bolts of different standards, then the tools shall be provided in compliance with that specification and shall include spanners, taps and dies for these nuts and bolts. Nuts and bolts for pressure parts shall be of the best quality bright steel, machined on the shank. All washers shall be included under the contract, including locking devices and anti vibration arrangements. Taper washers shall be fitted, wherever necessary. Where there is a risk of corrosion, bolts and studs shall be finished flush with the surface of the nuts. Bolts except for high strength friction grip bolts shall be designed so that with the nuts fully tightened, the stress intensity at the bottom of the thread shall not exceed half the yield point of the material under all conditions. All bolts, nuts and screws, which shall be subjected to frequent adjustment on frequent Signature of Bidder
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removal in the course of operation, shall be made of corrosion resistant steel or bronze. Spring type washers will not be permitted where they may damage any protective castings. Special tools, wrenches and devices found to be necessary for the completion of the work should also be provided under this contract.

2.11.4 FORGING: All highly stressed forgings shall be subjected to examination internally for the detection of flaw and heat treatment for the relief of residual stresses. Particulars of the heat treatment proposed for all forging shall be submitted to the purchaser.

2.11.5 CASTINGS: The casting shall not contain damaging defects and shall be satisfactorily cleared before use. The surfaces that are not machine finished and which will be exposed after their final installation shall be such that grinding at the site will not be required before painting. The presence of defective material shall be determined and it shall be removed down to sound metal. The cast parts shall be homogeneous and free from excessive nonmetallic inclusion. An excessive concentration of impurities or a separation of the alloy elements in the critical points of a cast part shall be sufficient reason for its rejection. The casting of the main parts, including all those subject to hydraulic pressure and all castings which undergo a major repair, shall be tested using radiographic, ultrasonic, dye-penetration, magnetic particle or any other standard non-destructive test method. The expenses incurred on such tests shall be to the suppliers account. In case of bus duct only 10% radiography of enclosure shall be done. Signature of Bidder
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Minor defects or imperfections, which definitely do not affect the strength or utilisation of the cast parts, may be repaired by welding, according to the accepted practice for the repair of such parts. Thickness and other dimensions of the cast parts shall agree substantially with the dimensions shown on the drawing and shall not be reduced by shop or casting practices to such extent that the effective strength of the cast parts shall be less than the stresses allowed by these specifications. Use of cast iron for parts subjected to tension or impact shall not be permitted without the approval of the purchaser.

2.11.6 WELDING Supplier shall specify clearly on all relevant drawings, the amount and type of material for each type of weld, supplier shall also provide detailed drawings showing joint preparation required for each type of welding to be carried out on site and at suppliers works. The parts to be joined by electric welding shall be cut precisely to the correct size by methods suitable for the type of weld to be used and to allow proper penetration and good fusion on the weld with the base metal. The cut surface shall not have visible defects such as scales; superficial defects caused by shearing or torch cutting operation or any other damaging defects. The surfaces of the edge to be welded shall be free from rust, oil, grease and other foreign matter. All welds exposed to water flow shall be ground to a smooth and even surface flushed with the adjacent plate. Supplier shall indicate on the detailed drawings, the type, sizes and material of electrodes he proposes to use for shop and/or field welding. Unless otherwise stated, all non-destructive tests shall be carried out. All major welding and all welding carried out on tanks and vessels, which will contain liquid under pressure or compressed air shall be subjected to 100% radiographic examination. In those cases where it is Signature of Bidder
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impossible to carryout radiographic inspection, or otherwise stated in specifications, it may be replaced by ultrasonic examinations or any other non-destructive test systems.

2.11.7 SURFACE TREATMENT AND PAINTING: 1. GENERAL Where necessary the work shall be painted or treated with protective coating to protect them from corrosion and to neat and pleasing appearances. This work shall comprise the surface treatment, priming and application of paint or metallic coatings in the suppliers workshops and at the site including all paint repair work becoming possibly necessary. Every possible attempt shall be made that the design of the equipment is such that all surfaces can be finish coated or recoated after erection at the site. Unless otherwise specified, the coating and painting shall be carried out in accordance with the latest International Standard (Protective coatings for steel structures, directions) or another equivalent approved standard. All priming and painting material shall satisfactorily fulfil the requirements imposed by the site conditions (considering also possibility of extended periods of storage at site) as well as the stresses to which the respective equipment is subjected during operation of the works Shade of the finishing coatings shall be as per the standard colour tables at the choice of the purchaser. Each coat of primer and paintings shall be compatible with the previous and subsequent coats. All pigmented primers and paints, which will be used for priming and painting at the site shall be delivered in original and sealed containers packed by the supplier. The supplier shall supply full details regarding the extent by which sand blasting; priming will be carried out in his workshops (or his subsuppliers as the case may be), at the site and after erection.

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2. SURFACE PREPARATION: Before the application of primers and paints the surfaces of steel or ferrous equipment shall be properly cleaned up to the base metal in accordance with ISO 8501-1: 1988 or Swedish Standard SIS-SS05, 59.00. Wherever practicable scale, rust and dirt shall be removed by abrasive blast cleaning with quartz sand or corundum. The blast cleaned surfaces shall correspond to standard gauges and the average surface roughness after sand blasting shall not exceed 40 micrometers or minimum blast cleaning guide to BSA 2 1/2 (ISO 8501 1: 1988). All water passages; pump-turbines and inlet & outlet valves shall be prepared as follows. Sand blasting to a minimum surface cleanliness or finish corresponding to standard recommended grade. Sand shall be quartz sand, washed, clean and dry and be gypsum and salt free. The practical size shall be between 0.7 mm to 2.00 mm and the average peak to valley profile obtained shall be 40-60 micrometers. If grit blasting is used, it shall have good angularity of form with sharp cutting edges and be free from half rounds. It shall be chilled iron on hard steel grit with a particle size not greater than 0.9 mm. The maximum peak to valley height thus obtained shall not normally exceed 100 micrometers. It is accepted that there will generally be isolated rogue peaks where the amplitude is abnormal, but nowhere shall these be greater than 150 micrometers. Parts, which cannot be blast-cleaned, shall be cleaned free from rust and scale by power tool cleaning to the highest possible degree, according to the above standards. The surface preparation for non-ferrous materials shall be to the approval of the purchaser and or consultant and will generally be required to conform to the recommendation of the coating manufacturer.

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All working of the material (e.g. welding, drilling, grinding) shall be completed and surface defects (e.g. weld splatter, burns, cracks, surface laminations and pitting), likely to be detrimental to the protective coating shall be removed before surface preparation begins. As regards welding joints, these shall be covered with one coat of appropriate primer shortly after welding wherever possible. Otherwise they must be cleaned with a steel brush before applying the first primer coat.

3. PRIMER, FINISHER AND PAINT APPLICATION Before the application of the primer all sand blasted or otherwise mechanically created surfaces shall be subject to thorough cleaning process during which all dirt, dust, grease, moisture etc. is removed so that the primer is applied on suitable surfaces. Clean cloth and pure dissolvent shall be used for this process. The primer may be applied by airless spray gun, roller or by brush. All subsequent coats of paint shall be applied using airless spray equipment, unless otherwise recommended by the paint supplier or approved by the purchaser and or consultant. Where the use of airless spray equipment is found impracticable, the supplier must be prepared to use brush application at no additional cost to the purchaser, such application being to the approval of the paint supplier and the purchaser. The paint suppliers instructions shall be followed implicitly with respect to the method of application of the paints, the drying time between coats and the temperature of the material being painted, where ambient temperature, relative humidity or dew point will affect the drying or curing of paint, the manufacturers recommendations shall be followed. Signature of Bidder
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Unless specifically recommended otherwise by the paint supplier or approved by the purchaser, not less than 24 hours, not more than five days shall lapse between priming and successive coats of paint. Each coat shall be free from runs, drops, pin holes, waves, lops, sag and unnecessary brush marks. Particular care shall be taken to provide adequate paint film cover on corners and edges, nuts and bolt heads. Equipment contained in cubicles, cabinets or similar enclosures shall be painted as if it were exposed to view and the inside surface of the enclosures shall be painted semi-gloss white. In sheet metal enclosures where otherwise the surface would not be protected against corrosion (e.g. between the surfaces of spot welded joints and behind stiffening channels), such surfaces shall be coated before assembly with an approved spot welding primer after preparation of the surface in accordance with the paint suppliers instructions. All paint shall be delivered to the point of use in unopened containers bearing the manufacturers label which shall include, where appropriate for special systems, date of manufacture, batch number and instructions. All paint shall be supplied in the ready-mixed condition and except to comply with the suppliers direction, mixing of paint by the supplier shall not be permitted. Machinery paint may be thinned, if necessary to permit satisfactory application, but the amount of thinner shall be kept to a minimum. Special attention has to be given to the two-pack coating. followed. The

application of these materials is no problem if the specification is strictly For a perfect application the following important and generally valid conditions apply: The prime coating should be applied immediately after or at least on the day of blasting (exception only in air conditioned rooms). Signature of Bidder
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After the mechanical treatment but before the top coating is applied, the prime coating has to be cleaned (grease, oil and other impurities) with solvents and/or hot stream. Application temperature for two-pack epoxy-resin coating at least 5C Surface temperature minimum 5C above dew point. Maximum atmospheric humidity: not higher than 75% The proportion of mixture for two component products is to be strictly followed. Waiting times between coatings to be observed according to specification. For multilayer it is advisable to change the shade of colour (for later abrasion). Otherwise abrasions have to be checked by measuring film thickness. Edges have to be pre coated. Not to prime a strip of 150 mm beside the planned site welds (especially important for zinc rich primers.). Prior to the top coating, the prime coating has to be repaired carefully.

4. GALVANISING: All drilling, punching, tapping, cutting and bending of the parts shall be completed and all burrs removed prior to galvanising. Galvanising shall be applied by the hot dipped process and shall consist of the smooth clean zinc coating free from defects and of uniform thickness. Original blast furnace raw-zinc (minimum purity 98%) shall be used. The zinc coating shall weigh not less than 600 g/m of area covered. Sheardizing or other alternative process shall not be used without the approval of the purchaser and/or consultant. Material on which galvanising has been damaged shall be re-dipped unless, in the opinion of the purchaser, the damage is local and can be Signature of Bidder
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repaired by applying a coat of galvanising repair paint where such repair is authorised the damaged area shall be cleaned by wiping with clean rags saturated with mineral spirits or xylene followed by wire brushing. After wire brushing, the area shall be re-cleaned with solvent to remove residue and shall be given a minimum of two coats of zinc primer containing not less than 98% (by weight) of metallic zinc in the dry film, which shall have a total thickness of not less than 60 micrometers. Galvanised surfaces should be kept apart in storage and transport. If this is impossible, they should be treated by dipping in a 10 to 18% solution of chromic acid, which should produce a coating of 12 micrometers. This coating must be removed before any painting is attempted.

5. METAL SPRAYING: Subject to the approval of the purchaser where an item is of a size or shape to render hot-dip galvanising impracticable, zinc spraying or other approved method of coating may be adopted. Metal spraying of surfaces shall comply with the following procedure: Surface preparation prior to spraying shall be dry grit blasting to a standard approved by the purchaser and/or consultant. Immediately after grit blasting, the surface shall be cleaned of any traces of blast products on the surface and in pockets, pits and corners by brushing with clean brush, blowing with compressed air or vacuum cleaning. The surface shall be coated with the metal spray before discolouration occurs. In the event of the surface becoming contaminated e.g. with rust, oil or dirt between blast cleaning and applying the metal spray, it shall be re-cleaned by repeating the above procedures. Care shall be taken to have as little roughness as possible on the sprayed surface.

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6. NON METALLIC COATINGS: Coatings in this category include sprayed or sheet linings, as applied to tanks, vessels and pipes carrying aggressive fluids and wrappings as applied to buried or immersed pipe work. The materials employed may be rubber, PVC - sheet, glass reinforced resin or plastic. Surface preparation and application of the coating shall be strict in accordance with the approved instructions of the coating supplier.

WETTED SURFACES 7. CORROSIVE MATERIALS The material to be protected is usually under water and exposed to constant flow. Erosion through water with a more or less high sand content is one of the main strains for these parts. Therefore the coating has to be of high quality, epoxy resin is best suited. In order to endure chemical aggression of soiled water, the coating material is mixed with coal tar, which is also resistant against bacteria, fungi and algae. The coating system is set up as follows: Prime coating: One layer of two pack high zinc pigmented epoxy primer. This primer is an active corrosion protection, above all to avoid under rustings if the topcoat is damaged or porous. Film thickness: 60 micrometers. Top coating: Two packs modified epoxy coal tar. Depending on the application place or the suitability of the part, there will be distinguish between: Two layers of two pack modified epoxy coal tar containing solvents of 100-150 micrometers: colour : black or red. This material can be applied by brushing or by airless spraying or the normal use more than one coat is necessary. Total film thickness: 260360 micrometers. - Or one layer of two pack modified epoxy coal tar solvent free material of 300 micrometers: colour: black.

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The material can only be applied with a special machine. Standard application is one coat. Because of the lack of solvents in the painting material, there is no danger of pores. micrometers. REMARK: Condensation zones where the colour is not visible from outside may be coated with epoxy coal tar. Total film thickness: 360

8. NON-CORROSIVE MATERIALS Normally highly alloyed stainless steels, Ni:Cr. 4:13 (can be corrosive if soiled) and bronze e.g. red brass are not to be coated. It is important, however, that the contact areas stainless steel/normal steel are carefully protected by coating, also a stripe of the non-corrosive material, otherwise an amplified corrosion may occur (Contact corrosion). Machine with long rest periods (e.g. pumps) are exposed to increased localised corrosion similar to pitting (localised corrosion) usually on the base materials when the coating is porous and damaged. EXCEPTION: If a stainless steel part required a coating due to reasons such as photographing or decoration, a water and oil resistant synthetic resin primer should be applied. required by the purchaser. Such coating has to be especially

9. ZONES WETTED BY CONDENSATION: The main strain for zones wetted by condensation is the permanent rewetting, i.e. interchange: wetting - drying. The visible surfaces are less stressed. However, surface quality and appearance (shade of colour) require a high standard of material. Gloss and semi gloss finishes facilities cleaning. Due to practical reasons visible and invisible (dry) surfaces are not differentiated. materials. The same applies for visible surface of stainless

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The coating system is set up as follows: Prime coating: One layer of two-pack zinc rich epoxy primer to avoid under rusting if the topcoat is damaged or porous. Film thickness 60 micrometers. Intermediate Coating: One layer of two-pack micaceous iron oxide epoxy paint (two coats if exposed to condensation). The micaceous iron oxide in lamellar from embedded in the epoxy oxide is a perfect pore protection and has excellent adherence properties for the top coating. Film thickness: 60 micrometers, Top coating: One coat: Either polyurethane acrylpolyol micaceous iron oxide coat of 60 micrometers (recommended for outdoor coating providing a mat glossy surface). Or polyurethane top coating of 60 micrometers with a glossy surface, usually applied for indoor coatings. The polyurethane based topcoats have very good abrasion and mechanical resistance in addition to a proven corrosion protection and excellent colour retention. Total film thickness: 180-240 micrometers. REMARK: Parts covered with epoxy coal tar on the waterside should be coated with the same material on the condensation waterside if the shade of colour is not important.

10. OIL WETTED SURFACES: For Oil tanks, bearing casings, servomotors etc. a standard coat as a one pack synthetic resin primer is sufficient. This coat is oil and water resistant up to 150C. The first primer is applied before the tightness test and the second coat is applied after assembly. thickness: 80 micrometers, The total film

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11. COATING OF MACHINED SURFACES: Machined surfaces require a two-pack epoxy resin zinc chromate or zinc phosphate pigmented prime coat to improve adhesion to the base material. A standard top coating may then be applied, depending on the strain the parts are exposed to total film thickness: 120 - 160 micrometers. REMARK: Generally sand blasting after machining (if possible) is preferred because of the adhesion of the paint. Sand blast surfaces may then be coated in the normal manner.

12. BLANK SURFACES These surfaces are only to be protected for transportation and temporary storage with a soluble lacquer.

13. PIPEWORK WATER PIPES All such pipes, except those of corrosion resistant material shall be blast cleaned and be coated by dipping in acid free hot bituminous compound to give an acceptable finished coating thickness. Ends of pipes and tubes subject to weld joining at the site shall be left uncoated over a distance of approx. 100 mm. After site welding the erection welds shall be coated with 2 layers of zinc-rich primer containing not less than 95%(by weight) of metallic zinc in the dry film, which shall have a total thickness of not less than 60 micrometers. Finishing of the ends of pipes and tubes interior shall be by a layer of zinc rich chlorinated rubber paint. The exterior of small pipes shall be carefully cleaned and pickled and coated with 2 layers of zinc-rich chlorinated rubber paint. Exterior surfaces of pipes and tubes, except those of corrosion resistant materials shall be primed with three layers of red lead paint on Signature of Bidder
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chlorinated rubber/synthetic resin basis (total minimum thickness of the dry film: 100 micrometers). Un-insulated and unwrapped pipes and tubes shall receive two subsequent layers of finishing paint on the same basis (total minimum thickness of the dried finishing coats: 60 micrometers).

OIL PIPES Both the interior and exterior shall be thoroughly cleaned and pickled and rinsed very carefully to an approved method. The exterior surfaces shall subsequently receive two layers each of oil resistant priming and finishing varnish or enamel, A corrosion prevention compound shall protect the interior of fuel carrying pipes.

AIR PIPES Same treatment and painting as for the water carrying pipes. purchaser will decide on the finishing shades at a later date. The

AIR DUCTS External surfaces shall be coated with 2 layers each of priming and finishing paint.

14.

CUBICLES AND CABINETS FOR INDOOR INSTALLATION After careful sand blasting all cubicles and cabinets shall be given two priming and two finishing coats of varnish or enamel which in case of those carrying oil or liable to oil vapour exposition shall be oil resisting. A minimum dry film thickness shall be 100 micrometers in total. The insides of cubicles and cabinets where condensation is liable to occur shall be coated with four layers of an approved anti-condensation

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composition. Other inside surfaces shall be coated with at least two layers of varnish of semi glass white. External surfaces of cubicles and cabinets shall be given to suppliers standard primer and machinery enamel or appropriate enamel for cubicles being used indoors for electrical equipment. All cubicles being located in one row must be painted with the same shade.

FOR OUTDOOR INSTALLATION These cubicles and cabinets shall be given after careful sand blasting and hot dip galvanising coat inside and outside. After etching these should receive two layers each weather resisting varnish or enamel.

15. STEEL CONSTRUCTIONS INDOOR Same shall be thoroughly sand-blasted and provided with (two hours later) three layers of red lead primer on chlorinated rubber/synthetic resin basis (total minimum dry film thickness: 100 micrometers.) Finishing shall be by 2 respective coatings on the same basis (total minimum dry film thickness of finishers: 60 micrometers). Areas subject to oil and grease shall receive four layers of oil resistant priming and finishing (varnish or enamel). This shall apply in particular to all transformers. OUTDOOR After careful blast cleaning with an approved method and cleaning of the surface after this process, all steel structures shall be heavily hot dip galvanised.

16.

WORKSHOP EQUIPMENTS, PUMPS, COMPRESSORS ETC. Treatment as per the suppliers practice, and coating with the suppliers standard primer and machinery plant.

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17.

PLATFORMS,

HANDRAILS,

COVER

PLATES,

TRENCH

COVERS, ACCESS LADDERS ETC. All gratings shall be heavily hot-dip galvanised. chequered plates need no treatment and protection. Ferrous chequered plates shall be heavily hot dip galvanized. Handrails shall be heavily hot dip galvanized. These should after etching receive 2 layers of oil resisting varnish or enamel. 18. PARTS IN CONCRETE The surfaces shall be cleaned from mill scale, dirt, oil, grease and other residues and shall be covered before leaving suppliers premises with a substantial coating of Portland cement wash or other proprietary coating. For parts in concrete, it is important that the zone between visible surface and zone in concrete, a stripe of approx. 0.5 m of the concrete be coated, along the visible surface. Components under high pressure (penstocks or spiral cases) touching in concrete should be sealed additionally. Aluminium alloy

2.11.8 BALANCING For small rotating machinery all rotating parts and assemblies shall be well balanced both statically and dynamically at the suppliers works. The supplier shall rectify any out of balance that may occur during erection at site. Over dimensioned and heavy rotating machinery shall be statically and accurately balanced at the point of installation.

2.11.9

DOWELLING At all stages of assembly, where accuracy of fit has to be assured on-site, dowel holes shall be provided with dowels to assist reassembly and load resting if needed.

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2.12

ELECTRICAL EQUIPMENT

2.12.1

GENERAL The various auxiliaries and controls shall be suitable for operation on following power supply mains. i) ii) iii) 400V, 3 phase, 50 Hz A.C. 230V, single phase, 50 Hz A.C. 220 V D.C.

The above power supply will be available with : 10% for AC voltage and + 10% and -15% for DC voltage and + 3% and -5% frequency variations for AC supply . If any other voltage is needed, the supplier shall make his own arrangement with suitable power converters, transformers etc. to derive the required supply. The cost thereon is deemed to have been included in the bid. Electricity for construction work will be supplied free of charge by purchaser.

2.12.2

PUMPS AND MOTORS Unless otherwise specified, oil pumps shall be directly coupled to driving motors and their type, capacity and performances shall be best suited to the requirements. The efficiency of the pumps shall be as high as practicable consistent with good design. As far as possible, the pumps shall be of standard size to facilitate replacement of parts. The pump shall be of the self priming type, if however any external means of priming are employed these shall be stated in bid & shall be subject to the approval of the purchaser. Driving motors to which pumps are coupled shall confirm to the general standards laid down in this specification. Gear motors, if employed shall be subject to the purchasers approval.

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The alternating current (A.C) motors of rating 120kW shall be provided with direct on line starter at supply voltage of 400V and those of rating > 120kW shall be provided with star/delta starter. Rated power of motors shall be guaranteed at 85% rated voltage and 95% of rated frequency with closed air cooling according to IEC standard with interchangeable possibility. The pump capacities and the rating of the driving motors shall have liberal margin over the requirements. Motors shall be drip proof. All pumps shall be designed and constructed to ensure quiet and satisfactory operation without undue noise or vibration under all conditions of discharge and pressure. Centrifugal pump casings shall be designed to produce smooth flow with gradual changes in velocities. In addition, the pumps shall be easily removable and replaceable. Suitable gaskets shall be provided for all pipe joints to ensure that they are leak proof. If any strainers are required with the pumps, these shall be included in the bid and be duplex type or with by pass to enable periodic cleaning. All pumps shall be complete with the necessary piping, both on the suction and delivery sides and with all fittings suited to the size and duty of the pump. Adequate number of valves as stated earlier shall be furnished with each pumping unit to suit its operation and maintenance. Wherever necessary, pumps shall be provided with suitable flow meters or flow indicators and pressure gauges to measure the discharge and the pressure delivered by the pumps. Suitable eye bolts or lifting lugs shall be provided on each pumping set to facilitate handling.

2.12.3

ELECTRIC MOTORS AND MOTOR CONTROL GEAR All motors furnished by the supplier, for driving the unit auxiliaries and other apparatus shall be directly coupled to the

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apparatus driven and shall be suitable for operation on purchasers power supply. All motors to be supplied shall be energy efficient motors. The enclosure of each motor shall be of the type best suited to the service conditions of the motor and shall be subject to the approval of the purchaser in every case. The motor shall generally conform to the relevant Indian or IEC or other equivalent standards. The insulation shall be moisture, oil, oil vapour, drip proof and the motors shall be entirely suitable for the operation in the tropical climate conditions prevailing at site with 100% humidity (degree of protection IP 54 or as applicable). Motor shall be provided with varnish cambric or glass insulation class F and shall be used for connections from the windings to the terminals. All motor terminals shall be of stud type and totally enclosed. The capacity, speed and torque characteristics of the motors shall be suitable for the starting and operating requirements of the associated apparatus. starting, protective The supplier shall furnish necessary and control gear with each motor.

Instantaneous and thermal overload protection shall be provided for the motors together with remote indication of the operation of the protective gear, wherever necessary. In the case of essential motors stoppage of which would result in serious damage the thermal overload protection devices shall be arranged to give alarm only, without disconnecting the motors. Red and green indicating lamps shall be furnished for indication of the closed and open positions respectively of motor contacts. The control and indication equipment shall be suitable for operation with 220 V DC supply. Signature of Bidder
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Special type of motors, not adequately covered by the specification may be offered for any special application, but these shall be subject to the approval of the purchaser.

2.12.4

SMALL WIRING All small electrical wiring of various equipments, panels, etc. shall be completed at the suppliers work as far as possible. All small wiring shall be arranged neatly into flat or rectangular groups and shall be adequately supported with cleats etc. The small wiring shall be so arranged as to reduce the number of bends or crossing to a minimum. There shall be no splices in the wire and all connections shall be made at the terminal studs or terminal blocks. Similar circuit shall be arranged to terminate as far as possible on adjacent terminals to facilitate grouping and to minimise the number of interconnecting cables. Secondary or control wiring including leads from the current transformers, temperature detectors, alarm contacts, speed and pressure switches etc, shall be enclosed in conduits and shall be carried to dust and water proof and oil tight cabinets located conveniently for connection to the control cables. Pressure circuits shall be suitably protected so that failure of one circuit shall not cause the progressive failure of adjacent circuits. Alternating current circuits, direct current circuits, shall be grouped separately and the wiring of each of these groups shall preferably be segregated. For the purpose of easy identification, tracing and reconnection the wiring shall be colour coded according to relevant international or IS standards and shall be fitted near the terminals with ferrules or such other cap indelibly marked with the identification number corresponding with that of the associated terminal blocks. When an electrical circuit is extended to several

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pieces of equipment necessitating sectionalising of circuit wiring at the terminal blocks of the corresponding equipments common identification numbers shall be used for the designation of the circuit at all the terminal blocks and connections. The terminals and circuit designation for all wiring shall be subject to the approval of the purchaser. All small wiring shall be switchboard type, single conductor, tinned annealed copper wire, PVC insulated cables as per relevant Indian or International standards, insulated with varnished cambric, which has proved its utility in tropical region against hot damp and moist climatic conditions and wiring complying with the relevant international standards. All small wiring shall have oil and oil vapour proof insulation. The sizes of the wiring for different circuits shall be so chosen as to provide ample margin for the purposes intended and shall be subject to the approval of the purchaser.

2.12.5

TERMINAL BLOCKS Terminal blocks shall preferably be made of suitable moulded plastic material and shall be provided with brass stud inserts for terminating the outgoing end of the cubicle wiring and the corresponding wiring of the incoming end. Provision shall be made on each block for holding 15% extra connections. Easily removable shrouds, moulded from transparent dielectric material, shall shroud all blocks. The terminal block shall be of disconnecting type and suitable for max. 1000 V service and dielectric test of 2000V. Sufficient space for receiving the control cables inside the switchboard at the bottom of the switchboard cubicles and mounting arrangements for the terminal glands shall be provided.

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Terminal block compartment shall be separated from the remainder of the equipment by oil and oil vapour proof barriers and scale, wherever necessary.

2.12.6

MEASURING INSTRUMENTS All instruments and meters shall be suitable for operation under the climatic conditions prevailing at site. The instrument cases shall be dust proof, water tight, vermin proof and specially constructed to adequately protect the instruments against damages for deterioration due to high ambient temperature and humidity, special care being taken in the protection of instruments for indoor and outdoor services also. The dials, pointers etc., shall be designed to facilitate glare from instrument window and by providing clear, bold, dial markings. The size of dial and length of the scales of indicating instruments shall be subject to the approval of the purchaser in each case. The scale of the indicating instruments which are to be mounted on mosaic board shall cover approximately 3000 movement of the indicator size 48 x 48 mm. Supplier can follow his standard practice for other instruments. The scale plates of panel mounted indicating instruments shall have a permanent white matt finish with black graduation. The pointer or the pointer indicating and contact setting (in contact working instruments) shall be distinguished from the main pointer by a distinct colour and/or shapes. Instruments mounted on panels shall be of the semi-flush finish type and shall be back connected. All instruments on a switchboard or instrument panel shall be of matching pattern, shape and finish so as to present a pleasing appearance consistent with the functional requirements. The finish of the instrument case shall be subject to the approval of the purchaser. All instruments shall be designed for accurate measurements of the

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quantity or state under all conditions of operations and any error due to change in the ambient temperature, over the entire range of temperatures obtainable at site, shall be kept to a minimum. The instruments shall be provided with all the auxiliary appliances and any special tools required for their maintenance. MKS (meter-kilogram-seconds) units shall be used for marking the instrument dials. The range shall generally be such that the normal operating values are indicated in the middle third of the scale. All electrical instrument coils shall be designed for continuous operation on at least 120 percent of the full rated current and voltage of the instruments. The instrument coil rating shall be coordinated with those of the associated instrument transformers. The VA burden of instrument coils shall be as low as possible, consistent with the best modern design. Electrical indicating instruments shall comply generally with the requirements of the Indian/IEC or any other International Standards and shall be of the accuracy specified in relevant sections. Recording instruments shall be of the strip chart type with chart scales having a suitable width. The chart shall be gear driven by a self-starting synchronous motor wound spring device having ample torque even at reduced voltage and with at-least 8 hours spring reserve under all normal conditions of operation. The recording instruments shall be of withdrawal type for easy access to maintenance work. Sufficient number of chart rolls, recording ink for five years of operation and any special tools required for the maintenance of the instruments shall be furnished with each recorder. Integrating watt and VAR hour meters shall comply generally with the requirements of the international standards.

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Instruments provided with contacts shall have contacts suitable for 230V, A.C. or 220 V D.C. circuits. All instruments shall have as high accuracy as possible consistent with best modern design. The construction of instruments shall be mechanically sound and shall ensure permanence in the accuracy. The limits of error for different instruments shall be stated in the bid and their accuracy classification, where otherwise not specified, shall be subject to the approval of the purchaser. All instruments shall be tested in accordance with the requirements of the standard, wherever specified. In cases where no specific standards are mentioned, the supplier shall submit the list of the standards in accordance with which the instruments are proposed to be manufactured and tested and these shall be subject to the approval of the purchaser in every case. The instruments shall be capable of withstanding the following tests viz., effect of shock, effect of vibration, effect of humidity and dielectric tests of 2000 V to ground for one minute in accordance with relevant standards.

2.12.7

FLOW RELAYS Flow controllers, used throughout the works shall be equipped with adjustable contacts suitable for 220V D.C. System designed to change position on a decrease in flow below predetermined value.

2.12.8

LIMIT SWITCHES Any limit switch shall be entirely suitable for its specific application. Particular attention shall be paid to potentially harmful environmental conditions, including water, oil, dust, dirt, temperature variations and differential expansions, where switches operate through linkages. Precautions shall be taken to

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eliminate variations of setting and incorrect operations resulting from wear or tolerance. Operating voltage shall be 220V D.C.

2.12.9

CONSTRUCTIONAL REQUIREMENTS FOR CUBICLES AND PANEL BOARDS Switch boards, control, relay and metering panel shall be of robust, industrial type design and manufacture, formed of a steel frame and covered with smooth steel plate. The steel plate shall be sufficiently thick and properly stiffened to prevent distortion. If required, flush mounted hinged steel doors with latches shall be provided; doors shall be of the lockable type by means of approved key locks. The key lock shall be of the same type for all panels. All cubicles shall be fully enclosed and protected according to the protection class given in the specification. The lowest degree of protection shall be IP 44. The frames of the cubicles shall be designed to permit firm anchoring on the floor. The frames shall permit easy erection and allowance shall be made for extension of the cubicles by additional similar ones. Suppliers supply shall include all necessary mounting brackets, framing, foundation bolts and respective embedded metal to permit proper installation of the cubicles.

2.13

EARTHING The Supplier shall provide earthing terminals on all the equipments supplied under the contract and shall connect the earthing conductors to these terminals as approved or directed by the purchaser. The Supplier will provide the earthing conductors from the station earthing bus to the equipment. Supplier shall do equipment earthing. The Supplier shall provide suitable test terminals at convenient points

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of the equipments being supplied to enable periodic testing of the receptivity and insulation level of the equipments. Purchaser will provide earth mat and mild steel flats. Supplier shall provide suitable earthing terminals with bimetal clamps, washers, nut bolts, lug etc. suitable for both connections.

2.14

UNITS According to the latest edition of the relevant Indian and/or IEC publications shall be used for this contract. For the purpose of design/calculations, SI Units shall be used.

2.15

PROTECTIVE GUARDS Suitable guards shall be provided for protection of personnel on all exposed rotating and/or moving machine parts. All such guards with necessary spares and accessories shall be designed for easy installation and removal for maintenance purpose.

2.16

STORAGE AT SITE The supplier shall furnish complete instructions regarding the storage of the equipment at site. If at any time after the receipt of equipment at site, supplier or his representative desires to draw the attention of the purchaser to the conditions of storage, which in his opinion might affect the state of the equipment stored, he shall do so in writing to the purchaser. Periodical inspection of stored items shall be the responsibility of supplier.

2.17

RATING PLATES, NAME PLATES AND LABELS A rating plate of non-corrodible material metal sheets shall be attached to major and auxiliary item of equipment supplied. This plate shall be permanently engraved with the designed full load ratings, serial number,

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type, number, date of manufacture and other identification deemed necessary. Where necessary, diagram plates shall also be supplied. A name plate shall be provided to identify the service of major items of plant supplied. The purchaser shall approve the identifying description. Devices shall be identified by name plate on both front and rear of all desks, panels, cubicles etc. Names plates or labels shall be manufactured of stainless steel or aluminium alloy with engraving of contrasting colour or alternatively for indoor use of transparent plastic material with lettering engraved on the back and filled with enamel. These shall be in English language only.

2.18

TESTS In accordance with stipulations of General Conditions of Contract and Special Conditions of Contract the test shall be performed. Brief details of tests are as follows but shall not be limited to the same.

2.18.1

GENERAL Inspection and testing of the equipment shall include all inspections, tests, checks, procedures etc. Whether mechanical, hydraulic or electrical as required to ensure that the equipment supplied meets the requirements of the technical specifications. The tests include, but are not limited to the following. Chemical analysis of materials Destructive and non-destructive tests of materials Check and examination of welds Check of fits and assemblies Dimensional checks Inspection of paints and coatings (thickness and porosity) Hydrostatic pressure and tightness tests Balancing tests

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Shaft run-out tests Electrical tests Running tests (inclusive measurements of vibration and noise levels). Functional tests Performance tests Load and overload tests Load rejection and load taking-up tests Acceptance tests (prototype output and efficiency tests) Type tests if specially required

The technique, equipment and instrumentation to be used for these tests, checks, inspections, examinations etc. shall generally be in accordance with the relevant internationally accepted standards, rules or codes mentioned in except where specifically mentioned in the technical specification. If in the purchasers and/or consultants opinion instruments, apparatus, devices etc. used by the supplier (or sub supplier) need calibration or re-calibration then such instruments, apparatus, devices etc. shall be calibrated at the suppliers cost by an independent authority or institute subject to approval by the purchaser.

2.18.2

RANDOM SAMPLE TESTS These tests are to be carried out on random samples from a lot of equipment, parts or material. The purchaser and / or consultant shall do the choosing of samples to be tested, parts etc. and the complete lot of equipment be presented for this purpose. The number of samples taken will be either at the discretion of the purchaser and/or consultant, particularly for small lots, or shall conform to the generally accepted rules and standards of statistical testing. The whole lot, of which the samples have been

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taken, shall be considered satisfactory if none of the sample tested has failed. Should any one of the samples fail, even in any one test, the following shall apply. a) b) SMALL LOTS: All pieces shall be fully tested. LARGE LOTS: A second set of samples, identical in number to the first one, shall be chosen and tested. If the set passes all tests satisfactorily, the lot shall be considered to be accepted. If again one or more sample fails in the tests, either the whole lot shall be rejected of all pieces of the lot be fully tested individually. The decision as to which of the two alternatives shall be adopted shall be with the purchaser. Pieces of lots which have been declared non acceptable and samples which have failed in test must be marked immediately and must not be presented for test again.

2.18.3

TESTS AT SUPPLIERS WORK Before any material, equipment, aggregate, apparatus etc. is packed or dispatched from the supplier or sub-suppliers works, all tests, inspections, checks, examinations etc. required by the relevant and international accepted standards, rules or codes shall be carried out as far as practicable and agreed in the specifications. All equipment, materials, aggregates, apparatus and other parts of components of the works to be tested, inspected, checked, examined, etc. at the suppliers or sub-suppliers works shall be properly accessible for testing and inspection work. There shall be no interference or disturbance from other shop activities when conducting the tests and inspections. It shall be understood that all equipment materials, aggregates, apparatus and other parts or components will be adequately

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shielded and protected against weather whilst being tested, inspected, checked and examined. Parts and components shall be assembled to the fairest possible and agreed extent and dimensional checks shall be performed on all major assemblies, sub-assemblies, parts and components especially when close tolerance and fits are being involved (tolerance of shafts, clearance between stationery and moving parts, connecting dimensions for the assembly with other elements and supplies, combined functioning of electrical equipment etc.) Components and parts to be weld assembled at the site, shall be tag welded in the shops to permit visual and dimensional check of the fits and transmissions. All such components and parts shall be match marked properly to ensure correct assembly and welding at the site. If dimensional checks show discrepancies in measurements, which may affect the fit transition clearance, assembly or dismantling of the respective part or component, immediate, proper, and workman like correction or modification is a must. Such correction or modification shall, however, in no way lead to sacrifice with respect to reliability of operation or interchangeability and shall be performed only after the agreement of the purchaser and/or consultants has been obtained. If the correction or modification cannot be carried out in accordance with the terms mentioned above, the part or component concerned may be subject to rejection. Doubtful, used, weak and faulty materials or products will also become automatically liable for rejection. Shop testing shall also cover the hydrostatic pressure testing of equipment which can be finish assembled in the suppliers or his sub contractors premises.

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Pumps, fans, compressors and apparatus shall be tested at the manufacturers works. If two or more identical pumps, fans, compressors and apparatus etc. are supplied a complete performance test is to be carried out on the first unit only. Such performance test shall comprise the verification of the discharge capacity against discharge pressure, power input and efficiency and other performance data requested in the specification. The respective test diagrams shall be provided. prove doubtful or unsatisfactory. Evidence and diagrams of previous type tests undertaken on identical design of pumps, fans, compressors and apparatus may be acceptable instead of further complete performance tests, but the purchasers and or consultants approval must be sought in each case. A test at the duty point will, however, in any event be required. Particular requirements have also been set out in the specifications. As far as possible tests on pumps in the manufacturers works shall be carried out with suction conditions as those after installation at the site. Cubicles, cabinets and control boards shall, prior to their inspection and testing, be completely definitely assembled, equipped and wired internally in the suppliers or his sub contractors shops. Shop testing shall include functional tests as the case may be part or complete assemblies to the extent practicable and agreed. Such tests shall be performed under, as far as possible in operation like conditions. When requested by the purchaser the functional tests shall be repeated or extended until proof has been obtained that the Signature of Bidder
53

Subsequent units

need to be tested only if test results obtained from the first unit

Signature of Purchaser

functioning of the assemblies will comply with the requirements of the specification.

2.18.4

TESTS AT SITE During erection and installation work at site, the equipment shall be subject to tests which may include but not be limited to the testing, checking, inspection and examination of all equipment assembled/welded and set up at the site. The procedure may be confirmed up to final acceptance of the works. The supplier shall provide at his cost, all competent personnel (including those from sub-supplier) as well as all equipment, material and other services required for the proper and the complete testing and putting into commercial service of all equipment. If in the opinion of the Purchaser not sufficient competent personnel have been delegated, the Purchaser may request the Supplier to send additional appropriate competent personnel to the site. Further to the tests, checks, examinations etc, stipulated in technical specifications, the tests at the site shall comprise but not be limited to: Checks and examination of welds Hydrostatic pressure tests Tightness tests Dielectric tests Dry rotation tests (with clearance and run out checks) Functional checks (on protective devices, automatic and manual controls, monitoring, supervisory equipment etc.) Running tests Reliability tests Performance tests and determination of characteristic data and tests in particulars of the turbine and generator.

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Turbine acceptance tests (in accordance with IECPublication for field acceptance tests to determine the hydraulic performance of hydraulic turbines)

Regulator acceptance tests (in accordance with the IEC Publication 308, 1970, International Code for testing of speed governing systems for hydraulic turbine)

Stability tests of the unit when running in parallel with all such tests and checks shall be performed in the presence of the Purchaser and/or his Consultant. If not satisfied with the performance or outcome of the tests and checks he shall have the liberty to ask for additional tests or repetition of the same.

2.18.5

RELIABILITY TESTS After the supplier has notified the purchaser and received his agreement that the equipment is ready for commercial services, the generating units may be operated continuously at rated speed and maximum output for a maximum period compatible with site conditions. After successful completion of such tests, the unit shall be operated under the various conditions envisaged within the limits of maximum output either continuously or intermittently, including mode changing operation for a period of ninety (90) days with a view of obtaining useful information and to verify if the interest of specifications are met or otherwise. The purchasers staff will operate the equipment with the assistance and as per the advice of the suppliers staff during the reliability test period. The supplier may request any minor adjustments, which may be necessary provided that such adjustments do not in any way, interfere with or prevent the use of the equipment by the purchaser or result in reducing the output or decreasing the efficiency.

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If any failure or interruption occurs in any portion of the equipment covered by the contract due to, or arising from faulty design or materials, or workmanship (including construction at site) sufficient to prevent full use of the equipment, all the reliability tests shall be repeated after the supplier has remedied the cause of failure or interruption.

2.19

APPLICABLE STANDARDS Unless otherwise specifically stated, the applicable standards would be the latest revisions of the relevant IEC standards/codes or other standards, which are equivalent to IEC. In case the material and equipment is manufactured in India, relevant Indian Standard, if available shall be applicable. The supplier is requested to get himself acquainted with Indian Electricity Acts and Rules and follow those. Generally applicable standards are as under but not limited to: IEC standard for main pump turbine IEC 193(1963) International code for model acceptance tests of hydraulic turbines (code X) Amendment No.1 (1977) (code K) IEC 193A (1972) IEC 308(1970) IEC 497(1976) IEC 41(1991) First supplement (code P) International code for testing of speed governing system to hydraulic turbine (code X) International code for model acceptance tests of storage pumps (code X B) Field acceptance test to determine the hydraulic performance of hydraulic turbine storage pumps and pump-turbines.(code XK) IEC 545(1976) IEC 609(1978) Guide for commissioning, operation and maintenance of hydraulic turbines (Code S) Cavitations pitting & valuation in hydraulic turbines, storage pumps & pump turbines (Code P)

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IEC 994(1991)

Guide for field measurement of vibration and pulsation in hydraulic machines (turbine, storage pumps and pump-turbines) (Code XB)

IEC 995(1991)

Determination of prototype performance from model acceptance tests of hydraulic machines with consideration of scale effects. (Code V)

Note: IEC 198(1966) acceptance tests of pump turbines and IEC 609 (1978) Thermodynamic measurement are replaces to IEC 41 (1991) IEC standard for accessories of pump turbine.

IEC 298(1990)

A.C. metal enclosed switchgear and control gear for rated voltage above 1 KV and up to and including 52 kV (code XA) Amendment No.1 (1994) (Code K)

IEC 264

Packaging of winding wires 264.1, 264.2, 264.2.1, 264.2.2, 264.2.3, 264.3, 264.3.1, 264.3.2, 264.3.3, 264.3.4, 264.4, 264.4.1, 264.4.2.

IEC 502(1994)

Extruded solid dielectric insulated power cables for rated voltage from 1 kV up to 30 kV (code XA)

IEC 227

Polyvinyl chloride insulated cables of rated voltage up to and including 450/750 V, 227.1(1993) (code S), 227.2(1979)(code K), 227.3(1993) (code Q), 227.4(1992) (code H)-227.5(1979) (code P), Amendment No.1 (1987) (code B), Amendment No.2 (1994) (code D), 227-6(1985) (code L).

IEC 228(1978)

Conductors

of

insulated

cables

(code

M)

Amendment No. 1(1993) (code D) IEC 228 A (1992) First supplement, Guide to the dimensional limits of circular conductors (code E) Signature of Bidder
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IEC 287(1982)

Calculations of the continuous current rating of cables (100% load factor) (code XB) Amendment No. 1 (1988) (code G) Amendment No.2 (1991) Amendment No 3(1993) (code E) (code L)

IEC 287.1.2(1993) Part 1: Correct rating equations (100% load factor) and calculations of losses - Section 2 Sheath eddy current loss factor for two circuit in flat formation. (Code U) IEC 287.2-1(1994) Part IEC 947-2(1989) 2: Thermal resistance section 1: and calculation of thermal resistance.(Code V) Part 2: Circuit breaker (This publication Superseds IEC 157-1 (Code XB) Amendment No.1 (1992) (code U) Amendment No.2 (1993) (code S) IEC 947-4-1(1990) Part 4 contactors and motor starters Section 1 Electro mechanical contractors and motor - starter (code XD) (This publication supersets IEC 1581(1970) and its Amendment (1983) and 158-1c. IEC 269 Low voltage fuses Amendments No.1 (1994) (code B) 269-2(1986) Part 2 Supplementary requirements for fuses for use by authorized persons (fuses mainly for industrial application) (code G) 269.2.1. (1987) Part2 Supplementary requirements for fuses for use by authorised persons (code D) Amendment No. 1 (1993) (code F) Amendment No.2 (1994) (code B) 269-3 Part 3 Supplementary requirements for fuses for uses by unskilled persons (code L) 269-1 (1966) Part 1 General requirements (code XB)

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269-3.1

Part 3 Supplementary requirements for fuses for uses by unskilled persons (code XD) 269-4 (1986) Part - 4 Supplementary requirements for fuse links for protection of semiconductor devices (code U)

IEC 357 IEC 364 IEC 508 IEC 408 IEC 439

IEC 947 - 5 - 1 Electrical installation of buildings Methods for measuring the performance/electric ironing machines for semi conductor IEC 147 IEC 947 - 3 Low voltage switchgear and control gear assemblies. 439 - 1, 439-2, 439-3, 439-4.

IEC - 51

direct 51-9

acting

indicating

analogue

electrical

measuring instruments and their acessories.51-1 to IEC 145(1963) IEC 52(1988) IEC 255 IEC 72 IEC 404 VAr hour meters. (Code R) Class 0.5.1 and 2 alternating current watt hour meter (code w) Electrical relays 255 - 1.00 to 255-23. Dimensions and output series for rotating electrical machines 72 -1 to 72 -3. Magnetic materials 404-1, 404-2, 404-3, 404-4, 404-5, 404-6, 404-7, 404-8, 404 -8.1, 404-8.2, 404-8.3, 404-8.4, 404-8.5, 404-8.6, 404-8.7, 404.8.8, 404-8.9, 404-8.10, 4049, 404-10, 404-11, 404-12. IEC 34-9(1990) Part 9 Noise limit for rotating, electrical machines (code K) IEC 34 Signature of Bidder Rotating electrical machines
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34-1, 34-2A, 34-3, 34-4, 34-5, 34-6, 34-7, 34-8, 349, 34-10, 34-11, 34-11-2, 34-11-3, 34-12, 34-13, 14-14, 14-15, 34-16-1, 34-16-2, 34-17, 34-18-1, 3418-2, 34-183. IEC 76 Power transformers 76-1 (1993) - 76-2 (1993), 76-3 (1980), 76-3-1 (1987), 76-5 (1976). IEC 56(1987) High voltage alternating current circuit breakers (code XH) Amendments No.1 (1992) (Code M)831, 871

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SECTION - III

SCHEDULE OF REQUIREMENT A) MECHANICAL LOT B) ELECTRICAL LOT

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SECTION

III

SCHEDULE OF REQUIREMENT INDEX

Sr. No.

Description

Page No.

MECHANICAL LOT 3.1. 3.2 3.3 3.4 3.5. 3.4 Turbine Butterfly Valve Station Auxiliaries Spares. . ELECTRICAL LOT Generator and Static Excitation Equipment Spares. . 72 69 63 65 66 67

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SECTION-III SCHEDULE OF REQUIREMENTS A 3.1 MECHANICAL LOT TURBINE 1 No. Vertical shaft Francis turbine. Turbine shall consist of 1 No. 1 Set. 1 Set Intake pipe of suitable length between main inlet valve and spiral case. Expansion joint, air release valve and thrust collar complete. Penstock pipe piece between penstock and BFV of required length with stiffeners, installation material, pipes, valve etc. complete. Valve shall be suitable for operation from inlet valve floor. 1 Set Guide Vanes, greaseless bearings (self-lubricated type), regulating apparatus, servomotor double acting type etc. complete with locking device, oil pipelines, valves, pressure gauges, limit switches etc. One One One One One Stay ring and spiral case. Runner in one piece or divided in minimum parts Head cover and upper wicket gate ring in one piece or divided in minimum parts. Bottom ring, lower wicket gate ring and runner chamber in one piece or divided in minimum parts. Elbow type Draft tube liner. Draft tube steel liner shall extend up to the point where it is connected to tailrace. The liner shall be complete with drain valve, drain piping, manhole with door, pressure gauges, manometers, probes, anchors, turn buckles etc. One
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Shaft
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One

Shaft seal with cooling water system complete including pressure reducers, strainers, filters and plant to provide clean water.

One

Guide bearing with pads, oil coolers, Resistance temperature detector (R.T.D.s), Dial type thermometers (D.T.T.s) etc. with piping , valves etc.

One Lot

Pit liner provided with ribs, anchor hooks etc. Thermometers, thermal relays, all level gauges and relays, water pressure gauges and relays etc. Gauges, temperature indicators etc. for mounting on Gauge Panel.

1 Set

Oil leakage system if needed (requirement shall be justified at bidding stage) complete with tank, motor-pump sets, pipes, valves, level switches, gauges etc.

1 Set 1 Set Lot

Water level measuring devices. mechanical over speed device Control and Power Cables :Power cables for local control centres to equipments, local control centres to unit control boards and up to distribution centres provided by Purchaser, shall be provided by the Supplier. Power cables between two equipments which are in the scope of this contract shall be supplied by the Supplier. All control cables, racks, cleating, ferrule, glands etc. for entire system of equipment covered under the scope of supply of the supplier shall also be provided by the supplier. All cables shall be of FRLS copper conductor.

Lot Lot

Oil, grease, lubricants sufficient for first filling and 25% spare quantities. All accessories viz. sole plates, foundation and anchor bolts, platforms, ladders, guards, hand rail, bolts, nuts, turn buckles etc. complete including requirement during installation and of permanent nature.

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1 Set 1 Set 1 Set

Turbine junction box. Runner inspection & maintenance platform suitable for fixing in the draft tube. Necessary instrumentation, control, safety devices etc. along with the spares and special tools and plants required for erection, operation & maintenance including the following. Runner removal tools complete. Hydraulic jacks for pre-stressing of the shaft coupling bolts. Hydraulic jacks for pre-stressing of the head cover and bottom ring. Tools and Tackles required for handling of guide and thrust bearing. All tools for assembling and dismantling guide bearing, shaft seal, bottom ring, runner, guide vane, guide vane link, turbine shaft support collar etc. Test equipment required for hydraulic pressure test of spiral case and stay ring.

1 Set 1 Set

All test kits, instruments, meters etc. for commissioning, routine and special tests at site. Slings for handling the bearing, runner, shaft head cover, servomotor etc.

GOVERNOR 1 No. Turbine regulator of digital type.

3.2 1 No.

MAIN INLET VALVE (MIV) Butterfly valve about 2000 mm internal diameter provided with service and maintenance seals complete with oil hydraulic drive, main and stand-by pump-motor unit for

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servomotor closing/opening operations complete with air valve, by pass valve, draining system all accessories gauge, meter, indicators etc. complete. 1 Set Erection and maintenance tools for butterfly valve.

3.3

STATION AUXILIARIES

3.3.1 COMPRESSED AIR SYSTEM Compressed air system for generator mechanical brakes and general requirements comprising of adequate No. of power plant compressors, pressure receivers, pressure switches, pressure gauges, temperature detectors, pipe lines, valves, control panels etc shall be provided.

3.3.2 COOLING WATER SUPPLY SYSTEM Cooling water system required for of unit is tapped from penstock before butterfly valve and the water after circulation shall be discharge in to Tail race. Cooling water supply system shall include following * * * * Booster pump-motor units. Control Switchgear. Valves strainer duplex filters and piping with control devices, instruments etc. complete. The piping shall be complete from tap from penstock up to discharge point. 3.3.3 DRAINAGE SYSTEM & DEWATERING SYSTEM Comprising of adequate no. of submersible type, pump-motor units, complete with control, protection and switch gear panels, level control devices, piping, valves, check valves, clamps, supports, anchors etc. The piping shall be complete from pump room up to discharge point.

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3.4

SPARES A) 1 Set 1 Set 1 Set 1 Set 1 Set 1 set 1 Set 1piece 1 Set 1 Set 1 Set 1 Set 1 Set 1 Set 1 set Lot 1 Set TURBINE Guide Vanes. Guide vane stem bearing. Guide vane stem seal. Guide bearing segments. Piston rings for servomotor. Shear pins for guide vane mechanism Necessary spares for shaft seal Shaft seal water filter elements Removable protective bush of shaft Solenoid coils per solenoid used. Flow relay of each type used. Annunciator lamps of each type used. Mercury thermometer of each type used. Resistance thermometer of each type used. Limit switch of each type used. Friction elements for guide vanes Necessary recording charts for one year operation. Consumables such as all packing, gasket and jointing material used throughout the turbine assembly , including those for the servomotors and for man doors. 1 Set Ten per cent(10%) of all bolts, screws, nuts and washers used up to and including M30 size. B) 1 set 1 Set 1 Set 1 Set FOR GOVERNOR AND OIL PRESSURE SYSTEM Oil Pump complete with motor. Hydraulic amplifier . Pilot and control valve complete. Transducers. Equipment for changing turbine speed 1/4 Set

1 Set

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1 Set 1 set 1 Set 1 set 1 Set 1 Set 1 Set 1 Set 1 Set 1 Set 1 Set

Equipment for limiting the opening of Guide vanes. Oil pump for pumping leakage oil. Printed circuit boards used for speed and guide vanes limit setting. Safety relief valve Setting potentiometer of each type used. Float switches, pressure, flow and temperature relays of each type used. Solenoids for each type of solenoid valve used. Fuses of each type used. Each kind of filter used. Complete set of all packing, gasket and jointing material used. Ten percent(10%) of all bolts, screws, nuts and washers up to and including M 30.

C) 1 Set 1 Set 1 Set 1 Set 1 Sets 1 Set 1 Set 1 Set 1 Set 1 Set 1 Set

FOR BUTEERFLY VALVES. Service seal with all fixing. Maintenance seal with all fixing Servomotor piston rings and packings Instrument and indicator of each type used. Control solenoid of each type used. Flow relay and manostat of each type used. Limit switch of each type used. Valve of each type used. Necessary recording charts for one year operation. Complete set of all packing, gasket and jointing material used throughout the regulator equipment. Ten percent (10%) of all bolts, screws, nuts and washers up to and including M 30.

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D)

FOR STATION AUXILIARIES DRAINAGE AND DEWATERING EQUIPMENT Completely assembled submersible pump-motor set CONTROL AND SAFETY DEVICES i) Limit Switches ii)Level Switches iii)Float Switches iv)Pressure Switch v)Flow Relays COMPRESSED AIR SYSTEM i) Piston Rings ii)Unloader valves iii) Bolts iv) Gasket v) Oil filter elements vi)All types of valves 1 Set 1 Set 1 Set 1 Set 1 Set 1 Set 1 Set 1 Set 1 Set 1 Set 1 Set 1 No.

B 3.5

ELECTRICAL LOT GENERATOR AND STATIC EXCITATION EQUIPMENTS. Two Nos. Vertical shaft generator suitable for direct coupling with Vertical shaft Francis turbine. Generator shall comprise of: One No. One No. One No. Closed circuit ventilation system air-cooled type Stator assembly complete with frame, core and winding. Rotor assembly complete with spider rim, brake, jacks, field winding etc.

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One No. One No. One No. One No.

Shaft with coupling flanges and bolts etc. complete. Bottom bracket with lower guide bearing, complete with supporting structure oil reservoir etc. Top bracket with combined thrust and upper guide bearing complete with oil reservoir and supporting structure etc. Forced lubrication system for combined thrust and guide bearing with externally mounted oil coolers complete with all the oil and water piping with valves, flow relays.

One Set. One Set

High-pressure injection lubrication system for lubrication of thrust bearing during starting and stopping of the unit. Air coolers (Air/Water heat exchangers) with valves, connecting piping, flow meter, thermometers and other fittings for generator cooling.

One Set.

Sole plates, foundation bolts, dowels and other fittings required for proper erection, levelling and alignment of stator and bottom bracket and top bracket.

One Set. One Set.

Air guide cum air seal assembly. Brake and jack cylinders complete with all the necessary internal and external pipe work, valves, electrical remote switches with contacts and with brake dust collector.

One No.

Speed signal sensing device.Signal sensing device shall be complete with casing suitable to cover over speed device also.

One Set. One Set

Brush gear system with slip rings and brushes. Static excitation system complete with excitation transformer, thyristor cubicles, field flashing system, battery field flashing provision, field suppression cubicle with field breaker and discharge resistor, etc. complete.

One No. One Set.

Digital voltage regulator. All instruments and devices such as dial type thermometers, pressure gauges, resistance temperature

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detectors, thermostats, flow relays, oil level switches etc. complete shall be provided. One Set. One Set. Turbine, generator gauge panel containing temperature gauge both of turbine and generator. Temperature scanners to be mounted on unit control board for monitoring temperature of thrust and guide bearings, stator and field windings, cold and hot air temperature of generator cooling air with 3 sets of contracts. Each set consisting of two potential free normal/open contacts operating at two different levels of temperatures to be used for external annunciation scheme. The scanner shall be suitable to operate on the inputs from RTD (Resistance Temperature Detectors). One Lot Local control boards for equipment wherever necessary for control indication and alarm of the system shall be provided. One Set One Set One Lot Rotor lifting device if required. Complete erection tools required. Testing equipment comprising the following I) 5kV megger, mains operated. II) 10kV megger, mains operated. III) Lubricating oil filter (Centrifugal type) IV) 10kV, tan-delta measuring kit One lot One Set: One Set One Set One Set Mulsifire system Operation and maintenance tools Current transformers on Neutral side of generator. Current transformers in tap-off for excitation transformer. Shorting Links for dry out and short circuit test In =1000 A. One Set
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1No. 1No. 1No. 1No.

All special tools required for erection and maintenance.


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One Set One set One Set One set Lot Lot One Set One Set

12Nos. Single Phase Current transformers for Generator protection LAVT cubical with PTs, Lighting arrestor, Surge capacitor, isolator cubicle Generator neutral Neutral grounding cubicle with grounding transformer, resistor and voltage transformer. Connectors, support structure hardware etc. Fittings, accessories. Special tools required for erection and maintenance. Microprocessor based supervisory control and Data acquisition system

One Set

Microprocessor based protection relays ( Main and Backup)

SPARES

1. 1 Set 2 Nos. 1 Set 2 Nos. 1 Set 1 Set

GENERATOR Stator upper and lower bar with insulating material to form 1/3 stator winding. Rotor field coils complete with insulation Generator Guide bearing segment/pads Brake assembly with shoes. Brushes with Brush holders. Brake liner Generator air coolers Oil coolers for combined bearing. Dial type Thermometer Over speed device.

1 /2 set 1 Set 1 Set 1 No

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1 Set 1 Set 1 Set 1 Set 1 Set Set 1 No

Thermostat for air circuit and bearing etc. water flow relays for air coolers ,bearing etc. Gaskets for brake cylinders Gaskets . washers for air water coolers. Speed device equipment. Fans with driving electrical motors. Embedded detector for bearings.

2.

EXCITATION AND DIGITAL VOLTAGE REGULATOR EQUIPMENT Parts of magnetic contactor

1 Set 1 Set 1 Set 1 Set 1 Set 1 Set 1 Set 1 Set 1 Set 1 Set 1 Set 1 Set 1 Set 1 Set 1 Set 1 Set 1No 1 No

Contactor Operating coils Printed circuit board for DVR(modules). Uninterrupted Power supply in DVR Converting measuring and supervision units for slips stabilization Rotor angle limiter Rotor Current limiter Stator Current limiter Pulse Comparison units Digital Voltage Adjuster Digital potentiometer Feed back module Grid control unit Pulse Amplifier Pulse Supervision unit Voltage supervision unit Over current relay for excitation transformer Rotor earth fault relay

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1 No 3 Nos 1 No 1 No 1 Set 1 Set 1 Set 1 No 3Nos 2Nos 1 Set 1 Set 1 Set 1 Set 1No 1 No 1 No 3 Nos 1 No 1 No 1 Set 1 Set 1 Set 1 No 3Nos 2Nos 3 1 Lot 1 Set 1 Set 1 Set

Network filter Thyristor element and fuse Thyristor ridge Field breaker De-excitation discharge resistor ripping coil Closing Coil Field flashing rectifier Blocking diodes for field Ventilation fans Grid control unit Pulse Amplifier Pulse Supervision unit Voltage supervision unit Over current relay for excitation transformer Rotor earth fault relay Network filter Thyristor element and fuse Thyristor ridge Field breaker De-excitation discharge resistor Tripping coil Closing Coil Field flashing rectifier Blocking diodes for field Ventilation fans Copy of software Interfacing cable each type Report printing papers Spares of computer

Supervisory Control and Data Acquisition System

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1 Set 4. Protective Gear 1 Lot 1 No. 1 No. 1 No. 1 Set 5 Panels 1 Set 1 Set 1 Set 1 Set 1 Set 1 Set Five of Each kind. 1 Set 1 Set One of Each kind 10% of installed Quantity One pair Of each kind

Spares of printer Copy of software I/P module each type O/P Relay module Power supply module Connecting cables Indicating lamp each type used Push button/ selector switches Auxiliary relays Meters each type used Fuse carrier and base Fault, operation and symbol indicator assembly. Lens for symbols

Indicating LED & Lamp Fuse of each size used Transducer

Wrapping label and marketing strip

Plug-in type connection accessories

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LAVT AND NG CUBICLE 1 No. PT 11kv/ 110v/ 110v J3 J3 J3 Core-1, 100VA, CL. 0.2 Core-2, 200 VA, CL 3P. 1 No. 1 No. LA Surge capacitor

CURRENT TRANSFORMER ( CT) 1 Set 1 Set CTs single phase as used in Generator Protection Circuit CTs single phase as used in Generator neutral circuit

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SECTION - IV

MATERIAL OF MAJOR COMPONENT

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SECTION NO. IV MATERIAL OF MAJOR COMPONENT INDEX Sr. No. No. 1. Material of major component 79 Description Page

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SECTION - IV MATERIAL OF MAJOR COMPONENTS The description of materials and the tables attached to this section shall be deemed to form part of these specifications. The bidder shall note the requirements and shall state in his bid that the requirements are fully complied or otherwise. In any case, he must supply the information about the materials to be used in the construction of the plant and equipment in a tabular form.

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KAL Hydro Electric Project ( 1X15 MW) Material List of the turbine and its Auxiliary Equipment
No Name of parts Type of material Main material IS or equiv. Chemical composition of material C(%) P(%) S(%) Other elements contents Ultimate tensile strength Us Mpa 750 540 ~ 640 400 ~510 490~610 570~720 740 740 440 540 440 400~510 400~510 400~510 250 400~510 400~510 930 Yield strength Ys Mpa 550 275 215 295 420 540 540 205 345 205 215 215 215 / 215 215 785 Mechanical properties of the material and design stress Normal design stress (primary) Mpa 150 68.75 100 122.5 142.5 148 148 / / / 107.5 100 107.5 50 100 100 523.3 Normal safety factor 1/5 Us 1/4 Ys 1/4 Us 1/4 Us 1/4 Us 1/5 Us 1/5 Us / / / 1/2 Ys 1/4 Us 1/2 Ys 1/5 Us 1/4 Us 1/4 Us 2/3 Ys Abnormal design stress (primary) Mpa 366.6 183.3 143.3 196.6 280 360 360 / / / 143.3 143.3 143.3 / 143.3 143.3 / Elongation Zero tenacity (%) temp / / 27J 27J 47J / / / / / / 27J / / / / 78J 15 20 24 23 20 13 13 20 18 20 24 24 24 / 24 24 15 Hardness (HB) 285 152 / / / 217~277 217~277 201 163~229 201 / / / 241 / / 269~331

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16

Runner Turbine shaft Head cover Stay ring Spiral case Guide Vane Guide vane stem Wearing plate Stationary wearing ring Guide vane operating ring Bottom ring Draft tube liner Guide vane Servomotor piston Guide vane servomotor cylinder Turbine pit liner Connecting bolt between main shaft and runner/ Sealing plate for main shaft seal Inlet valve extension pipes Oil sump tank

casting forging plates plates plates casting casting Plates casting plates Plates Plates Plates casting Plates Plates Chromium molybdenum steel Plates Plates Plates

SCS6 SF540A SM400B SM490B SM570 SCS5 SCS5 SUS410 SCS1 SUS410 SS400 SM400B SS400 FC250 SS400 SS400 SCM435

0.06 0.60 0.22 0.20 0.18 0.06 0.06 0.15 0.15 0.15 / 0.22 / / / / 0.33~ 0.38 / 0.18 /

0..40 0.030 0.035 0.035 0.035 0.040 0.040 0.040 0.040 0.040 0.050 0.035 0.050 / 0.050 0.050 0.030

0.030 0.035 0.035 0.035 0.035 0.040 0.040 0.030 0.040 0.030 0.050 0.035 0.050 / 0.050 0.050 0.030

17 18 19

SS400 Stainless Steel overlay SM570 SS400

0.050 0.035 0.050

0.050 0.035 0.050

400~510 570~720 400~510

215 420 215

/ 142.5 107.5

/ 1/4 Us 1/2 Ys

/ 185.25 143.3

/ 47J /

24 20 24

/ / /

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No

Name of parts

Type of material

Main material IS or equiv.

Chemical composition of material C(%) P(%) S(%) Other elements contents Ultimate tensile strength Us Mpa 480~620 550~670 450 Yield strength Ys Mpa 265 410 225

Mechanical properties of the material and design stress Normal design stress (primary) Mpa 120 137.5 90 Normal safety factor 1/4 Us 1/4 Us 1/5 Us Abnormal design stress (primary) Mpa 176.6 273.3 150 Zero Elongation tenacity (%) temp / 27J / 21 18 19 Hardness (HB)

20 21 22

Pressure oil tank Air receiver Valve body for main distributing valve of governor Piston for main distributing valve of governor Butterfly valve body Butterfly valve rotor Butterfly valve extension pipes Butterfly valve shaft Governor pressure oil pipes Oil pressure system pipes

Plates Plates casting

SB480 SPV410 SC450

0.33 0.18 0.35

0.035 0.030 0.040

0.040 0.030 0.040

/ / /

23

forging

SF540A

0.60

0.030

0.035

540~690

295

196.6

2/3 Ys

20

152/

24 25 26

Plates Plates Plates

SM400B SM400B SM400B

0.22 0.22 0.22

0.035 0.035 0.035

0.035 0.035 0.035

400~510 400~510 400~510

215 215 215

100 100 100

1/4 Us 1/4 Us 1/4 Us

143.3 143.3 143.3

27J 27J 27J

24 24 24

/ / /

27

forging

SF490A stainless steel overlay STPG370

0.60

0..030

0.035

490~590

245

122.5

1/4 Us

163.3

22

134

28

Carbon steel pipe Carbon steel pipe

0.25

0.040

0.040

370

215

92.5

1/4 Us

143.3

30

29

STPG370

0.25

0.040

0.040

370

215

92.5

1/4 Us

143.3

30

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MATERIAL LIST OF THE GENERATOR AND ITS AUXILIARY EQUIPMENT


Chemical composition of materials C(%) P(%) S(%) Other elements contents Mechanical properties of the materials and design stress Normal design Normal Abnormal Zero stress(Primary) safety design tenacity factor stress temp. (Primary) Mpa 100.0 1/4 Us 143.3 68.8 100.0 142.5 175.0 147.5 135.0 1/4 Ys 1/4 Us 1/4 Us 1/4 Us 1/4 Us 1/4 Us 183.3 200.0 300.0 400.0 196.7 183.3 47J -

No.

Name of parts

Type of material

Main material IS or equiv

Ultimate tensile strength Us Mpa 400 ~ 510 540 ~ 640 400 570 ~ 720

Yield strength Ys Mpa 215 275 300 450 600 295 275

Elongation

Hardness

1 2 3 4 5 6 7

Stator Frame Stator Core Stator Coil Field Coil Main Shaft Pole Core Rotor Rim

Plates Silicon Steel Copper Copper forging plates Massive plates Laminate plates forging forging plates

SS400 C2552 C3 104 No.3-4 C3 104 No.2 SF540A PCYH300 SM570 PCYH600 SF590A SF540A SS400

0.60 0.18 0.60 0.60

0.050 0.030 0.035 0.030 0.030

0.050 0.035 0.035 0.035 0.035 -

(%) 24 20 21 20 13 18 20

(IIB) 152 167 152

700 590 ~ 690 540 ~ 640

8 9 10

11 12

13

14

Thrust Runner Thrust Block Basemetal Bearing Bearing metal Upper & Lower Bracket Miscella neous Cover Sole Plate

white metal plates WJ2 SS400 -

0.050 0.050

0.050 0.050

400 ~ 510 400 ~ 510

215 215

100.0 100.0

1/4 Us 1/4 Us

143.3 143.3

24 24

plates

SS400

0.050

0.050

400 ~ 510

215

107.5

1/2 Ys

143.3

24

plates

SS400

0.050

0.050

400 ~ 510

215

107.5

1/2 Ys

143.3

24

NOTE :

Com p osi ti on of ma ter ia l s ha ll b e a s pe r I S/ AS T M

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SECTION V

TECHNICAL SPECIFICATIONS OF TURBINE

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SECTION NO. V TECHNICAL SPECIFICATION OF TURBINE I N D EX CLAUSE NO. Description PAGE NO. 5.1. 5.2. 5.3. 5.4. 5.5 5.6 5.7 5.8 5.9 5.10 5.11 5.12 General Type and rating Guarantees vis-a-vis liquidated damages Field test and acceptance test Detailed Construction specifications of component turbine. Governing System Electrical Equipment Drawings and Manuals to be furnished after award of contract. Assembly and inspection at factory Test Certificate and inspection reports Tests on site Standards ANNEXURES Annexure V-1 to V-5 DATA SHEETS 131 148 127 127 129 129 112 123 126 85 85 86 89 90

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SECTION V

TECHNICAL SPECIFICATIONS OF TURBINE 5.1 GENERAL and associated auxiliaries. 5.1.2 The turbine and generator unit shall match in respect of speed, overpressure, over-speed and runaway speed, moment of inertia, outputs, coupling and other requirements. 5.1.3 For operational and design requirements, relevant provisions of section I shall be applicable. 5.1.1 This section covers technical specification and requirements of Turbine

5.2 2)

TYPE AND RATING: : 1 No. : Vertical shaft single stage Francis type turbine in a steel spiral case and suitable for direct coupling with the generator. Type

1) Number of units

3) The hydraulic data and the other data regarding water conveyance system is as follows:

B) LEVELS : a) Minimum Draw Down level b) Full Reservoir water level c) Maximum tail water level d) Minimum tail water level 140.50 m 170.00 m 35.00 m 32.00 m

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B) OPERATION HEADS 1. Maximum net head 2. Minimum net head 3. Rated net head 4) Head variation 5) Design Discharge 117.00 m 84.00 m 106.00 m 79.24 to 110.37% 17.69 m3/s

The turbine shall be designed based on the hydraulic data mentioned above. GUARANTEES VIS--VIS LIQUIDATED DAMAGES:GENERAL: The supplier shall guarantee that the turbine in its entirety, including all related equipment, material and structure furnished under this specification will be free from defects in design, material and workmanship. The Supplier shall warrant the successful operation of all such equipment. (i) EFFICIENCY GUARANTEE: - The weighted average efficiency of full size turbine under rated net head of 106 m at rated speed guaranteed as per formula given below. Eav=1/3 (E100+E75+E50) Where Eav = weighted average efficiency. E100, E75, E50 are the efficiencies respectively at 100%, 75%, 50% of rated turbine output. For Efficiency Guarantee, Bidder shall give values of efficiencies at 100%,75% and 50% of rated turbine output in data sheets and also in Annexure V-5 of this section. The above guarantee shall be based either on field tests or on model tests as per IEC test codes. If field test is opted, this shall be performed within 90 days of commissioning of turbine. For this purpose the provisions of inspection and field repair of the machine before the test would be Signature of Bidder
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5.3

shall be

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applicable. The penalty on account of shortfall in efficiency is given in Volume-I. (ii) OUTPUT GURANTEE: - The supplier shall give guarantee in respect of values of turbine output at rated net head of 106 m , maximum net head of 117m and minimum net head of 84.0m. The supplier shall also give guarantee for the maximum output (110%) from turbine. any short fall in output is given in Volume-I. (iii) CAVITATION GUARANTEE: - The turbine runner shall be guaranteed against excessive pitting due to cavitation for a period of 4000 Hrs of actual operation within a period of 24 months from the date of commissioning but before expire of warranty period. The supplier shall however, be entitled to make sure within six months after commissioning that cavitation damage is not caused or aggravated by local defects of turbine shape as well as to repair the damage that may have been caused and take steps to prevent future cavitation damage. Existence of excessive pitting is defined as the rate of metal removal from the runner due to cavitation more than the rate given by formula. W=0.1 D kg per 1000 hrs of operation. Where W = loss of weight of metal due to cavitations in kg. P = Runner discharge diameter in meter. The guarantee does not cover the removal of metal by erosion, corrosion, the presence of injurious foreign elements in the water, or the removal of metal by chipping and grinding preparatory to repairing the pitted area. The cavitations damage shall be evaluated by the sum of all separate masses. The mass for each part damage shall be calculated as half the product of its maximum depth, the area with a depth exceeding 0.5 mm and the density of the material. Penalty for

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Should the runner show excessive pitting within the guarantee period specified above, Supplier undertakes to repair the runner by welding, chipping and grinding. Cavititation damage is of spongy nature. The damage by erosion and corrosion is distinct from cavitation and can be identified by visual inspection. (iv) MAXIMUM MOMENTARY OVERSPEED: The supplier shall guarantee that the maximum momentary over speed under most unfavourable transient conditions according to IEC 41(1991), sub-clause 2.3.4.14 will not exceed 1.50 times the rated operating speed. (v) MAXIMUM STEADY STATE RUNAWAY SPEED: The Supplier shall guarantee that the maximum steady state runaway speed according to IEC 41(1991), sub-clause 2.3.4.15 will not exceed 1.70 times rated speed. (vi) MAXIMUM/MINIMUM MOMENTARY PRESSURE: The supplier shall guarantee that the maximum and the minimum momentary pressure under most unfavourable transient conditions according to IEC 41(1991), sub-clause 2.3.5.7 shall not exceed guaranteed values of data sheets. (vii) VIBRATION AMPLITUDE: The amplitude (zero to peak) of vibration according to Rathbone chart shall be less than 75 m (microns). Should for any reason the above limit exceed, the supplier shall take at his own cost, all steps to remedy the situation and to reduce the vibration to the above stated limits. Signature of Bidder
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(viii) NOISE LEVEL: When units are in operation at most unfavourable conditions in any mode, noise level measured in the turbine pit shall not exceed 90 dB(A). Further, the maximum noise level, on the turbine and generator floor levels at a point outside barrel shall not exceed 90 dB(A). (ix) RESONANCE: The supplier shall guarantee that turbine is capable of operating continuously and smoothly without hunting in the entire operating range. The supplier shall confirm that the turbine design is such that the power pulsation at generator terminal is within 1.5% at full load and 5% at partial load of actual rated output.

5.4

FIELD TESTS AND ACCEPTANCE TESTS Only the tests regarding vibration, noise, temperature-rise, stable operation, over speed and over pressure shall be conducted to verify the guaranteed performances. The performance guarantees i.e. output and efficiency figures for turbine equipment being supplied under this contract shall be on the basis of report of turbine model test already carried out by the supplier for similar profile. The Supplier shall submit the test reports along with calculations to prove the efficiency and output of the turbine. If the calculations are agreeable to the purchaser the model test will not be insisted and the turbine on the basis of data furnish by the contractor will be accepted. If the model test reports of similar profile is not available with the Supplier then model test shall be carried out by supplier without extra cost to Purchaser. To ascertain guaranteed performance values, the model test result form basis of acceptance. The guarantee at the discretion of Purchaser shall be subject to verification by field test. Charges for field test shall be shown

separately in price schedule. If the field tests are decided to be done for 89 Signature of Bidder Signature of Purchaser

final acceptance, for arriving at the liquidated damages for nonconformity with guaranteed values, field tests will prevail, if the results obtained during field tests differ from those guaranteed by the Supplier, he shall pay the liquidated damages as per the provisions stipulated in Volume-I. Irrespective of whether the field efficiency & output test is conducted or otherwise the supplier shall have to prove at site the guarantees of energy generated and water released during turbine mode in one-week operation cycle. The supplier will have to establish and prove the relation of; * Energy generated during operation cycle of one week. No bonus will be given to supplier in case of better results however Purchaser reserve the rights to reject the equipment in case of failure to meet the guaranteed values with variation limit specified in Annexure III-2 of Volume-I.

5.5

DETAILED

CONSTRUCTION

SPECIFICATIONS

OF

COMPONENTS OF TURBINE 5.5.1 STAY RING AND SPIRAL CASE ASSEMBLY i) CONSTRUCTION: Stay ring and spiral cases shall be of welded construction. High tensile, high strength steel plates confirming to material list attached with Section IV shall be used. Intake pipe of suitable length to connect Butterfly valve with spiral case shall also be of similar material. The assembly shall be designed to account for fatigue stresses induced due to increasing operational duties for example frequent starting, stopping, and abnormal conditions. Steel plate, which is used in the construction, shall be free from defects such as harmful seams, laminations, blisters, snakes and Signature of Bidder
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excessive scales and shall be tested for mechanical properties and physical composition. The assembly shall be manufactured at the factory into the minimum number of segments ( not more than two) within limitations suitable for transportation. Further, the method of construction shall be such that the critical welded joints, where the stress concentration occurs (Circular joints between stay ring and spiral case segments) shall be finished at factory and shall be stress relieved. Special precautions shall be taken by the supplier to prevent cracking in the spiral case plates adjacent to the stay ring bolting flange faces due to the discontinuity in the stay ring acting as a stress raiser. The stay ring shall be of Parallel plate design. The stay vanes shall be welded to the flat plates with full penetration welds. The stay ring shall be designed and shaped to direct the water flow with a minimum frictional loss and to eliminate vibrations. The trailing edges of stay vanes shall be shaped so as to minimise vortex formation. The surface of stay ring and the welded joints in contact with water shall be ground to a smooth finish. Holes not less than 100 mm and preferably 150 mm in diameter shall be provided in the lower stay ring to facilitate the placing of concrete. Suitable provision shall be made for closing the holes after the concrete is placed. Suitable grout holes with plugs shall be provided in the stay ring as required for concreting and grouting. Air vent holes shall be provided through the webs in isolated pockets. The stay ring shall be designed to withstand all forces acting upon it, hydraulic conditions during hydrostatic testing and operation of the turbine including the loads due to the generator Signature of Bidder
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and rotating turbine parts with the spiral case empty. The stay ring shall also be designed to withstand the forces transmitted to it from the spiral case under abnormal condition pressure. Under these conditions, the maximum stresses induced shall not exceed 67% of yield point stress of the material used. Welding of the stay ring shall be in accordance with requirements of these specifications. The weld shall be ground smooth to 3.2 micron (roughness). All other areas of the stay ring in contact with water shall be finished to roughness not exceeding 6.4 microns (roughness).The stay ring shall be stress relieved before machining. All butt welds and welds to spiral case plate shall be examined by 100% Radiography Test and stay vane to shroud welds shall be examined by Ultra sonic Test. All welds shall also be checked by Penetration Test or Magnetic particle test. Any defects discovered shall be repaired in accordance with relevant code. The stay ring shall be painted. All paint applied for protection of wetted surfaces during shipment shall be removed at site and surfaces shall be prepared and painted according to specifications. It shall be possible to perform site welding of spiral plates without pre-heating. Also, the quality of the steel shall be such that post weld heat treatment is not required. The circumferential joints shall be designed to give a strength equivalent to that of the longitudinal joints of corresponding sections. For convenience in transportation and erection at site, each divided segment of the assembly shall be provided with bases for installation and lifting hooks. Spiral case shall have a manhole of at least 600 mm. internal diameters, for access to facilitate inspection. The manhole shall Signature of Bidder
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be provided with door made of steel plate. It shall be fixed to spiral by means of bolts. The manhole cover shall also withstand maximum water pressure. Spiral case shall be provided with pipes for the following purposes (but not limited to) with necessary valves. _________________________________________________ Sr. I) ii) Description Drain pipe for the spiral case. Piping for the by pass valve of the Butterfly valve. iii) Stainless steel piezometer taps for the purpose of flow measurement during operation : iv) Any other piping & tapping required to make the equipment complete Lot 4 1 Quantity 1 Nos. _________________________________________________

The foundation items such as sole plates, packing, levelling jacks/screws, tie rods and turn buckles etc. in sufficient quantity shall be supplied along with spiral case. Expansion joint, thrust collar, air release valve and such other assemblies which are necessary shall be provided. ii) HYDRAULIC PRESSURE TEST ON SITE A hydraulic pressure test of the spiral case and stay ring assembly shall be conducted before concreting. The suitable test pressure (24Kg /cm) shall be gradually increased in steps. The final pressure shall be maintained for sufficiently long time (30 Signature of Bidder
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minutes) to allow inspection of field joints for leaks. repeated three (3) times.

The

pressure shall then be reduced. This pressure cycle shall be The rectification /repairs shall be carried to stop the leakage notified. After completion of repairs/rectifications, the assembly shall again be subject to pressure cycles. The hydraulic pressure tests shall be treated as successfully completed only if no leaks are notified and no visible damage to spiral case and stay ring is seen. The supplier shall provide one set of test equipment for performing the hydraulic pressure tests on stay ring, spiral case assembly. The test equipment shall include the following: * * * One test cone for the spiral case inlet. One test ring for the inner diameter of the stay ring with seals etc. One pump-motor set of adequate capacity and pressure flow and pressure gauges, dial gauges, isolating valves, relief valve etc., required to perform the pressure test and all pressure test equipment shall become property of the purchaser. The supplier shall provide the services of experienced personnel and all materials and tools necessary for taking measurements and conducting the pressure tests. Upon successful completion of hydraulic pressure test, the supplier shall submit the copies of the pressure test report, which should detail the following * * * Signature of Bidder The time of commencing the preparation of the test and completion of the major activities. Description of equipment. Test conditions.
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5.5.2 DISCHARGE RING The discharge ring shall be of plate steel welded construction and sectionalised as necessary to facilitate shipment and handling. It shall be of heavy section and adequately ribbed externally to secure proper anchorage to the concrete and to prevent distortion. The discharge ring shall have a flange at the top for bolting to the bottom ring or stay ring. The lower end shall have either a flange for bolted connection or an extension for welded connection to the draft tube cone. The necessary foundation bolts shall be supplied for anchoring the foundation ring to the concrete and adjusting jacks with steel bearing plates shall be furnished to facilitate levelling during installation. Suitable grout holes with plugs shall be provided in the discharge ring, as required, for concreting and grouting. The lower end of the discharge ring or alternatively the draft tube cone flange shall be machined to form a ledge for support of the runner during installation and also when disconnected from the generator. 5.5.3 GUIDE VANES AND REGULATING APPARATUS The number of guide vanes and the number of runner blades shall be coordinated in a manner to ensure that the turbine will operate without objectionable pressure pulsation and vibration. The guide vanes shall be of stainless steel casting having wear and corrosion resistance properties. The vanes shall be uniform in shape and their cross sections shall be such as to obtain a streamline flow of water with a minimum of friction and hydraulic disturbances during operation of the turbine. Each guide vane stem shall be provided with greaseless self lubricated bearings and a water seal. All bolts and nuts for the seals shall be of bronze or stainless steel. The system of bearings and water Signature of Bidder
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seals provided including the construction details should be fully described in the bid. The turbine guide bearing shall be designed so that guide vanes will not be lifted up by water pressure of leakage water from the lower portion. The guide vanes shall be accurately machined and ground so smooth that surface roughness shall not exceed 6.3 Ra. All vanes shall be interchangeable. The guide vane regulating apparatus shall be of ample strength to withstand the maximum forces imposed on it under most severe operating conditions. All parts having relative contact in motion shall be provided with self-lubricating greaseless bearings. of lost motion and friction. A suitable shear pin or breaking link shall be provided between each vane stem and the regulating ring and shall be strong enough to withstand the maximum operating forces, but which will break in the event of excessive forces acting in either the opening or closing direction and will protect the rest of the mechanism from damage in case one or more of the vanes become blocked. Locking device, oil pipelines, valves, pressure gauges, limit switches etc shall be provided. As a precaution against damage when a guide vane is free to rotate due to breakage of a shear pin or link, the vane shall be restrained from excessive movement by means of a friction device located on the vane stem, which provides a restraining force between the levers. The friction device shall be designed to resist independent movement of the vane for the maximum hydraulic torque at any guide vane position. The friction device mechanism on each vane shall be tested during installation to ensure performance as designed. A manually adjustable stop shall be incorporated, with which the motion of the guide vanes in the opening direction can be positively limited. Signature of Bidder
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The whole

mechanism shall be designed to have closing tendency and minimum

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5.5.4 SERVOMOTORS Turbine shall be provided with two (2) Nos. oil pressure operated double acting hydraulic servomotors. The combined capacity of the servomotors shall be sufficient to supply the maximum force necessary to operate and hold the guide vanes at any desired position at the minimum oil pressure. Further, the servomotors shall be rigidly supported and shall be capable of moving the guide vanes from a completely closed position to a fully open position in one stroke and vice versa. Cushioning shall be provided in the last ten percent (10%) of the stroke in each direction. The servomotor cylinders shall be provided with flanges for connecting oil piping. Connection for pressure gauges shall be provided at each end of each cylinder. An air vent and a drain cock shall be provided on each servomotor for draining purpose. The inner surface of the cylinder shall be bored accurately to a uniform diameter. The surface finish shall be such that roughness shall be within 1.6 micron. The piston fitting shall be such as to allow the piston to travel, freely and smoothly but to reduce oil leakage past the piston to an absolute minimum. Chevron type packing shall be used for this purpose. Each piston shall be fitted with not less than three piston rings, suitably shaped to give close contact and uniform pressure on the cylinder walls. The servomotor piston rod shall be provided with lubricated bearings. Lubrication shall be arranged to ensure that lubricant is admitted to high pressure areas regardless of vane position. This piston rod shall be arranged for adjustment of stroke. The connecting rod shall be of forged steel and of uniform cross section. A specially designed and a strong joint using accurately ground pin of hardened steel shall be provided between piston rod and connecting rod. The joint shall be provided with greaseless bearings of self-lubricating type. Signature of Bidder
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The servomotor cylinder shall be designed and so located that the force for moving the turbine guide vanes shall be divided approximately equally between the two cylinders and shall be applied in substantially equal magnitude to opposite sides of the vane regulating ring and tangentially to the ring. Provision shall be made for adequate field alignment of the servomotors using levelling or dutchmen (shim) plates supplied by manufacturer. The servomotor flange shall be dowelled in the field to its mounting flange. A manual locking device of a simple construction to permit locking the guide vanes in the fully open and closed positions and capable of withstanding safely the full operating force of the servomotors shall be provided at the servomotors. The device shall be such that it can be easily engaged and disengaged by one man. Besides, limit switches (with electrical contacts suitable for operating on 220 V D.C. system) shall be provided, to indicate the fully open and fully closed positions of the guide vanes and for using in the control circuit as interlocks for starting the unit. All contacts shall be wired up to terminal box placed in the turbine pit. By-pass connections, equipped with orifices and/or adjustable needle valves, with a secure means of locking the adjustment, shall be provided on the servomotors to retard connections shall be fitted with check valves to prevent sluggish movement during opening the guide vanes from the fully closed position. A suitable pointer and graduated scale shall be provided to indicate the stroke of the servomotor (i.e. % guide vane opening from the closed position) in steps of 5 %. The scales shall be calibrated in the field and marked closed at one end of the scale and opened at the other end. The servomotor stroke must be capable of manual adjustment. Means for positively locking the adjustment must be provided. Signature of Bidder
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Servomotor cylinders and all the oil piping and valves in the system shall be shop tested to a pressure equal to 150% of the design pressure of the oil system. 5.5.5 RUNNER The turbine runner shall be integrally cast in one piece. The material used shall be proven for erosion and corrosion resistant properties. The contours of the runner vanes shall be accurate and shall be hand finished so that the vane profile precisely conform to the model design within the tolerances set out in IEC publication 193, Chapter - IV. The runner vanes shall be evenly and symmetrically spaced. The surface of the runner in contact with water shall be ground to a smooth finish so as to achieve surface without any humps or hollows. The surface roughness shall be : Entire blade high pressure side surface and low pressure side surface except following3.2 Ra. Blade low pressure side surface and band inner surface beyond outlet width corresponding point .1.6 Ra. Entire crown inner surface and band inner surface except above 3.2Ra. The runner band, the crown and shaft coupling surfaces shall be accurately machined and ground. If required these records shall be made available to purchaser on request. To prevent seizure of runner during starting and stopping the vertical running clearance between the runner band and the discharge ring shall be zigzag. Provision shall be made to permit aeration of the draft tube through the runner crown. Runner and turbine shaft shall be connected by coupling. To facilitate replacement of runner in future and interchangeability, connecting parts shall be accurately finished and use of template and keys shall be Signature of Bidder
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provided. Connecting bolts shall be suitably covered to minimise resistance when rotating in water. The runner shall be designed to withstand safely the dynamic stresses at maximum runaway speed. The runner shall be designed to support its own weight and the height of the turbine shaft when disconnected from the generator shaft with the runner resting on a shoulder of the discharge ring or draft tube liner flange. The supplier shall provide complete arrangement of runner removal through the generator stator. 5.5.6 HEAD COVER AND BOTTOM RING HEAD COVER It shall be of a heavy construction, adequately ribbed and so shaped as to give rigid support to the guide bearing and the regulating ring. All welds shall be fully penetrated and stress relieved. Only the radial ribs, if used, may be fillet welded. The head cover shall be designed to withstand safely and without detrimental deflection the maximum water pressure and all other forces acting upon it. The deflection of the head cover shall be small enough to obviate the possibility of rubbing of the guide vanes and bending the vane stems. The underside of the head cover shall be designed to minimise friction and eddy losses between the head cover and the runner. The space between shall be adequately drained to relieve water pressure and to minimise hydraulic thrust. Head cover shall be in one piece or divided in minimum possible number of parts. Construction of head cover shall be such that the parts such as turbine bearing, shaft seal etc. shall be easily accessible for easy maintenance without requiring the head cover to be dismantled. The head cover and bottom ring shall be provided with replaceable stainless steel liners between them and runner. Signature of Bidder
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The head cover assembly shall be provided with machined sets for the turbine guide bearing, guide vane regulating ring, shaft seal, guide vane and any other equipment. The part of the head cover, which constitutes the guide bearing support structure, shall be so designed as to provide a rigid support. A retaining ring or pads shall be furnished to prevent any lifting tendency of the guide vane-regulating ring. The seat for the guide vane regulating ring shall be provided with a renewable stainless steel liner accurately machined so as to ensure minimum lost motion and friction in the operation of the guide vane regulating ring. At least four (4) Nos. opening for inspection shall be provided in the head cover to allow entry and check clearance of the runner crown seals. The opening shall be provided with doors which are bolted to the head cover. The lower surface of the head cover shall be machined to provide smooth surface to the water passage at the entrance to the runner. A renewable stainless steel seal ring or rings, accurately machined to form a master seal with the runner crown and shaped to reduce leakage, shall be secured to head cover. Any hydrostatic pressure built up behind the seal rings shall be relieved through built-in pressure relief holes. The seal rings (on head cover) may be of the same composition as the sealing face on the runner provided it is at least 50 B(Brinnell) lower in hardness. Leakage of water through the seal shall be directed to the draft tube without building pressure under the head cover. Renewable stainless steel facing plates shall be provided on the lower face of the head cover between the stay ring and runner seal. The surface finish of the facing plates shall be smooth. Signature of Bidder
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Supplier shall provide isolating valves, check valves and all necessary piping and fitting within the turbine pit for air, leakage water, air admission etc. A minimum of three (3) Nos. piezometer connections shall be provided on the head cover. These shall be connected to a common manifold and equipped with suitable valves and a pressure gauge. These connections shall be arranged so that fluctuations of water pressure under the head cover can be measured. The pressure gauges shall be mounted in the turbine pit. Walkways around the head cover and turbine bearing shall be provided with gratings or suitable opening to facilitate visual inspection of equipment located below the walkways. For welding purposes, the head cover shall be considered as a pressure vessel. All butt welds shall be examined by 100% UT or RT. All other welds shall be fully examined by PT or MT. Any weld defects shall be repaired in accordance with these specifications. An adequate number of eye bolts shall be supplied to lift the head cover. The head cover shall be designed to pass through the generator bore in the place during erection and dismantling and with the runner and shaft in place. The supplier shall furnish an air valve piping within the turbine pit, terminating in standard pipe flanges at the limits of the pit liner. All components of the automatic air valves shall be made of non-corrosive material. Balance pipe shall be provided with a valve having adjustable opening at suitable position between the head cover and upper draft tube liner. Efficient draining arrangement for leakage water from guide vane shall be provided and described by the supplier. Signature of Bidder
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Head cover shall be of such structure that leakage water from the turbine will not stay but can be drained. Two drain pumps one a.c. motor driven and other d.c. motor driven shall be provided to drain the water collected in the head cover. BOTTOM RING The bottom ring shall be as for as possible in one piece or sectionalised in minimum parts as necessary for handling, shipment and removal. If the ring is of welded design, all butt welds shall be fully penetrated and all welds shall be stress relieved before machining. The bottom ring shall be of heavy and rugged construction and all necessary anchors and adjusting screws shall be provided. Bronze bushings shall be provided for the lower stems of the guide vanes. The bushing shall be interference fitted and suitably locked in place. The bushings shall be self-lubricated. A renewable stainless steel seal ring or rings shall be supplied to limit the amount of leakage around the runner. The bottom ring shall be designed to be adequately bolted and dowelled to the stay ring and the discharge ring. Removable stainless steel plates shall be provided on the upper face of the bottom ring below the guide vanes, extending radially inward to the entrance of the runner. 5.5.7 DRAFT TUBE AND DRAFT TUBE LINER: Draft tube shall be of the elbow type. The draft tube liner shall comprise of the upper draft tube liner (UDTL) of conical shape, which is connected to the discharge ring by flanges and the lower draft tube liner (LDTL) of elbow shape and further extension of appropriate hydraulic shape finally becoming circular. The scope of supply and erection shall be upto the tail race. Draft tube shall be designed hydraulically such that the efficiency of the turbine is optimum. Signature of Bidder
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Draft tube liner shall extend upto hydraulic profile with exit velocity of less than 4m/s at maximum discharge. The UDTL shall be of stainless steel and machined accurately for connection to the discharge ring. It shall extend for sufficient distance below the centre line of the distributor to protect the concrete around the draft tube from scouring and pitting. A watertight and airtight manhole door, having a clear opening not less than 750 mm, complete with studs and nuts, shall be provided in the draft tube liner. A sufficient number of levelling screws, jacks, turn buckles and holddown bolts shall be provided to permit centring, levelling and securely holding the liner, both vertically and laterally, during assembly and while concrete is being placed. position. These holes shall be plugged and ground flush after the placement is complete. Also, suitably spaced grout holes shall be provided to facilitate final low pressure concrete. These grout holes shall be plugged and ground flush after grouting is completed. Upper draft tube liner (UDTL) shall be provided with following piping and necessary valves: * * * * * * * Test cock for water level detection. Piping for mounting the balance pipe. Drain pipe for leakage water from guide vanes. Piping for water level detector. Piping for measuring the water pressure in the draft tube. A compound pressure gauge for measuring pressure in draft tube. Anchors, stiffeners, turn buckles, etc. Sufficiently large holes shall be provided in the draft tube liner for placing of concrete, in difficult

Drain pipe with water valves shall be provided for draft tube at the lowest point. The drainage pipe shall be taken up to dewatering sump. The drain valves shall be gate type and shall be provided with Signature of Bidder
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sufficiently long stem and on hand wheel suitable for operation from the valve floor. The supplier shall provide a strong aluminium platform to be located in the upper draft tube liner (UDTL) for access to the runner. Provision shall be made in the liner for the support of this platform. The platform shall be so constructed that the same can be installed and removed from manhole. Steel lined outlet of draft tube shall be connected to the tailrace. Steel for this pipe shall be same as that of draft tube and suitable to withstand maximum pressure during transient and steady state conditions. All fixtures, stiffeners, anchors, supports, rail line for erection etc. shall be provided for them. 5.5.8 TURBINE SHAFT: It shall be provided with integrally forged coupling flanges for connecting to the generator shaft and to the runner. It shall be of ample size to operate at any speed up to the maximum runaway speed without detrimental vibration or distortion and to transmit the maximum output. The maximum stress induced under such abnormal condition shall not exceed 67% of the yield point stress. Besides, the shaft shall be designed to withstand safely the shocks and abnormal stress induced under conditions of line to line short circuit, faulty synchronising and turbine trip-outs without harmful vibrations or distortions. The shaft system shall be designed so that the first critical speed shall be at least 1.25 times the maximum steady state runaway speed, which may occur under most unfavourable transient conditions of turbine. The shaft shall be accurately machined all over and polished smooth in the portions where guide bearing and the shaft seal sleeve are fitted such that surface finish is within 0.4 microns.

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The shaft shall be bored axially to a diameter of atleast 150mm throughout its entire length to facilitate baroscopic inspection of the shaft material. The sleeve shall be made in two halves removable and renewable and securely fastened to the shaft. After assembly on the shaft, the sleeve shall be accurately machined and polished. The sleeve shall be made of non-nickel bearing stainless steel. Effective means shall be adopted for the prevention of corrosion of the shaft underneath the sleeve. Suitable oil baffles and water detectors shall be provided between the main guide bearing and the shaft seal. The amount of shaft run out shall be checked by rotating the finished turbine shaft in a lathe or lining device in factory. The amount of runout shall not exceed the recommended values in NEMA standard No. MG5.1.-3.04 (R 1979) for vertical hydraulic turbine generator shaft run out tolerances. Two bands shall be marked on the shaft for reference during alignment. The bands shall be concentric with the shaft and polished to a finish of 0.4 micron (roughness). The turbine - generator shaft coupling shall be designed in accordance with ANSI B 49.1 The lower shaft coupling to the runner shall be dimensioned so far as is practicable in accordance with ANSI Standards. Immediately above the bearing housing a circumferential line shall be inscribed on the shaft and an adjustable pointer shall be mounted on the bearing housing opposite this line to indicate if any axial movement of the shaft occurs, and to permit re-alignment after thrust bearing dismantling. The turbine supplier shall be responsible for the final reaming of the coupling bolt holes, aligning of the turbine and generator shaft and conducting the combined run-out to NEMA Standard No. MG-5.1-3.04 (R 1979). The field alignment procedure for shaft and bearings shall be approved by the Purchaser prior to the start of assembly. Under the conditions of Signature of Bidder
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rotational test, the run outs at the turbine bearing shall not exceed 0.10 microns per meter length of shaft between the generator top guide bearing and the turbine guide bearing. Hydraulic jack for pre-stressing of shaft couplings bolts, head cover & bottom ring shall be provided. 5.5.9. SHAFT SEAL The axial movement type shaft seal shall be provided below the guide bearing to prevent the leakage of water along the shaft. The sealing shall be achieved by rings of tough fibre and metal carbon one rotating with the shaft and other stationary. The seal components shall be hydraulically designed to suit the worst operating conditions. The loading of the seal faces may be regulated by springs. Any wear, which may take place, shall be restricted to seal components and not the shaft. All seal components including seal faces may be manufactured in suitable number of parts to facilitate, both initial assembly and maintenance. The rings shall be of self-compensating type and shall automatically adjust for wear during its full operational life. The wearing of the seal shall be minimum with a guaranteed life of at least 20,000 operating hours. A wear indicator shall be provided to monitor the wearing rate. The shaft seal shall be so designed as to prevent the high pressure water flowing out during turbine operation. A secondary maintenance-sealing device shall be provided to allow the carbon seal rings to be serviced. This secondary maintenance-sealing device shall prevent leakages along the shaft when the turbine is stationery and subject to tail water pressure and shall be compressed air operated. Suitable means, such as lifting bolts and backing out studs, shall be provided to facilitate installation and removal of shaft seal parts. Signature of Bidder
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The shaft seal shall be arranged for water lubrications. Two or more connections for water shall be provided. These shall be evenly spaced on the periphery to admit supply of clean water at a sufficiently high pressure to remove dirt and foreign matter from the seal. The supplier shall be responsible and shall provide the necessary equipment to maintain the quality and quantity of sealing water requirements. The supplier shall provide the necessary water filtration equipment, piping and valves, including pressure-reducing valves, if required. The piping and fittings within the turbine pit terminated by unions or flanges shall be continued outside the turbine pit. Piping shall be provided with a sufficient number of unions to permit easy removal. All bolts, nuts, screws and hardware used in connection with the shaft water seal shall be of bronze or stainless steel. The shaft seal housing shall be made of wear resistant material of high durability and shall be sufficiently rigid. 5.5.10 GUIDE BEARING (SEGMENT TYPE) The turbine guide bearing shall be segment type and shall be selflubricating i.e. lubrication shall be automatically achieved by means of centrifugal action of the rotating shaft. The use of any external electrical pump for circulation of oil shall not be made. The bearing design shall be such that no water shall enter the lubricating system via the shaft seal and there shall be no appreciable loss of oil by leakage or by overflow from any part of the oil system under any condition of operation including starting, stopping and over speeding during trip outs. Further the bearing shall be designed to operate satisfactory (i.e. without any damage) under following conditions: i) Continuous operation at any speed between 30% and 110% of rated speed at no load and maximum load. Signature of Bidder
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ii) iii)

For 15 minutes at maximum runaway speed. For 15 minutes, upon sudden rejection of maximum power and in continuation thereafter till the unit comes to standstill as a result of tripping and interruption of cooling water supply.

The bearing area and the bearing oil reservoir capacity shall be such that temperature of the segments shall not exceed 70oC under worst conditions of operations. The lubricating oil shall be cooled by means of heat exchangers placed outside oil reservoir. The heat exchanger shall be tested in the shop and before assembling on site under a pressure equal to 200% of the maximum operating pressure for a period of two hours. The bearing shall be located as near to runner as possible consistent with the distance assumed in shaft system analysis and keeping in view the space required for accessibility and maintenance of the shaft seal. The construction of the bearing and bearing oil reservoir shall be such that inspection, adjustment or dismantling and removal of the bearing segments shall be possible without requiring dismantling of the head cover and/or disturbing the major parts of the turbine. The mechanical design of the bearing shall take into account the abnormal radial forces during starting, stopping, trip-outs and running at runaway speed of the unit and also provide axial movement of the shaft. The bearing segments shall be truly cylindrical in shape, the cylinder formed by assembly. The segments shall be concentric with the shaft, the bearing segments shall be of heavy sections and shall be provided with a continuous, strong and rigid supporting arrangement. method of construction shall be fully described in the bid. The adjustment of the bearing segments by use of shims or radial studs shall not be acceptable. The bearing oil reservoir shall have sufficient capacity to supply the required amount of oil to the turbine guide bearing and provide cool oil to the bearing under all conditions of load. The bearing design shall Signature of Bidder
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prevent the leakage of oil down along the shaft. Piping for filling oil in the bearing and reservoir shall be separate from the drain piping. The supplier shall supply and install the following indicating and protection devices for guide bearing. One dial type thermometer to indicate the hottest part of the bearing. The thermometer shall have two (2) sets of separately adjustable contact suitable for operating alarm and tripping circuits at 220 V D.C. The thermometer indicator shall be mounted on Gauge panel. The resistance temperature detectors R.T.D (Pt 100 Ohms at 0oC) One for bearing segment and one for oil indication and recording the temperatures at unit control board. One direct reading water flow meter with two electrical contacts (suitable for operation at 220 V D.C. for signalling low cooling water supply / stoppage of cooling water supply. One oil level gauge properly graduated marked in litres and high and low level adjustable alarm contacts with 220V.D.C. contact rating. 5.5.11 PIT LINER, WALKWAYS, PLATFORMS AND STAIRWAYS A pit liner of plate steel welded construction with servomotor pockets if requested shall be provided for the full height up to generator lower bracket. It shall be made in sections as necessary for shipment. The internal diameter of the pit liner shall be such to allow the removal of the head cover, the turbine runner and regulating ring easily. The bottom of the pit liner shall be prepared for welding to the stay ring with full penetration welds. The pit liner shall be provided with sufficient number of stiffeners and anchors so that distortion of the liner shall not occur during life time operation of the unit. Signature of Bidder
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If servomotor pockets are provided a suitable arrangement to transmit, the servomotor reaction forces through the pit liner to the surroundings concrete shall be made. The section of the pit liner containing the servomotor pockets shall be stress relieved and the surfaces of the servomotor support plates shall be machined after stress relieving. Working, operating and inspecting walkways and platforms complete with floor plates and/or gratings, stairs and handrails shall be furnished in the turbine pit to provide convenient and safe access to all operating equipment and point of lubrications if any. The design of the floor plates, gratings, stairs and handrails shall facilitate easy removal to permit free access. Monorail and a electric hoist of adequate capacity shall be provided in the turbine pit for easy handling of the guide vanes and other parts. 5.5.12 Tools and tackles required for handling guide bearing shall be provided by Supplier. 5.5.13 Test equipments of all kinds, which are necessary for erection, testing & commissioning at site shall be provided. 5.5.14 Turbine junction boxes suitable for mounting on barrel wall outside shall be provided. 5.5.15 Control and power cables:All power cables for local control centres to equipment, local control centres to unit control boards and up to distribution centres provided by the purchaser shall be provided by the supplier, all power cables between two equipment covered under the scope of this contract shall be provided by the supplier. All the control cables between equipments covered under the scope of this contract shall be provided. Racks, cleats, Signature of Bidder
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ferrule, glands etc for entire system of equipment covered under the scope of supply of the supplier shall also be provided by the supplier. All power and control cables shall be of FRLS copper conductor type. 5.5.16 Oil, grease, lubricants sufficient for first filling and 25% spare quantities shall be supplied. 5.5.17 All accessories viz. sole plates, foundation & anchor bolts, platforms, ladders, guards, handrail, bolts, nuts, turn buckles etc complete required during installation shall be provided by the supplier. 5.5.18 Thermometers, thermal relays, oil level gauges and relays, water pressure gauges and relays etc. to install near the equipment, on Gauge panel and Unit control board shall be provided by the Supplier. 5.5.19 Oil leakage system if needed (requirement shall be justified at bidding stage) complete with tank, motor-pump sets, pipes, valves, level switches, gauges etc.

5.6

GOVERNING SYSTEM Turbine shall be provided with electronic PID governor to control the turbine during starting, stopping and operation at any load.

5.6.1

The governor system should have following qualities: i) ii) iii) iv) v) Fast acting Stable (No hunting). Reliable High sensitivity. Easy control.

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The governing system shall be designed to perform the following functions. 1) 2) 3) Unit start-up. Idling and synchronisation Normal stopping and emergency shut-down with necessary monitoring and safety functions. In addition the governing system must allow the operation of the unit either in frequency control (i.e. speed governing) function or in output control function. In frequency control function, the frequency (and therefore the operating speed) shall be maintained at set point, when the unit is in isolated operation or in idling mode. Configuration The governing system comprising of oil pressure system, the hydro mechanical cabinet (HMC) i.e. actuator and the electronics shall divide functionally so as to achieve, Local i.e. Manual Control or remote control of the unit. The manual control shall be directly from the HMC i.e. actuator cabinet. The remote control shall be from Unit control board or from SCADA system. The speed governor shall have the following facilities and performance. 1) 2) 3) 4) 5) Speed adjusting range Adjusting range of permanent droop Adjusting range of incremental momentary speed droop Adjusting range of time constant of damping Governor dead band 0 - 15 sec 0. 02% 0 - 50% 85 - 105% 0 - 6% In output control function, the power output of the unit shall be maintained at set point.

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6)

Gate setting operation The speed governor shall be capable of gate setting operation by the load limiting device and will be capable of easily changing over from automatic operation to gate setting operation or vice versa.

7)

Gate opening regulating device This device shall be capable of the following control. a) b) Starting gate opening control. Control of maximum output gate opening.

8)

Protective device: The protective device shall be capable of fully closing the guide vane in case that a trouble occurs in the speed governor and shall stop the turbine quickly.

5.6.2

Both the speed control governor and power output governor shall actuate the same servo-positioner through the opening set point.

5.6.3 The electronic PID controllers behaviour shall be enhanced by special means such as disturbance super position and secondary variable super position. Speed sensing The speed sensing for governor operation shall be taken from toothed disc method or via transducers using residual remainance. 5.6.4 CHARACTERISTIC PARAMETERS OF PID- CONTROLLERS. (Definitions as per IEC 308/1970) i) Permanent Droop (bp)

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The permanent droop shall establish a defined relationship between the controlled variable X and relative servo position or any other signal, in the steady state condition, e.g. ii) Speed control : between frequency and servo position. Power control: between power and frequency.

Minimum setting range for speed control shall be 0-10% linearity (maximum allowable deviation of permanent droop) for any value of Y(servomotor stroke deviation) from the maximum stroke permanent droop bs 5%

iii)

Proportional gain(kp) kp = 1/bt. where bt = temporary speed droop kp = adjustable between 0.6 to 10 %

iv)

Integral action time constant.(Td) Minimum adjusting range 1 to 20 sec.

v)

Derivative action time constant (Tv) setting range : between 0 and 2 sec.

vi)

Command signal adjustment (for controlled variables speed, power output etc. and load limiter). a) Command signal range for speed control. + 6% to - 10% with bp = 4% b) Command signal setting times shall be adjusted so as to exceed the shortest servomotor stroke as defined by limiting orifices. Setting times should not be less than 20 sec.

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vii)

Time setting range. a) b) Speed setting Power output setting c) Limiter. -between 20 and 100 s -between 20 and 80 s for full travel of servomotor - between 20 and 80s for full travel of servomotor

viii)

Control Inaccuracy(ix/2) speed control ix/2<2 x 10-4 Power output control ix/2 <1 x 10-2

ix)

Parameters of servo positioner. Input Output: :Electrical signal or position of pilot servomotor. Relative position of the main servomotors

For servo positions, the following applies:a) Minimum servomotor opening and closing times Tg and Tf shall be separately determined to satisfy water hammer and over speed limitations. The limiting orifices shall be so dimensioned that the actual stroke times in the presence of the highest supply pressure and lowest required regulating capacity is not lower than the allowable stroke time. b) Time constant (Ty) of the main servo positioner to be introduced in digital stimulation system shall lie between 0.1s and 0.25s. Near the zero displacement, higher values of Ty shall prevail due to overlap and grooves. c) Servo positioner inaccuracy in follow up arrangement (ia/2) which has a major influence on dead band shall be kept small i.e. < 0.2% for the complete servo positioning system. Signature of Bidder
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d) e)

Control system dead time constant (Tq) shall be less than 0.25s. Dynamic response of servo positioner. Setting of servo positioner shall be so chosen that the dynamic response of servo positioner corresponding to a damping ratio (D) between 0.8 and 1.1 is achieved.

5.6.5 MANUAL CONTROL Manual control of setting of turbine power directly via the actuators bypassing the governor control loop shall be provided. In that case, the safety of unit shall rest with over speed protection. 5.6.6 FOLLOW - UP CONTROLS Following follow-up controls shall be provided: i) ii) The power output governor command signal shall follow the actual power output signal in the speed control mode. The speed command signal shall follow the actual frequencysignal in the power output control mode or during the start up phase (speed command signal pre-adjustment). iii) iv) v) The manual control set point shall follow the actual actuator position in the various control modes. In case of remote control, respective local control shall follow the respective command signals. It shall be possible to adjust the pre-opening of varying heads to minimise start up times. 5.6.7 OPTIMISATION CONTROL Special control configuration shall be provided to optimise the system with respect to overall plant efficiency, smooth running or other criteria.

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5.6.8 MONITORING, PARALLEL POSITIONING OF AMPLIFIERS The deviation of the position of each servomotor from the average of the total shall be monitored and a warning or shut down shall be initiated when it exceeds the set limit. Also, the control deviation of the individual positioning loop shall be monitored. If it does not return to approximately zero in a given time span, a warning or a shutdown shall be initiated. 5.6.9 OPERATIONAL TRANSITIONS Following stipulations shall apply : i) ii) iii) Synchronisation Band (0.995 to 1.01) f network. Speed change rate for synchronisation : dx/dt = 0.003 per sec. ts/t0.8 = no 1.5 to 3.0 Note : ts - Time at which the unit is synchronised. t0.8 - Time at which 80% speed is reached. iv) tE/tM = 2.5 to 4.0 Where tE = Regulating time after which the speed deviation from idling speed remains below 1% tM=Time after which load rejection takes place. v) nmin/n = 0.85 to 0.95n nmax nmin n = Maximum speed after load rejection (at tM) = Lower speed after a load rejection. = Rated speed.

5.6.10 OIL PRESSURE UNIT SYSTEM The oil pressure system shall be amply designed to meet all requirements of governor system.

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i)

Purpose Oil pressure unit system shall be used for operation of the guide vane.

ii)

System a) The pressure oil supply system shall comprise of 2 sets of pressure oil pumps directly coupled with the 400V A.C. motors (1 set for normal operation and 1 set for stand-by). 1 set of sump tank, 1 set of pressure tank and other accessories. b) Compressed air required shall be taken from one of the two Air receivers. Necessary valves pipes etc. required shall be provided by supplier. c) Operation method of the pressure oil pump shall be of the continuous operation type using unloader valves. When the normal oil pump stops during operation of turbine or in case of the first stage of oil pressure drops, stand-by pump shall start automatically. d) Changeover between the main and stand-by pumps shall be carried out through the changeover switch provided on the motor control panel and shall operate automatically. In case of drastic depression of oil level, both pumps shall operate simultaneously. Besides, starting and stopping shall be carried out not only automatically but also manually from the motor control panel and from unit control board. Operating mechanism shall be oil/water or alternatively oil/oil will be considered.

iii)

Composition and Design One set of the oil pressure unit system shall comprise of the following items.

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Pressure oil pumps . . . 2 sets (one for normal and one for stand-by) a) Each pressure oil pump shall be vertical shaft screw pump. The oil flow rate per pump at the maximum delivery pressure shall be sufficient for operating the guide vanes from the fully opened state to the fully closed state without supply of pressure oil from the pressure tank. Each of these pumps shall be of capacity sufficient to cover leakage losses with a safety margin in excess of 2. Design of pressure tank shall be according to draft TC4/WG 14.4(Sec.102 of Feb.88) b) The normal operating oil pressure shall be adequate. System shall have sufficient oil under pressure to operate servomotor in close-open-close or open-close-open cycles (three operations) of guide vanes without requiring charging of system. c) Each set of normal and stand-by pumps set shall be provided with following accessories. i) ii) Unloader valve Safety valve 1 set 1 set 1 set 1 set 2 sets

iii) Non return valve iv) Strainer v) Induction motors

(One for normal and one for stand-by) Each motor shall be vertical shaft, 400V, 50 Hz., 3 phase AC induction motor and shall be used for driving the pressure oil pump. vi) iv) Signature of Bidder Motor control panel for oil pressure system 1 set Pressure tank/air oil accumulator 1 No.
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a)

Capacity of pressure tank shall be sufficient to keep the oil pressure in the pressure tank higher than the turbine shut down oil pressure, supplying the oil to pressure tank from pressure oil pump, at minimum oil pressure and oil level (i.e. oil pressure and oil level at the time when the unloader valve resets and the pressure oil pump begins to deliver the oil to the pressure tank) (first stage operation), and moreover to keep oil pressure in the pressure tank higher than the minimum allowable oil pressure even when guide vane servomotor are operated for one stroke from the fully open state to the fully close state at the turbine shut down oil pressure (second stage operation). Besides, the pressure tank shall be so designed that the amount of leakage oil during above-mentioned duty is assumed to be within maximum permissible range. The capacity of OPU tank shall be designed in such a way that the turbine operation cycle (O-C-O) is performed at minimum pressure without oil pumps in action.

b)

Amount of residual oil in the pressure tank at the minimum allowable oil pressure shall be amply more than the oil consumption in the first stage and second stage operations and shall be sufficient to operate for next cycle of stroke and thereafter prevent sucking of air or sludge.

c) d)

A manhole for inspection shall be provided. Following accessories shall be supplied.(oil pressure relays shall be housed in the turbine control board)

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i) Automatic oil level control device ii) Oil level gauge (with stop valve with check valve) iv) Safety valve (if any) v) Solenoid valve for air supply vii) Oil pressure relays v) Sump tank a)

1 set 1pce. 1 pec 1pec. 1 set

iii) Oil pressure gauge (with stop valve) 1pec.

vi) Oil supply valve and oil drain valve 1pec

Total capacity of the sump tank shall be 120% of oil volume in the pressure oil complete system. The sump tank shall be designed to allow drainage of hydraulic system into the tank. It shall also be designed to allow a complete emptying for maintenance purposes and to remove the dew point of water, e.g. by providing a slightly inclined bottom. Cooling/heating of the system oil shall be provided to limit oil viscosity variations. Separate oil vapour exhaust equipment shall be provided.

b)

Sump tank shall be provided with a cooler so that oil temperature will not become too high. Oil/water cooling coils of cooler shall be made of seamless steel pipes and shall be free from water leakage.

c) d)

A manhole shall be provided for inspection. The following accessories shall be supplied. i) Dial type oil level gauge with alarm contact ii) Oil level relays (for low oil level warning and for high oil level warning) 1 pec. each 1 pec.

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iii) Dial type thermometer. vi) Pipes and valves.

1pec

Pipes and valves necessary for all pressure supply system, and also a complete set of flange couplings, bolts, nuts and packing required shall be supplied.

5.7

ELECTRICAL EQUIPMENT CONTROL AND MONITORING DEVICES. These shall be provided as per the Annexure V-2 through V-5 appended to this section. The control and monitoring devices shall include but not limited to following: 1. Automatic operation control devices a) i) ii) iv) Solenoid valves. For opening and closing of the inlet valve For starting and stopping of unit For the brake of the generator 1 pec. 1 pec. 1 pec

The solenoids shall be so arranged that they do not remain continuously energised in whichever case the unit is running or in standstill. b) c) d) e) 2) All necessary limit switches All necessary auxiliary relays All necessary relay valves All necessary piping and valves 1 set. 1 set. 1 set. 1 set.

Turbine control board (Gauge Panel) The turbine control board shall be of cubicle type of steel plates and shall be arranged in line with the speed governor cabinet. In front of the turbine control board, a name plate shall be mounted.

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The turbine control board shall be capable of manual operation of the turbine and auxiliaries such as flowing of cooling water, opening and closing of the inlet valve of the turbine, starting, stopping, and operation of the brake, etc. Manual operation shall be of such type as to actuate the solenoid by operation of the switches on the turbine control board individually. The control board shall house the solenoid valves etc., shall be provided with the measuring instruments, operation indicators, on the front surface and shall keep sufficient space so that inspection and adjustment can be carried out easily. The turbine control board shall comprise the following. a) Control switch change-over switch (local-remote) b) Manual operation switches for : i) Solenoid valves for opening and closing of the butterfly valve. ii) Solenoid valve for starting and stopping of turbine. iv) Solenoid valve for the brake of the generator v) Other solenoid valves housed in turbine unit control board vi) Limit switches vii) Auxiliary relay. viii) Piping and valves. ix) Indicating lamps. 1 set 1 set. 1 set. 1 set. 1 set. 1 No 1 No. 1 No. 1 No.

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Oil pressure relays : i) For starting condition of turbine. (operates when oil pressure for guide vane operation is same as or higher than the specified value.) ii) iii) iv) v) vi) vii) For alarm at oil pressure drop For quick stop at operating oil pressure drop For start and stop of the stand by oil pump For oil level control For Actuator pressure. Water pressure relay for spiral case pressure. Instruments : i) ii) iii) iv) v) vi) vii) Signature of Bidder Water pressure gauge for steel lined shaft Water pressure gauge for spiral case. Pressure gauge for oil pressure tank. Dial thermometer for turbine bearing Dial thermometer for upper guide bearing of generator Dial thermometer for lower guide bearing of generator. Dial thermometer for thrust bearing of generator.
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1 No. 1 No. 1 No. 1 No. 1 No. 1 No. 1 No.

1 No. 1 No. 1 No. 1 No. 1 No. 1 No. 1 No. Signature of Purchaser

viii)

Dial thermometer for inlet and outlet of each air cooler of generator. 1 No. 1 set.

ix)

Sequence indicators.

5.7.3 PUMP JUNCTION BOX AND ELECTRICAL ITEMS. Supplier shall supply all the necessary switches, contactors, magnetic starters and relays for satisfactory operation of the plant. All electrical items supplied by supplier shall comply with the appropriate section of IEC- Standards. Supplier shall provide and install terminal boxes at locations approved by purchaser, and shall provide and install all wiring and conduit from equipment to these terminal boxes. All electrical wiring and conduit within the turbine pit, including wiring for pressure and flow switches, temperature relays and thermometer, alarms shall be provided. All wiring shall be stranded wire, insulated with 1000 V oil proof insulation. For turbine a common junction box shall be provided. All controls, indications, alarms shall be brought by the supplier up to this junction box. Supplier shall supply schematic diagrams, wiring diagrams drawings and catalogue numbers for all electrical components. Alarm contacts shall be suitable for voltages up to 250 V D.C. outlined

5.8

DRAWINGS AND MANUALS TO BE FURNISHED AFTER AWARD OF CONTRACT These shall be submitted as per the list given in Annexure V-1 to this section. Mode of submission of these drawings will be intimated to successful bidder in due course.

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5.9

ASSEMBLY AND INSPECTION AT FACTORY. 1. Distributor assembly - Head cover, bottom ring, and guide vanes regulating mechanism (excluding runner and shaft) shall be assembled by using assembly stand and following shall be checked. Side and bedding face clearances of guide vanes. - Stroke of servomotor and its relation to guide vane opening. - Match marking and doweling shall be done. 2. Draft tube liner and cone assembly and match marking 3. 4. Runner and shaft assembly and dowelling Pressure oil system comprising Sump tank air/oil accumulator, actuator, servomotor and connected piping ------------ in the presence of Purchasers representatives Manufacturers -inspection certificate -in the presence of Purchasers representative

5.10

TEST CERTIFICATE AND INSPECTION REPORTS: LEGEND 1) 2) : Composition and physical properties of the material in the following components shall be supplied. For welded joints. The welded joints of the following assemblies/components shall be examined by ultrasonic and/or radiographic methods

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3) 4) 5)

For hydraulic pressure test and leakage test. Dimensional accuracy. For surface finish. 1 2 3 4 5

Sr. No Particulars of Assembly 1 2 3 Runner - Runner rim, runner blades Shaft - Main shaft

5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20

Spiral case, ring and stay vanes: Spiral case, stay ring, Parallel plates, Stay vanes, Steel plates, draft tube liner, Support cone. Head cover and regulating apparatus: Head cover, Wearing rings (rotating), Facing plates, Coupling bolts, Bottom ring. Draft tube Liners Stay ring / spiral assembly Head Covers B.F. valve. Bottom ring and / discharge ring. Sump tanks air/oil Servomotor/cylinders. Penstock and Specials. Oil sump tank. Oil pressure tank. Oil coolers. Guide vane servomotor cylinders. All the components of the turbine Runner vanes crown and blank surfaces. Stay ring upper & lower surfaces. Stay vanes. Guide vanes.
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accumulators,

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21 22

Bearing pads. Head cover facing plates.

5.11

TESTS ON SITE. After completion of erection each of the sub system shall be individually operated and tested to verify if the specified performance/functional requirements are achieved. The following are illustrative list. i) ii) iii) iv) v) vi) Pressure oil system. Compressed air system. Cooling water system, Governing system according to IEC 308. Dewatering and drainage system. B.F. valve.etc.

5.12

STANDARDS. Turbine and governing system shall be designed, manufactured and commissioned to the latest I.E.C standard accepted standard practices. A few of the standards are listed below but not limited to. IEC-41/1991 IEC- 545 IEC-607 IEC-609 IEC-193/1965,193-A/1972 and 995/1991 IEC-994/1991 ASME IEC- 308 Scale model testing. Guide for field measurement. Tank and hydraulic cylinders. Governor testing. Field acceptance tests. Commissioning procedure. Thermodynamic method measuring. Cavitations pitting evaluation.

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ASME VIII, ASME V ASTMA 435 ASTMA 609, ASTMA 709 IEC 404 ASME Boiler and pressure vessel code section VIII, Dim 2 Low cycle fatigue. IEC- 34.9 ISO- 1996 VDI-2056 Noise limits for electrical machines. Noise measuring. Vibration limit. . ASTMA A 388 and welding materials

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ANNEXURE V-1 LIST OF DRAWINGS, DESIGNS AND MANUALS TO BE SUBMITTED BY THE SUPPLIER AFTER THE AWARD OF CONTRACT Sr. No. 1 I 1 Brief Description To be submitted within months from the award of contract 3 3 Remark

2 DRAWINGS General plans and sections showing all essential details of turbine assembly, setting and water passages Plans and cross sections of power house showing layout of equipment listed below, floor arrangement, principle dimensions and scope of works - Penstock pipes to be provided at both sides of the Inlet valve to connect penstock and spiral casing. - Inlet Valve. - Turbine components - Governing system - Pressure pumping systems for governing - Stay ring and spiral case - Draft tube and draft tube liner - Generator outline - Generator barrel - Speed signal device, excitation equipment - Line and neutral end cubicles - Unit control board - All unit auxiliaries - All station auxiliaries viz. cooling water system,drainage& dewatering system, compressed air systems. etc. Cross Section through Turbine and longitudinal section of turbine in machine hall
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4 For approval

For approval

3.

For approval

Signature of Bidder

Signature of Purchaser

4.

Installation drawings of: - Draft tube liner, elbow and cone - Spiral case/stay ring assembly - Guide apparatus, regulation and operating mechanism - Runner and housing - Shaft and shaft seal - Head cover, lower and upper coverings - Guide vanes and sealing - Turbine bearing, lubrication and cooling - Test equipment for pressure testing of spiral case - Turbine platform in Turbine pit. Governor, governing scheme and connection diagram, hydro mechanical and electrical cabinets Control diagram for Turbine Runner removal arrangement. Schematic diagram for auto control of Turbine Drawings of tools, tackles and erection devices Leaking piping Embedment in: - DT liner and cone concreting - Stay ring and spiral case concreting - Generator barrel concreting Area velocity curve for draft tube Layout plan and cross-sections showing details of floor openings (for piping, cables etc.) - Trenches - Block-outs/cut outs - Openings in concrete

6 6 6 6 6 8 8 8 6 8 12

For approval

5.

For approval

6. 7. 8. 9. 10. 11.

8 3 8 3 8 3 6 6 3 8

For approval For approval For approval For reference For reference For approval For approval For approval For reference For approval

12. 13.

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132

Signature of Purchaser

14.

Layout of piping of: - Cooling water - Dewatering and drainage - Air pipe lines - Oil piping Interconnection and wiring diagrams and cable schedules of Turbine equipment, unit and station auxiliaries Panel drawings

6 6 6 6

For approval For approval For approval For approval

15.

8 6

For reference For approval

16.

1 II. 1. 2.

2 MANUALS Manuals for storage preservation and handling of the supplied goods Manual for erection/dismantling, testing and commissioning of the supplied goods. Operating manual giving instructions for all the Dos and Donts Manual giving schedule detailed maintenance

8 8 20 20

For reference For reference For reference For reference

3. 4.

Signature of Bidder

133

Signature of Purchaser

ANNEXURE V2 SCHEDULE OF INDICATING AND RECORDING INSTRUMENTS FOR TURBINE AND EQUIPMENT ASSOCIATED WITH IT Sr.No . Item Type of instrument device 3 On or near the equipment or locally 4 Number Provided At GeneratorAt Governor gauge Cabinet panel 5 6 Total At Unit Control Board 7 8 9 i. Through RTDs for alternate segment ii. Through 2 RTDs one for hot and other for cold oil. Remark

1 1

2 TEMPERATURE OF i. Guide bearing segment ii. Guide bearing oil

24 point indicator (Provided by Gen-Motor manufacturer)

iii. Cooling water at Outlet of guide bearing iv. Guide bearing segment. v. Guide bearing Oil. vi. Cooling water at outlet of guide bearing. vii. Governor sump oil. PRESSURE AT i. Inlet to Butterfly valve i.e. penstock. ii. Draft Tube. iii. Inlet & outlet of cooling water to the guide bearing. iv. Guide vane servomotor. v. Governor oil pressure receiver vi. Spiral pressure near Butterfly valve

ii. Through 1 RTDs liquid bulb sensor. DTT DTT DTT DTT PG +RL PVG PG+RL PG+RL PG+RL PG+RL 1 1 2 2 1 1 1 1 1 1 1 1 1 1 2 1 1 1 2 1 2 2 2 2 Flow relay shall be mounted only for outlet point Liquid bulb sensor Liquid bulb sensor Liquid bulb sensor Liquid bulb sensor

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134 Signature of Purchaser

1 3

5.

2 vii. BFV oil Pressure LEVELS OF. i. Oil in governor sump tank ii. Oil in Air/Oil pressure receiver iii. Oil in leakage oil tank iv. Oil in guide bearing reservoir FLOW OF. i. Cooling water inlet to guide bearing ii. Cooling water inlet to shaft seal. Iii Discharge through spiral case . STATUS INDICATION FOR i. Governor Oil pump No.1 running/standstill/fault ii. Governor Oil pump No.2 running/standstill iii. Leakage Oil pump for governor running/standstill/fault iv. Head cover drain pump running/standstill/fault v. Guide vane remained open after close

3 PG+RL Sight gauge + relay -do-do-doFlow indicator -do- doLamp -do-do-do-do-

4 1 1 2 1 1 1 1 Set Set Set Set -

5 1 -

6 --

7 -

8 1 1 2 1 1 1 1 1 Set Set

One for high level and one for low level

Covered under (PG+RL) Covered under (PG+RL) To indicate rate of flow .

Set Set 1

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2 vi. Guide vane lock in/out vii. Dome light ix. Main inlet Butterfly valve open/transit/close OTHER ITEMS i. Setting of guide vane limiter and gate position ii. Turbine speed iii. Governor speed droop setting iv. Governor balance meter indication v. Wearing of shaft seal detection vi. Water in guide bearing Oil reservoir vii. Ammeter with panel switch for each motor viii. Voltage with selector switch for each 415 volts bus bar.

3 -do-do-doGate limiter and gate position indicator Tachometer -doGovernor balance meter Water detector Water detector Ammeter Voltmeter

4 1 Set 1 1 1 set 1 set

5 1 -

6 1 1 1 1 -

7 2 Set 1 1 1 -

9 2 1 Set 2 2 1 2 1 1 set 1 set 1 set

10

ADDITIONAL INDICATING AND RECORDING INSTRUMENTS (To be recommended by Supplier)

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136 Signature of Purchaser

ABBREVIATIONS : RTD means Resistance temperature detector DTT means Dial type thermometer PG means Pressure gauge PVG means Pressure/Vacuum gauge BFV means Butterfly Valve PG+RL means pressure gauge and guard relay NOTE: 1 2. 3. 4. Dial type thermometer and relays shall be used for alarm annunciation/shut down also. Turbine and generator supplier shall co-ordinate in joint use of indicators/recorders, wherever possible. Supplier shall indicate changes if any required in number, type and location of instruments. Information will also be fed to microprocessor based control system covered under scope of supply of generator supplier. (Information such as bearing temperatures, cooling water parameters, water pressure, draft tube pressure, spiral pressure. Governing system parameter, servo strokes, guide vane opening and limit, inlet valve parameters, compressed air system details) For this purpose necessary tapping points shall be provided by turbine supplier in consultation with generator supplier.

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ANNEXURE V3 SCHEDULE OF CONTROL FOR TURBINE AND ITS ASSOCIATED EQUIPMENT Sr. Description No Type of device
L oc a l l y

Number Provided At
G e n er a t or

Total Re m ar k At

At

or in the
vi c i n i t y

Go verno r Unit

gauge Cabinet C on t r ol panel Board 5. 6. 1 7. 1 8. 2 9.

1. 2. 1 Guide vane limit control 2. Auto / manual Selection for Governor operation Selection of 3. location of governor control (local/ remote) -do-

3. Raise Lower switch Selector switch /

4. -

4.

Speed load control

Raise / Lower Switch

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138

Signature of Purchaser

5.

Speed droop Control

Control Switch Locking device

6.

Turbine Guide vanes Locking

7.

Emergency Turbine shutdown

Push button

Governor Oil pump starting/ stopping. No.1

-do-

Governor Oil Pump No. 2 Starting/ Stopping -do2 2 4

10

Main / standby Selection of governor oil pump

Selector Switch

11

Auto / manual -domode selector of governor oil

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139

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pump No 1 Auto / manual -do12 Selector for Governor oil pump No. 2 Local / remote -do13 Mode selection for governor oil pumps. Control of oil 14 leakage pump Push button 1 1 2 2 1 1 1 1

Auto / manual Selector 15 Selection for oil leakage pump Headcover 16 stopping 17 18 Unit starting / Control stopping Butterfly valve ON/ OFF (Closing / Opening) switch Push button Push switch

pump starting / button

1 1

1 2

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140

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ADDITIONAL CONTROLS (TO BE RECOMMENDED BY SUPPLIER)

NOTE :

1.

The items quantities and locations of control devices tentatively indicated. The supplier shall indicate changes if any.

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ANNEXURE V4 SCHEDULE OF CONTROL FOR TURBINE AND ITS ASSOCIATED EQUIPMENT Sr. Description of operation No Sensing device Type Annunciation at Quantity G o ver n or
Ca b i n e t

Unit Control Board

1. 1

2. HIGH TEMPRETURE OF i. Guide bearing pads. ii. Guide bearing oil. iii. Guide bearing cooling water discharge. iv. Governor oil in sump tank

3.

4.

5.

6.

DTT DTT DTT DTT

1 1 1 1

A -

A+AS A A A

2.

LOW QUANTITY OF COOLING WATER. i. Cooling water flow to guide bearing ii. Cooling water flow to shaft seal iii. Cooling water flow to runner labyrinth. -do1 A Flow realy -do1 A 1 AS

3.

LOW LEVELS OF i. Oil in guide bearing oil reservoir low Level Relay
142

A+AS

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ii. Oil in governor Oil sump tank low iii. Oil in governor air/oil pressure receiver iv. Oil in BFV air/oil receiver 4. HIGH LEVEL OF i. Oil in oil leakage unit ii. Water in Turbine head cover 5. LOW PRESSURE IN I. Governor air/oil pressure receiver ii. Governor air/oil pressure receiver very low 6. HIGH PRESSURE OF I. Oil in governor oil pressure receiver 7. FAILURE OF i Shear pin

-do-do-do-

1 1 1

AS A+AS A+AS

Level relay Float

1 1

A A

Pressure switch -doPressure switch Limit Switch

1 1

AS A

Set

ii.Speed sensing system iii. Power supply to unit control board iv. Supply to governor cubicle Signature of Bidder

-Voltage relay -do-do-

1 1 1

A A A

A AS AS

143

Signature of Purchaser

8. 9

Unit over speed detection Water in guide bearing oil detection.

Speed relay Water detection

1 1

A -

As A

10

Emergencies

Emerg ency

AS

AS

shutdown switch

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144

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ADDITIONAL SAFETY DEVICES (TO BE RECOMMENDED BY SUPPLIER)

ABBRIVATION:DTT means dial thermometer. A means alarm annunciation AS means shut down and annunciation A+AS means two stages for alarm and shut down NOTE : 1. Items, quantities and locations of devices are indicated and supplier shall indicate changes if any.

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INDICATION, CONTROL AND SAFETY DEVICES FOR AUXILIARY EQUIPMENT Sr. No. Item Type of instrument device Number Provided/Annunciation On or near At Auxiliary At At Unit the generator Governor Control equipment Motor Cabinet Board locally Control Board 4 5 6 7 Lot Lot Lot 4 4 Lot Lot Lot Lot Lot Lot Lot 4 4 Lot Lot Total Remark

1 A

2 INDICATION/RECORDI NG 1. Air compressors for Brakes standstill/ running 2. Drainage & Dewatering and pumps Standstill Running Main 1, Main 2 3. Cooling water pressure (High/Low) 4. Pressure in Air receiver for Brakes 5. Pressure in air/oil receiver for Governor 6. Ammeter with selector switch 7. Current and voltage meter for three phase indicationsVoltmeter with selector switch for each 415 V motor

3 Indication Lamp Indication (pressure Gauge+RL) (pressure Gauge+RL)

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146 Signature of Purchaser

DEPARTURE FROM SPECIFICATION ( To be filled by the Bidder.)


Item Descriptio n of d ep arture Reference to C lau se in th e sp ecification

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DATA SHEETS
DATA SHEETS OF TURBINE 1) 2) 3) Name of the Manufacturer Type Guaranteed rated capacity (output) at a rated net head of 106 m 4) A) i) ii) iii) B) i) ii) iii) C) Full gate output at a net head of 117.0 m (max) 84.0 m (min) 106.0 m (Rated) Corresponding Discharge For 4A) Above 117.0 m (max) 84.0 m (min) 106.0 m (Rated) Guide vane opening Corresponding to rated Net Head of 106m at i) ii) iii) 100 % output 75 % output 50 % output :---------------------:-. % % : m3/sec :- m3/sec :-KW :-KW :-KW :-. KW :-. :-.

:-. m3/sec

:-%

Guide vane opening corresponding to 110 % output shall be 100 % D) E) Head at 110% Output Discharge at 110% output
148

:-m :- m3/sec Signature of Purchaser

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5) A)

Guaranteed efficiencies at net head of 106 m for following outputs

i) ii)

100 % output 75 % output

:-.% :-% :-% :-------------------------

iii) 50 % output B) Guaranteed arithmetic mean Of the above efficiencies Curves of efficiencies (at diff. heads) The drawing shall be submitted. C) i)Best efficiency of Turbine at rated Head condition ii) Corresponding Turbine output iii)Corresponding Gate opening iv) Corresponding Discharge 6) 6. A) 7 Direction of Rotation when viewed from top Normal speed Specific speed (at rated head & rated output) 8 Maximum runaway speed Of the generating unit 9 Turbine discharge a) at rated head and rated output

:-.. :-.% :-. :-% :-..m/s :-. :-..rpm :-m-Kw

:-rpm

:-.. m3/sec

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b) at runaway condition c) at 110 % output (max. head) 10 Momentary rise in speed on suddenly reducing load to zero from a) 110 % load b) Rated load (100 %) c) full load d) full load 11 Time of gate closing for regulation in item (10) above a) 110 % rated load rejection b) Full load rejection c) full load d) full load

:- m3/sec :-. m3/sec

:-% :-% :-.% :-%

:-sec. :-.sec. :-.sec. :-.sec.

12

Momentary drop in speed on increasing load from zero to a) b) c) d) 110 % of rated load Full load full load full load :-..% :-% :-% :- ..%

13

Time of gate opening for regulation in item (12) above. :-sec.

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150

Signature of Purchaser

14

Flywheel effect a) of the generating unit for regulation stated in item (10) & (12) above. b) of turbine runner & shaft :- tm
2

:-tm

15

Maximum gross head on turbine (inclusive of water hammer) at the time of gate closure in (10) above.

16

Runner a) Material i) Cone ii) Blades b) Material of wearing ring c) No. of blades d) Weight e)Inlet dia. f) Velocity of water ( Full gate, 106 m Net head) :-.. :-. :- :- :- :- :-.m/sec.

17

Shaft a) Material b) Weight c)Diameter/bore d)Length e)Material of sleeves

:-. :-Kg. :-.mm/mm :-mm :-..

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f)Method of removing and attaching the sleeves. :-..

18

TURBINE GUIDE BEARING 1) Type of guide bearing [adjustable segmental type self lubricated bearing] 2) Diameter of turbine guide bearing 3) Radial clearance of turbine guide bearing 4) Number of segments 5) Total effective surface of all segments 6) Circumferential length of segments 7) Axial length of segments 8) Dynamic viscosity of oil 9) Maximum temperature for -oil film -segment ( 70 o C ( r) ) :. ......... o C : ............... o C :-....mm :- . mm :-...m/s 2 :.........m 2 :-..............mm :-..... . : ...............mm :-

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10)Total flexibility of turbine guide bearing [not more than:0.4mm/MN(d)] 11) Quantity of lubricated oil reservoir 12) Quantity of cooling water 13) Total losses in guide bearing at rated load 14)Permissible duration of operation of the unit at rated load without supply of cooling water. 19 Head Cover a) Material and construction b) Weight c) Rating of AC pump motor for prevention of accumulation of water d) Rating of DC pump motor for prevention of accumulation of water e) Method of ensuring water tightness at shaft entry and description of the arrangement proposed. :-.. :- :-.. :- :-. : ............minutes :..... ...kW :-..mm/MN :-..... ..m 3 :-....... 1/s

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20

Discharge Ring a) Material and construction b) Method of connection to the stay ring. :-. :-..

21

Guide Apparatus a) Material and construction of wicket gates b) No. of wicket gates c) Height of wicket gates d) Material of wearing plates above and below vanes e) Material of guide vanes bearing (stainless steel) ( lubrication bearings DEVA type (d) ] f) Leakage through full closed gates under maximum static head g) Torque on turbine due to the above leakage. :- :-.. :- :-. :- :-.

22 A)

SPIRAL CASE AND STAY VANES Spiral case :- acceleration etc.) a) Type (constant velocity,

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b) Material and Construction c) Thickness i) maximum ii) minimum d) Weight e) Elevation of centre line of distributor f) Max. velocity of water for full load at rated head at outlet pipe from MIV g) Velocity of water for full load at rated head. i) at inlet to spiral case ii)at 900 from inlet iii) at 1800 from inlet iv) at 2700 from inlet h) Method of erecting and Concreting the spiral case B) Stay ring i) Material and construction of Stay ring ii) Number of vanes

:-. :-.mm :-mm :-kg

:-m

:-m/sec

:-m/sec :-..m/sec :-m/sec :-m/sec

:- :-

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iii) Weight 23 Turbine pit liner a) Material and construction b) Height (approx) c) Diameter d) Weight 24 Draft Tube a) Elevation of the lowest point in draft tube b) Distance from the C.L. of the unit to the draft tube exit. c) Velocity at draft tube exit d) Extent of the draft tube covered with a steel liner from unit centre line. e) Thickness of the steel liner f) Weight of the steel liner 25) PENSTOCK:a) Taper piece between penstock and MIV i) Inlet diameter

:-.kg

:-. :- mm :-mm :-.kg

:-.m

:-.m :-m/sec

:-.mm

:-.mm :-.kg

:-..mm

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ii) outlet diameter iii) Thickness iv) Test pressure 26 Servomotors (for guide vanes) a) Main servomotors rating (Guaranteed ample for turbine operation) b) No. of servomotors c) Material of servomotor cylinder d) Material of servomotor piston e) Material of servomotor piston rings f) Dia of servomotor piston

:-.mm :-.mm :-.kg/cm2

:-..kg.m :-.

:-.. :-

:-.. :-.mm :-..mm

g) Stroke of servomotor piston h) Minimum oil pressure for satisfactory operation i) Minimum time for full gate movement under (h) above

:-.kg/cm2

:-sec.

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157

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27

Governor a) Rating b) Guaranteed sensitivity (Min. speed change to which governor will respond) c) Range of adjustment of speed droop characteristic d) Stable operation guaranteed for a min speed droop of e) Guaranteed range of speed level setting for which governor will control the turbine effectively f) Range of adjustment of gate closing time g) Range of adjustment of gate opening time h) Type of Governor i) Minimum turbine speed at which governor operation will start :-. :-. :- :-. :- :-.% :-.

28

Max safe oil pressure for the governor oil system :-. kg/cm2

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158

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29

Max. velocity of oil in pipe parts of actuators and servomotors of inter connection pipes. :-m/sec

30

Oil pressure system a) main oil pump i) Type of pump ii) Capacity of pump (LPM) iii) Rating of pump motor KW rpm b) Stand by oil pump i) Type of pump ii) Capacity of pump (LPM) iii) Rating of pump motor KW rpm c) Quantity of oil in one filling :d) Max. rate of oil consumption from pressure tank e) Capacity of sump tank f) Total capacity of pressure tank g) Number of complete operations which can be performed by the amount of oil in the pressure tank :-.. :-. :-.. :-. :-.. :-.. :-. :- :-. :-.. :-. :-

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with oil pump not work 31 LUBRICANTS a) Specification of oil b) Specification of other lubrications 32 33 34 Weight of turbine rotating parts Max. hydraulic thrust Heavies package for shipment a) Name b) Weight c) Dimensions (L x B x L) 35 Largest package for shipment a) Name b) Weight c) Dimensions (L x B x H) 36 Heaviest assembly to be lifted by crane a) Name b) Weight c) Dimensions (L x B x H)

:-

:- :- :- :-..

:- :-. :-

:- :- :-

:- :- :-

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41

Longest assembly to be lifted by crane a) Name b) Dimensions (L x B x H) c) Max . Length :- :-. :-.

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ANNEXURE -V-5 GUARANTEED AND OTHER TECHNICAL DATA FOR TURBINE


Sr. No. Maximum 100 % continuous output power P max at 100% guide vane power opening. For max. net head of 117m Turbine output power (KW) Discharge (m3/s) Percentage guide vane opening For Rated net head of 106 m Turbine output power (KW) Discharge (m3/s) Percentage guide vane opening For min. net head of 84 m Turbine output power (KW) Discharge (m3/s) Percentage guide vane opening 100% 100 % 100% 75 % output power 60% output power 50% output power Minimum continuous power on stable basis

1 a) b) c) 2 a) b) c) 3 a) b) c)

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SECTION - VI TECHNICAL SPECIFICATIONS OF MAIN INLET VALVES

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Section VI TECHNICAL SPECIFICATION OF MAIN INLET VALVES INDEX Sr. No. 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 6.10 6.11 6.12 6.13 6.14 ANNEXURES Annexure VI-1 List of drawings, designs and manuals to be submitted by the supplier after award of contract. Annexure VI-2 Departure from specifications. Data Sheets 182 181 179 Description General. Design requirements. Design specifications and performance. Construction. Valve operating mechanism. Oil pressure supply system for Inlet valve. Pressure system oil. Accessories. Hydraulic pressure test at site. Tools and Equipment Drawings, designs and manuals to be submitted after award of contract. Inspection and tests. Miscellaneous. Spares. 175 178 178 Page No. 165 165 166 167 171 172 174 174 175 175 175

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SECTION VI

MAIN INLET VALVE

6.1

GENERAL The Inlet valve shall be butterfly type. Any fittings, accessories of apparatus which may not have been specifically mentioned in these specifications but which are indispensable for reliable operation of the plant shall be provided by the supplier at no extra cost to the purchaser.

6.2

DESIGN REQUIREMENTS BASIC DESIGN DATA i) ii) iii) iv) v) vi) Number of inlet valves Purpose. Nominal diameter of inlet valve Test pressure. Operation. Opening Closing time of Inlet valve: -at still water -at rated discharge -under breakdown discharge vii) viii) ix) x) Opening time (including time required to open by pass valve) By pass valve accumulator. The Inlet valve and its control system shall be suitable for frequent opening and closing . The minimum opening and closing operations per day shall be five each. : 90 sec. : Oil pressure operated. : : : 90 sec. 40 sec. 30 sec. : by oil pressure : : : : One Turbine guard valve. 2000 mm Diameter 24 kg/cm2

Inlet valve shall have its own pressure oil system with air/oil

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Signature of Purchaser

6.3

DESIGN SPECIFICATIONS AND PERFORMANCE. The Inlet valve shall be free from vibration or other abnormality under steady-state operating conditions and under any possible transient conditions and shall have sufficient strength and rigidity against maximum transient water pressure.

6.3.1. REQUIRED SERVICE CONDITIONS It shall always be possible to close the Inlet valve safely, without vibrations or pressure surges, particularly 1) In normal service conditions with turbine guide vanes closed i.e. without significant water flow and with pressure almost equal on both sides. 2) In case of emergency with turbine guide vanes fully open i.e. with rated discharge and with full pressure on one side of the closing element near the end of closure. 3) In case of an accidental rupture of the pipe between the Inlet valve and the turbine inlet (i.e. with the breakdown discharge and the whole pressure on one side already at the beginning of closure.) 6.3.2. GUARANTEES Guarantees for Inlet valves must be given by the Bidders for: 1) 2) 3) 4) 5) Low level of vibration and noise during closing. Strong construction and adequate design of housing. Proved design of rotating parts. High level of water sealing. Minimum losses in the opened position.

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6.3.3. CONTROL Control of Inlet valve shall be hydraulically by means of its own oil pressure unit. The opening shall be performed by an oil pressure unit discharging into the valves opening cylinders. Closing of the valve shall be by closing weights and the discs hydraulic self closing tendency with closing cylinders acting as brake. Following modes of control shall be provided. Manual local from the respective control cabinet near Inlet valve location. Automatic operation from the unit control board and from computer system as a part of automatic control sequence of Turbine Generating Unit. 6.3.4. DISCHARGE SHUTDOWN PERFORMANCE Inlet valve shall be capable of shutting down rated discharge of turbine at all heads safely and reliably under unbalanced conditions. Also Inlet valve shall be capable of closing during emergency conditions, safely and completely against full unbalanced flow occurring as a result of breakdown of guide vanes and/or expansion joint or downstream air valve. 6.3.5 AMOUNT OF WATER LEAKAGE. Amount of water leakage past downstream side seal shall be less than 0.5 litre per minute at the maximum static pressure of 138. m.w.c. 6.4 CONSTRUCTION. 6.4.1 VALVE BODY Valve body shall be made of welded carbon steel plates. Valve body shall be suitably minimum divided if necessary considering Signature of Bidder
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Signature of Purchaser

transportation and shall be connected by flange at site. Valve body shall be of sufficiently stiff structure to withstand the maximum water pressure to cause no detrimental deformation even against the constant maximum hydrostatic design pressure. Valve disc shall be provided with valve trunnion of forged steel at both ends and each trunnion with a stainless steel bushing or stainless steel welding overlay at the sealing and bearing portions. Valve trunnion shall be designed to be safe under maximum pressure and shall smoothly move in the bearing. Valve trunnion shall have sufficient diameter and shall not cause excessive deflection. Trunnion bearing shall be self-lubricating with bronze backing and with Teflon fabric liner. Trunnion bearing seals shall be on both ends of each bearing and shall be made of self lubricating PTFE compound with integrated Rubber-o-ring. Bearings shall be capable of safely supporting the weight of the valve disc and force caused by water pressure and shall be capable of operating the valve smoothly. Water operated, movable stainless steel seal, seal rings shall be provided at both the upstream and downstream sides. Wearing surfaces adjacent to seal rings shall be lined with corrosion resistant material.

6.4.2 SERVICE SEAL AND MAINTENANCE SEAL The inlet valve shall be supplied with a service seal and maintenance seal. The service seal shall be located on the downstream side of the valve with a flexible rubber (or other adequate better material) and shall not be split. It shall be adjustable and repairable. The service seal in the valve Signature of Bidder
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Signature of Purchaser

casing shall be of corrosion and erosion resistant material (for example stainless steel service seal) The maintenance seal shall be located on the upstream side of the valve. It shall allow maintaining, repairing or replacing the valve in situ with the upstream waterways fully pressurised. The design of this seal shall ensure required tightness in closed valve position and shall not tend to flutter under any possible hydraulic conditions in the pressure shaft. The complete material and sequence of replacing the service seal shall be furnished by the bidder in his bid comprising explanatory write ups, sketches and drawings. 6.4.3 VALVE DISC Valve disc shall be of lattice (biplane) type made of steel plates and shall have sufficient strength against all operating conditions so that no detrimental deformation is caused. Besides, valve disc shall not cause any abnormal vibration during full opening and closing operation or transit fluttering and shall not cause much water leakage. Valve disc shall be provided with valve trunnions of forged steel at both ends and with seal ring made of carbon steel overlaid by stainless steel at the sealing portions. Valve trunnions shall be designed to be safe under the maximum dynamic pressure and shall smoothly move in the bearing. Valve trunnions shall have sufficient diameter and shall not cause excessive deflection. Valve disc shall be welded steel structure or cast structure but shall not be lens type. Arrangements for removal of air trapped in the pressure shaft shall be made and shall remain operative during operations.

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6.4.4. PRESSURE BALANCING BY PASS VALVE A needle type by pass valve of adequate size (i.e. dimension) shall be provided keeping in view the requirement of overall opening time in the turbine mode. The valve shall be operated by means of pressure oil system provided for the valve operation. The sealing of by pass valve shall be leak proof and its operation shall be by oil pressure of the governor oil pressure unit. The by-pass valve shall not cause pitting by cavitations and excessive vibration and noise during operation. It shall operate reliably and shall be capable of safely preventing water leakage when closed. By pass valve shall be fitted with an oil operated needle valve fitted with a hand operated geared guard valve.

6.4.5. AIR VALVES Suitable capacity air admission valve shall be provided on down stream side of valve to protect spiral case and shall also act as air exhaust valve during pressuring of spiral case. However leakage of water shall not occur during operating conditions. Suitable air valve shall also be provided on the upstream of inlet valve to protect pressure shaft.

6.4.6. CONNECTING PIPE A) the penstock. The connecting pipe shall be made of same

material as penstock (ASTM 517 Gr. F or equivalent) and shall be provided up to 12000 mm from the centre of Turbine towards the penstock with 300 mm allowance, and shall have inner diameter of 2000 mm and shall withstand the maximum water pressure caused by Signature of Bidder Turbine operation.
170

The inlet valve and Signature of Purchaser

connecting pipe shall be connected by rigid flanges and connecting bolts and nuts and packing shall be supplied. The connecting pipe shall be equipped with a complete set of pipes, valves etc. required for dewatering of penstock. B) Connecting pipe shall be provided between the inlet valve and the spiral. The connecting pipe shall be made of same material as penstock (ASTM 517 Gr. F or equivalent). The connecting pipe shall be equipped with a complete set of pipes, valves etc. required for dewatering of spiral.

6.5

VALVE OPERATING MECHANISM Valve operating mechanism shall comprise of the servomotor, operating rod, lever-closing weight etc. During closing, the servomotor shall act as a brake. The servomotor shall be of balancing type and heavy supporting plates with anchor bars, fastenings etc. shall be provided to mount it on its foundation block. Main parts of the operating mechanism such as servomotor, rod, lever and connecting part with the valve trunnions shall have strength and capacity sufficient for safely and reliably shutting down against maximum discharge and opening full flow discharge under all operating conditions of plant without causing any excessive vibration and other abnormality. Dimensions of rods shall be so as to transmit all operational forces without deflections all pivots shall be preferably of the self-lubricated type. The closing weight shall be of cast iron and fast securely to their levers. Operating mechanism shall be provided with a locking device for manually locking of both the main valve and by-pass valve when they are closed. Operating mechanism for the valve including the piping and valves shall safely and reliably operate during the service for a long period of time. Parts which come in contact with water shall be made of stainless steel.

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Limit switches for open / close, transmitters, contacts etc. for local and remote operation and indication of valves shall also be provided.

6.6

OIL PRESSURE SUPPLY SYSTEM FOR INLET VALVE

6.6.1 PURPOSE Oil pressure supply system shall be used for operation of the inlet valve, by pass valve and operation control devices for the valve. 6.6.2 SYSTEM Each system shall comprise the following: One sump tank located adjacent to inlet valve and dimensioned for 120% of the combined oil volume in the servomotor in fully open position, oil piping and valves and pumps. The tanks shall be provided with a filling opening (with strainer and cover), breather, breather openings, sight oil level gauge with cocks, drain with cock and one man hole for inspection, dial type oil level gauge and oil level relays for oil level low / high warning. Two screw type silent running and self-priming oil pumping units each with suction strainer and capable for continuous operations. The pumps shall be vertical type coupled directly with their moisture and dust proof alternating current 400V electric induction motors. Both pumping units shall be identical and equipped with complete control system permitting the selection of either unit acting as stand-by and starting automatically as when other pumping unit fails. One small pressure oil accumulator in parallel arrangement between the oil pump and servomotors and located in the cabinet of pressure oil unit. This accumulator shall act as a buffer and oil pressure holding means to prevent the oil pump from too frequent starting. Signature of Bidder
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One hand operated double acting oil pump mounted in the sump tank. The control valves for the inlet valve drive. All valves such as safety valve, non-return valve etc. All oil piping and shut off valves within the oil sump tank and between the oil pumping set and servomotors. Control cabinet containing following instruments and switches.

Two pressure gauges for indication of upstream and downstream water pressures of inlet valve along with recording facilities. One pressure gauge for indication of oil pressure with contacts. One selector switch for local, manual, remote control of inlet valve. Control switches of pumps. One pump selector switch. Three push button switches for opening, stopping and closing of butterfly valve. One switch with ON and OFF position for testing of oil pumping unit. One electric heating element. All necessary relays, fuses, signal LED lamps, terminal blocks and other equipment for a complete and safe local and remote control of the inlet valve.

The cabinet shall be of self-standing sheet metal type, moisture, vapour, vermin and dust proof with lockable front door. All wiring shall be run in the most efficient manner from point to point. There shall be no jointing or teeing of wires between terminals. All control cabling between individual devices, instruments, switches etc. up to control cabinet of inlet valve shall be provided. Control of pumps shall also be possible from the unit control board located in the Control Room.

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Pressure switches shall regulate on off control operation of pressure oil pumps. When the normal oil pumps fails, the standby pump shall start automatically. Change over between the normal operation and stand-by pump will be carried out through the changeover switch provided on the control cabinet. Besides, starting and stopping shall be carried out not only automatically and remotely but also manually from control cabinet.

6.7

PRESSURE SYSTEM OIL First filling plus 25% extra quantity of pressure system oil, required for inlet valve and its pressure oil system shall be supplied by the supplier. Supplier shall suggest the oil equivalent available in India for future maintenance and operation of the plant.

6.8

ACCESSORIES Following shall be supplied but shall not be limited to All necessary sole plates, foundation bolts, anchors etc. for inlet valve and servomotor. All platforms, ladders, stairs, handrails, plate coverings, hooks, pulley blocks etc. necessary for obtaining easy and safe access to parts and item which are fitted with equipment. The name plates showing makers name, serial number, year of manufacture, type, rating, capacity etc. for valve assembly and servomotor shall be provided. All necessary washers, bolts, nuts etc. of high quality steel. All necessary turn buckles and pipe jacks needed for erection, operation and maintenance.

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6.9

HYDRAULIC PRESSURE TEST AT SITE If the transport limitations permit, the inlet valve shall be despatched in one piece duly assembled and pressure tested in workshop. In case, it is not possible to transport assembled valve to project site, it shall be pressure tested again at site (upto 1.5 times of design pressure for a period of not less than 60 minutes) after its erection. To carry out this pressure testing at site the supplier shall provide one set of bulkheads common to the two inlet valves and all necessary pickings and jointing material and testing equipment.

6.10

TOOLS AND EQUIPMENT One sets of ordinary and special spanners, wrenches, special tools, slings, ropes etc. for the proper erection and maintenance of the inlet valve shall be supplied. One set of spanners and standard tools and equipment. Each set shall be supplied with a sheet metal lockable toolbox, fitted internally so that the tools may be stored in an orderly manner. The heavy tools and equipment shall be marked as to size and purpose.

6.11

DRAWINGS, DESIGNS AND MANUALS TO BE SUBMITTED AFTER AWARD OF CONTRACT These shall be submitted as per the list given in Annexure-VI-1 of this section. Mode of submission of drawings, designs will be intimated to the successful bidder in due course.

6.12. INSPECTION AND TESTS Inspection and tests at factory shall be carried out by the supplier as per list given below: LEGEND 1. 2. Material analysis. Tensile test.
175

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3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15.

Notch impact test. Bending test. Visual inspection. Magnetic particle examination. Liquid penetration examination. Ultrasonic test. Radiographic test. Pressure test. Leakage test. Dimensional check. Erection check. Welding procedure approved by purchaser. Corrosion protection.

Suffix A :- Test at workshop in the presence of Purchaser. SUBMISSION OF TEST CERTIFICATES :The supplier shall submit six (6) copies of test certificates to the purchaser as per the procedure given below : For inspection and testing specified to be done in presence of Purchase Test certificates shall be submitted for approval. For all other inspection and testing test certificates showing that the specified tests/inspection has been carried out successfully by the supplier, shall be submitted for reference. Following assembles will be inspected

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Sr.No. Particulars of Assembly 1. Bipartition flanges 2. Connection flanges 3. Bearing hubs. 4. Cylinder Shell 5. Valve body 6. Disc trunnions. 7. Disc plates. 8. Valve disc. 9. Assembled valve, seat, body and disc. 10.Operating mechanism a.Cylinder flanges b.Cylinder shell c.Welded cylinder d. Cylinder covers e. Piston rod. f. Piston rod heads g. Assembled operating mechanism. 11. Operating mechanical lever hub. 12. Auxiliary valve. a. By-Pass valve. b. Air valve. Signature of Bidder

3 4 5 6

10

11

12

13

1 1 4 5

8A 7 A 8A 12A

10A 11A 12A 13A

8A 7 A 10 A 11 A 12 A 9A

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13. Upstream pipe a. Connecting flange. b. Cylinder Shell. c. Welded pipe. 14. Downstream pipe. a. Flange rings. b. Cylinder shell c. Welded pipe.

8A 8A 10 A 12 A 11 A

6.13. MISCELLANEOUS Relevant provisions wherever applicable needed for indicating, recording instruments, control switches, safety devices, gauges, flow meters, etc. for normal operations and field test shall be made by valve supplier in consultation with turbine supplier and facilities needed by supplier of control and protection system. 6.14. SPARES Spares shall be supplied as per Section-III of this volume.

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ANNEXURE VI - 1 List of drawings, designs and manuals to be submitted by the supplier after the award of contract. Sr. No. Brief Description Within months Remark From the date of Notification of award of Contract 3 4 6 6 6 6 6 6 6 6 under worst 6 6 6 6 6 6 6 For approval For approval For approval For approval For approval For approval For approval For reference For approval For reference For reference For approval For approval For approval For reference

1 DRAWINGS 1. 2. 3. 4. 5. 6. 7. 8.

2 i) Arrangement of Inlet valve ii) Installation of Inlet valve Valve servomotor Tools, tackles and erection devices of Inlet valve Arrangement of Inlet valve piping Outlet pipe with dismantling joint Control gear diagram for Inlet valve Arrangement of air valve Foundation of valve and servomotor and loading on foundations, operating and earthquake conditions

9 10 11 12 13 14

Arrangement of operating mechanism Sealing arrangement Pressure oil system with piping Compressed air system piping Layout with section of trenches, block outs etc. for piping & cables Interconnection and wiring diagram and cable schedule

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DATA 1 2 3 Opening and closing characteristics. Max. Efforts and Max. Toque on foundation and steel shaft. Consideration made in data about loading on foundation of main inlet valve and servomotors. 4 Adequacy of oil supply system. MANUALS 1. 2 3. 4. 5. Manuals for storage, preservation and handling of the supplied goods Manual for erection/ dismantling testing and commissioning of the supplied goods Maintenance manual Tolerance for assembly List of consumables, oils & Spares 12 20 12 12 For reference For reference For reference For reference 12 For reference 3 3 For approval For approval 3 For approval 3 For approval

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ANNEXURE VI 2 DEPARTURE FROM SPECIFICATION (To be filled in by Bidder.) Item Description of departure. Reference to clause in the specifications

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DATA SHEETS 1 2 3 4 5 6 7 8 9 Type Nominal diameter Material of valve Material of valve disc Design pressure Test pressure Factor of safety over yield point Time of opening Time of closing during Normal operation During emergency 10 11 12 13 14 15 16 17 18 19 a) i) ii) iii) Leakage through closed valve Method of opening Method of closing No. of Servomotor Whether maintenance seal is provided Location of maintenance seal Weight of valve Weight of heaviest part to be transported (Lx BxH) Oil pressure system Main oil pump Type of pump Capacity of pump Rating of pump motor KW rpm ::.. .. ::.. .. LPM :.. ::::::::::.. .. .. .. .. .. .. .. .. .. .. Kg Kg Sec. Sec. Ltr/Sec. ::::::::.. .. .. .. .. .. .. .. Sec. Kg/cm2 Kg/cm2 mm

Dimension of largest part to be transported :-

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b) i) ii) iii)

Standby oil pump Type of pump Capacity of pump Rating of pump motor KW rpm ::.. .. .. ::.. .. LPM

c)

Quantity of oil in one filling of valve oil :system.

d)

Maximum rate of oil consumption from :pressure tank

..

Ltr/Sec.

e) f) g)

Capacity of sump tank Total capacity of pressure tank

::-

.. .. .. Ltr.

Number of complete operations which can :be performed by the amount of oil in the pressure tank with oil pump not working.

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SECTION VII

TECHNICAL SPECIFICATIONS OF STATION AUXILIARIES

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SECTION VII TECHNICAL SPECIFICATIONS OF STATION AUXILIARIES. INDEX Sr. No.. 7.1 7.2 7.3 7.4 7.5 7.6 7.7 7.8 Description General. Schedule of Requirements. Compressed Air System. Drainage and Dewatering System. Cooling Water System. Standards. Inspection and Tests. Drawing and Data To Be submitted with Bid. 7.9 Drawings, Designs and Manuals to be furnished after Award of Contract. 7.10 Spares. 201 201 Page no. 186 186 188 191 195 199 200 201

ANNEXURES. Annexure - VII-1 List of Drawings, Designs and Manuals to be submitted by the supplier after award of contract. Annexure - VII-2 Departure from specifications. Data Sheets 206 205 202

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SECTION VII

TECHNICAL SPECIFICATIONS OF STATION AUXILIARIES.

7.1

GENERAL. This section covers the technical specification and requirement of the station auxiliary system/equipments. Any fittings, accessories of apparatus which may not have been specifically mentioned in these specifications but which are indispensable for reliable operation of the plant shall be provided by supplier at no extra cost to the purchaser. The capacities and ratings mentioned for various auxiliaries in the scheme shall be rechecked by the supplier and these shall be subject to approval by the purchaser. Relevant provisions of section No.I shall be applicable.

7.2

SCHEDULE OF REQUIREMENTS.

7.2.1 COMPRESSED AIR SYSTEM. 1) Compressed air system shall consist of following :-. 2 Nos. of compressors :- (one main and one 100% stand-by) to cater the compressed air requirement of by). Air Receivers: 1 No. of adequate capacity Air Receiver located at suitable location. Generator brakes, Governor OPU, shaft seal etc. .(one main and one 100% stand-

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Piping and Valves: All pipes, valves required for the entire compressor system and to lead the compressed air to individual equipment with pressure gauges, pressure switches etc. 2)

Motor Control Centre: For the compressors mentioned above, motor control centre to be located near compressor shall be provided.

3)

Cabling: All power and control cabling between the motor control centre to compressor motor sets and all devices such as pressure switches, etc. complete with clamps, trays, ferrules etc. All cable shall be of FRLS copper conductor cables.

7.2.2 DRAINAGE AND DEWATERING SYSTEM. 2 sets submersible type or pump motor adequate capacity shall be provided. Out of these, one set will be in normal operation and other as standby. Piping and Valves: All piping required complete with necessary valves, fittings etc. Motor Control Centre: Motor Control Centre for all the above Two (2) sets and to be located in pump room shall be provided complete with suitable starter. Cabling: All power and control cabling between the motor control centre to pump motor sets and all devices such as level switches, flow relays etc. complete with clamps, trays, ferrules etc. All cable shall be of FRLS copper conductor cables. type pump motor sets of

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7.2.3 COOLING WATER SYSTEM. The cooling water for main plant shall be tapped from penstock before BFV. The cooling water after circulation shall be discharged into tail race. The supplier shall decide whether booster pumps are required for circulation of water with sufficient pressure.

Piping and Valves: Piping, manifold and valves required penstock to each equipment and discharge piping from each equipment to tail race. Motor Control Centre : Motor Control Centre for all the above pumpmotor sets complete with suitable starter. Cabling : All power and control cabling between motor control centre and cooling water pump-motor sets complete with clamps, trays, ferrules etc. All cable shall be of FRLS copper conductor cables. NOTES: Motors : All motors of auxiliary systems mentioned above shall be suitable for operation at 3 phase, 400 V system, and shall have class F insulation with temperature rise corresponding to class B insulation. All motors and starters shall be suitable for 15 times on/off operation per hour. Degree of protection for motors : IP-54. 7.3 COMPRESSED AIR SYSTEM.

7.3.1 OPERATION SYSTEM. - Starting and stopping of the air compressors shall be carried out automatically by pressure relays mounted to pressure system and to general requirement air pressure reservoirs and by manual operation from the motor control panel. - Two Nos. of air compressor shall be provided one for normal operation and other as stand-by. Normal operating air compressors shall be selected as desired by change-over switch mounted on motor control panel. The standby pump shall be selected automatically when air pressure drops because of a trouble in the normal operating air Signature of Bidder
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compressor or other reason. The stop when the pressure is restored.

air compressor shall automatically

7.3.2 ACCESSORIES OF COMPRESSORS. Following accessories and fittings shall be provided to each set of air compressors :-Water Separator -Check Valve -Unloader for starting -Lubricating device -Water flow relay (in case of water cooling type) -Cooling device -Drain disposal device -Interlock switch -Pressure reducer ( to match required brake pressure) : 1 set. : 1 set. : 1 set. : 1 set. : 1 set. : 1 set. : 1 set. : 1 No. : 1 set.

7.3.3 PRESSURE AIR RECEIVERS. (a) Maximum and normal working air pressure, starting pressure of the standby air compressor and alarm pressure shall be decided through mutual discussion with Purchaser contract. (b) Air receivers shall be provided with the following accessories :i) Air pressure gauge (for mounting to the turbine control panel) ii) Air pressure gauge (for mounting to the air pressure reservoir). Signature of Bidder
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after the award of

: 1 No.

: 1 No.

Signature of Purchaser

iii) iv)

Air pressure relays Feed air valves, exhaust air valves, check valves, drain valves & other stop valves.

: 1 set.

: 1 set. : 1 set.

v)

Safety valves

7.3.4 MOTOR CONTROL CENTER FOR COMPRESSED AIR SYSTEM. From 400 V A.C. auxiliary supply scheme, one feeder shall be brought to this motor control centre. Power cable for this purpose shall be provided by the supplier. Following equipment shall be provided by the supplier on the motor control centre:1. Incoming Breakers 2. Bus-Bars 3. Feeder Breakers 4. Control Switches : 1No. : Entire length of panel. : 4 Nos. +2 Nos. spare. : ON/OFF Switch for each compressor. Priority selector switch Auto manual switch 5. Indicators 6. Indicating Meters 7. Starters 8. Selector Switch 9. Protection : ON/OFF/ Trip Lamps for each compressor. : i) 1No.Voltmeter with selector switch. : ii) 1No. Ammeters with selector switch. : ON line starters. : LOCAL/REMOTE for each compressor : thermal over current relay

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7.3.5 PIPES AND VALVES. All pipes and valves required up to the respective equipment shall be supplied along with complete set of flange coupling, bolts, nuts and packing. Main bus pipeline for braking shall be duplicated. All compressed air piping shall be of seamless steel. 7.3.6 LUBRICANTS. Sufficient quantity required for first fill of lubricant, grease, oil etc. plus 25% extra shall be supplied and included in bid cost. 7.3.7 CABLES. Power supply cables and all control cabling from motor control centre to compressors, receivers etc. is included in Bidders scope. Compressor starting shall be regulated from the pressure switches provided on air receivers. The motor control centre shall be located near compressor. Cables from each auxiliary system equipment to its control panel (both of which are included in suppliers scope) shall be supplied. Cables for interconnection between computer and computer based control panel shall also be supplied. All cable shall be of FRLS copper conductor cables.

7.4

DRAINAGE AND DE-WATERING SYSTEM. The drain water of entire power house and fire hydrant discharge will be collected in Drainage and Dewatering pit located in the machine hall. The supplier shall inform purchaser after detailed design and calculation the size of pit required. For dewatering of draft tubes gravity drain shall be considered. Necessary piping shall be laid by supplier up to the Drainage and Dewatering pit. The water in the pit shall be discharged at suitable location outside the power house. Drainage and dewatering system shall comprise of following:

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7.4.1 PUMP-MOTOR SET. a) Pump: The pumps shall be of submersible type and sturdy and of proven design with one or multi stage and with a double seal fitted to pump shaft. The pumps shall be suitable to handle the raw and unscratched water having turbidity of about 6000 ppm without any damage or adverse effect to any parts of the pump. The bowls shall be made of closed grain cast iron free of any defects. The pump impellers shall be of one cast iron or phosphor bronze and shall be dynamically balanced. Lockout shall be provided to arrest the excess lift of impeller at the time of starting. The pump bearing shall be of self-lubricated type. Fully streamlined discharge case-cum non-return valve shall be provided at the outlet of each pump. The non-return valve shall be spring loaded needle type. Depending on the water level in the sump pit the pumps shall start or switch-off automatically with the help of float controls. All the control cables required for these purpose shall be provided by the supplier. b) Motor: Motor shall be of squirrel cage, induction type, 400 V, 3 phase, alternating current directly coupled to the pump and forming a part and parcel of pump-motor set. The motor shall be wet type. DOL starter shall be provided. The motor shall be provided with dual seal arrangement and sand guard for its protection from outside water. The stampings used in motor shall be double varnished to have better anti-rusting property. The rotor as well as stator shall be vacuum impregnated with superior quality varnish and shall be baked under the controlled conditions to ensure proper and long life. Stainless steel sleeves ground to close tolerance shall be provided at the bearing locations. The motor winding wires shall be made of water resistant type insulation and shall be of copper. Bearing assembly shall be fitted Signature of Bidder
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with tilting pad bearings, mounted on stainless steel balls, and shall be supported by rocking pins. Bearings shall be suitable to absorb the vertical thrust. Suitable rubber diaphragm shall be provided to the motor for pressure compensation. All fasteners shall be chemically treated for protection against rust. The entry of power supply cables to the motor shall be through suitable cable gland, fitted on the body of motor and cable entry arrangement shall be fully watertight. The bidder shall furnish the details about arrangement of cable entry to the motor, in his bid. Bidder shall also supply details of arrangement for disconnection of the cable (outside the water.) in order to remove the pump. The pump shall have nameplate indicating: Name of manufacturer: Type, rating and rpm: Serial number of pump: Discharge and head values for duty point: Following accessories shall be supplied per 1 set of pump: Pressure gauge Check valve : 1 No. : 1 No.

Check valve and a valve on delivery side : Lot. Induction Motors. Driving motors for above-mentioned pumps will be AC 400 V, 50 Hz, 3 phase induction motors. 7.4.2 PIPING AND VALVES. Piping, manifold, valves etc. required for lifting the water from Drainage and Dewatering pit to Discharge point shall be provided.

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7.4.3 FLOAT CONTROLLERS. Float controllers shall be provided in the sump pit. The control cables from these controllers shall be taken to motor control centre for regulation of motor starting. 7.4.4 MOUNTINGS AND SUPPORTING ARRANGEMENTS. Foundation mountings for pump motors, supporting arrangement for columns of suction and delivery pipes shall be supplied. 7.5.5 MOTOR CONTROL CENTRE FOR DRAINAGE AND

DEWATERING PUMPS. From 400 V auxiliary supply scheme, one feeder shall be brought to this motor control centre. Following equipment shall be mounted on the motor control centre: 1) 2) 3) 4) 5) 6) Incoming breakers Bus bar Feeder Breakers Control switches Indicators Indicating meters : 1 No. : Entire length of panel : Two numbers + Two numbers spares. : On/Off switch for each pump. : On/Off /Trip lamps for each pump i) One No. Voltmeter with selector switch. ii)One No. Ammeter with selector switch. 7) 8) Starters Selector 2 Nos on line starters. i) Local/remote for each pump - 2 Nos. ii) Auto/manual for each Pump 2Nos. iii) Priority selector switch -1 No. Signature of Bidder
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Signature of Purchaser

9)

Protection

: Thermal over current protection

10)

Cables :- Power supply cables and all control cablings from motor control centre to motors, load controllers etc. is included in Bidders scope. Cables from each auxiliary system equipment to its control panel (both of which are included in suppliers scope) shall be supplied.

Motor starting shall be regulated from the float controllers provided in drainage and dewatering sump.

7.5

COOLING WATER SYSTEM.

7.5.1 PURPOSE. This system shall be used for supplying cooling water for following purposes: 1) Cooling water for generators equipped with water cooled heat exchangers 2) 3) 4) 5) Cooling water for generator guide and thrust bearings Cooling water for Turbine guide bearing and shaft seal. Cooling water for Turbine governor oil pressure system Other requirements if any.

The cooling water for main plant shall be tapped from penstock before BFV. The cooling water after circulation shall be discharged into tail race. The supplier shall decide whether booster pumps are required for circulation of water with sufficient pressure. If booster pumps are required then following specification shall be applicable. One motor- pumps is specified for normal operation conditions and one pump shall be provided as stand-by pump . Signature of Bidder
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Signature of Purchaser

The above mentioned motor pumps will pump water from penstock and supply to each equipment and discharge piping from each equipment back to the draft tube. Starting and stopping of the cooling water pump shall be normally carried out by automatic control ( from main plant start sequence program) and in case of trouble in the normal working cooling water pump, the standby cooling water pump shall start automatically. Besides, it shall be so arranged that the normal working and stand by cooling water pumps can be started and stopped by manual operations at the motor panel. 7.5.2 PUMP MOTOR SETS. a) Pumps: - The pumps shall be centrifugal type and sturdy and proven design with one stage and with a double seal fitted to pump shaft. The pumps shall be suitable to handle the raw and unscratched water having turbidity of about 6000 ppm without any damage or adverse effect to any parts of the pump. The impellers shall be made of cast iron or phosphor bronze and shall be dynamically balanced. Lockout shall be provided to arrest the excess lift of impeller at the time of starting. The pump bearings shall be self lubricated type. Fully streamlined discharge casecum-non return valve shall be provided at the outlet of each pump. The non-return valve shall be of spring loaded needle type. All the control cables required for these purpose shall be provided by the supplier. b) Motors: - Motors shall be of squirrel cage, 400 V induction type, 3 phase, alternating current directly coupled to the pump and forming a part and parcel of pump motor set. The motor shall be wet type. The motor shall be provided with dual seal arrangement and sand guard for its protection from outside water. Signature of Bidder
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Signature of Purchaser

The stampings used in motor shall be double varnished to have better anti-rusting property. The rotor as well as the stator shall be vacuum impregnated with superior quality varnish and shall be baked under the controlled conditions to ensure proper bonding and long life. The motor winding wires shall be made of water resistant type insulation and shall be of copper. Bearing assembly shall be fitted with tilting pad bearings, mounted on stainless steel balls, and shall be supported by rocking pins. Bearings shall be suitable to absorb the vertical thrust. Suitable rubber diaphragm shall be provided to the motor for pressure compensation. All fasteners shall be chemically treated for protection against rust.The entry of power supply cables to the motor shall be through suitable cable gland, fitted on the body of the motor and the cable entry arrangement shall be fully watertight. The bidder shall furnish the details about arrangement of cable entry to motor, in his bid including type of starter. Bidder shall also supply details of arrangement for disconnection of the cable (outside the water) in order to remove the pump. The pump shall have nameplate indicating: Name of Manufacturer, Type, rating and rpm, Serial number of pump, Q (discharge) and H (head) values for duty point. 7.5.3 FILTER AND STRAINER The cooling water from (penstock) shall be first passed through rotary automatic cleaning water filter. The cooling water to be fed to shaft seal and runner labyrinth shall be again passed through fine strainers. The filters and strainers shall be provided as under : Signature of Bidder
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Signature of Purchaser

Main rotary filter automatic & manual Fine filters for shaft seal (automatic and manual) Fine filter for runner labyrinth (manual) Strainer

The main strainer and filter shall have a capacity sufficient for passing the cooling water requirement of entire power station. The automatic strainer shall be capable of automatically changing over by rotating the strainer at pre-determined intervals and cleaning inside of strainer automatically. The design of manual strainer shall be such that the cleaning is carried out by manual operations of valves. 7.5.4 MOTOR CONTROL CENTRE FOR COOLING WATER PUMPS From the 400 V A. C. auxiliary supply scheme, one feeder shall be brought to this motor control centre. Following equipments shall be mounted on this motor control centre: 1) Incoming Breakers 2) Bus-Bar 3) Feeder Breakers 4) Control Switches 5) Indicators 6) Switches 7) Indicating Meters 8) Starters 9) Selector Switches : 1 No. : for the entire length of panel. : 2 Nos. + 2Nos. spares. : ON/OFF switches : ON/OFF / trip lamps. : i) 1 No. Voltmeter selector Switch ii) 1 No. Ammeter Selector Switch : i) 1 No. Voltmeter ii) 1 No. Ammeter : DOL type : i) LOCAL/REMOTE for each pump. ii) AUTO /MANUAL for each pump. 10) Cables: Power supply cables and all control cabling from motor control centre to pumps, float controllers etc. is included in Bidders scope. Cables from each auxiliary system equipment to Signature of Bidder
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Signature of Purchaser

its control panel (both of which are included in suppliers scope) shall be supplied. Cables for interconnection between computer and computer based control panels shall also be supplied. 7.5.5. PIPING AND VALVES; Piping, manifold, valves etc. required from penstock to each equipment and discharge piping from each equipment to draft tube shall be included in Suppliers scope of works 7.5.6. PRESSURE GAUGES Pressure gauges shall be provided as required. 7.5.7 PRESSURE CONTROLLERS Pressure controllers shall be provided in the cooling water system. The control cables from these controllers shall be taken to motor control centre for regulation of motor starting. 7.5.8 MOUNTINGS AND SUPPORTING ARRANGEMENT Foundation mountings for pump motor sets, supporting arrangements for suction and delivery columns shall be supplied.

7.6

STANDARDS Equipment shall be in accordance with the latest IEC standards or equivalent internationally accepted standards. Some of the standards are listed below but shall not be limited to: IEC 298 IEC 264 IEC 227 IEC 287 IEC 269 IEC 364 - Cased equipment - Common clauses, IEC 502 - M.V. Cables - PVC Conductor and Cable. - Calculations and Dimensions. - Fuses. - Installation
199

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IEC 439

- Operating Mechanism, IEC 51-1 to 51-5 - Counters, IEC 255 (1 to 22) - Relays - Motors - Magnetic Materials - Noise - Vibrations - Corrosion Protection - Steel Plate Testing - Welding Materials - Cast Part testing - Forged part testing

Measuring Devices. IEC 145 & 521 IEC 72 IEC 404 IEC 349 & ISO 1996 VDI 2056 Swedish Standard 515 ASTMA 435 ASME V ASTMA 609 & 709 ASTMA 388

7.7.

INSPECTION AND TESTS The Supplier shall carry out inspection and tests at factory and site in respect of auxiliaries as per the list given below LEGEND 1. 2. 3. 4. 5. 6. 7. Material test Non-destructive inspection of assemblies/components. Pressure test Workmanship test Assembly inspection Operational tests Commissioning tests

SUBMISSION OF TEST CERTIFICATES The supplier shall submit 6 copies of test certificates to the Purchaser as per the procedure given below: i) FOR INSPECTION AND TESTING SPECIFIED TO BE DONE IN PRESENCE OF PURCHASER. Test certificates shall be submitted for approval. Signature of Bidder
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ii)

FOR ALL OTHER INSPECTION AND TESTING Test certificates showing that the specified tests/inspection has been carried out successfully by the Supplier, shall be submitted for reference.

7.8

DRAWINGS AND DATA TO BE SUBMITTED WITH BID Bidder shall submit in his bid information and general drawings describing and illustrating the equipment he proposes to offer, in such a manner as to make possible a complete understanding of the equipment on which bid is based. The information shall include all essential dimensions, types of materials to be used in major parts with the chemical and physical properties of materials and the schematics, layout drawings, control schemes and data for the: 1. 2. 3. Cooling water system Drainage and dewatering system Compressed air system

All Data Sheets enclosed with this section must be completely filled in by the Bidder.

7.9

DRAWINGS, DESIGNS AND MANUALS TO BE FURNISHED AFTER AWARD OF CONTRACT These shall be submitted as per the list given in Annexure VII-I to this section. Mode of submission of drawings and designs will be intimated to the successful Bidder in due course.

7.10

SPARES Spares shall be supplied as per list under Section III of this Volume.

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ANNEXURE award of contract. Sr. No. DRAWINGS 1. Layout and dimensional Drawings showing equipment for, * Cooling water pumps room * Compressor room * Trenches, blackouts etc. for pipe line and cables * Support details of pipelines 2. 3. 4. 5. 6. 7. 8. 9. Pipe layout of cooling water system Schematic of cooling water system. Motor control centre panel for cooling water system Arrangement diagram of compressed air system Pipe layout of compressed air system Schematic of compressed air system Motor Control centre panel for compressed air system Arrangement of drainage and dewatering system. Signature of Bidder
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VII - I

List of drawings, designs and manuals to be submitted by the Supplier after the

Brief Description

Within months from the date of award of contract

Remarks

For approval 6 6 3 6 6 6 6 6 6 6 6 6 For approval For approval For approval For approval For approval For approval For approval For approval Signature of Purchaser

* Drainage and dewatering Pump room 6

10. 11. 12. 13

Pipe layout of drainage and dewatering system Schematic of drainage and dewatering system Motor Control centre panel for drainage and dewatering system Interconnection and wiring diagram and cable schedules of equipment 8 6 For reference For approval 6 For approval 6 For approval 6 For approval

14.

Foundation / support arrangement of, * Cooling water pumps * Drainage/dewatering pumps * Compressor air equipment, air receivers * All water piping, valves pump columns * Switchgear panels of cooling water, drainage/dewatering and compressed air system.

DATA 1. 2. 3. Adequacy of cooling water system Adequacy of dewatering and drainage pit size and volume Adequacy of pump capacity for cooling water, drainage and dewatering system 4. Adequacy of compressed air
203

3 3

For approval For approval

For approval

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systems including capacities of compressors and air receivers. 3 For approval

MANUALS 1. 2. Manual for storage, preservation and handling of the supplied goods. Manual for erection, dismantling, testing and commissioning of the supplied goods. 3. 4. Maintenance manuals List of consumables, oils, grease, spares etc. 10 For reference 10 18 For reference For reference 10 For reference

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ANNEXURE VII- 2 DEPARTURE FROM SPECIFICATION (To be filled by Bidder) Item Description of departure Reference to Clause in specification

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DATA SHEETS

COMPRESSED AIR SYSTEM

-Total number of compressors -Discharge of one compressor at working rated pressure . ........ . -Rated working pressure of compressor -Rated power of compressor motor -Rated speed of compressor motor -Total number of air tanks -Volume of one air tank for general ............ ... ... m3 kg/s N m3/s kg/s

... MPa .. kW .. rpm ................

requirement -Air leakage during operation

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COOLING WATER SYSTEM TECHNICAL DATA SHEET FOR SUBMERSIBLE MOTOR PUMP-UNITS ALTERNATIVELY TURBINE PUMP - MOTOR SET

Cooling Water Pumps

Offered Value

Quantity Type of operation Manufacturer Type Rated speed Discharge heads Corresponding Discharges Qn (at Hn) Efficiency (nominal point) Power Rating Motor Voltage Type of starter

.......... ..........

.......... .......... rpm .......... m

.......... m3/sec .......... % .......... kW --------------------------

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DRAINAGE AND DEWATERING SYSTEM TECHNICAL DATA SHEET FOR SUBMERSIBLE MOTOR - PUMP UNITS ALTERNATIVELY TURBINE PUMP- MOTOR SET

Drainage Pumps Quantity Type of operation Manufacture Type Rated speed Discharge Heads Hn

Offered Values ............

............

............ rpm ............. m3/sec ............. m

Corresponding Discharges Qn (atHn) Efficiency (Nominal point Motor power Materials body Impeller Shaft ............. ............ ............ kW ............. m3/sec ............. kW ............ m3/sec

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SECTION VIII

TECHNICAL SPECIFICATION OF GENERATOR

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SECTION NO. VIII TECHNICAL SPECIFICATION OF GENERATOR I N D E X Sr.No. 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 8.9 8.10 8.11 812 Description Scope Standards Type and main characteristics Particular mechanical design characteristics Particular electrical design considerations Performance Guarantee Technical specifications of Generator. Technical specifications of Static Excitation Factory test for Generator-Motor and related equipment. Material test Site tests for Generator and related equipment. Drawings, Designs, Studies and Manuals to be submitted by the supplier after award of contract 8.13 Spares ANNEXURE Annexure VIII-1 DATA SHEETS Data Sheets 276 271 270 259 266 270 PAGE NO. 211 211 212 212 213 215 216 249 258

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SECTION VIII TECHNICAL SPECIFICATION OF GENERATOR 8.1 Scope : This section covers technical specification of one number of three phase vertical shaft synchronous generator and related equipment including static excitation equipment. The generator shall be of 15 MW rated output, 0.9 p.f.,11 KV, 375 rpm. 3 ph. 50 Hz, Vertical shaft synchronous Generator and capable of giving continuous output of 110% of rated output. The generator shall be suitable for direct coupling to the turbine specified under Section V. Any fittings, accessories or apparatus which may not have been specifically mentioned in these specifications but which are indispensable for reliable operation of the plant shall be provided by the Supplier at no extra cost to the Purchaser.

8.2

STANDARDS The applicable standards but not limited to : 1) 2) 3) 4) 5) IEC..... 34 ( parts ...........) VDE Standards of group 0530 IEC 85 (Insulation classes) ANSIB 49-1-1967 Shaft couplings, Integrally Forged Flange type for Hydro Electric units. N.E.M.A. LG 2 Vertical Hydraulic Turbine Generator Shaft Run out tolerances shop check or IEEE 810 whichever stipulated severe conditions. 6) 7) 8) 9) V.D.I. 2056 for provisions regarding Radial Vibration Amplitudes. V.D.I . 2060 for provisions regarding Rotor balancing. Rathbone curves for provisions regarding Radial & Axial Vibration accelerations. I.E.C. 287 - Calculation of continuous current rating (100% load factor).

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10) 11) 12) 13)

I.E.C. 38 - Standard Voltages I.E.C. 71 - Insulation co-ordination ( Part 1,2, &3 ) I.E.C. 136 - Dimension of brushes & brush holders for electrical machinery. Please refer list of standards contained in Mechanical Lot. These are also applicable wherever relevant.

8.3

TYPE AND MAIN CHARACTERISTICS For rating and other parameters of the Hydro generator, please refer Technical Data Sheet enclosed here with. The bidder shall fill in these Data Sheets and submit them in his bid. The bidders shall specifically note the requirement and fulfill it in all respect without fail.

8.4

PARTICULAR MECHANICAL DESIGN CHARACTERISTICS In addition to the provisions contained in section I of this volume regarding operational and other design requirements, the equipment specified in this section shall also comply with the following stipulations: 1) All parts of the generator shall be designed to withstand safely the electrical, mechanical and other stresses which may be induced during abnormal conditions such as runaway speed and electrical faults and the machine shall shutdown and come to standstill position without damage. The electrical faults which shall be considered must include faulty synchronising, sudden three phase short circuit, two phase short circuit and terminal short circuit at 50% poles at normal voltage with simultaneous over-speed for 3 sec. The design shall be such that stresses induced in any part under steady state runaway condition and electrical fault conditions shall not exceed two-thirds of yield point strength of the material used in that part. 2) Static and Dynamic stability of the Mechanical Parts :

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Critical speed of the complete shaft line (generator + turbine) must be beyond 120% of maximum runaway speed during most unfavourable conditions. The rigidity of the entire shaft line must be such that asymmetries of the stator air gap will not be increased markedly. Oscillations of rotor and shaft line must not be initiated by pulsations of the torque or vertical hydraulic thrust from the turbine or by sub-harmonic oscillations resulting from the stator winding or by pulsating torques originated by failures (e.g. sudden short circuits ) etc. The stator must be safe against core buckling. Its circular stability and the centricity of the shaft line must be safely secured. 3) Vibrations & Balancing: The relative locations of the combined thrust and guide bearing, the generator lower guide bearing and the turbine guide bearing shall be so determined that vibrations shall be minimum and a smooth operation is ensured on the whole of the operating range i.e. at any load and at any head within the range specified in section I & Section V of this Volume . 4) Hydraulic Thrust: The unit and its thrust bearing shall be designed to support the combined weight of the rotating parts of the generator and turbine including the maximum hydraulic thrust due to the turbine during transient conditions.

8.5

PARTICULAR ELECTRICAL DESIGN CONSIDERATIONS 1) Generator Rated Voltage (Un) The rated voltage (Un) of Generator shall be 11.0 kV. The continuous automatic voltage regulation shall be ensured within the range 0.9 Un to 1.10 Un (Un 10%).

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Rated frequency is 50 Hz.

The supplier shall guarantee rated

continuous output within the range of frequency from 47.5 Hz. to 51.5 Hz and voltage range of 0.9 Un to 1.1 Un. Supplier shall furnish information regarding outputs available below 47.5 Hz. (47 and 46 Hz) and duration of such output. Rated power factor is 0.90 (over excited) - 1.0-0.90 (under excited) The most unfavourable sudden two phase terminal short circuit at nominal voltage, 50% pole short-circuits with simultaneous over speed for 3 seconds shall be considered. No damage whatsoever must occur to the generator itself and the foundations in either case. 2) STATOR WINDING CONNECTION The stator winding shall be star connected and neutral point to be grounded through primary of power or voltage transformer and resister. 3) Winding Insulation Class The stator and field windings shall be entirely insulated with class F materials (thermosetting type). 4) Wave form and Telephone Harmonic Factor ( THF) The wave form of the open-circuit terminal voltage shall not deviate from a true sine wave by more than 5%. The Telephone Harmonic Factor shall not exceed 1.5%. 5) Limits of Temperature and Temperature Rises The maximum output which should be available at its terminals at shall power factors cos 0.9(over excited)...1...0.90(under excited) be 18.333 MVA . When the generator operates at rated output, power factor, speed and voltage, the stator and field winding temperature rise of generator measured by embedded thermostat temperature detector and resistance method shall not exceed 750 C & 850 C respectively. When the generator operates at maximum output, rated power factors, speed and voltage, the stator and field winding temperature rise of Signature of Bidder
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generator measured by embedded thermostat temperature detection and resistance method of generator shall not exceed 850 C and 950 C respectively. 6) Short Circuit Ratio, Direct Synchronous reactance and Direct - axis transient reactance Short circuit ratio of the generator shall not be less than 1.00. Direct synchronous reactance shall not be higher than 1.10 p.u Direct - axis transient reactance (unsaturated value) shall not be higher than 0.45 p.u. 7) Dielectric strength: a) The stator and rotor windings shall withstand the following power frequency test voltages for 1 minute: 2.75 times of rated voltage (11 kV) before coil insertion 2.25 times of rated voltage (11 kV) after coil insertion and at the time of completion of coil assembly. b) The rotor winding shall withstand 10 times of rated field voltage for 1 minute. 8.6 PERFORMANCE GUARANTEE: Generator Performance Guarantee:The guarantee parameters for hydro generator are output, temperature rise and efficiency at rated condition for voltage, power factor etc. Field test on completely assembled generator shall be carried out by the supplier and the result of test shall be treated as acceptance tests. These field tests are to be conducted within the 90 days from the date of commissioning of unit and within the warranty period of the Generating unit. All expenses in connection with tests at site is considered as included in contract price. Any shortfall in the values of guaranteed parameters shall be subjected to penalty or rejection in accordance with the limits and tolerances given in Volume-I. However, if due to the grid conditions, it is not possible to carry out field tests within 90 days from the date of commissioning, the matter shall be decided at that time. Signature of Bidder
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1) Efficiency Guarantee: - The efficiency of the generator shall be guaranteed by the supplier. The efficiency shall be determined by the summation of losses method as specified in IS 4889- 1968 or /and latest amendment there to and shall be subject to the tolerances specified in IS: 4722 -1968. Any shortfall in the values of guaranteed parameters shall be subjected to penalty or rejection as given in Volume-I. 6.2 Output and Temperature rise Guarantee:The hydro generator shall be guaranteed to give its rated and 10% overload output at rated voltage and power factor without exceeding the temperature rises. Any shortfall in the values of guaranteed parameters shall be subjected to penalty or rejection as given in Volume-I. The contractor shall be given all reasonable opportunities to make good and meet the guarantees before the application of penalty or rejection of hydro generator as a result of above clauses.

8.7

TECHNICAL SPECIFICATION OF GENERATOR 1) All material to be used shall be suitable and adequate for the purpose intended and shall conform to the IEC standards. No patching, blocking, shimming or any other similar means of overcoming defects, discrepancies or errors shall be permitted without approval of Purchaser. The generator design shall be such that the movements and deformations due to temperature variations are compensated and the loads and resulting forces, which would act on the foundation, are substantially reduced. It should further be ensured that: i) ii) No buckling of stator core laminations takes place. The concentricity and the size of air gap shall remain unchanged. The unit shall be designed for unit assembly during erection and for the removal of the complete assembled generator rotor during major

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maintenance programs. This design shall permit the assembly and dismantling operations to be performed as conveniently and quickly as possible with the facilities of the powerhouse crane. Entire stator and rotor shall be built at site to avoid any deformation in transit. Proper stator and rotor lifting device for connecting to power house crane shall be provided. The necessary information regarding the shape of the hooks shall be taken into consideration. Supplier shall declare along with bid his work plan for stator and rotor building at site on service bay, built up in situ or partial building on service bay and situ. Periods for such activities shall be distinctly shown and his proposal for execution of job shall be declared in the bid. Bidder shall note that entire stator and rotor are to be built at site. Considerations in the design shall be given to the following requirement for maintenance program. -The largest component of the turbine shall be capable of withdrawal through the stator bore after removal of the unit superstructure and generator rotor. - Rotor field poles shall be arranged in such a manner as to permit easy removal with the rotor in place. Field pole electrical connections shall be located in a position to facilitate ease in inspection, separation and reconnection. -The phase terminals of the windings shall be brought out of the generator concrete housing for proper connections with bus duct. The neutral terminals of the phase shall be brought out separately to abominate current transformers before forming the star point of the winding (Please refer the single line diagram). The two ends of field windings shall be connected to two slip rings mounted on shaft. 2. STATOR GENERAL The stator shall consist of a frame with air/water heat exchangers on its outer periphery, built-in laminated core with radial air ducts and bar Signature of Bidder
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winding in slots. The stator frame shall also support the upper bearing bracket, upper deck and the bushing of the phase bus bars and generator neutral connection. A portable, steel fabricated, inspection ladder shall be provided. STATOR FRAME The stator frame shall be fabricated from steel plates and shall be of welded construction. The frame shall be sufficiently strong to withstand the most severe forces during the abnormal conditions e.g. sudden short circuit & faulty synchronisation. Air coolers shall be mounted around the outer periphery of stator frame. The frame shall be provided with adequate number of horizontal stiffeners. STATOR CORE The stator core shall be made of low loss, high grade, non-ageing, silicon magnetic steel laminations having a favourable bending coefficient. The lamination shall be accurately punched and deburred so as to obtain very smooth surface at winding slots and keys slots. Each lamination shall be coated on both sides with class F insulating layer to eliminate inter lamination and eddy current circulation. The stator core shall be built up in stacks of equal height as far as possible, the bottom and top most stacks shall give a special treatment so as to form solid mass. While stacking the lamination, intermediate pressure treatment shall be given several times and the whole core should be pressed at both ends, by means of clamping rings with fingers pressing over teeth portion to ensure high tightness and mechanical strength of the core. The stack of laminations must be firmly anchored to the frame and pressed together in a firm and uniform way, which does not require readjustments after installation. In particular, vibration of stator as a

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whole is practically eliminated during any operating condition and stator migration phenomenon is avoided during life expectancy. The supplier shall describe in his bid the measures and means that will be provided by him totally to avoid the displacement of stator core punching. For cooling of the core and winding in the slots, the core shall be divided into several packets spacer punching provided with radial air ducts of appropriate height and breadth shall be used between the packets. To reduce the stray losses and temperature rise, the lamination in the end packets shall be cut radially . After completion of core building, a low induction core test with flux density of 1.0 T shall be conducted to find out if any laminations are short-circuited. The testing procedure shall be simple and efficient such that the same can be repeated on the core even at a later date. In case the design of core is such that neither a heating of the core nor an induction test of finished core with rated flux are necessary, the completed core shall be tested by means of non-destructive magnetizing test for detecting and locating short circuit faults in the core. STATOR WINDING The stator winding shall be two layer bar winding; the winding shall be connected in star. Each phase winding shall be so distributed around this stator as to minimize unbalanced magnetic pull and the circulating current between the parallel circuits. Each bar shall be composed of an assembly and a glass lapped tape impregnated with epoxy resin shall insulate these strands. The insulated strands shall be transposed according to roeble process along the entire core length. The two ends of each phase shall be brought out to terminals on the stator frame. The line and neutral terminals shall be made suitable for connection to bus duct. The arrangements shall be Signature of Bidder
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such that their connections with the conductor of bus duct are possible in a straight manner i.e. without any bend. The main and neutral leads and associated current transformers in neutral leads shall be protected by suitable non-magnetic enclosures to prevent accidental contact by personnel. Final details of the main and neutral lead termination at the unit shall be subject to approval by purchaser. All bolted main current carrying terminals shall be silver-plated. All neutral connections of the stator windings shall be parallel and all neutral current transformers shall be mounted beyond the generator housing and before the formation of neutral. The neutral lead shall terminate at the neutral cubicle, which shall contain the grounding transformer, resistor and accessories. The neutral shall be connected to ground through the primary of a voltage or power distribution transformer. The secondary of this transformer shall be loaded with a resistor to draw sufficient current under a maximum single-phase ground fault condition. The neutral grounding equipment, cubicle, interconnections, and ground connections shall be supplied. All generator windings, connections between individual windings or between a winding and a related generator component as well as all other primary connection and conductor shall be made of copper in accordance with applicable material standards. All bolted main current carrying terminals shall be silver-plated. The insulation of coils shall be continuous and of equal thickness along the entire coil. Insulation materials used shall be class F designed conforming to the requirements of IEC standards and manufactured in accordance with modern technology. Functional evaluation of insulation system shall be provided according to IEC 3418-1/1992. The duro plastic insulation system used shall have excellent dielectric, thermal and mechanical properties with proven reliability to withstand high voltages not only under operational Signature of Bidder
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conditions but also under severe fault conditions. The insulation on the stator coils shall be sufficiently durable so that in case it is necessary to remove coils, removal and replacement may be effected without damage to the insulation of any of the other coils. The quality and life of the insulation shall not be impaired in attaining the above requirements. Class F insulation of proven design and which has shown no breakdown shall be used. The details of the installation where such insulation system is used shall be stated in the bid. Generator winding cyclic & ageing tests (see IEC-34-18-1/1992-02Functional evaluation of insulation system for rotating machine.) to determine the life span under cyclic thermal loadings shall be conducted by the Bidder. If the supplier has already conducted such tests at shop, type test reports shall be furnished with the bid. The construction of winding bars and the winding in slots shall be fully explained with drawings and detailed description. The class F insulation system used shall be proven. The bidder must furnish examples where the same system is used and is in trouble free operation. Corona shielding applied to the fully insulated bar shall have the following structure. The straight part of the bar shall be covered with a conducting varnish (outer corona protection) in order to avoid potential differences between the surface of insulation and the core iron. The bend end portions of bars are covered with a semi-conducting varnish and in addition a special tape be wound over a certain portion to ensure the desired potential distribution (Capacitive control of potential distribution). These measures would avoid creeping discharges along the surface of insulation or even a breakdown. The bars shall be carefully inserted in slots and properly aligned. It shall be ensured that the wedges are firmly and permanently seated and

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there are no possibilities of damaging the core lamination edges in the slot. Rewedging should be virtually not necessary. The packing shall be effective in both the circumferential and radial directions. When installed, the coil sides shall be tight within the slot so that a 0.5 mm. filler gauge will not enter any gap between the coil and slot sides. The 0.5-mm. fillers gauge no-go standard shall apply to at least 90% of the stacked core length. The remaining 10% has individual go length of less than 0.80 mm. After final wedging, there shall be no measurable radial clearance between the coil and slot or wedge. Slot wedges shall be of phenolic or glass-reinforced polyester material, highly resistant to thermal ageing and designed to minimize any tendency to relax the radial pressure exerted on the coils. The stator coil insulation, wedging, packing, brazing and tying shall be such as to minimize the effect of thermal shock and of additional differential expansion which may occur as a result of the cyclic loading. End connections of the stator coils shall be made at the top of winding. The end portion of the winding shall be rigidly supported to prevent any movement and distortion even under the most unfavourable short circuit conditions. No metallic part, which does not correspond to class F, shall be used for this purpose. The slot portion of the bars must be manufactured to close tolerances. No grinding of insulation will be permitted to achieve required dimensions. The connections between half coils shall be covered in the ends by glass fiber insulation caps. Bracing shall make all connections in end windings. The strands of corresponding upper and lower layers bars shall be soldered at the connecting end using copper clips to ensure adequate mechanical strength and conductivity. A fiberglass-insulating cap shall be placed Signature of Bidder
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over each connection and filled with an epoxy compound to secure it to the ground insulation. The winding overhang portion shall be rigidly supported, lashed together by impregnated glass cords so as to form a rigid cone, which can withstand the forces due to a sudden short circuit. The system must be described in bid. phase current. Each winding bar shall be subjected to tangent delta measuring kV test in shop and the dielectric losses of each coil shall be measured in the factory and also after assembly at site. Resistance elements for temperature recorder shall be mounted at 6 positions in the portions where the stator coils of each phase are presumed to show the highest temperature. 3) ROTOR GENERAL The rotor shall consist of a spider, laminated rims with brake ring at the bottom, salient poles with field coils and damper winding cage as well as upper and lower shafts to be bolted to the upper and lower flanges of the hub. ROTOR SPIDER The rotor spider shall be of fabricated structure. High strength high yield steel shall be used in the construction of the central hub and the radial arms. The attachment of laminated rotor rim with the spider arms shall be designed to withstand the maximum forces induced in the runaway condition of the unit. The arrangement of arms shall not only compensate the expansion and contractions during operation of generator but also those due to welding. Signature of Bidder
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Circulating primary split-phase current

under normal operating conditions shall be less than 2.5% of total rated

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Approved tests for material and welds such as X-ray and ultrasonic tests and/or liquid penetration tests to ensure the reliability of the whole spider shall be conducted. ROTOR RIM The rotor rim shall be of laminated floating type i.e. it should be attached to the spider by means of wedges driven in between the key supports on spider arms and the slots on the inner periphery of the rim. The rotor rim shall be made up of circular segmental punching from sheet steel, stacked overlapped layer by layer around the outer periphery of the spider. The laminated rims shall be clamped to a compacted ring of solid segmented end plates by means of high tensile axial bolts so as to ensure firm mechanical connection between the adjacent segments of any two layers for transmission of tensile forces. The shape and geometry of laminations and the pattern of stacking shall be such that the completed rim corresponds to an ideal homogenous cylinder as the uniform distribution of mass. The brake ring shall be provided at the bottom of rim. The brake ring may be constructed in segments so as to allow any replacement. ROTOR POLES The pole body shall be made up of steel laminations made of same material as is used in construction of rim laminations. number of bolts. The poles shall be secured to the rim by means of wedges in such a way as to allow the removal of poles in the vertical direction without requiring removal of the rotor out of the stator bore. The pole laminations shall be held tight between end plates by means of suitable

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FIELD COILS AND DAMPER WINDING The field coil shall be made up of turns of flat rectangular copper cut to appropriate length and width. To increase the cooling surface area, alternate turns shall be provided with conductor of greater width so as to form on the outer side, a finned surface. The insulation system of class F shall be used to ensure compact assembly with excellent electrical and mechanical properties. The turn insulation should be thoroughly cemented to adjacent turns to permit removal of field pole coil as a unit. The pole core insulation must be separate from the coil. Special attention shall be paid to ensure prevention of end turns of a coil from deforming or slipping due to centrifugal forces on the inter-connections. End turn insulations must be reinforced if necessary. The field coils of poles shall be connected by means of flexible copper plates to form as field winding whose ends are brought out for connection with slip rings. The coils shall be tested at medium frequency test voltage or impulse voltage test on the terminals. During this test, the magnetising current must be measured and this current shall not differ by more than 10% between various coils. Low resistance damper winding of fully caged construction shall be provided to improve stability under fault conditions and specially to reduce voltage disruption under conditions of single-phase fault. SLIP RINGS The slip rings shall be in an accessible location above the rotor. The slip rings shall be so arranged as to minimize the possibility of an operator causing a short circuit between slip rings while changing or adjusting the brushes. Provisions shall be made for reversing the polarity of the slip rings to obtain uniform wear on both slip rings. The maximum run out of the slip rings shall not exceed 0.25 mm. The Signature of Bidder
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brushes shall be staggered, and the slip rings shall be so located that they will not interfere with the removal of the upper guide bearing. The brushes and slip rings shall also be so positioned as to avoid contamination by oil vapour or oil leakage from this bearing. The lead from the slip rings shall run directly to the field breaker and discharge resistor. An extra set of slip ring brushes, insulated brush holders, and terminals shall be provided. One 45 mV drop shunt to be mounted in the generator field leads shall be furnished complete with calibrated shunt leads for connection to a field current ampere meter. A separate slip ring and brush assembly shall be mounted on generator shaft for the field winding earth fault relay and the leads shall be terminated in the generator terminal box. The slip ring and brush gear shall be separately enclosed from the generator housing. It shall be so arranged that ventilating air from the ring and brush gear housing cannot enter the generator housing. This will prevent suspended carbon dust from the brushes entering the generator housing. A self-fan or motor fan shall be provided for cooling and exhausting the carbon dust. Isolating switch for the fan motor shall be located within the brush gear housing. 4) BRACKETS UPPER BRACKET Upper bracket shall be designed to accommodate combined thrust and Generator upper guide bearing and also to lift the complete stator from erection bay to the generator pit. It shall also support top flooring. The flooring shall be divided into a number of sections so as to allow withdrawal of air/water heat exchangers and or rotor poles.

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LOWER BRACKET Lower bracket shall house lower guide bearing. The arms of bracket shall be bolted at inner end to central body and the outer end to foundation. Combined braking and jacking cylinder equipment shall be mounted on the arms of bracket. The overall size shall be such that the bracket can be withdrawn through stator bore. A steel plate cover (suitable air guide) shall be provided beneath the lower bracket to ensure the circulation of cooling air within the generator housing. NOTE: The design of the brackets shall conform with the bearing arrangement proposed. 5) BEARINGS GENERAL The combined thrust and upper guide bearing and the separate lower guide bearing shall be liberally designed so that operations at following conditions are guaranteed without any damage. Continuously at any speed from 30% to 110% rated speed at no load and maximum load condition. For 30 minutes at any speed down to 10 rpm. For 15 minutes at any speed between rated speed and maximum runaway speed. The allowable time of operation at runaway speed and at interruption of cooling water shall be 15 minutes. For not less than 15 minutes at rated speed and full load without cooling water supply. Operating Conditions The bearing shall be designed such that the maximum temperature of the bearing pads does not exceed 70 degrees C.

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Positive means, preferably using pressurised air, shall be provided to effectively stop the oil and / or oil vapour being drawn into the generator. THRUST BEARING The thrust bearing shall be amply designed to carry the weight of the rotating parts of the unit and the downward hydraulic thrust of the turbine under all starting, running, and stopping conditions met in operation, commissioning, and maintenance. Thrust block shall be integrally forged with the shaft. The one part thrust bearing runner plate shall be directly connected to the thrust block so that it would serve as the guide-bearing journal also. The thrust bearing pads are to be supported by adjustable pivots in such a manner that the thrust is equally distributed. These pads, which shall be babbitted, shall be tiltable in all directions and arranged in such a way that a wedge shaped oil film is automatically formed to transmit the load, as soon as the runner begins to turn. Only proven thrust bearing design will be acceptable. The combined thrust and guide bearing assembly which includes oil sumps, thrust pads, high pressure lubrication equipment, guide bearing pads and temperature detectors shall be arranged in such a way that it would permit easy inspection, adjustment and dismantling. The thrust bearing shall be provided with a high-pressure oil system for injecting pressurised oil below thrust bearing pads during the frequent starting and stopping of the machine. The forced pressurised oil system for providing the high pressure oil to the thrust bearing surfaces which will be operative during starting and running down the unit shall include two nos. of oil pumps, one driven by a 400V 3 phase 50Hz motor and a standby pump driven by a 220V D.C. motor, complete with auto change over proper starting gear etc.,

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all high pressure piping, flexible hose, strainers, regulators and check valves. The control equipment shall be of the heavy duty type. One pressure gauge to indicate establishment of oil film shall be provided having two sets of adjustable, electrically independent contact (both set closed at normal operating pressure and open at low pressure), one set to be used as an interlock to prevent starting the generator unit, if pressure to establish an oil film is not available and the other set to be used for operation of indicating lights. The contacts shall be suitable for use in 220V D.C. circuits. Suitable damping devices shall be provided in the high pressure piping system, if necessary to prevent undue pulsations of the pressure gauge. The pumping unit shall be of sufficient capacity to force the oil completely between the thrust bearing surfaces when the unit is at standstill. The high pressure oil grooves on the bearing pads shall be so designed that they will not interfere with normal lubrication of the bearing while the high pressure system is shut down. The control arrangement for the pumps shall be subject to purchasers approval and shall include provisions for remote control of the system, annunciation or failure of the A.C. motor driven pump, and automatic start of the stand-by D.C. motor on failure of the A.C. motor - driven pump. The bearing oil shall be cooled by means of externally placed oil / water heat exchangers. The cooling capacity shall be 150%. The cooling tubes shall be of non-corrosive metal e.g. stainless steel and shall be tested to a hydrostatic pressure of 1.5 times of maximum pressure for a period of 10 minutes. The cooling water supply system shall be designed jointly by turbine and generator suppliers. Manufacturer shall supply all necessary valves and controls. The main shut off valve for the bearing water supply shall be A.C. motor operated with manual override.

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The thrust bearing shall be equipped with the following : 1 No. Oil level indicator in the bearing reservoir with high and low level alarm contacts. 3 Nos. Dial type thermometers two nos. in the bearing metal to indicate the hottest part of the bearing and one no. in the oil. Each controller shall have two electrical contacts. The controllers shall also have a contact to indicate loss of bulb pressure. The dial indicators shall be mounted on the gauge panel. 7 Nos. Resistance temperature detectors shall be located in alternate shoe and two in the oil, with leads brought out to the terminal block panel. 1 No. Direct - reading water flow gauge with two alarm contacts. 1 No. Oil - water contamination detector.

GUIDE BEARINGS The generator shall be provided with two guide bearings. One combined with thrust bearing and mounted in the upper bracket and second mounted separately in the lower bracket. The guide bearings shall be capable of withstanding the radial forces generated not only during starting, stopping and normal operations but also during operation at runaway speed. The bearings shall be of the segmental and easily adjustable type. A design utilizing shims as the means for adjustments will not be acceptable. Each guide bearing shall be designed and constructed so that it can be adjusted or dismantled without disturbing the thrust bearing or the generator rotor. The guide bearings shall be of oil-immersed, selfoiling type. The guide bearing which is combined with the thrust bearing shall be located in the same oil reservoir as the thrust bearing, and the vertical side of the thrust bearing block shall be used for the Signature of Bidder
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journal surface of the upper guide bearings. Effective means shall be provided for cooling the bearings. Water cooling for the separate guide bearing design shall be similar to that of the combined guide and thrust bearing. Each guide bearing shall be equipped with the following : 1 No. Oil-level relay in the bearing reservoir with high and low level alarm contacts. 3 Nos. Dial type temperature controllers two nos. embedded in the bearing metal to indicate the temperature of the bearing and one no. thermometer in the oil. The controllers shall have two sets of electrical contacts. The controllers shall also have a contact to indicate loss of bulb pressure or loss of power to the instrument. The panel. 3 Nos. Resistance temperature detectors. Two Nos. shall be located in recesses in the bearing metal on diametrically opposite sides of the bearing and one in the oil, with leads brought out to the terminal box. 1 No.Direct-reading water flow gauge with two low-flow alarm contacts. One Oil-water contamination detector. Adequate baffles shall be provided, if necessary to prevent excessive churning or aeration of the oil. Each lubrication system shall include suitable oil reservoirs, supply and drain oil piping, valves, including valve bypass piping for flushing the lines and necessary appurtenances. Oil filters of the low pressure drop type shall be provided in the oil supply line to the thrust bearing oil circulating system. Supplier shall provide the initial supply of lubricating oil required to fill the entire lubricating system. The quality and the specification of indicator shall be mounted on the gauge

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the oil shall correspond with the ones available in India. Further, sufficient flushing and cleaning oil shall be included in the supply. All bearings shall be adequately insulated, where necessary, to prevent the flow of circulating currents through the bearings. contacts. 6) BRAKES AND JACKS Brakes shall be provided for bringing the unit to stop when the speed is reduced to approximately 10% of rated speed. The brakes will be operated by air pressure and shall be mounted on the lower bracket. The brake shoes shall bear on a brake which is an annular ring attached to the rotor. The brakes shall be liberally designed keeping in view the frequent stops of the unit (six times per day) and with margins to allow for emergency conditions. The mechanical brake shall be effective for either forward or reverse rotating direction and shall be automatically released after the generator stops. The brakes shall be capable of operating, without appreciable wear and tear of the brake shoes from 50% rated speed in emergencies. The brake shoes liners must be able to withstand at least 3 years operations. The braking system shall be so interlocked that application of brakes will not be possible at speeds exceeding 50% of rated speed. The brakes shall be suitable for use as hydraulic jacks, capable of lifting the complete rotating parts of the unit through a sufficient distance to permit the assembly or dismantling of the thrust bearing. The vertical lift available for this purpose will be limited by turbine clearance. One portable high pressure oil pump unit shall be supplied for jacking the rotor in the raised position. The design of the brakes and jacking system shall be such that, after jacking operation, all the oil including any leakage of oil past the brake position, shall be drained to the oil sump. A type of brake in which oil is present in the brake cylinder during braking operation will not be Signature of Bidder
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insulation monitoring system shall be provided with necessary alarm

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permitted. Provisions shall be made for mechanical blocking the rotor in the fully raised position. The blocking device shall be such that it will be unnecessary to maintain hydraulic pressure on the jacks while the rotor is in the raised position. A brake dust extraction system shall be provided by the supplier. A position switch having two sets of contacts shall be provided for each brake shoe. One set of open contacts (when brakes OFF) shall be wired in parallel and will be used for brakes ON indication. The set of closed contacts (when brakes OFF) shall be wired in series and will be used in the unit start interlock circuit. Wires from both sets of contacts shall be brought out and terminated in the generator terminal box. The equipment shall be complete with necessary control cabinet, piping, valves, fixtures etc. 7) SOLE PLATES AND FOUNDATION BOLTS The supplier shall provide adequate number of soleplates, anchor bolts etc., for fixing lower bracket and stator frame to foundation. The whole anchorage shall be designed and constructed to resist the forces under most abnormal condition, resulting from sudden short circuit or faulty synchronising. The supplier shall furnish the detailed drawings & calculations to the Purchaser for his consent and approval. 8) AIR COOLING SYSTEM The generator shall be cooled by means of closed circuit ventilating system. The cooling air shall be circulated to effectively and uniformly cool the rotor poles, the stator winding, the stator core along the coil and peripheral areas. The complete details of the system shall be furnished in the bid. To facilitate inspection and cleaning of the windings and to permit removal and replacement of field poles and stator winding coils, the air baffles provided to control the direction of air flow shall be so designed that they may be removed in segments, Signature of Bidder
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with relative ease. Hinged panels in the baffles may be supplied to permit convenient access to parts of the unit. The circulating air shall be of cooled by air / water heat exchangers evenly spaced around the stator frame. The air shall be cooled to a temperature not exceeding 450C. Baffles shall be provided for separation of the generator air cooling system from the Turbine pit. The air/water heat exchangers shall have sufficient capacity to maintain the cooled air temperature not exceeding 450 C. on the housing unit, with cooling water inlet temperature of 350 C, when one exchanger is out of service and the unit is in operation at full power. The discharge pressure at the exit of the heat exchanger shall be sufficient to discharge the water to draft tube. The air cooling coils shall be stainless steel or copper nickel material and able to withstand a test pressure equal to double maximum working pressure for a sufficient length of time to permit adequate inspection of leaks. The heat exchangers shall be equipped with suitable automatic air vent valves and the entire system shall be provided with suitable drain outlets. The pressure drop through the cooling heat exchangers shall be stated by supplier. The heat exchangers shall be provided with connections having brass plugs in an accessible position, one on the supply and one on the discharge pipe, to permit the attachment of a manometer. The heat exchangers shall be conveniently located to facilitate cleaning without removing them from the generator. To minimize the frequency of maintenance each heat exchangers shall be provided with 20% additional cooling coils to maintain adequate cooling during service even if some of the tubes are clogged. The supplier shall supply all piping, including terminations to the outside of the unit housing. The discharge water piping will be All cooling water terminated similarly and supplied by supplier.

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piping shall be lagged with approved insulation to prevent condensation. Main water piping for the cooling water shall be of mild steel of appropriate strength with valves for open / close operation at the water entry and exit of each cooler element. Cooling water piping inside the barrel shall be provided with anti-condensation paint. The manifolds of cooling water supply and exhaust pipe inside the generator housing shall be placed in a trench below the walkway in the housing. Cooling elements shall be arranged in such a way that the cooling water always remain in the heat exchangers. Access to all tubes for inspection and cleaning shall be possible without disturbing the header piping. The heat exchangers shall be mounted in such way as to facilitate assembly, dismantling, maintenance and repairs. interchangeable between each other. They must be The necessary water headers

shall be furnished with the heat exchangers. All connections between coolers and headers shall be of flange type. Isolating valve shall be provided in each connection between each coolers and headers so that any heat exchangers can be removed without interfering with the operation of remaining coolers. Approved means for draining and releasing entrapped air of all coolers and pipe work shall be provided. Condensed water on cooler surfaces shall be collected in receiving dishes installed below the coolers and drained to the station drainage pit. All piping shall be of flanged construction, using standard piping sizes suitable for its function. The system shall be provided with the following : 2 Nos. resistance temperature detectors (pt. 100 ohm), one mounted suitably for measuring the cooling water inlet temperature and other mounted for measuring the cooling water exhaust temperature.

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One or more resistance temperature detectors for each exchanger mounted with suitable mechanical shields to measure the temperature of the cooled air entering the generator rotor. Resistance temperature detectors shall be supplied in accordance with the relevant IEC- standards. The location and method of mounting of these resistance temperature detectors shall be such as to avoid the necessity for removing the resistance temperature detectors when the exchangers are removed from the machine for servicing. One approved direct-reading type water flow gauge with low-flow alarm contacts shall be fitted on the exchangers. The indicating dials shall be mounted on the gauge panel. Dial-type indicating thermostats with adjustable alarm contacts shall be supplied and installed in the inlet air path entering each exchanger and for the discharge air from each exchanger. The indicating dials shall be mounted on the gauge panel. All gauges required to ensure proper functioning of the cooling system shall be provided by supplier and all alarm contacts and solenoids shall be suitable for 220V D.C. 9) HEATERS Adequate no. of electric heaters, designed and located conveniently within generator housing to prevent condensation of moisture or sweating during idle periods shall be provided. Heaters shall be designed and wired for operation of a 400-V, 3-phase, 4 wire circuit. The supplier shall furnish all wiring within rigid conduit between the individual heaters and heater circuits terminal box which shall be furnished for installation, within the generator housing or at other approved locations, except that flexible conduit may be used for connections to the individual heaters when required. Provision shall be made to switch on the heater automatically by thermostatic control whenever the generator is shut down. The thermostatic control device

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for switching on the heater shall be of the differential type with adjustable differential range of 0-100C approximately. 10) SHAFT AND COUPLINGS The generator shaft shall be of one single piece and shall be coupled with the turbine coupling and thrust collar. The upper guide bearing collar shall be forged integral with the shaft. Shaft shall be of forged, open hearth or electric furnace, carbon or alloy steel and properly heat treated in one piece and coupling with thrust collar is also acceptable but detailed description of design, fixation of shaft and thrust block and generator for trouble free operation shall be proven. The shaft shall be machined accurately all over and polished at the guide bearing region. At least two concentrically true polished surface bands at approved location for dial type eccentricity indication shall be available. All half coupling of the shaft shall be of the integrally forged pattern. Coupling dimensions for connections of turbine to generator shall be agreed upon by the generator and the turbine suppliers and shall be in accordance with relevant IEC standards. The generator supplier shall provide the generator and turbine shaft coupling and the coupling bolts and nuts as well as the nut guard on the turbine side of coupling. The coupling bolts shall be provided with locking devices and shall have dimensions and tolerances in accordance with reverent IEC standards. Design of shaft assembly for the complete set (turbine and generator) shall be done jointly by the turbine and generator suppliers, who will solely be responsible for calculations of the first critical speed. Ensuring the correctness of the shaft length and coupling flange machining shall be the combined responsibility of both suppliers. Generator supplier shall be responsible to shift the turbine shaft to his

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work and return the same when done with. Cost therefore is deemed to have been included in the bid price. Drilling of coupling boxes in the upper flange of turbine shaft and that on lower generator coupling flange shall be performed in generator suppliers works. 11) RUNNER AND MAIN SHAFT The turbine shaft shall be before hand completely machined with coupling bolt holes drilled 3 mm. under size. Generator supplier shall be responsible and shall take extra care in the final reaming of the coupling bolt holes and the coupling and aligning of the turbine shaft and generator spider before shipping to site. The supplier will also supply the steel drilling template and pin gauge for the coupling. The main shaft shall be material inspected by radiographic inspection or ultrasonic inspection and after confirming no defect existing inside, the final machining shall be proceeded. The coupling between the turbine shaft and generator spider shall be sized to suit relevant standards. The coupling shall be amply strong to transmit the power involved and in addition, carry the downward thrust of the turbine. For the protection of the bearings from damages due to shaft current, a perfect insulation shall be done in the supporting part of the thrust collar. The critical speed of the main shaft due to unbalance of the rotating parts shall be higher than 120% of the maximum momentary speed which may happen at the transient time such as load rejection of runaway condition of the turbine. The supplier shall prepare shaft critical speed computer analysis which shall be approved by Purchaser. The following design and machining tolerances shall apply to the driving disc, runner plate and coupling flange where applicable. - Where the thrust load is supported by the bottom surface of a driving disc or shaft flange, the following tolerances shall apply. The surface Signature of Bidder
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of the driving disc or integral shaft flange supporting the rotating ring or turbine runner shall be parallel with the plane of the coupling face, fitted on the driving disc or shaft flange, and be normal to the axis of the turbine shaft. Deviation from normal shall not exceed 25 micrometers, as measured by rotating the shaft assembly on a lathe, and checking with a dial indicator -The thrust-bearing runner plate support surface shall not be convex. -Where the driving disc, rotating ring, or thrust collar is used as a guide bearing journal, the bearing surface shall be turned true to the axis of the coupled shaft, within a tolerance not exceeding 50 micrometers as determined by rotational test and measured by dial indicator. -The upper and lower surface of the thrust bearing plate shall be faced true to the bore (Shall not have a rotational error as measured by dial indicators) within a tolerance such that the cumulative error of the two surfaces shall not exceed 25 micrometers. The surface shall not be convex. 12) GENERATOR HOUSING The generator housing shall be made of concrete to be constructed by Purchaser. Only the upper surface of housing shall be non-magnetic plate fabrication to ensure an air tight joint between the housing and concrete. If generator is provided with water sprinkler fire protection system, arrangements to lead the discharge water collected in the housing to the dewatering pit should be indicated by the supplier. Dimensions of housing shall be so chosen that a clear passage of at least 750 mm. is available all around the generator. Top and bottom covers shall be made of non- magnetic materials to avoid heating due to stray fluxes. Top covers of generator housing pit shall have removable panels to permit withdrawal of coolers and poles from above by means of the power house crane. Access doors in the Signature of Bidder
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generator housing shall also form part of supply. airtight, lockable and interlocked. 13) GENERATOR

Doors shall be

TERMINAL BOX, ELECTRICAL ITEMS AND

WIRING & PIPINGS. All electrical items supplied by supplier shall comply with the appropriate sections of the relevant IEC standards. They shall be arranged in a manner approved by the Purchaser. The supplier shall provide and install terminal boxes in locations approved by Purchaser, and shall provide and install all wiring and conduit from its electrical components to these terminal boxes. All wiring shall be standard wire, with oil proof insulation. Further a common marshalling box shall be provided. Wiring from all individual terminal boxes shall be brought by the supplier up to this marshalling box. Leads for all auxiliary electrical circuits such as current transformers, resistance elements, limit switches; various kinds of relays shall be supplied up to the terminal blocks installed in the air housing. All wiring within the generator housing, including main field leads, lighting, resistance temperature detectors leads and control and indicating leads shall be adequately clipped or otherwise supported and protected. The wiring shall be bundled and tied together, where possible, to provide a neat arrangement. The wiring passing through openings in metal members of the generator, or otherwise passing over or near metal edges, shall be carefully protected against abrasion. A cable trough shall be provided by supplier, mounted to the inside surface of concrete air housing and extending around the complete unit for carrying the wiring. To facilitate disconnecting the generator field leads when removing the top bracket, supplier shall supply and install a junction box just inside the stator casing at a suitable location and he shall supply and install the field leads from the slip rings to this box, with cable terminals at both ends. These leads will be extended by Signature of Bidder
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cables or insulated bars, supplied and installed by the Supplier from the junction box to the field circuit breaker. Supplier shall supply and install a cable through inside the casing to carry the cables of bars from the slip rings to the junction box and to the point of exit through the casing. In general, close attention shall be given in order to prevent failures or shutdowns occurring as a result of generator vibration. The wire insulation shall be resistant to flow and abrasion under the conditions to which it may be exposed. Liquid type flexible conduit shall be used where wiring may be exposed to oil or water leakage. All piping shall be supplied such as feed / drain oil pipes of the generator bearing oil tank, oil jacks, piping of oil level relays and oil level gauges, feed / drain water pipes for bearing coolers and air coolers, connecting pipes between respective coolers, drain pipes of leakage oil and leakage water at respective positions and other piping installed in the generator air housing and barrel including valves and flanges. 14) GENERATOR HOUSING LIGHTING Suitable lighting, which shall also include the area under the generator rotor, and a minimum of four convenient outlets, shall be provided in the generator housing. A terminal box shall be supplied to terminate the supply leads, lighting, wiring etc. Supplier shall supply and install lighting control switches at service door. 15) GENERATOR FLOORING, PLATFORMS ETC. All necessary floor plates and curbing including floor covers for all pipe and cable trenches as required for completing the floors on and around the generator and their related installation shall also be supplied. Floor plates shall be of anti-skid type or similar safety pattern. The generator shall be provided with suitable platforms, Signature of Bidder
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stairways, handrails etc. for access to various generator parts. Necessary hooks, pulleys etc., for handling shall be provided. Suitable guards, over and around all energised or moving parts shall be provided for the generator and their accessories. Wherever required, suitable mesh wire barriers shall be provided within the generator housing / pit for protection of workmen while generator is in operation. 16) CREEP DETECTORS A creep detector shall be provided complete with all necessary wiring and controls to perform the following functions. When the unit has been brought to rest by closing of the guide vanes and application of brakes, the detector shall operate if shaft rotation occurs after expiration of the normal stopping period. The total rotation required to operate the detectors shall not exceed 10 degrees of shaft movement. On operation the detector shall perform the following functions. Close an annunciation contact which shall be wired to the generator terminal cabinet. When the high pressure oil pump provided for unit starting and stopping is on automatic control, start the high pressure oil pump. De-energize the brakes if the brakes are on automatic control. When the unit is started under normal control, detector shall be disconnected to prevent spurious control and annunciation signals. 17) TEMPERATURE DETECTORS The Supplier shall provide six resistance temperature detectors (pt. 100 ohm at 0 degrees C) per parallel circuit per phase, embedded in the various parts of the stator winding in accordance with relevant IEC standards. Signature of Bidder
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Twelve resistance temperature detectors (pt. 100 ohm at 0 degrees C) shall be embedded in a suitable location, six at each end of the stator core for temperature measurement for the detection of end iron heating. Twelve resistance temperature detectors shall be equally spaced in the stator core for temperature measurement at 12 teeth locations. RTDs and hotspot temperature indicator shall be furnished. Requirements of temperatures to be measured have been described; however supplier shall decide number of scanners required. The exact location of the temperature detectors in the stator winding and core shall be subject to the approval of purchaser. All temperature detectors in and around the generator shall be wired to the terminal box mounted on the outside of the generator air housing. This terminal box shall be separated from other terminal boxes. All connections from the temperature detectors to the terminal boards shall consist of twisted leads in shielded cables. The leads from each stator bearings, water and air temperature detectors shall be brought in a neat and substantial manner to suitable terminal blocks located in a terminal box on the generator barrel. This box shall be used exclusively for resistance temperature detectors. The terminal box, to be provided by supplier shall have provision for connection to external conduit and wiring. The leads shall be supplied as twisted three wire leads suitably shielded and otherwise protected to minimize stray pick-up. The insulated leads shall be capable of with-standing an applied potential test of 2000V to ground for 1 min. Resistance Temperature Detector (RTD) leads. Separate terminals shall be provided for terminating the shields of individual The resistance temperature detectors shall be platinum type and have a resistance of 100 ohms at 00C. Resistance ratio between 00C and 1000C shall be 1.3926.

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All temperature measuring equipment and its connections supplied by supplier shall be accurately calibrated against accepted standards.

18)

OIL GAUGES AND OIL LEVEL RELAYS The following oil gauges and oil relays shall be provided. a) i) ii) b) i) ii) Oil gauges : For thrust and lower guide bearing oil tank For upper guide bearings oil tank Oil level relays For thrust & upper guide bearing oil tank For lower guide bearing oil tank : Oil gauge : The oil gauge shall be of gauge type or float type and free from oil leakage. The oil gauges shall be mounted on a convenient position for inspection. The gauge shall be clearly marked on the surface with standard oil level, the upper limit and lower limit of oil level. Oil level relay:The relays shall be accurate in operation and mounted on a convenient position for inspection and shall be provided with alarm contacts for rising and lowering of oil level and provided with automatic reset mechanism when the oil level is restored within the normal range. : 1No. : 1No. : 1No. : 1No.

19)

Sufficient lubrication oil for the generator shall be supplied by the supplier. The supplier shall recommend the suitable lubricating oil for the generator.

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20)

GAUGE PANEL The supplier shall provide a free standing metal-enclosed combined turbine and generator gauge panel. The panel shall be of the cubicle complete with doors, padlock hasps, adequate ventilation system to ensure that the interior conditions are held within limits suitable for the equipment mounted therein. The supplier shall mount all instruments and relays including turbine and generator bearings temperature indicator with alarm and trip contacts and shall install and wire the flow indicator and auxiliary equipment associated with the turbine: One turbine shaft seal water flow indicator with auxiliary turbine and generator bearings thermometer equipment. One set of indicators. One spiral case pressure gauge. Terminals blocks shall also be provided for the turbine and generator guide bearings oil level switches. Bidders are requested to verify the provisions of indicating, recording, control, annunciation equipments required for satisfactory operation of the plant. The instruments and devices to be supplied, installed and connected to the terminal blocks shall include but not be limited to : One set of generator bearing cooling water flow indicators with auxiliary equipment. One set of generator bearing oil flow indicators with auxiliary equipment. One set of generator bearings with thermometer indicators. One set of generator water / air heat exchanger outlet water flow indicators with alarms and auxiliary equipment. One set of generator water / air heat exchanger inlet air and discharge air thermometer indicators.

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One starter and controls for slip rings and brush gear housing exhaust fan. Starters for generator high pressure oil pump motors for thrust bearing with separate control switches. Fluorescent lighting fixtures to provide supplementary illumination integrally built along the full length of panels.

21)

FIRE PROTECTION A dry type deluge fire protection system shall be provided by supplier complete with deluge valve, control unit and sprinkler rings with atomising nozzles. The atomising nozzles shall be so placed that the streams of water will be directed on the top and bottom coil ends and connections of the stator winding. The exact direction of flow shall be subject to approval by purchaser. The fire fighting system shall be of emulsifier water jet system and shall be designed to inject sufficient quantity of water in the form of jets to extinguish the fire in minimum possible time. The fire extinguishments shall be achieved by a combination of cooling and smoothening effects. The system shall comprise of a minimum of two ring headers inside the generator at different elevations so that every corner of generator is protected. Both the headers shall be fed at two points through pipes of higher size with water under pressure. The Bidder shall indicate the pressure at which the water is required. Each of the ring headers shall be fitted with specially designed nozzles equally spaced on the ring so that every centimetre of the protected area is covered by atomised water spray. The water-discharging device shall be so designed to achieve fairly uniform size of water droplets. The size of water droplet shall be such that it has sufficient energy to reach the point of combustion despite air resistance opposing force of gravity or the diverting movement of air caused by thermal

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updraft etc. The system shall also be designed in such a way that steam is generated in sufficient amount so that air is displaced and extinguishing of fire is quicker. Following points shall be considered in the design of components: i) ATOMIZED WATER SPRAY NOZZLES Nozzles shall be specially designed having three parts of holes arranged, in such a manner that jet of water flowing out of one hole strikes against the jet of water emerging out of another hole at right angle such that the collision of two high velocity jets results in very fine fog formation required for extinguishing the fire. ii) PIPES & FITTINGS Steel tubes with thread flange joints shall be used. The tubes shall be suitably bent to size at factory for ready installation. iii) iv) WATER MOTOR GONG The jet of water itself shall operate a gong to give an alarm. INLINE STRAINER For cleaning the water of impurities, foreign particles etc. suitable strainer is required. This shall be made of stainless steel and shall be installed in the pipeline itself. Arrangements for cleaning the strainer shall also be provided. v) VALVE A suitable valve shall be provided in the pipeline, which should open automatically in case of fire and allow water to the ring headers. Details thereon shall be described. vi) DRAIN VALVE A drain valve should be provided in the pipeline to drain the water.

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vii)

HEAT AND SMOKE DETECTORS Suitable number of heat detectors and smoke detectors shall be provided in the generator for detecting fire break out.

viii)

CONTROL SYSTEM The control system shall be designed in such a way that the moment a fire break out is detected, motorised valve is opened and water under pressure is injected into the generator. A manual push button shall also be provided to open the motorised valve. In addition, provision shall also be made for mechanical operation of valve so that in the event of failure of auto sequence, push buttons etc. the valve is opened mechanically and water is fed to the ring header. Fire alarm shall be provided in the control room and also in all parts of powerhouse.

ix)

SAFE DISTANCE FROM LIVE EQUIPMENT The ring headers, smoke / heat detectors etc. shall be provided in the generator such that the clearance between un-insulated live parts of generator and any portion of water spray system is not less than the minimum clearances stipulated.

x)

TESTING OF THE SYSTEM Suitable provisions for testing the system without discharging water into the generator shall be made.

xi)

WATER DRAINAGE: Supplier shall prepare a scheme for drainage of the water from generator housing to dewatering pit from where water will be pumped out into the switchyard.

22)

CABLE SCHEDULES AND WIRING SCHEDULES The supplier shall prepare cable schedule and wiring schedules of the station equipment as a whole. Terminal wiring diagrams for the

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equipment and plant not covered by this package will be furnished by purchaser to the generator supplier and he shall prepare consolidated wiring and cabling schedule for the entire power station.

8.8

TECHNICAL SYSTEM

SPECIFICATIONS

OF

STATIC

EXCITATION

8.8.1 GENERAL 1) TYPE, CHARACTERISTICS AND PERFORMANCE The generator excitation system shall be of the solid- state controlled rectifier (static thyristors) type, complete with excitation transformer and solid-state type of digital voltage regulator (DVR) and rectifier controls, capable of providing negative exciter voltage and extremely rapid changes in generator excitation voltages. The excitation system shall take out the power from terminal voltage of generator through a power supply transformer and supply it to the field winding of generator. The field flashing circuits shall be supplied from an auxiliary transformer / rectifier assembly suitable for connection to a 400-V, 50-Hz., 3- phase supply of a capacity to be specified by supplier. Provisions shall also be made for field flashing from the station battery in emergency with manually deployed connections, preferably transfer links. The field flashing equipment shall be rated to supply approximately rated excitation current continuously for test purposes and shall be capable of adjustment in 10% steps from 10% up to 100% rated voltage. Excitation supply shall hold during break period of change over of supply from Station Auxiliary Transformer / D.C. supply to Unit Auxiliary Transformer, acceptable break period shall be indicated by the Bidder. Signature of Bidder
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The thyristors shall be used for the rectifier of excitation system. The supplier shall supply forced cooled type 110% duty thyristor cubicle so that the excitation system shall be capable without exceeding the temperature limit of the thyristor with one thyristor per phase out of service. Indicator lights to indicate and locate the thyristor failure shall be provided. A suitable protection shall be provided to protect the thyristor from the surge, which might enter from the generator field and power supply transformer. Connections between the secondary of the transformers, air circuit breaker, and static excitation equipment shall be made with bus bars or cables. The air circuit breaker shall be draw-out type individually enclosed and electrically operated. All controls, protection and operations of the equipment shall be either automatically or electrically operated, suitable for operation through remote control panels located at the unit control board. Remote control shall be limited to as few controls as possible, and shall include only such functions as stop-start and a raise-lower. The excitation equipment shall be designed to be capable of starting and running at reduced capacity and independent of a separate station service A.C. supply. Components and wiring shall be suitably designed and shielded to prevent excessive noise. The design of the excitation system shall be such that the effect on the balanced and/or residual Telephone Influence Factor (TIF) of the associated Generator is minimal and shall not cause the TIF to exceed the limits specified in applicable IEC standards. The final parameters for performance, capability, system response, etc., shall be confirmed by supplier and approved by Purchaser. Voltage regulator shall have dual channels consisting of two identical electronic control circuits plus a common voltage matching, fixed excitation, output selection and relay circuit. Usually both the main and stand by channels shall be energised and functional. However, only output selection circuit to control the converter will switch the Signature of Bidder
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output of main channels. If this channel fails then the controls shall be automatically switched to standby channel. The normal mode of operation shall be auto-control. Additionally, manual control of the excitation shall be available for testing and setting up purposes or in unlikely event of failure of the auto control of both channels. The auto-control circuits shall consists of two interdependent feed back control loops (Voltage and Current) with limiting circuits for underexcited MVAr, rotor heating, current and power system stabilisers. The excitation system shall be capable of switching from 25% of rated generator voltage and at 60% of voltage it shall be capable of supplying rated excitation current. The time constant of excitation system shall be less than 0.10 sec. 2) CAPABILITY With rated generator voltage, the excitation system shall be capable of delivering continuously, within rated temperature rise, any value from 0 to 120% of the field current required when the generator is operating at 110% of rated voltage, and rated power factors at 0.90 (overexcited). With rated generator voltage, the excitation system shall be capable of providing a ceiling current to the field of not less than 1.5 times rated field current for at least 30 seconds. De- excitation time between rated voltage and 10% of voltage shall not be more than 10 sec. 3) SYSTEM RESPONSE With the generator initially at rated apparent output power, rated voltage, power factor and speed, the excitation system shall be capable of changing from rated field voltage to 100% of ceiling voltage within 25 to 30 ms. for a sustained drop in generator terminal voltage of 10 %. The rated voltage shall be calculated assuming that at rated apparent power, field winding is operating at rated field current. Response in the negative (reverse) direction to suppress terminal Signature of Bidder
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voltage shall be similar. The small signal gain, defined below, shall be variable from 25 to 300 and should be lockable to prevent tampering. Excitation response shall be guaranteed with 4s. 4) CEILING VOLTAGE The exciter ceiling voltage with rated generator voltage and rated field voltage and current shall not initially be less than 1.5 times the excitation voltage required for rated field current with the operational field temperature. The exciter ceiling voltage with rated supply voltage and 1.5 times rated field current shall not be less than 2.0 times rated field voltage with the field windings temperature 1250C. With supply voltage less than rated value, the ceiling voltage may be reduced approximately in proportion to the reduction in supply voltage. With positive field current flowing, the excitation system shall be capable of providing a negative ceiling voltage of no less than 75% of the positive ceiling voltage for forcing the field current to zero. 5) OVER VOLTAGES The excitation system may be subjected to lightning and switching surges and dynamic over voltages, and shall be able to withstand them without damage to equipment or loss of life. The static excitation equipment shall comprise of: Microprocessor based Digital Voltage Regulator cubicles. Thyristor cubicles. Switchgear cubicle (Field breaker, de-excitation resistor, field flashing etc.). Excitation Transformer connected directly to the thyristor cubicle. Power supply to cubicles shall be duplicated and no interruption shall be allowed during changeover.

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8.8.2 DIGITAL VOLTAGE REGULATOR 1) Micro-processor based voltage regulator shall be digital type. It shall be liberally designed so as to be as reliable as possible and shall incorporate sufficient redundancy so that failure of any control equipment will not cause mal-operation of the system. 2) The digital voltage regulator should periodically calculate the control signal from measured and reference values. Calculation should be repeated at every short time intervals where by an apparently continuous regulator output characteristic is produced. 3) Calculation is to be carried out in binary system. The analog measured values of generator voltage and current as well as field current must be transformed in an Analog / Digital converter into binary signals. From the calculated control signals, pulses should be generated for firing the thyristor. 4) Various control functions like voltage regulation, limitations of field current, rotor angle, stator current, slip stabilising etc. shall be stored as programs to be executed in a cyclic pre-programmed manner. 5) 6) Control to maximum converter voltage shall be achieved in less than 10 milliseconds thus ensuring fast reaction to network disturbances. Internal conditions monitoring of devices with light emitting diode (LED) indication be provided which means short failure detection times. 7) 8) 9) 10) Set values shall be digital, absolutely reproducible and not vulnerable to changes ensuring long term stability Number of different units shall be small so that spare parts stock could be kept to a minimum. Low sensitivity to external electro-magnetic influences shall be ensured which means high noise immunity. Electrical control points shall be bare minimum to reduce potential trouble sources.

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11)

Comprehensive measuring and setting shall be possible, which should enable direct setting of characteristics values without the necessity of calibration instruments.

12)

The Digital Voltage Regulator shall perform following functions: Regulation of generator voltage. Limitation of field current. Limitation of stator current. Stabilization of power pulsations. Power factor control.

13)

A local control, input and display unit shall be provided for communication with the processing unit during operation. It should be possible, from this control unit, to call up the stored parameters, measured values etc. and to change control parameters such as limit values or characteristics values of the control algorithms.

14)

It should be exceptionally reliable with no changes in operating performances. If even a failure should occur, it should announce itself so that it can be removed fast.

15) 16)

Frequency drop compensation shall be provided to ensure over excitation compensation of transformer in the event of low frequency. Automatic reactive power compensation or power factor regulation should be provided. The power factor regulating range shall be manually adjustable from lagging power factor 90% to leading power factor 90% rated output and rated voltage.

17)

Current regulating equipment The current regulating equipment shall be provided in order to approach the operating power factors to unity when the generator current exceeds 105% of the rated current due to a voltage drop during generating operation.

18)

In case the load is rejected due to any external fault during generating operation at the rated output, rated voltage and rated power factor, the

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voltage rise of the generator 19)

shall be less than 20% with speed

regulation of 35% without opening the field circuit breaker. Emergency demagnetising device Emergency demagnetising device shall be provided so as to perform quick demagnetisation of generator in the event of electrical internal fault of the generator. 20) Two independent modes of operation are envisaged. i) ii) Automatic mode with automatic channel in service. Emergency manual mode with the help of manual channel. Voltage adjusting device shall preferably, not be potentiometer but a solid-state device for example, push button controlled analog register etc. In the automatic channel, the control shall be through DVR, DVR should derive its sensing signal through Voltage Transformers and Current Transformers in the generator main terminal circuit. This shall be compared with a highly stabilised auto reference value. Correction pulse generated shall be fed to the gate of thyristors. Output of DVR should thus control the firing angle of thyristors thereby adjusting the excitation current to the required level. In the manual channel, the voltage variation and excitation current shall be changed manually, while in auto mode also, the manual channel shall follow the auto channel so that all resistances of manual channel are at the correct positions corresponding to those of auto channel so that, if due to a minor fault the channel changes to manual the unit will not trip. DVR shall have two auto channels i.e. one main, one stand-by together with one manual channel only. Each channel shall be fully independent with separate pulse control unit, pulse amplifier and power supply units.

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8.8.3 1)

THYRISTOR CUBICLE This cubicle contains full three phase thyristor bridges with its associated equipment. The design should be modular in such a way that changing of a thyristor or part of a bridge shall be easily possible. In case forced ventilation system is adopted, noise level outside the panel shall be negligible. 2) Number of thyristor cubicles provided shall be such that, even with failure of one thyristor bridge, the generator should be able to supply rated output and with failure of two bridges, the generator should trip. 3) All thyristors shall be fuse protected. Voltage safety factor for thyristor, defined as the ratio between the maximum operating voltage and the rated peak cut-off voltage shall be more than 2.5. Excitation response shall not be less than 4.0 s. 4) 5) Suitable protection shall be provided for thyristor to prevent voltage spikes from reaching them and damaging them. Over voltage protection to protect the thyristor bridges and the field circuit shall be provided.

8.8.4

SWITCHGEAR EXCITATION CUBICLE This cubicle shall contain all switchgear equipment necessary for the operation of excitation. Field breaker and all equipment necessary for rapid suppression of generator-motor field circuit shall be provided. The principle of suppression of field shall be the reversing of rectifier operation into an AC converter operation and shunting the generator field terminals by a discharge resistor. Over-voltage protection devices, start-up excitation devices, auxiliary relays and contactors shall be provided. All in feeds from station battery shall be taken through D.C./D.C. converters. Redundancy shall be built in, in modules.

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8.5.5 1)

EXCITATION TRANSFORMERS Three phase, dry type, Excitation Transformers shall be of indoor type cast resin or equivalent dry insulated for direct connection to the bus ducts and cable connection to the thyristor cubicle. Transformers shall conform to IEC 726. 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) They shall be totally moisture proof They must be free from partial discharge up to 150% of the rated high voltage. They have to be resistant against sudden temperature changes. The insulation must cease fire and must not contain any PVC material. The cores shall be built up of high grade oriented crystal magnetic steel sheets, insulated on both sides. The cores shall be compressed sufficiently to avoid any undue noise generation and vibration. All metal parts shall be amply protected against corrosion. Coil casting or impregnating process must be conducted under vacuum and pressure. High voltage and low voltage windings shall be separated by a high grade insulating material cylinder. Adequate consideration shall be given to thermal coil dilation. Transformers must be able to withstand a short circuit on their low voltage terminals without suffering any damage. The time for which the transformer should withstand such short circuit should not be less than the longest fault clearing time for generator. 12) 13) 14) 15) Cooling system of the transformers shall be as far as possible natural or shall occupy minimum space available on the floor. Suitable built-in over-heating protection device shall be provided. Transformers shall be impulse voltage tested according to IEC. Short circuit impedance shall be according to choice of design for excitation system.

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16)

Total losses at rated load should be at minimum.

8.8.6 Lightning Arrestors, Voltage Transformers, Surge protection capacitors and Neutral grounding equipment are included under Section X characteristics and performance requirements of these items. Generator supplier shall coordinate with the supplier of these equipments in respect of

8.9

FACTORY TESTS FOR GENERATOR AND RELATED EQUIPMENT Tests to be conducted in factory on various material, assemblies etc. statements. legends of the nomenclature of tests is as below ; LEGEND FOR FACTORY TESTS OF ELECTRICAL LOT 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) Test at shop on random sample of raw material. Test at shop on random sample of raw material and on semi or fully finished part. Test at shop on 5% of consignment . Check straightness of bolts taking random sample of 10 bolts per machine. Test at shop in the presence of Purchasers representative. Test at shop on each piece. Spot check at shop of brazed parts of semi or fully finished parts. Test at shop on random sample of one per sheet. Test at shop on complete sheet. Test at shop - once per item. Test to be conducted by manufacturer and Test Certificates given to Purchaser. on generator at different stages of manufacture are indicated in the enclosed

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SUBMISSION OF TEST CERTIFICATES The Supplier shall submit 6 copies of test certificates to the Purchaser as per the procedure given below : i) FOR INSPECTION AND TESTING TO BE DONE IN PRESENCE OF PURCHASERS REPRESENTATIVE. Test certificates shall be submitted for approval. ii) FOR ALL OTHER INSPECTION AND TESTS Test certificates showing that the specified tests / inspection has been carried out reference. successfully by the Supplier shall be submitted for

8.10

MATERIAL TEST 1 2 3 4 5 6 7 8 9 1 0 ROTOR RIM SHEETS: Tensile Test Chemical analysis Visual check Dimensional check 1 1

Sr.N Particular of Test o. 1)

2)

ROTOR RIM BOLTS Tensile Test Chemical analysis Visual check Dimensional check

3)

FIELD WINDING (POLE COIL) FINISHED Tensile Test

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Sr.N Particular of Test o. Visual check Dimensional check Test for short circuited turns Acceptance test of each piece Insulation Simulation Test 4) POLE FINISHED Visual check Dimensional check High voltage test Test for short circuited turns Weight check Acceptance (H.V.Test) 5) DAMPER BAR Hardness Test Visual check Dimensional check Electric conductivity Test Acceptance consignment 6) DAMPER SEGMENT RAW Hardness Test Visual check Dimensional check Acceptance consignment 7) POLE LAMINATION SHEETS
260

1 0

1 1

Test of each piece

5% of

Test

on

on 5% of

Test

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Signature of Purchaser

Sr.N Particular of Test o. Tensile Test Chemical Analysis Visual check Dimensional check Induction Test 8) POLE AND PLATE RAW Tensile Test Notched Bar Impact Test Chemical Analysis Ultrasonic Test Visual Test Dimensional Test Acceptance Test of each piece 9) POLE END PLATE MACHINING Visual check Dimensional check Acceptance Test of each piece

1 0

1 1

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Sr.No 10)

Particular of Test POLE BOLTS Tensile Test Chemical analysis Visual check Dimensional check

1 0

1 1

11)

ROTOR LAMINATION Tensile Test Notched Bar Impact Test Chemical Analysis Ultrasonic Test Aging characteristic Acceptance Test of each piece

12)

STATOR SHEETS Tensile Test Chemical analysis Visual check Dimensional check

LAMINATION

Induction Test with determination of specific losses at 1.0 and 1.5 t 13) STATOR PUNCHING Tensile Test Chemical analysis Visual check Dimensional check 14) STATOR RIM BOLTS
262

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Tensile Test Chemical analysis Visual check Dimensional check 15) STATOR FRAME Tensile Test Notched Bar Impact Test Chemical Analysis Ultrasonic Test Aging characteristic Acceptance Test of each piece Trial Assembly 16) STATOR FINISHED Tensile Test Visual Test Dimensional check Test for short circuited Turns Acceptance Test of each WINDING BARS

piece(H.V. Test) with Tangent delta measurement Insulation simulation Test 17) WATER/AIR EXCHANGER (EACH) Tensile Test Visual Test Dimensional check Hydrostatic Test HEAT

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18)

OIL COOLERS (EACH) Tensile Test Visual Test Dimensional check Hydrostatic Test

19)

GENERATOR SHAFT Material Analysis Tensile Test Notch Impact Test Visual Inspection Magnetic particles Examination Ultrasonic Test Dimensional check Roughness Test Baroscopic Inspection Matching with Pump-Turbine shaft

20)

BRAKE AND JACK Visual Test Dimensional check Measurement of Stroke Hydrostatic Test

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Sr. No. 21)

Particular of Test E.T.D. Calibration Test Check and setting of switches and relays THERMOMETER

1 0

1 1

THERMAL SWITCH

22)

VARIOUS RELAYS

SWITCHES

AND

Check and setting of pressure, Level, Flow Temperature switches and Relays 23) STATIC EQUIPMENT A) FOR EACH SET H.V. Test Functional Check of modules by simulation Control sequence interlock Test B) FOR ONE SET Load Test and current sharing Test on thyristor bridge Heat run test on thyristor bridges Heat run and Impulse test on excitation transformer EXCITATION

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8.11

SITE TESTS FOR GENERATOR AND RELATED EQUIPMENT Site tests to be conducted on various assemblies in presence of Purchaser are as below but shall not be limited to. DURING ERECTION STATOR WINDING : D.C. Resistance. Insulation Resistance. H.V. Test Dielectric Test. D.C. Resistance Insulation Resistance. H.V. Test Rotor Impedance. Dielectric Test High frequency induced voltage test on poles.

ROTOR WINDING :

MEASUREMENT OF CENTERING AND LEVELLING Together through upper bracket, Stator Core, Lower Bracket and Turbine Upper Cover and Casing. UPPER AND LOWER GUIDE BEARING Insulation Resistance Check of vibration response Check of setting of oil level switches. Check of shaft alignment together with Turbine Shaft. Check of vibration response. Check of slip ring deflection.

SHAFT :

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HIGH PRESSURE INJECTION OIL SYSTEM FOR THRUST BEARING: Check of settings of pressure switches, relays etc. Check of pumps Operational check in all modes. Check of setting of pressure switch, limit switches, relays etc. check of pumps. Operation pump check in all mode. Magnetic flux test Di-electric Test. Measurement of stator winding resistance D.C. resistance. Measurement of stator winding insulation resistance. Measurement of stator winding impedance. H.V. Test Check of concentricity of core. Check of core height. Measurement of Rotor winding D.C. resistance. Measurement of rotor winding impedance. Measurement of rotor winding insulation resistance. H.V. Test Check of concentricity.

BRAKE AND JACK SYSTEM

STATOR FINISHED

ROTOR FINISHED

DURING PRECOMMISSIONING AND POST COMMISSIONING 1) AUXILIARIES Auto/Manual operation of all auxiliary system connected with Generator .

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2)

OTHER GENERATOR TESTS NO LOAD TESTS : Initial run Check of smooth run at gradually increased speed from zero to rated speed Vibration and noise level measurement Running test of bearings Recording of bearing metal and oil temperature at rated speed no load until all bearings reach stable temperature. OVER SPEED TESTS Functional check of vibration & seismic monitor Run for 2 minutes at 150% over speed. Commissioning test . Auto / Manual synchronising. Load rejection at 1/4, 1/2, 3/4 ,1.1& 1.0 of rated output at rated power factor. Oscillograph measuring of voltage rise at each rejection. Normal stopping operation of generator Quick shut down tests. Emergency shut down test. Vibration and noise level measurement. Check of operation of various controlling and regulating. Temperature recording of windings and bearings. Vibration and noise level measurement. Measurement of thrust bearing bracket deflection.
268

BEARING HEAT RUN

EXCITATION SYSTEM SYNCHRONISING TEST LOAD REJECTION TESTS

SHUT DOWN TESTS

LOAD TESTS

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6)

STATIC EXCITATION SYSTEM Measurement of insulation resistance. H.V. Test. . Functional test of system component. Loading characteristic test. Measurement of range of voltage regulation. Measurement of range of power factor regulation. Test of generator current limiter and exciting current limiter. CHARACTERISTIC AND PERFORMANCE

8) -

GENERATOR TESTS :

Open circuit characteristic (without step-up power transformer). Three phase sustained short circuit condition characteristic. Line to line sustained short circuit condition (without step-up power transformer) Various Reactances Measurement of Air gap Measurement of Noise level. Measurement of Moment of Inertia. Determination of balanced and residual component of telephone harmonic factor (THF) Measurement of following losses (according Calorimetric method) i) ii) iii) iv) v) Losses in active iron and additional no load losses in metal parts. Losses due to friction and windage Stator winding copper losses at 750 C Additional load losses Field winding copper losses at 750 C to IEC 34-2A

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vi) vii) -

Excitation system losses + ac/dc link) Electrical losses in brushes.

(Excitation transformer + thyristors

Measurement of vibration and noise level at rated output Measurement of all bearing temperatures at rated output. Measurement of reactive power Determination of generator guaranteed output with reference to guaranteed temperature rise. Determination of generator guaranteed efficiency

8.12

DRAWINGS,

DESIGNS,

STUDIES

AND

MANUALS

TO

BE

SUBMITTED AFTER AWARD OF CONTRACT BY THE BIDDER. The list of drawings, designs, studies, data needed and manuals etc. required to be submitted by the supplier is enclosed with this section (Please refer Annexure VIII-1 - I).Mode of submission of designs and drawings will be intimated to the successful bidder in due course.

8.13

SPARES Spares shall be supplied as per the list under Section - III of this volume.

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ANNEXURE VIII-1 DRAWINGS, DESIGNS AND MANUALS TO BE FURNISHED AFTER AWARD OF CONTRACT. Sr. No. Brief description within months Remarks from the date of award of contract 1 I 1. GENERATOR Arrangement drawings describing and illustrating the information of: * General layout drawing *Combined turbine and cross section * General arrangement and overall dimensions of generator showing position and marking of main and neutral leads, important elevations etc * Thrust and guide bearing Assembly * Air circulation arrangement * Excitation system * Description of thrust bearings and data regarding construction, adjustment, accessibility and method. * Description and section of and rotor insulation stator Generator 3 For approval 2 3 4

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2. Installation, assembly drawings of : 1 Generator coupling Top and bottom brackets Thrust and lower guide bearings Upper Guide bearing Rotor Stator Foundation Stator windings Rotor arrangement including poles Slip ring arrangement Generator brakes Assembly of stator and rotor with lifting arrangement Speed arrangement Vapour seal assembly Lifting drawing beam and attachment 10 6 For approval For approval sensing element 10 For approval 8 8 8 8 6 10 10 10 10 10 For approval For approval For approval For approval For approval For approval For approval For approval For approval For approval 2 and turbine shaft 3 8 4 For approval

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3. Drawings illustrating dimensional details with schematics for : 1 2 Lubrication and cooling of thrust and Generator exchangers, air cooling system with heat gauge panel oil guide bearings 10 10 10 10 10 10 D.V.R. For approval For approval For reference For reference For reference For reference guides etc 3 10 4 For approval

Turbine- Generator and water piping Schematic diagram of jack system

Schematic diagram of air,

brake &

Thermometers, R.T.Ds etc General scheme giving details of excitation system, Thyristors, field breaker, field discharge resistance, etc. Arrangement of generator heaters Arrangement of rotor pit service bay, Rim and on building stools handcooler thrust

10 6

For reference For approval

loading on service bay floor. 10 10 10 For approval For reference For reference coverings etc. of oil

Arrangement of staircase, rails, doors, Arrangement withdrawal Schematic diagram of bearing High of 4 lubrication system

Pressure injection 6 For approval

Layout, plan and cross sections of floor openings for piping, cables Signature of Bidder
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Signature of Purchaser

etc. for units for: Trenches Block- out / cut- out etc Opening in barrel 6 7 8 9 10 11 Sole plate, stator and bracket fixing Barrel opening Layout of cooling water piping Layout of oil piping and air piping Drainage Layout of arrangement Mulsifire, for fire mulsifire water jet system 12 For approval protection system with schematics and equipment details. 12 Cable schedules for all 12 For approval equipments of entire power station as a whole and covering all equipment under i) Electrical lot. ii) Mechanical lot 13 Detailed wiring schedules for interconnection of equipment stated in (12) above 12 For approval 6 6 6 6 For approval For approval For approval For approval 10 For approval

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MANUALS. 1 1 2 Manual for storage, preservation and handling goods 2 Manual dismantling, goods 3 Manual DONTs 4 Manual giving detailed 20 For reference maintenance schedule giving operating 20 For reference instructions for all the DOs and for erection testing / and 18 For reference of the supplied 3 18 4 For reference

commissioning of the supplied

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DATA SHEETS 1) 2) Name of Manufacturer Manufacturers type reference 3) 4) Type Line voltage Rated Maximum Minimum 5) Normal :::Synchronous :-----------------kV -----------------kV -----------------kV ----------------rpm :::.-------------------------------------------------------------------------------

speed ( For a system frequency of 50 Hz) 6) A) Guaranteed conditions continuous specified in output under temp. rise item 6 (b) and under the terminal conditions of a) Rated output at 11 kV , 0.9 power factor (lag) b) ) Maximum continuous output at 11 kV , 0.9 power factor (lag) B) Maximum temperature rise for the rated output and continuous maximum output over and above the cooled air temp. of 450c Signature of Bidder
276

::-

-----------------------------------------

Signature of Purchaser

with temp. of cooling water not exceeding 350c a) stator winding by RTD b) stator winding by resistance c) other parts by thermometer Rated output ------------------------------------------------------Guaranteed efficiency generator terminal at of 11 voltage overall the kV 0.9. Maximum continuous .output --------------------------------------------------------

7 A)

power factor (lag) and rated speed and 750c wdg .temp by summation of losses method as per IS & subject to tolerance as specified in IS i) ii) iii) iv) 110 % of rated load Full load full load full load ---------------------% ---------------------% ---------------------% ---------------------%

B) Guaranteed arithmetical mean of above efficiencies. 8 Inherent regulation i.e Increase in voltage at constant Speed and excitation on taking off Signature of Bidder
277

---------------------%

Signature of Purchaser

i) load

110 % of rated ii) Full load

---------------------% ---------------------% ---------------------% ---------------------%

iii) full load iv) full load Generator Reactances a) Synchronous reactance ( saturated ) i)Direct Axis xd ii)Quadrature axis-xq b) Direct axis transient resistance i) saturated

9)

---------------------% ---------------------%

---------------------% ---------------------% ---------------------% ---------------------% ---------------------% ---------------------% -------------------ohm

ii) unsaturated c) Sub transient reactance i)Direct Axis xd ii) Quadrature axis-xq d) Negative phase sequence reactance e) Zero phase sequence reactance f) Resistance of armature winding at phase at 75
0

c -------------------ohm

g) Resistance of field winding at75 0c

10)

Generator Time constants

:-

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a) Direct axis transient , open circuit b) Direct axis transient short circuit 11) Generator characteristics curves :a) open circuit characteristics curve b) Full load saturation curve i) Zero power factor ii) 0.9 power factor c) Generator power capability diagrams 12) 13) Short circuit ratio Synchronizing power ( at 11 kV) Full load, 50 cycle , 0.9 p.f.(lag) 14) a) Fly wheel effect of the rotating parts of the Generator and exciters. b) Inertia constant 15) Stress levels. a) Maximum speed :-

-------------------Sec -------------------Sec

----------------------------------------------------------------------------------------------------------------------

-------------------------------- -- kW/Electrical radiation

--------------Tm2

---------KW Sec/kVA

---------------------rpm

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(Runaway speed) which all parts are guaranteed to withstand safely for 5 minutes b) Name and location of parts having the least factor of safety under runaway or short circuit condition c) Guaranteed minimum factor of safety based on yield point of material at runaway speed 16 Embedded temperature detectors in a) stator winding i) Number ii) type b) core i) Number ii) Type c) teeth i) Number ii)Type ------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

17

Static Excitation equipment a) Name of manufacturer

:------------------------------280

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Signature of Purchaser

b) Type c) Continuous rating of excitation equipment d) Ceiling Voltage and duration e) Primary Voltage rang allowed for continuous operation f) Minimum primary Voltage for ceiling operation g) AVR output range h) Accuracy of AVR control i) D.C battery equipment j) Looses at full load in static Excitation equipment k) No. of Thyristor bridges l) Excitation Transformer a) Rating b) Type c) Basic Impulse level

---------------------------------------------- ----------------------------------------------------

---------------------------

------------------------------------------------------------------------------------------------------..

--------------------------

--------------------------------------------------------------------------------kV(peak)

18)

Generator coolers a) No of air coolers b) Maximum safe water ------------------------------------kg/cm2


281

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Signature of Purchaser

pressure c) Cooling water requirement at 350c and for full load on generator i)Quantity of water ii) Water pressure d) Temp. of cooled air under condition c ) 19 Stator a) Material of stator core b) Insulation of lamination c) Stator frame construction d) No of sections in which divided for transport e) Insulation of stator winding f) Stator i) Height including end winding ii) Diameter at air gap Signature of Bidder
282

--------Ltr/minutes per cooler -----------kg/ cm2 --------------------0c

-------------------------------------------------------------------------------------------------------------

----------------------

--------------------mm --------------------mm Signature of Purchaser

iii) outside diameter of frame iv) shape v) Weight 20) Generator Housing a) Height b) Diameter (D) c) No. of generator pit heaters d) No. of temp. detector for fire protection 21) Rotor a) Construction of field poles b) Method of attaching field poles on rotor rim

--------------------mm

--------------------mm --------------------kg

--------------------mm --------------------mm -----------------------------------------------

-------------------------

------------------------

-----------------------c) Rotor rim material and construction d) Rotor spider material e) Field winding construction -------------------Signature of Bidder
283

------------------------------------------------------------------

Signature of Purchaser

f) Insulation of field winding g) Construction of damper winding h) Air gap width i) Factor of safety at max. runaway Speed based on yield point of material 22) Shaft a) Material b) Diameter c) Length d) Diameter of axial holes e) Weight f) Diameter of coupling flange 23) Thrust and guide bearing a) Cooling water at Signature of Bidder
284

---------------------------------------------

--------------------mm

---------------------

----------------------------------------------------------------------------------------------

--------------------kg --------------------mm

Signature of Purchaser

350c required j) ii) Quantity Pressure ----------------------------------------------------------------------------------------------------

b) Location of bearing

c) Thrust bearing and guide bearings i)Type ii)Diameter of bearing iii) Bearing area iv) No of pads 24) 25) Bearing (Bracket) Material and construction Height that the rotor must be raised to dismantle the thrust bearing 26) Generator brake and jacks a) Air pressure range for the brakes for satisfactory operation b) Speed at which brakes are to be applied during normal shut down Signature of Bidder

Thrust Bearing

Guide Beaing

--------------------------

-----------------------------------------------

-----------------------------------

------------------------------------------------------------------------------------------------

---------------------

--------------------------

285

Signature of Purchaser

c) No of brakes d) Stopping time of generator 27) 28) 29) Oil pressure for jacking Capacity of jacking pump Lubricating system A) Oil a)Specifications b)Quantity for filling i) Thrust and guide bearing system ii) Lower guide bearing c)Oil cooling arrangement d) Description of arrangement to prevent circulating current in the bearing 30) 31) 32) Weight of generator rotating parts. Weight of complete generator Total load on thrust bearing ( including hydraulic thrust etc.)

------------------------------------------------------------------------------------lpm

-----------------------

----------------------------------------------------------------------------------------------

-----------------------------------------------------------------------------

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33)

Heaviest package for shipment a) Name b) Weight c) Dimension ------------------------------------------------------------------------

34)

Largest package for shipment ------------------------a) Name b) Weight -----------------------c) Dimension

35)

Heaviest Assembly to be lifted by power house crane a) Name b) Weight c) Dimension --------------------------------------------------------------------------

36)

Largest assembly to be lifted by the power house EOT crane

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a) Name b) Weight c) Dimension

--------------------------------------------------------------------

37)

Recommended crane capacity

--------------------------

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288

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TABLE NO.1 GUARANTEED VALUES OF GENERATOR LOSSES AND EFFICIENCY AT RATED VOLTAGE Un and cos -0.90 (overexcited) No. Losses (According to IEC 34-2) Symbol unit Apparent power at generator terminals Smax= 110 % SN = 100% SN =75% MVA MVA MVA Losses in active iron and additional no load Pfe kW Losses in metal parts 1 Constant Losses due to Turbine bearing losses Pu.g.b kW losses friction and windage (*) Generator bearing losses Pl.g.b. kW Windage and friction losses Pwi+f kW Brushes losses Pbr kW 2 Excitation Field voltage Uf V parameters Field current If A 3 Load losses Stator windings copper losses at 75 C Pcu 1 kW Additional load losses Padd. kW Field winding copper losses at 75 C Excitation system losses (excit trasf. + thyristors + ac/dc links) Electrical losses in brushes 4: 5 6 SUMMATION OF LOSSES CALCULATED GENERATOR EFFICIENCY GUARANTEED GENERATOR EFFICIENCY Pcu2 Pe.s Pe.br Ip f i G.c f jG.g kW kW kW kW

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TABLE NO.2 GUARANTEED VALUES OF GENERATOR LOSSES AND EFFICIENCY AT RATED VOLTAGE Un and cos -1.00 No. Losses (According to IEC 34-2) Symbol unit Apparent power at generator terminals Smax SN = 100% 75% 110 % MVA MVA SN MVA Losses in active iron and additional no load Pfe kW Losses in metal parts 1 Constant Losses due to Turbine bearing losses Pu.g.b kW losses friction and windage (*) Generator bearing losses Pl.g.b. kW Windage and friction losses Pwi+f kW Brushes losses Pbr kW 2 Excitation Field voltage Uf V parameters Field current If A 3 Load losses Stator windings copper losses at 75 C Pcu 1 kW Additional load losses Padd. kW Field winding copper losses at 75 C Excitation system losses (excit trasf. + thyristors + ac/dc links) Electrical losses in brushes 4: 5 6 SUMMATION OF LOSSES CALCULATED GENERATOR EFFICIENCY GUARANTEED GENERATOR EFFICIENCY Pcu2 Pe.s Pe.br Ip f i G.c f jG.g kW kW kW kW

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TABLE NO.3 GUARANTEED VALUES OF GENERATOR LOSSES AND EFFICIENCY AT RATED VOLTAGE Un and cos -0.90 (underexcited) No. Losses (According to IEC 34-2) Symbol unit Apparent power at generator terminals Smax SN = 100% 75% 110 % MVA MVA SN MVA Losses in active iron and additional no load Pfe kW Losses in metal parts 1 Constant Losses due to Turbine bearing losses Pu.g.b kW losses friction and windage (*) Generator bearing losses Pl.g.b. kW Windage and friction losses Pwi+f kW Brushes losses Pbr kW 2 Excitation Field voltage Uf V parameters Field current If A 3 Load losses Stator windings copper losses at 75 C Pcu 1 kW Additional load losses Padd. kW Field winding copper losses at 75 C Excitation system losses (excit trasf. + thyristors + ac/dc links) Electrical losses in brushes 4: 5 6 SUMMATION OF LOSSES CALCULATED GENERATOR EFFICIENCY GUARANTEED GENERATOR EFFICIENCY Pcu2 Pe.s Pe.br Ip f i G.c f jG.g kW kW kW kW

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SECTION IX SUPERVISORY CONTROL AND DATA ACQUISITION SYSTEM

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SECTION NO. IX Supervisory control and data acquisition system I N D EX SR. NO. 9.1 9.2 9.3 General Requirements Computer based SCADA system Unit control Board Departure from specification Data Sheets Description PAGE NO. 294 295 305 309 310

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SECTION IX SUPERVISORY CONTROL AND DATA ACQUISITION SYSTEM

9.1

GENERAL REQUIREMENT:1 2. i) ii) iii) 3. Comprehensive system for automation of the power station complex as a whole shall be provided by the supplier. The plant to be controlled shall consist of the following:One No.:- Turbines-Generator set including all connected auxiliaries. Station service auxiliaries 220 kV switchyard equipments. The system shall use the most up to date & proven technology based on microprocessors reliable transducers which require no or little maintenance and/or calibration during services. 4. The system shall be arranged to provide (2) two levels of controls :- viz i) ii) Plant Control in automation mode from Unit Control board or from LCD console. Unit control, in manual mode, from Unit Control board or from respective control cubicles ( Generator excitation cubicle, auxiliary equipment control board and generator metal clad switchgear cubicle/etc.) 5. Normally, the plant control in remote automatic mode shall be used. When the communication link is not available, or when the equipment in Central Control Room is being inspected and/or is under repairs, the control and monitoring functions of the unit can be performed in Unit Control in Manual Mode,.

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9.2

COMPUTER BASED SCADA SYSTEM :-

9.2.1 System: Computer based SCADA system shall be used. Computer based SCADA system uses microprocessor based control technology physically distributed through out the power house. The separate microprocessor units are linked together by a number of digital communication paths to form a completely integrated control system.

9.2.2 Control Parameters: SCADA system should be complete with primary sensors, cables analysers/transmitters, monitors, system hardware/ software and peripherals etc. to monitor/control the following parameters. Generator stator and rotor winding temperatures Generator and turbine bearing temperature Lubrication oil temperatures Status of generator cooling system Governor control monitoring of turbine speed Generator terminal voltage, current, KW, KVAR, KVA, KWH, Hz, PF, field voltage and field current. Annunciation for violation of permissible limits of above parameter Turbine guide bearing temperature detector Generator guide & thrust bearing temperature detector Guide and thrust bearing oil level indicator Generator winding temperature detector Turbine speed Generator speed Governor oil pumps, oil pressure indicator and low pressure indicator and low pressure switch

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Cooling water pumps, section and discharge pressure switch / gauge. Inlet pressure gauge at inlet of turbine SCADA should provide monitoring of parameters listed above. The list may have additional parameters as per requirement and shall be finalised during design stage.

9.2.3 SCADA should have following controllers: Unit controller Common plant controller/ supervisory control Remote supervisory control

9.2.4 Unit Controller: It is microprocessor based / PLC based and is required to perform all functions as below. It is required to have capability to implement closed loop PID function for governing and to perform all monitoring, control, protection and recording functions that a power plant required independently. (a) It should monitor and control items Turbine wicket gate Turbine/ Generator RPM Generator power out put Generator excitation Generator breaker Line breaker (b) Automatic unit control modes should include following: Unit automatic start sequence Unit automatic shutdown sequence Unit automatic synchronizing Unit wicket gate set point control

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Unit load set point control Unit flow control (c) The unit should include digital governor with proportional, integral and derivative gains. The governor be with in a position loop controlled by speed loop and capable of 0-10% droop. A manual position control should be provided. Following governing functions should be provided. Speed evaluator Speed control Speed set point adjustment Gate limiter Start up and shutdown control of turbine Position controller for guide vanes with power amplifier for control of servo valve. (d) Unit Auto synchronization The controller should automatically synchronize the generator to the bus by reading the slip frequency (generator-bus) and adjusting the governor speed set point until the correct slip frequency is obtained while sending voltage raise/lower pulses to the voltage regulator to match generator voltage to bus voltage. When the slip frequency is obtained and the generator and bus voltage are equal, the controller shall send a close breaker command when the generator voltage and the bus are in phase. An additional external synchro check relay should also be provided to supervise the controller close breaker command and the manual close breaker command. The controller should follow synchronization limits in terms of breaker closing angle and voltage matching condition specified by generator manufacturer. (e) Shutdown sequence The shutdown sequence provided by controller should be such that the turbine generator set from any moving state to a complete standstill with

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all auxiliaries correctly shutdown. The unit controller should automatically shut down if the control system detects turbine mechanical system faults; generator electrical faults or specific shut down conditions are generated within system. Following three types of shutdown to be performed on the turbine/generator set should be provided by the controller. (i) Normal shutdown A normal shutdown should be initiated by a shutdown command that has been issued by an operator either from UCB or from supervisory LCD console. This sequence should allow the plant to be shutdown in a standard orderly manner. After the plant has completely shutdown it should return to a state in which it can be restarted again on the issuing of a start up command. (ii) Emergency shutdown An emergency shutdown should be initiated if a failure occurs in a critical item of plant, which is likely to cause unsafe operation of plant such as an electrical trip. The plant should quickly and safely shutdown with lockout to avoid damage to plant or injury to personnel. The plant should be blocked from restarting again until the fault is rectified and acknowledged by the operator from either UCB or from supervisory system. (iii) Unit start-up sequencing The controller should allow the unit to be started manually (if all permissive are met) and bring generating unit speed to synchronous speed. Alternately if automatic start up mode is selected either locally or remotely (UCB or LCD console) then unit should automatically start provided all the start up permissive are met. The unit controller should allow parameters of the start-up sequence to be configured to match the turbine generator.

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(iv) Lockout The controller should include a generator lockout function. Whenever the lockout function is on it should inhibit the generator from starting. Any alarm should be configurable as a lockout alarm. The lockout should be reset by resetting the lockout relay on UCB. When the lockout is on, it should be displayed on the screen annunciator. (v) Automatic power control modes The unit controller when the unit is not under plant control mode should be capable of several forms of automatic power control. The operator should be able to select automatic power control modes at any time and enter a new set point at any time. The available power control modes should meet the requirements of system. Gate position should be automatically controlled to match the wicket gate to a position set point. Gate position should be controlled to match the kW output of the Generator to a kW set point. Regardless of the kW set point, the generator output should be limited by a maximum kVA limit specified during configuration. Gate position should be controlled to match a flow set point that is calculated by the controller from a flow versus gate position curve for the operating head which is entered during the configuration process. (vi) Override control The controller should provide at least two override controls that when enabled will take over turbine control from the Automatic Power Control mode when certain set point limits are reached. When these interim conditions return to normal, the controller should automatically revert to the primary automatic power control mode. The controller should modulate the turbine output so that the measured generator stator temperature (hottest of the three phases) does not exceed the Temperature Control set point. Signature of Bidder
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(vii) Reactive power control The controller should have four reactive control modes, one manual and three automatic. The generator capability curve should be entered into the controller during configuring. All automatic reactive power control modes should be limited by the generator capability curves. If an operator enters a set point, that will take the generator outside its capability curves, the reactive power control program should control reactive power to get as close to the set point as possible, but remain within the generator's capability. Manual: The controller should provide operator capability, using "raise/lower" keys on the VDT keyboard and the "raise/lower" switch on the manual control panel to control voltage and reactive power. Automatic VAR control: The controller should automatically control the generator output to that VAR set point set by operator. The generator point. Automatic PF Control: The operator should enter power factor set point from the keyboard and the controller should automatically control the generator output to that power factor (leading or lagging) set point set by operator. The generator voltage limit and capability curve should not be exceeded regardless of the power factor set point. Automatic voltage control: The controller should automatically control the generator output to match that voltage set point set by operator. The generator voltage limit and capability curve should not be exceeded regardless of the voltage set point. voltage limit and capability curve should not be exceeded regardless of the VAR set

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Alarm Annunciation There should be two types of alarms used by the controller. One type should be the external alarms from contacts fed into the digital inputs of the controller and the second, the internal alarms generated by the controller. All alarms, whether internal or external, should be capable of being configured to cause different sequences. Unit controller should be capable of providing audible and visual alarms in the event of faults occurring in the power plants. The instant the fault occurs the relevant fault indicator is activated. All faults have to be acknowledged by the operators and can only be reset when the fault has been resolved. The list of faults on occurrence of which audible warning should be given will be finalised during design stage. .(viii) Manual control panel The unit controller should have a manual control panel that bypasses the processor and allows the generator to be operated manually. The manual operation shall be done from UCB. The manual control panel should include start relay circuitry that is station battery powered. Manual switches to trip and close the breaker, turn the field on and off, start and stop the turbine and raise and lower the voltage should also be included. The gate should be capable of manual operation by a potentiometer that is located on a manual control panel and should be calibrated to position within 0.1 percent. (ix) Unit Protection The protection system shall be based on the use of discrete microprocessor based relays with the following features: Continuous self monitoring Online display of actual values Should be capable to communicate with supervisory system through unit controller. Details of protection relays are covered in section -XI . Signature of Bidder

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(x) Supervisory Controller It should monitor and control the status of power plant, provide automatic unmanned operation, log data, display the process through a mimics, Depending on the station requirements, the operator should be able to enter set points for power output, voltage and power factor. It should also have online documentation and expert diagnostics, efficiency management and plant management. 9.2.6

Operator Interface Requirements: The controller should use a video display terminal or PC as the main operator console. It should have powerful graphical user interface to the operators. The operator should be able to completely operate the plant by typing commands/function key on the keyboard or by push button on control panel. All information required to operate the plant should be shown on the screen. A printer should be used to print out plant information. Symbols and colours specified in the international standard IEC 204 should be used for display.

9.2.7

Screen display: The screen display should include all metering, indication and annunciator information normally displayed on a typical power plant control panel. This should include all metered data such as three phase generator volts and amps, generator watts, VARS, power factor, speed and frequency. This display should also show generator stator and bearing temperatures, breaker status, line volts, line frequency, and kilowatt-hours. The time and date should also be displayed with time to the minute. Screen data should be updated promptly whenever actual data changes. Alarm and status information should be updated within one second of actual changes. Analog data should be updated within two seconds of a change. Calculated value such as temperature, watts,

VARS, and power factor should be updated within five seconds of an 302 Signature of Bidder Signature of Purchaser

actual change. All DC analog readings on the screen display should have configurable scale factors. All except speed should have configurable labelling on the screen. The AC scaling should be configurable by specifying WYE or DELTA and maximum AC voltage and current. Data shown on the display should have the following minimum accuracies. AC Voltage 1% of full scale AC Current .1% of full scale Frequency .005 HZ DC Inputs .25% of full scale KW, KVAR, PF .25% of full scale Temperatures + .5 degrees C 9.2.8

Annunciator display: A portion of the screen should be dedicated for an annunciator. Alarms should be displayed in order of occurrence with the oldest alarm at the top of the screen. The sequence of alarms should be distinguishable if alarms are more than 1/60 th of a second a part. The display should include space for a least 23 alarms. When an alarm clears, the alarm below it should move up to fill in the blank space keeping the sequence. No alarms should be lost. Any alarms that do not fit on the screen should be saved until there is room. Alarms should flash until the acknowledge key on the keyboard is pressed. If the alarm is still on after it is acknowledged, it should stop flashing but remain on the screen. If the alarm has cleared, it should be disappeared from the screen when the acknowledge key is pressed. The annunciator should display both alarms that are internally generated by the controller and alarms that are sensed external to the controller.

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9.2.9 Control status display: The display should include an indication of the status of the turbine i.e., starting, stopping, synchronizing, etc... 9.2.10 Automatic control status display: The display should show the current automatic control mode, its set point, turbine gate limit, and any overriding control modes. 9.2.11 DT Keyboard: The keyboard should be a standard keyboard with upper and lower cases, ten key numeric pad and at least ten function keys. The function keys should be assigned important functions. The operator should be able to start and stop the turbine from the keyboard using simple commands. The operator should be able to enter set points via keyboard, select any one of automatic power control modes and select any one of reactive power control modes 9.2.12 External Interface Supervisory Controller should have a number of protocol modules which should provide connectivity to other devices including remote terminal units and programmable logic controllers. 9.2.13 Event Recording and Data Logging (a) Data logging Their should be a provision for a data logging printer at the plant to provide data logging at adjustable intervals, trouble logs and operator comments entered manually at the keyboard. The data logging interval for each printers should be adjustable by the operator in increments of one minute.

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(b) Alarm and status logging All alarms annunciated on the screen should be recorded on the data log, time-tagged to 1/60 of a second resolution. Plant status or operational changes should also be recorded on the data log, time-tagged to 1/60 of a second resolution. The operator should be able to enter comments on the log manually through the keyboard.

(c) kWH logging Plant watthours should be accumulated and recorded on the data log at both daily and monthly intervals. The integrated power generation controller should have the capability to accumulate these data by one of two methods: internally, by a calculation method based on direct monitoring of generator CT and PT inputs, or externally, by receiving and totalizing counts from pulse initiator output from an external watthour meter.

9.3

UNIT CONTROL BOARD (UCB) Unit Control Board shall be installed in Control Room. Controls, Indications, Alarms etc. required on UCB are given below : 1. All control switches required for manual operation shall be mounted on this board. 2. Following control switches for Auto operation of plant shall be provided on UCB a) b) c) a) b) Unit Start/Stop Auto/ Manual Emergency Stop Operation indication window 30 window annunciator for Electrical fault
305

3. Three annunciation windows shall be provided.

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c)

30 window annunciator for Mechanical fault

4. Digital clock for indication of time 5. Digital type temp. scanner (0-150oc) with selector switch for temperature indication of selective equipments of power plant such as stator, rotor, guide bearing etc. shall be provided. 6. Following meters shall be provided. 7. Guide Vanes Limiter Position Indicator (0-100%) Guide Vanes Position Indicator (0-100%) Runner blades Limiter Position Indicator (0-100%) Runner blades Position Indicator (0-100%) Generator Voltage Meter with Selector Switch (0-20 kV) Generator Current Meter with Selector Switch (0-10 kA) Generator MW meter (MW-0-20 MW) Generator MVAr Meter Generator Power Factor Meter (0.9 over excited ....1.0 ...0.9 under excited). Frequency Meter 45-55 Hz Field Voltage Meter 0-500 V Field Current Meter 0-4000A Turbine Speed Indicator 0 to 500 rpm Speed/Load Setting Indicator. Running Hour Meter (Hours)

Dual channel AUTO/MANUAL Synchronizer shall be provided. Auto synchroniser shall consist of following modules :PHASE DETECTION MODULE : This module shall detect the phase difference between incoming

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generator and grid voltage. Output of the module shall be a pulse train whose width should vary as the phase difference. FREQUENCY DIFFERENCE MEASUREMENT MODULE : This shall measure the frequency difference between the incoming generator and grid voltage in the frequency difference of 0.01Hz to 1.00 Hz. POLARITY MODULE : This module shall compare the frequency difference obtained with the set value. (The set value is the one which is set on the front plate of the module) The module should then generate control signals for frequency matching. VOLTAGE DIFFERENCE MEASUREMENT MODULE : This shall measure the voltage difference between the incoming generator voltage and grid voltage and generate control signals for voltage matching. VOLTAGE COMMAND MODULE: This shall issue final command to AVR for raising or lowering the incoming generator voltage depending upon the measured condition. Interposing relays shall be provided for this purpose. FREQUENCY COMMAND MODULE : This shall issue the final command to the E.H.G for lowering or raising the incoming generator frequency depending on the measured condition. Interposing relays shall be provided for this purpose. BREAKER COMMAND MODULE : After the voltage and frequency are matched this module shall issue the closing command to the breaker. It should also take into account the breaker closing time which can be set on the front plate of the module. Signature of Bidder
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AUTOMATIC POWER OFF MODULE : After synchronisation, the feed back is received in this module which shall switch off the auto synchroniser. POWER SUPPLY MODULE : This module should accept the input voltage of 230V A.C. and generate necessary voltage required for functioning of auto synchroniser.

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DEPARTURE FROM SPECIFICATION (To be filled in by Bidder.) Item Description of departure. Reference to clause in the specifications

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DATA SHEETS MAIN CONTROLLER UNIT CONTROL BOARD Sr. No. 1 2 3 3.1 3.2 3.3 i) ii) 3.4 3.5 3.6 i ii iii iv 3.7 i ii iii 3.8 Manufacturer / Type No of CPU Characteristics of CPU Microprocessor Maximum memory capacity ( Program/data) Maximum No of flags Retentive Non Retentive Maximum No of Timers 0.01-9990s Maximum No of Counters 0-999s Max. Number of inputs/outputs Digital inputs Digital outputs Analog inputs Analog outputs Power supply module Voltage Frequency Converters Programming Language ::::::::::----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------:-------------------------::::----------------------------------------------------------------------------------------------------:::::-----------------------------------------------------------------------------------------------------------------------------Description Offered By Supplier

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WORK AND OPERATING STATION Sr No 1 2 3 4 5 6 7 a b c d Description Manufacturer /Type Number of CPU CPU Details RAM Capacity Hard Disc capacity Operating system Video display unit Number Display screen Key board Printer :::::::::::Offered by supplier -----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

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SECTION X TECHNICAL SPECIFICATION FOR LAVT CUBICLE, NG CUBICLE AND ISOLATOR

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SECTION NO. X TECHNICAL SPECIFICATION FOR LAVT CUBICAL,NG CUBICAL, GENERATOR EXTENDED TERMINALS I N D EX SR. NO. 10.1 10.2 10.3 Scope Codes and Standards Removable and Shorting Links. Data sheets Description PAGE NO. 314 316 317 318

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SECTION- X TECHNICAL SPECIFICATION FOR LAVT CUBICLE, N.G CUBICLE AND ISOLATOR CUBICLE 10.1 SCOPE :The scope of these specifications shall cover the design, manufacture, assembly, testing at manufacturers works before despatch, supply, delivery, supervision, onsite erection, testing and commissioning of:LAVT CUBICLE One set of lightning arrestor and voltage transformer cubicle of sheet steel construction shall be supplied complete with fluorescent lamp, internal wiring, space heater etc. The equipment details are as under:-

1)

1 set

11000/ 3/110/3V/110/3V PT Core-1, 100 VA, Cl 0.2 Core-2, 200 VA, Cl 3P

1 set

11000/ 3/110/3V/110/3V PT Core-1, 100 VA, Cl 0.2 Core-2, 200 VA, Cl 3P

1 Set of 12 KV, 10 KA lightning Arrestor 1 Set of 12 KV, Surge Capacitor 3 Nos. MCB 2) N.G. CUBICLE One set of NG cubicle of sheet construction complete with space heater, marshalling box, illumination lamp etc. The cubicle shall have following : 1 No. Disconnecting link 1 No. 11/3 KV/220 V single phase NG transformer 1 No. secondary loading resistor.

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Galvanised steel supports, shorting bar etc. 3) A) BUS DUCT 1000 A, 11 kV, segregated phase busduct for the inter connection between Generator terminals and LAVT cubicle. Following taps shall be provided Tap for Excitation Transformer End terminals for interconnection of LAVT cubicle with Isolator cubicle. Segregated phase busduct for generator neutral connection to NG cubicle. Phase busduct comprises of 3.2 thick Aluminium alloy enclosure and Aluminium alloy conductor in box formation shall be provided. CURRENT TRANSFORMERS :Following CTs shall be provided on Generator phase side . Current Transformer 1000/5A 30 VA CL 5P 20 for Generator Diff. Protection Current Transformer 1000/5A 30 VA CL 5P 20 for Transformer Diff. Protection Current Transformer 1000/5A 30 V.A .0.2 for AVR Current Transformer 1000/5A 30 V.A CL 5P 20 for other protection relays. Following CTs shall be provided on Generator Neutral side. Current Transformer 1000/5a 30 VA CL 5P 20 for Generator Diff. Protection Current Transformer 1000/5A 30 V.A CL 5P 20 for overall Diff. protection .

a) b)

B)

4) a) b) c) d)

e) d)

Note:- The power transformer is not in the scope of supply of this contact. Also synchronising is proposed to be at 220 kV switchyard supplier for following aspects. a) CT specification on 220 kV side for Overall Diffi Protection. b) Control and power cable termination Signature of Bidder
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c)

d)

5)

10.2

Coordination regarding exchange of information regarding status of 220 kV breakers, breaker closing and opening command from SCADA system etc. UAT is not in the scope of this contact. Diff .protection of UAT is included in the scope of this contact .Main plant supplier shall coordinate with other supplier in respect of exchange of information regarding CT specification requirement ,control and power cable termination etc. ISOLATOR CUBICLE :- For the purpose of keeping main power transformer in charged condition during major shutdown of power plant ,a motor operated isolator cubicle with 1000 A current carrying capacity shall be provided . A tap for connection of 11 KV XLPE cable between isolator cubicle and power transformer shall be provided .It shall possible to operate the isolator from USB . To avoid operation of isolator during operation of the main plant . Lock and key arrangement shall be provided for push buttons . The isolator contacts shall be taken in the auto plant operation sequence programme such that at all times isolator shall be in closed position before starting the machine. CODES AND STANDARDS All Equipment shall be designed ,manufactured and tested in accordance with standards mentioned as below :CURRENT TRANSFORMERS 15) IEC 185/1987 Current Transformer 16) IS- 2705 Current Transformer VOLTAGE TRANSFORMERS 17 ) IEC-186/1987 Voltage Transformer SURGE PROTECTION CAPACITOR 18 ) IS-3070 19) VDE-0657 Lighting Arrestors Capacitors

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GENERATOR NEUTRAL EARTHING 20) IS-3151 NOTE :IS Indian Standard IEC - International Electro technical Commission VDE Verband Deutscher Eletrotechniker 10.3 REMOVEBLE AND SHORTING LINKS Earthing Transformer

10.3.1 SCOPE The scope of this specifications shall cover the design ,manufacture, assembly and testing at manufacturers works before dispatch, supply delivery ,supervision .on site erection ,testing and commissioning of :1 set of three phase removable links to be provided in the main run to facilitate disconnection of generator and step up transformer during testing , commissioning and maintenance. 1 set of three phase removable links to be provided for tap run to unit auxiliary transformer (UAT) to facilitate disconnection of CTs. And UAT during testing , commissioning and maintenance. 1 set of three phase removable links to be provided for tap run to exitation transformer (ET) to facilitate disconnection of CT;s ,VT-1.VT-2 and ET during testing , commissioning and maintenance. 1 set of removable links in the run of neutral bus duct for segregation of generator phase from neutral point. One (1) three phase set of bolted type main run shorting links for the purpose of drying out of generator stator before commissioning or for carrying out sustained short-circuit tests shall be provided.

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Sr. No. 1 2 3 4 i) ii) iii) iv) 5 i) ii) iii) iv) 6 7 8 i) ii) iii) 9

10

DATA SHEETS CURRENT TRANSFORMER MAIN RUN Description Manufacturer / type : Rated Primary Current (A) :- Rated Secondary Current (A) :- Rated Secondary Output : :Measuring (1) ..............VA :Protection (2) ...........VA :Protection (3) ..................VA :Protection (4) .................VA Accuracy Class Measuring (1) ..............VA :Protection (2) ...........VA :Protection (3) ..................VA :Protection (4) .................VA :Instrument security factor : Accuracy limit factor for Protection : core Short time current rating Thermal current (Ith) :- KA Dynamic current (Idyn.) :- KA Short circuit duration :- Sec One minute Power Frequency :- KV withstand Voltage (between bus-bars and secondary windings) Inter turn insulation of secondary winding : - one minute across complete :- KV winding - one minute between the sections :- KV Temperature rise of winding :.K

11

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Sr. No. 1 2 3 4 i) ii) 5 i) ii) 6 7 8 i) ii) iii) 9

10

CURRENT TRANSFORMER TAP OFF RUN TO EXCITATION TRANSFORMER Description Offered by supplier Manufacturer / type : Rated Primary Current (A) :- Rated Secondary Current (A) :- Rated Secondary Output : :Measuring (1) ..............VA :Protection (2) ...........VA Accuracy Class Measuring (1) ..............VA :Protection (2) ...........VA :Instrument security factor : Accuracy limit factor for Protection : core Short time current rating Thermal current (Ith) :- KA Dynamic current (Idyn.) :- KA Short circuit duration s :One minute Power Frequency :- KV withstand Voltage (between bus-bars and secondary windings) Inter turn insulation of secondary winding : - one minute across complete :- KV winding - one minute between the sections :- KV Temperature rise of winding :.K

11

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Sr. No. 1 2 3 4 ii) iii) iv) 5 ii) iii) iv) 6 7 8 i) ii) iii) 9

10

CURRENT TRANSFORMER NEUTRAL TERMINAL Description Offered by supplier Manufacturer / type : Rated Primary Current (A) :- Rated Secondary Current (A) :- Rated Secondary Output : :Protection (1) ...........VA :Protection (2) ..................VA :Protection (3) .................VA Accuracy Class Protection (1) ...........VA :Protection (2) ..................VA :Protection (3) .................VA :Instrument security factor : Accuracy limit factor for Protection : core Short time current rating Thermal current (Ith) :- KA Dynamic current (Idyn.) :- KA Short circuit duration s :One minute Power Frequency :- KV withstand Voltage (between bus-bars and secondary windings) Inter turn insulation of secondary winding : - one minute across complete :- KV winding - one minute between the sections :- KV Temperature rise of winding :.K

11

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Sr. No. 1 2 3

VOLTAGE TRANSFORMERS VT-1 & VT-2 Description Offered by supplier Manufacturer /type :. Primary Rated Voltage (kV) :- KV rms Secondary Rated Voltage - core 1 (measuring) :- V - core 2 (Protection) :- V Accuracy Class - core 1 (measuring) - core 2 (Protection) Rated Burden - core 1 (measuring) :- VA - core 2 (Protection) :- VA Thermal Burden - core 1 (measuring) :- VA - core 2 (Protection) :- VA Voltage Factor - Continuous service :. - During 8 hours :. - During 4 hours :. Short-circuit current (guaranteed for secondary windings.)

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SURGE PROTECTION CAPACITORS AND LIGHTING ARRESTERS

Sr. No. A 1 2 3 4 4 5 6 B 1 2 3

Description Surge Protection Capacitors Manufacturer / type Max. Voltage for equipment (kV) Rated voltage Rated capacitance Dielectric Temperature class Insulators creepage distance min Lighting Arresters Manufacturer/ type Rated Voltage (kV) Number of stacks

Offered by supplier ::::::: KV KV microfarad mm/kV

::-

KV

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GENERATOR NEUTRAL EARTHING Sr. No. A 1 2 3 4 i) ii) iii) 5 6 i) ii) B Description LOADING RESISTOR Manufacturer / type Max. system voltage for equipment (Um) Rated current (A), 10 s. Overload capacity 1s. (A) 2s. (A) 5s. (A) Resistance t = 20 C Test Voltage one minute 50 Hz (kVrms) Impulse 1.2/50 microsecond (kVcr) Neutral voltage transformer or neutral point grounding transformer Manufacturer /type Year VT or power transformer is commercialised Primary Voltage Secondary Voltage Burden Class One minute 50 Hz test voltage Impulse test voltage 1.2/50 second micro Offered by supplier ::::::::: KV A A A A ohm ..(kVrms) .. V

1 2 3 4 5 6 7 8

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.. KV .. V .. VA .. .. KV rms ..

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BUSDUCT DESIGNATION : Technical Particulars:1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) 12) 13) 14) 15) 16) Name of manufacturer Rated voltage ::OFFERED BY BY SUPPLIER

Continuous current rating at rated voltage :Type Reference standard Symmetrical short Circuit rating One minute power Frequency with-stand Impulse level (1.2/50) Micro sec Frequency Enclosure-a) shape b) Material Conductor material Support Insulator Ambient Insulator Temperature rise of enclosure above ambient ::::;_ ::::::-

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SECTION XI PROTECTIVE GEAR

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SECTION NO. XI PROTECTIVE GEAR I N D EX SR. NO. 11.1 11.2 11.3 Scope Requirement Data sheets. Description PAGE NO. 327 327 330

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SECTION- XI
PROTECTIVE GEAR
11.1 Scope:For the protection of Turbine Generator set, Excitation Transformer, Main Transformer, unit auxiliary transformer microprocessor based Protection Relay scheme shall be provided.

11.2

Requirement :Protection scheme.

1) protection scheme shall consist of main protection scheme and backup 2) Protection scheme shall consist of a) Protection panel to accommodate all protection equipments. b) Power supply unit: - Two power supply unit shall be used in each protection scheme (main and backup) changeover between the power supply unit shall be automatic. c) Input module: - it shall consist of transformer module, relay module etc. d) CPU module with storage. e) O /P relay module. f) Software g) LCD console to load software and setting the parameters. h) Interfacing cables. 3) 4) 5) LED Indication of each protection shall be provided on panel. Master trip relay with hand reset shall be provided. Protection CTs on 220 KV side, UAT differential protection CTs, 220 KV Generator circuit breaker are not in the scope of this contract. The Protection relay supplier shall co-ordinate with 220 KV equipment supplier and other contractors for following co- ordination aspects. a) Step up transformer differential protection :CT specification on 220 KV side & cable termination. Signature of Bidder
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b) Overall differential protection :CT specification on 220 KV side & cable termination. c) UAT differential protection:CT specification & cable termination.

11.3

Following protection shall be covered by protection system. 1) Generator Differential Protection. 2) Overall Differential Protection. 3) Step-up transformer differential protection. 4) Generator Stator Earth- fault protection. 5) Generator-Rotor Earth- fault protection. 6) Voltage controlled over- current protection. 7) Loss of excitation (Minimum reactance protection) 8) Reverse power protection. 9) Under-impedance protection. 10 ) Thermal over-load protection. 11) Negative sequence phase current protection. secondary Winding of step-up transformer. 13) Over-frequency protection. 14) Under-frequency protection. 15) Generator over-voltage protection. 16) Generator under voltage protection 17) Step-up transformer over-current protection. 18) Step-up transformer over-fluxing protection. 19) 20) 21) Excitation transformer differential protection. Unit auxiliary transformer differential protection. Any other protection required. 12) Restricted earth-fault protection for star- connected

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DEPARTURE FROM SPECIFICATION (To be filled in by Bidder.) Item Description of departure. Reference to clause in the specifications

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DATA SHEET 1 2 3 4 5 6 7 8 9 10 Name of Manufacturer Type Designation Size of panel No of input analog modules No of analog inputs per module No of input digital modules No of digital inputs per module No of output relay module No of outputs per modules No of power supply module ( Details shall be furnished ) 11 12 No of CPU modules List of protection function provided (separate list shall be furnished ) 14 Whether Master trip relay is provided :::::::::::::-

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15 16 17

Will the operating console be supplied Operating language Operating voltage

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SECTION XII DRAWINGS

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