w aarvee associates Greenk® actitets engineers & constants pvt 10.1 CHAPTER - 10 ELECTRICAL AND MECHANICAL DESIGNS Introduction The utility of Pumped Storage Project has evolved a long way as one of the power system tools to perform multiple functions. While the fixed speed synchronous generator can meet the peak power demand in quickest possible way, the pumping operation has immense contribution in maintaining frequency at lean hour and maintaining the plant load factor of Thermal generation plants. With the advent of technological advancement to meet the need of the power system network, variable speed machines are gradually felt necessary because of their many advantages over the conventional fixed speed machines. Specially, with the present trend of development of renewable energy in India, grid management will become critical in future, In such scenario one of the options in integrated power system management is variable speed pumped storage project, It has some other definite advantages when analysed on long term basis over life cycle of project. Considering the above scenario, only Variable speed units has been considered for the basic design of the electro - mechanical equipment to achieve the following: i, Capability of machine to operate for entire head variation range - Generated power from renewable energy shall be evacuated to PGCIL grid in Round The Clock (RTC), to achieve that pumped storage project shall operate to run for entire head range for generation of minimum possible load. ii, Efficient Power utilization in pumping mode with variation of head, discharge and Power by the DFIM units instead of Fixed power utilization for any head and dis- charge by fixed speed machines. Best optimum efficiency along the head range can be achieved by varying speed in both turbine & pump modes for DFIM units which is not the case with fixed speed units, ili, Full Operating Flexibility (both in Pumping & Generation Mode) — Since power gener- ated from renewable sources i.e. from Solar and Wind is not constant and will fluctu- ate frequently, to evacuate constant power of 1200 MW to grid required deficit power will be generated from pumped storage project, Hence full flexibility from 1 MW to 1200 MW required. To meet the drastic change in the grid/IREP requirements Fast variation of power can be achieved by controlling the slip frequency of Rotor by AC excitation system of the units causing speed variation of the machine as it is evident that by changing the speed the fol- lowing are the changes in the machine parameters. Detailed Project Report of Pinnapuram Pumped Storage Project Rev - RO Page 208RY aarvee associates Greenk® actitets engineers & constants pvt N(speed) 00 H(head), N(speed) co Q’(Discharge”), N(speed) oo P'(Power’) Due to certain limitations in the efficient operating range and conditions in the machines the units of 240 & 120MW capacity will be operated with an operating range around 30 to 100% of its range in turbine mode and 60 to 100% (based on head) of its range in pump mode by varying the speed. In addition, two smaller units of 120 MW capacity are envis- aged with Hydraulic short circuit to mitigate the requirements of full flexibility from 1 MW to 1200 MW in a combination of operations in generator/motor with minimal hydraulic losses which is one for the reason for opting two capacities. For this one penstock taking off from the upper reservoir, will be bifurcated in to two being fed to the units of 120 MW and the delivery side of the units are again connected to common Tail race tunnel as hy- draulic short circuit to connect to the two units. ‘* Ease of Operation & Maintenance because simple PH layouts ~ If all machines considered with variable speed, it is easy for operation of units and maintenance of critical spares. ‘* Higher Efficiency for entire head range of operations ~ With DFIM technology i.e. with variable speed machines we can achieve higher efficiencies for entire head range compared with fixed speed machines. Proposed project is with renewable sources i.e. with wind and solar, generated power is not constant and will fluctu- ate, Hence pumped storage project shall run at higher efficiencies to achieve maximum power. ‘* Capability of machines to ramp up and ramp down in minimum time - During shutdown of Solar and wind generation to facilitate evacuation of power to grid within minimum possible time is possible with variable speed machines. Technical particulars of all the types described below considering variable speed units with DFIM for all the units, The proposed storage component of Pinnapuram IREP of 1200 MW is envisaged to have 6 vertical reversible pump-turbines driven generating units (4 X 240MW & 2 X 120 MW). The prime mover for all six generators shall be Reversible Vertical Francis Turbine suitable for bidirectional operation, During the Generator mode of operation, the power shall be generated at 18 KV for both 240 MW units and 120 MW units. The generated power will be transmitted through Generator Step-Up Transformer (GSUT) to 400kV Gas insulated switchgear (GIS). Auxiliary power required during start-up of plant will be delivered from 400kV GIS through Station Transformer (ST) to the medium voltage system (11kV). Detailed Project Report of Pinnapuram Pumped Storage Project Rev - RO Page 209RY aarvee associates Greenk® actitets engineers & constants pvt The same turbine shall act as a pump and shall operate in Motor mode for pumping the water from lower reservoir to upper reservoir. The installed capacity of a pumped storage scheme is influenced by the requirements of daily peaking power requirements, flexibility in efficient operation of units, storage available in the reservoirs and the area capacity characteristics. The key to the flexibility of the pumped storage hydro is to speed the facility that can go from storing energy (pumping water into the upper water body) to the generation of energy (releasing water from the upper water body through the turbines to the lower body of water). The pure reversible turbine equipment requires stopping and reversing the water flow, this can take 5 to 6 minutes per cycle. Basis for selection of machines: Larger Uni 4 no’ 240MW Size of larger unit is based on the limiting the width of powerhouse and diameter of water conductor system consists of intake tunnel, surface penstocks & vertical and horizontal underground pressure shafts for the following design considerations: * Suitable for handling and fabrication of ferrules + Maximum excavated diameter for underground intake tunnel, vertical and horizontal pressure shaft in consideration of rock column in between and top cover require ments to suit geological conditions + Size of adit for transportation of ferrules for construction of pressure shaft + Economical diameter of the pressure shaft in consideration of techno-commercial aspects as per IS:11625-1986 + Limiting to the width of 25.5 m of pit excavation of surface powerhouse Based on the above studies the optimal diameter works out 7.5m suitable for generation of 240 MW unit. Smaller Units ~ 2 n 120MW + Pinnapuram PSP will consume power during the pumping mode from other power sources viz. Solar & Wind power of capacities 3000 MW and 500 MW respectively. + To pump water in the time slot of 6PM to 6AM (Night Hours), minimum power avail- able from wind generation on an average in different seasons (more than 6 months) will be varying from 60MW to 120MW. During night hours only wind power will be available. Minimum MW consumed by 120 MW unit is in the range of 65 MW to 72 MW, Accordingly, to utilize that generated wind power during night hours for pump- ing 120 MW units are selected. + As 120 MW variable speed machines are also envisaged in the scheme with hy- draulic short circuit the necessary requirements from 1 to 120 MW can be met from Detailed Project Report of Pinnapuram Pumped Storage Project Rev - RO Page 210w aarvee associates Greenk® actitets engineers & constants pvt these machines. In case any additional power available can also be utilized for pumping in combination of 240 MW and 120 MW units. * Similar situation may arise during the daytime therefore, flexibility is kept such that even less availability of Solar/Wind power, pumping operation could be started, In lieu of the above in Pinnapuram PSP, larger units of 4nos-240 MW and smaller units of 2nos- 120 MW are planned for 1200 MW installed capacity. Description of Operational Flexibility: The units of 240 & 120MW capacity will be operated with an operating range of around 30 to 100% in turbine mode and 60 to 100% (based on head) in pump mode by varying the speed. In addition, two smaller units of 120 MW capacity are envisaged with Hydraulic short circuit to mitigate the requirements of full flexibility from 1 MW to 1200 MW in a combination of operations in generator/motor with minimal hydraulic losses. Ih order to mitigate the additional power available for pumping and meet the requirements of the grid by generating the power from the IREP scheme in efficient way the full flexibility is considered.As PSP is connected to RE power where this power is intermittent and uncertain, To account the intermittency and uncertainty adjustable/variable speed machines are considered against fixed speed machines as the Power consumption in motor mode cannot be regulated with respect to the power availability from renewable energy grid. Description of Power Availability: Pumped storage plant will be operated based on quantum of power required as per the PPA commitment round the clock, When power generated through solar & wind is equivalent to PPA commitment, power will be evacuated to grid directly. When power less than PPA commitment is generated through solar & wind generation, PSP will be taken in generation mode to augment and evacuate to grid. When power generated through solar & wind is excess than the PPA commitment, then PSP will be operated in pumping mode to consume power. iii) Minimum and Maximum Power Generated by Renewable Grid: ‘Wind Power Generation range : 35 MW to 450 MW Power Generation from wind is around 100 MW and below in case of lean season, Solar Power Generation range : 4.5 MW to 1000 MW In non solar season power generation from Solar is under lower side. 10.2 Electro-Mechanical Equipment The Electro-Mechanical equipment required for the proposed scheme comprises of the following: > Main inlet valve. Detailed Project Report of Pinnapuram Pumped Storage Project Rev - RO Page 211RY aarvee associates Greenk® actitets engineers & constants pvt v v SALIENT FEATURES OF E&M EQUIPMENT: Reversible Turbine and its auxiliaries like HP/LP air compressor system, water depression system, lubricating oil system, Governor and its oll pressure unit and cooling water system etc. Variable speed DFIM/ Generator/Motor and its auxiliaries voltage source converters, transformers, Cooling system, Brakes, PLC and Automation arrangement etc., Control, Protection, metering, measurement and annunciation panels and 400KV feeder panels. Isolated Phase Bus duct shall be provided for connecting generator/Motor GCB to the Generator Step-up transformer, UAT, LAVT, NGT etc,, for trouble free reliable operation. Generator circuit breaker & phase reversal device etc. with all accessories. Generator Step-up Transformers with off circuit tap changer along with control and protective gear and breakers etc, 400KV Gas Insulated switchgear (GIS) units is proposed for connecting to two different sources separated by bus Sectionalizer. ‘Auxiliary Power supply system consisting of unit auxiliary transformers, station auxiliary transformer, D.G Set for alternative emergency supply and station/unit auxiliary boards for station auxiliaries, unit auxiliaries, HT & LT switchgear. Control supply system consisting of AC supply, station battery, charger and its distribution system. The station auxiliaries like 3 Nos. of EOT cranes (2 nos, at service bay and 1 no at unloading bay), Air Compressor system, Dewatering and Drainage system, firefighting equipment, Air conditioning, Ventilation system and illumination system, Cooling water system, High pressure oil injection system, jacking oil system, public addressing system etc. Power evacuation system consists of transmission line, protection/ metering equipment, CT's, PT's, LA's along with its supporting structures and Receiving end equipment including bay extension at the other end, PLCC, 48V DC battery system. SCADA system with necessary panels and workstations for GIS and for power plant operation from Local and Remote. 1 [Powerhouse a_ {Type Surface Powerhouse (Pit type) b__|Center Line of Unit El. 292.10 m c_|Service bay level El. 306.30 m Detailed Project Report of Pinnapuram Pumped Storage Project Rev - RO Page 212WY saree associates actitets engineers & constants pvt Greenk® Unloading Bay Level El. 330.30 m via Electromechanical Equipment Pump Turbine Francis type, vertical shaft reversible pump-turbine b {Total No of units 6 no's (4 X 240MW & 2 X 120 MW) [Cumulative Design Discharge (Turbine Mode) 1100.97 m*/s 2.1 |240 MW Turbines a [Total No of units 4 Units (All units are Variable speed) b_ | Turbine Capacity 240 MW c_| Turbine Design Discharge 219.24 m’/s for each Unit d__|Rated Head in Turbine Mode 122.23 m [Pump Capacity 253 MW (approx.) f [Rated Head in Pump Mode 127.93 m g {Synchronous speed 136.36 rpm 2.2 |Generator-Motor a |Type Three phase, alternating current asynchronous, generator motor semi umbrella type with vertical shaft b [Number of units 4 Units c_ [Rated Capacity Generator - 240 MW Pump Input ~ 253 MW d_ [Rated Voltage 18 KV 2.3 |Generator Motor Transformer Outdoor Single-Phase Power transformers with ON- a [Type Load tap changer (OLTC) b [Number of units 12 Units c__|Rated Capacity of each unit 100 MVA d_ |Rated Voltage Primary — 18 KV ; Secondary - 400 kV adjustable range of the secondary voltage: -10% to +10% in 1.25% steps 2.4 |120 MW Turbines a {Total No of units 2 Units (both are Variable speed) b [Turbine Capacity 120 MW 112 m’/s for each Unit Detailed Project Report of Pinnapuram Pumped Storage Project Rev - RO Page 213w aarvee associates actitets engineers & constants pvt Greenk® d= |Rated Head in Turbine Mode 121.53 m [Pump Capacity 136 MW (approx.) f |Rated Head in Pump Mode 128.73 m g_ |Synchronous speed 187.50 rpm 25 |Generator-Motor ‘Three (3) phase, alternating current synchronous, a [Type generator motor semi umbrella type with vertical shaft b |Number of units 2 Units ¢ [Rated Capacity Generator - 120 MW Pump Input ~ 136 MW d__ [Rated voltage 18 KV 2.6 |Generator Motor Transformer Indoor, 3-Ph transformers with On-load tap changer a [Type (otTc) b_ [Number of units 2 Units c__|Rated Capacity of each unit 150 MVA Primary — 18 KV ; Secondary - 400 KV d__ Rated Voltage adjustable range of the secondary voltage: -10% to +10% in 1.25% steps 3. |400 kV Gas Insulated Switchgear (Gis) a_ | Type of GIS Indoor Type b_ | No. of GIS units ¢ | Location Inside GIS Building above ground d_ | Scheme Double Busbar Arrangement with bus Sectionalizer 4 |Power Evacuation a |Voltage Level (KV) }400 KV b__|No. of Transmission lines Two Double Circuit Transmission Line {Conductor Quad Moose One double circuit line to Central Pooling Substation d [Terminating at (CPSS) and other double circuit line to PGCIL SS SITE AMBIENT CONDITIONS: Altitude < 1000 MSL b [Design ambient air temperature _[Min: 10 Deg C and Max: 45 Deg C Detailed Project Report of Pinnapuram Pumped Storage Project Rev - RO Page 214w aarvee associates Greenk® actitets engineers & constants pvt ¢ [Average relative humidity Max: 95% and Min: 30% d {Seismic Zone Zone II 10.2.1. Main Inlet Valve (MIV) Each Turbine is provided with main inlet valve of Hydraulic operated Butter Fly Valve type with dead weight closing and having pressure oil operated servomotor mechanism in order to achieve quick closing to cut off the water supply for the Turbine in the event of any machine tripping on a lock out fault. The mail inlet valve will be of lattice type with maintenance & service seals designed to open under unbalanced conditions and close against full flow in emergency. The main inlet valve shall be normally opened by hydraulic system and closing system with dead weight for closing. Hydraulic operated Bypass valve is provided across the main inlet valve for smooth operation with pressure balance condition. i) Dismantling Joint: The Joint shall be of Telescopic type and located on downstream of valve facilitating dismantling of valve during maintenance. il) Servo Motor: Servo Motor of single acting type comprising of fabricated steel cylinder with covers, piston and pressure oil system will be provided in a complete shape. 10.3. Pump Turbine Water samples shall be collected, and petrographic analysis shall be performed to understand the quality of water. However, as the water used for this project is irrigation water without any catchment area, it is expected that water will be clear and no requirement of silt & abrasion coating/painting is anticipated. The Turbine/Pump turbines shall be of 6 nos vertical shaft Reversible Francis type coupled to Generator-Motor Type of Turbines = _|Vertical shart Reversible Francis type Unit Ratings & Numbers = POMW 4 Nos 120 MW - 2 Nos Maximum Head(Turbine) 138.00 Rated Head 122.23 Minimum Head 105.30 Maximum Pumping Head = {143.90 Rated Pumping Head 12793 Minimum Pumping Head = [111.20 Specific Speed — Turbine Mode = [18125 Specific Speed ~ Pump Mode 48.75 Synchronous Speed (240MW) = [136.36 Detailed Project Report of Pinnapuram Pumped Storage Project Rev - RO Page 215aarvee associates BO BE Sect eronatsne Greenke Synchronous Speed (120MW) 187.50 Setting of Turbine/Pump Turbine -27 m Below minimum Tail Race Level Max Pressure rise 35 % Max Speed rise 50% 10.3. Runaway speed for 15 min of duration and critical speed 150% of rated speed and ci 120% of runaway speed al speed is The min. load for continuous operation 30% of the rated capacity in generation mode, Combined Weighted efficiency based upon the efficiencies average of various outputs Pump Mode ~ 92.0% (approx.) [Turbine Mode - 91.44% (approx.) Design life of Runner and other hydraulic passages component against pitting caused by cavitation 50 years Each pump turbine shall include: > Main Inlet Valve (MIV) with all accessories and associated auxiliary equipment including upstream connection piece. > Spiral case inlet sleeve connected to the Main Inlet Valve downstream sleeve. > Spiral case and the stay ring > Head cover and the bottom ring. > Operating ring, the wicket gates and their control system. > Runner and bolting for connection to the turbine shaft. > Turbine shaft and bolting for connection to the generator shaft. > Turbine guide bearing. Main shaft seal. v > Draft tube cones. Draft tube lining. v > Hydraulic power supply, the governing air/oil pressure tanks. v turbines. Instrumentation and protection devices required for correct functioning of the > Equipment cabling, motors, filters, etc,, including the cubicles and terminal boards. > Parts embedded in the 2nd phase concrete. > An aeration system for the runner. 1 Tur e Auxiliaries a) Unit wise cooling systems with all accessories, Detailed Project Report of Pinnapuram Pumped Storage Project Page 216 Rev - ROWY saree associates actitets engineers & constants pvt Greenk® b) Unit wise Pressure oil tanks / systems for unit governing & MIV systems with all accessories ©) High Pressure compressed air system with common air compressors & Air receivers and unit wise air receivers with associated valves and piping with instruments for water depression of runner chamber and other station requirements. d) One (1) set of spare parts, tools & tackles of all equipment. LIST OF SPARE PARTS S.No Description of item Qty. 1 [Wicket gate bearing bushes (Upper, Middle, 2 Sets Lower, links) 2 [Servo motor, sealing and piston rings 2 Sets 3 |shaft sleeve, Shaft seal Sealing ring segments & [2 Sets maintenance seal 4 [Bearing pads/Segments (Guide and thrust 1 complete set of each type bearings) 5 |Control & Power supply modules of Governor —_—|2 Sets 6 [Proportional valves, control valves 2 Nos. of each type used. 7 [Oil pumping unit with unloader valve 2.Nos. 8 [HS Lube Oil Unit 1No. 9 [Brake/ Jack units 1 Set 10 Air, oil / water coolers 1 set of each type used for one complete unit 11 _ [Compressor spares 1 Set 12 [Valves 1 No. of each type used 13 _[Instruments/ relays 2.no.s of each type used 10.3.2. Functional Descri CONTROL: Unit’s auxiliaries shall be controlled by the SCADA system, through the Unit Control Boards. Unit operating point and regulation shall be controlled by the unit set point controller. It shall also be possible to control locally the main elements (pumps) from local control boxes or from LV boards (selectable local/remote switches). Local control shall be performed in a safe and convenient manner, and all information (faults, alarms, measurements, status) necessary for such control shall be displayed Detailed Project Report of Pinnapuram Pumped Storage Project Page 217 Rev - ROfer sees exces Greenke locally. If the system consists of redundant subsystems, the priority of operation of such subsystems shall be selectable, either from SCADA system or locally. MONITORING: The system shall be monitored by the SCADA system. All information (such as faults, alarms, measurements, status of equipment, external orders, running time, number and type of operations, performance information (net head, speed, output, flow rate, etc...) that is necessary for effective and convenient control and monitoring by the SCADA system shall be transmitted through SCADA Local Control Boards, List of Spares for SCADA system: 1. Controller of each type - CPU, Communication card - 1 No 2.Network equipments of each type - Ethernet switch - 1 No 3. GPS Master clock - 1 No 4, Servers/operators workstation - 1 No. 10.3.3 Power a. Turbine Mode: > All Turbines (variable speed) shall be designed to generate rated output at generator terminals at the rated head and will follow the pattern of machine hill curve at minimum and maximum heads. > Variable speed turbines, in normal operating conditions and for all the range of heads, the powers will be between 30 % and 100 % of the rated output in turbine mode. > When the power demand is less than the minimum operating power of 120 MW unit, the units shall be operated in Hydraulic short circuit condition to generate the required power. b. Pump Mode: > All units shall be capable of operating over the entire head range. > Operating range of the units shall be designed such that the units are required to operate in Hydraulic short circuit condition if the available excess power for pumping is less than the minimum power required to start the 120 MW unit. When the available power is greater, the units shall be able to operate in combination of units without operating in Hydraulic short circuit condition also. > Range of Unit Operation: ‘Turbine Mode: 240MW Unit: 72MW - 240MW. 120MW Unit: 36MW - 120MW Detailed Project Report of Pinnapuram Pumped Storage Project Rev - RO Page 218RY aarvee associates Greenk® actitets engineers & constants pvt Pump Mod 240MW: 140MW - 253MW 120MW: 6SMW - 136MW 10.3.4 Unit start-up — shutdown a) Unit start-up — shutdown ‘As per pre engineering discussions had with E & M equipment manufacturers techno economical mode change timings are arrived/recommended with number of starts stops of units are envisaged for about Eight per day in different modes. Start- up and shutdown time duration shall be according to requirements to bring the machine into service in quickest possible time to meet the grid conditions as described below: S.No. Description Time (Sec) 1__[Standstil to Turbine mode (Full load) 85 to 120 2 [Turbine mode (Full load) to Standstill 130 to 270 3 Standstill to Pump mode (Full load) 240 to 300 4 [Pump mode (Full load) to Standstill 130 to 180 5 __ [Turbine full load to Pump full load 390 6 __ [Pump full load to Turbine full load 210 7 __ [Pump condenser to pump full load 60 8 Pump full load to Pump condenser 60 7 Turbine no load to turbine condenser 60 8 __| Turbine condenser to turbine no load 60 b) Weighted Average Efficiency: Weighted Average Efficiencies specified by OEM in the pre contractual stage is tabulated below. WAE of 120MW unit in Generation mode: 90.91% WAE of 120MW unit in Motor mode + 91.57% WAE of 240MW unit in Generation mode: 90.94% WAE of 240MW unit in Motor mode : 91.65% 10.3.5 Materials and Construction Features of Turl a. Runner: The turbine runner will be integrally cast / welded in stainless steel material having 13% chromium and 4% nickel and properly stress relieved. The runner will have suitable no. OfF vanes polished and ground smooth and will be mounted on the turbine shaft, Adequate number of relief holes will be provided in the runner for the water past runner crown seal. Detailed Project Report of Pinnapuram Pumped Storage Project Rev - RO Page 219w aarvee associates Greenk® actitets engineers & constants pvt Runner removal shall be envisaged from turbine top cover side through Stator bore. b. Guide Vanes: Each Unit shall be provided with suitable number of Guide vanes and operating mecha- nism. The turbine shall be equipped with one set of fabricated stainless-steel guide vanes with integral stems and trunnions. Suitable number of wicket gates shall be provided to control the flow of water for regulation of the unit. The guide vanes shall be uniform in shape. The number of guide vanes and the number of runner vanes shall be coordinated in a manner to ensure that the turbine will operate without objectionable vibrations. Guide vanes will be of cast stainless steel material conforming to 13% chromium and 4% nickel and finished smooth. Guide vane operating mechanism will be of forged or fabri- cated steel. Each guide vane will be supported with self-lubricated bearings. Synthetic rubber seals will be provided to prevent leakage of water. The guide vanes will be oper- ated by guide vane servomotor for which the pressurized oil will be supplied from the pressure oll system. The control of guide vane opening will be through the governor. ¢. Guide Vane Operating Mechanism: The operating mechanism shall consist of all elements for connecting the wicket gates to the wicket gates servomotors including levers, links, Wicket gate operating ring, servomotor connecting rods and pins of enough strength to withstand the maximum load that can be imposed on it by the most severe operating conditions. Parts having relative motion and contact shall have self-lubricating bearings. ‘Turbine/pump Shai A turbine/pump shaft will be provided for mounting the turbine runner. The material of turbine/pump shaft will be of carbon steel forging conforming to BS 29 or ASTM A 668 Class D. The shaft will have adequate diameter to operate safely in combination with generator, The turbine shaft will be connected directly to the generator shaft by means of a suitable coupling. d. Shaft Sleeves: The shaft will be provided with renewable stainless-steel sleeve. The sleeve will be of split construction and securely fastened to the turbine shaft. e. Shaft Seal: The shaft seal will be provided to prevent leakage of water through the gap between the shaft and turbine cover. ‘Two (2) shaft seals shall be provided one as main working seal and another as mainte- nance seal, Working seal will be applied with water tapped from cooling water system Detailed Project Report of Pinnapuram Pumped Storage Project Rev - RO Page 220RY aarvee associates Greenk® actitets engineers & constants pvt with redundant source from firewater tank/penstock. Maintenance seal is inflatable seal and will be applied at the time of unit standstill condition. f. Turbine Bearing: The turbine bearings shall be segmental, adjustable pad, immersed Babbitt type of adequate design to operate safely under all conditions. The design of bearing and oil reservoir shall permit their inspection adjustment or removal without disturbing the head cover or major dismantling of other parts of the turbine. The bearing design shall be such that no water shall enter the lubricating system via the shaft seal and there shall be no loss of oil by leakage past the lower oil shedder or by overflow from any part of the oil system under any condition. g. Stay Ring Assembly: The stay ring assembly will be made of fabricated steel plate conforming to ASTM A516 Gr 60/70 / A 216 Gr WCB. The stay ring assembly will have set of streamlined stay vanes to guide the water flow. h. Spiral Casing: Spiral casing will be of welded construction fabricated from steel plates conforming to IS -2062 Gr. 'B’ designed to withstand the maximum operating pressure including water hammer. The spiral casing segments will be welded to the stay ring. The spiral casing will be anchored in concrete. The upstream flanged end of spiral casing will be bolted to the dismantling joint of turbine inlet valve. i. Draft Tub The draft tube will be made of fabricated steel plates conforming to IS — 2062 Gr. - 'B’. Draft tube will be fabricated in suitable parts namely draft tube cone and draft tube liner etc. and will be heavily reinforced by ribs and anchored in the concrete. j. Pressure Oil system: Each Pump-turbine shall be provided with a separate pressure oll system for operation of Pump-turbine wicket gate servomotors through governors and for the operation of MIV. The oil pumping unit will be provided for supply of pressurized oil for the following: a) Guide vane Servomotors b) Turbine inlet butterfly valve For regulation of water flow through guide vanes, the pressurized cil will be supplied through servo valve, which will receive an electronic signal from governor. The oil- pumping unit will be provided with two pumps (one main and one standby) with auto- changeover facility along with other required accessories. For ensuring availability of stored pressurized oil, adequate capacity of nitrogen piston type accumulators / HP air pressure vessel system for the governor pressure oil system. The pressure oil system will Detailed Project Report of Pinnapuram Pumped Storage Project Rev - RO Page 221RY aarvee associates Greenk® actitets engineers & constants pvt be provided with necessary instrumentation and control system for the safe and reliable operation of the units. OPU system for the inlet valve and for Governing system is of adequate capacity confirming to three complete operations i.e. Close - Open - Close which could be carried out with absence of power supply to the pumping unit. k. Governing System: The turbine will be controlled by servo valve based electronic governor. The Governor in general shall be designed in accordance to IEC 61362. The system will be so designed that the main functions of speed control, power control are handled as a separate program parts and shall be programmed to suit Francis turbine having adjustable guide vanes. The speed signal sensing should be redundant with three sensors selected on different working principles for control and protection functions Governor will also support RGMO mode of operation as per clause 5.2(f) of the Indian Electricity Grid Code with latest amendments. ‘The Governor shall meet following Functional requirements: a. The Governor shall function based on the commands and set points given by the Unit Controller and the control of the pump turbine is to be carried out besides give set points and commands to VSI controller. b. The Governor shall operate in conjunction with the unit (controller) control system and controller of the Voltage Source Inverter (VSI) of DFIM. The power controller of Governor is integrated with VSI controller, In Turbine mode the unit is to operate in power control, slip control (synchronous condenser) modes and frequency influence control mode, ©. The performance of the governor shall meet all the conditions & grid requirements. d, CEA stipulations viz Restricted Governing mode operation (RGMO) & Free governing mode operation (FGMO). e, Independent Grid mode of Operation f. Line charging Mode of Operation 9. Black starting mode of operation. h. Condenser mode of operation i, Integration with synchronizing panel with auto synchronizer, j. Grid support for LVRT, HVRT etc. compliance stated in the DFIM specifications. k, Local & Remote-control operation feature, |. Minimum setting range of the permanent droop shall be 0-10%. m. The speed dead band shall not exceed 0.02% at the rated speed. Detailed Project Report of Pinnapuram Pumped Storage Project Rev - RO Page 222w aarvee associates Greenk® actitets engineers & constants pvt n. When generator is operating connected to the system with sustained load demand, the peak to peak magnitude of the sustained power oscillation caused by the gover- nor with 2% or more speed droop setting, shall not exceed +1% of the rated capac- ity. ©. Sensitivity of governor shall be 0.01 %. p. The governor dead band time shall not exceed 0.20 second for speed change of 0.1 Hz or Larger and the dead band adjustment range shall be 0 to +3Hz. q. The range of Adjustment to speed setting 90% (of rated speed at no load) 110% (of rated speed at full load) and maximum speed droop, Governor key control parameters shall be as below: ‘+ Speed control accuracy: + 1 rpm * Load control accuracy: <0.5% + Control cycle time: < 50 milli sec |. Cooling Water System: Water required for cooling and shaft sealing of the machine will be taken from the Tail race and supplied to various coolers such as turbine bearing coolers, generator bearing oil coolers, governor oil cooler, stator air coolers and turbine shaft seal, Power transformer heat exchangers etc. through booster pumps and suitable duplex strainers as required. The cooling water system will be provided with necessary instrumentation such as flow switches, differential pressure switches across the filters and pressure switches etc., for safe and reliable operation of the units. The raw water will be cleaned through motorized automatic online self-cleaning simplex filter (1 working + 1 standby) before supplying to the equipment. m.HP_ Air mpressor tem blow wn (Runner Aeration/water blowdown system): The High-Pressure air system will cater to the needs of Tail water depression whenever the Machine is required for starting the unit in pump modes and to be operated in the Condenser mode from other modes or standstill. The runner and upper cone of the draft tube need to be blown out from water by depressing tail water level by feeding high pressure compressed air into the draft Tube, Runner and Bottom Ring for startup of Pump Turbine in Pump mode and commence condenser operation Centralized redundant compressor station with common and unit dedicated air receiver tanks is envisaged. Each unit dedicated tank will be designed for 2 blow downs. HP Compressed air system shall essentially consist the following equipment: a. 4x 50% (2W +25) HP Air compressors (Oil free screw compressor) b. 2x 100% Air driers. Detailed Project Report of Pinnapuram Pumped Storage Project Rev - RO Page 223w aarvee associates actitets engineers & constants pvt Greenk® 10.4 ¢. 2Nos common air receivers d. 6 Nos Unit air receivers e. Associated piping, valves, instrumentation High pressure compressed air system shall permit the runner dewatering for synchronous condenser mode. System shall permit 2 consecutive runner dewatering operations for each unit. Compressor shall be sized to ensure Re-filling of high-pressure tanks in shorter period. The system for each unit shall be provided with necessary piping and pneumatically operated Air valves controlled by Unit governor oil pressure system. Generator - Motor The plant consists of 6 nos Generator/ Motor units. The generators will be three-phase Doubly Fed induction machines of vertical shaft type directly coupled to their respective turbines. The operating capabilities of units considered as per CEA regulations. The nameplate rating of the DFIM units proposed are as follows: \Variable Speed Doubly Fed Induction Type of Machine Machine type Bearing Arrangement [Semi Umbrella type Each Unit Rating 240MW. Number of Units 4No's [Terminal Voltage 18 KV [Variable Speed Doubly Fed Induction Type of Machine Machine type Each Unit Rating 120 MW Number of Units 2 No'’s Machine Terminal Voltage 18 KV [Common Parameters: No of Phases 3 Phase Frequency 50 HZ 47.5 Hz - 51.5 Hz (-5% to +3% of normal JOperating Frequency range frequency) Power Factor in Generation Mode 0.90 Lag & 0.95 Lead Power Factor in Pump Mode 0.95 (Lead) (Class of Insulation of Generator stator Class - F jand rotor windings Temperature rise Limited to Class - B ‘Type of cooling Air cooled Detailed Project Report of Pinnapuram Pumped Storage Project Page 224 Rev - RORY aarvee associates Greenk® actitets engineers & constants pvt [Stator winding connections = [star Hype of duty = [Continuous No. of line terminals to be brought = [Three (3) lout No. of neutral terminals to be brought = [Three (3) Jout Degree of protection for generator = [p23 lenclosure Excitation system response ratio = _[As applicable for DFIM inertia constant (H) = _[Bs Approx. cycle Eificiency - For complete cycle ¥ Y press = |s0.44% Jof Generation and Motor Modes I. INSULATION AND TEMPERATURE RISE: Insulation of the motor shall be envisaged as follows: a. Stator winding: Thermo setting Epoxy resin of Class-F insulation. b. Rotor winding: Thermo setting Epoxy resin of Class-F insulation. With a maximum cooling water temperature of 35° C. the motor- generator shall be capable of delivering rated output to pump continuously at any voltage and frequency in operating range and rated power factor without exceeding the following temperature rise over a maximum ambient Temp of 45° C . a. Stator winding: 85° C above ambient b. Field winding: 95° C above ambient ©. Bearings by embedded: 70° - 80° C above ambient Il. COOLING SYSTEM: The Motor-generator will be provided with a closed re circulating cooling system complete with air ducts, water cooled surface air coolers, water header, metal housing, alarm devices, flow indicators, manually operated isolating valves and all other accessories. The coolers will be placed symmetrically around the stator. III. NOISE LEVEL: ‘The noise level of the generator will be limited to 90 db when measured at 1m from any component of the generator. IV. STATOR FRAME: The stator frame will be of welded steel structure. The core will be built up CRGO silicon steel laminations of high quality and low loss designed and fabricated to prevent hot spots Detailed Project Report of Pinnapuram Pumped Storage Project Rev - RO Page 225w aarvee associates Greenk® actitets engineers & constants pvt VL vo. vir. and / or loose spots. The stator frame with core and windings will be shipped from the factory /works in suitable segments considering transport limitations. The stator steel structure and is provided with suitably arranged braces to form a stiff and vibration free construction. The interior of the stator casing partly forms the cooling ducts and therefore the braces in the stator frame are arranged in such a manner that optimum air flow will be obtained. For easier transportation the stator casing is split up into several sections. The sections of the stator casing are damped together by means of liberally dimensioned bolts. STATOR CORE: The stack of laminations constituting the active part of the generator is made of silicon alloy steel sheets. The segments are coated with an insulating varnish of good thermal and mechanical properties on both sides and stacked interleaved. STATOR WINDING: The stator winding is designed as a pitched two-layer winding which is arranged to obtain a near sine wave curve by suppressing the harmonics. The stator winding is a transposed bar winding Each bar consists of several transposed, insulated strands in order to reduce the additional copper losses. ROTOR SPIDER: All materials of the rotor parts are designed for the highest stress which may occur due to centrifugal force during runaway conditions. The stub shafts of forged alloy steel properly annealed are fiange-connected to both sides of the rotor hub, The complete shaft will be tested exhaustively in the works of the shaft manufacturer to ensure conformity to the material and structural standards. The rotor has a suitably designed hub for the connection with the shaft. ROTOR LAMINATIONS: The rotor core is constructed in the same way as the stator core. The rim sheets are made of silicon alloy steel sheets, This reduces the additional losses in the teeth of the rotor rim. The segments are coated with an insulating varnish of good thermal and mechanical properties on both sides and stacked interleaved. In order to ensure cooling of the package and the installed winding, the entire package is subdivided into several partial stacks with intermediate ventilation ducts, The design and assembly process is analogous to the stator lamination stack. After heating, the segmental rim is shrunk on the webs with keys placed between the webs and the rim to achieve the desired prestress. Detailed Project Report of Pinnapuram Pumped Storage Project Rev - RO Page 226RY aarvee associates Greenk® actitets engineers & constants pvt x ROTOR WINDING: The Rotor winding is designed as a pitched two-layer winding which is arranged to obtain a near sine wave curve by suppressing the harmonics. The bars of the two-layer rotor winding consist of partial conductors, in order to reduce the additional losses. The Mica ‘Tec™ insulation system is also used for insulation which corresponds to class F. The support of the rotor end winding has the task of receiving the centrifugal forces. At the same time, enough cooling of the winding head is to be ensured, The involute section where the end region of the rotor winding is held by support rings and U-bolts/Retaining ring/single bolt locking against the occurring centrifugal forces. The Rotor leads are guided in grooves which are milled into the shaft. Particular attention is paid to the mechanical stress in the shaft and the possible losses caused by eddy current losses. BREAKING AND JACKING: Each generator is provided with combined braking and lifting jacks. In the jacks, two flu- ids are alternatively used: compressed air for braking and high-pressure oil for lifting, The cil and air circuits are completely separated. Generator shall be provided with pneumatically operated brakes of adequate capacity to bring the rotary parts of the generator and turbine to stop from about 10% of rated speed during normal operation, The brakes may be applied at higher speed during emergency shutdown of the unit, in order to bring the rotor to rest faster. The brakes shall operate automatically and/or manually from local brake control panel or Generator/unit control panel by means of push buttons/ control switch with necessary interlocks. Dynamic braking system is also considered for reduction in the mode change timings and effective braking. Once the unit has been running, in generator, motor or condenser mode and a stop order has been issued, the shaft line will keep rotating and slow down due to friction torque. In order to reduce the stop time, the excitation & control system shall include an electrical brake function The electrical braking can be activated at any speed from maximum synchronized rotating speed to 0 rpm. The electrical braking performance shall be such that the stopping time is approximately 1/10 of the purely mechanical stopping time, The generator will be provided with air-operated brakes to bring the rotating parts of the generator to rest from about 15% of the rated speed during normal operation. The brakes will be suitable for application at higher speed during emergency shutdown of the unit in order to bring the unit to rest at a faster rate. The brakes will operate manually/automatically from local panel/unit control board. Detailed Project Report of Pinnapuram Pumped Storage Project Rev - RO Page 227RY aarvee associates Greenk® actitets engineers & constants pvt xL, XII 10.4.1 SLIPRINGS & BRUSHES: The excitation of the generator will be applied via a static excitation system. In this case, the excitation power respectively the slip power is transferred from the AC excitation to the 3-phase rotor winding via brushes and slip rings. The slip ring holders are arranged on the shaft end opposite the turbine side and are insulated to the shaft. For protection against contact, it surrounds a housing in which the brush holder is also situated. The accessibility is ensured by appropriate openings. The cooling air of the slip rings is completely separated from the cooling air of the generator, which ensures that the generator cannot become polluted by carbon dust. THRUST AND GUIDE BEARINGS: The thrust and guide bearings provided will be of self-circulation type complete with oil coolers, temperature, oil level measuring instruments and oil purification connections. The thrust pads will support the total weight of the generator and turbine-rotating parts including the maximum hydraulic thrust of the turbine. The thrust bearing will be provided with a high-pressure pump lubrication oil system, which will be operated during starting and stopping. The thrust bearing will consist of selflubricated pivoted pad type. The thrust and guide bearing housing will have plug in type heat exchangers to dissipate heat in the oil during unit operation. The generator top guide bearing on top of generator will be of the self/forced circulation type with oil coolers temperature, oil level measuring instruments and oil purification connections. Operating Condition - DFIM The Doubly Fed Induction Machine (DFIM) shall be connected to a hydraulic pump / turbine whose rotation can be reversed, The DFIM shall be able to operate in three modes: a. Generator, driven by the hydraulic turbine, rotating one way The DFIM shall be driven with the hydraulic turbine. The rotating speed of the DFIM can then be adjusted to optimise the turbine operating point according to various criteria such as efficiency, cavitation, hydraulic stability etc. b. Motor, driving the hydraulic pump, rotating the other way The DFIM shall drive the hydraulic pump duly drawing power from the grid. The rotating speed is controlled so as to adjust the power used from the grid, The mechanical power required by the pump shall vary from minimum to maximum rating. Condenser Mode, in both turbine and pump rotating direction. Starting Method of DFIM uni ‘As these Pump-turbines are of larger size and in order to minimise the starting power drawl from grid, runner aeration system(Water depression system of runner) is used. By Detailed Project Report of Pinnapuram Pumped Storage Project Rev - RO Page 228RY aarvee associates Greenk® actitets engineers & constants pvt 10.4.2 admitting of required Pressurised Air into the runner the water get depressed well below to the runner bottom to enable friction free rotation (as the viscosity of air is very less than water) and reduced power drawl for starting. With the stator in shorting condition and applying the Variable voltage and variable frequency to the rotor winding from the AC excitation system the machine starts running in pump mode direction. Once the machine attains the speed equal to grid frequency the unit will be synchronised to the grid system by opening the shorting breaker of stator and then closing the main Generator circuit breaker. To enable pumping of water air will be released from runner and pump will be loaded, ‘The DFIM rotor shall be connected to a power converter supplying a three phase sine wave at a desired slip frequency. The power converter shall also be used for motor start. DFIM shall be started either fully automatic or with manual step-by-step procedure using SCADA/PLC system. DFIM shall be stopped or tripped through manual or automatic from protection relays. Resistance / Thermo Couple Type Temperature Detectors Duplex type platinum RTDs of required quantity suitably distributed in the stator for measuring the temperatures of core, teeth & windings shall be embedded for indication/recording and alarm as well as for tripping the unit in case of high temperature. All RTD terminals shall be brought out to a separate terminal box mounted on stator frame and further will be extended for SCADA / recorders for automation along with sufficient DTTS for local indication. Similarly, suitable detectors along with suitable communication will be provided for rotor winding temperature measurements also. Condition mor ring system: The Condition Monitoring system is designed to monitor the operation behaviour of Pump Turbine & DFIM unit and to assess its condition to allow a condition-based maintenance by prediction of abnormality and take preventive action. Following are the condition monitoring systems envisaged for this project. a. Vibration of Pump- Turbine & DFIM b. Air Gap of DFIM units c. Partial Discharge Off-line Monitoring of DFIM d, Shaft Current on line Monitoring of Pump- Turbine & DFIM e. Cooling & winding Temperature on line Monitoring of DFIM f. Cooling and Commutator Temperature on line Monitoring of DFIM Detailed Project Report of Pinnapuram Pumped Storage Project Rev - RO Page 229fet caven cece Greenke LIST OF GENERATOR ~ MOTOR SPARES: Sr. No. Description Qty. ‘A_|MAIN DFIM SPARES 1. _ |For one stator windings comprising one third (1/ 3) of all bars used 2sets 2 For one generator stator all necessary material for fixing, clamping, 2 sets jointing including slot wedges. For one Rotor windings comprising one third (1/ 3) of all bars used 2sets For one generator Rotor all necessary material for fixing, clamping, jointing including slot wedges sets 5. Generator Thrust Block 2 sets Generator Thrust bearing segments/pads complete set with support & (one set per each Generator of 240MW &120 MW) 2 sets Generator Upper guide bearing shell along with segments/pads 7 complete sets (one set per each Generator of 240MW 84120 MW) sets Generator Upper guide bearing segments/pads complete sets (one set ®_|per each Generator of 240MW &120 MW) 2 set Generator Lower guide bearing segments/pads complete set (one set| © |per each Generator of 240MW 8120 MWY) asst Generator Lower guide bearing Shell along with segments/pads 1°. complete set (one set per each Generator of 240MW &120 MW) Peels i. Brake lining pads for 240 MW and 120 MW units 2 sets 12. _|Air/Water Heat exchangers 100% quantity of each generator 1 set 13. _| Jacking Oil Pump each with Motor one for each generator 2 set 14, _ [HP Oil Lubrication Pump each with Motor one for each Generator 2 nos, 15. _|slip rings, brush holders complete for one Generator 2 set set of slip rings including mounting Sinsulation materials for one 16. Generator 2 sets 17. One Lot of carbon Brushes for each generator 2 sets 18. [One lot of seals and gaskets for each generator. 2 sets 19. _|DTT (Dial Type Temp. Thermometer) for each generator 2 sets 20.__ |RTDs (Resistance Temperature Detectors) of each type for 240 MW 2 sets Instruments for bearing lubrication system, thrust bearing, upper and| 1 No. of 21. lower guide bearings etc. Each type 1 set of 22. _|Valves for each generator each type Detailed Project Report of Pinnapuram Pumped Storage Project. Rev - RO Page 230w aarvee associates Greenk® actitets engineers & constants pvt 10.5 Generator Circuit Breaker with Disconnector and PRDS The Generator Circuit breaker for 240 MW units shall be three phase, single pole SF6 Gen- erator Circuit Breaker (GCB) of rating 24KV, 11000Amps, short circuit rating of 80KA/3Sec with motor operated Starting switch, Voltage transformers, motor operated disconnecting switch, Phase reversal switch, lightning arrester, surge capacitors, control cubicle, with all necessary accessories. ‘The Generator Circuit breaker for 120 MW units shall be three phase, single pole SF6 Gen erator Circuit Breaker (GCB) of rating 24KV, 5500 Amps, short circuit rating of 63KA/3Sec with motor operated Starting switch, Voltage transformers, motor operated disconnecting switch, Phase reversal switch, lightning arrester, surge capacitors, control cubicle, with all necessary accessories. Considering the Motor capacity as 264 MW at 0.95 PF, reactance 15% the fault current contribution from motor is 60 KA whereas fault contribution from generator transformer side with impedance 15% is 65 KA. Hence 80 KA GCB for 240 MW unit is envisaged. Similarly Considering the Motor capacity as 132 MW at 0.95 PF , reactance 14% the fault current contribution from motor is 32 KA whereas fault contribution from generator trans- former side with impedance 15% is 32 KA, Hence 63 KA GCB for 120 MW unit is envis- aged. Each Generator shall be connected to the Generator Step-up Transformer via a Generator Circuit Breaker. The bus potential transformers, surge capacitors and surge arrestors lo- cated between the generator breaker and the generator shall be integrated in a cubicle, Online Gas density monitors shall be provided for each gas compartments. Mechanical and electrical interlocking shall be employed to prevent in appropriate application of the GCB, disconnect switches and earthing switches. Dual redundant power control supplies shall be provided. DISCONNECTOR: ‘A disconnector shall be provided on the transformer-side in series with the circuit-breaker The disconnector shall be a tubular telescopic unit, with the moving contact on the termi- nal side and fixed contact tube on the circuit-breaker side. The control of the disconnector including the interlocking circuit shall be accommodated in the GCB-system control cubi- de, A local/remote switch and pushbuttons for local control shall be provided, Phase Reversal Disconnecting Switch (PRDS) Motor operated Phase Reversal Disconnecting Switch envisaged for Generator and motor operation with suitable short time withstand current. Detailed Project Report of Pinnapuram Pumped Storage Project Rev - RO Page 231fae Greenke SALIENT FEATURES OF GCB, DISCONNECTOR AND PRDS: S.No Description Parameter 1 [Type 3Phase gang operated Single pole operated SF6 Gas type 2 Location of installation Indoor Horizontal In between Asynchronous machine which acts as Generator & motor and Generator 3. [Mounting step up transformer. connected to /Aluminium tube isolated phase bus duct system at both ends. 4 Reference standard IEEE Std.C37.013--IEC-62271-37-013 5 Nominal system voltage 24 KV 6 _ [Power Frequency 50 Hz 7 [Rated continuous current 11000Amps 5500Amps 8 [Rated dielectric strength: (Ph-E) a) Power frequency withstand voltage 60 KV b) Impulse withstand voltage (1.2/50uS)_|125 KV 9 [Rated dielectric strength: Across terminals a) Power frequency withstand voltage 60 KV b) Impulse withstand voltage (1.2/50uS)_|125 KV 10 | Rated short circuit duty cycle CO-30min-CO 240MW [120 MW 11 _ [Rated short circuit current 80KA/3Sec__|63 KA/3 Sec 8 _[Disconnector Continuous current rating 11 KA for 240 MW unit and 5.5 KA for 120 MW unit 5 | Power frequency test voltage to ground 50 KV rms. 6 _ |Full wave impulse test voltage to ground _|125 KV peak 7 | Power frequency test voltage across 60 KV rms contacts 8 |Full wave impulse test voltage across 145 KV peak contacts E [Phase reversal disconnecting switch (PRDS) Detailed Project Report of Pinnapuram Pumped Storage Project Page 232 Rev - ROw aarvee associates Greenk® actitets engineers & constants pvt 1 | Continuous current rating 11 KA for 240 MW unit and 5.5 KA for 120 MW unit 2 [Rated Short time withstand current 80 KA/1 secs for 240 MW Unit 63 KA/1 Sec for 120 MW unit LIST OF GCB SPARES: [S.No Description of item Qty 1 _ [Oil pump motor for operating mechanism of C.B. No 2__|ClosesTrip coil No 3__|SF6 density indicator No 4 _ [Carbon brushes No 5__|SF6 density monitor relay No 6 _ [Catch gear mechanism unit 1No 7 _ [Position switch unit 1 set 8 _ |Sf6 gas pressure switch 1 set 9 [Spring charge motor 1No. 10 [Circuit breaker pole for big unit No. 11 _|Circuit breaker pole for small unit 1No. 10.6 Isolated Phase Bus Duct The bus duct shall be air cooled, Isolated phase type in which each conductor shall be supported on epoxy cast resin insulator at an interval as per the successful type test de- sign and enclosed by an electrically continuous individual aluminum housing separated from adjacent phases by an air space. The enclosure shall be made of Al. alloy grade sheet rolled to form standard sections, ‘Transport sections shall be welded at site. The IPBD enclosures are supported using sup- Porting structures at suitable locations. Horizontal runs of enclosures are supported with sliding arrangement up to 10mm to align the bus duct with equipment whereas vertical supports are designed for rigid and sliding mountings. Disconnecting links shall be provided at each end of generator, generator transformer, tap off etc. as per requirements. Rubber bellows are provided for connection between the bus duct and generator, trans- formers and cubicles. Three enclosures are shorted together by means of aluminum plates to provide a closed electrical path for enclosure currents which will be provided with holes to receive station earth bus. Detailed Project Report of Pinnapuram Pumped Storage Project Rev - RO Page 233RY aarvee associates Greenk® actitets engineers & constants pvt Bus duct for 240 MW unit shall be Aluminum, 3 phase, 36 kV class, 11000 amp indoor main isolated phase bus ducts (IPBD) with tap off connections to current limiting reactor in the run of the main IPBD that include bus conductors, Generator main & neutral termi- nal chambers, bimetallic & flexible connection at generator and GCB end, GCB and PROS end and PRDS to transformer ends (Three single phase power transformers), vibration pads, supporting insulators, housing and supports, ground bus wall / floor frame assem blies, seal off bushings, necessary fixtures for support of bus ducts with the wall / ceiling and all other sundries to complete the equipment. Bus duct for 120 MW unit shall be Aluminum, 3 phase, 36 kV class, 5500 amp with short circuit capacity of 63 KA/3 Sec indoor main isolated phase bus ducts (IPBD) with tap off connections to current limiting reactor in the run of the main IPBD that include bus con- ductors, Generator main & neutral terminal chambers, bimetallic & flexible connection at generator and GCB ,GCB and PRDS end and PRDS to transformer ends, vibration pads, supporting insulators, housing and supports, ground bus wall / floor frame assemblies, seal off bushings, necessary fixtures for support of bus ducts with the wall / ceiling and all other sundries to complete the equipment. Interconnection between Generator neutral terminals and Generator Neutral Grounding Terminals (NGT/NGR Cubicle) along with adapter box from stator terminals terminated at generator barrel to the seal off bushing and after the placement of CTs, formation of neu- tral and connection of single conductor to NGT/NGR cubicle. Tap off ducts from main IPBD comprising of 36 KV, 1500 A with short circuit current ca~ pacity of 120 KA/3 Sec for connection to Current Limiting Reactors including bus conduc- tors, bimetallic and flexible connections, supporting insulators, vibration joints, grounding arrangement, necessary fixtures for support of bus ducts and all other sundries to com- plete the equipment are envisaged. For Delta formation with vector group of YNd11 from three single phase Generator Trans- formers of rating 100 MVA each adaptor boxes with necessary accessories has been envis- aged. Steel structure (one for each unit) for supporting the main & tap off bus ducts in its run along with foundation bolts / embedment plates and U clamps for supporting the IPBD envisaged. Salient features of IPBI Number of phases of the system Three clo Nominal operating voltage 18 KV Highest system voltage 36 KV Voltage variation + 10% Detailed Project Report of Pinnapuram Pumped Storage Project Rev - RO Page 234fae Greenke e Frequency 47.5-51.5 lOne-minute power frequency f — |withstand test voltage 70 KV (rms) g__ |Impulse withstand test voltage 170 KV (peak) h Rated Continuous current: 240 MW unit 120 MW Unit i) Main Bus 11000 Amps —_|5500 Amps ii) Tap off bus 1500 Amps i Short Circuit current rating: 240 MW 120 MW i) Main Bus (Symmetrical) 80/3 Sec [63 KA/3Sec ii) Tap off bus (Symmetrical) 120KA/3 Sec Maximum hot spot temperature rises j _ Jabove 45°C ambient temperature at [continuous rating i) Bus conductor 65 Deg C ii) Enclosure and support structures where accessible 30 Deg C k [Bus conductor material [Aluminium L__ [Bus bar material Al. alloy grade 91E as per IS 5082 M__ [Material of bus enclosure [Aluminium alloy List of Isolated Phase Bus Duct SPARES: S.No Description Qty 1 [Copper flexible jumpers 1 set (each type 1 No.) 2 [Current transformers 3 Nos. Of each type 3 [NGT&NGR 1No. 4 Rigid jumpers 1Set 5 __ [Epoxy resin insulators used in main bus _[5% of total qty 6 _|Epoxy resin insulators used in tap-off bus [5% of total qty Seal off bushing 7 Main Bus -3 Nos. 1 Set Delta Bus - 3 Nos. Tap off Bus - 3 Nos. 8 Rubber bellow 1Set Limit switches of each type 1 Set 10 —_|MCB of each type 1Set 11 __ [Fuse of each type 1 Set Detailed Project Report of Pinnapuram Pumped Storage Project Page 235 Rev - ROw aarvee associates Greenk® actitets engineers & constants pvt 10.7 10.8 Lighting System Energy efficient illumination fixtures i.e. LED type with suitable fixtures to meet the required illumination levels as per standards are envisaged for plant and pothead yard illumination system. The power station lighting system will comprise the following: Normal 230V AC Lighting System: The lighting circuit in the normal 230V AC lighting system would be fed through 11.0/0.415KY, 3phase, 4 wire transformers connected to 415V distribution system Direct Current Emergency Lighting system: Direct current emergency lights would be provided at strategic points in the power sta~ tion, viz. Near entrances, staircases, the main control room, Turbine area, switchyard area etc. ‘These would be fed from the station 220V DC system and would be off when the normal ‘AC power supply is available, These would be automatically switched on when the normal AC supply fails. ‘The proposed illumination levels for various areas are given below: - Control Room 300 lux Switchgear/MCC room 250-300 lux TG building 250 lux Outlying areas 30-40 lux Switch yard 25-35 lux Stores 100-150 lux Battery Room 100 lux Administration building and Office rooms 300 lux Roads 20 lux Cabling All cables will be selected to carry the full load current under site conditions, with permissible voltage drop/dip. In addition, these cables will be rated for short circuit capacity wherever required. The following types of cables will be used: The following cables are envisaged for speci project: a. 400 KV XLPE CABLE: 400KV 3 nos power cables of 1000 Sqmm - 400 / 231 kV XLPE Single-core XLPE High Voltage Cable with Aluminium laminated sheath are envisaged. XLPE cables shall meet the following technical parameters. Conductor Material - Annealed Copper Conductor Type - Stranded compacted circular Detail led Project Report of Pinnapuram Pumped Storage Project, Rev - RO Page 236RY aarvee associates Greenk® actitets engineers & constants pvt Size - Single Core, 1000 sq.mm The conductor shall consist of annealed copper. The form of the conductor shall be stranded compacted circular. Stranded compacted circular shall consist of wires stranded together & then compacted as per IS standard IS:8130, IS:7098 Conductor Screening as per IS:8130, IS:7098 Material - Semiconducting Compound Type - Extruded Resistivity = Shall not exceed 1000 ohm-m The conductor screen shall consist of an extruded layer of semi conducting compound. The conductor screen of semi conducting compound not only eliminates the risk of electri- cal discharge at the interface between conductor and insulation but also presents a very smooth interface with the insulation to eliminate any localized stress concentration. Insulation as per 1S:7098 Material = High Purity XLPE satisfying Table 2 of 1S: 7098 (Part III) Type ~ Extruded Dielectric Power Factor — As per IS: 7098 (Part II) / IEC 60840 The insulation material shall be extruded cross linked polyethylene and shall be applied over the conductor screen in strictly controlled atmospheric conditions. Insulation Screening as per 1S:8130, IS:7098 Non-Metallic part Material - _ Semiconducting Compound Type - Extruded Resistivity = Shall not exceed 500 ohm-m. Water Blocking Tape Material = Semiconducting Non-woven water barrier tape Metallic part as per 1S:8130, IS:7098 ‘Type & Material - Extruded Corrugated Aluminum sheath Extrusion of conductor, insulation and insulation screen shall be carried out in one single operation to ensure perfect bonding without any surface irregularities in the boundary lay- ers. The insulation screen shall be provided over the insulation by extruding the semi conduct ing compound to minimize the possibility of ionization on the outer surface of the dielec- tric. Extruded semi conducting layer is followed by a semi conducting non-woven water swellable tape. Inner Sheath Material = PVC Compound or thermoplastic poly- Detailed Project Report of Pinnapuram Pumped Storage Project Rev - RO Page 237fer sees exces Greenke ethylene compound ‘The PVC compound shall conform to type ST2 of IS: 5831 - 1984. The thermoplastic poly- ethylene compound shall conform to 1S: 7098 (Part-IIT). Armor The Armor shall be of non-magnetic metallic wires. Material — Annealed copper wire Type - Applied helically Outer Sheath Material “Extruded PVC Compound or thermoplastic polyethylene a) To protect the metallic sheath from electrochemical or galvanic corrosion, it shall be covered with PVC compound or thermoplastic polyethylene compound, PVC shall be flame retardant low smoke (FRLS) type in line with standards ASTM-D-2863-77/ IEC 754-1/ ASTM-D-2843-77, The PVC compound shall conform to type ST2 of IS: 5831 — 1984, The thermoplastic polyethylene compound shall conform to IS: 7098 (Part- 1m). EHV Cable termination: Cable sealing ends shall be terminated with suitable terminations at the Generator Trans former with Gil to Oil bushing end & Plug in type termination at GIS end, Oil to Air bush- ing sealing end termination at Station Auxiliary Transformer End & Plug in type termina- tion at GIS end. There shall be no joints in the cables. Salient features of 400 KV EHV cable: S.No. [Technical Particulars Ratings [General System Requirements 1. _ [Highest system voltage (KV) 420 KV 2. [Design Ambient Tempurature 45°C 3. _ [Frequency of the system Normal condition (Hz) 50 +3% to -5% Current Rating 1, _| Short circuit withstand current for 1 second (KA) 63kArms 2. | Momentary short circuit current (KA) 157.5kAp Cable Cross Section 1, _ | Nominal Cross- Section of Conductor (sq.mm) 100 2. _ | No. of cores single b, HT & LT POWER CABLES For 18KV power cables - 18KV (UE) grade, stranded aluminum conductor, XLPE insulated, Detailed Project Report of Pinnapuram Pumped Storage Project Rev - RO Page 238w aarvee associates Greenk® actitets engineers & constants pvt 10.9 extruded PVC Inner sheathed, armored, extruded FRLS-PVC (Flame retardant and low smoke - poly vinyl chloride) outer sheathed cables conforming to IS-7098. For low voltage power cables - 1100 V grade, stranded aluminum conductor, extruded PVC insulated, extruded PVC inner sheathed, armored, extruded FRLSPVC outer sheathed cables conforming to IS-1554. . CONTROL CABLES 1100 V grade, annealed high conductivity copper conductor, extruded PVC insulated, ex- truded PVC inner sheathed, armored, and extruded FRLS-PVC outer sheathed. meeting the requirements as specified in 15-5831, d, SIGNAL AND SUPERVISORY CABLES ‘Annealed tinned copper conductor in stranded circular construction, extruded PVC insu- lated, extruded PVC inner sheathed, armored, and extruded FRLS - PVC outer sheathed, in twisted pairs and screened, Cables will be laid in ladder type galvanized steel cable trays or in trenches. e. CABLE TRAYS All the cables will be laid in Perforated GI cable trays with supporting structures in hori- zontal laying and with Ladder type GI trays in Vertical placement. Copper tinned lugs will be provided for all the terminations along with identification ferrules and Tags. Necessary cable glands with fire protection sealing barriers shall be provided. The construction of the cable trays shall be suitable to withstand the associated cable load without undergoing bending or sagging. The cable trays will be of suitable width and length, Necessary provi- sion will be made to connect adjacent trays and the necessary components such as splicer plates, Hexagonal head screws, nuts and washers along with 90-degree Horizontal Elbow, Horizontal Tee etc. to fix the trays will be included in the scope of supply. The perforations provided shall be such that adequate ventilation is allowed and facilitate binding the ca- bles to the trays. Earthing Earthing of powerhouse & outdoor yard will be done as per IEEE 80 latest issue after measuring the soil resistivity. The risers from the earth mat will be connected to water conducting system to limit the overall ground mat resistance to less than 0.59. ‘Two independent earthing points (Pads) of bolted type shall be provided on opposite sides of generator stator casing and exciter for connecting earthing conductors. These earthing points shall be in addition to any earthing studs provided in the terminal boxes. The earthing pads shall be of non-corrosive metal, welded or brazed to the machine body. The size of the earthing pads shall be suitable to connect earth conductor. ‘Two earthing terminals shall be provided for all auxiliary equipment, cubicles etc. Earthing Detailed Project Report of Pinnapuram Pumped Storage Project Rev - RO Page 239RY aarvee associates Greenk® actitets engineers & constants pvt bus shall be provided for control panels. 10.10 Voltage Source Converter and Control System (AC Excitation System ) The excitation system shall enable the operation of the generator motor units in frequency regulation, voltage regulation modes within the capability diagram of the units. The excitation system shall manage the DFIM operating point parameters such as active power, reactive power or stator voltage, shaft or runner speed according to desired P,Q set points (given by operator through SCADA system) and optimizing rules. The excitation system shall include two types of controls: > Aguide vane regulation controlling the guide vane opening and thus the mechanical torque on shaft. > A rotor current regulation controlling the electromagnetic torque in air gap and the magnetizing current of the DFIM. ‘The AC excitation system shall be designed to perform the following functions: > Ensure the rotation of shaft line and voltage ramp up of DFIM stator > Bring the DFIM to synchronizing conditions > Keep the unit at a desired set point within the capability curve of the primary mover and the DFIM > Contribute to grid support through primary and secondary frequency control and primary voltage control > Keep the unit within stability limits whether hydraulic, or electrical and within thermal limits > Ensure safe state return in case of unit shut down whether normal shut down or trip whatever the cause > Ensure that all requirements arising from grid connection specification are met ‘The excitation system shall be connected to SCADA system. The harmonic content injected into the neighboring power grids must comply with IEC 61000-2-4 class 3 and IEC 61000- 3+6 standard, ‘The excitation system shall include two control strategies which can switched from one to ‘the other (a) Active and reactive loads are controlled by the voltage source inverter (VSI) while the speed of shaft line is controlled by turbine governor (b) Speed and reactive load are controlled by the VSI while the active load is controlled by turbine governor 10.11 Surge Protection & Neutral Earthing System The power generated will be fed to 18 KV side of the respective transformers through respective Generator Circuit Breakers with Lightning Protection & Voltage Transformer and Detailed Project Report of Pinnapuram Pumped Storage Project Rev - RO Page 240RY aarvee associates Greenk® actitets engineers & constants pvt neutral terminals after star formation are connected to Neutral grounding cubicle by means of Bus Duct. 10.12 Supervisory Control and Data Acquisition (SCADA) The function of plant central computer control system will be to provide automatic control for all the units as well as the data acquisition, alarm monitoring and data logging and archiving. Programmable Logic Controller (PLC), (Part of the SCADA system) located in the UCB, which will be entirely dedicated to the unit as well as plant control and data acquisition. One redundant PLC shall be dedicated for each unit in the UCB, The substation will have a dedicated PLC. Other PLCs and /or RTUs shall be provided for control and data acquisition of auxiliary services and intake. All PLCs will be connected to a central unit in the control room through fiber optical cables. The central unit, through a man machine interface (video displays, functional keyboards, pointers) will be used to provide efficient communication between the operators and the control system. The SCADA system will also be designed to interface and communicate with the grid displaying system through a telecommunication system, transmitting all the required data that is essential to the grid dispatching operator, 10.12.1 Generator / Unit Control Panel All operations such as starting, initiation of Auto synchronizing, bringing up to rated voltage and speed, operation and annunciation of various conditions and alarms, monitoring, data logging, recording and sequential event recording for generator and its excitation system shall be through SCADA. For this purpose, a selection shall be provided on the SCADA to select Auto or manual modes of synchronizing, Auto synchronizer shall connect the generator to the grid automatically after synchronizing the two systems. Sufficient interlocking and/or closure permissive shall be incorporated in this scheme. The equipment shall be supplied to control both the voltage and frequency of hydro turbine generator set to match with those of the grid, There shall be two independent outputs from Auto synchronizer and circuit breaker shall close only upon operation of both the outputs. Manual synchronizing of the Generator shall be possible from Generator control panel (cr), Synchronizing equipment consisting of Auto synchronizer, check synchronizing relay, guard relay, double voltmeter, double frequency meter, synchro scope, push buttons for voltage and speed control, control switches for GCB shall be provided on the generator control panel. ‘The unit is intended to be started, controlled in any of the modes from Generator Control Detailed Project Report of Pinnapuram Pumped Storage Project Rev - RO Page 241WY saree associates actitets engineers & constants pvt Greenk® Panel in local & from main control room of Powerhouse and from Remote. 10.13 Main Step-Up Transformer Power generated at 18 KV will be stepped up to 400KV by means of 13 no's (12 Nos. working + 1 No. spare) of 1-Ph 18/400KV 100 MVA oil filled transformers (for 240MW Units) & 2 Nos 18 /400KV 3-Ph 1SOMVA oil filed transformers (for 120MW units). These Step-up transformers will be installed in Transformer hall. Capacity of the transformers arrived based on the Power Factor 0.9, Derating factor. The main electrical parameters of each transformer will be: a b, « a. e f The nals Voltage ratio Rating Cooling Method 18KV connection 400KV connection On load tap changer 18 KV /400KV, 1Phase & 3 phase 3 x 100 MVA (1 Ph) for 240 MW units and 150MVA (3 Ph) for 120 MW units. OFWF (Gil Forced and Water Forced) Delta Star with neutral solidly earthed. In the range of +/-10,0% in step of 2.5% 18 KV terminals (Primary) will be suitable for Bus Duct connection and 400KV termi- for connection to GIS. The transformer will be equipped with the following accessories and metering instruments: > An oil conservator made of steel sheets with welded joints. A diaphragm airtight seal is provided with a breather connected into the air side of the diaphragm, A pressure relief device to protect against high pressure inside the oil tank. > Aas relay mounted in the pipe connecting the conservator to the transformer tank and having contacts for alarm and shutdown. > Awinding temperature indicator with sets of contacts for alarm and trip. > Anoil temperature indicator with alarm and trip contacts. > Anil level indicator with magnetic level gauge and alarm contact. > An on load tap changer for changing the high voltage winding taps. Salient features of Power Transformer: Technical Particulars 1 [Indoor Step Up 2 Standard IEC 60076 3 | a) No. of windings Two b) No. of Phases single 4 _| System frequency 50 Hz+3%8 - 5% ‘Type of mounting On wheels mounted on rails Detailed Project Report of Pinnapuram Pumped Storage Project Rev - RO Page 242w aarvee associates actitets engineers & constants pvt Greenk® 5 | a) KVArating of HV winding 100MVA single phase and 150 MVA , 3 Ph b) KVA rating of LV winding 6 | a) Low Voltage Winding 18 kV b) High Voltage Winding 400/V3kV (1Ph), 400kV (3Ph) 7 Neutral Effectively earthed. 8 Vector Group after 3-Ph formation | YNd11 9 a) LV. Terminals 36KV Porcelain type bushing. b) HAV. Terminals: 420KV RIP condenser type bushing suitable for oil to oil or oil to SF6 termination 10_| a) High Voltage Winding Graded b) Low Voltage Winding Uniform 11 | Type of cooling OFWF 12 | Impedance Voltage at normal tap | 15 % (IEC tol) 13 Insulating Medium Inhibited Mineral Oil (as per IEC:60296 and bid specification) 14 _ flap changing gear ON load tap changer 15 [Insulation Levels for windings HV HVN LV IHV:1425 1.2 /50 micro — second wave shape [1425 170 170 impulse withstand (kVp) Applied voltage (kV rms) 70 70 70 induced overvoltage withstand 630 70 70 (kvrms) 16 Permissible temperature rise over ambient temp of 50 Deg C for ONAN| &ONAF cooling [Of top oil measured by thermometer |50°C Jof winding measured by resistance [55°C 17. [Minimum clearance in air (mm) HV Phase to ground 3500 3500 18 [Bushing and Termination details : IHV winding Line end 420KV RIP Condenser bushing suitable for oil to oil or oil to SF6 termination Detailed Project Report of Pinnapuram Pumped Storage Project Page 243 Rev - RORY aarvee associates Greenk® actitets engineers & constants pvt Lv Winding 36KV porcelain bushing suitable for busduct arrangement. 19 [Insulation level of bushings HV Ww Lightning impulse withstand (KVP) 1425 170 Switching impulse withstand (KVP) |1175 NA 1 Minute power frequency withstand|630 70 voltage (kV rms) 20 [Noise Level As per NEMA TRI Latest issue 21 | No. of Coolers ‘Two nos. of 100% capacity one to act as main & other act as stand by st of Power Transformer Spares: S.No Description Qn 1__|Gaskets (All types) 1 set 2__ [Pressure relief device 1No. 3. |Gas detecting relay 1No. 4 [Buchholz relay 1No. 5__ [Temperature indicators ja) Oil temperature indicator (OTT) 1No. lb) Winding temperature indicator {(WTT) without 1 No. of each repeater} Oil and water flow indicator with electrical 6 1 No's each [contactors [Gas sampling device No. 8 [LV bushings 1 set HV bushings 1 set 10 __[HVN bushing 1No 11 _|Silica Gel breather with 10kgs of additional silica gel. One No. 12__ [Moc 1No. 13 |Lifting jacks and steel slings set. 14 __|Valves of each type 2No's 15 [Drain and vent plugs 2.No's Each type of MCB, auxiliary relay, contactor, heater, 16 2No's lamp and push button. 17 __|Pumps of each type INo’s Detailed Project Report of Pinnapuram Pumped Storage Project Rev - RO Page 244RY aarvee associates Greenk® actitets engineers & constants pvt 10.14 400kv Indoor GIS 400KV Gas Insulated switchgear (GIS) units with sectionalizes and with double bus bar arrangement proposed for the project. 400 KV GIS comprising the following bays: vv v > Generator transformer bays - 6 Nos. Station auxiliary transformer bays - Nos. Bus coupler bays =. 2Nos. Bus Sectionalizer bays = .2Nos. Line bays - 4 Nos. To facilitate evacuation of power to two different grid substations as well as to avoid complete interruption of power evacuation in case of any fault on the bus, bus Sectionalizer is considered. As the 400KV GIS consists 6 no's of unit bays, 2 no's SAT bays, 4 no's of line bays and PT and Bus coupler bays it is preferred to provide sectionalises to avoid from complete breakdown of the system and make availability of other section which is healthy in case of Bus fault. Indoor metal-enclosed phase segregated type SF6 gas insulated switchgear system rated for 400 kV, 3 phases, 63KA, 50 Hz consisting of following major items: a vvy v v y v v v v 3150A SF6 gas insulated metal enclosed bus bars complete in all respects, comprising of: Individual bus bars enclosures running the length of the switchgear, Single-phase surge arrestor, Single-phase, 2-core voltage transformers, Single-phase disconnector complete with manual and motor driven operating mechanisms, for isolation of voltage transformer, Single-phase safety earthing switches complete with manual and motor driven operating mechanisms, with each single-phase disconnector. Bus-coupler & bus sectionalize bay modules, each comprising of: 3+pole SF6 gas insulated circuit breaker, complete with dedicated operating mechanism, 4-core, multi ratio, 3-pole current transformers, 3-phase, single-pole group-operated disconnector complete with manual and motor driven operating mechanisms, 3-phase, single-pole group-operated safety earthing switches complete with manual and motor driven operating mechanisms, Local control cubicle for control of coupler bay, bus bar VT and disconnector. Generator bay modules, each comprising of: 3pole SF6 gas insulated circuit breaker, complete with dedicated operating Detailed Project Report of Pinnapuram Pumped Storage Project Rev - RO Page 245RY aarvee associates Greenk® actitets engineers & constants pvt mechanism for each pole, 5-core, multi ratio, 3-pole current transformer, vv Single-phase surge arrestors, v 3:phase, single-pole group-operated disconnector, complete with manual and motor driven operating mechanisms, v 3-phase, single-pole group-operated safety earthing switches, complete with manual and motor driven operating mechanisms, SF6 / SF6 bushings, Local control cubicle for control. v v d. Transmission line bay modules, each comprising v 3+pole SF6 gas insulated circuit breaker, complete with individual operating mechanism, > S-core, multi ratio, 3-pole current transformer, > 3+phase, single-pole group-operated disconnectors, complete with manual and motor driven operating mechanisms, > 3-phase, single-pole group-operated safety earthing switches, complete with manual and motor driven operating mechanisms, v S-phase, single-pole group-operated high-speed earthing switch, complete with manual and motor driven operating mechanism, v SF6 / air bushings for outdoor connections, y Local control cubicle for control. e. Gas insulated bus duct (GIB) for interconnection between GSU transformers and respective unit bays of GIS, f All necessary terminal boxes, SF6 gas filling, interconnecting power and control wiring, earthing connections, gas monitoring equipment and piping support structures etc., 9. Monitoring and diagnostic systems to monitor gas density, gas pressure, leakage, moisture, partial discharge etc., and also operating parameters such as current, voltage, temperature etc. complete with sensors, control/processor units, wiring/cabling in all respect and integration of the systems with plant SCADA system, Brief Description of components in GIS: Bus bars: Bus bar of each bay shall have separate gas compartment partitioned from adjacent bay. Each cable head shall be in separate gas compartment for circuits with two cable head Gas barrier insulators shall be painted with yellow colour. CTs shall be located in a Detailed Project Report of Pinnapuram Pumped Storage Project Rev - RO Page 246RY aarvee associates Greenk® actitets engineers & constants pvt separate gas compartment. Bus bars chambers shall be so arranged as to allow maintenance on one busbar, i.e. gas removal, and retain the other bus bar and circuits in service. The busbar phase conductor shall be aluminium adequately supported by cast resin insulators or other approved material equally supported, at least at both ends of each section making provision for free axial movement of conductor. Circuit Breaker: rcuit breakers shall be equipped with the operating mechanism. Circ breakers shall be of single pressure type. Complete circutt breaker with all necessary items for successful operation shall be supplied. The circuit breakers shall be designed for high speed single and three phase reclosing (as applicable) with an operating sequence and timing as specified. Circuit breaker shall be E1 - C2 — M2 class as per IEC 62271-100. Circuit breaker shall meet the duty requirements for any type of fault or fault location also for line charging and dropping when used on effectively grounded system and perform make and break operations as per the stipulated duty cycles satisfactorily. Circuit Breaker shall be of Single Break type and shall be suitable for an operating sequence of O-0.03 sec-CO-3 min-CO. Current Transformers: ‘The current transformers and accessories shall conform to IEC 61869 and other relevant standards except to the extent explicitly modified in the specification, The particulars of the various cores may change within reasonable limits as per the requirements of protection relay supplier. Voltage Transformer: The voltage transformers shall conform to IEC- 61869 and other relevant standards except to the extent explicitly modified in the specification. Voltage transformers shall be of the electromagnetic type with SF6 gas insulation. The earth end of the high voltage winding and the ends of the secondary winding shall be brought out in the terminal box. Isolators: Isolators shall be of the single-pole, group operated type, installed in the switchgear to provide electrical isolation of the circuit breakers, the transformers, double bus and transmission lines. The isolators shall conform to IEC- 6271-102 Salient features of 400 KV GIS Syster S.No. Technical particulars Parameters for 400KV Rated Voltage 400 KV (rms) System Voltage 420 KV (rms) Rated frequency 50 HZ Detailed Project Report of Pinnapuram Pumped Storage Project Rev - RO Page 247RY aarvee associates Greenk® actitets engineers & constants pvt 4. | Grounding Effectively earthed g, [Rated power frequency with stand voltage (1] 6. 4 cmsy min) line to earth Impulse withstand BIL (1.2/50 mic Sec) Line to 6. 1425 kVp earth 7. | Rated short time withstand current (1 sec) 63 KA (rms) 8. _| Rated peak with stand current 157.5kA (peak) Guaranteed maximum gas losses for complete 9. | installation as well as for all individual sections] As per IEC 6271-203 in Rated current normal/ at site (at 40-degree C 10. 3000 Amp. design ambient temperature) 1. | seismic teve Zone- II, as per IS-1893, Year-2002 Spares for GIS: 1, _[SF6 gas Pressure Relief Device assembly of each type 1 set SF6 Pressure gauge cum switch / Density monitors and pressure switch 2. _|as applicable, of each type. 2 sets Coupling device for pressure gauge cum switch for connecting gas 3.__ [handling plant of each type 1 set Rubber Gaskets, "O” Rings and Seals for SF6 gas for GIS enclosure of| 4._ [each type 2 sets 5.__ |SF6 gas (20 % of total gas quantity) L lot 6. _|UHF PD Sensors of each type along with BNC Connector 2 sets ‘Trip coil assembly with resistor as applicable of each type 3 sets Closing coil assembly with resistor as applicable of each type 3 sets Relays, Power contactors, push buttons, timers & MCBs etc of each type 9. [and rating 2 sets 10. [Auxiliary switch assembly of each type 2 sets 11. [Spring Charging Motor 2 sets Complete Spring Operating Mechanism including charging 12. _|mechanism etc. of each type 2 sets Limit switch and Aux. Switches for complete 3 phase equipment of| 13. |isolator, earth switch & fast acting earth switch. 2 sets Detailed Project Report of Pinnapuram Pumped Storage Project Rev - RO Page 248RY aarvee associates Greenk® actitets engineers & constants pvt 14, [Complete CT assembly 1 set 15. _|Complete PT assembly I set 16. [Complete Gas insulated Surge arrester 1 set 10.15 Control & Protection Equipment Integrated Numerical protection relays will be provided in redundant for each Generator and Generator transformer. Basic protections are indicated here under however, specific protections related to variable speed machines shall be considered at the time of detailed engineering. I. Generator protection Redundant Generator numerical protection relays shall be of different make as per the latest protection philosophy. Relays shall be IEC61850 complaint and shall have GPS time synchronization provision in addition with Disturbance Reporting and Event logging provisions. The following protections will be provided for the generators: - Backup Impedance (21) = Over Excitation (24) - Under Voltage/ Over Voltage (27/59) - Under Power (37) - Loss of Field/ excitation (40) - Negative phase sequence (46) - Thermal Over Loading (49) - Breaker Failure (50BF) = Voltage Restrained Over current (51V) - PT fuse failure (60FL) - 95% Stator earth fault (6462) - 100% Stator earth fault (64G1) - — Under/ Over frequency (810/U) - Generator Differential (876) = Annunciator (30) - Rotor Earth Fault (64F) - Master Trip relay (866) - Trip Circuit Supervision (95) - Split phase based inter turn protection - Overall differential protection with 3 winding inputs (Generator, GT HV, and Generator Tap off). Detailed Project Report of Pinnapuram Pumped Storage Project Rev - RO Page 249RY aarvee associates Greenk® actitets engineers & constants pvt Il. Turbine Protections The following protections will be provided: > Under/ Over Speed (12/14) > Governor Failure Relay (33/63) > Bearing Temperature (38T) > Oil pressure Failure (96.2 OPU) > Oillevels Shear pin vibrations ete TIT. Auxiliary Transformer Protections The following protections will be provided: > Under Voltage (27) > Instantaneous O/C & E/F (50/50N) > IDMT O/C & E/F (51/51N) > Master Trip (86) IV. Step-Up Generator Transformer Protections The following protections will be provided for step-up transformer: > Transformer Over Fluxing (49) Instantaneous O/C & E/F (50/50N) > IDMT O/C &E/F (51/51N) > Transformer Differential (87GT) > Restricted earth fault (64REF) > Annunciator (30) > Oil temperature, Alarm/Trip Aux (490A/OT) > Winding temperature, Alarm/Trip Aux (49 WA/WT) Buchholz/ Alarm/Trip Aux (63 A/T) v > High Speed Tripping (Master) (86T) > Trip Circuit Supervision (95) > Low il Level Alarm (LOLA) v Oil Surge Trip (OSRT) » Pressure Relief Device Trip Aux. (PRD-T) > Apparatus thermal device (26) > — Liquid Switch (71) 40Q0KV Line protections 400KV feeder protection shall be redundant with numerical protection relays and shall be of different make as per the latest protection philosophy. Relays shall be compatible to Detailed Project Report of Pinnapuram Pumped Storage Project Rev - RO Page 250RY aarvee associates Greenk® actitets engineers & constants pvt IEC 61850 Protocol. Disturbance Recorder evaluation cum event logger units shall be included. ‘The following protections will be provided for the lines: % Distance Protection (21) > Over/ under voltage (27/59) > AC Directional over current (67/67N) > Frequency (81) > Master Trip (86) > Trip Circuit Supervision (95) > AC Reclosing Relay / Auto Reclose (79) > Instantaneous Overcurrent Relay (50) > Phase Angle Measuring or Out-of-Step Protective Relay (78) > Bus Differential (87B) > Overvoltage Relay (59) > 400KV reactor protection v 400KV bus bar protection > 400KV cables protection (if EHV cables adopted) > Bus coupler protection List of Spares for Protection System: 1. Numerical protection relay (complete relay unit) - 1 No. of each type used. 2. Circuit breaker TNC switch for CB open & Close - 4 Nos, 3. Unit Emergency stop switch - 4 Nos. 4, High/Low burden trip relays/Master protection trip relays - 4 Nos. of each type used 5. Trip circuit supervision relay - 6 Nos. 6. Test handle - 2 Nos, 7. DC Change over relays - 4 Nos, 8. Trivector Meters (TVM) - 2 Nos. 9. DC Supply supervision relays - 4 Nos. 10. Any auxiliary item i.e. flag relays, single phase trip relays, voltage selection relays, interposing relays, selector switch items, MCBs, fuses and other miscellaneous - 4 Nos. 11. Spares for distance protection, bus bar protection peripheral units. VI. Safety Earthing & Lighting protection system Separate earthing grids will be provided for powerhouse and switchyard area and they will be interconnected. The buried portion of the earth conductor will be of mild steel and Detailed Project Report of Pinnapuram Pumped Storage Project Rev - RO Page 251