Power Generation Plant

J P Mukherji & Associates Pvt Ltd
WSSF-USI TECHNICAL SPECIFICATION Section –VI-D

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CONTRACT DOCUMENT FOR
POWER GENERATION PLANT
TABLE OF CONTENTS
Table of Contents
2400 POWER GENERATION PLANT..............................................................................4
2401 TURBO ALTERNATOR, ACCESSORIES AND SYSTEM.......................................5

2401-1 STEAM TURBINE...........................................................................................................9
1.0 Turbine Casing......................................................................................................9
2.0 Turbine Rotor......................................................................................................10
3.0 Combined Stop and Emergency and Control Valves..........................................10
4.0 Safety Valves and Quick Acting Non Return Valves...........................................10
5.0 Gland Sealing System........................................................................................11
6.0 Bearings.............................................................................................................. 11
7.0 Base Plate/ Sole plate.........................................................................................11
8.0 Governing System..............................................................................................11
9.0 Lubricating Oil and Turbine Control Oil System..................................................13
10.0 Emergency Supply DC System...........................................................................15
11.0 Condensing Plant................................................................................................15
12.0 Pressure reducing and De-superheating.............................................................18
13.0 Instrumentation and controls...............................................................................18
14.0 Piping..................................................................................................................22
15.0 Thermal Insulation and Lagging..........................................................................29
2401-2 SPEED REDUCING GEAR BOX................................................................................29
2401-3 ALTERNATOR, EXCITER AND AUXILLARIES.....................................................30
2401-4 AVR PANEL (EXCITATION PANEL).........................................................................39
2401-5 NEUTRAL GROUNDING RESISTANCE (NGR) PANEL........................................40
2401-6 LAPT AND SURGE CAPACITOR PANEL.................................................................40
2401-7 RELAY PROTECTION AND METERING PANEL...................................................40
2401-8 BATTERY, BATTERY CHARGER AND DC DB.......................................................44
2401-9 SYNCHRONISING PANEL..........................................................................................49
2401-10 ALTERNATOR BREAKER PANEL (11 kV HV BOARD).........................................51
2401-11 HV CABLE AND TERMINATION KITS (11 kV)......................................................62
2401-12 LV CABLES WITH GLANDS AND TERMINATION KITS (400V, 1.1 kV Grade).64
2401-13 EARTHING SYSTEM...................................................................................................67
2401-14 MOTOR CONTROL CENTRE....................................................................................69
2401-15 AC DISTRIBUTION BOARDS....................................................................................69
2401-16 COMMISSIONING SPARES........................................................................................90
2401-17 ONLINE UPS FOR TURBINE AUXILIARIES..........................................................90

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TABLE OF CONTENTS
2402 COOLING TOWERS, AUXILIARIES AND PUMPS...............................................92

2.1 General...............................................................................................................92
2.2 Scope of supply..................................................................................................93
2.3 Make up water pumps........................................................................................94
2.4 Circulating water pumps......................................................................................95
2.5 Auxiliary cooling water pumps.............................................................................95
2.6 Cooling Water Piping..........................................................................................95
2.7 Design criteria for piping.....................................................................................95
2.8 Design requirement of cooling tower...................................................................96
2.9 Maintenance requirement...................................................................................96
2.10 Electrical scope of work requirements.................................................................97
2.11 Features of construction......................................................................................97
2.12 Mechanical equipment........................................................................................99
2.13 RCC basin........................................................................................................ 100
2.14 Piping, valves and specialties...........................................................................100
2.15 Materials of construction...................................................................................101
2.16 Tests and Inspection.........................................................................................101
2403 AIR COMPRESSOR SYSTEM............................................................................102
3.1 Scope of supply includes:.................................................................................102
3.2 Codes & Standards...........................................................................................102
3.3 Design Requirements........................................................................................102
3.4 Air Compressor.................................................................................................103
3.5 Crosshead........................................................................................................ 103
3.6 Valve assemblies..............................................................................................103
3.7 Bearings............................................................................................................ 103
3.8 Intercooler.........................................................................................................103
3.9 Suction Filter.....................................................................................................103
3.10 Foundation bolts...............................................................................................104
3.11 Controls............................................................................................................104
3.12 After cooler/Moisture Separator........................................................................104
3.13 Electrical........................................................................................................... 104
3.14 Air receiver........................................................................................................104
3.15 Mountings.........................................................................................................105
3.16 Inspection and Tests.........................................................................................105
3.17 Surface Treatment............................................................................................106
3.18 Compressed air piping / tubing.........................................................................106
2404 AIR CONDITIONING AND VENTILATION SYSTEM...........................................106
4.1 General.............................................................................................................106

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TABLE OF CONTENTS
4.2 Codes and Standards.......................................................................................106

4.3 Performance test...............................................................................................107
4.4 Work schedule..................................................................................................107
4.5 Scope of work...................................................................................................107
4.6 SCHEME..........................................................................................................108
4.7 Detail Specification of Blower............................................................................108
4.8 Exhaust Fans....................................................................................................108
4.9 Filters................................................................................................................109
4.10 Sheet metal work, grills, diffusers......................................................................109
4.11 Air Conditioning System....................................................................................110
2405 EOT CRANE FOR CO-GENERATION POWER HOUSE (60 T /10 T)................112
5.1 Codes and Standards.......................................................................................112
5.2 Performance test...............................................................................................112
5.3 Work schedule..................................................................................................113
5.4 Spares..............................................................................................................115

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SECTION –VI-D
TECHNICAL SPECIFICATION
2400 POWER GENERATION PLANT
The plant and equipment included in the Contractor’s scope cover the requirement of
Two Turbo-alternators along with accessories. The Turbo-alternators along with ac-
cessories is part of the Cogeneration plant being installed by M/s. Wonji Shoa Sugar
Factory. The equipment included in the Scope of Supply and services are detailed in
the specifications but it is the responsibility of the Contractor to ensure completeness
of his supply within the terminal points defined in document. Hence, any equipment
not specifically included in the specifications but required for ensuring completeness
of supply, are assumed to be included in the contractor’s Scope.
Schedule of equipment included in the Scope of Supply and services are listed
hereunder. Each equipment bears identification Equipment code number, which must
be used by the Contractor in all his documents.
Equipment Quantity Description

No.
Turbo-alternator and Auxiliaries
2401-1 ONE Steam turbine
2401-2 ONE Gear box
2401-3 ONE Alternator and Auxiliaries
Electrical system
2401-4 AVR Panel (Excitation Panel)
2401-5 Neutral Ground Resistor panel
2401-6 LAPT and SURGE Capacitor Panel
2401-7 Relay protection and metering panel
2401-8 Battery, battery charger and DCDB
2401-9 Synchronization panel
2401-10 Alternator Breaker Panel (11 kV HV Boards)
2401-11 HV cable and termination kits (11 kV)
2401-12 LV cable with glands and termination kits (400 V, 1.1 kV)
2401-13 Earthing system
2401-14 Motor control centre (MCC)
2401-15 AC distribution board
2401-16 Commissioning spares
2401-17 Online UPS for Turbine Auxiliaries
2402 Three cells Cooling tower, Auxiliaries and pumps
2403 Two Air Compressor System
2404 Lot Air Conditioning and Ventilation System
2405 One EOT crane for power house (60 t & 10 t)
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Price of spares for 2 years normal operation shall be quoted separately along with list
of spares included.
2401 TURBO ALTERNATOR, ACCESSORIES AND SYSTEM
The Turbo-alternator shall be 30 MWe nominal rating (or best possible rating at given
steam parameters), multistage double extraction type, consisting but not limited to
following components:
- Steam Turbines, 30 MWe Nominal rating, double extraction

condensing
- Parallel shaft, speed reducing gearbox.
- Combined lubrication oil system, combined turbine control oil system.
- Steam jet air ejectors (2 x 100%).
- Water-cooled divided water box type shell and tube condensers.
- Thermal insulation and lagging.
- Alternators, 30 MWe NCR, 11 kV, 50 Hz, 3-phase, 0.8 pf.
- Instrumentation and Controls.
- Cooling tower
- Air conditioning and ventilation
- Air compressors
- EOT crane
- Local Instruments Panel
- Alternator panel.
- AVR Panel
- Excitation panel
- Neutral grounding panel
- Alternator breaker panel
- Synchronizing panel
- Electrical items
Boiler, which shall supply steam to the turbo-alternators, shall be generating steam at
66 bar (a) pressure and 515  5 oC temperature. After allowing for piping losses, the
steam conditions at turbine stop valve shall be 64 bar (a) pressure, 505 0C
temperature.
Factory shall be requiring steam for process at 9 bar (a) and 2.6 bar (a). For this
purpose, the turbo-alternator shall be double extraction condensing type. The
condenser pressure selected is 0.14 bar (a). Extraction at 9 bar (a) shall be
uncontrolled whereas the same at 2.6 bar (a) shall be controlled.
The turbo-alternator should be suitable to meet demands imposed during different

operating modes of the Co-generation plant. The modes are classified in 3 different
categories as listed below.
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Mode A: Factory “ON” & Grid “ON”
When co-generation plant and grid are running in parallel. This is the
mode for normal operation. Factory shall be operating in this mode for
about 4398 in a year.
Mode B: Factory “OFF” & Grid “ON”
When factory is not working, but turbo-alternators are running to

export power to grid. Factory shall be operating in this mode for about
776 hrs in a year.
Mode C: Factory “ON” & Grid “OFF”
When factory is operating but grid is off due to some reason. Turbo-
alternator shall be running at reduced load during this mode. Factory
shall be operating in this mode for about 89.8 hrs in a year.
Steam supply to each turbo-alternator and amount of extraction steam required by

factory during above modes is presented in enclosed flow diagram.
* Bidder to specify

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COGENERATION POWER PLANT TURBO-ALTERNATOR
Table 1
Sr. # Description Unit Mode A Mode B Mode C
1.0 Inlet live steam

- pressure bar (a) 64 64 64
-Temperature °C 505 505 505
- Flow t/h 164 130.2 59
2.0 Extraction Steam @ 9.0 bar
(a) / 180 0C at de-super-
heater outlet
1st controlled extraction t/h 19.80 13.72 0
For steam ejector t/h * * *
Bleed system pressure at No reduction in pressure down
battery limits to 40 % of MCR
3.0 Extraction Steam @ 2.6 bar t/h 117 71.8 42.6
(a) / 130 °C at de-super-
heater outlet
4.0 Power available at Alternator MW 31.30 27.20 10.40

Terminal
5.0 Condensing System
Condenser operating pressure bar (a) 0.14 * *

Condensing cooling water inlet °C 32 32 32
temperature
Condenser sizing To suit operation in all 3
modes
Condenser outlet water °C * * *
temperature
6.0 Alternator
Generation Voltage kV 11
System frequency Hz 50  5 %
Power factor 0.8 lag
Parallel operation with grid
7.0 Ambient conditions

Atmospheric conditions Dusty
prevalent in the plant
8.0 Duty requirements Continuous 8000 hrs in a year
9.0 The economical steam rate % 80-100
required at percentage load
10.0 Vibrations mm/sec Below 2.8
* Bidder to specify

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Sr. # Description Unit Mode A Mode B Mode C

11.0 The maximum noise level at [db(A)] 85
1.0 m distance for any
equipment from the equipment
shall be equal to or less than
12.0 The minimum continuous load % 15
at which the turbo-alternator is
expected to operate as a
percentage of the MCR load
Design criteria for maximum flows are indicated below:
- Turbo-alternator shall be designed for maximum inlet steam flow of 164 t/h at
64 bar (a) and 505 °C temperature
- Uncontrolled extraction at 9 bar (a) steam shall be designed for flow of 19.8
t/h at the outlet of desuperheater.
- For Controlled extraction at 2.6 bar(a) steam at extraction conditions of

temperature and pressure to be designed for maximum steam flow of 117 t/h
at the outlet of desuperheater.
- Condenser shall be designed for maximum steam flow of 50 t/h and pressure
of 0.14 bar (a).
30 MWe is nominal rating of the turbo-alternator. Contractor shall inform and

guarantee Maximum Continuous Rating (MCR) at alternator terminals based on
above conditions. The turbo-alternator shall be part of a bagasse based co-
generation plant in sugar factory where surplus power generated shall be exported to
Electricity Grid, hence maximum power generation shall be one of the main criteria
for selection. Maximum Economical rating shall be for conditions prevailing in Mode
A.
Guaranteed performance shall be for conditions during Mode A. The Contractor

shall submit performance curve and correction curves for variation in inlet steam
pressure and temperature.
The turbo-alternator shall be suitable for synchronizing with grid, diesel engine and
another turbo-alternator in future.
Governing system shall be of high accuracy electronic Woodward 505 E or

equivalent. The governors shall control speed, load, and steam pressure. The
governor shall be provided with DSLC so that both the TS sets will run in parallel load
sharing mode during islanding.
Condensate from turbine condenser shall be used as boiler feed water. Hence this
water shall be used as cooling water for gland steam condenser. Also steam
emanating from condenser steam jet ejector shall be used to further raise the
temperature of condensate from turbine. The condensate from gland steam
condenser and ejector steam shall be piped back to hot well of turbine condenser.
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The increase in the temperature of the condensate shall be advantageous for boiler
operation. The condensate line shall be up to hot well of boiler.
Material of construction for different parts shall be appropriate to the pressure,

temperature, speed, load, to which the parts are subjected and shall ensure long
trouble free operation. Qualities of material shall be specified.
Heavy parts such as casing, steam chest, rotor, bearing and gland housings shall be
stress relieved before machining. After stress relieving, the parts shall be rough
machined. After rough machining, the parts shall be subjected to secondary stress
relieving. After secondary stress relieving only the parts shall be final machined.
Wherever matching of top and bottom parts is required, final machining shall be done
only after blue matching of the parts.
All casting shall be thoroughly cleaned from inside and outside and no sand either
loose or fused should be allowed to remain the casting.
Quality assurance and control plan shall be submitted, listing various stages and
steps of quality control.
The turbo-alternator is to be operated through fully automatic and remote controls.

These controls shall be through Instrumentation provided by the Contractor, hooked
up with Distributed Control System (DCS), which shall be provided by the Employer.
Automatic and remote controlled operations shall be performed by the
instrumentation supplied by the Contractor as well as through Employer’s Distributed
Control System. All valves and dampers coming under the instrumentation control,
shall be motorised. Wherever standby pumps are provided, they shall be with
automatic cut in/cut out arrangement.
Specifications of various components are detailed below.
2401-1 STEAM TURBINE
Quantity: 1 No.
The turbine shall be double extraction condensing type machine. The design shall
ensure highest efficiency, reliability and availability. Inlet steam flow to the turbine
shall be through a main stop valve and three or more control valves.
The turbine shall be complete in all respects, including but not limited to turbine
casing, fully bladed rotor, combined stop and emergency valve (CSEV), control
valves, quick acting non-return valves (QCNRV) for both extractions, gland box with
sealing system, barring gear, bearings with housing, Electronic Governing System,
PRD’s if any.
1.0 Turbine Casing
The turbine casing shall be of symmetrical design, with an envelope, to reduce the
thermal stress to a minimum during load variations or temperature fluctuations. The
casing shall be horizontally split and permit examination of blading without disturbing
shaft alignment or causing damage to the rotor and blades. The turbine shall be
* Bidder to specify

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designed to permit expansion and contraction, in response to temperature changes,

in order to minimize misalignment and distortion.
Orientation of turbine steam inlet, extraction outlets and condenser cooling water inlet
and outlet nozzles shall match with locations of respective source/end users.
2.0 Turbine Rotor
Rotor, balance piston and disks shall be made from a single forging. Steam wetted
areas of rotor blades shall be ground and have mirror like finish and designed to
withstand shocks and vibrations during abnormal working. Blades shall be
manufactured from forged shaft or shall be die forged out of suitable chromium steel.
Complete rotor assembly shall be dynamically balanced. After balancing, fully bladed
rotor shall be subjected to an over speed test at 120 % of normal. Critical speeds of
the rotor shall not fall within  20 % range of operating speed. Rotor shall be
designed to withstand shocks likely to occur during abnormal operation.
A turbine shall be provided with mechanical type barring gear driven by AC motor to
rotate the turbine and alternator after shutdown or before starting. It should be
interlocked with lubrication oil system.
3.0 Combined Stop and Emergency and Control Valves
The main stop valve shall serve to isolate the turbine during emergency trips. Directly
connected to the steam chest, it shall be of rapid closing design.
The control valves are to be operated by a single servomotor directly attached to the
valve to minimize backlash. In order to minimize the losses during part load
operation, minimum three control valves shall be provided. The control valves shall
control steam admission independently.
Steam strainer shall be installed in the main stop valve
4.0 Safety Valves and Quick Acting Non Return Valves
4.1 Quick Acting Non Return Valves
For both 9 and 2.6 bar (a) extractions, quick acting non-return valves (QCNRV)
shall be provided to avoid reverse flow of steam to turbine. These valves shall
be fitted on the extraction steam piping between the turbine outlet and de-
superheaters of respective lines of 9 and 2.6 bar (a) pressure extraction steam.
The valves shall be oil operated.
4.2 Safety Valves
Three safety valves shall be provided, one for 9 bar (a) extraction steam and
two for 2.6 bar (a) extraction steam. These valves shall be fitted on the
extraction steam piping between the turbine outlet and de-superheaters of
respective lines of 9 and 2.6 bar (a) pressure extraction steam. The outlet of
* Bidder to specify

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safety valves shall be taken outside the powerhouse to safe elevation. The
valves shall be oil operated.
5.0 Gland Sealing System
Glands shall be labyrinth type and sealed with steam.
Suitable gland sealing system shall be provided with all controls. For cooling and
retrieving gland sealing steam, gland steam cooling condenser shall be provided.
Cooling water shall be condensate of turbine condenser. While passing through the
condensers, the temperature of condensate shall increase. Temperature increase in
condensate should be maximum, as this shall be used as boiler feed water.
Contractor shall indicate temperature rise.
Condensates of cooled gland sealing/leakage steam shall be piped back to turbine

condenser hot well.
6.0 Bearings
Radial and thrust bearings shall be liberally designed. Rise in bearing temperatures
shall be well within the maximum temperature, which the
bearing material can withstand.
7.0 Base Plate/ Sole plate
Suitable base plate either individual or combined with gear box shall be provided for
mounting the turbine. The base plate should be rigid in construction and suitable for
the application. The base plate shall be complete with mounting pad/ grouting pads,
sole plates, foundation and holding down bolts with nuts, adjusting shims etc.
Suitable openings shall be provided to pour the grout.
8.0 Governing System
8.1 General Control Philosophy
The governing system shall control following parameters:
- Speed
- Load
- Inlet steam pressure
- 2.6 bar (a) Extraction steam pressure
- Over speed
The governor shall ensure controlled acceleration and shall prevent over speed
without tripping the unit under all operating conditions. Governor shall have linear
droop characteristic with suitable range for stable operation and shall have provision
to adjust droop in fine steps.
* Bidder to specify

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Speed control
Speed shall be kept constant irrespective of load and pressure.
Load control
Load controller shall control speed during start-up, isolated operation and during load
throw off condition. In this mode of operation the speed governor shall regulate inlet
steam flow through turbine.
Inlet steam pressure control
The control shall function as a supervisory control for maintaining steam pressure at
turbine stop valve. The control shall sense pressure in steam line upstream of turbine
stop valve and shall act to increase steam flow into the turbine with increase in
upstream pressure and vice-versa with decrease in upstream pressure.
9 bar (a) extraction steam control
Extraction at 9 bar (a) pressure shall be uncontrolled extraction/bleeding, which

means the flow shall vary as per demand irrespective of pressure. The uncontrolled
extraction shall not affect the inlet steam flow through turbine.
2.6 bar (a) extraction steam control
Extraction at 2.6 bar (a) pressure shall be controlled extraction. Extraction pressure
controller shall operate only on LP control valve by sensing downstream pressure
and inlet control valve opening shall not be affected. Extraction steam flow limiting
control with adjustable set point shall be provided.
Over speed trips
The trip mechanism shall function independently of governing valve. Interlocks shall
be provided so that trip resetting cannot be effective unless steam admission is as
per normal starting procedure.
8.2 The Governing System
The governing system shall be a digital microprocessor based programmable

governing system, Woodward 505 E or equivalent. The system shall operate with
high governing accuracy. Signal provided by the digital control system shall act on
hydraulic actuators, which shall operate the control valves.
The governor shall permit the turbine to start from rest and run up to the selected
nominal speed, maximum possible being the trip speed, under the control of the
governor. The governor shall have a derivative action in order to limit the speed
increase during partial or total load rejection. The governor shall be suitable to
synchronize and operate with Grid as well as other Turbo-alternator(s). The governor
shall have drooping speed v/s load characteristics and facility to adjust the same
from remote location of centralised control room. The governor shall be capable of
* Bidder to specify

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changing the operations automatically without causing disturbance in the controlled

parameters, during various modes of co-generation plant operation.
Self-diagnostics shall be integral part of the governor operation with clear indication
of the defective portions on the front LCD screen.
8.3 Additional Features
The governor shall include, but not limited to following additional features:
- Bump less transfer of control on 2.6 bar (a) extraction pressure during mode
C on grid failure
- Acceleration control
- Extraction steam flow limiting controls
- kW limiter
The governor shall include, but not limited to following remote set point adjustments
for:
- Speed
- Inlet pressure steam
- Load
- Trip and start
- kW limiter
On sudden load throw off from rated load to no load, the speed shall remain below
tripping speed as per NEMA Class ‘D’ Standard.
Safety trips of the turbo-alternator shall include, but not limited to following:
a) Steam inlet pressure lower than the pre-set pressure
b) Steam inlet temperature lower than pre-set temperature
c) Condenser vacuum below pre-set value
d) Lubricating oil pressure falling below pre-set pressure
e) Excessive axial thrust wear trip.
f) Excessive vibration trip
9.0 Lubricating Oil and Turbine Control Oil System
The lubrication and turbine control oil system shall be complete in all respects to
provide lubricating oil to the bearings of turbine, gear box, and alternator; gears of
gear box and supply control oil for governing system.
The oil outlet temperature at any bearing shall not exceed the maximum permissible
temperature of the oil.
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The oil piping should be complete with requisite valves, fittings, strainers etc and is
entirely in the Contractor’s scope.
Suitable electric heaters shall be provided to maintain oil temperature when the
turbo-alternator is idle.
The system shall be complete with following parts and all necessary interconnecting
pipes and fittings for the oil supply.
Oil reservoir, complete with all fittings like oil level indicator, filter (in the discharge
pipe) and lubricating oil vapour extractor shall be provided. Inside of the tank shall be
de-salted and rust proof. All openings in the tank shall be dust and water proof.
Main lubricating oil pump shall be positive displacement pump for 100% oil flow,
with suction filter. The pump shall be driven by gear box low speed shaft. Individual
pump shall be provided for each turbine.
Auxiliary lubricating oil positive displacement pump for 100% oil flow with AC
motor drive and automatic cut-in, when the lubricating oil pressure falls below a
preset value shall be provided. Individual pump shall be provided for each turbine.
Emergency lubricating oil pumps shall be for 30% oil flow with DC motor drive,
cables, motor starter, separate battery and battery charger of adequate capacity to
operate the pump with automatic cut-in at preset value. Individual pump shall be
provided for each turbine.
Oil vapour extractor with AC motor drive
Overhead oil tank, capacity of oil tank shall be suitable to hold 30 minutes oil
requirement of all the turbines. The tank shall be complete with piping, valves,
fittings, supports etc. and shall be fitted on powerhouse building columns at
maximum possible height above ground level. Inlet piping for oil supply to tank shall
be from auxiliary oil pump. Outlet piping shall be from tank outlet at its bottom to all
the bearings of turbine, gearbox and alternator and gears of gearbox. Tank shall be
fitted with necessary vent and drain connection.
The overhead tank shall be lined with stainless steel sheet and all the piping and
fitting also shall be out of stainless steel.
Oil coolers, each of 100% capacity, with in-situ changeover valve while turbine is
running. Two coolers for each turbine shall be provided.
Oil filters, each for 100% capacity, with in-situ changeover valve while turbine is
running. Filter size shall be 40 microns for lubricating oil and 10 microns for the
control oil. Two filters for each turbine shall be provided
For the hottest ambient condition at site, the oil outlet temperature at any bearing
shall not exceed the maximum permissible temperature of the oil.
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Oil centrifuge of adequate capacity is to be provided to remove suspended matter,

water droplets, sediments etc, from lubrication and control oil system. The unit shall
be with drive and movable.
Employer shall provide a cooling water pipe at an elevation of about 12 m from

ground level near power house building. Contractor shall draw all his cooling water
requirements from this. Requisite piping, fitting, valves, strainer shall be all in the
Contractor’s scope of supply. Flange on above said Employer’s cooling water piping
shall be terminal point for all cooling water requirements of turbo-alternator.
10.0 Emergency Supply DC System
For operation of lubricating and control oil pump, emergency DC power supply
system shall be provided. The system shall be a dedicated system only for operation
of the lubricating and control oil pumps of both turbines.
The system shall be complete in all respects and all necessary items such as DC
Motor, Starter, Battery and Battery Charger along with Cables, Cable termination,
supports etc shall be provided.
11.0 Condensing Plant
The condenser shall be non contact shell and tube type surface condenser. The
condenser shall be designed as per Heat Exchange Institute standards for steam
surface condensers and ASME Section VIII Division-I.
Size of the condenser shall be suitable to meet power generation demand during
different modes of co-generation plant operation. Condenser and accessories shall
be designed for maximum steam flow of 50t/h. Adequate margin of safety shall be
provided.
Condensing plant shall be complete in all respects including, but not limited to
following:
1. Condenser & accessories

- Two condensers, one for each turbine.
- Expansion bellow between turbine and condenser
- Hot well with water level control
- Thermal relief valve
2. Vacuum Package
- Two Steam jet air ejectors for each turbine, Capacity: minimum 120 %
each.
- One Hogging ejector for each turbine for initial building of vacuum
- Rupture disc
3. Condensate extraction pump minimum 120 % capacity each.
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11.1 Condenser
Water-cooled steam turbine condenser shall be of horizontal shell and tube

type. The steam inlet connection shall be solid and rectangular section and
welded to condenser shell. The condenser shall be of divided water box type.
Condenser shell shall be of carbon steel construction and shall withstand all
mechanical stresses without deformation. The condenser shall be provided
with inlet and outlet water boxes with flanged cooling water connection.
Condenser shell shall incorporate an integral hot well and shall be fitted with
man way, instrument connections etc.
Heat transfer section shall be in the form of high efficiency tube bundle and
designed and located to optimise peripheral distribution of steam. The air
removal shall be by steam jet ejectors described below.
Contractor shall indicate maximum and minimum amount of cooling water

required for condenser, and rise in temperature of cooling water when inlet
temperature is 32 0C during different modes of co-generation plant operation.
11.2 Vacuum package
The air extraction system shall consist of twin element two-stage steam
ejector. Each ejector shall be fitted with isolating valve on the motive steam
inlet and air suction inlet and discharge system shall be complete with
necessary pipe work, valves drain, traps etc.
The motive steam required for ejector shall be 9 bar (a) pressure steam. 9 bar
(a) pressure steam shall be taken from the extraction steam piping or from
suitable location by the Contractor. The Contractor shall submit quantity
requirement and this quantity shall be added to the steam quantities furnished
in flow diagrams i.e. this quantities shall be considered as steam consumption
of turbo-alternator.
The Contractor shall make the arrangement provided for starting the hogging
ejector for creating vacuum in the condenser, before the turbo-alternator is
started.
Condensate extraction pumps with condensate control system to maintain hot

well level shall be provided.
The arrangement of DM water for condenser hot well for initial filling shall be
made by the supplier.
11.3 Condensate Extraction Pump
Quantity: 2 Nos. (1 No. for one turbine)
Two condensate extraction pumps each of 120% capacity shall be installed

for each turbo alternator out of which one will be operating and one standby.
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Vertical multi-stage turbine pumps shall be designed to extract condensate

from turbine condenser. Pump shall draw feed water from the hot well of
condenser and deliver to the Employer’s boiler hot well.
Condensate extraction pump shall have sufficient head to pump the turbine
condenser condensate through gland cooling condenser and ejector steam
condensers to boiler hot well, which shall be 15 m above ground level, and
the storage tank shall be under 2.5 bar (a) pressure. Thus the pump shall
have additional 35 m head over and above that required by the Contractor’s
system.
Each unit shall be supplied with the following:
- Base plate
- Flexible coupling and guard
- Holding down bolts
- Foundation bolts
- Casing vent with cock.
- Casing drain with plug
Type Vertical multi-stage turbine pumps

Capacity m3/h *
Head (Suitable to pump m *
condenser outlet water
to Employer’s boiler
feed water tank)
Liquid to be pumped Condensate
- Specific gravity 1.0
- Temperature ºC *
- Viscosity *
Suction pipe Size mm *
Delivery pipe Size mm *
Suction & Delivery Flanged
connections
Material of Construction
Casing Cast iron
End plates Cast iron
End covers Cast iron
Wear plate Cast iron
Impeller Stainless steel
Shaft Carbon steel
Shaft Sleeve Stainless steel
Gland Suitable for operating temperature of
condensate
The turbine gland leakage steam shall be piped to gland steam cooling
condenser, which shall be non-contact type. Condensate extracted from the
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turbine condenser hot well shall be used as condensing water. Condensate of

cooled gland leakage steam shall be taken back to turbine condenser hot
well.
Motive steam of jet ejector used for air removal from condenser also shall be
cooled by turbine condenser condensate and condensate from cooled steam
also shall be taken back to turbine condenser hot well.
12.0 Pressure reducing and De-superheating
Complete pressure reducing system shall be provided by Contractor to reduce the

pressure of 1st extraction steam to 9 bar (a) and 2nd extraction steam to 2.6 bar (a).
De-superheater for 9 bar (a) steam
De-superheater shall be provided to reduce temperature of extracted 9 bar (a) steam

to 180 ºC. The de-superheating water used shall be from the feed water pump
suction header of boiler at temperature of 105 ºC. However, de-superheater shall be
suitable for 95 ºC temperature of de-superheating water.
Contractor shall install suitable desuperheating water pumps. Desuperheating water

piping is completely in Contractor’s scope.
De-superheater for 2.6 bar (a) steam
De-superheater shall be provided to reduce temperature of extracted 2.6 bar (a)

steam to 130 ºC. The de-superheating water used shall be from the feed water pump
suction header of boiler at temperature of 105 ºC. However, de-superheater shall be
suitable for 95 ºC temperature of de-superheating water.
Contractor shall install suitable desuperheating water pumps. Desuperheating water

piping is completely in Contractor’s scope.
13.0 Instrumentation and controls
13.1 DCS System
The centralised control/monitoring of the complete co-generation plant shall

be from a centralised control room where the Distributed Control System
(DCS) and its sub systems including the operator consoles shall be located.
The Distributed Control System (DCS) shall have data acquisition, and control
the entire plant operational parameters.
Instrumentation supplied by the Contractor shall be of PLC based controls

and suitable for hooking up to the employer’s DCS system. The indicators
and controls shall be displayed on computer screen and the controls shall be
actuated by and through the computer. For this purpose, all the valves and
dampers having automatic and remote controls shall be motorised.
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13.2 Contractor’s Instrumentation
The Contractor shall provide electronic instrumentation and computerized

controls for automatic and remote control of both the turbo-alternators. A
master control console for the control of the turbo-alternator from the
centralised control room shall be provided. The indicators and controls shall
be displayed on computer screen and the controls shall be actuated by the
microprocessor for both machines.
The centralised control room operator should be able to observe and control
various parameters either through Contractor’s PC or Employer’s DCS
system.
Sensing elements like transmitters shall be electronic type with 4 to 20 mA

output. All controls, except actuators, shall be solid state electronic type.
Actuators shall be pneumatic. All controls and actuators shall interface with
the control system through I/P converters. The master controller shall be a
microprocessor interfacing with the sensors, the valves and the actuators.
The output signals from the microprocessor shall first interface with the I/P
converters and then with the pneumatic automatic/ remote/manual stations
which in turn shall be connected to the valves and actuators.
The manual stations shall be mounted near the turbo-alternator for use by the
operator. In manual mode the operator should be able to operate the valves
and actuators without the microprocessor. Local control shall over ride
automatic / remote control.
Range of pressure, vacuum and temperature gauges shall be at least 1.5

times the maximum values attained.
Contractor shall draw all his electrical requirements of 400 and 230 Volts from
the electrical panels supplied by him. All necessary cabling, wiring, fitting etc
shall be provided by Contractor. If any other voltage is required for any
instrument, step down/step up transformers shall have to be provided by
Contractor.
Complete turbine start up and supervisory panel with all operating, indicating
and monitoring devices necessary for start up and continuous operation of the
turbine with alarm annunciation shall be provided. All necessary wiring,
cabling, tubing, terminal blocks, pressure switches with frames supports shall
be provided.
Arrangement for recording and integration of parameters shall be provided.
13.3 Turbine Control and Indicating Instrumentation
Instrumentation and control panels shall be with complete turbine start up and
supervisory functions for both turbo alternators including, but not limited to
following. This should also include the temperature scanner for all bearings,
steam, condensate etc.
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a) speed
b) load
c) emergency and control valve lift
d) control oil pressure
e) journal bearing metal temperature
f) thrust pad metal temperature
g) axial position of thrust collar relative to its own housing
h) differential expansion between shaft and casing at any critical point
j) bearing pedestal or shaft vibration
k) appropriate steam and metal temperatures and their differentials,
especially with a view to ensure safety during starting operations and
under transient conditions
l) Annunciators and alarms, wherever required
m) turbine accessories Interlock and Protections
All these shall be installed in the centralised control room.
13.4 Turbine safety and protection system
The turbo-alternator shall be equipped with, but not limited following safety
devices for both turbo alternators, with indication, trips and alarms as
applicable.
a) low lubricating oil pressure

b) over speed (minimum two electronic pickups and one mechanical)
c) excessive axial displacement
d) excessive thrust bearing wear
e) excessive vibration
f) excessive bearing temperature
g) low condenser vacuum
h) emergency push button trip located in the centralised control room
and on or near turbo-alternator
i) high alternator winding temperature
j) high alternator bearing temperature
All these shall be installed in the centralised control room.
13.5 Local Instrumentation Panel with Display in Centralised Control Room
Following indicating instruments shall be installed on for both turbo alternators

or local panels near the turbo-alternators and also displayed on the PC in
centralised control room.
This shall consist of, but not limited to the following instruments.
a) live steam pressure transmitter with display

b) extraction steam 9 bar (a) pressure transmitter with display
c) extraction steam 2.6 bar (a) pressure transmitter with display
d) exhaust steam 0.14 bar (a) pressure transmitter with display
d) gland steam pressure gauge
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e) live steam temperature element

f) extraction steam 9 bar (a) pressure temperature element
g) extraction steam 2.6 bar (a) pressure temperature element
h) exhaust steam 0.14 bar (a) pressure temperature element
i) gland steam temperature gauge
j) lubricating oil pressure gauge
k) governing oil pressure gauge
l) lubricating oil temperature indicator
m) turbine bearing temperature indicators
n) gear box bearing temperature indicators
o) turbine speed indicator (in control panel)
Recording and Integration
Facility should be available in the PC to record and integrate various

parameters.
Parameters, which require Recording and Integration facility for both turbo
alternators individually, are listed below.
Item Centralised control room
Live steam:
- Temperature Recording
- Pressure Recording
- Flow Recording-Integrating
9 bar (a) steam:
2.6 bar (a) steam:
Exhaust steam: (Condenser)
Running hours Integrating
Power generated Recording-Integrating
13.6 Dedicated Independent Micro Processor Based System
Following functions of the turbine shall be realised by dedicated independent

micro processor based system and shall be interfaced with the DCS through
serial communication for monitoring/interlocking purpose:
a) Turbine vibration monitoring
b) Turbine governing
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14.0 Piping
All piping connecting two or more equipment supplied by the Contractor; and
between the Contractor’s equipment and Employer’s equipment outlined under
Terminal points, shall be provided by the Contractor. The piping shall be complete
including, but not limited to valves, traps/collecting tank with automatic level control
wherever applicable, fittings, drains, vents, bends, Tees, Strainers, etc.
66 bar (a) Pressure Steam
66 bar (a) pressure steam piping from outlet of steam distribution header up-to inlet
of turbo-alternators shall be provided by the Contractor. Necessary provision for
loops, steam blow-off etc shall be made by Contractor.
9 bar (a) Pressure Steam
9 bar (a) pressure steam piping from outlet of both turbo alternators up-to outlet
flange of de-superheaters shall be provided by the Contractor. 9 bar (a) pressure
piping for steam requirement of ejectors shall be completely in the scope of
Contractor. Outlet flange of de-superheaters on 9 bar (a) steam line shall be the
terminal point of Contractor’s scope of supply.
2.6 bar (a) Pressure Steam
2.6 bar (a) pressure steam piping from outlet of both turbo alternators upto
Desuperheater outlet flange shall be provided by the Contractor. Outlet flange of
Desuperheaters on 2.6 bar (a) steam line shall be the Terminal point of Contractor’s
scope of supply.
0.14 bar (a) Pressure Steam
Complete pipeline from outlet of turbine to the condenser including expansion bellow
shall be in the Contractor’s scope of supply.
14.1 Design criteria for piping
a. The design of the piping system shall be based on the ANSI B 31.1
code. In addition the statutory requirements of the Boiler Regulation
shall also be taken care of wherever required.
Flexibility and stress analysis shall be made for all piping systems with
operating temperatures above 100 oC.
The correct locations of hangers and supports, with as applicable

spring stiffness, shall be considered for the flexibility analysis.
Suitable expansion loops restraints and anchors shall be provided so
as to ensure compliance with the applicable codes and to limit the
stress and reactions to within the allowable values.
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b. The flow velocities in pipes shall be limited to the following values:
Super heated steam : 35 to 40 m/sec

Saturated steam : 20 to 35 m/sec
Cooling water : Upto 3 m/sec
c. Drains at all low points and vents at all high point shall be provided.
d. All local instruments shall be located on pipelines so as to render them

observable from the nearest available platform.
e. Oil drains shall be sized to run no more than half full when flowing at a
velocity of 0.3 m/sec and shall be arranged to ensure good drainage
14.2 Materials
Pipe materials for various services and materials for fittings, flanges,
fasteners shall not be inferior to the specifications given below.
All piping except for cooling water, raw water and air services shall be of
seam less steel. For cooling water and raw water and air applications the
piping could be ERW.
a. Steam services at temperatures 505 ºC, Alloy steel piping as per

ASTM A-335 or equal.
b. Other services Carbon steel piping as per ASTM A -106 Grade B or

ASTM A -53.
c. Fittings and flanges: As per applicable codes conforming to pipe

material specifications.
d. For cooling water and raw water applications the piping material shall
be BS Black Medium Class or equivalent.
e. For services air applications the piping shall be IS:1239 Black Medium
Class or equivalent.
f. For instrument air applications BS GI pipes (see also detailed

instrumentation specification) or equivalent
g. The fittings for ERW applications shall be as per BS or equivalent.
14.3 Hangers and supports
a. The Contractor shall design, fabricate and furnish erection drawings

for all hangers, anchors, guides, clamps, stops and supports, auxiliary
structures, etc required for the proper installation and support of the
piping.
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b. It is desirable that supports should as far as practicable, be arranged

adjacent to the pipe joint.
c. Constant load hangers/spring hangers shall be provided wherever

necessary for critical piping systems.
The variation between hot and cold loads, if variable spring hangers
are used, shall not exceed  25 % of the rated load.
d. Lugs and additional structural members should be suitably welded to

the pipes wherever necessary for hangers and restraints.
14.4 Valves
a. All valves shall be suitable for the service conditions i.e. flow,
temperature and pressure under which they are required to operate
and those performing similar duties shall be interchangeable with one
another unless otherwise approved.
b. All gate valves shall be of the full way type and unless otherwise
approved and when in the full open position the bore of the valve shall
not be obstructed by any part of the gate.
c. Globe valves shall have curved or spherical seating and the discs
shall be free to revolve on the spindle.
d. All non-return valves shall have an arrow cast or embossed on the

side of the valve body to indicate the direction of the flow.
For severe service conditions cushioned check valves are preferred to

obviate valve chatter. In case of swing check valves the body seat
shall be inclined at such an angle to the vertical as will facilitate
closing and prevent chatter.
e. The internal diameter of all valve ends to be connected to pipes shall

be the same as the internal diameter of the pipe to which they are
joined so as to minimise use of reducers/expanders.
f. Where applicable valves shall be of the outside screw and yoke type.
g. All the important valves shall be fitted with indicators so that

percentage of valve opening can be readily determined locally and in
the control room.
h. Steam valves shall not be fitted in an inverted position. Eye bolts shall
be provided where necessary to facilitate handling heavy valve or part
of valves.
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i. Special attention shall be given to operating mechanism for large size

valves with a view to obtaining quick and easy operation and to
ensure that minimum of maintenance is required.
For valves of size 250 mm and above either bevel or spur gearing
shall be provided to facilitate manual operation.
j. The materials, design and construction of all types of valves shall be

subject to the approval of the Employer.
k. All sampling and root valves furnished shall be of integral body bonnet
type.
The piping shall be complete including, but not limited to valves,
traps/collecting tank with automatic level control wherever applicable,
fittings, drains, vents, bends, Tees, etc.
14.5 Construction
Where steel pipe work is to be welded it shall be carried at by the electric arc
process and shall conform to relevant BS or equivalent standards. Welding
shall only be carried at by suitably qualified welders who shall hold a current
welding certificate in accordance with the appropriate British Standards or
equivalent.
All the shop welds or site welds for steam piping shall be subjected to x-ray
examination as per latest BS standards or equivalents.
The Contractor shall be responsible for determining the locations of site butt
welds to break the piping runs into separate sections for the purpose of
shipment to site, and for properly and clearly designating each section for
correct site assembly.
All welding elbows shall have a mean radius of 1.5 times the diameter of pipe
where possible short radius elbows may be used only where space
requirements dictate.
All welded fittings shall be as strong as the pipe to which they are welded.
Welded branch connections and special welded fabricated fittings shall be

fitted and reinforced as required by the latest relevant piping code.
A change in the line size on horizontal runs is to be made only through

eccentric reducers with the flat at the bottom.
All horizontal lengths of pipes should have 1 in 1200 slope towards flow.
14.6 Preparation for site assembly
All pipe work supplied for site butt welding shall have ends machined and
protected.
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Prefabricated piping sections shall be capable of being fitted into place

without springing or forcing except where cold pull is required.
The outside surface of the piping shall be painted with one coat of red oxide.
All flanges and nozzles shall be protected with wood or suitable covers and
thread end greased and protected.
14.7 Flanges and Fasteners
All flanges and orifice plate flanges standard to schedule unless otherwise
stated an arrangement drawings.
Loose flanges or cutting lengths shall be supplied to allow for mirror alignment
errors of plant locations.
All bolts, nuts and washers plus 10% spare shall be supplied.
14.8 Pipe Supports
Piping shall be provided with suitable supports to ensure that no undue

stresses are placed on adjoining pipe work and equipment.
Piping connected to equipment shall be so supported that included

equipment, valves etc., can be readily removed without additional supports
and with a minimum or dismantling.
Anchor supports shall be supplied for those pipe runs demanding this from of
fixing and shall be fabricated in accordance with the pipe.
All supports, hangers, anchors, etc., for aligning and controlling the piping
shall conform to BS 3974 Pt 1-3.
Proper expansion facilities shall be provided for pipes meant for hot fluids.
All steam piping shall be analysed for the supports and stress. The stress
analysis report shall be submitted.
14.9 Steam Traps
For all steam piping, steam distribution header, suitable steam traps with by-
pass arrangement shall be provided as required. Drain pockets shall be
provided at each trap point.
14.10 Valves
All valves shall be rising spindle outside screw type. Valves shall be installed
so that any plant item may be isolated from the service and process lines and
to allow tanks and vessels to be drained and vented.
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14.11 Gaskets
The Contractor shall include for supply of gaskets required for jointing of pipe
flanges for H.P. steam piping for 66 bar (a) pressure and 515 °C temperature.
Spiral wound metallic type gaskets shall be used.
14.12 Pipe testing
Prior to application of any insulation each section of completed piping system

shall be subjected to hydraulic test.
The required test pressure will be held for minimum 8 hrs during which time
an inspection will be made of all joints and connections.
All testing equipment shall be supplied by the Contractor. This include pump,
pressure gauges, etc.,
The test pressure will be 1.5 times the working pressure unless otherwise
specified in applicable standards or instructed by the Employer.
14.13 Condensate Piping
a. Condensate from turbine condenser
All condensate piping from turbine outlet to ejector/gland cooling

outlet, whichever is later, including, but not limited to following shall be
in the Contractor’s scope
- suction line from the hot well of turbine condenser to

condensate extraction pump
- delivery line from outlet of condensate extraction pump to feed

water system storage tank.
- piping from ejectors to gland steam condenser outlet
b. Condensate from gland steam condensers and ejectors
Condensate from gland steam condensers and ejectors shall be piped

back to respective turbine condenser hot well. The complete piping
shall be in the Contractor’s scope of supply.
14.14 Air Supply Piping
Complete air supply piping for instrumentation and controls and any other
use, if required shall be in the scope of Contractor.
Complete air supply piping, including but not limited to valves, fittings,
moisture separator, supports, vents, drains etc, from the compressor to the
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end users shall be in the scope of Contractor. Air Compressor is included in

the scope.
14.15 Cooling Water Piping for condenser, alternator and oil cooling
Cooling water for condenser is completely in the scope of Contractors. The

cooling water pumps, suction, delivery to condenser and return line from
condenser to top of cooling tower is included in the Contractors scope.
Cooling water piping for alternator and oil cooling is also completely in
Contractor’s scope. Piping for condenser shall be separate from alternator
and oil cooling water piping. For this, separate pumps shall be supplied and
installed, which is in Contractors scope.
Piping supports, gaskets, fasteners, various nozzles, flanges and valves shall
be supplied to match the total requirement of water.
14.16 General Usage Water
Employer shall provide a pipe with flange for general purpose water at one
point near power house building, approximately 12 m above ground level.
This shall be Terminal point for Contractor. All piping from this point to end
users shall be in Contractor’s scope of supply. This shall include all piping for
wash, dust suppression and other general usage as required. Piping
supports, gaskets, fasteners, various nozzles, flanges and valves shall be
supplied to match the total requirement of water.
14.17 Drain Water
Contractor shall divide drain water in two streams; one steam for the re-
circulation water for bearing cooling and a second stream for once through
usage such as for washing, gland cooling, etc.
Contractor shall provide piping, fittings etc and collect all the re-circulation
water and drain water in two separate collection tanks of adequate capacity.
Outlet of these tanks shall be preferably at least 1.5 m above ground level, so
that Employer can provide piping and/or drain channels so that water flown by
gravity to Employer’s re-circulating and drain water system.
The Contractor shall indicate location of above collection tank on drawing.
Required piping supports, gaskets, fasteners, various nozzles, flanges and

valves shall be supplied to match the total requirement of water. Outlet flange
on above tank shall be Terminal point for Contractor.
14.18 Drain for general purpose water piping
Contractor shall collect all drains in a tank installed preferably 1.5 m above
ground level. All drain piping up to this tank shall be in Contractor’s scope of
supply. Drain water piping for traps, drains from various equipment including
blow down tank, compressor, pipelines etc. up to drain water collection pipe,
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Outlet flange on above tank shall be Terminal point for Contractor.
14.19 Valves and Fittings
All valves, fittings, pipe supports gaskets and fasteners shall be in

Contractor’s scope of supply. Piping shall be with insulation and cladding
wherever appropriate.
Valves and fittings should preferably be of same make and of modular design
so as to facilitate interchange-ability and reduction in variety. Contractor shall
furnish schedule of valves covered under all sections compositely.
All steam valves including 75 mm and above shall have equalizing bypass
with valve arrangement. Valves shall be of rising spindle type unless
specified otherwise. All valves up to and including 40 NB size shall be socket
welded and above 40 mm shall be flanged bolted type. Automatic and remote
control valves shall be balanced type and motorised.
Contractor shall specify quality, size and thickness of pipe.
15.0 Thermal Insulation and Lagging
High grade insulating materials for the exposed portion of the turbo-alternator and
accessories, including but not limited to steam turbine casing, control valve and
exhaust nozzles up to flanges, all condensate piping, steam piping should be
insulated.
Insulation material of appropriate quality including but not limited to ceramic wool,
mineral wool, insulation bricks/mats, hard settling compounds, holding lugs/studs,
stainless steel wire mesh for forming mattress-covering, Hessian cloth, paint, etc.
shall be provided.
In addition to insulation, the turbo-alternator and accessories shall be provided with

minimum 1 mm thick aluminium cladding.
At steady state operation the difference in temperature between the ambient and the
outside surface of insulation shall not be more than 20 ºC.
2401-2 SPEED REDUCING GEAR BOX
Quantity: 1 No.
A speed reducing gearbox shall be provided to reduce turbine speed to drive the
alternator at 1500 rpm. The gears shall be of helical design.
It shall be capable of transmitting the maximum rating of the set and be able to
withstand 20 % over speed over a period of minimum five minutes. The gearbox shall
also be designed for the short circuit condition of the turbo-alternator. All bearings of
the gearbox shall be readily renewable and it shall be possible to inspect the
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bearings and the gears readily without disturbing the shaft alignment. Illuminated
sight glasses shall be provided to inspect the lubricating oil drain from each individual
bearing.
Gearbox shall be complete with following:
- Reduction gears
- Coupling between turbine and gear box and between gear box and alternator
- Shaft vibration monitoring
- Bearing temperature monitoring
- Lubricating system
The coupling between turbine and gearbox shall be flexible and membrane type to
allow free expansion and misalignment. The coupling between gearbox and
alternator shall be gear type/flexible. The couplings shall be designed to withstand
torques developed during wrong synchronization with other machines or the grid.
Engaging/disengaging motorized barring drive having provision for manual operation,

shall be provided. Barring gear shall be interlocked with lubrication system to prevent
its operation without lubrication.
AGMA Service factor shall be 1.3 minimum on strength rating.
Base Plate
Suitable base plate either individual or combined with turbine shall be provided for
mounting the gearbox. The base plate should be rigid in construction and suitable for
the application. The base plate shall be complete with mounting pad/grouting pad,
sole plates, foundation and holding down bolts with nuts, adjusting shims etc.
Suitable openings shall be provided to pour the grout.
2401-3 ALTERNATOR, EXCITER AND AUXILLARIES
Quantity: 1 No.
General
The alternator and Exciter shall comply with BS or equivalent IEC or equivalent IS
and designed to operate within the specified temperature rises and to withstand all
normal operating conditions including suddenly applied loads, switching surges and
short circuits external to the alternator.
The Alternator shall be totally enclosed, revolving field, brushless type provided with
fully interconnected damper winding in the rotor faces. Excitation shall comprise of
directly coupled overhung exciter armature with shaft mounted rotating rectifier
assembly, Permanent Magnetic Generator with surge suppressors. The alternators
shall be fitted with suitable surge capacitors for protection from switching and other
surges.
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Alternator of 37500 kVA / 30000 kW at 0.8 Power Factor with class F insulation and
temperature rise to restricted to class B, enclosure shall be IP-54 suitable for 27 C
ambient temperature and 30 C cooling water, altitude of approx. 1580 m from Mean
Sea Level complete with
- Stator winding temperature detectors
- Bearing temperature detectors
- Anti-condensation heaters
Alternator Parameters -
Sr. Description Unit Details
1.0 Rating & Performance

1.0 Applicable code BS OR equivalent
IEC OR equivalent
IS
1.1 Nominal Output kVA 37500
kW 30,000
1.2 Duty Continuous
1.3 Rated Voltage V 11000
1.4 Voltage variation required from % ± 10
Rated Voltage
1.5 Rated Power Factor Lag 0.8
1.6 Rated Current A 1970
1.7 Rated Frequency Hz 50
1.8 Frequency variation required from % ±5
Rated Frequency
1.9 Combined voltage and frequency % ±10
variation
1.10 Rated Speed Rpm 1500
1.11 Rotation viewed from NDE Clock wise
1.12 No. of phases Three
1.13 Type of connection Star
1.14 No. of line connections Three
1.15 No. of Neutral connections Three
1.16 Enclosure – Alternator IP 54
1.17 Enclosure – Exciter IP 54
1.18 Cooling System CACW
1.19 Excitation System Brushless
1.20 Short circuit ratio Not less than *
0.45
O
1.21 Design Ambient Temperature C 27
1.22 Altitude from Mean Sea Level meters Approx. 1540
1.23 Max. Permissible capacitive kVAR *
Loading P.F. Lead
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1.24 Max. Permissible inductive kVAR *

Loading P.F. Lag
1.25 Steady state 3 phase Short Circuit KA *
Current
1.26 Max. Initial Short Circuit Current KA *
(peak)
1.27 3 Phase Short Circuit withstand s *
time
1.28 Max. Continuous negative % *
sequence current withstand
1.29 Max. Deviation from sine wave IS 4722, IS 5422
OR equivalent IEC
OR equivalent BS
1.30 Max. Value of I 2 * t for transient *
operation under system fault
condition
1.31 Synchronous Impedance Ohms *
1.32 Max. Noise level at 1m from Db *
equipment within IS limits (Max. 90dB(A))
1.33 Max. Permissible impact load MW *
1.34 Mode of earthing * / NGR
1.35 Insulation class
1.36 Alternator Stator F
1.37 Alternator Rotor F
1.38 Exciter armature F
1.39 Exciter field F
1.40 Temperature rise restricted to
1.41 Stator B
1.42 Rotor B
Type of winding treatment
1.43 Stator VPI or better
1.44 Rotor Roll impregnation /
VPI or better
1.45 Stator lamination withstand time for s *
I = IPH (Min. 3s.)
1.46 Permissible Earth fault current for A ≥ Phase current of
Stator lamination the alternator
1.47 Max. Vibration mm/s *
1.48 Max. Harmonic content in output % Less than 5
1.49 Overload capacity- 50 % s 30
1.50 Overload capacity- 10% in every Hour 1
12 hour interval
Efficiency at rated Power Factor
1.51 100% load % *
1.52 75% load % *
1.53 50% load % *
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1.54 25% load % *

1.55 Critical speed of Alternator rpm *
1.56 Surge Capacitor Voltage kV *
1.57 Surge Capacitor Capacitance Micro Farads *
2.0 Reactances
2.1 Base MVA MVA *
2.2 X d (Sat) % *
2.3 X d (UnSat) % *
2.4 X’ d (Sat) % *
2.5 X’ d (UnSat) % *
2.6 X” d (Sat) % *
2.7 X” d (UnSat) % *
2.8 X 2 (Sat) % *
2.9 X 2 (UnSat) % *
2.10 X 0 (Sat) % *
2.11 X 0 (UnSat) % *
3.0 Inertia Constant
Moment of Inertia(GD2) Kg m2
3.1 Alternator *
4.0 Excitation System
4.1 Excitation system type Brushless
4.2 Excitation supply PMG
4.3 Short circuit excitation equipment PMG
4.4 Discharge resistance rating Suitable discharge
resistor in exciter
circuit
4.5 Redundant Thyrister circuits Required
4.6 Parallel Diodes Required
4.7 Diode Failure compensation * / Required
4.8 Quadrature Droop compensation * / Required
4.9 Exciter rating kW *
4.10 Exciter nominal response >1
4.11 PMG rating kVA *
4.12 PMG Voltage V *
4.13 PMG frequency Hz *
4.14 AVR make *
4.15 AVR type, sensitivity, burden *
4.16 AVR steady state voltage accuracy % 0.5
4.17 AVR response time ms <100
4.18 Voltage change for 100% load % <15
change
4.19 Alternator voltage regulation % Less than 0.5
5.0 Cooling system
5.1 Type of cooler CACW
5.2 Mounting *
5.3 No. of coolers/ Sections *
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5.4 Capacity of cooler/ section % *

5.5 Cooling water requirement LPM *
5.6 Redundancy in cooling system *
5.7 Arrangement of cooler tubes Horizontal
5.8 Material of cooling tubes Admiralty Brass
5.9 Cooler tube side design pressure kg/ cm2 *
6.0 Bearing
6.1 Type of Bearing for DE, NDE Sleeve
6.2 Mounting End shield
6.3 Lubrication Forced Oil
6.4 Type of lubrication ISO VG 46
6.5 Oil pressure for bearing lubrication kg/ cm2 *
6.6 Quantity of oil required LPM *
7.0 RTDs
7.1 Per Phase No. 2
7.2 Each Bearing No. 1
7.3 Inlet Required
7.4 Outlet Required
7.5 Microprocessor based Multipoint Required
Temperature scanner with Min. 2
spare channels and separate
output contacts for Alarm and Trip
for each channel
8.0 Space Heater
8.1 Alternator Required
8.2 Exciter Required
9.0 Terminal Box Suitable for Copper
11 kV, UE grade,
XLPE Cables
10.0 Weights
10.1 Total weight of Alternator kg *
10.2 Total weight of Stator kg *
10.3 Total weight of Rotor kg *
10.4 Total weight of Exciter kg *
10.5 Heaviest lift kg *
11.0 CO2 Based Integrals Fire
fighting system for Alternator
11.1 Details *
11.2 Detectors *
11.3 Nozzles *
11.4 Piping *
11.5 Other details *
Tolerance to be applied for characteristics of synchronous alternator shall be in

accordance with BS or equivalent IS or IEC standards.
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Form & Symmetry of Voltages and Currents
In case of an AC Generator, the circuit, which it supplies, is assumed to be virtually

non-deforming and virtually balanced as defined in items (a) and (b) below.
a) None of the instantaneous values should differ from instantaneous value of

the same phase of the fundamental wave by more than 5% of the amplitude
of the latter.
b) In a balance circuit the negative sequence component and zero sequence

component should not exceed more than 5% of the positive sequence
component.
Even if the limits specified above occur simultaneously in service at the rated load,
this shall not lead to any deleterious temperature in the Alternator.
Irregularities of the Waveform
When tested on open circuit and rated speed and voltage the telephone harmonic
factor (THF) of the line-to-line terminal voltage shall not exceed 1.5%.
Earth Terminals
Machine shall be provided with means for connecting a protective conductor or an

earth conductor, such means being identified by the appropriate symbol or legend.
The earth terminal shall be designed to ensure a good connection with the earth
conductor without any damage to the conductor or terminal. Accessible conducting
parts, which are not part of the operating circuit, shall have a good electrically
conducting connection with each other and with the earth terminal. The earth terminal
shall be designed to accommodate an earth conductor of cross sectional area in
accordance with the following table.
Sr. # Cross sectional Area of the Live Cross sectional Area of the Earth
Conductor Protective Conductor
(mm2) (mm2)
1. 4 4
2. 6 6
3. 10 10
4. 16 16
5. 25 25
6. 35 25
7. 50 25
8. 70 35
9. 95 50
10. 120 70
11. 150 70
12. 185 95
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Sr. # Cross sectional Area of the Live Cross sectional Area of the Earth
Conductor Protective Conductor
(mm2) (mm2)
13. 240 120

14. 300 150
15. 400 185
Exciter
When running at rated speed, rated power factor, the Alternators shall be capable of
developing for a short time their rated voltage and current equal to 125% of the rated
current
Ceiling Voltage (Up)
The ceiling voltage shall not be less than 1.4 times the rated excitation voltage for not
less than 10 s.
Initial Excitation system Response
The reciprocal of the initial excitation system response shall be less than 2 s.
Voltage Regulation
a) Steady State Condition
The alternator, when driven at rated speed and operating with normal
excitation control system, which includes an automatic voltage regulator, will
maintain the voltage under steady state conditions within  0.5 % of rated
voltage for all loads between no load and rated load at rated power factor.
b) Transient Condition
The alternator, when driven at rated speed and giving the rated voltage on
No-load under the control of excitation and voltage regulating system, when
switched on to a symmetrical load shall absorb 35 % of rated current at rated
voltage and power factor between 0.4 and zero lagging. The initial voltage
drop shall be limited to 15 % of rated voltage and the voltage shall recover to
at least 94 % of rated voltage in less than 1.5 seconds.
Voltage Control
The static accuracy of the alternator voltage shall be better than  0.5 % at all
symmetrical loads from no-load to rated load. The voltage level shall be set
steplessly with  10 % of the rated voltage. The alternator shall have drooping speed
v/s kVAR load characteristics and facility to adjust the same from remote location.
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Neutral Earthing
The Alternator shall be suitable for continuous operation with the Neutral at or near
Earth potential. It shall also be suitable for operation on Unearthed systems with one
line at earth potential for infrequent periods of short duration for e.g. as required for
normal fault clearance.
The insulation for Neutral and Line shall be uniform.
Limits of Vibration Severity
Limits shall be as per BS or equivalent IS or IEC standards.
Overspeed
The Alternator shall withstand an over speed not less than 1.2 times the Max. rated
speed for min. 2 Minutes.
Power Factor
Unless and otherwise specified the Alternator design Power factor shall be 0.8 Lag.
The Alternator must be capable of delivering rated load at designed power factor.
The same power factor shall be considered for overload conditions.
Rating Plate Details
The Alternator name plate shall have following of details:
a) Reference: BS/IS/IEC Standard No.

b) The Manufacturer’s name
c) The manufacturer’s serial number and identification mark and year of
manufacturer
d) Frame reference as per BS or equivalent IS or IEC.
e) Type of machine
f) The class of rating or the duty type as per BS or equivalent IS or IEC.
g) Rated Voltage
h) Rated current
i) Rated frequency
j) Rated power factor
k) No. of phases
l) Winding connection with symbol
m) Rated excitation current and voltage at rated output
n) Rated output in kW, kVA
o) Rate speed
p) Permissible over speed
q) Class of insulation
r) Temperature rise permitted
s) Max. ambient temperature(Considered) O C.
t) Max. water temperature (Considered) O C
u) Designed Altitude (Considered) approx. 350 m from Mean Sea Level.
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v) Total Mass of machine in kg.
Base Plate
The alternator shall be built on a fabricated rectangular steel base/sole plate, which
forms the main constructional member and provides locations for all the other
components.
Bearing
There shall be two sleeve bearings, each mounted in a short pedestal on a stool,
bolted to the base plate.
Each bearing liner may be made from steel lined with white metal and split on the
center line.
A low-pressure oil supply shall be taken from the turbine oil system. Each bearing
shall have a sump and an oil ring for lubrication during run-down.
Both bearing pedestals shall be insulated from the base plate. A removable link shall
be provided to earth the drive and bearing and to facilitate testing of the bearing
insulation.
Enclosure and Ventilation
The radial ducts provided in the stator core and the design of the end-winding
ventilation shall ensure optimum uniformity of temperature.
Totally enclosed arrangement is required, incorporating air-to-water heat exchanger

shall be IP54. Air-to water heat exchangers shall be designed to match the inlet
temperature, pressure and analysis of the cooling water supply, to restrict ingress of
water in the event of tube failure. Tubes shall be of ADMIRALTY BRASS material or
equal, with epoxy coated carbon steel tube plates and headers, based on a
maximum working pressure of 350 kPA (50 psi).
Routine Tests
The manufacturer shall conduct all the routine tests as per BS/IS/IEC without any
extra charge. Following Routine tests shall be conducted in the presence of
Employer’s / Project Manager’s representative at no additional cost.
Following routine tests shall be conducted:
i) Measurement of winding resistance (Stator, Rotor, Exciter)

ii) Insulation resistance test
iii) Phase sequence test
iv) Regulation test
v) Measurement of open circuit characteristics
vi) Measurement of short circuit characteristics
vii) High voltage test
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viii) Measurement of bearing current (For machines >1000 kW)

ix) Pressure test on coolers
x) Dielectric tests
Sr. # Machine/ Part Test Voltage (rms)

1. Insulated winding for generator 1000 V + 2 (Rated Voltage).
capacity up to 10000 kVA and
24000 V
2. Field windings up to 500 V 10 Times rated field voltage (Min
1500 V)
3. Field windings above 500 V 4000 V + 2 (Rated Field Voltage)
xi) Insulation Resistance Test:
Sr. # Rated voltage (ac) Test voltage for Insulation

Resistance (dc)
1. Up to 660 V 500 V
2. Above 660 V up to and including
1000 V
1100 V
3. Above 1100 V up to 11000 V 2500 V
4. Above 11000 V to 22000 V 5000 V
xii) The generators above 3.3 kV, 1000 kVA will be tested for polarization index
(PI) of insulated winding. The method for measurement of polarization index
shall be in as per IS/BS/IEC Standards.
2401-4 AVR PANEL (EXCITATION PANEL)
Quantity: 2 Nos.
Excitation panel consisting of digital microprocessor based, one operating with one
Auto, one Manual Channel and one as hot standby with one Auto, one Manual
Channel (with automatic changeover switch) Automatic Voltage Regulator and
secondary modes and complete with all other accessories. An over voltage relay,
Excitation current limiter, DC Voltmeter, DC Ampere meter, AC Voltmeter showing
Alternator Terminal Voltage, Diode failure detection and fine adjustment devices shall
also be provided. The AVR shall be suitable for parallel operation with similar turbo
alternator(s), DG Set(s) and national electricity Grid. Excitation system complete with
DC Ampere and Voltmeters, circuit breaker, field discharge resistance, “ON”, “OFF”
indicating lamps. The AVR shall have Set P.F/ Set kVAR mode. The AVR shall be
suitable for remote operation, Increase, Decrease Voltage from Synchronising panel.
The regulator shall be provided with a remote control facility, including but not limited
to the following:
- Hand-auto changeover switch for Bump less transfer from Channel 1 Auto to
Channel 2 Auto and vicevarsa.
- Bump less one Auto, one Manual Channel transfer from Channel 1 Manual to
Channel 2 Manual and vicevarsa.
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- Manual voltage control

- Excitation support system
- Under frequency protection
- Set Power Factor mode / Set kVAR mode
2401-5 NEUTRAL GROUNDING RESISTANCE (NGR) PANEL
Quantity: 1 No.
The neutral isolator and neutral grounding resistor shall be housed in this panel. It
should be possible to operate the neutral isolator from remote and facility to
Close/Open the Isolator manually on load also, in case of Power/Motor failure.
Neutral grounding panel shall be provided with necessary interlocks, Motorised
isolating switch and the requisite grounding resistance, earth fault CT, differential CT,
Restricted Earth Fault CT, Indicating lamps etc. The resistance shall be of punched
steel grid type. Panel shall have Enclosure IP –51. The resistance and other HV
section shall be separated to achieve the enclosure protection and dissipation of
heat.
Max. allowable Temperature rise = 375 ºC for 10 secs.

Resistance Value = 3.723 Ohms.
Motorised Neutral Isolator Rated Current = 2000 A, 11 kV
2401-6 LAPT AND SURGE CAPACITOR PANEL
Quantity: 1 No.
This panel will consist of Lightning Arrestor (LA), Potential Transformer (PT) and
Surge Capacitor. LA shall be of heavy duty and suitable surge capacitor for
protection from switching and other surges.
2401-7 RELAY PROTECTION AND METERING PANEL
Quantity: 1 No.
General for All LV Panels
This specification covers the design, material, construction features, manufacture,

inspection and testing, delivery to site and performance testing of metal enclosed
Low Voltage Switchgear of voltage not exceeding 1000 V AC.
Set of panels consisting of:
- Relay Protection and Metering Panel

- Excitation – AVR Panel
- Synchronising Panel
- 110 V DC Battery Charger &DCDB
- Motor Control Centres (MCCs)
- AC Distribution Boards
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Sheet Metal Work
The switchgear frame shall be fabricated using suitable mild steel structural sections
or pressed and shaped cold rolled sheet steel of thickness not less than 2.5 mm.
Frames shall be enclosed by sheet steel of thickness not less than 2 mm CRCA,
smoothly finished, levelled, and free from flaws. Doors and covers shall be made of
sheet steel of thickness not less than 2 mm CRCA. Stiffeners shall be provided
wherever necessary.
The complete structure shall be rigid, self-supporting, free from vibration, twists and
bends.
Painting
All the panels shall have suitable 7 tank process treatment. Painting shade shall be
Light Bus Grey Exterior and Bright White Interior, Powder coated type.
Constructional Features
Switchgear shall be:
a) of the metal enclosed, compartmentalised, indoor, floor mounted modular

type
b) made up of the requisite vertical sections
c) of dust and vermin proof construction
d) provided with degree of protection IP 51
e) easily extendable on both sides by the addition of vertical sections after

removing the end covers.
f) provided with a metal steel frame made of structural steel channel section
properly drilled for mounting the switchgear along with necessary mounting
hardware. Hardware shall be zinc plated and passivated.
g) provided with labels on the front and rear indicating the switchgear
designation.
h) provided with cable entry facilities at bottom with 3 mm thick removable un-
drilled gland plates and necessary cable glands. For single core cables these
plates shall be non-magnetic.
i) of uniform height of not more than 2300 mm.
j) of single front execution.
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k) provided with gaskets all round the perimeter of adjacent panels, panel and
base frame, removable covers and doors.
l) The maximum mounting height of operating handle / switch indicating

instruments shall not exceed 1800 mm from FFL and the minimum height not
below 400 mm.
Operating devices shall be incorporated only in the front of the switchgear.
Cable alleys shall be provided with suitable hinged doors. It shall be possible to
safely carry out maintenance work on cable connections to any one circuit with the
bus bars and adjacent circuits live. Adequate number of slotted cable support arms
shall be provided for cleating the cables.
Rear of single front switchgear shall be provided with removable panels/hinged

doors. It shall be possible for one person to remove and fix the removable panel.
All doors shall be provided with concealed type hinges and captive screws.
Relay Protection Panel
Quantity: 1 No.
This shall accommodate the mainly but not limited to following protection relays.
- Voltage restrained over current relay

- Earth fault relay
- Restricted earth fault relay
- Differential relay
- High-speed master trip relay
- Over voltage relay (2 Elements)
- Under voltage relay (2 Elements)
- Reverse power relay,
- Reverse reactive power relay
- Under frequency (Min. 2 Stages)
- Over frequency relay (Min 2 stages)
- df/dt (Min. 2 stages)
- Field failure relay
- Rotor earth fault relay (2 Stages)
- Trip circuit supervision relay
- Negative phase sequence over current relay
- DC failure trip relay
- VT Fuse Failure relay
All the relays shall have suitable contact multiplication and Trip arrangement. Except
High speed Trip Relay, VT Fuse Failure Relay & Trip Circuit supervision relay all the
relays should be digital, Microprocessor based with Redundant Relay. Final selection
shall be done after Employer/Project Manager’s approval. All relays shall conform to
BS/IS/IEC specifications and shall be suitable for communicating with DCS. The
relays shall be provided with windows based software. The Contractor shall submit
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Electrical Fault – Action- Alarm- C.B. and / or Turbine trip Logic diagram for all the
protections provided.
Metering Panel
Quantity: 1 No.
This shall accommodate the following. All the meters shall be digital type having
accuracy CL – 0.5 or better. All the necessary controls shall be provided on this
panel. The panel may be suitably divided in to sub sections like Metering Panel and
Annunciation Panel.
Meters:
- Ammeter (individual Phase wise)

- Voltmeter (individual Phase wise)
- Integrating type kWh meter with reverse lock
- kW meter
- kVAR meter
- kVA meter
- Power factor meter
- Frequency meter
- Running hour meter
Microprocessor based Multipoint Temperature scanner for Alternator with Min. 2

spare channels and separate output contacts for Alarm and Trip for each channel
Energy monitor and recording Meter which shall monitor all the electrical parameters
and communicate with DCS having accuracy CL – 0.5 or better.
Indicating Lamps
Indicating lamps shall be LED type and as required but not limited to following:
- For breaker ON, OFF, Tripped position

- Neutral Isolator ON
- Neutral Isolator OFF
- Auxiliary AC, DC Supply on
- Auxiliary DC Supply Failure
Audio-visual alarm annunciation with different tone and having Amber Indication for
Alarm and Red Indication for Trip faults for the following:
- DC Supply failure
- Winding temperature high Alarm
- Winding temperature Very high Alarm
- Bearing temperature high Alarm
- Bearing temperature Very high Alarm
- Inlet Air temperature high Alarm
- Outlet Air Temperature high Alarm
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- CB trip when turbine trips

- All the electrical faults Alarm & Trip.
2401-8 BATTERY, BATTERY CHARGER AND DC DB
1.0 110 V, 200 Ah BATTERY SETS
Quantity: 1 set
General
This specification covers requirement of stationary lead acid storage batteries

complete with battery racks, inter cell and inter tier connectors and all other
accessories.
Codes and Standards
The design manufacture and performance of the equipment shall comply with all
currently applicable statues, regulations and safety codes.
Unless otherwise specified, the equipment shall conform to latest applicable

IS/BS/IEC standards.
Construction
The batteries offered shall be maintenance free type. The battery shall be suitable for
indoor type installation.
Plates
Plante Positive Plates
The plante positive shall be cast solid in pure lead in one piece and shall have
adequate mechanical strength. It shall be electro-mechanically formed and shall be
capable of operating under normal working condition without buckling or cracking.
Tubular Positive Plates
The tubular positive plates shall consist of a suitable bar with spines cast of suitably
alloyed lead to give adequate mechanical strength. Porous acid resistant and
oxidation resistant tubes shall be inserted one over each spine. After insertion the
tubes shall be adequately filled and packed with active material before lower ends re
closed by a common bar. The construction and material of the tubes shall be such as
to reduce loss of active material and to withstand normal internal stresses developed
during service.
Negative Plates
The negative plates shall normally be of box type. End negative plates if of box type
may be of the half pasted type. Pasted plates shall have adequate mechanical
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strength and shall be so designed that the active material is maintained in intimate
contact with the grid under normal working conditions.
Containers
The containers shall preferably be made of glass for battery with plante type positive
plates. The containers for the battery with tubular type positive plates can be of hard
rubber, glass or plastic.
Vent Plug
The vent plug shall be of the anti-splash type, preferably with more than one exit
hole, and shall allow the gases to escape freely but shall effectively prevent acid
particles or spray coming out. On removal it shall script drawing of the electrolyte
samples, servicing and checking.
Acid Level Indicators
Containers shall be provided with built in acid level indicators.
Separators
The battery separator when used shall maintain the electrical insulation between the
plates and shall allow the electrolyte to permeate freely. The separators shall be of
wood or other acid resisting materials.
Connectors
Inter cell and inter row connectors shall be of led or lead plated copper depending on
the discharge rte to which the battery will be subjected.
Terminal Posts
Terminal posts shall be designed to accommodate external bolted connection

conveniently and positively. All the metal parts of the terminals shall be of lead or
lead coated type. Bolts heads and nuts except seal nuts shall be hexagonal and shall
be lead covered. The junction between terminal posts and cover and between cover
and container shall be so sealed to prevent any seepage of electrolyte.
Electrolyte
The electrolyte shall be battery grade sulphuric acid conforming to latest editions of
relevant IS. Required quantity of electrolyte for first filling with 10% extra shall be
supplied in non returnable containers.
Water
Water used for preparing of electrolyte and also to bring the level of electrolyte to
correct height during operation/testing shall conform to BS Accessories
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The battery shall be complete with accessories and devices including but not limited
to following:
i) Battery racks
ii) Porcelain insulators, rubber pads etc.
iii) Set of inter-cell, inter-row and inter-bank connectors, cables up to battery
charger as required for the complete installation.
iv) Electrolyte for first filling and 10% extra
v) Stand insulators PVC sheets
vi) Spanner
vii) Accessories for testing and maintenance
a) One - (-3.0 to + 3.0) Volts DC Voltmeter with suitable

leads for measuring cell voltage.
b) One- Hydrometer for measuring specific gravity of
electrolyte in steps of 0.005
c) One- Filler hole thermometer fitted with plug cap and
having specific gravity correction scale.
d) Three- Pocket thermometers acid resisting funnels.
e) Two- Acid resisting jugs of adequate capacity
f) Two- Rubber aprons
g) Four- Rubber gloves
h) Two- Cell lifting straps
i) Set- Terminals & cable boxes with glands for connecting
cables as required
Spare connectors
Spare Vent plugs
Spare Nuts and bolts
Suitable set of spanners
PVC spill trays under the battery cells.
j) Two- Rubber siphon
Battery Racks
Battery racks shall be constructed from good quality teak wood and painted with two
coats of approved acid resisting paint. The construction of the racks shall be suitable
for fixing to a flat concrete floor. The racks shall be rigid, free standing type and free
from warp and twists. The completed racks shall be suitable for being bolted and to
form a continuous row.
Ventilation
The Contractor shall indicate in the tender the requirement of ventilation in the
battery room. The battery shall operate satisfactorily over the entire range of
temperature indicated without affecting its normal life. If any special ventilation is
required the same shall be indicated.
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Capacity
The standard ampere hour capacity at ten hour rate of discharge of the battery has
been based on the requirement of the loads. Contractor shall guarantee that the
capacity of the battery offered is adequate for the duty specified (All loads being
coincident from the instant of supply failure even at minimum ambient temperature. It
may be assumed that the battery is fully charged at the start of the cycle and is
discharged to a voltage of 1.85 V /cell at the end of the cycle.
Charging
The battery shall be suitable for Float and Float Cum Boost Charge type of charging.
Life
The Contractor shall quote in the offer the guaranteed life of the battery.
Identification
Each cell shall be marked in a permanent manner to indicate the following

information:
i) Cell Number
ii) Type of positive plate
iii) Ah capacity at 10 Hour rate
iv) Type of container
v) Manufacturer’s name
vi) Month & year of manufacture
Coordination with Battery Charger Vendor
If battery charger is procured separately, Contractor shall coordinate with battery

charger in regard of layout, connections charging voltage requirements etc.
Tests
All the routine tests shall be performed free of cost at Contractor’s works and shall be
witnessed by Employer’s/Project Manager’s representative.
The tests shall be comprising of:
i) Visual Inspection
ii) Dimensional check
iii) Capacity check
iv) Retention of charge test
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2.0 BATTERY CHARGERS AND DCDBS FOR ABOVE BATTERY SETS
Code & Standards
The design, manufacture and performance of equipment shall comply with all
currently applicable statues, regulations and safety codes. Nothing in this
specification shall be construed to relieve the Contractor of his responsibilities.
Unless otherwise mentioned specified, equipment shall conform to latest applicable
standards.
Type
The battery charger shall be static type with SCR/IGBT connected in three-phase full
wave bridge circuit. The SCR transformer shall be indoor dry type double wound with
adequate no. of primary and secondary taps.
The charger shall be Float and Float Cum Boost Charge type.
Rating
The charge shall be suitable for charging 200 Ah substation batteries continuously.
The Float Cum Boost Charger shall be designed for supplying the boost charging
current requirement of the batteries. It shall be responsibility of the Contractor to
coordinate with the battery manufacturer and ascertain the float and boost charging
currents and voltages required by the battery.
Charger Cubicle & Wiring
Cubicle accessories and wiring shall conform to LV switchgear specification below

1000 V. Enclosure shall be IP –54.
Accessories
Each charger shall include but not limited to following:
One Set SCR/IGBT rectifiers connected in three phase full wave bridge circuit
with ripple filtering device.
One Set Double wound dry type main transformer of suitable rating with
adequate primary and secondary taps for the charger output voltage
control.
One Set Booster transformer as required.
One Set Transformer for Float Cum Boost charger (FCBC)
One Set Transformer for Float charger
One Set Transformer for FCBC
Two Set Automatic voltage regulator unit for Float and FCBC with Manual /
Auto control switch
Two set Course and fine control knobs for Manual control.
One Set Selector switch for Mode selection.
Set Separate DC Voltmeters and Ammeters for Float and FCBC mode
One Centre zero ammeter with shunt for battery circuit
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One set Incoming TPN MCB of required rating.

Set output two pole MCBs on each output side pf charger and Distribution
Board for DC Loads. Min. 15 outgoing MCBs shall be provided.
Indication & Protection
Following Indication shall be provided:
- Three LED Indicating lamps for Incoming supply.

- Overcurrent Float
- Float charger fail
- Rectifier fuse failure
- Overcurrent Boost
- Rectifier fuse failure
- DC Earth leakage
- AC Thermal overcurrent relay
Following Protections shall be provided
- DC Earth leakage
- AC Thermal overcurrent relay
Performance
The automatic voltage regulator shall regulate the DC Voltage within  1 % of the set
value from No load to Full load under the supply voltage and frequency variation of 
10 % and  5 % respectively. The charger shall have built-in current limiting feature
to drop the output voltage on currents more than 110% of rated current. Suitable
ripple filtering circuits shall be provided to give smooth DC output. The ripple content
shall be limited to less than 5%.
Tests
All the routine tests as listed in applicable standards free of cost shall be carried out
at Manufacturer’s works in presence of Employer/Project Manager’s representatives.
3.0 DC DISTRIBUTION BOARD (DCDB)
The DC Distribution shall be metal enclosed conforming to specifications of LV

Switchgear. Comprising of One No. Incomer Double pole MCB of adequate capacity
and Min. 15 no. Double pole MCBs suitable to carry equipment load current in each
DCDB.
2401-9 SYNCHRONISING PANEL
Quantity: 1 No.
The Synchronising scheme shall incorporate necessary equipment, controls so that

the Turboalternator(s) can operate in Droop-Droop, Droop-Isochronus, Isochronus-
Base load modes of operations as may be required in actual operating conditions.
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The provision shall be made in the scheme with necessary equipment, which will be
required by turboalterntor(s) when operating in parallel with the grid. The panel shall
be equipped with MMI (Man Machine Interface) if required. The scheme should be
designed such that it should be fully functional in Automatic/Manual modes of
operation as operator’s instructions. It is intended to Synchronise 2 X 30 MW TA sets
with EEPCO grid.
The synchronizing panel shall be preferably Desk type complete with push button
operation, Rotary Control Switches, Indicating lamps, Digital Meters, Semaphore
indicators, Necessary Interlocks, Inter panel wiring, Mimic diagram of Cogeneration
scheme, Discrepancy switches with Audio visual alarm, Dead Bus Relays.
Synchronising panel shall mainly comprising of but not limited to following:
1) Automatic synchronizer with auto voltage and frequency matching, CB closing

with CB closing time compensation
2) Synchroscope with check synchronising facility (LED type)
3) Digital Frequency meter (2 Nos.)
4) Digital Voltmeter (2 Nos.)
5) Indicating lamps (LED type)
6) Control switch and fuses
7) Auto/ Manual Synchronising Switch
8) Breaker Selection Switch
9) Luminous Push Buttons for Low/Raise of Frequency
10) Luminous Push Buttons for Low/Raise of voltage
11) Voltage Transformers
12) Current Transformers
13) Dead Bus closing scheme comprising of Dead Bus Relays
14) Load sharing device (kW, kVAR) with load sharing signal and facility to adjust
individual loading of TAs for operating TA in parallel.
15) Discrepancy switches with audio-visual alarm.
16) Digital meters for kW, kVAR of all TAs shall be provided.
17) Provision of remote control operating facility to hook up with and operated from
Employer’s DCS system.
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It should be possible from the Synchronising Panel to Synchronise the TAs across
following Circuit Breakers (CBs):
1) TA incomer CBs (Two Nos.) (Included in this package)

2) Export CB (One No.) (CB will be added later provision for synchronization
shall be made in this panel)
3) Across Bus Coupler (One No.) (Included in this package)
4) Cogen Aux. Feeder for synchronising with Black start DGs (Two Nos.)
(CBs will be added later provision for synchronization shall be made in this
panel)
The required VT signals, Governor, AVR remote set point of TA and DGs shall be
brought and controlled from this panel.
The panel shall be provided with required CB Selection switches, Local/Remote

switches and Discrepancy switches for each CB, Raise/Lower Luminous Push
Buttons. The Dead Bus closing scheme shall be provided with the help of No Volt
relays for all the CBs.
The Neutral Grounding Isolator Open / Closed position shall be indicated using
semaphore indicators and provision of operation shall be given in this panel.
There shall be provision of connection terminals in every panel for remote control on
centralized panel (wherever required) provision of 4 - 20 mA for monitoring system
shall also be provided.
2401-10 ALTERNATOR BREAKER PANEL (11 kV HV BOARD)
Quantity: 1 No.
General
11 kV HV Board (i.e. Alternator Breaker Panel) shall have one Circuit Breaker (CB).
This CB shall be of 11 kV, 2500A, 26.24 kA for 3s. rating and Bus bars has to be
designed for 11 kV, 4000A, 26.24 kA for 3s.
Codes and Standards
The design, material, construction, manufacture, inspection, testing and performance

of metal-clad switchgear shall comply with all currently applicable statutes,
regulations and safety codes in the locality where the Equipment will be installed.
The Equipment shall also conform to the latest IS or equivalent BS or IEC standards.
This specification covers the design, material construction features, manufacture,

inspection and testing at the Contractor’s works, delivery to site and performance
testing of Metal-clad Switch- gear rated 11 kV.
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Metal-clad switchgear and control gear shall comprise metal-enclosed switchgear

and control gear in which components are arranged in separate compartments with
metal-enclosures intended to be earthed.
The metal-clad switchgear and control gear shall have separate compartments for
the following components:
a) Each set of busbars

b) Current transformers
c) Voltage transformers on incomer side
d) Each main switching device
e) Cable chamber suitable for heat shrinkable or push on type cable termination
of cables.
f) Metering and relaying devices.
The partitions of fore listed compartments shall have the following degrees of
protection:
Complete protection against approach to live parts or contact with internal moving
parts i.e. each set of busbars, compartments of each set of busbars shall be provided
with protection against approach to live parts or contact with internal parts, by tools,
wires or similar objects of thickness greater than 1.0 mm i.e. Class IP - 4X.
Switchgear shall comprise indoor, metal-clad, Draw-out type circuit breakers.
Switchgear shall be dust, moisture and vermin-proof.
All doors, panels, removable covers shall be gasketted all around with neoprene
gaskets. All louvers shall have screens and filters. Vent openings shall be covered
by fine mesh on the vertical face. The screens and grills shall be made of either
brass or galvanised iron wire mesh.
Metal-clad unit shall comprise rigid welded structural frame enclosed completely by
metal sheets, minimum 2.5 mm thick (hot rolled) or 2.0 mm thick (cold rolled), smooth
finished, levelled and free from flaws.
Switchgear design shall comprise fully compartmental execution having separate

vertical sections for each compartment. Compartments with doors for access to
operating mechanism shall be so arranged as not to expose high voltage circuits.
Switchgear cubicles shall be provided with hinged doors on the front with facility for
padlocking door handles.
Structure, buses and control wiring troughs shall be so designed and arranged to
make future extensions readily feasible.
Instruments, relays and control devices shall be mounted flush on hinged door of the
metering compartment located in the front portion of cubicle. Panel door shall be
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supported by strong hinges and braced in such a manner as to ensure freedom from
sagging, bending and general distortion of panel or hinged parts. All auxiliary relays
not requiring manual resetting will be mounted inside the LV compartment.
Switchgear cubicles shall be provided with bottom sheet metal plates 2 mm thick
(minimum). Removable gland plate shall be 3 mm thick.
Mounting in the form of mild steel channels properly drilled shall be supplied along
with anchor bolts for mounting the switchgear cubicles. These shall be despatched
in advance so that they may be installed and levelled when concrete foundations are
poured.
Each switchgear cubicle shall be fitted with a label on the front and rear of the
cubicle. Each switchgear shall also be fitted with label indicating the switchgear
designation, rating and duty. Each relay, instrument, switch, fuse and other devices
shall be provided with separate label.
Painting
Panel shall have suitable 7 tank process treatment. Painting shade shall be Light Bus
Grey Exterior and Bright White Interior, Powder coated type.
Safety Interlocks
Switchgear shall be provided with following interlocks:
Breaker shall not be possible to draw out unless the associated circuit breaker is in
the open position.
Compartment door of a breaker shall not open unless the breaker is in open position.
Caution name plate, 'Caution Live Terminals' shall be provided at all points where the
terminals are likely to remain live and isolation is possible only at remote end, i.e.
incoming terminals of main isolators.
Main Busbars
Main busbars shall be of copper and non-segregated type.
Busbars shall be located in air insulated enclosures and segregated from all other
compartments of the cubicle. Direct access or accidental contact with busbars and
primary connections shall not be possible. To provide a seal between adjacent
cubicles, busbars shall be taken through seal-off bushings or insulating pads.
All busbars joints shall be thoroughly cleaned and antioxide grease shall be applied.
Plain and spring washers shall be provided to ensure good contacts at the joints and
taps. Wherever aluminium to copper connections are required, suitable bimetallic
connectors or clamps shall be used.
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Busbars shall be rated in accordance with the service conditions and the rated
continuous and short time current ratings specified in Data Sheet A. Maximum
temperature of the busbars and busbar connections, under operating conditions,
when carrying rated normal current at rated frequency shall not exceed 85 OC.
(40+45 = 85)
Busbars shall be adequately supported on insulators, to withstand dynamic stresses

due to short circuit current specified in Data Sheet for 11 kV HV Switchgear. Busbar
support insulators shall conform to relevant standards.
The busbar clearances in air shall be suitable for 26.24 kA for 3 sec. short circuit
levels specified in Data Sheet for 11 kV HV Switchgear.
Busbars shall not be painted and all performance characteristics specified shall be
obtained with unpainted busbars.
Circuit Breakers
Circuit breakers shall be SF6/VCB type. These shall conform to relevant standards
specified and shall be of draw out type. Circuit breakers shall comprise three
separate identical single pole units operated through a common shaft by the
operating mechanism.
Circuit breakers shall be suitable for switching duty of Generators.
Isolating plugs and sockets for power as well as control circuits shall be of robust
design and fully self aligning. Plugs and sockets for power circuits shall be silver
faced and shall be insulated with PVC or other insulating material shrouds.
SF-6 circuit breakers shall have completely sealed interrupting units for interruption
of arc inside the SF6 gas chamber. It shall be possible to isolate easily the SF6
interrupter unit from the breaker operating mechanism for mechanical testing of the
interrupter to check loss of SF6 gas.
The SF6/VCB breakers shall be complete with surge arrestors to provide protection
to the equipment controlled by the breaker, against switching surges.
Breaker internal wiring up to the plug shall be similar for all breakers.
Operating Mechanism
Circuit breaker shall be power operated, by a motor charged spring operated

mechanism. Main poles of the breakers shall be such that unless otherwise
specified, the maximum difference between instants of contacts touching during
closing shall not exceed half cycle of rated frequency.
Operating mechanism shall be provided with non-pumping feature, electrically and

mechanically. Electrical anti pumping feature shall be obtained by means of an
auxiliary relay.
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Main poles of the breaker shall operate simultaneously. There shall be no

objectionable rebound and the mechanism shall not require any critical adjustment.
It shall be strong, rigid, positive and fast in operation.
Mechanism shall be such that failure of any auxiliary spring shall not prevent tripping
and will not cause tripping or closing operation of the power operated closing
devices. When the circuit breaker is already closed, failure of any auxiliary spring
shall not cause damage to the circuit breaker or endanger the operator.
A mechanical indicator shall be provided to show open and closed positions of

breaker. It shall be located in a position where it will be visible to the operator
standing on the front of the switchgear with cubicle door closed.
The closing coil shall operate correctly at all values of voltage between 80 % and 110
% of the rated voltage. A shunt trip shall operate correctly under all operating
conditions of the circuit breaker up to the rated breaking capacity of the circuit
breaker and all values of supply voltage between 50 % and 110 % of rated voltage.
Mechanical trip and close devices shall be provided for manual operation of the
breaker. Access to mechanical closing device shall be only after opening the cubicle
door. However, the mechanical trip device shall be brought out to the front of the
cubicle door.
Working parts of the mechanism shall be of corrosion resisting material. Bearings,

which require grease, shall be equipped with pressure type grease fittings. Bearing
pin, bolts, nuts and other parts shall be adequately pinned and locked to prevent
loosening or changing adjustment with repeated operation of the breaker.
Auxiliary switches mounted on the fixed portion of the cubicles and directly operated
from the breaker operating mechanism on each breaker having 8 'NO' and 8 'NC'
potential-free contacts rated for 10 A 220V AC and 0.5 A (inductive breaking) 110 V
DC shall be provided. The contacts shall be in addition to those utilised in the control
circuit of each breaker and shall be exclusively meant for the Employer’s use in
external interlocks and controls.
Spring Operated Mechanism
Spring operated mechanism, shall be complete with motor, opening spring, closing
spring with limit switch for automatic charging and all necessary accessories to make
the mechanism a complete operating unit.
Breaker operation shall be independent of the motor, which shall be used solely for
compressing the closing spring.
Closing action of the circuit breaker shall compress the opening spring ready for
tripping.
When closing springs are discharged, after closing a breaker, closing springs shall
automatically be charged for the next operation.
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Motor shall be such that it requires only about 30s for fully charging the closing
spring. Motors shall be rated for or 220V AC and shall operate satisfactorily at all
values of voltage between 80% to 110% of rated voltage.
Mechanical indicators to indicate charged and discharged condition of spring shall be

provided.
Operating Mechanism Control
The closing and tripping control shall be by a control switch mounted on the cubicle
door.
The mechanical trip and close devices shall be provided on the breakers in addition
to above.
Earthing
An earthing bus shall be provided and extend throughout the length of the
switchgear. It shall be bolted/brazed to the framework of each unit and each breaker
earthing contact bar.
The earth bus shall have sufficient cross section to carry the momentary short circuit
and short time fault current for 3 second, without exceeding maximum allowable
temperature rise.
Suitable clamp type terminals at each end of the earth bus shall be provided to suit
the size of the Employer’s earthing conductor.
All non-current carrying metal work of the switch-board shall be effectively bonded to
the earth bus.
Bolted joints, splices, taps etc. to the earth bus shall be made with at least two bolts.
Hinged doors shall be earthed through flexible earthing braid.
Positive earthing of circuit breaker frame shall be maintained when it is in the

connected position and in all other positions whilst the auxiliary circuits are not totally
disconnected.
Cubicle Module Accessories and Wiring
Cubicle accessories and wiring shall include following accessories:
The Contractor shall carry out Inter-cubicle wiring between cubicles of same
switchgear. The Contractor shall furnish separate schematics, internal and
inter-cubicle wiring diagrams and external cable connection diagrams for each
cubicle. The external connection drawings shall indicate all external connections to
be made by the Employer to the respective cubicles from the Employer’s remote
equipment.
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Terminal blocks (including 10 % spare terminals) with complete internal wiring and
inter-cubicle wiring as required.
Inter-cubicle looping of control space heating supplies for all the panels of switchgear
shall be carried out by the Contractor.
Cable Termination Compartment
Supply of Cable glands and termination kits is included in the scope of Contractor.
Adequate space shall be provided in the switchgear to install and terminate the
cables.
Gland plate for control and power cables shall be of removable type and shall be of 3
mm thick.
Instrument Transformers
The current transformers and voltage transformers shall conform to the requirements
stipulated in relevant standards specified.
The CTs and VTs shall be of cast resin type (insulation Class 'F') and shall be able to
withstand the thermal and mechanical stress resulting from the maximum short circuit
and momentary current ratings of the switchgear. These shall be completely
encapsulated.
CTs shall have polarity marks indelibly marked on each transformer and at the
associated terminal block. Facility shall be provided for short circuiting and earthing
the CT secondary at the terminal blocks.
VTs shall be protected on their primary sides by current limiting HRC fuses with
interrupting ratings corresponding to breaker rating and on secondary side with
MCBs. Provision shall be made such that the primary fuses can be handled only in
the de-energised position.
Miscellaneous Accessories
Heater & Light Point
Each switchgear cubicle shall be equipped with heater to prevent moisture

condensation within the enclosure and shall be complete with Miniature Circuit
Breaker (MCB) for power supply. Heaters and MCBs shall be suitable for continuous
operation on 220 V, 1 phase, 50 Hz, AC supply, 20 W Fluorescent tube light with
door switch shall be provided in control cubical.
Plug Point
A 220 V, 1 phase, 15A, 50 Hz, AC Industrial type plug socket, top with MCB shall be
provided in the interior of each cubicle.
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Tests and Test Reports
The Contractor shall completely assemble, with all the associated equipment
including bought out items mounted and wired and test each cubicle as per relevant
standard. All routine tests shall be carried out as per this standard.
Valid Type test certificate shall be furnished along with routine tests reports.
Copies of the test certificates shall be submitted for the Employer’s approval before
despatch of the switchgear. Bound copies of complete test results as specified in the
distribution schedule shall be furnished with the switchgear. These shall include
complete reports and results of the routine tests as also certified copies of type tests
carried out on equipment of identical design.
Oscillographic test records for closing and tripping timings of the breakers shall also
be furnished.
DATA SHEET FOR 11 kV HV BOARD
Sl. Particulars Preferred Offered

No. Specification Specification
1.0 Switchgear Cubicles And Main

Bus Bars Rating
a) Rated voltage, phases and 11 kV, 3 ph, 50 Hz

Frequency
b) System Neutral earthing
Effectively Earthed Alternator earthed
through NGR
Non Effectively Earthed For 11 kV HV board
c) Maximum system voltage 12 kV
d) One minute power frequency With 28 kV (rms)
stand voltage
e) 1.2/50 μs impulse Withstand 75 kV (peak)
voltage
f) Short circuit breaking current 26.24 kA (rms)
And time duration 3 Sec.
g) Continuous current rating of 4000 A
bus bars under site reference
ambient temp.
h) Maximum temperature of busbars, 85 OC
droppers, connectors & contacts
at continuous current rating under
site reference ambient temp.
1.1 Switchgear Constructional
Requirements
a) Thickness of sheet steel
enclosures, doors & covers
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Structural Members 2.5 mm

(Vertical/Horizontal)
Front / Rear Door of LV Chamber 2 mm
(Cold Rolled)
Removable gland plate 3.0 mm
b) Protection for the Switchgear IP- 4X
c) Finish and Colour Shade Powder coated

Interior Bright white
Exterior Siemens RAL 7032
d) Earthing Bus
Material Copper
Size 50 x 10 mm
e) Bus duct and Cables connections * 11 kV, Copper, UE
grade, XLPE cable(s)
from alternators.
For Extension of
panel bus bars
trunking from both
sides.
f) Clearance in air of live parts 3 mm / kV (Minimum)
Phase to Phase To suit impulse
withstand voltage
Phase to Earth To suit impulse
withstand voltage
g) Bus bar insulation Unpainted
1.2 Circuit Breaker Particulars
a) Circuit breaker type VCB / SF6
b) Voltage frequency and No. of 11 kV, 3 ph, 50 Hz
phases
c) Rated operating duty O - t - CO - t’ – CO
O = Represents an opening operation.
CO = Represents a closing operation followed immediately (without
intentional time delay) by an opening operation.
t, t’ = Time intervals between successive operations.
t = 0.3 s (Dead time)
t’ = 15 s (time interval between successive interval)
O - 0.3 s – CO - 15 s - CO
d) Rated current at site reference Two TA Incomers of
ambient temperature 2500 Amps and One
Bus Coupler of 2500
Amps.
e) Rated Short circuit breaking 40 kA (rms)
current for 3s
f) Minimum no of auxiliary contacts 8 NO + 8 NC
g) Withstand test voltage
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One minute power frequency 28 kV (rms)

1.2/50 μs impulse 75 kV (peak)
h) Auxiliary control voltage
For closing / tripping coil & 110 V DC
Indication
For spring charging motor 220 V, AC, 50 Hz
For space heaters and cubicle 220 V, AC, 50 Hz
lighting
The breaker shall be in metal enclosed switchgear, horizontal mounting and
horizontal drawout type suitable for extension in both directions. Each breaker
shall be provided with necessary indications, Meters, protection relays.
1.3 Current Transformers CTs shall be single
phase, resin cast.
Arranged one (1) per
phase.
Rating : Appropriate
Class : 0.5, 5P20 &
PS Class
Burden : 20 VA.
1.4 Voltage Transformers Incoming VTs shall
be of resin cast, draw
out type complete
with HRC fuses on
primary side, V.T.
Fuse failure Relay
and MCBs on
secondary side.
Class : 0.5 & 3P
Burden/Phase:100VA
1.5 Indications
Indicating lamps, LED type rated for 110 V DC to indicate
breaker position colours shall be as follows:
Breaker - ON - Red lamp
Breaker - OFF - Green lamp
Breaker - Auto Tripped - Amber lamp
Breaker - Spring charged - Blue Lamp
Trip circuit Healthy - White Lamp
SF6 gas pressure low/Unhealthy circuit - Amber Lamp
1.6 Switch / Push Buttons
Breaker control switch of spring return to neutral type with
TNC contacts and lost motion device.
Emergency trip push button with mushroom type head
lockable type and having protective shroud.
Push button for trip circuit healthy supervision.
Rotary type Local / Remote switch.
1.7 Meters
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Microprocessor based meter to read Voltage, current,

kilowatt, kilowatt hour, Frequency, Power Factor etc. The
meter should be able to communicate with Employer’s
DCS.
1.8 Relays
Microprocessor based protection relays with Redundancy
shall be provided. The relays shall be suitable for
connectivity with Employer’s DCS.
Relays shall be suitable for 110 V DC.
Master Trip Relay shall be hand reset lockout type.
VT Fuse failure relay with hand reset contact and with flag
indicator.
1.9 Accessories
220 V, rated panel space heaters with 220 V, 16A, SPN
ON/OFF switch with thermostat.
One (1) No -Switch controlled 220V, 3 pin socket outlet.
20 W F.T.L. fittings with door switches.
One (1) No-220 V, 25A, SPN, ON/OFF switch for Single
phase, AC supply to panel.
One (1) No-25 A, DP, ON/OFF switch for 110 V DC supply
to panel.
HRC control fuses.
Terminals suitable for termination of control cables of size
2.5 sq. copper
8 point annunciation window with test, accept, reset facility
and hooters.
2.0 Special Notes
Earthed, metallic screens shall be provided in the rear
cable chamber to prevent inadvertent contact with the live
parts.
While shipping the switchgears, inter panel wiring shall be

disconnected and loose wires shall be properly ferruled.
Terminal blocks in each panel shall be provided to receive
their inter-panel bus-wirings.
Material and size conductor for wiring shall be as follows:

For CT Circuits - 4.0 sq. mm copper
For other Circuits - 2.5 sq. mm copper
All external cables entry shall be marked on terminal.
11KV, HV Panel to be earthed to earth grid.
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2401-11 HV CABLE AND TERMINATION KITS (11 kV)
Codes and Standards
The design, manufacture and performance of the cables shall comply with all
currently applicable statues, regulations and safety codes. The cables shall be
derated for laying in groups.
The cable should withstand the thermal let through energy in case of short circuit till
the protective device trips. The cable shall also be suitable for short circuit current of
the Alternator till protective device trips.
Unless otherwise mentioned the cable shall conform to latest applicable BS or

equivalent IS or IEC.
This specification covers the requirements Design, Manufacturing, Supply and

delivery of 11000 V (UE) Grade HV cables form Alternators to Alternator Incomer
CBs and associated accessories like straight joints, end joints and termination etc.
Construction
Conductor - Copper
Conductor Screen
Extruded semi conducting compound applied directly over the conductor to provide a
smooth surface and eliminate electrical stress concentration.
Insulation
Extruded super clean XLPE compound. The thickness of the insulation shall be
decided based on the permissible electrical stress (Minimum 3 kV / mm)
Insulation screen (Over Individual Core)
The insulation screen consist of two parts
Non-metallic, semi conducting compound extruded directly over insulation fully

bound. A layer of semi conducting fabric tape shall be provided over the extruded
layer to give bedding to the metallic parts of the screen.
Metallic screen consisting of nonmagnetic metal in the form of wire.
Binder Tape
Above metallic screen.
Outer Sheath
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Extruded PVC over the metallic screen/armour in case of unarmoured/armoured

cables respectively. In addition common covering for the three cores. Fillers etc. shall
be provided.
Single Core Cables
The cables construction shall be similar to three core cable except that the armouring
shall be of non-magnetic material.
Cable Accessories
Full details of the splicing and termination procedures shall be given in the tender by
the Contractor.
Total creepage distance of the outdoor insulators (If applicable) of cable sealing ends
shall be suitable for heavily polluted saline atmosphere and shall in any case not be
less than 25 mm / kV of highest line to line voltage. The protected creepage distance
shall be half of the total creepage distance.
Cable Drums
Cables shall be supplied in non-returnable drums of sturdy construction. All ferrous

and other metal parts of drums shall be treated with a suitable rust preventive finish
or coating to avoid rusting during transit or storage.
The length of cable on each drum shall be determined by the manufacturer

considering the transport limitations from works to site.
Tests
All the routine tests as per relevant IS or equivalent BS or IEC shall be carried out on
each size of cable required. The routine tests shall be conducted in presence of
Employer’s/Project Manager’s representative. Some of the routine tests are as
follows:
- Conductor resistance test

- Partial discharge test for screened cables
- High voltage test
If valid Type test certificates are not submitted, Contractor shall carry out Type Test
as per relevant BS or equivalent IS or IEC in presence of Employer/Project
Manager’s representative at additional quoted cost.
DATA SHEET FOR HV CABLES

1.0 Name of the manufacturer *
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1.1 Type of cable (PVC/XLPE) XLPE

1.2 Grade of cable (UE) Unearthed
1.3 Standard applicable *
1.4 Rated Voltage 11 kV
1.5 Maximum Voltage 12 kV
1.6 No. of cores and size *
1.7 Conductor material Copper
1.8 Overall diameter of cable * mm
1.9 Min. bending radius * mm
1.10 Weight of cable * kg / m
1.11 Max. AC resistance at 75 OC * Ohm / km
1.12 Current carrying capacity
i) In ground *
ii) In air *
iii) In ducts *
1.13 De-rating factor for various *
Conditions of laying
1.14 Overload capacity & duration *
1.15 Short circuit current rating and *
duration
2401-12 LV CABLES WITH GLANDS AND TERMINATION KITS (400V, 1.1 kV Grade)
Codes and Standards
The design, manufacture and performance of the 1.1 kV grade copper cables and
accessories like glands, termination, copper wires Conductor, PVC Insulated, Cores
laid up, PVC tape inner sheath, galvanised steel armoured, Outer sheath of extruded
PVC compound etc. shall comply with all currently applicable IS or equivalent BS or
IEC standards, statues, regulations and safety codes. All the cables shall be de-rated
for laying underground and in groups. Inter connecting and control cables between
Alternator and control panels, Instrumentation, all relays, Governor control motor,
speed indicator etc. shall be provided.
Construction
The cables shall be of copper conductor extruded inner and outer PVC sheath,
flat/round galvanised steel armour.
Cables up to 10 sq. mm conductor size shall have round steel armour. Above 10 sq.
mm size flat armour shall be used.
For Three and Half core cables the current carrying capacity of the neutral conductor
shall be 50% of that of the main phase conductors.
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The cables shall operate satisfactorily without any damage/deformation in shape and
size at site conditions and at a continuous conductor temperature of 70 OC.
The cables shall withstand the rated short circuit for One Sec. Without exceeding the
temperature of 160 OC
All cable shall be of 1100 V grade.
Tests
Following tests shall be conducted on cable length of each rating in the presence of
Employer/Project Manager’s representative free of cost:
- Conductor resistance test

- High Voltage test
- Insulation Resistance test
- Continuity check
- Check for ISI mark and embossed rating.
If valid Type test certificates are not submitted, Contractor shall carry out Type tests
as per IS or equivalent BS or IEC in presence of Employer’s / Project Manager’s
representative at quoted additional cost.
Cable sizes for various currents and Motor ratings shall be selected based on
following table:
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Sr. No. Cable Size Max. Current carrying capacity (in

Air) with deration factor of 0.8
1) 3.5 C x 400 sq. mm CU, PVC 418 A

2) 3.5 C x 300 sq. mm CU, PVC 361 A
3) 3.5 C x 240 sq. mm CU, PVC 319 A
4) 3.5 C x 185 sq. mm CU, PVC 266 A
5) 3.5 C x 120 sq. mm CU, PVC 206 A
6) 3.5 C x 70 sq. mm CU, PVC 144 A
7) 4 C x 35 sq. mm CU, PVC 95 A
8) 4 C x 16 sq. mm CU, PVC 58 A
9) 4 C x 6 sq. mm CU, PVC 33 A
10) 4 C x 2.5 sq. mm CU, PVC 19 A
DATA SHEET FOR LV CABLES

1.0 Name of the manufacturer *

1.1 Type of cable (PVC/XLPE) PVC / XLPE
1.2 Grade of cable (E) Earthed
1.3 Standard applicable *
1.4 Rated Voltage 0.400 kV
1.5 Maximum Voltage 1.1 kV
1.6 No. of cores and size As per schedule of
quantities
1.7 Conductor material Copper
1.8 Overall diameter of cable * mm
1.9 Min. bending radius * mm
1.10 Weight of cable * kg / m
1.11 Max. AC resistance at 75 OC * Ohm / km
1.12 Current carrying capacity
i) In ground *
ii) In air *
iii) In ducts *
1.13 De-rating factor for various *
Conditions of laying
1.14 Overload capacity & duration *
1.15 Short circuit current rating and *
duration
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2401-13 EARTHING SYSTEM
Codes & Standards
The Earthing of all the equipment shall comply with currently applicable statues,
regulations and safety codes. The earthing shall be installed in the conformity with
the requirement of Ethiopian Electricity Rules.
Unless otherwise specified the earthing shall conform to latest applicable BS

standard or equivalent IS or IEC.
This specification covers the requirement of earthing all the equipment including
Alternator, Motors, Distribution Boards, Push Buttons, MCCs etc. The specification is
intended to cover complete supply, installation, testing and commissioning of the
above systems.
Data
Maximum Fault level : 26.24 kA at 11 kV and 50 kA at 400 V
Duration of fault : 3s for 11 kV and 1s for 400 V.
Voltage variation : ± 10 %
Earth conductor : 2 Nos. separate
Earth Conductor material : Copper strip
Soil Resistivity : Shall be informed later.
Conductor size:
Following sizes of Copper Strip conductors shall be used:
Main earth grid : 50 x 10 mm
Earth risers for panels:

H V Switchgear : 50 x 6 mm
LV Switchgear : 25 x 10 mm
For Motors, Push buttons etc.: 2.5 sq. mm. Bare Copper wire.
Earth Electrode : GI Pipe size 3 m length x 65 mm diameter
Other Details
All the equipment must be earthed using two distinct earth conductors using two
distinct earthing points provided on the equipment body at two distinct earth pits.
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All the earth pits shall be numbered and painted on the cover.
The distance between two earth pits shall be minimum twice the buried length of the
earth electrode.
The earth pits shall be made as per Ethiopian Electricity Rules. Typical drawing for
earth pit shall be furnished to the Contractor.
Cable armours shall be earthed effectively. Screen of cables shall be earthed at

terminating ends.
Each earth pit shall have disconnecting facility for testing individual earth resistance.
Miscellaneous items like DBs, receptacles shall be effectively earthed.
All the earth pits shall be connected in parallel.
Two separate and distinct earth leads shall be used for earthing each
equipment/structures enclosing the power conductor and one earth lead for metallic
structure adjacent to electrical installation.
Metallic frames of all electrical equipment rated above 220 V, must be earthed by two
distinct connections with earth system.
Earthing cables crossing other metallic structures such as conduits, pipe lines etc.
shall be minimum 300 mm away from such structures.
All underground connections and joints in earthing system shall be brazed/welded.

Connections with equipment/structures shall be bolted type.
Conducting petroleum jelly shall be applied to contact surface of all bolted joints and
joints shall be covered with bituminous compound and taped.
When Copper conductors are connected to aluminium conductors the contact

surface of Copper shall be tinned to prevent bimetallic corrosion.
Neutral connection shall never be used for the equipment earthing.
Earthing conductor shall be protected against mechanical damage.
Earthing conductors running along structures shall be cleated at every 750 mm

interval.
Sizes of earth conductor for equipment shall be at least half the size of power
conductor, limited to max. 120 sq. mm of copper.
All earth lead connection shall be as short and direct as possible and shall be without
kink.
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The Alternator neutral from Neutral grounding panel shall be earthed at two distinct
earth pits using two separate earth conductors for each earth pit.
2401-14 MOTOR CONTROL CENTRE

2401-15 AC DISTRIBUTION BOARDS
Quantity: 2 Nos.
Specification of Motor Control Centre and AC Distribution Boards are as follows:
General
400 V A.C. System : Three phase and neutral, 50Hz, solidly earthed
System, Short Circuit rating of 50 kA for 1 s.
Control Supply : 110 V DC Supply.
Codes & Standards
The design, construction, manufacture and performance of equipment shall conform

to latest applicable standards and comply with all currently applicable statutory,
regulations and safety codes in the locality where the equipment will be installed.
Nothing mentioned in this specification shall be construed to relieve the Contractor of

his responsibility.
This specification covers the design, material, construction features, manufacture,

inspection and testing, delivery to site and performance testing of metal enclosed
Low Voltage Switchgear, Control gear of voltage not exceeding 1000 V AC.
The switchgear, control gear broadly covers following equipment Motor Control
Centres (MCCs) and Power and Motor Control Centres (PMCCs), Distribution Boards
(DBs), any other control gear, switchgear below 1000 V AC required for the supply of
power to and for the control of low voltage equipment in the TA package.
Sheet Metal Work
The switchgear frame shall be fabricated using suitable mild steel structural sections
or pressed and shaped cold rolled sheet steel of thickness not less than 2.5 mm.
Frames shall be enclosed by sheet steel of thickness not less than 2 mm cold rolled,
smoothly finished, levelled, and free from flaws. Doors and covers shall be made of
sheet steel of thickness not less than 1.6 mm cold rolled. Stiffeners shall be provided
wherever necessary. Required sheet steel thickness are indicated in Data Sheet for
LV Switchgear.
The complete structure shall be rigid, self-supporting, free from vibration, twists and
bends.
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Painting
As indicated in Data Sheet for L V Switchgear.
Switchgear shall be:
a) of the metal enclosed, compartmentalised, indoor, floor mounted modular

type
b) made up of the requisite vertical sections
c) of dust and vermin proof construction
d) provided with degree of protection as specified in Data Sheet.
e) easily extendable on both sides by the addition of vertical sections after

removing the end covers.
f) provided with a metal steel frame made of structural steel channel section
properly drilled for mounting the switchgear along with necessary mounting
hardware. Hardware shall be zinc plated and passivated.
g) provided with labels on the front and rear indicating the switchgear
designation.
h) provided with cable entry facilities at top/bottom as required with 3 mm thick

removable undrilled gland plates and necessary. For single core cables
these plates shall be non-magnetic.
i) of uniform height of 2300 mm only.
j) of single front execution (double front if required and with prior approval from
Employer)
k) provided with gaskets all round the perimeter of adjacent panels, panel and
base frame, removable covers and doors.
l) The maximum mounting height of operating handle / switch not exceed 1800
mm from FFL and the minimum height not below 400 mm.
m) provided with busbars running at the top or bottom, as required, all along the
length of the switchgear in a separate sheet steel enclosure.
Operating devices shall be incorporated only in the front of the switchgear.
The switchgear shall be divided into distinct vertical sections each comprising:
a) A completely metal enclosed busbar compartment running horizontally.
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b) Individual feeder modules arranged in multi-tier formation. It is essential that

the modules are integral multiples of the basic unit size to provide for flexibility
in changes, if any, at site.
c) Enclosed vertical busbars serving all modules in the vertical section. For
safety isolation of the vertical busbars, insulating barrier with cut-outs shall be
provided to allow the power stab contacts to engage with vertical busbars.
d) A vertical cable alley covering the entire height. The cable alley shall be
minimum 300 mm wide for motor control modules and 500 mm wide for circuit
breaker control modules.
e) A horizontal separate enclosure for all auxiliary power & control buses, as
required, shall be located so as to enable easy identification, maintenance
and segregation from the main power buses. Tap - off connections from
these buses shall be arranged separately for each vertical section.
Each vertical section shall be equipped with space heaters, which may be located
conveniently.
One metal sheet shall be provided between two adjacent vertical sections running to
the full height of the switchgear except for the horizontal busbar compartment.
However, each shipping section shall have metal sheets at both ends.
All equipment associated with a single circuit shall be housed in a separate module
compartment of the vertical section. The compartment shall be sheet steel enclosed
on all sides and the rear, with the withdraw-able units in position or removed, except
on the cable alley side. A plate cover with a slot to permit wiring connections shall be
provided on the side corresponding to the cable alley. The front of the compartment
shall be provided with a hinged door.
For draw-out type modules, only the handles of control and selector switches, push
buttons, knobs & cut-outs for lamps and meters shall be arranged on the front doors
of the respective compartments to permit operation without opening the door. On
circuit breaker controlled circuits, protective relays shall be mounted on the front door
of the compartment. All other equipment pertaining to a circuit shall be mounted on
the withdraw-able chassis. All cut-outs shall be provided with gaskets for the
purpose of dust-proofing. All Air Circuit Breaker modules shall be Electrically
Operated Draw-out type (EDO)
Current transformers shall not be directly mounted on the buses. Current

transformers on circuit breaker controlled circuits shall be mounted on the fixed
portion of the compartment.
In breaker compartments, suitable barriers shall be placed between circuit breakers

and all control, protective and indication circuit equipment including instrument
transformers. External cable connections shall be carried out in separate cable
compartments for power and control cables.
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The withdraw-able chassis shall move on suitable guides and on suitably plated steel
or stainless steel rollers or balls to facilitate easy withdrawal.
Rear of single front switchgear shall be provided with removable panels/hinged

doors. It shall be possible for one person to remove and fix the removable panel.
All doors shall be provided with concealed type hinges and captive screws.
The withdraw-able chassis housing circuit breakers shall be of the fully draw out type.
Fixed Type Construction
In this type of construction all power connections to the equipment mounted on the
withdraw-able mounting plate shall be of the bolted type. All control circuit
connections to equipment mounted on the withdraw-able mounting plate shall be
carried out through conventional terminal blocks mounted in the respective mounting
plate. It shall be possible to draw-out the mounting plate after unbolting/unscrewing
all the power and control circuit connections to the equipment mounted on the
withdraw-able mounting plate. All feeders except ACB shall be of fixed type
construction.
Interchange ability
All identical equipment and corresponding parts including chassis of draw-out

modules of the same size shall be fully interchangeable, without having to carry out
modifications.
The draw-out contacts shall be only between copper/copper alloy/aluminium faces,

which are silver or tin plated.
Provision of ventilating louvers is considered undesirable. If the Manufacturer

considers ventilating louvers essential, these may be provided. However, all
ventilating louvers shall be provided with fine-screened brass meshes to prevent
entry of vermin and dust.
All dummy cubicles necessary to meet the requirements of this specification shall be
included in the Manufacturer's scope.
Main and Auxiliary Buses
Main Buses & Taps
Switchgear shall be provided with three phase or three phase and neutral busbars.
Busbars shall be of uniform cross section throughout the length of the switchgear,
and up to the incoming terminals of feeder circuit breaker / Moulded Circuit Breaker.
The busbars shall be made of high conductivity Electrolytic grade Copper.
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Busbars shall be provided with at least the minimum clearances in air as per
applicable standards for a 500 V, 3 phase system.
Separate supports shall be provided for each phase of the busbars. If a common
support is provided for all three phases, anti-tracking barriers shall be incorporated.
Auxiliary Buses
Auxiliary buses for control power supply; space heater power supply or any other
specified service shall be provided. These buses shall be insulated, adequately
supported and sized to suit specified requirements. The material of control power
supply buses shall be Electrolytic grade Copper. The material for space heater
power supply buses shall be same as that for the main power buses. Supply
transformer(s), auxiliary busbars and necessary connections to the supply
transformers and associated circuits shall be in the Contractor's scope.
Air Circuit Breakers (ACB)
Air Circuit breakers shall be -
Of the electrically operated, air-break, draw-out type, mounted along with its
operating mechanism on a wheeled carriage moving on guides, designed to align
correctly and allow easy movements.
Of the shunt type.
Provided with an operating mechanism.
Provided with mechanically operated targets to show 'Open', 'Closed', 'Service' and
'Test' positions of the circuit breaker.
Provided with mechanically operated, red 'trip' push button, shrouded to prevent
accidental operation.
Provided with locking facilities in the 'Service', 'Test', and 'Isolated', positions. In test
position the breaker will be tested without energising the power circuits. The breaker
shall remain fully housed inside the compartment in the test position.
Provided with 8 NO + 8 NC potential free auxiliary contacts, rated 10 A at 220 V AC

and 0.5 A (inductive breaking) at 110 V DC.
Provided with 'Red', 'Green', and 'Amber' indicating lamps to show 'Closed' 'Open',
and 'Auto-tripped' conditions of the circuit breaker when breaker operation is
controlled by a control switch.
Circuit breakers shall be provided with the following interlocks:
It shall not be possible to plug-in a closed circuit breaker, or to draw-out a circuit

breaker in the closed position.
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It shall not be possible to operate a circuit breaker unless it is in the fully plugged-in,
test, or fully isolated position.
Whenever required panels, breakers shall be provided with key interlocking device to
prevent paralleling of two breakers.
Closing and trip coil shall operate satisfactorily under the following conditions of
supply voltage variation:
Closing coils - 85 % to 110 % of rated voltage.
Trip coils - 50 % to 110 % of rated voltage.
Following series trip releases with adjustable settings shall be provided:
a) Overload
b) Short circuit and
c) Under voltage
d) Earth Fault
In addition to the adjustable current setting range, short circuit releases shall be
provided with at least four adjustable time delay settings.
Facilities shall be provided for blocking the under- voltage release, if so required at
site.
Each of the forgoing releases shall be provided with a single pole, double throw,
potential free alarm contact.
The breakers controlling motors shall operate satisfactorily under following

conditions:
a) Direct-on-line starting of the specified motor.

b) Breaking load current of the specified motor.
Operating Mechanism
Circuit breaker shall be provided with electrical Power operated mechanism.
Electrical Power operated mechanism shall be of the motor wound spring charging
stored energy type.
All stored energy mechanism shall be provided with mechanical indicators to show
the 'Charged and Discharged' conditions of the spring.
Circuit breakers provided with stored energy operating mechanisms shall be provided
with the following interlocks.
a) The circuit breaker shall not close unless the spring is fully charged.
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b) Shocks, vibrations, or failure of springs shall not operate the breaker or

prevent intended tripping.
Power operated mechanism shall be:
a) Provided with a universal motor suitable for operation on AC and DC control

supplies with voltage variation from 85 % to 110 % rated voltage.
b) Designed to enable a continuous sequence of closing and opening operation
as long as power is available and at least one opening operation on power
supply failure.
c) Provided with emergency manual charging facilities.
d) Provided with facilities for remote panel closing and opening operations as
per breaker module designation and respective control scheme drawing.
Spring charging time for power-operated mechanism shall not exceed 15 seconds.
Power operating mechanism shall be provided with the following additional features.
a) Closing of the circuit breaker shall automatically initiate recharging of the

spring ready for the next closing stroke.
b) The motor shall be mechanically decoupled as soon as the emergency

manual-charging handle is coupled.
Protection Co-ordination
It shall be the responsibility of the Manufacturer to fully co-ordinate the overload and
short circuit tripping of the circuit breakers with the upstream and downstream circuit
breakers/fuses/motor starters, to provide satisfactory discrimination. The selection
shall be in accordance with Type-II Coordination.
Motor Starters
Contactors
Motor starter contactors shall be of the electromagnetic type rated for uninterrupted
duty.
Main contacts of motor-starter contactors shall be of silver plated copper.
Each motor-starter contactor shall be provided with 2 NO and 2 NC auxiliary

contacts.
Insulation class of operating coils shall be Class E or better.
Operating coils of contactors shall be suitable for operation from the control supply
system.
Contactors shall comply with all other requirements of applicable standards.
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Contactors shall be of the double break, non-gravity type.
Direct on-line Starters
Direct on-line starters shall be suitable for Class AC 3 utilisation category as

specified in applicable standards. Unless otherwise specified DOL Starters shall be
used for motors up to and including 22 kW / 30 HP.
Automatic Star-Delta Starters
Automatic star-Delta starters shall comprise three sets of contactors one for the line,
one for the star point and one for the delta, and a timer relay to automatically change
the connections from star to delta.
Start delta starters shall be suitable for AC 3 utilisation category as specified in

applicable standards.
Unless otherwise specified Star-Delta Starters shall be used for motors from 22.1 kW
/30.1 HP up to and including 250 kW.
Thermal Overload Relays
Starter shall be complete with a three element, positive acting, ambient temperature
compensated, time lagged thermal overload relay with adjustable settings. The
setting range shall be properly selected in accordance with the rating of the motor.
Thermal overload relays shall be hand reset type.
Single Phasing Preventers
Single phasing preventer relays shall be provided to protect motors against single
phasing. The relay shall not operate for supply voltage unbalance of + 5 %. The
relay shall operate in the event of a single phase fuse blowing even though the motor
e.m.f. in the concerned phase is of the order of 85%.
After sensing single phasing, the relay shall operate with a time delay of 2 to 3 s. The
relay shall not operate for a 3 phase power supply failure. The relay shall be of the
hand reset type with a hand reset push button. Visual indication for the operation of
the relay shall be provided.
The relay shall be suitable for application to protect reversible and non-reversible
motors. The relay operation shall be independent of the motor kW rating, the loading
conditions prior to the occurrence of the single phasing and rpm of the motor. The
relay shall be of the fail-safe type and shall operate to trip the motor when the relay
internal wiring is accidentally open circuited.
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Switch and Contactor Ratings
Switch and contactor ratings for various motor starter modules shall be selected
based on the following table. Manufacturer shall select appropriate ratings for MCCB
and ranges for thermal overload relays as per TYPE II coordination.
The rated thermal current as well as the rated operational current ratings of the
contactors for the duty class and utilization shall be selected by the Manufacturer
from his available ratings such that the values are not lower than the minimum
current rating specified.
Moulded Case Circuit Breakers (MCCB)
Moulded case circuit breakers (MCCBs) shall be provided for all the outgoing feeders
and motor controls. The MCCBs shall conform to the latest applicable standards.
MCCBs shall be Current Limiting type. The short circuit withstand capacity of the
MCCBs shall be as specified in the Data Sheet for LV Switchgear. If not specified the
minimum short circuit withstand capacity of MCCB shall be 50 kA for 1 s.
MCCBs in AC circuits shall be of triple pole construction arranged for simultaneous

three pole manual closing and opening and for automatic instantaneous tripping on
short circuit and overcurrent. If required power closing device for remote operation
may be provided. Operating mechanism shall be quick- make, quick-break and
trip-free type. The ON, OFF and TRIPPED positions of the MCCB shall be clearly
indicated and visible to the operator when mounted as in service. On the front door
of the feeder Rotary Operating handle with padlocking facility, door interlocking and
door interlock override facility shall be provided.
The instantaneous short circuit release shall be so chosen by the Manufacturer as to

operate at a current in excess of the peak motor in rush current and a range of
settings shall be provided for the Employer’s selection.
Earth Fault release shall be provided wherever MCCB is used as Incomer. All
incomer MCCBs shall be 3Pole + Neutral type (TPN).
Under voltage release shall be provided to all MCCBs.
For feeder rating above and including 63 A upto 629 Amps MCCB shall be used.
Miniature Circuit Breakers
Miniature circuit breakers for use on motor, space heater control circuits shall comply
with the requirements of applicable standards. For ratings from 0.5 A to 63 A MCBs
shall be used. Incomer MCBs shall be 3 Pole+ Neutral Type (TPN)
Current Transformers
Current transformers shall be of the dry type resin cast.
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Current transformer shall have a short time withstand rating equal to the short time
withstand rating of the associated switchgear for one second.
Unless otherwise specified, the minimum performance requirement of current

transformers are as follows:
a Measuring incomer breaker CTs - 15 VA, accuracy class 1.0 and an

instrument safety factor of 5.
b. Measuring feeder wise CTs - 5 VA, accuracy class 1.0 and an instrument
safety factor of 5.
c. Protective CTs-15 VA, accuracy class 5P and an accuracy limit factor of 10.
Not with standing the above clause it shall be the Contractor’s responsibility to co
ordinate the current transformer burden with the requirements of relays, instruments
and leads associated with that particular current transformer.
Test links shall be provided in both secondary leads of the CTs to easily carry out
current and phase angle measurement tests.
All current transformers shall be earthed through a separate earth link on the terminal
block to permit easy measurement of the current transformer insulation resistance.
(CTs built-in with the thermal relays of the contactors are excluded)
Voltage Transformers
Voltage transformers shall be of dry type cast resin.
Unless otherwise specified, the minimum performance requirements of voltage

transformers are as follows:
a. Measuring VTs - 50 VA per phase and accuracy class 1.0.
b. Protective VTs - 50 VA per phase and accuracy class 3.0
Dual purpose VTs - 100 VA and dual accuracy class 1.0 / 3.0 for metering and
protection respectively. VA is per phase.
All secondary windings of voltage transformers including open delta windings shall be
rated for 110 V per phase.
Voltage transformers shall have a continuous over- voltage factor of 1.2 and short
time over voltage factor as follows:
- 1.5 for 30 seconds in case of effectively earthed system.

- 2.6 for 30 seconds in case of non-effectively earthed system.
Voltage transformers shall be complete with suitable rated primary, secondary and
tertiary fuses. Primary fuses shall have a rupturing capacity equal to the rupturing
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capacity rating of the associated switchgear. Fuses shall be provided on each sub
circuit.
It shall be possible to replace voltage transformers without having to de-energise the

main bus bars.
The terminals of VT secondary and tertiary windings, which are required to be

connected to earth, shall be earthed by an isolating link without a fuse.
Relays
The following clauses shall apply to the protective relays.
Relays shall be -
a. enclosed in dust proof flush mounting draw-out type cases.

b. accessible for setting and resetting from the front
Provided with positive acting hand-reset flag indicators visible from the front.
Access to setting devices shall be possible only after the front covers are removed.
Access to resetting devices shall be external to the case.
Auxiliary relays shall be rated to operate satisfactorily between 70 % and 110 %

rated voltage.
Each relay shall be provided with at least two separate voltage free contacts.
The relays shall be digital microprocessor type
Make and type of relays shall be subject to the Employer’s approval.
Control Transformer
Adequately rated single phase, two winding, dry type transformers shall be provided
for supply to the switchgear control and alarm circuits, space heaters in plant
equipment and space heaters in the switchgear and motor winding heating circuits.
Common control transformer rating shall be adequate to cater for all the control
equipment connected across it.
All transformers of 500 VA and above shall be controlled by switches on the primary
side.
Common control transformer shall have fuses on all line leads of each winding and
control transformer in individual module shall have fuse in the line lead of only
secondary winding. The fuses shall be of proper rating to protect the control
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transformers against overloads and short circuits. The neutral or the earth lead shall
have earth link instead of fuses.
Indicating Instruments
All Electrical indicating instruments shall be Electronic type with accuracy of CL 0.5
or better. Suitable for flush mounting.
Ammeters provided on motor circuits shall be provided analogue meters type with a
suppressed extended scale to indicate motor starting current. (Where DOL / Star-
Delta Starter is used as starting device)
Watt-hour meters shall be of the direct reading Static type complete with cyclometer
type dials and reverse running stops.
Indicating Lamps
Indicating lamps shall be:
- of the LED type and of low watt consumption.
- provided with translucent lamp covers of colours 'Red', 'Green' and 'Amber' as
required in the control wiring diagrams.
- Lenses shall be easily replaceable from the front.
Control And Selector Switches
Control and selector switches shall be:
- of the rotary type
- adequately rated for the purpose intended (minimum acceptable rating is 10 A

continuous at 220 V AC and 0.5A (inductive break) 110 V DC
- provided with escutcheon plates clearly marked to show the positions.
Control switches shall be:
- of the spring return to normal type
- provided with pistol grip type handles.
Control switches for circuit breaker control shall be provided with:
- contact development as specified.
- sequencing device
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Wherever required control switches with built-in flashing type discrepancy lamps shall
be provided to control circuit breakers in lieu of the normal control switch, red, green
and amber indicating lamps. The discrepancy lamp shall be replaceable from the
front of the module door.
Selector switches shall be:
- of the maintained contact stay put type(If required). Switches in ammeter

circuits shall have make-before-break type contact.
- provided with oval handle.
Push Buttons
Push buttons shall be:
- of the momentary contact, push to actuate type rated to carry 10 A at 220 V

AC, 0.5A (inductive breaking) at 110 V DC.
- fitted with self reset, 2 NO and 2 NC contacts.
- provided with integral escutcheon plates marked with its function.
- 'Start', 'Open', 'Close' push buttons shall be Green in colour.
- 'Stop' push buttons shall be Red in colour.
All other push buttons shall be black in colour or shall be decided as per application.
‘Emergency Stop' push buttons shall be Mushroom Head Type of the lockable in the
pushed position type and rotate to release and shall be shrouded to prevent
accidental operation. Key shall be required for the operation of the push button if
specified.
Push button switches with a built-in indicating lamp shall be supplied whenever
asked by Employer / Project Manager.
Space Heaters, Panel Illuminating Lamps
Filament type 220 V, 40 W lamps shall be provided in Cable Alleys and wherever
necessary.
Space heaters for switchgear panels shall be:
- suitable for operation on a supply system specified.

- provided with single pole MCB with overload and short circuit release.
- provided with thermostats to cut off the heaters at 45 OC.
- Space Heater shall be provided in each Cable Alley.
Window Type Alarm Annunciators
The alarm annunciation scheme wherever required / specified in control wiring

drawings shall incorporate the following features:
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- visual indication of the fault by means of flashing lit alarm windows.
- audible alarm on the occurrence of the fault.
- Amber / Red facia units to differentiate trip alarm from non- trip alarms. The
facia unit shall be made of LED type indicating lamps.
- acknowledgement of occurrence of fault, incorporating audible alarm

cancellation features.
- resetting the scheme after the faults have been cleared.
- facility to test the healthy condition of the lamps automatically excluding units
indicating existing faults.
- prevention of mall-operation of the scheme when the push buttons are

pressed incorrectly or in a wrong sequence.
- initiation of the complete sequence of audio-visual alarms in the event of a

new fault occurring at the time of accepting an existing fault.
- suitable for operation on a 2 wire, 110 V DC supply with a supply voltage

variation between 80 % and 110 % of the rated voltage.
- suitable for operation for fleeting (15 milli sec. duration) as well as the
persistent faults.
- facility for a separate audio-visual alarm to indicate 'Alarm supply failure'.
- facility for duplicating the audio-visual alarm at a second location.
Window alarm Annunciators shall incorporate the following constructional features:
- flush mounted facia units, each of which is provided with two lamps and a
series resistor and a ground glass plate in front of the inscription.
- plug in relays mounted behind the facia units
- The alarm annunciation scheme shall comprise the following equipment.
- a facia unit complete with relays for each fault.
- a common alarm bell.
- 'Accept' , 'Reset' and 'Lamp Test' push buttons.
- Alarm supply failure, 'Accept' and 'Reset' push buttons.
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Internal Wiring
Wiring inside the switchgear shall be carried out with 1100/650 V grade, PVC,
flexible, stranded, insulated conductor wires. Minimum size of conductor for power
circuits is 4 sq. mm. copper conductor. Control circuits shall be wired with copper
conductor of at least 4 sq. mm. for CT circuits & 2.5 sq. mm. for other circuits
Engraved identification ferrules, marked to correspond with the wiring diagrams shall
be fitted to each wire. Ferrules shall be of yellow colour with black lettering.
Wires forming part of a tripping circuit of circuit breaker shall be provided with an
additional red ferrule marked 'T'.
Spare auxiliary contacts of all equipment forming part of the switchgear shall be
wired up to the terminal blocks.
Wiring for equipment if supplied by the Employer for which the Contractor has to
provide cut-outs (where indicated) shall be provided up to the terminal blocks.
Spare and unassigned modules shall be complete with internal wiring.
Wiring shall be terminated on preferably stud type terminal blocks such that the wires
are connected by cable lugs with nuts & washers/lock-nuts.
Not more than two connections shall be made on any one terminal.
Terminal Blocks
Terminal blocks (both for power and control circuits) shall be as specified for CT and
VT circuits. It shall comprise of finely threaded pairs of brass studs of at least 6 mm
diameter, links between each pair of studs, washers, nuts and locknuts.
The studs shall be securely locked within the mounting base to prevent their turning.
Insulated barriers shall be provided between adjacent terminals.
Terminals for circuits with voltage exceeding 125 V shall be shrouded. Terminal
blocks shall be grouped depending on circuit voltage. Different voltage groups of
terminal blocks shall be segregated.
Terminal blocks shall be adequately rated to carry the current of the associated
circuit. Minimum rating of the terminal block is 10 A..
Terminal blocks for CT secondary lead wires shall be provided with shorting and
disconnecting/Earthing facilities.
Control terminals for external connections shall be suitable for terminating at least
two conductors each of 4 sq. mm. size.
Terminal blocks should be Clip on type.
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Labels
All labels shall comprise black letters of Min. 10 mm height on a white background.
Labels shall be made of non-rusting metal or 3 - ply lamicoid.
Labels shall be properly fixed, with provision to prevent distortion due to expansion.
Earthing
Each PCC, MCC and PMCC shall be provided with an earth busbar at the bottom
running along the entire length of the board.
At either end of the earth bus nuts, bolts and washers shall be provided for bolting
the Employer’s earthing conductor of size and material indicated in data sheets.
Earth busbars shall be supported at suitable intervals.
Positive connection between all the frames of equipment mounted in the switchboard
and earth busbar shall be provided by using insulated copper wires/bare busbars of
cross section equal to that of the busbar, or equal to half the size of circuit load
current carrying conductor, whichever is smaller.
All instrument and relay cases shall be connected to the earth busbar using 1100 V
grade, 4 sq. mm. stranded, copper earthing conductor.
Inspection
Stage and Final Inspection of LV Switchgear Assembly will be carried out at the
Manufacturer’s Works as per need to be assessed from time to time.
Tests
The manufacturer shall conduct all the routine tests as per IS or equivalent BS or IEC
some of them are listed below without any extra charge. The manufacturer shall
furnish valid Type test certificate for equipment, if not shall conduct Type tests at no
extra cost.
Type Tests
Contractor shall submit valid Type test certificate for the following tests:
Temperature rise test on power circuits.
Short time current tests on power circuits.
Routine Tests
Following routine tests shall be conducted at Manufacturer’s work.
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Rated Primary Injection for all power circuits
High voltage test.
Rated Secondary Injection test for electrical control, interlock and sequential
operation tests.
Verification of wiring as per approved schematic.
Mechanical operation test.
Test Reports
The Contractor shall completely assemble with all the associated equipment
including bought-out items mounted and wired and test the switchgear as per
relevant standards. All Routine Test shall be carried out as per relevant standards in
presence of Employer / Consultant.
Certified copies of all Type Test Certificates shall be furnished along with Routine
Test Report for the Employer’s approval at least one week prior to the Final
Inspection.
Copies of the Test Certificates shall be submitted for the Employer’s / Project
Manager’s approval before despatch of the Switchgear in case inspection / testing is
not done in presence of Project Manager’s / Employer’s Representatives. Bound
copies of complete test results as specified in the distribution schedule shall be
furnished with the switchgear. These shall include complete reports and results of
the routine test as also certified copies of type test carried out on equipment of
identical design.
Drawings & Data
Information as per Data Sheet shall be supplied along with Offer.
The Manufacturer shall submit following drawings for approval.
a) Complete assembly drawing of the Switchgear showing G A, Plan, Elevation,

Typical Sectional Views and Location of Cable compartment, busbar
chamber, metering and relay compartment and terminal blocks for external
wiring connection. Foundation plan showing location of foundation channel,
Anchor bolts and Anchor, Floor Plans and openings for cables etc.
b) Schematic diagram for control and supervision of the switchgear.
c) Bill of Material.
d) Mounting / Erection details
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Notes:
1) No SFUs shall be used.
2) Up to 62A MCB shall be used.
3) Including and above 63A up to 629A MCCB shall be used.
Including and above 630A, EDO type ACBs shall be used.
Suitable number of spare feeders shall be provided in each MCC.
Contractor shall submit all details of MCCs and Sub MCCs for Employer’s / Project
Manager’s approval.
The switchgear shall be designed for installed load.
For Motors up to and including 22 kW, DOL Starters shall be used unless specified
otherwise.
For motors above 22 kW up to 250 kW Star-Delta Starter shall be used unless

specified otherwise.
DATA SHEET – FOR LV SWITCHGEARS (MCC, ACDB etc.)

1.0 General Construction of

Switchgear
a) Applicable Standards IS/BS/IEC
b) Applicable for TA Auxiliaries
c) Type & Construction Fully Compartment

type, Extensible, Dust
& Vermin Proof
d) Degree of Protection IP 54
e) Material of Construction CRCA Sheet Steel
f) Material thickness
Front / Rear Door of LV Chamber 2 mm
Structural Members 2.5 mm
(Vertical/Horizontal)
Gland Plates 3 mm
Partition for LV Chamber 1.6 mm
g) Painting type Powder Coated
h) Paint Shade
Exterior Siemens RAL 7302
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Switchgear
Interior Bright White
i) Cable Entry
For incoming cables Top / Bottom
For outgoing cables Top / Bottom
j) i) Acceptable temp rise inside the 40 ºC
panel above ambient temp.
ii) Ref. Ambient temp 27 ºC
iii) Altitude 1540 m from Mean
Sea Level
k) Socket / Space heater / internal Required
cubicle lighting
l) Control Supply for spring charging 220 Volt ± 10%
motor
m) Control Supply for Closing and *
Tripping Coils, Annunciators,
Indicating Lamps, And luminous
push buttons
2.0 Bus Bars
a) Material
3 Phase and Neutral Electrolytic grade
Copper (Purity should
not be less than 95%)
b) Voltage Rating 400 Volt ± 10%
c) System Frequency 50 Hz ± 5%
d) H V Power Frequency withstand 2.5 kV for 1 Minute
test voltage
e) Rated Current
i) Continuous *
ii) Short time 50 kA for 1 s
f) i) Maximum limit of temp. 850 C
ii) Thermal Class Class A
g) Sleeving Heat Shrinkable PVC
Colour Coded
3.0 Air Circuit Breaker
a) Insulation Voltage 690 Volts
b) Type Electrically operated,
draw-out type
c) Type of Trip Required Shunt
d) Rated Voltage, Current 400 Volts / *
e) No. of Poles 3 Pole and Neutral
Contactor for Incomer
f) Insulation level 2.5 kV for 1 Minute
(1 minute power frequency
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Switchgear
withstand voltage)
g) Electromechanical Interlocking No
required
h) Operating Mechanism Spring charged
Mechanism
Electrically Operated
Stored energy type.
i) Spring charging Motorized
4.0 Current Transformers
a) Type Air Core Epoxy Cast
Resin CTs
b) Mounting On the Bus Links
c) CT Ratio *
d) Burden 15 / 5 VA (Minimum)
e) Class As required
For Feeders above 5 kW / 6.7 HP Three CTs with Ammeter Selector Switch
shall be provided and for feeders below 5 kW / 6.7 HP direct acting Ammeters
can be provided.
5.0 Selector Switch
a) Type Rotary Type
b) No. of positions As per requirement
c) Contact rating 10 A - 220 V AC,
0.5 A - 110 V DC.
6.0 Starters
a) Starter type For motors up to and
including 22 kW
Direct On Line type.
For motors above 22
kW up to 250 kW Star
Delta type.
b) Class of duty AC – 3
7.0 Moulded Case Circuit Breaker
a) Type of MCCB Current Limiting Type
b) No. of Poles Required 3 Pole with Neutral
Link
c) Power closing device required As required
d) Type of Releases As specified in
technical
specification.
e) Accessories & Auxiliary As required
f) Short circuit withstand capacity Same As that of
busbar rating of
respective panel
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Switchgear
8.0 Fuses (Control)
a) Type HRC
b) Voltage 400 / 220, V AC
c) Rating As per requirement.
9.0 Contactor
a) Type Air Break Contactor
b) Rated voltage of main contacts 400 Volts
c) Rated duty AC 3
d) No. of auxiliary contacts required 2 NO + 2 NC
10.0 Ground Bus

a) Material Electrolytic grade
Copper
b) Size 25 x 10 mm
11.0 Push Button
a) Type Flush Mounted &
Shrouded
b) Rating 10 A - 220 V AC,
0.5 A - 110 V DC,
c) No. of contacts required 2 NO + 2 NC
d) Emergency Push Button Mushroom Type
e) Colour As per requirement
12.0 Indicating Lamps
a) Type LED Type
b) Colour As required
c) Min. Lumen Output 300 Lux
13.0 Indicating Meters
a) Type Digital for incomer
feeder
Analogue Moving Coil
type with extended
scale for starters.
b) Dial Size (Minimum in case of Min. 50 x 50 mm
Analogue meters)
c) Accuracy Class Class 0.5 or Better
14.0 Relays
a) Digital Microprocessor based Required
b) Type of Relay *
i) Over current *
ii) Short Circuit *
iii) Under Voltage *
c) CT Ratio *
d) Class of Accuracy *
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Switchgear
15.0 Single Phase Preventer (SPP) For motors above
than and including 75
kW
2401-16 COMMISSIONING SPARES
Contractor shall supply the commissioning spares. List of spares to be supplied shall
be submitted.
Spares
The spares for two years normal operation shall include, but not limited to following :
(to be finalised later)
For each Turbine
1) 1 set of journal bearings

2) 1 set of thrust bearing
3) 1 set of gasket and fasteners
- Gasket for governor valve
- Gasket for emergency stop valve
- Packing for lubricating oil filters
- Packing for control oil filters
4) 1 set of pressure switches
5) 1 gland condenser fan
6) 1 set of speed pickups
For each Gear box
1) 1 set of bearing
For each Alternator
1) 1 set of bearings
2) 1 set of seals
2401-17 ONLINE UPS FOR TURBINE AUXILIARIES
Quantity: 2 Nos.
General
This specifications covers in brief the technical requirements for the On Line
Uninterrupted Power Supply System
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It is not the intent to specify herein all the details pertaining to the design, selection of
material/equipment, procurement, manufacture, installation, testing and commis-
sioning, however, the same shall be of high standard of engineering and shall comply
to all currently applicable standards, regulations and safety codes.
Codes and Standards
The supply, installation, testing and commissioning of any equipment / materials /

accessories, etc. shall comply with the latest applicable standards and codes of
practices.
Specific requirements
The UPS shall be capable to deliver to non-linear loads.
It should be capable to handle high crest factor loads.
The design should conform to latest IEC, ISO standards.
It shall have low harmonic contents, DC ripples.
It should be maintenance free.
It shall have self diagnostic features and display.
It shall have low noise.
It should be capable of taking 10% overload continuously.
Data Sheet – A For Online UPS
1) Input Voltage : 400 V AC ± 10%, 3 phase
2) Input Frequency : 50 Hz ± 5%
3) Output Voltage : 220 V ± 1%
4) Output frequency : 50 Hz ± 1%
5) Rated capacity : 10 kVA, 220 V
6) Overload capacity : 110% continuous

125% for 10 minutes
7) Total harmonic contents : less than 2%
8) DC ripple : less than 1%
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9) Enclosure : IP 41 or better with integral forced air

cooling fans
10) Input harmonic filter : If required, to bring harmonic

contents to specified limits.
11) Fault diagnostic Unit, Data logger : Required
12) Back up time : 3 hours
2402 COOLING TOWERS, AUXILIARIES AND PUMPS
2.1 General
This specification is intended to cover the design, manufacture, delivery, erection,

testing and commissioning of Induced draught cooling towers, auxiliaries and pumps
Supplies and services shall be rendered in conformity with proven engineering

principles, taking into account the current state of the art technology. The
requirements of the contract must be fulfilled in its entirety.
The supplies and services within the scope shall be rendered inclusive of all
appliances and interconnecting arrangements with other supplies necessary for
installation of all accessories for satisfactory operation and maintenance.
The scope of supply and services shall include all necessary work and supply of
equipment and material whether mentioned in these specifications or not, but which
are necessary for the satisfactory, reliable and safe operation and maintenance and
required for achieving guaranteed performance of the plant.
Any equipment, device or material even if not included in the original bid but found
necessary for the safe and satisfactory functioning of the unit under the bid shall be
supplied, erected and commissioned by the Contractor at no extra cost to the
Employer as though such equipment, material or work were originally specified and
formed part of the scope of work.
2.1.1 Codes and Standards
The design, material, construction, manufacture, inspection, testing and performance

of Induced draft cooling towers and pumps shall comply with all currently applicable
statutes, regulations and safety codes in the locality where the equipment will be
installed. Nothing in this specification shall be construed to relieve the Contractor of
this responsibility. The equipment shall also conform to the latest applicable Indian
and/or British standard and publications of the Cooling Tower Institute and the
Hydraulic Institute.
2.1.2 Performance test
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The Contractor shall conduct the performance test on the tower after commissioning
of the tower and pumps when the atmospheric condition and heat load are close to
the duty condition specified. It is the responsibility of the Contractor to conduct the
test and also supply on land all instruments with calibration certificates and other
equipment required for the testing of the tower. Contractor shall furnish, immediately
after award of contract, detailed test procedures and suggested period for testing for
review and approval by the Employer.
2.1.3 Work schedule
The earliest feasible schedule to be given by the Contractor. Along with the bar chart
including major activities for supply, erection and commissioning. The quality
assurance plan for the major equipment shall be furnished.
2.2 Scope of supply
a. Three cells of cooling tower of 1400 m3/h capacity each, shall be

considered to handle 4200 t/h water.
b. Water distribution system, entire fills and support.
c. Fans.
d. All support steel structure.
e. All associated mechanical, electrical and instrumentation jobs within

battery limits.
f. All piping, valves and fittings within scope of work.
g. All civil works such as RCC basin, foundations, pump house etc.
h. Fans shall be of open type, multi blade construction with the blades of
aerofoil section. Fan blade shall be of FRP construction. These shall
be of easily removable and adjustable pitch type. Blade shanks and
hubs shall be suitably insulated to prevent electrolyte corrosion.
i. Prime mover for the fan driver shall be an AC electric motor of squirrel
cage induction type
j. Cooling water recirculation pumps to supply cold water for condenser and
back to the top of cooling tower. Three pumps each of capacity 1400
m3/h and head of 34 m shall be supplied.
k. Auxiliary water pumps for alternator air cooling and oil cooling. Two
pumps each of capacity 500 m3/h and head of 20 m shall be supplied.
2.2.1 Scope of erection and commissioning
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a. Mechanical/Electrical/Instrumentation and controls
All items covered under scope of supply including base plates,

foundation bolts, anchor boxes, etc.
b. Consumables
Specifications including brand names and quantities of all consumable

materials such as lubricants, flushing oil, hydraulic fluids etc required
for start -up, initial filling, commissioning and performance tests and
yearly requirements of the same for normal operation are to be
submitted by the Contractor.
However, supply of all consumables required for start-up,

commissioning, initial filling and performance tests is included in the
scope and shall be supplied by the Contractor at appropriate time.
c. Spare parts
A minimum requirement of spare parts sufficient for the two years of

normal trouble free operation shall be listed and priced by the
Contractor in the spare parts schedule.
In addition to the above spares the Contractor shall also supply spare
parts (commissioning spares) along with this main equipment as per
his experience, for replacement of damaged or unserviceable ones
during the execution of the project at site, to avoid delay in the project
schedule. The Contractor is expected not to fall back on the Employer
from his stocks (for such replacements) which are meant for two years
of trouble free operation after the equipment are taken over. The
owner reserves the right to Employer any unutilised commissioning
spares.
d. Special maintenance tools and tackles
Two sets of special tools and tackles required for operation

maintenance, inspection and repair neatly packed in steel boxes
complete with instructions for the cooling tower, pumps and all other
equipment covered in this scope of work.
2.3 Make up water pumps
These pumps shall be installed in the existing service water pump house of the sugar
factory. These pumps will supply water from overflow collection tank of clarifier to
cooling tower basin for initial fill up as well as to meet make-up requirements.
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Two Horizontal centrifugal pumps, each of 250 m3/h capacity at 20 m head shall be
installed. These pump units shall be complete with electric motor, coupling guards,
base frame, starter, etc.
Necessary valves, piping both suction connection from the clarifier overflow tank and
discharge pipe upto cooling tower basin is included in the scope of supply.
2.4 Circulating water pumps
These circulating water pumps shall circulate water from cooling tower basin to
condensers of double extraction condensing type turbo-alternators and back from
condenser to top of the cooling tower water distribution system. There are two
condensers.
Three horizontal centrifugal pumps, each of 1400 m 3/h capacity to develop a head of
34 mwc. Out of the four pumps, three will be in operation and one will be a standby
unit. All pump units shall be complete with electric motor, coupling guards, base
frame, starter, etc.
Scope of supply shall be upto inlet flange/header of condenser and from outlet flange
of condenser to the top cooling tower. Required isolation valves, non-return valves,
local pressure and temperature gauge, etc shall be provided.
2.5 Auxiliary cooling water pumps
These pumps shall be installed in the pump house near cooling tower to supply
cooling water from cooling tower basin to oil coolers of turbine and air coolers of
alternator of co-generation power plant. The return line from respective coolers or
common header from powerhouse shall be connected back to cooling tower.
Two horizontal centrifugal pumps, each of 500 m 3/h and develop a head of 20 m. Out
of two pumps, one will be in operation and one will be a standby unit.
Both pump units shall be complete with electric motor, coupling guards, base frame,
starters, etc.
Scope of supply of valves, piping, fittings, etc include up to inlet flange/header of

respective consumers of powerhouse turbo-alternator and return line up to cooling
tower. Required isolation valves, non-return valves, local pressure and temperature
gauges, foundation bolts, etc shall be included in the scope of supply.
2.6 Cooling Water Piping
All piping shall be in Contractor’s scope of supply. This shall include cooling water for
the turbine, instrument compressor and other bearings.
Piping supports, gaskets, fasteners, various nozzles, flanges and valves shall be
supplied to match the total requirement of water.
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2.7 Design criteria for piping
All suction pipes shall be designed for velocity not exceeding 1 m/s and
delivery/discharge piping for velocity not exceeding 2 m/s.
All piping shall be designed to withstand at least double the working pressure in the
system.
2.8 Design requirement of cooling tower
The equipment offered shall be capable of cooling the rated capacity of water
through the specified range at the design wet bulb temperature. The range of cooling
shall be 12 ºC from 42 ºC to 30 ºC. The approach shall be 5 ºC maximum.
Each cell shall be identical with the other cells of the tower in all respects. The total
heat load and flow shall be equally shared amongst the number of operating cells.
The structure shall be designed for wind and other loads as per BS or equivalent.
The equipment shall be designed for the continuous operation throughout the year.
The specified design wet bulb temperature of 24 ºC includes the necessary re-
circulation allowance. Hence Contractor shall design his cooling towers based on this
design wet bulb temperature without considering further re-circulation allowance.
Contractor shall offer a fan diameter which has already been supplied and installed
by
him in other cooling towers and has been in satisfactory operation for at least two
years. List of similar installations should be furnished by Contractor.
While arriving at the air flow through the tower, due consideration shall be given to
heat carried away by evaporation and enthalpy correction of altitudes. Contractor
shall furnish detailed heat balance calculation in support of the air flow through the
tower. Contractor shall also furnish the basis of the enthalpy values indicated.
Contractor shall take into account the effect of heat recovery, because of provision of
recovery stack, while arriving at the fan power consumption. Contractor shall furnish
along with the bid, detailed calculations for the guaranteed power input to fan and
this should clearly be indicated as how the effect of recovery stack is considered. No
credit will be given during bid evaluation if a Contractor indicates higher power
consumption and claims that the heat recovery is not considered.
For the fans Contractor shall furnish his or his sub Contractors experience list clearly
indicating fan diameter, kW rating, material of construction, year of commissioning
and user’s satisfactory report.
The motor rating of the cooling tower fans shall be at least 125 % of the fan power
requirement at the motor output shaft to take care of any changes in tower loading or
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fan performance at a later date, Contractor shall furnish calculations for arriving at
the motor rating.
2.9 Maintenance requirement
Suitable access shall be provided for maintenance of drift eliminators.
Suitable access door shall be provided on each side for approach to the inside of the
tower. Fan stack shall also be provided with inspection door.
All isolation valve shall be easily accessible.
Suitable handling facility shall be provided for handling mechanical equipment (i.e.
fan and other accessories). The handling equipment shall be a part of the cooling
tower and shall be self contained including all necessary hoist, chains etc., to
erect/dismantle mechanical/electrical equipment and transport them from fan stack to
ground and vice versa. Contractor shall demonstrate use of this handling facility
immediately after completion of tower erection.
2.10 Electrical scope of work requirements
Contractor will need to distribute power to all drive of controls in his battery limits and
provide for all required switch gear, fuses, relays, main isolator, etc.
All motors shall be squirrel cage induction motors suitable for direct on line/star delta
starting as required. Motors shall conform to the enclosed specification.
Contractor’s scope shall include routine tests on all the motors and furnishing type
test certificates conducted on similar motors.
2.11 Features of construction
The cooling tower shall be complete with tower, basin foundation and mechanical
equipment as described below, the tower shall be of double inlet flow type of
construction. The tower shall be of induced draft type with the fans located on top of
the tower. Contractor should give all relevant data, drawings, design to Employer for
civil construction. If Contractor, is bidding for any other type of cooling tower, he
should furnish full details of the same along with drawings, literature, etc.
a. Casing
Casing of field erected towers shall be of RCC/FRP. External casing as well

as partition walls in between cells shall be provided with air tight access
doors.
b. Inlet Louvers
The water loss in the louver openings shall be prevented with proper slope,
width, spacing and tightness of louvers. Louvers must be properly designed to
give uniform distribution of air with minimum pressure drop and must be able
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to withstand corrosive atmosphere. Slip fit type louvers may be provided for
access to interior of tower.
c. Fill and Fill Supports
Fill shall be of V shaped bars made of extruded PVC supported on SS:304.

Splash bars shall be adequately supported to prevent staging and damaging.
The tower shall be levelled so that water will be uniformly distributed over the
splash bars and does not cause channelling.
d. Supporting Structure
Hot dipped galvanised steel supporting structure shall be designed to

withstand the wind or earthquake loads, dead load such as weight of the
tower and circulating water and line load and live load.
The supplier cal alternatively quote for RCC structure.
e. Drift Eliminators
The drift eliminators shall be designed to keep the drift loss to a maximum of
0.1 % of the circulation rate. The air pressure drop across the eliminators
shall be kept to a minimum by providing a proper number of air flow direction
change across the eliminators, the water collected in the eliminators shall be
returned to the tower basin and shall not mix with the discharge air stream,
eliminators shall be multi-pass herringbone type or angular honey comb
arrangement.
f. Water Distribution System
The hot water shall be distributed to the fill through distribution basins through
distribution nozzles. Hot water shall be distributed to the basin by steel pipes.
The water shall be equally distributed among the working cells by having
control valves in the supply pipes. These shall also serve as isolating valves
for the cells. The control valves shall be easily accessible for any
maintenance work.
g. Recovery Stack
Recovery stack shall be of proper shape to improve the fan performance and
of FRP construction. The height of the stack shall be sufficient to recover the
velocity and discharge the humid air at a sufficiently high level to minimise re-
circulation. The minimum clearance between the stack and fan blades shall
be maintained along with entire periphery of the stack to prevent the rubbing
of fan blades while rotating.
The height of the FRP stack shall be sufficient to recover the velocity and
discharge the humid air at a sufficiently high level to minimise re-circulation.
The minimum clearance between the stack and fan blades shall be
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Page - 99 / 115
maintained along with entire periphery of the stack to prevent the rubbing of
fan blades while rotating.
h. Fan Deck
The fan deck should be sturdy in construction to transmit the live loads to the
frame to support a stack and act as an access platform for the mechanical
equipment and distribution system.
i. Internal Walkways
Walkways with platform and suitable hand rails shall be provided inside the
towers. The draft eliminators shall be easily accessible from these walkways.
j. Hardware
The hardware used shall be a combination of hot dip galvanised steel, naval
brass, phosphor bronze, silicon bronze and stainless steel. Generally all
hardware material above fan deck level shall be hot dip galvanised steel and
rails shall be SS 304 and nails shall be screw shank type. All hardware item
to be SS:304.
2.12 Mechanical equipment
Fans
Fans shall be of open type, multi blade construction with the blades of aerofoil
section. Fan blade shall be of FRP construction. These shall be of easily removable
and adjustable pitch type. Blade shanks and hubs shall be suitably insulated to
prevent electrolyte corrosion.
Fan Drives
Fan drives shall be with:
a) Drive with Reduction gear
The gears shall be of spiral bevel, helical or worm type. The gear reduction
may be of single stage or multi stage. All gear drives shall be of enclosed type
and shall operate in oil bath. Remote oil level indicators, fill and drain lines
shall be provided. The service factor of the gear drive with electric motor as
the prime movers shall be as follows: 2 for spiral level and helical for
intermittent services. For worm gear drive the service factor shall be not less
than 1.7.
b) The drive shafts shall have flexible coupling at both driving and non driving
ends. This shall be of hollow hot dip galvanised carbon steel. The flexible
coupling bushing shall be rubber. Drive shafts shall be dynamically balanced.
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c) All exposed moving parts of the drive shall have metallic safety guards.
Prime Mover
The fan driver shall be an AC electric motor of squirrel cage induction type
conforming to attached specifications and Data Sheet.
Accessories
The following accessories shall be provided :
Ladder
An steel ladder shall be provided for each recovery stack.
Distribution Basin Cover
The hot water distribution basin shall be provided with a suitable cover to avoid direct
sunrays falling on the distribution through or basin, to minimise algae growth and to
prevent choking of distribution nozzles from external falling objects.
Hand Rail
Double hand rail of hot dip galvanised steel pipe (32 mm nominal dia) shall be
provided on all open sides of the fan deck and distribution basin cover.
Fan Guards
Each fan guard shall have a suitable wire mesh safety guard.
Locally mounted instruments
The following instruments shall be supplying by Contractor:
- Temperature gauge on cold water outlet pipe near basin

- Temperature gauges on the hot water inlet to each cell
- Float switches to indicate high/low levels in the basin
- All necessary instruments required for testing the cooling tower shall be
loaned by Contractor
- Vibration limit switch to stop the fan on excessive vibrations
- Foundation bolts
2.13 RCC basin
Contractor shall provide all relevant data, designs, and drawings to the Employer for
Civil and structural construction. The complete construction is by the Employer. Also
Contractor shall give the data for RCC staircase upto fan deck slab.
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The Contractor shall consider in his design Hot dipped GI structure and RCC basin
for cooling tower with a common outlet channel. The structure shall be designed as
per BS or equivalent. Cooling tower basin shall be provided with partition for isolation
purposes. Basin shall be water tight without the use of any fillers, paints or sealing
compounds.
2.14 Piping, valves and specialties
Piping upto 150 mm shall be as per IS:1239. From 150 mm to 600 mm it shall be of
IS:1972. Above 600 mm piping shall be fabricated from plates of BS in accordance
with IS:3539. Joints upto 65 mm shall be screwed. Joints 80 mm and above shall be
butt welded or flanged.
Valves upto 65 mm shall be of bronze, to IS:778 with the ends screwed to IS:554.
Valves of 80 mm and above shall be of cast iron with ends flanged. Scope will in-
clude supply & installation of supply & return headers at cooling tower. P & I with
valves to pumps; supply & return cooling water lines with required supports, ground
protection, bends, gauges etc supply & return headers near turbine condenser. Es-
timated distance from condenser is 200 m. Contractor to give takeoff for per 10 m.
2.15 Materials of construction
All materials of construction shall be of tested quality. These shall be free from
defects, imperfections, of latest manufacture and shall be of certified quality for
physical and chemical properties. Materials shall be of BS, ASTM, IS or any
equipment standard. Liberal factor of safety shall be used in selecting the materials.
2.16 Tests and Inspection
Performance Test
Field erected units after complete erection and commissioning shall be field tested for
performance. The test shall be conducted at a time when the atmosphere conditions
correspond to as soon as possible the design conditions. The test shall be conducted
in accordance with the standard procedure for acceptance test of Cooling Tower
Institute, USA.
Visual Inspection
After completion of work, equipment shall be offered for visual inspection by

Employer and/or his representatives. Any work or competent not in accordance with
the specification and approved drawings shall be redone or replaced to the
specification of the inspector. Stage inspection if specified shall be offered to improve
the quality of the final product.
Material Test Certificates
Test certificates of the materials of the various components for the cooling tower shall
be furnished.
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Welding Test
All welding procedure and welders test certificates shall be offered for Employer’s
approval if specified. All welding shall be performed by shielded electric area, gas or
other approved methods. All welding shall conform to BS and the qualification of the
welding operators shall be at least equal to the requirement of BS.
Painting and Protections
All parts which are subjected to wetting and drying alternatively shall be painted with
three water proof coats as per relevant standards.
All exposed steel and cast iron surface shall be given three coats of rust and
corrosion resisting paint.
MCC
Quantity: 2 Nos.
The MCC shall be as per the specifications given under clause 2401-15
2403 AIR COMPRESSOR SYSTEM
Quantity: 2 Nos.
3.1 Scope of supply includes:
- Two (2) air compressors (1 working + 1 standby) reciprocating air

compressors of required capacity.
- One air receiver
- One heat less air drier with twin absorption tower
- Necessary instrumentation and local control panel
- Compressor air piping, valves, piping, fittings, supports etc
3.2 Codes & Standards
After cooler - IS:4503/TEMA ‘C’/’R’
Air compressors & exhausters positive - IS:5456-1969

displacement type testing of
Air compressor plants with operating - IS:6206-1971

pressure up to 10 bars
Pipes - IS:1239 Part I duty medium/heavy
* Bidder to specify

Page - 103 / 115
Fittings - ASTM B16.9-Butt Welded

ASTM B16.11-Srewed & Socket
Flanges - DIN/ANSI 16.5/IS:6392

BOLTS/NUTS IS:1363
3.3 Design Requirements
The air compressor will be installed on permanent/stationary foundation or shall be

skid mounted in the plant room. The compressor, motor, pulley, V-belt guard, after
cooler, moisture separator, air receiver, etc may be mounted on a skid which shall be
anchored to the floor. If the compressor is to be installed on stationary foundation,
the structural design of the foundation, anchor bolts, first and final grouting shall be in
the scope of the Contractor.
3.4 Air Compressor
Reciprocating non lubricating type two compressors, complete with moisture

separator, air receiver, pressure switch, drive motor, safety valve, etc for supplying oil
and moisture free air for instrumentation and control. The compressor shall be with
automatic unloading arrangement and pressure switch to maintain requisite pressure.
Out of two, one compressor shall be operating and one standby. Automatic start
arrangement shall be provided to automatically switchover the standby compressor in
the event the running compressor suddenly stops.
Capacity and pressure of each compressor shall be suitable to operate the instru-
mentation and control system.
Compressor fitted with automatic mechanical air governors which enable them to
load and unload at pre-adjusted cut-in and cut-out pressures.
3.5 Crosshead
Preferably be provided with replaceable white metal/Aluminium lined shoes to save

Crosshead guide wear.
3.6 Valve assemblies
Low clearance, low lift, automatic double dampened valves, two cushion plates with
spring plates to reduce shocks of valve plate impact on valve body and give longer
life.
3.7 Bearings
Two main bearings, white metal lined thin walled main and big end bearing,
preferably extra main bearing on belt wheel side for taking belt pull load, extending
bearing life.
* Bidder to specify

Page - 104 / 115
3.8 Intercooler
Conforming to BS/TEMA heat exchanger standard, with shell & tube type, floating
head tube bundle for easy removal, with efficient moisture separator. Drain valve for
removing moisture. Flanged connections for water inlet and outlet. Additional ports
for de-scaling chemical circulation be provided.
3.9 Suction Filter
In closed metallic box with replaceable/cleanable filter element. Preferably to be

provided with suction filter choking indication by vacuum valve. Filter is of dry type
with silencing arrangement.
3.10 Foundation bolts
Foundation bolts of suitable size and according to structural strength requirement

shall be provided along with compressor.
3.11 Controls
Following control switches should be provided :
1. High discharge pressure/temperature cut-out switch.

2. Oil low pressure cut-out switch.
3. Capacity control
Capacity control should be on pneumatic circuit of copper/PVC tubing rigidly secured

upto suction valves on both the sides. Pneumatic circuit opened and closed on the
logic pressure switches set with minimum differential pressure of 0.2 kg/cm 2 (g)
through solenoid valves-three port, two way. The air required for unloading shall be
taken from the air receiver.
3.12 After cooler/Moisture Separator
Horizontal, water/air cooled shell and tube type, removable tube bundle types after
cooler for cooling discharge air 5 0 above outlet cooling water temperature. If to be
mounted separately on case foundation, necessary foundation bolts are to be
supplied complete with moisture separator, manual/auto drain trap.
The heat exchanger should conform to the BS or TEMA ‘R/C’ design standards and
shell with IS:2825 standard for unfired pressure vessels. The after cooler heat
exchanger shall preferably of water through tubes for easy cleaning and
maintenance.
The moisture content of the outlet air shall not be more than 0.1%.
3.13 Electrical
MCC shall be as per rthe specifications under clause 2401-15
* Bidder to specify

Page - 105 / 115
The starter panel shall be front operated, front maintained, floor mounted, self
supporting sheet steel structure of thickness 2 mm minimum duly painted with shade
631 of BS.
The compressor MCC shall be in the plant room. The electrical cable from MCC to
the compressor panel shall be considered in Contractor’s scope.
3.14 Air receiver
Air receiver shall provide a fly wheel effect, that is, it shall meet the varying demands
without compressor regulation functioning incessantly.
The Air Receiver shall also condense and trap as much as possible the moisture in
the compressed air and also to let oil and other impurities settle down.
Manufacture should submit his design and drawings for approval clearly indicating
corrosion allowance.
Air receiver shall be manufactured according to BS but the design pressure shall be
assumed as maximum working pressure plus 10 %. Receivers shall be regarded as
Class II vessels.
3.15 Mountings
Each air receiver shall be provided with a safety valve preferably of the direct spring
loaded type and shall be so constructed and adjusted so as to permit the air to
escape from the air receiver without increasing the pressure beyond 10 % above the
working pressure
A drain valve or cock shall be provided either for manual or automatic operation, at a
point for enabling the draining of the condensate.
Pressure gauge shall be fitted to each receiver. The bourdon type of gauge
conforming to BS is recommended. The dial shall be graduated in bar and graduation
shall be from zero to not less than one-and-half times, and not more than twice the
design pressure of the receiver.
Fusible plugs may be fitted to safeguard the installation in case of excessive rise in
temperature due to fire. The position of fusible plug where fitted shall be such that
discharge of the plug will not do injury to any person.
3.16 Inspection and Tests
Inspection
The requirements of inspection shall be as per BS.
Hydraulic Test
* Bidder to specify

Page - 106 / 115
Every receiver shall be tested at the manufacturer’s works by hydraulic pressure to

1.5 times the design pressure. While under pressure the air receiver shall be struck
with a hammer on both sides and close to welded seams and a thorough
examination made. The pressure shall be maintained for 10 minutes.
Installation
Proper foundation details for the receiver and the support shall be provided by the
Contractor.
3.17 Surface Treatment
An appropriate surface protection shall be given inside and outside of air receiver to
prevent corrosion.
3.18 Compressed air piping / tubing
Complete air supply piping for instrumentation and controls and any other use, if
required shall be in the scope of Contractor.
Complete air supply piping, including but not limited to valves, fittings, moisture sep-
arator, supports, vents, drains etc, from the compressor to the end users shall be in
the scope of Contractor.
2404 AIR CONDITIONING AND VENTILATION SYSTEM
4.1 General

testing and commissioning of Ventilation system for various control rooms and cabins
and Air Conditioning System for CENTRALISED Control Room are included in the
scope of supply

* Bidder to specify

Page - 107 / 115

4.2 Codes and Standards
The design, manufacture, testing and performance of the Ventilation system and Air
Conditioning System shall comply with the requirements of applicable
British/American/ Indian Standards such as those indicated in the respective sections
of this specification, and those standards specified therein, in so far as they apply.
The Contractor should specifically mention relevant codes.
4.3 Performance test
After completion of erection, the plant shall be trial operated and performance tested
as detailed in the relevant sections of the specifications. The Contractor may note
that the performance parameters guaranteed shall be considered in the bid
evaluation.
The Contractor shall furnish these and other parameters as required in the
performance data sheets.
4.4 Work schedule
4.5 Scope of work
The ventilation system will generally include the following for various control rooms
and cabins which are included in the scope of supply.
Control rooms and cabins – Aluminium or steel frame construction, pre-fabricated,

with suitable glass panels, doors. Ventilation system shall be supplied and installed
by the Contractor in the power house building as required.
The ventilation system will generally include:
- Tube axial fan
- Propeller type exhaust fans
- Roof extractors
- Fresh air filters
- Pressurised ventilation system for MCC and PCC room and turbo-alternator
room
* Bidder to specify

Page - 108 / 115
- Dilution ventilation system for battery room
- Exhaust ventilation system for power house building
- 11 kV HT room
The area of each room where positive supply ventilation system to be provided is as
given below
11kV HT switch gear room - 8m width x 18m length x 5m height

PCC & MCC room at ground level - 8m width x 36m length x 4.5m height
PCC & MCC room at 4.5m elevation - 8m width x 12m length x 4.5m height
The detail architectural drawing can be obtained from the Employer, for duct routing,
opening for grills and blower location.
The Contractor shall submit detail drawing for ducting, diffuser/grills, and blowers
along with the offer for approval.
4.6 SCHEME
A forced ventilation system is proposed to maintain the positive pressure in 11kV

switchgear room, PCC & MCC rooms. The temperature inside the room shall be
maintained within the range as specified in the relevant norms. The contractor shall
take into consideration the equipment inside the room, furniture, no of windows with
glass, persons working in the area for calculating the load. Contractor has to submit
detail calculations to consultants for their approval.
Exhaust Ventilation system shall be provided for compressor room, cable gallery, TG
hall, battery room, toilets and pantry. The Contractor has to provide details of exhaust
fans and to indicate their locations on the drawing for approval.
4.7 Detail Specification of Blower
The air circulation shall be done with centrifugal fan. The fan shall be S1DW,
centrifugal type. Forward curved blades shall be of GSS, while blades of other
shapes are MS, treated and painted after manufacture. The fan assembly shall be
statically and dynamically balanced.
The fan bearings shall be mounted on the fan scroll and not on the panels of the
casing. The motor unit shall be totally isolated from the casing using cushy foot or
equivalent. Vibration isolators beneath the structural frame and canvas connection
between the fan mouth and the outlet connection of the fan suction.
A single square flange outlet shall be provided for the fan.
The ducting shall commence from the fan discharge with canvas connection and
shall have volume damper in each branch.
* Bidder to specify

Page - 109 / 115
The fan static pressure shall be so selected to cater resistance of external circuit of,
Filter bank at inlet, Duct length, Exit losses at damper / grills / diffusers etc. The flow
against static pressure curve for the fan diameter selected shall be submitted.
Electrical motor selected shall be having at least 15% margin over brake kW.
Blower shall confirm to AMCA standard or BS for manufacturing. All the test and
standard shall be provided for the blower.
4.8 Exhaust Fans
The fans shall be designed for industrial ventilation work. The construction shall be
from MS frames, resilient rubber mouths, cast aluminium hub and four way pressed
steel blades with broad surface to give large air discharge with quite operation. All
the fans shall be with three-phase electrical squirrel cage induction motor and
preferably with low rpm and low sound level in dB.
4.9 Filters
The coarse filters shall have efficiency rating of not less than 90%. The filters shall be
cleanable and shall incorporate synthetic material media, which shall be housed in
spray painted MS angle frame.
The fine filters shall have efficiency rating of not less than 90.5% for partials size
down to 10 microns by particle count. The filters shall be cleanable and shall
incorporate synthetic material media.
4.10 Sheet metal work, grills, diffusers
The working drawing for ducting will have to be prepared by Contractor giving due
attention to the structural features of the building and to other site requirements.
Sheet metal used for ducting shall be plain galvanised sheets confirming to Class IV
Grade BS.
The thickness of the sheet used for rectangular ducting shall be as given below
Maximum Size of Duct – mm Thickness – mm

Upto 750 0.63
751 to 1500 0.80
1501 to 2250 1.00
2251 and above 1.25
The fabrication of ducting include details of transverse joint connections, bracing,

seams, longitudinal joints etc. will be as per BS.
All civil work involved including drilling, chipping, grip bolting and other related works
shall be within the scope of the Contractor.
Dampers shall be placed in ducts at every branch supply for proper volume control
and balancing the system.
* Bidder to specify

Page - 110 / 115
All supply air diffusers shall be powder coated extruded aluminium sections.
All supply air grills shall be of powder coated extruded aluminium sections and shall
incorporate both horizontal and vertical louvers.
All inspection / access doors shall incorporate hinges and handles.
4.11 Air Conditioning System
Scope of work
Design, Manufacture, Supply, Erection, Testing and Commissioning of the Air

Conditioning System for Main Plant Control Room. The size of the control room shall
be 8 m x 48 m x 5m. The control room shall be located at the elevation of 9 m.
The detail architectural drawing can be obtained from the client, for duct routing,
opening for grills and location of packaged air conditioning unit, condenser etc.
The Contractor shall supply detail drawing for ducting, condenser piping, packaged
unit. The design calculations for the capacity, QAP shall be submitted along with the
drawing for approval.
Scheme
The Air Conditioning system is to be provided for Main Plant Control Room. Package
type Air Conditioners of suitable capacity shall be provided. The package unit shall
be suitable for maintaining the temperature of 22.2 ºC ± 1 .1 ºC and relative humidity
of 55 ± 5%. The package units shall be located in a plant A.C. room, adjacent to the
control room. The condenser shall be located above the plant A.C. room at 13 m
elevation.
Specifications
Package air conditioners
Based on the load calculations suitable package type air conditioning unit shall be
provided. Compressor shall be of hermetically sealed type. Condenser shall be air-
cooled type. Cooling coils shall be provided with fins. The cooling fans shall be of
higher diameter and lower speed. Package unit filters shall be cleanable polythene
types. Refrigerant piping shall be of copper with sufficient thickness.
Filters
The coarse filters shall have efficiency rating of not less than 90%. The filters shall be
cleanable and shall incorporate synthetic material media, which shall be housed in
spray painted MS angle frame.
* Bidder to specify

Page - 111 / 115
The fine filters shall have efficiency rating of not less than 90.5% for particles size
down to 10 microns by particle count. The filters shall be cleanable and shall
incorporate synthetic material media.
Sheet metal work, grills, diffusers
The working drawing for ducting will have to be prepared by Contractor giving due
attention to the structural features of the building and to other site requirements.
Sheet metal used for ducting shall be plain galvanised sheets confirming to Class IV
Grade BS.
The thickness of the sheet used for rectangular ducting shall be as given below
Maximum Size of Duct – mm Thickness – mm

Upto 750 0.63
751 to 1500 0.80
1501 to 2250 1.00
2251 and above 1.25
The fabrication of ducting include details of transverse joint connections, bracing,

seams, longitudinal joints etc. will be as per BS..
All civil work involved including drilling, chipping, grip bolting and other related works
shall be within the scope of the Contractor.
Dampers shall be placed in ducts at every branch supply for proper volume control
and balancing the system.
All supply air diffusers shall be powder coated extruded aluminium sections.
All supply air grills shall be of powder coated extruded aluminium sections and shall
incorporate both horizontal and vertical louvers.
All inspection / access doors shall incorporate hinges and handles.
Thermal insulation shall be provided, the insulating material will be bonded to duct
frame by applying bituminous paint on the ducts.
The insulation shall be properly wrapped with aluminium foil.
The contractor shall provide false ceiling. All the necessary civil work for fixing the
false ceiling is in the scope of contractor.
Electrical
MCC shall be as per rthe specifications under clause 2401-15
* Bidder to specify

Page - 112 / 115
The starter panel shall be front operated, front maintained, floor mounted, self
supporting sheet steel structure of thickness 2 mm minimum duly painted with shade
631 of BS.
The compressor MCC shall be in the plant room. The electrical cable from MCC to
the compressor panel shall be considered in Contractor’s scope.
2405 EOT CRANE FOR CO-GENERATION POWER HOUSE (60 t /10 t)
One crab of 60 t SWL capacity and one crab of 10 t SWL capacity with independent
trolley mounted on same gantry bridge.
General

testing and commissioning of electrically operated over head crane.

5.1 Codes and Standards
The design, manufacture, testing and performance of the electrically operated over
head crane shall comply with the requirements of applicable British/American/ Indian
Standards such as those indicated in the respective sections of this specification, and
those standards specified therein, in so far as they apply. The Contractor should
specifically mention relevant codes.
5.2 Performance test
After completion of erection, the crane shall be trial operated and performance tested
as detailed in the relevant sections of the specifications. The Contractor may note
* Bidder to specify

Page - 113 / 115
that the performance parameters guaranteed shall be considered in the bid

evaluation.
The Contractor shall furnish these and other parameters as required in the
performance data sheets.
5.3 Work schedule
Specifications
One # three motion electrically operated overhead travelling (EOT) crane indoor duty
conforming to BS 466 :1984 specifications OR equivalent Class II as per IS 3177
(1977) and IS 807 having one crab of 60 t SWL capacity and one crab of 10 t SWL
capacity with independent trolley mounted on same gantry bridge. Crane gantry
bridge shall be double girder box type construction.
The crane span shall be to suit the Powerhouse building span. The gantry length
shall be suitable for one end to the other end of the Powerhouse.
The Power house building layout is shown in Drg No. 3LO-1952.
The crane shall be complete in all respects including but not limited to current
collectors, power input wires/cables etc
Major details are furnished below.
Columns centre to centre distance of building - 16 m
Length of building - 82 m
Height of column upto Eaves level - * m
Height of crane hook above ground level - * m
Operation - Indoor
The crane travel shall cover the entire length of the Powerhouse building.
The crane shall be electrically operated, bridge type fabricated construction and shall
be complete with all accessories including main girder, rails, cables, panels, gearbox
rope, drum with wire etc. Access walkways with hand railing shall be provided along
the full span length on either side of the bridge girders. Suitable buffers shall be
provided on the trolley and bridge structural frames at suitable places to absorb the
shock of impact without transferring to the structural frame. Bridge and trolley track
wheels shall be of forged steel and shall be double flanged with cylindrical straight
tread and shall have hardness not less than 250 BHN.
* Bidder to specify

Page - 114 / 115
Hooks shall be swivelling type and solid forged heat-treated alloy or carbon steel
suitable for the duty. The swivels shall operate on ball or roller thrust bearings with
hardened races. Locks to prevent hooks from swivelling shall be furnished. The lifting
hooks shall comply with the requirements of BS: 2093 or BS: 3017 and if required,
shall have a safety latch to prevent rope coming off the hook.
Hoist ropes shall be of extra flexible, and out of plough steel rope with well lubricated
hemp core and having minimum six strands of 37 wires per strand with an ultimate
tensile strength of 160/180 kg/mm2.
Centralised hand operated grease lubrication shall be provided for all bearings.
All the drive motors shall be of crane duty. Totally enclosed, suitable for operation on
a 400 V, 3 phase, 50 Hz AC. Motor winding insulation shall be Class F with the
temperature rise restricted to Class B.
For hoisting, long and cross travels of the crane as well as auxiliary hoist, motors
shall be of high starting torque Class D characteristics.
Pendant type push button shall be supported independently of the electrical cable,
and the arrangement shall facilitate the operator to operate the crane standing away
from the load. All control equipment for the crane shall be housed in dust tight, sheet
steel cabinets. Illumination lamps shall be provided on the crane.
Indicative speeds are furnished below
a For main hook of 60t lifting capacity
Vertical lift - 0.75 m/min

Longitudinal travel - 8.00 m/min
Cross travel - 8.00 m/min
b For auxiliary hook of 10t lifting capacity
Vertical lift - 4.00 m/min

Longitudinal travel - 8.00 m/min
Cross travel - 8.00 m/min
Main hoist motor should be squirrel cage TEFC and long travel and cross travel
motors should be slip ring TEFC. All motors should be of crane duty.
Drive Type of motor kW Rating
Hoisting drum TEFC sq. cage * 1 hour

Long travel TEFC slip ring * 1/2 hour
Cross travel TEFC slip ring * 1/2 hour
Auxiliary hoist TEFC sq. cage * 1/2 hour
* Bidder to specify

Page - 115 / 115
All gear boxes shall be totally enclosed, dust proof, helical type conforming to BS 436
and with designed service factor of 2. All couplings shall be of flexible gear type /
centrifugal type. All brakes shall be of Electro-hydraulic thruster operated type.
Crane should be provided with a creep speed facility while hoisting at maximum
capacity to allow the heavier loads to be slowly and carefully handled. The crane
operation shall be from ground floor through pendent push button station moving
along with the crab.
The Contractor shall provide the loading data, span details, head room requirement,
etc., to enable the Employer to arrange suitable design columns for the crane.
5.4 Spares
List of spares for two year operation and maintenance, with price shall be furnished
for the EOT crane.
* Bidder to specify

Power Generation Plant

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J P Mukherji & Associates Pvt Ltd

WSSF-USI TECHNICAL SPECIFICATION Section –VI-D

2400 POWER GENERATION PLANT..............................................................................4

2401 TURBO ALTERNATOR, ACCESSORIES AND SYSTEM.......................................5

WSSF-USI TECHNICAL SPECIFICATION Section –VI-D

2402 COOLING TOWERS, AUXILIARIES AND PUMPS...............................................92

WSSF-USI TECHNICAL SPECIFICATION Section –VI-D

4.2 Codes and Standards.......................................................................................106

WSSF-USI TECHNICAL SPECIFICATION Section –VI-D

2400 POWER GENERATION PLANT

Equipment Quantity Description

WSSF-USI TECHNICAL SPECIFICATION Section –VI-D

2401 TURBO ALTERNATOR, ACCESSORIES AND SYSTEM

- Steam Turbines, 30 MWe Nominal rating, double extraction

The turbo-alternator should be suitable to meet demands imposed during different

WSSF-USI TECHNICAL SPECIFICATION Section –VI-D

Mode A: Factory “ON” & Grid “ON”

Mode B: Factory “OFF” & Grid “ON”

When factory is not working, but turbo-alternators are running to

Mode C: Factory “ON” & Grid “OFF”

Steam supply to each turbo-alternator and amount of extraction steam required by

WSSF-USI TECHNICAL SPECIFICATION Section –VI-D

COGENERATION POWER PLANT TURBO-ALTERNATOR

Sr. # Description Unit Mode A Mode B Mode C

1.0 Inlet live steam

4.0 Power available at Alternator MW 31.30 27.20 10.40

Condenser operating pressure bar (a) 0.14 * *

7.0 Ambient conditions

WSSF-USI TECHNICAL SPECIFICATION Section –VI-D

Sr. # Description Unit Mode A Mode B Mode C

Design criteria for maximum flows are indicated below:

- For Controlled extraction at 2.6 bar(a) steam at extraction conditions of

30 MWe is nominal rating of the turbo-alternator. Contractor shall inform and

Guaranteed performance shall be for conditions during Mode A. The Contractor

Governing system shall be of high accuracy electronic Woodward 505 E or

WSSF-USI TECHNICAL SPECIFICATION Section –VI-D

Material of construction for different parts shall be appropriate to the pressure,

The turbo-alternator is to be operated through fully automatic and remote controls.

Specifications of various components are detailed below.

2401-1 STEAM TURBINE

1.0 Turbine Casing

WSSF-USI TECHNICAL SPECIFICATION Section –VI-D

designed to permit expansion and contraction, in response to temperature changes,

2.0 Turbine Rotor

3.0 Combined Stop and Emergency and Control Valves

Steam strainer shall be installed in the main stop valve

4.0 Safety Valves and Quick Acting Non Return Valves

4.1 Quick Acting Non Return Valves

4.2 Safety Valves

WSSF-USI TECHNICAL SPECIFICATION Section –VI-D

5.0 Gland Sealing System

Glands shall be labyrinth type and sealed with steam.

Condensates of cooled gland sealing/leakage steam shall be piped back to turbine

7.0 Base Plate/ Sole plate

8.0 Governing System

8.1 General Control Philosophy

The governing system shall control following parameters:

WSSF-USI TECHNICAL SPECIFICATION Section –VI-D

Speed shall be kept constant irrespective of load and pressure.

Inlet steam pressure control

9 bar (a) extraction steam control

Extraction at 9 bar (a) pressure shall be uncontrolled extraction/bleeding, which