expansion of sugar plant from 5000 to 7500tcd

Tender document for Modernization cum Expansion Shri Someshwar SSK, Someshwarnagar

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EXPANSION OF SUGAR PLANT FROM

5000 TO 7500TCD SHRI SOMESHWAR SAHAKARI SAKHAR KARKHANA LTD.,

SOMESHWARNAGAR, TAL; BARAMATI,

DIST: PUNE-412306

MAHARASHTRA, INDIA

NOTICE INVITING TENDER

FOR

DESIGN, SUPPLY, ERECTION AND COMMISSIONING OF

COMPLETE ELECTRIFICATION OF MILLING TANDEM VIZ.

FIBRIZER, MILLS, DISTRIBUTION AND CONVERTER

TRANSFORMER, ACCESSORIES etc Tender No 4. SSSKL/ELECTRICAL/2020

DECEMBER 2020

TENDER NOTICE

CONSULTANT

VASANTDADA SUGAR INSTITUTE

MANJARI (BK), PUNE, MAHARASHTRA


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TENDER PACKAGE NO. 4

TECHNICAL SPECIFICATIONS AND SCOPE OF SUPPLY OF HT AND LT ELECTRICALS SYSTEM.

Design, Manufacture, Supply, Erection and Commissioning of all electrical system as per following.

1.0 11 kV SWITCHBOARDS

Introduction This specification covers the design, manufacture and supply of 11 kV switchboard

incorporating draw out vacuum circuit breakers. The 11kV switchboard shall be capable of

continuous and reliable operation at the full load rating specified where continuity of operation

is of prime importance. Workmanship shall be the highest grade and the entire construction in

accordance with the best modern practice. The HT switchboard shall be capable of

withstanding the severest stresses likely to occur in actual service and of resisting rough

handling during transport. The HT switchboards shall have incoming and outgoing feeders as

shown in the enclosed single line diagram. Circuit breaker shall be suitable to withstand inrush

magnetizing currents of transformers and capacitor bank ON and OFF. Circuit breaker shall be

suitable for interruption of the motor current under all conditions, without causing over

voltages / switching surges that may damage the motor insulation, owing to chopping currents

/ multiple reignition. Feeders meant for motor feeders shall also be additionally be provided

with surge arrestor / suppressor, to protect the motor from over voltages and surges. The

SUPPLIER shall furnish adequate details /

documents / calculations to substantiate that the motor will not get affected by over voltages /

surges under any circumstances of breaker operation.

System

The HT system shall be suitable for the following system:

- Rated voltage : 11 kV, 3 phase

- Rated frequency : 50 Hz

- Fault level : 40KA for 3 sec

The Switchboard shall be suitable for non-effectively earthed system with max.voltage of 12 kV,

power frequency voltage of 28kV rms for synchronization breakers and 28 kV rms, Impulse

withstand voltage 75 kV, short time rating 40KA rms, dynamic rating 110 kA.

Conductor - Electrolytic grade aluminium alloy

Enclosure - IP 4X


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Maximum busbar temp. - As recommended by IEC

Circuit breaker type - Vacuum

Operating duty - O-.3s-CO-3 min-CO

Control Voltage - 110 V DC

Earthing System - Resistance Earthed / Unearthed

Standards

The design, manufacture and performance of equipment covered by this specification shall

conform to the relevant Standards, as listed under Clause 1.0 of ‘Codes & Standards’, in this

document.

Specific Requirements

Construction- The switchgear shall be metal clad, free floor standing, totally enclosed, dust and

vermin proof with draw out type circuit breakers. Vertical units shall be assembled to form a

continuous line up of uniform height and depth. The panel structure shall house the

components contributing to the major weight of the equipment such as circuit breaker, main

horizontal bus bars and other of the components is adequately supported without deformation

or loss of alignment during transit or during operation. Each unit of the switchgear shall have

necessary internal sheet metal barrier to form separate compartments for buses, instruments,

relays, cable connections etc. Adequate barriers shall permit personnel work safely within an

empty compartment with the bus bars energized. Checking and removal of components shall

be possible without disturbing the feeder. All auxiliary equipment shall be easily accessible to

facilitate their operation and maintenance. It shall be possible to set all relays and measuring

instruments without de-energizing the switch gear. All doors and openings shall be fitted with

dust excluding neoprene gaskets with fasteners designed to ensure proper compression of the

gaskets. When covers are provided in place of doors, generous overlap shall be assured

between sheet steel surfaces with closely spaced fasteners to preclude the entry of dust. The

panels shall have a rear cable chamber housing the cable and connections. The design shall

ensure generous availability of space for easy installation and maintenance. Cabling and

adequate safety for working in one section without coming into accidental contact with live

part in an adjacent section. The HT switchboard shall be constructed only of materials capable

of withstanding the mechanical, electrical and thermal stresses, as well as the effects of

humidity, which are likely to be encountered in normal service.

All insulating materials used in construction of the equipment shall be non-hydroscopic

material, duly treated to withstand the effects of high humidity high temperature tropical

ambient service conditions. Creepage distances shall comply to those specified in relevant


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standards. Each panel shall be provided with space heater to prevent condensation and the

same shall be equipped with differential thermostat to automatically cut in and cut out the

heater so as to maintain interior temperature of 5 Deg.C., above the ambient and should have

manual disconnect switch. The height of the panel shall not be more than 2400 mm. The total

depth of the panel shall be adequate to cater for proper cabling space. Provision shall be made

for permanently earthing the frames and other metal parts of the HT switchboard through a

copper earth bus bar running throughout the full length of the switchboard at the bottom.

Draw out type switching units shall have sliding ground contact. It shall be possible to earth the

switchboard at two independent points on either ends for connections to the external earthing

network of the plant. It shall be possible to extend the switchgear in either

direction at a future date. Ends of bus bars shall be suitably drilled for this purpose. Suitable eye

bolt for lifting of panel shall be provided. On removing the eye bolts no holes offering access to

panel shall be provided.

Bus bars

The bus bars shall be epoxy moulded sleeved and made of high conductivity electrolytic grade

aluminum. The current in all current deration shall be 0.80 /Sq.mm for ratings up to 1250A &

0.7 A/Sq.mm for ratings above 1250A. The bus bar chamber shall be totally maintenance free.

The switchboard shall comprise 3 phase main bus bars which shall extend through all units of

the switchgear line up. The bus bar mating surface shall be tinned. High tensile bolts and spring

washers shall be provided at all bus bar joints. The bus bar shall be of uniform section

throughout and shall be sized to continuously carry the rated current without exceeding the

temperature rise of 40 Deg.C over the maximum ambient temperature specified in the design

basis Bus bars shall be colour coded for easy

identification of individual phases. Bus bars shall be supported at regular intervals and both,

bus bars and supports shall be adequately sized and braced to withstand short circuit level

without deformation. All bus supports shall be non-carbonizing material resistant to acid

alkalies and shall have non-hydroscopic characteristics. For long bus bars suitable expansion

joints shall be provided. Thermal design of the bus bars shall be based on the installation of the

switchgear in poorly ventilated condition. Bus bars shall be housed in a separate chamber

which shall be accessible for inspection only with special tools. The rating of bus bars shall be

same as that of incomer breaker rating.

Insulation Levels

The insulation level corresponding to the rated voltage are: - Nominal Voltage : 11 kV


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- Highest System Voltage : 12 kV

- One minute Power Frequency : 35 kV (rms Withstand voltage for synchronising 28 kV (rms)

CBs for other CBs

- 1.2/50 micro second impulse : 75 kV (peak)

- Clearance in air : As per IS/IEC

Vacuum Circuit Breakers

Circuit breakers shall be triple pole, vacuum circuit breaker, draw out type. The breakers shall

have motor operated spring charged mechanism with anti-pumping contactor. The control

circuit shall be suitable for local as well as remote control. Provision for manual operation shall

also be available.

The breaker sockets and plugs should be heavily silver plated. It should have adequate auxiliary

contacts required by plant control schematics plus 20% spare contacts for future use. Auxiliary

contactors or relays should be used to multiply the contacts. The operating mechanism shall be

robust design with a minimum number of linkages to ensure maximum reliability. The

operating mechanism shall be such that the breaker is at all times free to open immediately the

trip coil is energised. It is to be ensured that all the three poles open/close in unison to avoid

any eventuality of single phase operation of the generator. All controls shall be suitable for 85

% to 110 % for closing and 70% to 110 % for tripping of 110 V DC. Two (2) numbers of tripping

coil shall be used for tripping the circuit breaker and each shall be planned with dedicated DC

circuits. Control supply shall be 110 V DC. The breaker shall have the distinct positions

indicating: `Service ' position : With main auxiliary contacts connected `Test' position : With

power contacts fully disconnected and control circuit contacts connected `Isolated' position :

With both power

and control circuit Contacts fully disconnected The breaker trolley shall remain inside the

cubicle even in the drawout position. The trolley of the circuit breaker shall be so inter-locked

that,

- It shall not be possible to isolate it from the connected position or to plug it in from the

isolated positiowith the breaker closed.

- The circuit breaker can be closed only when it is in one of the three positions or when it is fully

out of the panel.

- It shall not be possible to open the breaker compartment door unless the breaker is drawn to

the isolated position or test position.

- Inadvertent 'pushing in' of the drawout circuit breaker in service position, with auxiliary circuit

plug not in the position shall be prevented.


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The breaker shall be able to function even under condition of phase position that may arise due

to totally synchronisation or otherwise as per relevant IS or IEC standard.

The tips of the main contact shall be adequately silver plated to withstand arcing.

The operating mechanism shall be electrically controlled spring operated. Mechanism shall

have anti pumping and trip free circuitry. Local arrangement for operating the breakers both

electrically and mechanically shall be provided. The breaker trolley shall remain inside the

cubicle even in the draw out position. The trolley of the circuit breaker shall be so inter-locked

that,

- It shall not be possible to isolate it from the connected position or to plug it in from the

isolated position with the breaker closed.

- The circuit breaker can be closed only when it is in one of the three positions or when it is fully

out of the panel.

- It shall not be possible to open the breaker compartment door unless the breaker is drawn to

the isolated position or test position.

- Inadvertent 'pushing in' of the draw out circuit breaker in service position, with auxiliary

circuit plug not in the position shall be prevented. Automatic safety shutters shall be provided

to ensure the inaccessibility of live parts after the breaker is drawn out. The circuit breaker

trolley shall be provided with a heavy duty self aligning earth contact which shall make before

and break after the main isolating contacts during insertion into and withdrawal from the

service position of the breaker. Even in the isolated position positive earthing contact should

exist. Circuit breakers of identical rating shall be inter-changeable. Circuit breaker shall have

provision for manual re-charging. ON / OFF indicator and number of operation centre shall be

provided.

Earthing Trolleys

Bus earthing and cable earthing trolleys (one number each) shall be provided along with each

switchboard. Necessary safety interlocking shall be incorporated in the bus earthing trolley to

avoid insertion of trolley, when the bus is live. Similarly, suitable interlock shall be provided to

avoid insertion of cable earthing trolley, when the cable side is live (i.e) supply is extended from

remote for incomer feeders. These interlocks shall be of electro-mechanical type.

Current Transformers

The current transformer shall be cast-resin insulated type of adequate capacity and proper

characteristics on secondary as specified. The current density should not be more than 1000

amps/sq.inch. CTs shall withstand stresses originated from short circuit. They shall have ratios,

output and accuracy as specified in the drawings. All CTs to be of ingle core type in generator,


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tie and Spare-1 feeders and the CTs required for busbar protection. Other CTs may be of

multicore type. CTs should preferably of bar primary type. They shall be mounted on the

switchboard stationary part. The secondary CT leads from all panels should be terminated on

the front of the board on easily accessible shorting type terminal connectors so that operation

and maintenance can be carried out when the panels are in service. CTs shall be suitable for

continuous loading of 120% of rated current. CTs shall be subjected to heat run test.

Potential Transformer

The potential transformer shall be cast-resin insulated type. It shall be drawout type and easily

accessible so that the same can be attended to or replaced when the panels are in service

condition. The potential transformers shall be protected through HRC fuses on

primary side and MCBs on secondary side. They shall have ratios, outputs and accuracies

specified. The drawout mechanism shall disconnect the primary connection before

the PT or its primary fuses become accessible. All PTs shall be single phase type. They shall have

voltage factor of 1.2 times continuous and 1.9 times for 8 hours.

Integrating Meters

Integrating meters of the Trivector or equivalent types capable of indicating all phase

instantaneous parameters and recording kWH, kVARH and kVAH directly shall be provided. The

meters shall be suitable for measuring “Import” as well as “Export” power parameters. These

should be suitable for 3 phase, 4 wire 50 Hz circuits with unbalanced loading and with two sets

of elements connected to current and potential transformers of specified ratio. 3 The

trivectormeter shall be of digital type, class 0.2 or better with communication port, RS485

interface - MODBUS RTU protocol, for hooking up to PC / DCS.

Indicating Lamps

Indicating lamps shall be of cluster LED type low watt consumption, provided with series

resistor where necessary and with translucent lamp covers. Bulbs and lenses shall be easily

replaceable from the front. Following indicators are required on the panel having lens colours

as follows:

Breaker ON : RED

Breaker OFF : GREEN

Auto trip : AMBER

Trip Circuit healthy : WHITE


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Relays

All protective relays shall be back connected, draw out type, suitable for flush mounting and

fitted with dust tight covers. All relays shall be mounted on the front of the panel and shall be

specified as per requirement. The current and the voltage coils shall be rated as specified. All

relays shall have built-in flag / indicator to indicate operation. All

tripping relays shall be suitable to operate on the specified DC voltage. Feeder / transformer /

motor protection / bus bar protection relays shall be of numeric / microprocessor type with

self diagnostic facility, RS 485 communication port with MODBUS protocol for interfacing with

PC / DCS, software for data downloading & configuration. Feeder / transformer protection

relays shall have IDMT / highest over current & earth fault elements. Motor protection relays

shall have highest over current & earth fault protections, locked rotor protection and current

unbalance protection. Alpha numeric display shall be available for the relays and all fault data

shall be displayed in natural language, without needing to refer codes / manuals. The bus bar

protection shall be of with high impedance relay. The sensitive earth fault relay shall be of

microprocessor type / numeric type. Master trip relay and trip circuit supervision relays shall

be provided, wherever specified.

Control Switches and Push Buttons

Control switches shall be of the heavy duty rotary type with name plates clearly marked to

show the operation. They shall be semi-flushed mounting with only the front plate and

operating handle projecting. Circuit breaker control switches shall be of the spring return to

neutral type, while local / remote selector switches and instrument selector switches shall be of

the stay-put type.

Internal Wiring

Internal wiring and inter-panel wiring for all circuits shall be carried out with 1100/660 V grade,

single core, multi strand, PVC insulated copper conductor wire of minimum 2.5 Sq.mm for other

control circuit. The wiring shall be neatly bunched adequately supported and properly routed

and terminated in the respective terminals with suitable lugs. There

shall not be more than two wires connected at a terminal. Wires shall be identified by

numbered ferrules at each end. The ferrules shall be of ring type and non deteriorating

material. All control circuits shall have MCBs mounted in front of the panel and

shall be easily accessible.


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Terminal Blocks

Terminal blocks for the LT connections shall be of 660V grade of stud type and of adequate

current rating. The insulating barriers shall be provided between adjacent terminals. Provision

shall be made for label inscription on terminal block. Cables

should never be terminated directly on components. Provision shall be made for CT terminals

shorting links, remote ON/OFF pushbutton, remote ON/OFF indication and remote ammeter.

20% spare terminals shall be provided on each terminal block.

11 KV XLPE Cables & Cable Termination,

HT cables will be 11 kV (UE) suitable for use in medium resistance earthed system,

stranded & compacted aluminium conductor, extruded semi conducting screen over

conductor, XLPE insulated, extruded semi-conducting compound in combination with copper

tape screened, extruded PVC compound type ST-2 inner sheath ( only for 3-c cables),

aluminium round wire armoured for single core and flat/strip galvanized steel for three core

cable, and overall PVC outer sheathed, confirming to latest revision of IS/IEC .

The cable size calculations to be submitted by supplier for current rating, voltage drop and

fault level withstand capacity of cable.

Tests

The cables and other equipment included in this Specification shall be factory-tested in

accordance with the applicable codes and standards. Routine test certificate for cable, cable

trays shall be furnished.

The HT switchboard shall be designed to facilitate outgoing power connection through XLPE

insulated armored cables with bottom entry. Ample space for connection of these

cables shall be provided at the rear of the switchboard. The cable termination arrangement

shall be of adequate size and design to receive the required number of cables as specified.

Proper cable clamping arrangement shall be provided. Minimum height of 700mm shall be

maintained between gland plate and the terminals for the HV cables. Detachable gland plate

of adequate thickness shall be provided for the

cable entry into the panel. Sufficient space shall be provided to avoid sharp bending and easy

connection. Gland plates to be made up of nonmagnetic material, wherever single core cable

are used. Suitable shrouds shall be provided to prevent accidental contact with live outgoing

terminations of other feeders while carrying out maintenance on

one feeder.


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Labels

Name plates of approved design shall be provided to represent circuit designation for each

feeder. Material for name plates shall be anodized aluminium. They shall be firmly secured with

fasteners.

Painting

All metal surfaces shall be chemically cleaned, degreased and pickled in acid to produce a

smooth clean surface, free of scale, grease and rust. After cleaning, phosphating and

passivation treatment, the surface shall be given two coats of zinc rich epoxy primer and baking

in the oven. After primer, it shall be given two coats of epoxy paint, shade RAL 7032, in semi

matt finish. Sufficient quantity of touch up. 3.6.6 Battery, Battery Charger cum DCDB :

11KV Distribution / Converter transformer /spare feeder.

Protective Equipment All protective equipment shall be included and installed in the low

voltage compartments of the switchgear as below .

1) Inverse time 3-phase over current relays and earth fault relay with instantaneous

attachments also .

2) High speed tripping relay, Anti pumping relay, Trip supervision relay, Breaker contact

multifunction relays.

3) Cable differential protection with CBCT for all feeders

4) Aux relays for Transformer protection for Aux. Transformer feeders.

5) For Fibrizer Motor feeder provide the MPR and Temperature scanner .

The relays shall be provided with local manually resettable lockout devices

All relays shall be of flush-mounted, draw out and numerical type.

Tripping voltage of relays shall be 110 Vdc

All relay shall be Numerical type only .

1. Indicating Instrument and Measuring Transducer

All indicating instruments shall be included and installed in the low voltage compartments of

the switchgear. The following instruments are required :


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Bus PT feeder :

a) One voltmeter with selector switch

Outgoing feeder: Outgoing feeder for Transformer/ Spare feeder.

a) One Ammeter with selector switch

b) One Trivector meter which can measure electrical energy and also TOU & TOD

c) Annunciator for Alarms/Trip

d) All indicating Lamp shall be as per control schematic ( ie ON/OFF ,Auto Trip, Spring

charge , TC healthy )

e) Connection to instrument transformers directly

f) Voltmeter switch for each voltmeter (phase to phase, phase to neutral, and OFF)

g) KW. Transducer shall be provided for incoming feeders and outgoing feeder.

11 KV Current Transformer- The current transformers (CTs) shall be of dry type

insulated with epoxy resin. CTS for 11KV panel.

11 KV Potential Transformer The Potential transformers ( PTs) shall be of dry type

insulated with epoxy resin. PTs for 11KV panel

Tests

The 11 kV switchboard shall be tested for routine tests as per the relevant IS / IEC.

Drawings and Manual

The drawings and manual shall be submitted as per the ‘List of Drawings / Documents to be

submitted’.


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2.0 Transformers

Distribution/Converter Transformer:

The transformers shall have following specifications,

General:

This specification covers the supply design, fabrication, testing, packing, loading, unloading &

transportation of oil cooled power transformer.

The transformer shall comply with the latest edition of the following & other relevant Indian

Standard Specifications,

IS 335 : Insulating Oil

IS 1271 : Classification of insulating materials

IS 2026 (Part I) : Power Transformers - General

IS 2026 (Part II) : Power Transformers - Temperature rise

IS 2026 (PART III) : Power Transformers – Insulation &

dielectric tests

IS 2026 (Part IV) : Power Transformers - Terminal

markings, Tapping & Connections

IS 2099 : High Voltage Protection of Bushing

IS 2705 (Part I & III) : Current Transformer

IS 3202 : Code of Practice for Climate Proofing

IS 3639 : Power transformer fitting and

accessories

IS 6600 : Guide for loading of oil immersed

transformers

IS 5 : Painting

a. Construction :

a. Transformer tank shall be of welded sheet steel construction and provided with gaskets

steel cover plates. Base shall be suitably reinforced to prevent any distortion during

lifting. Base channels shall be provided with skids and pulling eyes to facilitate handling.

b. All covers and seals shall be oil and air tight and shall not be affected by mineral oil or


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synthetic oil action. Detachable radiators equipped with air vent drain plug and lifting

lugs shall be provided with cut off valves to permit removal of any radiator unit without

emptying the tank. Radiators shall be securely braced to prevent undue vibration.

- All fasteners and bolts etc. shall be galvanized or zinc passivity. All surfaces to be

painted shall be thoroughly cleaned, decaled, made free from rust and given a

priming coat of rust resisting paint followed by two finishing coats of approved

shade. Paint shall be suitable to withstand specified atmospheric conditions.

b. Terminals and marshalling box :

Windings shall be brought out and terminated on terminal bushings and cable box.

- Cable end box shall be supplied with cable lugs & glands. The lugs shall

be non-soldering, long barrel, crimping type

- Terminal chamber for cable box shall have gasketed cover plate bolted to

it.

- Marshaling box shall be weatherproof, waterproof with IP 55 enclosure.

All protective devices and neutral CTS shall be wired by means of PVC

insulated armored cables up to the marshaling box. Terminals shall be

bolted type only. Removable gland plate with compression type glands of

non-magnetic material shall be provided.

c. Cooling :

- The cooling of the transformer shall be ONAN . The operation of forced

air circulation fans shall be controlled automatically by temperature

in oil tank.

d. Oil :

The Transformer shall be supplied with first filling of oil. Additional 10%

quantity of oil shall be supplied in sealed drums. The cost of the

additional oil shall be included in tender.

f. Accessories :

Following minimum accessories shall be necessarily included in the scope

of Supply in addition to the accessories required as per CBIP guidelines.

a. Oil conservator complete with oil filling plug & cap. Oil drain valve &

magnetic oil level gauge .

b. Silica Gel Breather – It shall be mounted such that the silica gel

shall be visible from the ground level and the breather is removable from

the ground.

c. Shut off valve between conservator & main tank.


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d. Explosion relief vent mounted on the tank with double diaphragm

& equalizer pipe. The explosion vent shall be rotatable in all

directions.

e. Air release plugs.

f. 150 mm dia. magnetic oil gauge with low level alarm and trip

contact.

g. 150 mm dia. oil temperature indicator with maximum reading

pointer and a set of contacts for alarm and trip.

- 150 mm dia. winding temperature indicator with maximum

reading pointer and set of contacts for alarm & trip.

- Thermometer pocket with mercury in glass thermometer (0-120

°C)

- Bottom drain valve- with pipe nipple. It shall be possible to drain

off 90 % of the oil within 10 minutes.

h. Sampling valves with plug.

i. Filter valves with threaded adapter top & bottom.

j. Inspection cover on top plate.

k. Two grounding (Earthing) Pads placed on opposite sides with

tapped holes, M-12 Bolts and spring washers.

l. Jacking pads, hauling lifting lugs.

m. Bidirectional Flanged Wheels.

n. Rating plate. terminal marking plates & name plates.

o. Double Float type Buccholz Relay with Alarm and Trip

contacts.

p. Cable disconnection chamber for LV side.

q. 2 core Neutral CT on HV side for Restricted Earth Fault and

Stand by Earth Fault.

r. Forced air Circulation Fans with required control gear and

support structures.

g. Core and winding :

- Transformer shall be double wound, core type with cold

rolled grain oriented lamination perfectly insulated and

clamped to minimize vibrations and noise.

Care shall be taken to insulate core fastening bolts to

reduce losses and avoid hot spot. All parts of the magnetic

circuit shall be bonded to earth.

- Windings shall be of copper and shall be designed to


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withstand the specified thermal and dynamic short circuit

stresses.

h. Tapping :

- On Load Tap Changing arrangement shall be provided on High

Voltage side of the gen .transformer & OCTC for others..

- The OLTC mechanism shall be provided with Oil surge relay,

Automatic Voltage Relay and RTCC panel.

- Under conditions of external short circuit, the tap changing

equipment must be capable of carrying the same current as the

winding.

i. Inspection and testing :

Purchasers representative shall be given free access in the works

from time to time for stage inspection & progress reporting.

- Tests shall be carried out at manufacturers works at his expenses

in presence of the purchasers representative. All routine tests as

specified in IS 2026 shall be conducted.

- Heat run test and type tests as per IS 2026 shall be

conducted on the transformer at manufacturers works.

- Impulse Test shall be carried out on all three phases of H.V.

and L.V. winding of the transformer.

- Contractor shall also furnish a list of guaranteed technical

particulars with his offer.

j. Drawings and documentations :

- General arrangement drawing for the following shall be submitted

with bid.

Transformer

Marshalling Box

LV Cable box and H.V. Bushing

Cooling plan

All drawings shall be submitted in 5 copies of which one will be

returned duly commented/approved.

- Owners approval of manufacturers drawings shall not relieve the

manufacturer of his responsibility for supplying equipment


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conforming to relevant IS or for any mistakes, errors or omissions

in his drawings.

- Manufacturer shall submit FINAL Prints of all drawings in 5 sets

incorporating all changes during approval, inspection &

commissioning stage.

k. Packing and transport:

- The main tank shall be oil filled during transportation. All

accessories shall be packed separately during transportation. Care

shall be taken to pack the radiators such that radiator fins are not

damaged during transportation. Packing dimension shall be

furnished much in advance of transportation.

- All accessories shall be wrapped with polythene sheets before

packing.

All valve flanges including those for the radiators shall be closed by

blank flanges.


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TECHANICAL DATA :

No

Description

Distribution Converter

Transformer Transformer

( 2.5 MVA) (1.5 MVA)

1 No. of 2 2

Transformers

2 Maximum

Continuous

Rating (MVA) at

ONAN cooling:

a. HV 2.5 @ ONAN 1.5 @ ONAN

b. LV 2.5 @ ONAN 1.5 @ ONAN

3 Temperature rise

above ambient of

50 Deg. C:

a. Winding 55 50

b. Oil 50 45

4 Maximum flux 1.7 Tesla 1.7 Tesla

density in any part

of the core of

rated voltage and

frequency

5 Over fluxing

withstand

requirement:

a. 110% Continuous Continuous

b. 125% 10 Sec. 10 Sec.

6 . a. Rated Voltage

in kV:

i. HV Winding 11 11

ii. LV Winding 0.440 0.690

b. Voltage 10% 10%


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Variation

7 Vector Group Dyn11 Dd0yn11

8 a. Rated 50 50

Frequency

b. Frequency Variation ± 5% ± 5%

9 Neutral Earthing Effectively Earthed Unearthed

System

10 Maximum current 300 Amps/ 300

density of winding Sq.cm Amps/Sq.cm

11 Maximum losses

(in kW):

a. No load3 2.2KW 1.3KW

b. Load4 20KW 12KW

c. Auxiliary Load -- --

loss in ONAF

duty

12 Insulation levels in kV (Highest /

power Frequency / impulse):

a. HV 12/28/75, 12/28/75,

b. LV 1.1 / 3 / - 1.1 / 3 / -

13 Tap Changer:

a. Type Off-Circuit Off-Circuit

b. Make Reputed Reputed

c. Tapping + 5% in steps + 5% in steps

Range of 2.5% of 2.5%

14 Voltage for Relays 110V DC 110V DC


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15 Percentage 7.15% without

negative tolerance

6.25% / 6.25%

Impedance Without negative

tolerance

16 Insulation Oil Conforming to Conforming to

IS:335 IS:335

17 Termination Arrangement:

a. HV Cable box (air Cable box (air

filled) suitable filled) suitable

for XLPE for XLPE

cable, 1Rx 3x300

Sq mm

cable, 1Rx 3x300

Sq mm

b. LV Busduct Cable box for

chamber each secondary

and each box

suitable for 1R x

3C x 300

Sq.mm, LT

XLPE cable

c. Neutral For connecting --

earth flat

18 Neutral bushing 6000(**)/1A, Not Required

Current Cl.PS, Vk >

transformer rating 700V, RCT <12

Ohms with

Imag < 30 mA at

50% Vk

AVR Not Required Not Required

19

20 RTD (Duplex),


20

for monitoring

Temperature for

PURCHASER

Use

i. For Oil 1 1

ii. For Winding 1 1

3.0 Plant Lighting.

The scope under this section shall be to providing illumination in complete plant (i.e.

boiler, power house , mill house internal road street Light , etc.) turbine home panel

room, transformer room, DG set room, castle room below turbine platform, battery

room, etc. the lighting shall be designed for one of LED light fitting, HPSV flood lights,

High bay mercury lamps, Medium bay fittings. The average illumination level shall be 200

lux in all the above mentioned areas. The lighting system shall be designed for use of

tube lights in combination with mercury vapour and high pressure sodium vapour

lamps. All the and lamps fittings, sub-lighting and control accessories shall be included

in the scope of supply.

The power supply is drawn from main lighting distribution board to the sub lighting

distribution board and further to the lights fixture. The wiring for the complete lights

system shall be done with the help of PVC insulated and armoured copper conductor

cable running on walls ceiling, in under ground tracks as required. The lighting

receptacle shall be provided in the wherever required at about 15 points with 30 Amp.

Single phase connection. The flood light poles about 6 Nos. shall be installed in the HT

switchyard area for HPSV flood lighting.


21

Lighting Fixtures

LED Lighting fixtures for the entire project with required accessories as

mentioned below.

a) 200W LED fixtures

b) 150W LED fixtures

c) 2 x 24 W LED fixtures

c) 1 x 24 W LED fixtures

e) 200 W LED flood light fixtures

f) 80 W Well glass fixtures for Boiler area.

h) Plug & socket feeders of 32 A

i] bulk head fixture

The required cables from MLDB to SLDB, SLDB to fixtures shall be provided

along with required cable termination material.

Suitable

quantity.

4. Earthing

The work includes the supply and erection of earthing pits, GI / copper Flat, GI wire. GI

bolts, nuts etc for complete co gen project,3 MW TG Set & TG Panels, 11kv panel, co gen

PCC, MCC up ti incomer , power house Crane Panel etc.

5. Safety Equipment’s - one lot.

Safety equipments such as rubber mats, hand gloves, fire extinguishers, etc as per

statutory requirement.

6. Erection material

GI cable Trays, Cable glands, lugs, termination material, M.S. material for Power House &

Sugar house.

7. LT PCC ACB PANEL

Power Distribution Panels shall be suitable for operation on 3 Phase/single phase, 415

volts, 50 cycles, neutral grounded at transformer. All Power Distribution panels shall

be by a CPRI approved, reputed manufacturer. Distribution panels shall comply with

the latest Relevant Indian Standards and Electricity Rules and Regulations.


22

All the outgoing feeders up to and including 630A shall be FSU and 800A and above

shall be MDO ACB’s.

CONSTRUCTION FEATURES

All Main Power Distribution panels shall be designed for as per IEC 60439-1 for

indoor/outdoor installation, dead front, floor mounting/wall mounting type . The

Power Distribution Panels shall be undergone internal ARC Test for different type of

feeders, especially smaller rating feeders. The Power Distribution panels shall be

totally enclosed modular construction completely dust and vermin proof and shall be

with hinged doors, Neoprene gasket, padlocking arrangement and bolted back. All

removable/ hinged doors and covers shall be grounded by flexible standard

connectors. Power Distribution panel shall be suitable for the climatic conditions as

specified in Special Conditions. Steel sheets used in the construction of Power

Distribution panels shall be 2.0 mm for frame, 1.6 mm for doors and 2 mm for other

sheet metal works and shall be folded and braced as necessary to provide a rigid

support for all components. Joints of any kind in sheet metal shall be seam welded, all

welding, slag shall be rounded off and welding pits wiped smooth with plumber metal.

The general construction shall confirm to IS-8623-1977 (Part-1) for factory built

assembled switchgear & control gear for voltage up to and including 1100 V AC.

All panels and covers shall be properly fitted and square with the frame, and holes in

the panel correctly positioned. Fixing screws shall enter into holes tapped into an

adequate thickness of metal or provided with wing nuts. Self threading screws shall

not be used in the construction of Power Distribution panels. Height shall be 2350mm

max , A base channel of 75 mm x 40 mm x 5 mm thick shall be provided at the

bottom for floor mounted panels. Minimum clearance of 275mm shall be provided

between the floor of Power Distribution panels and the lowest unit. Power

Distribution panels shall be of adequate size with a provision of spare switchgear as

indicated in the scope . Switches shall be arranged in multi-tier. Knockout holes of

appropriate size and number shall be provided in the Power Distribution panels in

conformity with the location of cable/conduit connections. Removable sheet steel

plates shall be provided at the top to make holes for additional cable entry at site if

required.

Every cabinet shall be provided with Trifoliate or engraved metal name plates. All

panels shall be provided with circuit diagram engraved on PVC sheet. All live accessible


23

connections shall be shrouded and minimum clearance between phase and earth shall

be 20 mm and phase to phase shall be 26 mm.

. BUS BAR CONNECTIONS

Bus bar and interconnections shall be of high conductivity electrolytic aluminum alloy

complying with requirement of grade E 91 E of IS: 5082–1981 and of rectangular cross

section suitable for carrying the rated full load current and short circuit current

without overheating of phase and neutral bus bars and shall be extendable on either

side. Bus bars and interconnections shall be insulated with heat shrinkable sleeve of

1.1 KV grade and shall be colour coded. Bus bars shall be supported on glass fibre

reinforced thermosetting plastic insulated supports at regular intervals to withstand

the force arising from in case of short circuit in the system. All bus bars shall be

provided in a separate chamber and all connections shall be done by bolting.

Additional cross sectional area to be added to the bus bar to compensate for the

holes. All connections between bus bars and breakers shall be through extended solid

copper strips of proper size to carry full rated current and to receive the aluminium

bus bar through bimetallic strip / washer. The bus bars shall be de-rated suitably . .

Control Supply

Control Supply bus shall be of 240V for all the panel and this supply to be tapped from

Mains from the incoming side of the Panel incomer.

There shall be two control transformers in each panel with DP MCBs on incoming side

and with a changeover switch at outgoing side of transformers to provide redundant

control supply. 2 nos. 20A 2pin power sockets with 16A switch shall be provided in

each panel for maintenance purpose.

Control bus supply failure signal shall be arranged to connect it to DCS.

Low Voltage Air circuit-breakers

The Air Circuit Breakers shall be rated Service voltage of 690V AC and Insulation Voltage

of 1000V AC. The Air Circuit Breaker shall comply with latest international standards

IEC60947-2. The Air circuit Breaker shall be 3/4 Pole Motorised Draw out type capable

of handling rated current up to in ambient temperature of 50 deg Celsius. The vendor

shall furnish derating chart from the manufacturer in the submittals.


24

The Circuit Breaker shall have electrical lockout feature. In the event of maintenance in

downstream, the operator shall keep shunt trip coil energized to avoid unauthorized

closing of the Circuit Breaker. It shall not be possible to either rack out or rack in the

Circuit Breaker in closed position. The Circuit shall have suitable interlock to achieve the

same.

Draw out Circuit Breakers shall have three discrete positions Isolate/Test/Service

positions. It shall have visual indication to show position. The Circuit Breaker shall have

clear visual indication to show whether it is in closed or open condition. The closing

mechanism shall be spring charged mechanism. It shall be possible to visualize whether

spring is charged or discharged condition. The stored energy in the spring charged

mechanism shall be sufficient to ensure that, it shall be possible to open a circuit

breaker, reclose & open again.

The mechanical life of the ACB shall be at least 12000 operation with 60

operations/hour without the need of maintenance of contacts and arcing chamber

.Electrical life at rated voltage 440V shall be at least 9000 operations up to 2000A ACB’s

and 5000 operations for 3200A ACB’s without the need of maintenance of contacts and

arcing chamber

All ACB’s irrespective incoming or outgoing feeders shall have neutral protection. In case

3Pole ACB are offered based on application, it shall still be possible to protect the

neutral by providing an external CT.

The Air Circuit Breaker shall have Service Short Breaking capacity of 50ka (Ics, ) at

440volts AC. Circuit Breakers with less than 50ka (Ics) is not acceptable.

The protection release provided shall be microprocessor based. The protection release

shall have LSIG in incomer Circuit breakers and LSI on outgoing feeders.

– Release shall have standard test function.

– Protection Release shall have rating plug whereby over load setting range can be

adopted based on load conditions without modifying any internal components of the

Circuit breakers.

– All incomer Circuit Breakers shall have following additional protections as standard

1. Under and Over Voltage Protection

2. Under and Over Frequency Protection


25

3. Reverse Power Protection(On standby Generator ACB)

4. Residual current protection

– The protection against overload (L) with characteristic adjustable from 40 to 100%

and time delay is adjustable up to minimum of 90seconds(shall be standard feature on

all ACB’s)

– The protection of neutral must be set at 50%, 100%, 200% and OFF of the phase

currents without changing any component.

– ACB’s shall have built in Metering with a digital display shall indicate the following.

1. True RMS current

2. Voltage ( Phase-Phase, Phase-neutral, Residual Voltage)

3. Power – Active, Reactive and Apparent

4. Power Factor

5. Frequency and Peak Factor

6. Energy – Active, Reactive, Apparent, Counter

7. Harmonics analysis up to 40th order

The selective short circuit protection shall have setting possibility of either trip time

independent of current or with constant specific let through energy. They selection of

devices in upstream and downstream shall be such that complete discrimination is

achieved.

The protection release shall be suitable to achieve both current and Time discrimination

with downstream protection devices. Protection release considered shall have an option

to achieve Zone selectivity with which downstream equipments and cables are

protected against fault current in shortest possible time.

The protection shall store the following information in the event of tripping

1. Tripping cause

2. Current at which Circuit breaker is opened

3. Time stamp of the event( up to 48hours)

The protection releases shall have double ground fault protection option. In case fault is

in restricted area, it shall be possible to give command to trip the medium voltage

circuit breaker. There shall provision either for trip or alarm for this fault. In the event

the fault is in unrestricted area, only LV circuit breaker should trip.


26

The protection releases of Air circuit breakers shall have built in data log function. It

shall be possible for operating personnel to connect to Bluetooth device and data

should transferred to personal computer for further analysis.

The ACB shall have capability to upgrade from standard protection release to Protection

release with communication capability in the future. Where already indicated ACB shall

have communication capable protection release. The protection release shall have built

self diagnostics for over temperature. In the event of over temperature, it shall be

possible either to have alarm or trip option.

The operating mechanism shall be of the Open/Closed/Open stored-energy type. The

main contacts shall be designed such that no maintenance shall be required under

normal conditions of use.

The arc chutes shall be removable on site. It shall be possible to disconnect the circuit

breaker without having to open the door. The three possible positions (connected,

disconnected and test) shall be indicated.

Conformity with Standards

ACBs used in low voltage panels should conform to the International Standards IEC

60947, EN 60947, CEI EN 60947 and IEC 61000 and conform to the relevant EC

directives:

“Low voltage directive” (LVD) No. 73/23 EEC

“Electromagnetic Compatibility Directive (EMC) No.89/336 EEC

Functional characteristics

a. The circuit-breakers must have a rated impulse withstand voltage Uimp 12kV.

b. The circuit-breakers must be able to be supplied both from the top and bottom

terminals without de-rating their performances and without jeopardizing their

functionality.

c. The circuit-breakers with Higher Electrical & Mechanical life shall be preferred.

d. The circuit-breakers with lower watt loss shall be preferred.


27

Environmental characteristics

- Operating temperature: 50°C

- Altitude: operation without derating up to 1000 M.S.L.

- Suitability for being used in hot humid ambient. To this regard, the circuit-breakers

must undergo a Tropicalization process which makes them suitable for use in a hot-

humid ambient, in accordance with the international IEC 60068-2-30 Standards.

Construction characteristics

a. All the models should be available in 3 or 4 pole versions both in fixed version .

b. The circuit-breaker structure must be made of steel sheet.

c. In order to ensure maximum operator safety it is necessary to have total

segregation between the power circuit and control circuit, thus making double

insulation necessary.

d. Total segregation between the phases should be guaranteed for safety reasons.

e. All the circuit-breakers in the range should have the same depth and height with

the aim of standardizing the support structures of the switchboards and the

switchboards themselves as much as possible.

f. On the front, the circuit-breakers must indicate the exact position of the main

contacts and the condition of springs charged/discharged by means of certain

and reliable signals.

g. Tripped on fault flag/popup shall be there along with separate reset button on

the front other than OFF button.

h. Potential free trip signalling contact and remote electrical reset arrangement are

must for all EDO type ACBs.

i. The operating mechanism should be of the stored energy type, operated using

pre-charged springs and fitted with an anti-pumping device. The springs are

charged manually by operating the front lever or using a motor operator.

Accessories

The following accessories must be common to the whole range.

- Geared motor for automatic charging of closing springs

- Mechanical and electrical signaling of over current trip units tripped

- Auxiliary contacts which enable the state of the circuit breaker to be signaled

- Current transformer for the neutral conductor outside the circuit-breaker.

- Interlocks between circuit breakers, for interlocking two or three circuit


28

breakers both in horizontal and vertical position using flexible cables

Protection release functions

- The trip unit should not require an external power supply, being self

powered using the

current transformers installed on the circuit-breaker.

- Release must be of self-diagnostic type which can sense wrong connections at CT, trip

coil and rating plugs.

- The releases should have integrated LED fault indication for each type of protection i.e.

for L, S, I & G.

Switch Fuse Units, Disconnecting Switches and Fuses

All switches shall be load double break, heavy duty air break type provided with quick

make break manual operating mechanism. The operating handle shall be mounted in

the door of the compartment having the switch. Switches shall be designed to carry the

rated current continuously without overheating.

Barriers shall be provided to prevent interphase arcing and live terminals shall be

shrouded to avoid accidental contact.

The switches shall be rated for AC23A duty.

Auxiliary switches shall be provided with a minimum of two ‘NO’ contacts, rated for 5A,

230V AC.

Fuses shall be non-deteriorating HRC cartridge link type. ‘Diaze’ fuses are not

acceptable.

The fuses shall be provided with operation indicator which shall be visible without

removal of fuses from service.

Fuses shall be pressure fitted type and shall preferably have rims on the contact blades

to ensure good line contact.

It shall be possible to handle fuses during off load conditions with full voltage available

on the terminals. Wherever required, fuse pullers shall be provided.


29

INDICATING PANEL

All meters and indicating instruments shall be in accordance with relevant Indian

Standards.

The meters shall be flush mounted type. Indicating lamps shall be of LED type, and shall

be backed up with MCB.

WIRING

In wiring the single phase loads of a power distribution panel it shall be insured that

total load of various panel and/or consuming devices is divided evenly between the

phases and number of ways.

ANTI-CONDENSATION SPACE HEATERS

1 No. 100 W, 240 volts, single phase, 50 Hz AC Anti Condensation space heaters

controlled by thermostat and protected by 6 amps SP MCB’s/MPCB shall be provided in

each Main LT Panel synchronizing panel Power Distribution Panel, MCC’s and 1 No. 60

watt Anti Condensation space heater shall be provided in each cable alley of main

distribution boards and sub distribution boards. Supply and control equipment for the

above shall be provided by the vendors.

EARTHING

Earthing shall be provided as per IS: 3043-1987.

METERS

i. All voltmeters and indicating lamps shall be through MCB’s.

ii. Meters and indicating instruments shall be flush type.

iii. All CT’s connection for meters shall be through Test Terminal Block (TTB).

CURRENT TRANSFORMERS

Current transformers shall be provided for Distribution panels carrying current in excess

of 60 amps. All phase shall be provided with current transformers of suitable VA burden

with 5 amps secondary for operation of associated metering.


30

The CTs shall confirm to relevant Indian Standards. The design and construction shall be

dry type, epoxy resin cast robust to withstand thermal and dynamic stresses during

short circuits.

Secondary terminals of CTs shall be brought out suitable to a terminal block which shall

be easily accessible for testing and terminal connections. The protection CTs shall be of

accuracy class 5P10 and measurement CTs shall be of accuracy class I.

8.0 BUSBAR TRUNKING FOR PCC:

- The bus trunking shall be connected between LT side of transformers to the ACB Panel

and between ACB Panels to new PCC Panel as per SLD NO:

- The bus trunking shall be suitable for 3 phase 4 wire, 415 V 50 Hz, 0.8 power factor and

rating as given in BOQ.

- The bus bars shall be EC 91 E grade Copper as per relevant standards.

- The earth bus bar of GI Strip 75 X 10 mm shall run through out the length of the bus

trunking.

- All the above bus bar shall be mounted on epoxy type insulators at equal intervals.

- The bus trunking shall be fabricated from 2mm thick CRCA sheet steel with angle supports

where necessary.

- The sheet structure shall be carried out by 7 tank process and stove enameled type with

grey color shall be applied.

- Set of flexible copper joints shall be provided at transformer end.

- For the outdoor portion of the bus trunking canopy over and above the bus trunking shall

be provided.

- The necessary supports also to be supplied along with bus bar trunking.

- Makes: CPRI Approved type tested panel builder.

Short circuit calculations and temp. rise calculations for bus bar trunking shall be got

approved by supplier before manufacturing the trunking.

9.0 POWER AND CONTROL CABLES

1.1kV grade Aluminium, XLPE Armoured cable of adequate size from PCC to

respective MCC and to equipment. The length of cables shall be as per the plant

layout. Cable laying system overhead tray. LT Cables should be sized for derating

factor of not more than 0.7 and voltage drop of not more than 3%. All


31

interconnecting cables (Power +Control +Signal) for 12 MW TG & 6 MW TG are

included. The electrical Layout is enclosed herewith showing major equipment

location to work out the cable requirement. The Power cable shall be 3 core and

lighting cable shall be 31/2 core.

10.0 CABLE TRAYS :

Pre fabricated G.I. cable trays shall be considered by the bidder.

For size up to and including 150mm. the cable trays shall be perforated. The

trays including and above 300mm size shall be ladder type. The fabrication of

cable trays shall be done with 2mm thick sheet. Cable trays shall be hot dip

galvanized having minimum galvanizing of 110gm/sq. m uniform.

The quantities are estimated quantity bidder to estimate based on scope and plant layout. Unit rates shall be given for any addition or deletion of quantities.

11.0 DETUNED FILTERS –

Detuned filters as Power factor correcting capacitors & harmonic suppressor-

Suitable number and rating harmonic filter detuned type for power factor

correction harmonic suppression shall be supplied .

The PF to be maintained 0.95 and THD to be bellow 5% .

The harmonic filters combination of capacitors and reactors should suitably

detuned. The harmonic filter of suitable KVAR quantity should be supplied to improve

the power factor and also to eliminate the harmonic currents/ voltage to acceptable

level as per IEEE 519 and to compile with utility regulations. The filter should also

protect capacitors from harmonic overloading, avoid harmonic amplification, provides

reactive power compensation at fundamental frequencies & avoid undesirable

resonance phenomenon.

The harmonic filter comprises of reactor and capacitors should have cooling fan

unit with cut of point at 90oC temperature in the panel and should be as follows:-

The reactor should be design for thermal overload due to maximum fundamental

and harmonic current. The reactor shall be able to with stand the short circuit current

which can occur during fault condition as well as switching current and voltages. The


32

reactor should have power loss less than 2 Watt per KVAR , 7% reactance and 180%

linearity.

capacitor should be design for 1.3 times voltage with stand capability, 1.7 times current

with stand capability. The capacitor should be of APP/MD type.

The losses should not more than 0.3 Watt per KVAR. The capacitor should not have

negative tolerance. The test report for reactor and capacitors should be submitted

along-with calculations.

12.0 Scope of work in services

a. Design and engineering :

- Preparation of design calculations, detail drawings for switchyard and

allied work. - Preparation of cable layouts, Earthing Layouts and Lighting Layout

drawings - Preparation of panel layouts for H.T. switchgear, L.T. Panel room and

control room - Preparation of cable schedule, interconnection schedule and detail BOQ. - Preparation of foundation drawings and structural designs for

switchyard equipments. - Preparation of inspection plan and schedule. - Preparation of schedule for site testing and commissioning. - Preparation of relay co ordination with generator protection relays

including islanding scheme.

b. Statutory approvals :

- Obtaining approvals on drawing and designs from MSETCL, Local Electrical Inspector and Chief Electrical Inspector authorities.

- Liaison with MSETCL & MSEDCL authorities for testing, tie up and commissioning of switchyard equipments in the scope.

- Arranging inspections and approvals for commissioning of total cogeneration plant electrical from Local and Chief Electrical Inspector PWD

- Liaison with TQ & A as well as O & M division of MSETCL authorities at Pune and Mumbai for obtaining approvals on drawings, arranging inspections etc.


33

c. Inspections / Review Meetings :

- Making the arrangements for periodical and final inspection of all major

equipments in the system at manufacturers works - Attending the periodical review meetings at site or the agreed locations.

13.0 Battery Limits

For Power Supply -

From : Outgoing terminals of alternator . To : 1.Motor terminal of boiler and mill house. 2.Fibrizer and mill motors. 3. Up to PCC(boiling house) outgoing .

Earthing :Total Earthing system required for plant (excluding boiling house)is included in this package .

Illumination system : Entire Illumination system required for plant is included in this package .

14.0 Performance Guarantee

All equipment shall be guaranteed for workmanship and materials and for satisfactory performance in accordance with the relevant clauses of the General Conditions of Contract.

The guarantee for performance shall cover individual items and systems for their ratings/outputs, as required in the specification.

The PACKAGE supplier shall conduct performance/acceptance tests on each of the major items of equipment supplied to demonstrate that the equipment supplied is capable of achieving the performance parameters specified and contracted for, in accordance with the General Conditions of Contract, Instruments, gauges and flow meters installed for the normal operation of the equipment shall be made use of during the acceptance tests as far as practicable.


34

15.0 Bill of quantities,

S No Description Qty Unit Remarks

A Power house

1 11kV H.T. Panel 3 P 3 W 1600A with Cu / AL Bus bars 26.3kA/3sec with Electrically Draw out VCB Feeder with required CT , PT Relays for the following feeders

Set 1

a 1250A for TG Incomer No 1

b 1250A for spare feeder No 1

c 1250A for 2.5 MVA distribution transformer feeder Boiling House No 2

d 1250A for 1.5MVA Converter transformer feeder No 2

e 1250A for Fibrizer Motor No 1

f 1250A for spare No 1

g Bus PT No 1

2 Stand alone 11kV Panel 3phase 1250A with AL Bus bars 26.3kA/3sec with Electrically Draw out VCB Feeder with required CT , PT Relays for Fibrizer motor

Set 1

3 11kV 3phase 1250KW, 750 rpm Frbrizer motor Set 1

4 11kV 3phase ASR starter panel suitable for 1250KW, 750 rpm Frbrizer motor with 400Kva Capacitor panel

Set 1

5 11kV, XLPE AL Armored unearthed HT cable for the following For Distribution /converter Transformer of Cogen Section

a 1 x 3 x 300 Sqmm Mtr 1500

b HT KV Cable Termination Kit Nos 24

5 Transformer Section

a 11kV / 0.433, Dyn11, 2500 kva, Distribution Transformer ONAN,Dyn11 off circuit Tap changer with+5%,-10%Tap&suitable 7.15% impedance.

Set 2

b 11kV / 0.690-0.690v, Dyn11, 1500 /750-750kva , Converter Transformer ONAN, off circuit Tap changer sugar mill section

Set 2

6 LT Bus duct 3P, 4 W , 415 V 50Hz 4200Amp rating with Al bus Form Distribution Transformers to Boiler & Power House PCC ( 2.5 MVA DT Transformer )

Mtr 15


35

7 LT Bus duct 3P, 4 W , 415 V 50Hz 4200Amp rating with Al bus Form Distribution Transformers to Boiling House PCC ( 2.5 MVA DT Transformer )

Mtr 20

8 433v , 50Hz 3phase Cage 450KW, 1000 rpm , Mill drive Set 4

9 Mill VFD drive 3phase , 415 V 50Hz suitable for Mill Drive Set 5

10 Boiler & Mill house PCC 5000A 3 phase , 4 wire 4pole EDO ACB for distribution transformer incomer 1nos and 1 nos tie feeder between co-gen PCC and sugar PCC . Out going feeder as below .

set 1

Boiler VFD PANEL - 1000A MDO ACB Nos 1

Mill Non -VFD PANEL - 1000A MDO ACB Nos 1

Mill House MCC - 1000A MDO ACB Nos 1

APFC panel - 1000A MDO ACB Nos 1

Spare - 1000A MDO ACB Nos 1


Spare - 630A FSU - Nos 1

11 Boiling House PCC 5000A 3 phase , 4 wire 4pole EDO ACB for distribution transformer incomer 1nos and 1 nos tie feeder between Boiling House detail feeder shall be as per SLD

set 1

Clarification MCC - 1250A MDO ACB Nos 1

Evaporation MCC - 1250A MDO ACB Nos 1

Konti C/F -I 800A MDO ACB Nos 1

Konti C/F - II 1000A MDO ACB Nos 1

Injection House - I -1000A MDO ACB Nos 1

Injection House - II -630A FSU Nos 1

Spray House - 800A MDO ACB Nos 1

BATCH C/F - I 1250A MDO ACB Nos 1

BATCH C/F - I I 1250A MDO ACB Nos 1

Sugar House - 400A FSU Nos 1

MLDB - 250A FSU Nos 1

APFC panel - 1000A MDO ACB Nos 1

Spare - 1250 A MDO ACB Nos 1


Spare - 400 A FSU Nos 1

12 APFC PANEL with 400Kvar Capacitor Bank Set 2


36

13

Boiler: VFD panel 1. ID fan -90 KW x 2 VFD. 2. Feed pump - 55 KW x 2 VFD. 3. Baggase feeders -3.7 KW 6 no VFD.

Set 1

14

Mill - MCC/ VFD panel 1. Feeder table-11KW x 4 VFD 2. Cane carrier – 55 KW x 1 VFD. 3. Rake type Cane carrier – 37 KW x 1 VFD. 4. Raw juice pump – 37 KW x 1 VFD. 5. Imbibition juice pump – 11 KW x 1 VFD. 6. Imbibition hot pump – 15 KW x 1 VFD. 7. Kicker – 45 KW x 1 no star delta . 8. Leveller – 225 KW x 1 no ASR slip ring starter. 9. Un Strained juice pump- 11 KW x 2 no star delta. 10. Inter rake cane carrier – 22 KW x 4 star delta. 11. Rotary screen – 7.5 KW x 2 DOL. 12. Gear box oil pump – 7.5 KW x 2 DOL. 13. Mill hydraulic pump – 7.5 KW x 2 DOL 14. Cold water pump – 7.5 KW x 2 DOL. 15. Mill lubrication pump – 5.5 KW x 2 DOL. 16. Bagasse belt conveyor – 10 KW x 4 star delta. 17. Cane un loader crane – 630A supply feeder. 18. Mill crane – 400A supply feeder. 19. DCS – 200A supply feeder

Set 1

15 225 KW x 1 no ASR slip ring starter Panel . No 1

16 Miscellaneous Items Lot 1

a Fire Extinguisher

b Rubber mat

c Hand Gloves

17 MLDB for Lighting Set 1

SLDB Set 8

a) 200W LED fixtures Nos 60

b) 150W LED fixtures Nos 15

c) 2 x 24 W LED fixtures Nos 100

c) 1 x 24 W LED fixtures Nos 50


37

e) 200 W LED flood light fixtures Nos 10

f) 80 W Well glass fixtures for Boiler area. Nos 120

h) Plug & socket feeders of 32 A Nos 5

i] bulk head fixture Nos 5

18 1.1 kV Grade XLPE power and control cables from PCC to MCC ,

a 3.5 x 240 sqmm Mtr 3500

b 3.5 x 185 sqmm Mtr 1500

c 3.5 x 95 sqmm Mtr 800

d 4x 2.5 sqmm pvc cable Mtr 3500

e 4x1.5 sqmm pvc cable Mtr 4500

f 3x 16 sqmm pvc cable Mtr 2000

19 Galvanized cable trays of ladder / perforated type, for the entire LT section

450mm Mtr 2000

300mm Mtr 1500

20 Cable Termination Material i.e. double Compression Gland , Crimping type Lugs, Ferules , Crimping solvent and all types of Hardware

Lot 1

21 MS Steel Material i.e. Flat. Angle. Channels ,MT 10

a) 75X8 mm MS Flate for main earthmat) Mtr 500

b) 50x6 GI Flat ( for structure & cable tray earthing ) Mtr 1500

c) 8 SWG GI Wire (fencing) Mtr 300

d) 7/8 SWG GI Earthing wire for lightning Mtr 300

protection

e)50 x 6 Cu. Flat (Neutral ) Mtr 200

h) Treated earth pits 100 mm dia, 2.75M long CI pipe earth electrode (as per IS:3043)

Nos 50

22 Erection and commissioning for above system Lot 1

23 CEIG approval Lot 1


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16.0 MAKE OF COMPONENTS

S.No. Item Make

1 Transformers Voltamp / PETE / Rechem

2 Air Circuit Breaker L&T –C power

3 LA Elpro / Areva / Crompton / Oblum

4 CT and PT Areva / Crompton / Mehru / ITL

5 11KV Switchboard ABB

6 11KV XLPE Cables RPG/KEI

7 LT Cables RPG/KEI

8 LT switch gear L & T

9 VFD ABB/Damfos.

10 Protective Relays& relay panel Areva / Siemens /ABB

11 Push Buttons L & T /Siemens/Teknic/Vaishno

12 Indicating Lamps Teknic/Siemens/ L & T /Vaishno

13 Selector Switches Kaycee/Salzar

14 LT Capacitors-reactor(HF) Siemens / L. &T./Ambik

15 L.T. Panels CPRI Approved type tested panel builder

16 Bus trucking CPRI Approved type tested panel builder

17 Lighting fixtures Sisca / Wipro

Note :The makes of equipment given in this list shall only be followed for

execution of the project.


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17.0 GENRAL TECHNICAL REQUIRMENTS: FOREWORD The provisions under this section are intended to supplement general requirements for the

materials, equipments and services covered under other sections of tender documents is not

exclusive. However in case of conflict between the requirements specified in this section and

requirements specified under other sections, the requirements specified under respective

sections shall prevail.

GENERAL REQUIREMENT The bidders shall submit the technical requirements, data and information as per the technical

data sheets provided.

The bidders shall furnish catalogues, engineering data, technical information, design

documents, drawings etc., fully in conformity with the technical specification.

It is recognized that the Contractor may have standardized on the use of certain components,

materials, processes or procedures different from those specified herein. Alternate proposals

offering similar equipment based on the manufacturer’s standard practice will also be

considered provided such proposals meet the specified designs, standard and performance

requirements and are acceptable to someshwar SSK / VSI Unless brought out clearly, the Bidder

shall be deemed to conform to this specification scrupulously. All deviations from the

specification shall be clearly brought out in the respective schedule of deviations. Any

discrepancy between the specification and the catalogues or the bid, if not clearly brought out

in the specific requisite schedule, will not be considered as valid deviation.

Wherever a material or article is specified or defined by the name of a particular brand,

Manufacturer or Vendor, the specific name mentioned shall be understood as establishing type,

function and quality and not as limiting competition.

Equipment furnished shall be complete in every respect with all mountings, fittings, fixtures and

standard accessories normally provided with such equipment and/or needed for erection,


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completion and safe operation of the equipment as required by applicable codes though they

may not have been specifically detailed in the Technical Specifications. Materials and

components not specifically stated in the specification but which are necessary for

commissioning and satisfactory operation of the switchyard/substation unless specifically

excluded shall be deemed to be included in the scope of the specification and shall be supplied

without any extra cost. All similar standard components/parts of similar standard equipment

provided, shall be inter-changeable with one another.

18. STANDARDS The works covered by the specification shall be designed, engineered, manufactured, built,

tested and commissioned in accordance with the Acts, Rules, Laws and Regulations of

India.

The equipment to be furnished under this specification shall conform to latest issue with all

amendments (as on the date of bid opening) of standard specified, unless specifically

mentioned in the specification.

The Bidder shall note that standards mentioned in the specification are not mutually exclusive

or complete in themselves, but intended to compliment each other.

The Contractor shall also note that list of standards presented in this specification is not

complete. Whenever necessary the list of standards shall be considered in conjunction with

specific IS/IEC.

When the specific requirements stipulated in the specifications exceed or differ than those

required by the applicable standards, the stipulation of the specification shall take precedence.

Other accepted standards which ensure equivalent or better performance than that specified in

the standards specified for various equipments shall also, be accepted.

The bidder shall clearly indicate in his bid the specific standards in accordance with which the

works will be carried out.


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19.0 TECHNICAL SPECIFICATIONS OF FIBRIZER MOTOR STARTER & ASR ROTOR STARTER:

Fibrizer shall be suitable for 1250 KW drive HT motor. HT SLIP RING MOTOR:

a) Mounting - Horizontal foot mounted. b) Enclosure - CACA c) Rating - 1250 KW. d) Speed - 750 RPM e) Insulation class - F f) Duty - S1 (Continuous ) g) Direction - Bi-directional. h) Ambient temp - 50oC. i) Protection - IP 54. j) Input supply - 11KV, 50 Hz combined +/- 10%

The motor shall have base frame and suitable auxiliaries like space heater, RTD/BTD for winding and Bearing temp. Protection, Insulated NDE bearings along with suitable cable extension box, etc.

20.0 VCB STATOR STARTER & ASR ROTOR STARTER: One no. suitable VCB stator starter panels with one no. Auto slip regulator rotor starters shall be provided .The VCB panel shall have required CT’s & PT’s for metering and protection. A motor protection relay along with other required protections, indications, alarm and temperature scanner shall also be provided in VCB panel. Interlocking between VCB and ASR starter to be considered. The protection settings in the motor protection relay shall be done as per the motor data sheet and characteristics of the motor. It is the sole responsibility of the motor and VCB panel supplier. The no load KVAR and KVAR required at various loads shall be given by motor manufacturer. The VCB shall be of 1250 A rating and suitable for 40 KA 1 sec fault level.VCB shall have suitable Auxiliary equipments and auxiliary contacts. A Suitable Size &Run of XLPE (UE) 11 KV HT Alum. armoured cable to be provided between VCB panel to Rotor starter and to motor. Required size and no of control cables also to be provided. The drive system supplier shall submit motor data sheet , various characteristics curves of the motor and SR rotor starter/stator(VCB) starter drawings along with MPR settings. Makes: H.T. motor - KEC /CGL, ASR Rotor starter-EL Tech make, VCB- ABB. , Protection Relays -Siemens/ABB.,LT switchgear –L&T


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BATTERY LIMITS: 1) Civil foundations exclusive

21.0 TECHNICAL SPECIFICATIONS OF MILL MOTOR & VFD The Technical specification for the 4 nos MILL VFD Drive system shall be as follows. INVERTOR DUTY AC MOTOR : Rating : 450 KW. Base Speed : 1000 RPM Duty : S1 – Continuous (Over load class IV) Rated A.C. Supply : 690V+ 10%, 50 Hz + 5% ,3 Phase, Combined + 10%. Mounting : Foot mounting, Enclosure : TEFC / CACA Insulation Class : ‘F’ Class, temp. limited to class ‘B’ Cooling : Force cooling/CACA. Protection : IP – 54 Variable speed rang : 20% to 110% of base speed. Constant torque operation : 20% to 100% of base speed. Maximum Speed : 110% of base speed. Direction of Rotation : Bi-direction. Ambient Temperature : 50oC. Motor shall be having following construction feature .

Motor To be designed for bi direction, low speed operation.

Motor Duty shall be S1 continuous, suitable for mill drive.

Motor shall be suitable to work in a dusty, moist humid Atmosphere.

Motor shall have RTD’s (Two numbers for each phase) for winding and BTD’s for the bearing.

Motor windings shall be VPI treated & two coat of enamelled .

Motor shall be provided with space heaters.

Motor shall be provided with insulated bearing at the NDE

Motor shall be TEFC with single bare shaft extension with key way-key. And base frame.

Motor shall have cable extension box to easy accommodation of aluminium power cables.

Starting current of motor shall be less than or equal to 220% of rated to have soft start.

Test


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Motor shall be type tested and Routine tested.

AC DRIVE: The make of Drive and motor shall be of ABB / Damfos. The drive shall be of 6 Pulse type. Operating Voltage shall be 690 Volts AC. The drive shall also be of class IV over load class with design ambient of 50 Deg C. Timer Adjustment on Interface Unit Whenever a timer needs to be adjusted the Program/Run mode push button on interface unit is to be pressed and Timer can be adjusted from interface unit. Current ,speed Modification through MMI Unit: Supplier shall include a facility to modify the current and speed value through the MMI Unit provided the motor is stopped & there is no trip in the drive. This feature will be useful to modify the Motor current depends upon the load on Alternator. This mode is protected by the password to prevent unauthorized use. Panel Accessories • Meters :( L&T Rishabh ) Line Voltage ,Motor Line current. • Voltage/Ammeter Selector Switch : 6 Amps / Salzer make • PBs and Selector Switches : Teknic Make • Line Ind. Lamps(R,Y,B) : Pilot Lamps With Fuse Protection Panel/Cubicle shall have following specifications but not limited

The cubical fabricated from 14 SWG cold rolled steel sheets, free standing, passivated, and painted with anti-corrosive paints. & confirming IP-42 protection.

Ventilation shall be built in – louvers shall be provided with fine mesh& force cooling.

With all switch gear controls, Drive module, regulating modules interlocking relays, filters etc.

All required protections like Earth fault, phase to phase, di/dt, dv/dt, over current, over voltage, surge relay, overload relay’s etc.shall be provided.

All necessary meters, annunciations, controls shall be provided.

VFD Shall be preferably of DTC type.

VFD Shall be suitable to vary the speed of the 450KW cage motor in the range of 20% to 100% of base speed by varying voltage & frequency.

VFD Shall have provision to adjust v/f curve as per requirement.


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Speed regulation will be + 1% of base speed and should accept 4 to 20 mA signal for speed setting in auto mode.

Current limit shall be adjustable.

The protection class considered for our panels is IP42.

The ambient temperature considered is 40 Deg C for the drive panels and 50 degree C for Motor.

VFD Drives are to be selected as per the motor rating considering required derations.

All the Cable entry to be considered from bottom only.

The panels shall be of free standing, Floor Mounted, Front access

Door with neoprene gaskets on all edges of panel.

Ventilation openings shall be provided at the top of panel and on side covers by louvers suitably covered by fine wire mesh

Necessary thermister relays & RTD scanner with tripping facility shall be provided in the panel.

The panel shall be in three sections i.e. IP, DP,CP.

VFD Drive bi - directional in operation

The panel will have facility to accept 4 to 20 mA signal for speed setting in auto mode. Speed regulation with armature voltage feed back

Audio visual window annunciators will be provided.

One control desk with controls shall be provided for each motor to be controlled from this control desk with indications ,push button/selector switch like drive start/stop ,E. stop, fault reset., speed raise lower facility along with speed forward reverse ,inching facility. RPM meter, Ammeter .Voltmeter.

Other accessories required / standard shall be provided. Design Features 1. Incoming Supply through a suitable type and rating of ACB. 2. Semiconductor fuses on Input of Inverter . 3. Fuses & MCBs for all Circuitry Components. 4. System interlocking to be made efficiently to make the system foolproof. E.g. Motor Blower has been interlocked with the Compulsory conditions that have to be satisfied at any time. Hence the Motor cannot be started without Blower is ON. If at any time the Blower fails, the System will be tripped. 5. The incoming cables to the (Incoming / Control) panels shall be from bottom and also the out going cables will be from bottom for the Drive control panels. 6. Appropriate Copper cables shall be chosen for the Control Wiring and the Cable terminations would be crimped and ferruled according to drawing. 7. All the components shall be named appropriately and the Legends would be placed near the components for ease of Factory Engineers.


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8. Particular attention shall be given to the cross sectional areas of conductors, the selection of fuses or other protection, and protective earth connections. 9. Perspex and SMC sheets shall be provided to avoid any in-advertant contact with live parts. 10.The VFD/Panel shall be suitable to operate in worst supply conditions like - Voltage-621volt and Frequency-45Hz.contineously.Also it shall withstand momentary power failure conditions. 11.The drive system shall have required no of IOs(DI-6,DO-2,AI-2,AO-2). 12.The THD I at drive input shall specified and shall be minimum. 13.The Panel shall be facility to operate in Auto/ Manual as well as in Local/Remote/DCS mode. The panel supplier shall develop suitable logic for the same. 14.The current density of the busbar shall be 0.7 A/sq.mm. 15.he drive input output signals shall be galvanically isolated. 16 .Temperature scanner shall be provided in the panel. 17..A separate Space heater shall be provided for each vertical section of panel. 18.The drive shall be suitable for momentary voltage dip of 15%of normal system voltage for 1 sec. 19.The minimum operating height of the switch handle shall not be less than 500 mm from finished floor level. 20.Cable-Requiered size ,type & rating of cables between Converter Transformer to VFD panel and VFD panel to motor / PB station to be considered. Test: Drive system shall be type tested and Routine tested. NOTE:

1. 1 NO. SPARE VFD PANEL WITH HOT STAND BY TO BE CONSIDERED. 2. ALL INCOMING OUTGOING CABLE TO BE CONSIDERED.


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22. 0 LIST OF VFD / STARTERS Boiler: 1. ID fan -90 KW x 2 VFD. 2. Feed pump - 55 KW x 2 VFD. 3. Baggase feeders -3.7 KW 6 no VFD. Mill: 1. Feeder table-11KW x 4 VFD 2. Cane carrier – 55 KW x 1 VFD. 3. Rake type Cane carrier – 37 KW x 1 VFD. 4. Row juice pump – 37 KW x 1 VFD. 5. Imbibition juice pump – 11 KW x 1 VFD. 6. Imbibition hot pump – 11 KW x 1 VFD. 7. Kicker – 45 KW x 1 no star delta . 8. Leveller – 225 KW x 1 no ASR slip ring starter. 9. UnStrained juice pump- 11 KW x 2 no star delta. 10. Inter rake cane carrier – 22 KW x 4 star delta. 11. Rotary screen – 7.5 KW x 2 DOL. 12. Gear box oil pump – 7.5 KW x 2 DOL. 13. Mill hydraulic pump – 7.5 KW x 2 DOL 14. Cold water pump – 7.5 KW x 2 DOL. 15. Mill lubrication pump – 7.5 KW x 2 DOL. 16. Bagass cross carrier – 22 KW x 4 star delta. 17. Cane un loader crane – 630A supply feeder. 18. Mill crane – 400A supply feeder. 19. DCS – 200A supply feeder. Tentative single line diagram for electrical system


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