OWNER:

MAITHON POWER LIMITED

3rd FLOOR, NBCC TOWERS,
15, BHIKAJI CAMA PLACE,
NEW DELHI - 110 066

PROJECT MANAGER:
THE TATA POWER COMPANY LIMITED
CORPORATE CENTRE
34, SANT TUKARAM ROAD
CARNAC BUNDER
MUMBAI - 400009

PROJECT:
1050 MW MAITHON RIGHT BANK THERMAL POWER PLANT

BID SPECIFICATIONS FOR EPC CONTRACT

FOR
COAL HANDLING SYSTEMS PACKAGE
TENDER NO. TCE.4891A-H-500-004

VOLUME – IV
ELECTRICAL WORKS,
INSTRUMENTATION AND CONTROL

PROJECT MANAGER’S CONSULTANT:

TCE CONSULTING ENGINEERS LIMITED
73/1, ST.MARK’S ROAD
BANGALORE - 560 001

NOVEMBER 2007
ELECTRICAL WORKS
TCE 4891A-H-500-004 TCE CONSULTING ENGINEERS LIMITED CONTENTS:
TITLE MAITHON POWER LIMITED
COAL HANDLING SHEET 1 OF 2
1050 MW MAITHON RIGHT BANK TPP
SYSTEM
CONTENTS

SECTION SUB REV TITLE NO. OF

SECTION NO. SHEETS

VOLUME IV

ELECTRICAL WORKS
D2.01 R0 ELECTRICAL SCOPE OF WORK

D2.02 R0 EARTHING AND LIGHTNING PROTECTION

D2.03 R0 CABLES & CABLE CARRIER SYSTEM.

D2.04 R0 SERVICE TRANSFORMERS

D2.05 R0 MV SWITCHGEAR (6.6KV)

D2.06 R0 LT SWITCHGEAR / MCC

D2.07 R0 NON-SEGREGATED PHASE BUS DUCT

D2.08 R0 DC SYSTEM
D
D2.09 R0 LCP/ JB / PB

D2.10 R0 MOTORS

D2.11 R0 LIGHTING SYSTEM

D2.12 R0 NEUTRAL EARTHING EQUIPMENT

D2.13 R0 SPARES, MAINTENANCE TOOLS & TACKLES

D2.14 R0 DOCUMENTS TO BE SUBMITTED WITH BID

D2.15 R0 DOCUMENTS TO BE SUBMITTED AFTER AWARD OF

CONTRACT

D2.15 R0 CODES AND STANDARDS

TCE FORM 329 R3

TCE 4891A-H-500-004 TCE CONSULTING ENGINEERS LIMITED CONTENTS:
TITLE MAITHON POWER LIMITED
COAL HANDLING SHEET 2 OF 2
1050 MW MAITHON RIGHT BANK TPP
SYSTEM
CONTENTS

SECTION SUB REV TITLE NO. OF

SECTION NO. SHEETS

VOLUME IV

INSTRUMENTATION & CONTROL WORKS

D3.0 R0 INSTRUMENTATION AND CONTROL SYSTEM
D

TCE FORM 329 R3

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COAL HANDLING TITLE MAITHON POWER LIMITED SHEET : 1 OF 7

SYSTEM 1050 MW MAITHON RIGHT BANK TPP
ELECTRICAL SCOPE OF WORK

1.0 SCOPE AND BRIEF DESCRIPTION OF WORK

1.1
The scope of Contractor shall include design, manufacture, inspection, supply including
transportation to site, storage at site, transportation from place of storage to erection
site, erection, testing and commissioning and handing over in fully operable condition
satisfactory to Purchaser of all electrical equipment required for the coal handling
system for 2X525 MW Thermal Power Project, besides obtaining all statutory
clearances etc.
1.2 The major equipment/systems covered under scope of work shall be as follows but not
limited to the same:
¾ Service Transformers – 6.6 kV / 433 V, 3 phase, 50Hz, distribution
transformers for feeding supply to auxiliary loads complete with all fittings and
accessories for all auxiliaries of coal handling system and all other auxiliary
systems. 6.6kV/ 0.433 kV (as required) Transformer for feeding supply to 415V
Switchgears (as required to feed the loads coming in Coal Handling System)
and auxiliary system complete with all fittings and accessories.
¾ MV Switchgear (6.6 kV): Purchaser will provide duplicate feeders to serve as
incomers to this switchgear. MV Switchgear complete with SF6 / Vacuum
Circuit breaker / contactor / disconnector, Busbars, Instrument Transformers,
Relays, meters, terminal blocks, Dummy Panels, Bus Trunking & accessories
for feeding the complete Coal Handling System package loads is included in the
scope of this contract.

¾ LT Switchgear (415V) complete with Air Circuit breaker / contactor, bus bar,
Instrumentation Transformers, Relays, meters, terminal blocks, Dummy Panels,
Bus Trunking & accessories as required for the Coal Handling System.

It shall be the responsibility of the CHP vendor to finalise and propose the
quantity and locations of the LV Switchgear required to feed the auxiliary
systems connected with the Coal Handling System. In general a dedicated LV
switchgear shall be considered for each pump house / area / yard (covered as
part of the CHP) that are having a significant number of electrical consumers to
warrant a separate switchgear. The quantity and location of the switchgear
proposed by the Vendor will be subject to review and approval by the
Purchaser/Engineer.

¾ Segregated / Non-Segregated Bus Duct It is preferable to use Non-

segregated Bus Duct for connection between Service Transformer for Coal
Handling System and 415V Coal Handling System Switchgear. However, if
layout or other constraints do not permit use of NSBD, XLPE insulated cables of
adequate size and rating can also be considered to feed the LV Switchgear.

¾ JB/ PB - JB's as required for all systems pertaining to CHP, Local start/stop PB
for all motors and forward/reverse/off PB for all valve actuators, as well as PB’s
and JB’s required to meet requirements of local statutory bodies. All outdoor
JBs shall be of FRP / die cast aluminium make with IP-65 degree of
protection.

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ELECTRICAL SCOPE OF WORK

¾ Motors & Actuators - Drive motors for all rotating mechanical equipment with
gear reducer and coupling for all equipment wherever required.
¾ Cable & Cable Carrier System – shall consist of but not limited to
a) all MV/LV Power, control, instrumentation, fibre optic and any other special
cables required for proper operation, monitoring and control of the CHP system.
b) Cable raceway system consisting of cable racks, cable trays, Cable rack / tray
supporting structures, support members/channels for cable trays, cable tray covers,
cable trenches, Duct Banks, conduits, pipesleeves, hume pipes, associated
foundation and civil works, cable tray accessories, etc., as required.
c) Cable laying and cable termination including all necessary accessories like cable
termination kits, glands, lugs, tools for termination, ferrules, identification tags etc.,
d) Necessary fire protection systems like fire barriers, fire breaks, fire stops, and fire
proof sealing for wall/floor openings(after laying of all cables) and fire protective
coating systems etc., as necessary.
All the above items and any other item required for completing the Cable carrier system
shall be provided for the entire Coal Handling System. All cables shall be of FRLS
type only.

¾ DC System complete with Batteries, Chargers, Battery racks, Battery MCBs,

Distribution Board, associated flexible and power cables as required for Coal
Handling System package DC loads and for the emergency DC lighting for
CHP.

As a minimum requirement, 2X100% capacity 220V, dedicated battery of

suitable capacity with 2X100% float and boost chargers and DC distribution
board shall be provided for catering to the requirements of Coal Handling
System.

2X100% capacity, 220V dedicated battery of suitable capacity with 2X100%

float and boost chargers and DC distribution board shall be provided for any
remote or far away pump house loads that are coming under the CHP area.

¾ UPS System If UPS power supply is required for some of the CHP loads, a
dedicated Parallel redundant with static bypass UPS system of adequate rating,
shall be provided to feed the UPS load requirement for CHP loads. Purchaser
will not be providing any UPS supply for CHP requirements.
¾ Primary and Secondary Earthing and Lightning protection system for the
entire Coal Handling System area, buildings, Yard area etc., complete with
buried earthing grid and earth electrodes or earth pits for the entire area
covered in this package, shall be provided. This shall include conductors buried
in soil / embedded in concrete inside the buildings also.

All above ground earth conductors to which all the electrical equipment, metallic
structures are connected to have earth continuity for safety reasons, shall be
provided as part of this package.

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ELECTRICAL SCOPE OF WORK

In some portions of the power plant area, the buried earth conductors will be
provided by others. In such areas, CHP vendor shall provide secondary / above
ground earthing conductors for equipment / structures included in CHP, upto
connection to the nearest earth riser or earth pit of the power plant earthing
grid. The exact terminal points for primary earthing in power plant area, will be
informed to the CHP vendor during detailed engineering.

Lightning protection complete with vertical air termination rods, horizontal roof
conductors, down comers, test links and pipe electrodes shall be provided for
all structures for which the safety norms dictate requirement as per relevant
standards.

¾ Lighting and Power Receptacle System– Indoor, outdoor, road and yard
lighting, power and welding receptacle system for entire Coal Handling Package
areas shall be provided as part of this contract. This shall include, but not be
limited to, lighting transformers, normal and emergency Lighting DBs, AC / DC
lighting panels, towers, poles, lighting fixtures, lamps, aviation warning lights (as
applicable), Power sockets, welding receptacles etc for the entire coal handling
system covering all the buildings, outdoor areas, yard lighting, aviation warning
lighting in its scope as per the requirement. Lighting circuits will be protected by
MCB/ELCB as required.

¾ Air Conditioning and Ventilation System – Complete Air conditioning and

ventilation as required for the Coal Handling Package Relay and control
buildings, especially relay rooms, battery and UPS rooms, and any other rooms
requiring controlled atmospheres for equipment being supplied under this
contract is included under the scope of this Contract. All sizing calculations are
subject to approval by Purchaser including areas to be covered and shall not
attract additional cost.

Fire Detection, Protection and Alarm System – Complete Fire detection, protection
and Alarm System for Coal Handling Package equipment will be provided by the PES &
PWS package vendors( read as others). This shall include but not be limited to Analog
Addressible type Multicriteria detectors, LHS cables, Sprinkler systems, CO2 systems,
Manual Call Points, Fire protection system cabling, Local and Centralised Fire Alarm
Panels for CHP package areas and buildings, any other equipment required to detect /
tackle fire situations. Fire Hydrant system for the CHS package will be provided by
PWS package vendor (read as others). However, it shall be the responsibility of the
CHS Package vendor to coordinate with the other package vendors to enable smooth
and proper installation of the complete system to the entire satisfaction of the
Purchaser.
¾ Communication System Complete communication and Public Address
System for CHP areas will be provided by PES package vendor (read as
others). However, it shall be the responsibility of the CHS Package vendor to
coordinate with the other package vendors to enable smooth and proper
installation of the complete system to the entire satisfaction of the Purchaser.

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ELECTRICAL SCOPE OF WORK

¾ Special tools and tackles required for installation, operation and maintenance
of electrical equipment.

¾ Essential and Start-up spares for all equipment included in the scope. Bidder
shall furnish a comprehensive list of the same.

The scope shall include as a minimum, the design, basic and detailed engineering,
preparation and submission of all required drawings including support calculations for
1.3
Purchaser’s review and approval. A basic list of documents / drawings required is
given below as a guideline:

¾ Composite Key One Line Diagram clearly highlighting the scope of work
considered by the vendor.

¾ Protection and metering One Line Diagram clearly indicating the detailed
protection and instrumentation provided by the vendor.

¾ Detailed Single Line Diagram for 6.6 kV, 415V, DC & UPS systems, Lighting
and Power Receptacles SLD.

¾ Layout drawings - Electrical equipment layout including General Arrangement

layouts for all CHP areas/buildings/equipment, Cable tray and trench layout
drawings, lighting layout drawings, Earthing & Lightning Protection layout
drawings including earth mat details etc., as required by Owner with all
supporting calculations and documentation.

¾ Scheme drawings for all Switchgear / MCC /Motor modules/Control Panels.

¾ Block Logic Diagrams for 6.6 kV & 415 V systems.

¾ Vendor drawings for all equipments covered in the scope.

¾ Studies: Performing Electrical System Studies for the Coal Handling System
auxiliary systems including Relay Setting calculations relay co-ordination
studies, furnishing recommended relay settings, largest motor starting study.
All studies shall be carried out using internationally accepted software like E-
TAP / CYME / EDSA.

¾ Foundation drawings with supporting calculations.

1.4 The scope shall include submission of all required design calculations for:

¾ Bus Ducts – Calculation for Span and Supporting Arrangement, and busbar
and enclosure sizing. Heat loss and temperature rise calculations for conductor
and enclosure

¾ Sizing for MV Switchboard

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ELECTRICAL SCOPE OF WORK

¾ CT & VT Sizing

¾ Cable Sizing –All Power Cables.

¾ Voltage Dip & Drop Calculations

¾ Battery & Charger Sizing

¾ Earthing Conductor and Earth mat Sizing with Step & Touch potential.

¾ Lightning Protection System Design

¾ Lighting System Design and lux level calculations using well known
software like Calculux or Dialux.

¾ Selection of transformer impedances and tap ranges vis-à-vis Voltage

drops, Voltage dips and fault levels.

¾ Relay Setting and Relay Co-ordination graphs for the Coal Handling
System plant

1.5 The contractor shall include the following schedules in his scope:

¾ Cable Schedules – For all Power, Control and Instrumentation Cables.

¾ Interconnection cable Schedule for all cables supplied and installed by

contractor.

Data Sheets for all equipments shall be included in the vendor’s scope and shall be
1.6
submitted for approval by Purchaser.

A brief description of scope of work, design requirement, control philosophy and layout
for complete power plant is given in the subsequent chapter for understanding of
1.7
Contractor. However, Contractor shall include complete electrics for Coal Handling
System plant under his scope of work.

The required no. of Service transformers, HT Switchgears, LT switch gears, and MCCs
being planned by the Contractor shall be furnished and it shall be subject to approval of
1.8 purchaser/purchaser's Consultant. Similarly layout of electrical equipment in various
areas shall be provided as per approval of purchaser/purchaser's Consultant. The
minimum requirement of equipment to be considered is given in subsequent chapters.

The technical requirement of the Coal Handling System plant equipment involved as
1.9 per the scheme, are covered in appropriate sections forming part of this specification
and also as per relevant IS / International standards.

For all the inputs required by the Contractor from other packages, supply of the
1.10 required auxiliary relays and control cables, Field JBs, etc., laying and termination shall
be in the scope of the CHP Vendor.
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ELECTRICAL SCOPE OF WORK

2.0 ELECTRICAL SYSTEM DESIGN:

2.1 STANDARDS:

The design, manufacture, assembly and testing as well as performance of the

equipment and system shall conform to the relevant IS specifications (latest revision).
In case the Contractor is not in a position to comply fully with certain IS specifications,
or in respect of certain items for which there are no IS specifications, the Contractor
may base his proposals on IEC/BS/VDE/DIN recommendations or other reputed
national or international standards subject to the approval of the purchaser. All
equipment supplied and all work done including system design and detailed
engineering shall also comply with the statutory requirements of the Government of
India, the Government of Jharkhand and with the Indian Electricity Rules and all other
statutory bodies as applicable for the plant location.

2.2 CLIMATIC CONDITIONS

The climatic conditions generally prevailing at Jharkhand have already been described
in other volume.

Electrical Equipment selection and derating shall generally be based on ambient

temperature of 50 deg. C. For specific hot areas, the ambient temperature conditions
shall be taken into consideration and equipment suitably derated where necessary. In
hot areas of higher temperature conditions, the equipment shall be adequately
protected against damage from radiant heat and hot air.

The equipment offered shall be suitable for smooth efficient and trouble free service in
the climate of Jharkhand.

2.3 MAKE AND INTERCHANGEABILITY

Makes of all equipment and accessories are subject to prior approval by the Purchaser
and shall be without commercial / delivery implications.

Similar equipment and components shall be of same make, equipments of same type
and rating shall be interchangeable.

The purchaser has the option of selecting the manufacturers of electrical equipment,
instruments and controls and any other specialized items in the interest of
standardization and the contractor shall have to supply equipment of the particular
make, if so required.

2.4 DESIGN CRITERIA

2.4.1 Standard voltage levels

The standardised voltage levels as shall be adopted as specified elsewhere in this

specification.

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2.4.2 Permissible variations:

The system unit/plant equipment shall be designed suitable for variation in voltage and
frequency as indicated in the table below:

Variation in voltage and frequency:

Sl. Description Voltage Frequency
No.
1. Permissible variation for power supply with
rated performance/rated current and control
effectiveness maintained +/- 10% +/– 5%

2.4.3 Basic insulation levels

Equipment shall be designed suitable for basic insulation levels as given in the Table
below:
Sl.No. Nominal voltage kV BIL kV (peak)
1. 6.6 kV 60
2.4.4 Symmetrical short circuit ratings

The three phase symmetrical short circuit ratings of the switchgear at different voltage
levels shall be as indicated in the Table below:
Sl.No. Voltage level Symmetrical Making
Breaking capacity Capacity
1. 6.6kV 40 kA 100 kA
2. 415 V 50 kA 125 kA
3. 220 V DC Min.20 kA -
4. 110/230V AC UPS Min.20 kA -

The rated short circuit withstand duration 6.6 kV is 3 Sec, and 415V shall be 1 sec.
2.4.5 Criteria for selection of voltage levels for motors
A.C squirrel cage induction motors of ratings upto and including 200 kW shall be fed at
415 V, 3 phase, 50 Hz, with DOL start as applicable. A.C motors of ratings greater
than 200KW shall be connected to the 6.6 kV systems.
2.4.6 Motor starting and permissible voltage dips:
Voltage dip on starting of the largest motor with DOL shall be limited to 15% of the
nominal voltage at the motor terminals.

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ELECTRICAL EARTHING AND LIGHTNING PROTECTION

1.0 EARTHING SYSTEM

Earthing and Lightning system shall be provided for the buildings and structures
included in the scope of supply of Coal Handling System package complete with earth
grids and electrodes including those buried in soil in the plant area, embedded in
concrete inside the buildings and all above ground earth conductors shall be provided.
Lightning protection complete with vertical air termination rods, horizontal roof
conductors, down comers, test links and pipe electrodes shall be provided for all
structures for which the safety norms dictate requirement as per relevant standards
shall be provided.
2.0 Design Criteria
2.1 Fault Current & Duration
The earthing conductor shall be designed for 50 kA for duration of 1 second.
2.2 Conductor Material
The earthing system conductors and accessories as proposed are to be as follows:
(a) Conductors above ground level and in : Galvanised steel
trenches
(b) Conductors buried in ground or : Mild Steel
embedded in concrete
(c) Electrodes : GS Pipe / Rod
(d) Lightning protection air termination and : GS Flat
down conductors for buildings
(e) Exposed lightning protection air : Lead coated copper
termination on chimney top

The Contractor shall undertake the soil resistivity measurements at site and select
suitable type of conductors.
2.3 Size of Conductors
(a) Main Earthing Conductors
The earthing conductor sizes shall be calculated as per the following formulae.
If 1
= K
A t
A = Cross-section area in sq.mm
If = Maximum a.c. rms ground fault current amperes.
t = Operating times of the protective device to disconnect
the faulty circuit, in secs.
K = Factor depending on the earthing conductor, the
insulation and other parts, and the initial and final
temperature.
The factor “K” is determined by the formula

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( B  20) ( B  It )
K = sqrt( Qc Loge )
P 20 ( B  I1)
P20 = Electrical resistivity of conductor material at 20 deg. C
(ohm-m).
Qc = Volumetric heat capacity of conductor material
(J/deg.C/cu.m).
B = Reciprocal of temperature co-efficient of resistivity at 0
deg. C for the conductor.
I1 = Initial temperature of conductor, (deg.C).
It = Final temperature of conductor, (deg. C)
depending on the type of joints.
The calculated size shall be suitably (depending on the resistivity of soil) increased as
per table below to account for the loss of material (steel) due to corrosion in soil.
RESISTIVITY OF SOIL REDUCTION IN
OHM– METRIC THICKNESS /
DIAMETER, MM
<10 8.0
>10 <25 7.0
>25 <50 5.5
>50 <75 4.5
>75 <100 3.0
>100 1.5
b) Rod Electrodes
Galvanised steel rod electrodes of suitable diameter and length shall be used as per
the recommendation of IS-3043. For test pits electrodes shall be heavy duty type
(Class – C) GI pipe of suitable diameter with perforations. Electrodes installed in the
test pits will have disconnecting facilities. All the earth pit shall be provided with
disconnecting facility for inspection purpose.
c) Equipment Earthing Leads
The size of the earthing leads shall be decided based on the type of equipment and
structure to be earthed and shall be provided generally as per IS-3043 and also with a
view to minimise the number of sizes.
d) Conductors for lightning protection system
The size of conductors for lightning protection system shall be decided based on
mechanical strength.
3.0 Earthing System Layout
3.1 The earthing system design and installation shall generally comply with the following

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standards.
(a) IS-3043 : Code of practice for Safety
Earthing
(b) IEEE-80 : Guide for safety in
Alternating current sub-
station grounding
(c) Indian Electricity Rules
3.2 General
3.2.1 Metallic frames of all current carrying equipment, supporting structures adjacent to
current carrying conductors, structures in contact with earth, lightning protection
system conductors and neutral points of various systems shall be connected to a
single earthing system. Two earthing leads shall be used if rated voltage of equipment
is above 250V. If the rated voltage is 250V or below, one earth lead shall be
provided. Metallic structures adjacent to electrical equipment shall be earthed by one
earthing lead. Main earthing in switchgear rooms, buildings shall be in form of grids.
3.2.2 Earthing conductors in outdoor areas shall be installed at a minimum depth of 600
mm.
3.2.3 All cable trays in the plant buildings as well as inside the trenches shall be connected
to earth grid at an interval of about 10 m.
3.3 Earthing Conductors Inside Building
3.3.1 Main earthing conductors shall be buried in earth around the building. Minimum two
taps-off from this earthing loop shall be taken inside the building and connected to the
earthing grid embedded in the floor slab with approximately 50 mm concrete cover.
The earthing within the building shall be in form of grids.
3.3.2 In case, the building has more than one floor, each floor shall be provided with earth
grid as discussed earlier. Floor earthing grids shall be interconnected.
3.3.3 Each RCC / Steel column of the building shall be interconnected to the floor earthing
grid in the ground floor.
3.3.4 Cable trays, steel pipes / conduits, steel columns, etc., shall not be used as earth
continuity conductors.
3.3.5 Instrumentation system and computer system shall be provided with a dedicated
earthing system suitable for the equipment.
3.3.6 Earthing grids of all the buildings, outdoor yards shall be interconnected to form a
single grid for the plant.
3.3.7 Earthing grid design shall be done in such a manner that the grid resistance is less
than one ohm.
3.4 Earthing System Installation
3.4.1 The spacing between two electrodes shall be atleast equivalent to twice the length of
the electrode.
3.4.2 Earthing conductor running exposed on column, walls, etc., shall be supported by
suitable cleating, at intervals of 750 mm.
3.4.3 The earthing conductor crossing the road / track shall be laid in hume pipe or laid at a
greater depth to avoid damage.
3.4.4 When earth conductor passes through floors, walls, etc., suitable pipe sleeves shall
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be provided and the same shall be sealed appropriately after installation.

3.4.5 The connection between earthing pads / terminal to the earth grid shall be made short
and direct and shall be free from kinks & splices.
3.4.6 Metallic conduits and pipes shall not be used as earth continuity conductor.
3.4.7 Street lightning poles, flood light poles & towers, their junction boxes shall be
connected to the earthing conductor to be run along with supply cable. This earth
conductor shall be in turn connected to earth grid at two extreme points.
3.4.8 Flexible earth conductors shall be provided at expansion joints for earthing the gates,
operating handles, etc.
3.4.9 Equipment bolted connection after being checked and tested shall be painted with
anti-corrosive paint / compound.
3.4.10 Connection between the equipment earth lead and the grid conductor shall be welded.
For rust protection, the welds shall be treated with zinc chromate primer and coated
with zinc rich paint.
3.4.11 The cable sheaths, screens armour shall be earthed at both ends for multi-core
cables. For single core cables the same shall be done at one end (switchgear end)
only.
3.4.12 All bimetallic connections shall be treated with suitable compound to prevent moisture
ingression.
4.0 Lightning Protection System
Lightning protection system shall consist of vertical air termination rods, horizontal
roof conductors, downcomers, and pipe electrodes. The need for providing the
lightning protection system shall be established by calculating risk index value for
each building structure, etc., as per procedure given in IS-2309 and any building
whose risk index is more than 40 shall be provided with lightning protection.
4.1 Lightning Protection System Layout
4.1.1 The lightning systems design and installation shall generally comply with IS: 2309
code of practice for the protection of building and allied structure against lightning.
4.1.2 For cooling towers, air termination system will comprise of horizontal circumferential
conductors at the top.
4.1.3 Each down conductor shall be connected to a rod electrode, which in turn shall be
connected to the station earthing system through test links.
4.1.4 Lightning protection shall also be provided for building as required by the relevant
codes and subject to Owner / Project Manager's approval.
4.2 Lightning Protection System Installation
4.2.1 Conductors of lightning protection system shall not be connected with conductors of
safety earthing system above ground level.
4.2.2 The down conductors shall be welded to steel structures at 1000 mm interval or
cleated to wall at 750 mm interval. Wherever welded, the weld locations shall be
treated to provide rust protection.
4.2.3 Each down conductor shall be provided with a test link at a height of about 1000 mm
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ELECTRICAL EARTHING AND LIGHTNING PROTECTION

above ground level.

4.2.4 All the metallic structures within a vicinity of 2000 mm shall be connected to the
lightning protection conductors.
SHEET
(To be filled by the Contractor)
Lightning Protection

1 Whether lightning conductors have been

envisaged for the lightning protection.
2 Angle of protection.
3 Whether building is also protected.
4 Number of electrodes provided.
5 Earthing resistance value
6 Size of down conductors
7 Standard followed
8 Deviations if any on technical specification
Earthing
1 Material and size of earth strip for various
places
2 Gap between earth mat conductors-
lengthwise, breadthwise
3 Size of main outer strip
4 Galvanising content on GI strips
5 Value of earthing resistance (proposed to
be achieved)
6 Standard to be followed for galvanising
7 a)Type of electrodes
b)Size of material
8 Construction of earthing pit as per IS
9 Riser Connections
1) Material
2) Size
10 Treated earth pit
1)Material
2)Size

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ELECTRICAL EARTHING AND LIGHTNING PROTECTION

3)Length of each electrode

4)Total no.of pits
11 Deviations if any on technical specification

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ELECTRICAL CABLES & CABLE CARRIER SYSTEM

1.0 Cables
1.1 MV Cables
MV cables shall be 6.6kV(UE)/11kV(E) grade suitable for use in medium resistance
earthed system, with stranded & compacted Aluminium conductors, extruded semi-
conducting compound screen, extruded XLPE insulated, extruded semi-conducting
compound with a layer of non-magnetic metallic tape for insulation screen, extruded
FRLS PVC (Type ST – 2) inner sheath, Aluminium / Galvanised steel round wire
armoured extruded FRLS PVC (Type ST – 2) outer sheath, single / multicored
conforming to IS 7098 (Part II) IEC-60502 for constructional details and tests.
1.2 LT Power Cables
LT Power Cable shall be 1100 V grade, single / multicore, stranded Aluminium
conductor, XLPE insulated, with PVC inner sheath and outer sheath made of FRLS
PVC compound. The armouring shall be of Aluminium / Galvanised steel round
wire. The cable used for DC system shall be of single core type. All other details
shall be as applicable. Minimum conductor cross section of power cables shall be 4
mm2.
1.3 Control Cables
Control cables shall be 1100V grade, multicore, minimum 2.5 mm2 cross section,
stranded copper conductor having 7 strands, PVC insulated, inner PVC sheathed /
galvanised steel wire armoured and outer sheath made of FRLS PVC (Type ST-2)
compound. In situations where accuracy of measurement or voltage drop in control
circuit warrant higher cross sections as required shall be used. 4 mm2 copper
conductor cables shall be used for CT circuits all other specifications remaining
same.
1.4 Instrumentation Cables
Instrumentation cables shall be with stranded high conductivity annealed, tinned
copper, twisted pair (with min. 20 twists per meter) extruded PVC insulated with
overall and / or individual screening, extruded PVC inner sheathed, extruded outer
sheathed with FRLS PVC compound. The conductor size shall be minimum 0.5
mm2. Triplet cables similar to instrumentation cables can be used for RTDs.
Instrumentation cable’s cores/pairs/triplets shall be number and colour coded for
identification purposes.
1.5 Compensating Cables
If Thermocouples are used, then Compensating cables having conductors same as
the thermocouple type shall be used. Bidder shall propose in their offer the specific
details of construction and type of material being used for compensating cables (if
applicable). The compensating cables shall be offered in conformance with relevant
IS/IEC colour coding for each type of conductor.

2.0 Cable Properties

2.1 All single core power cables will have wire / strip armouring of Aluminium, whereas
multicore power cable will have Galvanised steel wire / strip armouring.

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ELECTRICAL CABLES & CABLE CARRIER SYSTEM

2.2 The outer sheath of all cables shall be of extruded layer of suitable synthetic
material compatible with specified ambient and operating temperature of the cables.
The sheath shall be resistant to water, UV radiation, fungus, termite and rodent
attack.
2.3 The outer sheath of FRLS PVC compound shall meet the following performance
requirements:
(a) The critical oxygen index value shall be minimum 29 when
tested at 27+20C as per ASTM-D-2863-77 and the
temperature index will be minimum 2500C at oxygen index
value of 21 when tested as per NES-715.
(b) The maximum acid gas generation as determined by titration
shall be less than 20% by weight when tested as per IEC-
60754-1 (1994).
(c) The smoke generation under fire shall have maximum smoke
density rating of 60% when tested as per ASTM-D-2843-7
(1988).
(d) The cables shall pass the hydraulic stability and ultraviolet
tests as per DIN 53387.
2.4 The finished cable shall pass the flammability test as per IEC-60322-1 (1993) and
IEEE-3833. In addition, it shall also pass flammability test as per Class F3 of
Swedish Standard SS-424-1475 (1978).
3.0 Design Criteria for Cable Sizing
3.1 Power cables
Power cable sizes shall be selected on the following basis:
3.1.1 Power cables shall carry the full load current of the circuit continuously under site
conditions considering the various derating factors like ambient air/ground
temperature, grouping, method of laying, etc.
3.1.2 Power cables shall withstand the fault current of the circuit for the duration not less
than the maximum time taken by the primary protective system to isolate the fault.
Fault clearing times for motor feeders and transformer feeders having high-set
instantaneous protection shall be 0.16 secs, and for incomers and tie feeders 1.0
sec.
3.1.3 For motors controlled by vacuum contactors with back-up HRC fuses, the minimum
cross-section of cables shall be based on the cut-off current of the fuses and its
fusing time.
3.1.4 For the cables to 415V motors and feeders protected by fuses, the cross section
shall be chosen according to the cut-off current of the fuse and its fusing time.
3.1.5 Voltage dip at motor terminals during starting of motors will be limited to the
following values.
For all motors – 15% of the rated voltage.
3.1.6 Voltage drop in feeder cables shall be limited to 3% during full load running

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condition.
3.1.7 For power supply to valve actuator motors, actuators of various isolating and
regulating dampers and exhaust fans, 3 core 2.5 mm2 stranded copper conductor
cable may be used in view of ease of termination. These cables shall be in other
respects similar to cables described in Clause 1.2 above.
3.2 Control Cables
3.2.1 Current transformers leads shall be checked for the lead burden vis-a-vis the current
transformer VA capacity and 4 mm2 cables shall be used for connection of CT to
loads. In case 4 mm2 conductors impose unacceptable high burden on CTs,
conductor of higher cross section shall be used.
3.2.2 Voltage transformer leads shall be checked for voltage drop, which shall be limited
to within 1% for all cases other than tariff metering. For tariff metering the voltage
drop shall be limited to 0.2%. In case the voltage drop with 4 mm2 Cu conductors
exceed this value, higher conductor sizes shall be used.
3.3 Instrumentation Cables
Instrumentation cables shall comply with the Electrical Properties suitable for the
Digital and Analogue signals.
3.3.1 Element identification : As per IEC-60189-2
3.3.2 Core wrapping : By non hygroscopic material by taping or by extrusion
3.3.3 Element screening : By copper tape of minimum 0.04 mm
thickness or by copper laminated
plastic tape.
3.3.4 Rip cord : Non metallic rip cord under the core Wrapping
3.3.5 Drain wire : A tinned copper drain wire of minimum 0.5 mm2 cross
section in contact with each screen of cabling element.
Cabling elements shall be any one of the following:
A 'Pair' of two insulated conductors twisted together designated by alphabet 'p'
printed on a binding tape at 200 mm intervals.
A 'Triple' of three insulated conductors twisted together designated by alphabet ’t’,
printed on a binding tape at 200 mm intervals.
Maximum length of lay in the finished cable shall be 120 mm.
Units
Cables shall be bunched together in units of twenty cabling elements or sub units of
five or ten elements, stranded in concentric layers. The units or sub units shall be
designated by p1, p2, p3, t1, t2, t3.., q1, q2, q3, or Q1, Q2, Q3 ..., etc. depending on
the combination.
Overall screening and armouring
Cables shall have an overall screen made up of copper/aluminium tape of 0.04 mm
thickness or copper/aluminium of 0.008 mm thickness laminated with plastic tape
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ELECTRICAL CABLES & CABLE CARRIER SYSTEM

with a minimum overlap of 15%.A drain wire of tinned copper with minimum 0.5 mm2
cross section shall be provided in continuous contact with the screen.
Inner and Outer Sheath
The inner and outer sheaths shall consist of black PVC compound.
Insulation Resistance
Minimum insulation resistance per km shall be 500 mega Ohm.
Mutual Capacitance
Mutual capacitance of any pair of conductors shall not exceed 120 nF/km.
Capacitance Unbalance
The capacitance unbalance between any two pairs shall not exceed 400 pF for 500
metre length of cable.
The construction, performance and testing of cables except as mentioned above
shall generally comply with the following standards:
IEC-60189 - Part-1: Low frequency cables and wires with PVC insulation and
sheath. General test and measuring methods
IEC-60189 - Part-2: (-do- Cables in pairs and triples).
4.0 Cable Terminations
4.1 All 6.6kV termination kits shall be of heat shrinkable type and suitable for XLPE
insulation.
4.2 All 1100V termination for XLPE/PVC power cables and control cables shall be by
crimping type tinned Copper / Aluminium lugs.
5.0 Cable Joints
Cable joints shall be avoided to the extent possible. If joints are unavoidable due to
circuit length, in excess of permissible maximum drum length, they shall be heat
shrinkable type having a short circuit withstand capacity of 40kA for 0.5 sec. for
6.6kV cables and 50kA for 0.5 sec. for 1100V grade cables.
6.0 Power Receptacles
3 phase, 4 pin, 63A power receptacles with switch shall be provided two in each
floor of the buildings covered in this scope. The receptacle shall be industrial heavy
duty type and shall have suitable interlock facility for safety. The receptacle shall
conform to IS 1293 and the switch to IS 4064.
7.0 Cable Carrier System
7.1 The cable carrier system shall be designed considering the following:
(a) Facility for easy laying of cables.
(b) Access to maintenance.
(c) Neat and aesthetic appearance.
(d) Safety of equipment & personnel.

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ELECTRICAL CABLES & CABLE CARRIER SYSTEM

(e) Ground water seepage.

7.2 Cables shall be laid in prefabricated ladder type trays and in conduits. Direct burial
of cable shall be avoided as far as possible. In case cables are buried, length of
burial shall be limited to about 10 M and depth of burial shall be about 750 mm.
Cable route markers shall be provided at every 15m intervals and at bends. Also
joint markers shall be provided at each joint.
7.3 Cable tunnels are not acceptable. Cables shall necessarily be run in overhead
racks.
8.0 Cable Installation and Accessories
8.1 All material and accessories required for cable installation like cable trays, tray
covers, support steel, etc., shall be hot dip galvanised and conduits/pipes shall also
be hot dip galvanised.
The racks/trays, conduits/pipes, trenches required to route the cables to individual
equipments shall be supplied and installed by the Contractor.
8.2 Separate trays shall be provided for HV Power/LV Power (AC&DC)/Control &
Instrumentation cables.
9.0 Cable Trays and Covers
9.1 Cable trays shall be of ladder / perforated type complete with all necessary coupler
plates, elbows, tees, bends, reducers, stiffeners and other accessories. Cable trays
of ladder and perforated types and the associated accessories such as coupler
plates, tees, elbows, etc., shall be fabricated from 12 gauge (2.5 mm thick) mild
steel sheets, cable tray covers shall be fabricated from 16 gauge (1.7 mm thick) MS
sheets. All the sheet steel shall be hot dip galvanised. Ladder type trays shall be
used for power cables and perforated type trays shall be used for control and
instrumentation cables.
9.2 Cables of sizes 120 mm2 and above shall be laid in single layer. Single core cables
used for 3 phase AC power circuits shall be laid in Trefoil form.
10.0 Fire-Proof Sealing of Cable Penetration
Cables / cable tray openings in walls and floors or through pipe sleeves from one
area to another or one elevation to another, between the units and within the same
unit, shall be sealed by a fire-proof sealing system. The fireproof sealing system
(FPSS) shall effectively prevent the spread of fire from the flaming to the non-flaming
side, in the event of a fire. The FPSS shall conform to the following requirements:
(a) FPSS shall have a fire rating of four hours.
(b) The FPSS shall be subjected to fire endurance test, hose stream test,
temperature measurement of non-flaming side as per ASTM-E119. 'Standard
method of fire tests of building construction and materials'.
(c) The FPSS will also conform to the incombustibility test carried out in accordance
with IS: 3144-1992.
(d) Under fire condition, the FPSS material shall not emit excessive smoke or any
corrosive or toxic fumes.

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11.0 Fire Break

11.1 Firebreak shall be provided by applying a suitable fire-resistant coating on cables for
the required length to meet the fire rating of two hours.
11.2 Firebreak shall be provided at an interval of 15 metres in the straight portion of each
of the cable tray above ground, at intervals of 30 metres in cable trenches and at 5M
for all vertical trays. All cable inter section and tee offs shall be provided with
firebreaks.

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ELECTRICAL SERVICE & BOOSTER TRANSFORMERS

1.0 General
1.1 Service transformers and Booster transformers (If required) shall be provided to
cater to the Coal Handling System Package LV loads. These transformers shall be
suitably rated as per the requirements of the corresponding loads to be fed. They
shall supply power to the 415V auxiliaries CHP loads. The neutral of these
transformers shall be solidly earthed. The transformers shall be provided with ±5%
off-circuit taps in steps of 2.5% on the HV side. The brief details of Service
Transformer & Booster Transformer are indicated in table below:
SL PARTICULARS SERVICE BOOSTER
NO. TRANSFORMER TRANSFORMER(IF
REQD)
1 MVA rating To be furnished by To be furnished by
Bidder with supporting Bidder with supporting
calculations including calculations including
margin of 10% over margin of 10% over
calculated load. calculated load.
2 Type of cooling ONAN ONAN

3 No load voltage ratio 6.6kV/433V 433V/415V

4 Vector group Dyn11, Yy0(To be verified by
Bidder),
5 Tap changer Off circuit Off circuit
6 Tap range +-5% in steps of 2.5% +-5% in steps of 2.5%
7 Impulse withstand 60kV peak As per IS
8 Power frequency withstand 20kV/3kV rms As per IS
9 Applicable standards IS 2026 all parts. IS 2026 all parts.
10 Quantity To be decided by Bidder To be decided by Bidder.
(Minimum 2 x 100%).
2.0 MVA Rating
2.1 Each transformer shall be rated to take care of the entire load on the respective
switchgear considering the outage of the other transformer. An appropriate load
factor with a minimum of 0.9 for continuously running loads and 0.4 for
intermittent loads like cranes, plug points, sump pumps, etc., shall be considered.
The rating established shall be taken into account, load variations during the
course of engineering. Due consideration for reduction in capacity due to
transformer regulation shall be given. Spare capacity of atleast 10% shall be
available in each transformer at the time of handing over the plant.
3.0 Specific Requirements
The transformer shall generally comply with all specific requirements including the
following:
(a) The transformer shall be hermetically sealed type with corrugated tank and

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ELECTRICAL SERVICE & BOOSTER TRANSFORMERS

cooling fins.
(b) The transformers shall be breather less type without conservator.
(c) Off-circuit tap changers with lockable operating handle and mechanical tap
position indicator shall be provided.
(d) Explosion vent with diaphragm shall be provided instead of pressure relief
device.
(e) The wheels shall be flat roller type
(f) Remote facility for winding temperature indication and top oil temperature
detector need not be provided.
(g) Impulse test, partial discharge test need not be conducted. However,
results of impulse test, short circuit tests conducted on similar rated
transformer shall be submitted.
(h) The transformer shall be suitable for Cable connection for HV and cable /
Busduct connection for LV side(To be finalised by Bidder depending on
Layout requirements).
(i) The neutral of the LV side of the transformer shall be brought out in a
separate cable box or if the same cable box is used for neutral also, then
metallic partition between phases and neutral shall be provided.
4.0 It is the sole responsibility of the Contractor to provide all equipment / accessories
and select the quantity and Ratings of all transformers to make the system
complete (as deemed by Owner) in all respects and no extras on any account will
be entertained.
5.0 Technical Requirements
The Service transformers and Booster Transformers shall comply with the
particulars indicated below and Contractor shall furnish the details in respective
column given below (To be separately submitted for transformers of different
ratings and type)
Sl. Unit Specification Bidder’s Data
No. Description Requirements
1.0 Transformer applications Service / Booster
Transformer
2.0 Type & make Oil filled, Outdoor,
two winding 3 phase
3.0 Applicable standard IS : 2026
4.0 Quantity *
5.0 Full load rating MVA *
6.0 Rating no load voltage HV/LV kV 6.6 / 0.433,
0.433/0.415
7.0 Impedance value % *

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ELECTRICAL SERVICE & BOOSTER TRANSFORMERS

8.0 Rated frequency Hz 50

9.0 Winding connection of Dyn11,
different windings and vector Yy0
group
10.0 System earthing
(a) HV Medium resistance
(b) LV Solidly earthed
11.0 Type of tap changer off Off Load
circuit/on load
12.0 Tapping range and number of +-5% in steps of
steps 2.5%
13.0 Type of voltage variation CFVV
(CFVV/VFVV/CbVV)

14.0 Overfluxing capability 110% continuous

15.0 Winding insulation type
15.1 HV Uniform
15.2 LV Uniform
15.3 Impulse withstand voltage of KVP As per standards
winding HV/LV
16.0 Power frequency withstand kV/ 20 / 3
voltage of winding HV/LV rms
17.0 Maximum temperature rise at
full load with 100% coolers:
(a) Oil o
C 50
(b) Winding o
C 55
18.0 Bushing particulars
18.1 Applicable standard for IS-2099
bushing
18.2 Clearance in air between mm HV – As per std.
phases
LV – 25
18.3 Creepage distance mm/k 31
V
19.0 No load loss kW *
20.0 Load loss kW *
21.0 Efficiency at full load % *

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Sl. Unit Specification Contractor’s

No. Description Requirements Data
22.0 Total estimated weight kgs *
23.0 Guaranteed No load current
When excited from LV side at Amps **
100% and 110% rated voltage
24.0 Max. Flux density when rated Wb/m **
2
and 110% rated voltage
25.0 Vacuum withstand capability mm of *
main tank, radiators and Hg
accessories
26.0 Weight
26.1 Core kg **
26.2 Net copper wt. HV/LV kg **
26.3 Oil kg **
26.4 Tank, coolers & fittings kg **
26.5 Total kg **
26.6 Untanking weight kg **

NOTE:
1.0 ‘*’ Information shall be filled furnished by Contractor along with offer.

2.0 ‘**’ Contractor shall furnish these details after award of contract.

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ELECTRICAL MV SWITCHGEAR (6.6kV)

1.0 MV SWITCHGEAR

1.1 MV switchgear shall be provided for feeding the 6.6kV Coal Handling System
loads and to feed 6.6kV / 0.433kV service transformers. The quantity of 6.6kV
switchgear supplied shall be adequate to make the Coal Handling System
package complete in all respects.

1.2 6.6kV System shall be 3 phase, 3 wire with medium impedance neutral
Earthing.

2.0 POWER SOURCES FOR SWITCHGEAR/INTER FACING.

The owner will provide two 6.6kV feeders from the plant station switchgear
including the 6.6kV cables upto the 6.6kV switchgear to be supplied by the
Coal Handling Systems vendor.

3.0 MANUAL & AUTOMATIC TRANSFER OF LOADS.

The 6.6kV switchgear shall be provided with Fast Automatic Changeover for
loss of one source and manual live changeover scheme for planned
changeover of supply from one source to another. These schemes shall be
realised in 6.6kV switchgear and included under the scope of this contract.
3.1 Automatic fast changeover scheme for changeover of supply from one source
to another source in case of one 6.6/0.433kV service transformer trip out shall
be provided. Blocking of fast change over shall be ensured if
a) Tripping is due to bus fault
b) Circuit breaker is in test position
c) Tripping of tie breaker if the switchgear incomer breaker does not trip
d) Auto changeover fails, all motor feeders shall be tripped before slow
changeover takes place.

3.2 The closure of the bus coupler / tie breaker shall be supervised by a synchro-
check relay permanently connected to and energised by the secondary
voltages of the line and bus PTs. The high-speed transfer shall be completed
within 40 milliseconds. If the phase angle difference between the two sources
exceeds the pre-determined setting of the synchro-check relay, which shall not
exceed 20 deg., an automatic “slow dead” transfer shall be made.

3.3 Provision shall be made for trip selection and if selected breaker does not trip,
the tie breaker shall trip along with remote annunciation.

3.4 To facilitate fast bus transfer operation, closing and opening operation time
difference shall be limited to 02 cycles (40 ms).

4.0 SPARE FEEDERS

In each of the 6.6 kV CHP switchgear, adequate spare feeders shall be

provided. Atleast one transformer feeder and one motor feeder (if applicable)
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ELECTRICAL MV SWITCHGEAR (6.6kV)

shall be provided as spare.

5.0 SHORT CIRCUIT CURRENT RATINGS

The switchgear shall be supplied as follows:-

(a) Minimum symmetrical short-circuit current withstand (busbar bracing)

capacity of 40 kA for three (3) sec. for 6.6kV or as per calculations,
whichever is higher shall be provided,

(b) Minimum momentary current rating of 100 kA peak for 6.6 kV systems or
as per calculations, whichever is higher shall be provided.

(c) Breaker rating shall be selected based on IEC-62271.

(d) Asymmetrical S.C current breaking capacity of the breaker shall consider
the higher time constant for decay of current in the vicinity of power
generating stations and the breaker offered shall be suitable for the
same.

(e) Calculations for arriving at the time constant at this plant shall be
furnished to justify breaker selection in accordance with IEC-62271.

6.0 CONTINUOUS CURRENT RATINGS

(a) The continuous current rating of the 6.6 kV switchgear buses, and their
incomer breaker, tie breaker shall be the maximum load on the bus due
to all the running Coal Handling System auxiliaries plus 20% margin
rounded to next higher standard rating. Further, the full load of all
ties/service transformers etc. shall be considered on one bus for
continuous current rating.
(b) The continuous current rating of the feeders shall be based on the name
plate current rating of the connected equipment with 20% margin.
(c) To have interchangeability of breakers, breaker rating shall be standard
and limited to two types / current ratings.

7.0 SPECIFIC REQUIREMENTS

7.1 The 6.6kV circuit breakers shall be vacuum / SF6 type. Rated operating duty
of the same shall be O-3min-CO-3min-CO. On/off control / fault / discrepancy
indications for each breaker shall be given. In case of vacuum breakers,
adequate over voltage & surge protections shall be provided for all equipment.
In case of ties, the contractor shall check the suitability of vacuum breakers for
ties and shall provide adequate protections accordingly for ties. Vacuum Circuit
Breaker shall have 3 Nos. Single Break Type completely sealed vacuum
interrupters. Vacuum Interrupters shall be latest state of the art, with axial
magnetic field principle without pinch off tube.

7.2 Motor feeders shall have local / remote selector switches on Switchgear. Local
operation shall be enabled only in test position.

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SYSTEM 1050 MW MAITHON RIGHT BANK TPP
ELECTRICAL MV SWITCHGEAR (6.6kV)

7.3 Space heating arrangement for MV motor shall be provided with interlocking
scheme to switch off when motor is ON. All MV panels shall be mounted on
ISMC 100 channels embedded in concrete.

7.4 Terminal arrangements shall be such that all terminals at switchgear ends
which are to be connected to remote alarms and indication at DCS shall be
separated out and shall be kept isolated from other Terminals. 240V AC, 110V
AC, 24V DC, 220V DC & other voltages shall be segregated to avoid mix up of
voltages. This is specifically required to avoid mixing of switchgear high
voltage to C &I low voltage system.

7.5 All the 6.6 KV equipments/devices like bus support insulators, CBs, CTs, PTs
etc mounted inside the switchgear shall be suitable for continuous operation
and satisfactory performance under the following supply conditions :-
(a) Variation in supply voltage - +/-10%
(b) Variation in supply frequency - +/-5%
(c) Combined voltage and frequency variations: +/- 10% absolute.

7.6 Switchgear shall be suitable for easy extension on both the sides. It shall be
possible at a later stage to add cubicles on both sides of the switchgear by
extending the bus bars

7.7 Secondary of CTs & VTs shall be made through disconnecting type terminals
with necessary shorting and Earthing facilities. All the control wiring shall be
through stud type terminal.

7.8 The breaker ratings indicated in the data sheets referred to the nominal rating
of the breaker. However, breakers shall be capable of carrying continuously at
least 120% of circuit breaker current at an ambient temperature of 50 deg. and
with breaker mounted inside the panel. If a higher rated breaker is necessary to
meet this, the same shall be used.

7.9 Dummy cubicles with horizontal bus bars, power control and annunciation
cable running through the panel, if necessary, to avoid beam interfering with
cable openings and to facilitate easy maintenance shall be provided.

7.10 All the bolted joints in body of the switchgear shall be earthed through flexible
jumpers.

7.11 The cable entry shall be bottom only with separate gland plate for power and
control cable. In case of single core cables, gland plate shall be of non-
magnetic material.

7.12 All the circuit breakers / vacuum contactors shall be of fully draw out execution
with “Test”, “Service “ &” Fully withdrawn “ positions.

7.13 All indicating and integrating instruments, protection and alarm relays,
operating and indicating devices shall be visible/ accessible without opening
the instrument compartment door. All the hand reset relays shall be mounted
on the panel at a conventional height for operation.

7.14 The switchgear shall be suitable for bottom cable entry. The height of cable
termination shall be such that termination & glanding shall be carried out
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SYSTEM 1050 MW MAITHON RIGHT BANK TPP
ELECTRICAL MV SWITCHGEAR (6.6kV)

easily, minimum shall be 700mm

7.15 All the internal wiring shall be carried out using 1100V grade, stranded copper
conductor with PVC insulation and shall be flame, vermin and rodent proof.
The minimum size of the copper conductor used for panel wiring shall be as
follows:
All circuit except CT & PTs : 1.5 sq. mm per lead.
(b) CTs/PTs : 2.5 sq. mm/per lead.
The minimum number of strands per conductor shall be 07. Extra flexible wires
shall be used for internal wiring of the Devices mounted on moving parts.
7.16 Following colour coding shall be used for internal wiring:-
(a) Red, Yellow & Blue : For respective phase /PT wires.
(b) Black : for neutral wires.
(c) Green : For Earth wires
(d) Red ferruled wires for trip circuit.
(e) All other with grey coloured wires.
7.17 The inter panel wiring shall be brought out to a separate set of terminal blocks
located near the slots meant for inter panel connecting wires.
7.18 At least 20% spare terminal shall be provided on each panel and these spare
terminals shall be uniformly distributed on all rows of terminal blocks. A
clearance of 250 mm shall be maintained between terminal blocks and gland
plate and 150 mm between two rows of terminal blocks.
7.19 The magnitude of switching surges produced under any and all operating
conditions shall not exceed 2.2P.U. rated peak line to earth voltage with time
to crest up to 01 micro seconds for the following conditions :-
Switching off motor running at full load.
Switching on decelerating motor.
Switching on/off motor with locked rotor.
Switching off unloaded transformer.

7.20 If the magnitude of the voltage surge produced exceeds this value, the vendor
shall provide surge arrestors to restrict the voltage peaks to above mentioned
value. The bidder shall furnish along with his bid, proof of his breakers /
vacuum contactors having been tested at internationally recognised test lab for
motor switching duty in addition to all other tests.

7.21 Breakers shall be with motor wound spring operating mechanism. Closing
action of the CB shall compress the opening spring ready for tripping.

7.22 In case of SF6 breakers, density monitor and two-stage pressure switch for
alarm and interlocking shall be provided. Breaker shall be capable to break
rated current at rated voltage at zero gauge pressure of SF6.

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SYSTEM 1050 MW MAITHON RIGHT BANK TPP
ELECTRICAL MV SWITCHGEAR (6.6kV)

7.23 Switchgear design shall comprise fully compartment execution having separate
vertical sections for each circuit. All the doors, panels, removable covers shall
be gasketted all around with neoprene gaskets. All louvers shall have screens
with filters. Each switchgear shall be fitted with a label on front and rear of
cubicle.

7.24 Switchgear shall have separate compartments for the following components

(a) Set of 3 phase busbars.

(b) Each of main switching devices.

(c) Instrument transformers.

(d) Cable termination.

(e) Metering and relaying devices.

The partitions of fore listed compartments shall have the following degrees of
protection
x Complete protection against approach to live parts or contact with internal
moving parts i.e. IPH-6 class.
x Compartments of each set of busbars shall be provided with protection
against approach to live parts or contact with internal parts, by tools, wires
or similar objects of thickness greater than 1.00 mm i.e. Class IPH – 4
7.25 CONSTRUCTION
x The switchboard shall be sheet steel fabricated, bolted true metal clad.
x Bellivelli washers shall be used for all the bolted connections for positive
bonding and Earthing of complete structures.
x Observation window shall be provided on rear cable compartment door for
viewing cable terminations.
x The connection between the busbars and the terminals of the circuit
breakers shall be suitable shrouded. Similarly all busbar joints shall be
shrouded.
x Automatic operated, metallic and earthed safety shutters shall be provided
to shroud bus side and cable side main disconnecting contacts of the circuit
breaker when the circuit breaker is taken to test position. The shutters shall
have CAUTION LABEL.
x Current transformer shall be provided on the cable side of circuit breaker.
x Doors of all switchgears shall be gasketed with neoprene gasket to prevent
entry of vermin and dust. No opening should be left. Steel screws, bolts
and washers shall be plated.
x Pressure release flaps / plates / valves shall be provided for different
compartments to vent the internal arcing faults.

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SYSTEM 1050 MW MAITHON RIGHT BANK TPP
ELECTRICAL MV SWITCHGEAR (6.6kV)

x One (1) no. panel illumination lamp with door limit switch shall be provided
in LT chamber of all panels.
x Busbars shall be of Copper with proper tin / silver plating at joints. Joints in
busbars shall be provided with FRP detachable shrouds. For long busbars,
suitable expansion joints shall be provided.
x It shall be possible to extend the bus bars at either end of the switchboard
for addition of future units. Both ends of busbars must be suitably drilled for
this purpose.
x Continuous running Earth Busbar shall be provided in cable chamber for
ease of cable armour Earthing.
x Surge arrestors, wherever provided shall be connected to earth bus
positively through Flexible cable / copper braid.
8.0 CUBICLE COMPONENTS AND ACCESSORIES
Each circuit breaker and contactor cubicle shall be complete with following
minimum accessories:-
(a) One spring return TNC switch.
(b) Large size cluster LED’s for following condition of breaker/contactor:-
(i) “ON”(Red)
(ii) “OFF” (green)
(iii) Trip relay supervision (White).
(iv) Spring charged (Blue)
(v) SF6 pressure Low/Very Low(Amber)
(vi) DC supply supervision (Violet)
(c) Limit switched for test and service position interlocking.
(d) Double pole switch for DC control supply and spring charging motor with
HRC fuses
(e) Anti pumping relay.
(f) Sufficient terminal blocks
(g) Auxiliary relays as required for contact multiplication
(h) Breaker operations counter.
(i) Protective relays along with trip circuit supervision relay and master trip
relay.
(j) Meters as indicated elsewhere
(k) Required CTs/ PTs/ CBCTs.
(l) Surge arrestors/ suppressor, if required.
(m) Space heaters.

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SYSTEM 1050 MW MAITHON RIGHT BANK TPP
ELECTRICAL MV SWITCHGEAR (6.6kV)

(n) One Local/Remote Switch.

(o) AC Supply On/Off switches with Short Circuit protection.
(p) Local remote switch for motor feeders.
9.0 BUS AND LINE PTs.
Bus PT over voltage factor shall be 1.2 continuous and 1.9 for 8 hours. All Pts
shall be 3 numbers of single phase PTs.
Each BUS and LINE PTs shall be complete with following minimum
accessories.
(a) PTs shall be fully draw out type with required no of cores and ratios, as
specified elsewhere.
(b) 6.6 kV link type HRC fuses on HV side and cartridge type 110V grade on
LV side.
(c) Voltmeter with selector switch.
(d) Under voltage and No voltage relays with timers and fuse fail relays.
(e) Tripping relays for tripping of motor feeder on prolonged loss of voltage.
(f) Required auxiliary relays.
(g) LED’s for voltage indication.
(h) Auxiliary PTs, as required.
(i) DC and AC control supply and changeover switches with Short Circuit
protection.
(j) AC/DC supply supervision LED’s and Relays.
(k) Earth fault relay.
10.0 CIRCUIT BREAKER / BUS BAR EARTHING FACILITIES.
(a) It shall be possible to connect each circuit or set of three phase bus bars
of the switchgears to earth, either through Earthing switch or through
Earthing truck mounted Earthing device.
(b) Earthing switches/ Earthing devices shall be mechanically/ electrically
interlocked with the associated breakers/Isolator to prevent Earthing of
Live circuits / Bus bars.
(c) In case the Earthing facilities comprises Earthing trucks to be inserted in
place of circuit breakers, separate Earthing truck shall be supplied for
each type & size of breakers.
(d) External Earthing truck shall be completed with PT and indicating lamps
to indicate, just prior to insertion in place, if the bus is live.
(e) Positive mechanism interlock shall be provided to prevent insertion of
Earthing truck in case busbars are in live condition.
(f) In case breaker design is with integral earth switches, it shall be
completed with requirements above. In such case quantity of Earthing
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SYSTEM 1050 MW MAITHON RIGHT BANK TPP
ELECTRICAL MV SWITCHGEAR (6.6kV)

truck, if indicated shall be redundant.

11.0 CIRCUIT BREAKER OPERATING MECHANISM.

Circuit breaker shall be power operated by motor charged spring operating
mechanism. It shall be strong, rigid, positive and fast in operation to ensure
that: -
(a) Main poles of the breaker shall be such that unless otherwise specified, the
maximum difference between the instant of contact touching during closing
shall not exceed half cycle of rated frequency.
(b) Operating mechanism shall be non-pumping electrically and mechanically
under every method of closing.
(c) The closing release shall operate correctly at all values of voltage between
85 and 110% of rated voltage. A shunt trip shall operate correctly under all
operating conditions of the circuit breakers up to the rated breaking capacity
of the circuit breaker and all value of supply voltage between 70 & 110% of
rated voltage.
(d) After failure of power supply to spring charging motor, at least one open-
close-open operation of the circuit breaker shall be possible.
(e) Closing action of the circuit breaker shall compress the opening spring
ready for tripping.
(f) When closing spring discharged, after closing a beaker, closing spring shall
automatically be charged for the next operation.
(g) Alternative means must be provided to charge the closing spring manually
when power supply to motor is not available.
(h) All Breakers shall be mounted on an integral breaker handling truck /
carriage with wheels for easy withdrawal on floor.
(i) Mechanical / Electrical interlocks shall be provided to prevent mal-operation
and in particular to ensure that :
x The breaker can be operated only if it is in service or in test position.
x Movement of the circuit breaker truck from service to test or test to
isolated position or in reverse order shall be possible only when circuit
breaker is off.
x In the operating positions of the breaker, the circuit breaker shall be
securely locked. It can be withdrawn or inserted only with appropriate
operations of the interlocking levers.
x The operating lever facilities to overcome the contact pressure at the
main disconnecting contacts while pushing in or drawing out.
x Test to isolated position of circuit breaker can be achieved only when
the control plug is removed.
x Isolated to test position of circuit breaker can be achieved only after

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SYSTEM 1050 MW MAITHON RIGHT BANK TPP
ELECTRICAL MV SWITCHGEAR (6.6kV)

inserting control plug.

x It shall not be possible to withdraw the breaker when it is in closed
position.
x It shall not be possible to plug in a breaker with Earthing isolator closed.
x It shall not be possible to close the Earthing isolator with breaker
plugged in.
x Pulling out of auxiliary circuit plug with breaker in service position shall
not be possible.
x Pushing in breaker to service position with auxiliary circuit plug not in
position shall not be possible.
x Opening of compartment door with breaker / isolating switch in Service
& Intermediate and ON position and vice versa shall not be possible.
(k) All the non-conducting metal parts of the circuit breaker truck shall be
bonded together and shall make perfect electrical connections to earth
through substantial sliding contacts, at service and test positions. Such
sliding contacts shall be arranged to make before power plug-in and
interrupt after power drawout.

(l) Isolator shall have quick make and quick break mechanism. The moving
blade of the isolator shall be dead when isolator is ‘OFF.
12.0 CURRENT TRANSFORMERS
12.1 Separate CTs / CT cores shall be provided for:
x Protection
x Metering
x Differential protection of motors
x Differential protection of transformers.
12.2 All CTs at 6.6KV level shall be dry resin cast only. The burden and the
parameters of the CTs shall be commensurate with the connected loads
including lead burdens changes during engineering stage and 20% spare.
12.3 In case of smaller rated CTs (say 300 Amp and less), at the expected fault
level, the CT saturation may result in the non-operation of the instantaneous
short circuit protection. In such cases, separate protection CT core with higher
ratio, selected to avoid saturation at high fault currents shall be provided.
12.4 Calculations for sizing and selection of various parameters shall be submitted
for owner’s approval.
12.5 For cable side Earthing and bus side Earthing separate earth switches / trucks
shall be provided for each 6.6 kV switchgear.
12.6 All breakers of identical ratings shall be interchangeable and suitable
mechanical / electromechanical interlocks to ensure that earth switch is not
closed / truck is not inserted when the bus or circuit is live shall be provided.
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SYSTEM 1050 MW MAITHON RIGHT BANK TPP
ELECTRICAL MV SWITCHGEAR (6.6kV)

Safety interlocks to prevent withdrawal when breaker in closed position shall be

included.
12.7 Operation of an earth switch shall not be possible unless the associated circuit
breaker is in the open position. Both electrical and mechanical interlocks shall
be provided.
12.8 No live parts shall be accessible on opening the circuit breaker compartment
door.
12.9 Circuit breaker shall be provided with safety shutters operated automatically by
the movement of the circuit breaker carriage, to cover the stationary isolated
contacts when the breaker is withdrawn. Padlocking facilities shall be provided
for locking the shutters positively in the closed position. It shall, however, be
possible to open the shutters intentionally against spring pressure for testing
purposes.
12.10 The breaker carriage shall be earthed before the circuit breaker reaches the
test position from fully withdrawn position. In case of breakers with automatic
disconnecting type of auxiliary disconnects, the carriage shall be earthed
before the auxiliary disconnects are made and the carriage Earthing shall break
only after the auxiliary disconnects break.
12.11 Caution name plate, “Caution Live Terminals” shall be provided at all points
where the terminals are likely to remain live and isolation is possible only at
remote end, i.e., incoming terminals of main isolators.
12.12 Each switchgear shall be provided with 2 nos., 220V DC auxiliary power supply
feeders each with 100% rating. Provision shall be made for changeover facility
such that in case of failure of one power source, other shall cut in
automatically. Local monitoring of DC supply shall also be provided for DC
supply before & after selection through LED.
12.13 All indication lamps shall be clustered LED type only.
12.14 An operation counter visible from outside shall be provided for each breaker.
Mechanical locking facility to prevent insertion of breaker if breaker under
permit shall be provided.

13.0 CONTROL ROOM ALARMS / INDICATIONS / SOE POINTS.

Following indications / alarms are the minimum to be provided in the DCS in

control room. In addition to the same additional indications / alarms
considered necessary during detailed engineering stage shall also be provided.
Out of these some shall be selected for the sequential event recording. For
each feeder grouped alarm for any abnormal condition of that feeder shall be
provided on the control panels. The control / interlock schemes for various
types of feeders shall be commensurate with their application. Status indication
of entire 6.6 kV and 11kV systems shall be available on the DCS.

(a) Breaker panel

(i) Status Indication

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SYSTEM 1050 MW MAITHON RIGHT BANK TPP
ELECTRICAL MV SWITCHGEAR (6.6kV)

x Breaker on

x Breaker off

x Breaker in remote

x Breaker in service

x Breaker in test

x Circuit side earthed

x Bus side earthed (as applicable)

x Breaker ready to close

(ii) Alarms

x L/O Relay operated

x SF6 gas pressure low (in case

of SF6 CB)

x Trip circuit unhealthy

x Breaker spring charged

(b) In addition to the above, the following alarms / trip shall be provided on the
DCS with grouped alarm for the following breakers:

(c) Incomers and bus coupler breakers

x Sources paralleled beyond pre-set

time

x Selected breaker trip

x Two sources out of synchronism

x Bus couple breaker / incomer breaker

spring not charged / spring charging
circuit trouble alarm and indication

(d) VT Panels

x Bus under voltage L/O relay operated

x Bus P.T fuse failed

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SYSTEM 1050 MW MAITHON RIGHT BANK TPP
ELECTRICAL MV SWITCHGEAR (6.6kV)

x DC supply – 1 failed.

x DC supply – 2 failed

x Bus PT not in service

x AC supply fails

x Bus earthed

(e) Motor Feeders

x Overload alarm

x Feeder fault / closing permissive not

available

x Breaker trip circuit trouble

x Trip through process interlock.

x Local push button pressed

x Breaker spring not charged and gas

pressure low alarm

(f) Service Transformer Feeders

x Oil temp High alarm & trip

x Oil level low alarm

x Winding temperature Hi alarm & trip.

x Buchholz relay alarm & trip.

x PRD operated

(g) Tie Feeders

x Sources paralleled beyond pre-set

time.

(h) Analog Parameters

All the parameters, for which the multifunction meters are indicated in
Clause 14.0 below, shall be displayed in the DCS in control room.
Communication port for this purpose shall be available in these
multifunction meters.

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SYSTEM 1050 MW MAITHON RIGHT BANK TPP
ELECTRICAL MV SWITCHGEAR (6.6kV)

(i) CONTROL
INCOMERS /TIE AND BUSCOUPLER CONTROLS
All the motors and other equipment shall be controlled from respective control
rooms/Control Panels/ DCS.
Emergency stop pushbutton shall be provided for all drives near equipment
except emergency drives and shall be wired directly to MCC. In case of
emergency drives, emergency start PB shall be provided.
IPR ’s shall be provided for breaker and other services control from DCS.
Interconnection with Purchasers DCS / UCP is included under the scope of this
specification.
14.0 METERING AND PROTECTION
CONTRACTOR shall provide adequate protection / metering for the switchgear
panels. Accuracy of all CT s/ PT s, meters on 6.6 kV & 11kV switchgear shall
be 0.5 class. All indicating instruments shall be 96 sq. mm.
RELAYS (NUMERICAL PROTECTION RELAYS)
All protective relay shall be numerical only and shall comply with the following
requirements.
x All relays specified shall be flush mounted in dust proof cases and shall
match the appearance of the instruments mounted on the same panel.
x Protective relays shall be withdrawal type. Trip circuits shall be
automatically broken and current transformer secondary circuits shorted,
when a relay is withdrawn from its case. A marking strip shall be
provided in front of each terminal block and a diagram plate at the back
of each case to identify connections.
x Provision shall be made for insertion of test plug at the front for testing
and calibration using external source of power without disconnecting
permanent wiring. Test plugs shall permit the shorting of any current
transformer circuits.
x All the protective Relays shall be latest Numerical Type, having
communication protocol – IEC60870-5-103.
x Relay shall have the following communication ports
(a) Front emergency port-RS232 for direct access of data through
Laptop.
(b) Rear service port-RS485.

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SYSTEM 1050 MW MAITHON RIGHT BANK TPP
ELECTRICAL MV SWITCHGEAR (6.6kV)

x Relay shall be type tested for EMC TEST for interference immunity.
Type test certificate shall be submitted for the offered relay.
x Relay shall have functional keys, available on the front keypad, for ease
of operations.
x Relay shall have freely programmable LEDs, Bis & BOs.
x Relay shall have fault recording facility and shall have facility to record
last 8 faults with real time stamping. Fault down loading and analysis of
fault with graphical representation shall be possible. Relay shall have
minimum 4x setting groups.
x Vendor shall include the hardware and software for communication of
relays for parameterisation and down load / analysis of fault data from
relays. One complete set of cables, accessories, Laptop PC with
licenses software and A4 LaserJet printer shall be included in the scope
of supply.

15.0 The minimum protections / metering required for various typical feeders shall
include, but not limited to the following:

(a) Incomers

Protections Metering

x Over current protection x Multifunction meter for

reading Current,
Voltage, kWH, kW,
kVAR etc.

x Earth fault protection x

x Local breaker backup x

protection

x Fuse failure relay x

x Alarm/trip for sources x

paralleled beyond pre-set
time.

x Differential Protection x

x Overall Differential Protection x

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SYSTEM 1050 MW MAITHON RIGHT BANK TPP
ELECTRICAL MV SWITCHGEAR (6.6kV)

(b) Tie / Bus breakers.

Protections Metering

x Over current protection x Multifunction meter for

reading Current,
Voltage, kWH, kW,
kVAR etc.

x Earth fault protection x

(c)Bus PT Feeders

Protections Metering

x Under voltage protection x Multifunction meter for

reading Current,
Voltage, kWH, kW,
kVAR etc.

x Fuse failure protection x

x No voltage protection x

x Trip of motor feeders for x

prolonged U/V

x Fast changeover trouble x

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SYSTEM 1050 MW MAITHON RIGHT BANK TPP
ELECTRICAL MV SWITCHGEAR (6.6kV)

(d) Motor feeders

Protections Metering
x Composite motor protection x Multifunction meter for
relay (99) which should have reading Current,
atleast include following Voltage, kWH, kW,
protections. kVAR etc.
(a) Thermal Overload trip and
alarm
(b) Locked rotor protection.
(c) Earthfault protection,
through CBCT.
(d) Over current protection.
(e) Blocking of motor starting
after allowed hot/cold starts
with remote alarms.
(f) Starting current
measurement and storage
facility.
(g) Negative phase sequence
protection.
The motor protection relay for
large motors shall be two sets
consisting of two relays of
different type which will
operate on different algorithm.

x Differential protection for motor x

feeders (rated 1000kW or
above) (this protection may be
provided in comprehensive
relay 99)

x Under voltage protection with x

fuse fail relay interlocking

x Short circuit protection (with x

high ratio CTs to avoid
saturation during sort circuit)

Additional Timer if motor

starting time > motor locked
rotor withstand tim

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SYSTEM 1050 MW MAITHON RIGHT BANK TPP
ELECTRICAL MV SWITCHGEAR (6.6kV)

(e)Service Transformer Feeders

Protections Metering

x Over current protections x Multifunction meter for

reading Current,
Voltage, kWH, kW,
kVAR etc.

x Earth fault protection x

x Short circuit protection x

x Protection for oil temp x

alarm/trip, winding temp.
alarm/trip, buchholz relay
alarm / trip PRD operated
16.0 TESTS AND TEST REPORTS

16.1 The VENDOR shall completely assemble, with all the associated equipment
including bought out items mounted and wired and test each cubicle as per
relevant standards. Oscillographic test records for closing and tripping timings
of the breakers shall also be carried out.
16.2 Routine tests shall be carried out on completely assembled equipment as per
relevant standards. Valid type test certificate shall be submitted. If valid type
test certificate is not available, type test shall be carried out on one of the
switchgear.
16.3 Functional tests shall be carried out to demonstrate the specified control and
interlocks.
16.4 Copies of the test certificates for all bought out items shall be submitted for the
Purchaser’s approval before despatch of the switchgear.
16.5 Same design / model of panel, breaker and interrupters as offered shall be
complete type tested for following tests and detailed type test reports shall be
submitted along with the bid.
x Short circuit test and short time current withstand test for 3 sec. for
panel and breaker.
x Duty cycle test.
x Mechanical Endurance test.
x P.F. and Impulse withstand test.
x Internal Arc test as per IEC for all compartments.
x Temperature rise test.

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SYSTEM 1050 MW MAITHON RIGHT BANK TPP
ELECTRICAL MV SWITCHGEAR (6.6kV)

TECHNICAL REQUIREMENTS – 6.6 kV SWITCHGEAR

The 6.6 kV switchgear shall comply with the particulars indicated below and
Contractor shall furnish the details in respective columns given below :

Sl. 6.6kV Contractor’s

Parameter Unit
No. Switchgear data

1.0 Switchboard cubicles and

Busbar ratings

1.1 Nominal system voltage, V, ph, Hz 6600 / 3 / 50

phases and frequency
1.2 System neutral Earthing Medium
resistance
earthed
1.3 Maximum system voltage V 6600
1.4 One minute power kV (rms) 20
frequency withstand
voltage
1.5 1.2 / 50 microsecond kV (peak) 60
impulse withstand voltage
0
1.6 Maximum temperature rise C As per IEC
of bus bars, droppers,
connectors and contacts at
continuous current rating
under site ref. ambient
temperature
1.7 Material of busbars Aluminium
1.8 Material of busbar Heat shrinkable
insulation PVC sleeve.
Removable bus
bar joints with
shrouds of
7.2kV
insulation
1.9 Busbar support insulator 7.2kV
1.10 Busbar joints / connections Silver faced
1.11 Busbar rating By Bidder
1.12 Short circuit current rating RMS 40kA for 3 sec
and duration

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SYSTEM 1050 MW MAITHON RIGHT BANK TPP
ELECTRICAL MV SWITCHGEAR (6.6kV)

TECHNICAL REQUIREMENTS – 6.6 kV SWITCHGEAR

The 6.6 kV switchgear shall comply with the particulars indicated below and
Contractor shall furnish the details in respective columns given below :

Sl. 6.6kV Contractor’s

Parameter Unit
No. Switchgear data

1.13 Momentary withstand Peak 100 kA

current
2.0 Switchboard
Constructional Details
2.1 Thickness of sheet steel mm Cold rolled -2
enclosures, doors and mm
covers
2.2 Thickness of gland plate mm 3.0, Non-
for 1 core cables magnetic
material
2.3 Degree of protection IP55
2.4 Colour finished shade Shade 631 of
(Enamel / epoxy) IS-5
2.5 Material of Earthing bus By Bidder
2.6 Clearance in air of live mm As per IEC
parts (Type test certificates
shall be furnished to
support the same)
2.7 Cable entry Bottom
3.0 Breaker details
3.1 Circuit breaker type SF6 / VCB
3.2 Voltage, No. of phases and kV, ph, 7.2 / 3 / 50
frequency Hz
3.3 Rated operating duty O-3 min-CO-3
min-CO
3.4 Total opening time <80ms
3.5 Total closing time <75ms
3.6 Trip free operating Motor operated
mechanism type spring charged.
Manual trip and
close facility to
be provided

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SYSTEM 1050 MW MAITHON RIGHT BANK TPP
ELECTRICAL MV SWITCHGEAR (6.6kV)

TECHNICAL REQUIREMENTS – 6.6 kV SWITCHGEAR

The 6.6 kV switchgear shall comply with the particulars indicated below and
Contractor shall furnish the details in respective columns given below :

Sl. 6.6kV Contractor’s

Parameter Unit
No. Switchgear data

3.7 Anti pumping feature To be provided

3.8 Short circuit current rating rms 40kA for 3 sec.
and duration
3.9 Momentary withstand kA (peak) 100
current
3.10 Auxiliary control voltage :
(a) For closing / tripping V, DC 220
coil / spring charging
motor
(b) For space heaters V, Phase 240 V, 1 phase
and lighting and plug
point
4.0 Current transformer
details
4.1 Type Cast resin bar
primary
4.2 System voltage and V, Hz 6600 / 50
frequency
4.3 Class of insulation Class ‘E’ or
better
4.4 Short circuit withstand 40 kA for 3 sec.
current and duration
4.5 Accuracy class P class for
protection and
0.5 for metering
5.0 Voltage transformer details
(3 x 1 ph VTs)
5.1 Type Cast resin
drawout type
5.2 Rated voltage - Primary V
6600 / 3
Secondary V 110 / 3
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SYSTEM 1050 MW MAITHON RIGHT BANK TPP
ELECTRICAL MV SWITCHGEAR (6.6kV)

TECHNICAL REQUIREMENTS – 6.6 kV SWITCHGEAR

The 6.6 kV switchgear shall comply with the particulars indicated below and
Contractor shall furnish the details in respective columns given below :

Sl. 6.6kV Contractor’s

Parameter Unit
No. Switchgear data

5.3 Method of connection – Star / Star

Primary / Secondary

5.4 Rated voltage factor 1.2 continuous

1.9 for 30
seconds
5.5 Class of insulation Class ‘E’ or
better
5.6 One minute power kV(rms) 20
frequency withstand
voltage
5.7 1.2 / 50 micro second kV(peak) 60
impulse withstand voltage
5.8 Accuracy class P class for
protection and
0.5 for metering
6.0 Meters
6.1 Accuracy class 0.5 for energy
meters
1.0 for others
6.2 Type of meters Digital
7.0 Codes and Standards
7.1 Circuit breakers IEC : 62271-
100
7.2 Metal enclosed switchgear IS : 3427
7.3 Current transformers IS : 2705
7.4 Potential transformers IS : 3156
7.5 Arrangement for switchgear IS : 5578
bus bars, main connection
IS : 11353
and auxiliary wiring
7.6 Bus bar support insulators IS : 2544

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SYSTEM 1050 MW MAITHON RIGHT BANK TPP
ELECTRICAL MV SWITCHGEAR (6.6kV)

TECHNICAL REQUIREMENTS – 6.6 kV SWITCHGEAR

The 6.6 kV switchgear shall comply with the particulars indicated below and
Contractor shall furnish the details in respective columns given below :

Sl. 6.6kV Contractor’s

Parameter Unit
No. Switchgear data

7.7 Degree of protection IS : 2147

7.8 Electrical relays for power IS : 3231
system protection
7.9 Electrical indicating IS : 1248
instruments
7.10 High voltage fuses IS : 5792
7.11 AC electricity meters IS : 722
7.12 Aluminium busbars IS : 5082
7.13 Code of practice for IS : 6005
phosphating iron and steel
7.14 (Off-load) isolators IS : 6005
7.15 HRC fuses IS : 1818
7.16 SF6 gas IEC : 60376

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SYSTEM 1050 MW MAITHON RIGHT BANK TPP
ELECTRICAL 415 V SWITCHGEAR

1.0 Power Sources for 415V Switchgear

This switchgear shall derive power from the designated service transformers or
from 415V switchgear based on geographical location and CHP system loads
requirement. Contractor shall propose the configuration/sources best suited for
the system without sacrificing the standby philosophy, reliability, flexibility of
operation. All switchgear shall be of fully drawout construction.
2.0 Feeder Details
2.1 Each of the switchgear shall be provided with two bus sections, two incomers and
a bus coupler rated for 100% of the loads connected to the switchgear.
2.2 For each auxiliary or load, one feeder shall be provided except for the following
cases.
(a) One feeder for maximum of 3 Nos. 415V, 3 phase plug points.
(b) One feeder for a maximum 3 Nos. isolator motor operating mechanism.
2.3 The switchgears shall be provided with suitable number and type of outgoing
feeders for the respective auxiliary loads of the system/area, power supply
feeders to various panels, lighting, space heating panels, control cabinets and all
other loads encountered in the plant to make the Coal Handling System package
complete. In addition, following feeders shall be provided in each bus section of
each switchgear.
(a) Spare feeders: Minimum of one no. feeder of each rating and type
(above quantity is the minimum requirement, at the time of handing
over the plant. Any additional quantity required for any
increase/changes during detailed engineering stage also shall be
duly considered).
(b) Bus VT module: 1 No.
(c) Switchgear 240V, 1 phase space heating: 1 No
(d) Switchgear test supply module: 1 No.
(e) 240V, 1 phase essential supply module with five Nos. 1 phase
outlets: 1 No.
2.4 Each feeder shall be provided with two nos. Interposing relays for start & stop.
3.0 Short Circuit Currents
3.1 The fault level on the 415V buses shall be calculated based on transformer
contribution and motor contribution and in any case shall not be less than 50kA
for 1 sec.
3.2 A margin of 5% over the S.C current thus calculated shall be applied and rounded
off to next higher standard ratings and this value shall be adopted for the
switchgear. The momentary current rating shall be 2.1 times this value.
3.3 Short time current withstand duration for switchgear and all components shall be
considered as one second.

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SYSTEM 1050 MW MAITHON RIGHT BANK TPP
ELECTRICAL 415 V SWITCHGEAR

4.0 Continuous Currents

4.1 The continuous current rating of the bus bars, their incomers, bus couplers of the
switchgear which are fed by the transformers shall be rated at the LV side full
load current of the corresponding transformers with 20% margin rounded off to
the next higher standard rating.
4.2 The continuous current rating of the bus bars, incomers, bus couplers of the
switchgear fed from other switchgears shall be the maximum load on the bus due
to all the running auxiliaries during any operation condition plus 20% margin
rounded off to the next higher standard rating. For the load calculation, load
factors to be considered shall be 0.9 for continuous loads, 0.4 for intermittent
loads.
5.0 Specific Requirements
5.1 The switchgears shall be fully drawout type, floor mounted, single / double front
and of modular design.
5.2 All bus bars, bus-taps shall be insulated with close fitting colour coded, sleeve of
PVC insulation with high dielectric strength.
5.3 The modules shall have service, test and fully withdrawn positions.
5.4 All air circuit breakers (ACBs) and moulded case circuit breakers shall be of short
circuit performance category as per IS 13947.
5.5 The MCCBs shall be of current limiting type. When MCCBs are used as short
circuit protection devices for motor modules they shall provide type 2 co-
ordination with associated contactor and thermal overload relay as per IS: 8544
under all operating conditions for the all currents upto the design fault current.
The MCCBs on upstream and downstream shall be co-ordinated. Test reports to
prove the requirements of Type-2 Co-ordination shall be obtained.
5.6 Generally the switchgear shall be designed for bottom entry of cable. Incomers
shall be suitable for Non-segregated phase bus-duct / Power cable as per
detailed engineering design requirement.
5.7 For each switchgear, for breaker control 2 Nos. 220V DC control supply shall be
provided with a manual selection for changing over to either supply. Necessary
voltage monitoring contactors (for remote alarm) and indication lamps shall be
provided.
5.8 Minimum of two NO and two NC spare contacts of all contactors, relay devices
shall be wired to terminal block.
5.9 20% spare terminals shall be provided for each module.
5.10 For CT & VT circuits disconnecting type of terminals shall be provided.
6.0 Module Details
6.1 Incomers & Bus Couplers
6.1.1 The incomer modules and bus coupler modules of all the switchgear shall be air
circuit breaker controlled.

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SYSTEM 1050 MW MAITHON RIGHT BANK TPP
ELECTRICAL 415 V SWITCHGEAR

6.1.2 The incomer modules shall be interlocked with their upstream breaker such that
they can be closed only when upstream breaker is closed and trip automatically
when upstream breaker is tripped.
6.1.3 Changeover scheme
All the switchgears with sectionalised buses will be normally operated with the
bus coupler breakers open. The bus coupler shall have Auto / Manual selector
switch. Auto changeover facility shall be provided for the switchgears such that if
there is a prolonged under voltage on any one of the bus sections, the respective
incoming breaker shall trip and the bus coupler breaker shall close, provided
voltage is available on the other bus section and the selector switch is in Auto
mode. The total changeover time shall be settable.
This auto changeover shall be blocked if the incoming breaker has tripped on a
bus fault or the bus coupler selector switch is in manual mode.
Manual live changeover shall be provided in the switchgear. In case of paralleling
of both power sources, the bus coupler shall trip after a settable time delay of 3 –
30 seconds and the condition shall be annunciated.
All hardware required for meeting the functional requirements stated above,
whether specifically listed out in the specification or not, shall be included in the
scope of supply.
6.1.4 The metering shall be through multifunction meters with suitable communication
ports for remote metering.
6.1.5 The following minimum protections shall be provided for incomers and
bus couplers.
x 3 phase inverse time over current relays
x Earth fault relay
6.1.6 Separate CTs shall be provided for protection and metering circuits.
6.2 Motor Modules
6.2.1 The modules for motors rated 100 kW and above shall be provided with locked
rotor protection relay (2 phases) and associated CTs.
6.2.2 The modules for the motors rated 125 kW and above shall be provided with
additional microprocessor based motor protection relays which has the cold and
hot withstand characteristics matching with motor characteristics.
6.2.3 Each motor feeder shall be provided with suitably rated 415/110V control
transformer, for arranging control supply for the module. All the necessary
auxiliary and main contactors shall be provided suitable for this control supply.
6.2.4 Essential Service Modules
During auto changeover of the supply the contactors in the affected bus would
have dropped off. The services, which shall be restarted immediately without time
lapse to keep the system operating, are considered essential services. Such
auxiliaries shall restart automatically without any action by the operator after an
auto changeover. These modules shall have additional hardware like timer, aux.
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SYSTEM 1050 MW MAITHON RIGHT BANK TPP
ELECTRICAL 415 V SWITCHGEAR

contactors and associated circuitry in the module. Such essential services shall
be identified during the detailed engineering stage and suitable module/scheme
shall be provided.
7.0 Control Room Alarms / Indication / SER Points
7.1 All switchgear/MCC where auto/manual changeover facility is specified, breakers
shall be provided for the incomers and bus coupler.
7.2 The DCS shall provide indication & alarms for the 415V auxiliary supply as given
below. Any additional indications/alarms considered necessary during detailed
engineering shall also be provided. Some of these shall be selected for sequential
event recording. For each breaker and bus, grouped alarm for any abnormal
conditions shall be provided in the plant DCS.
(a) Status indication in CRT
x Breaker on/off
x Breaker fault
x Breaker service
x Breaker selected for remote
(b) Alarms in CRT
x Breaker auto tripped/L/O Relay operated
x Bus under voltage
x Sources paralleled beyond pre-set time
x Common outgoing feeder fault
x Incoming 220 V DC control supply failed
x Bus PT fuse failed
x Bus PT not in service.
All switchgear/MCC where auto/manual changeover facility is specified, breakers
shall be provided for the incomers and bus coupler. Other distribution boards can
be provided with MCCBs.
7.3 The current and voltage measurements for each bus shall be available on the
DCS. The meters shall be multifunction meters.
7.4 The operation, indications and fault alarms for the motors of the auxiliaries shall
be displayed as covered in the specification as part of C&I requirements.
7.5 Module schematics to be followed shall be furnished to the successful Bidder.
The operation, indications and fault alarms for the motors of the auxiliaries shall
be displayed as covered in the specification as part of C&I requirements.
8.0 Tests
8.1 Switchgear shall be subjected to all tests as per relevant standards along with
following tests:

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SYSTEM 1050 MW MAITHON RIGHT BANK TPP
ELECTRICAL 415 V SWITCHGEAR

(a) Temperature rise test on power circuits

(b) Short time current tests on power circuits.
(c) Mechanical operation test
(d) Insulation resistance and 500V DC before/after 1 minute HV test
(e) Electrical control, interlock and sequential operation tests
(f) Verification of wiring as per approved schematic
8.2 Contractor shall submit available type test reports of temperature rise and short
circuit tests of similar switchgear. Also, calculations of temperature rise shall be
submitted for approval.
8.3 Routine tests shall be carried out on all associated equipment supplied with
switchgear as per relevant standards. Type test certificates of all associated
equipment shall be furnished.
8.4 Certified copies of all type and routine test certificates shall be submitted by the
Vendor before despatch of the switchgear.
9.0 Data to be furnished with the Bid and Technical Requirements
9.1 Experience list for the switchboards, breakers offered.
9.2 Descriptive literature/pamphlets on the switchboards offered and the main
components like circuit breakers, relays, and contactors.
9.3 Single line key diagram showing the interconnection of various switchgear/MCC,
ratings of all the bus bars, the incomer breakers and bus couplers/ties.
9.4 Technical particulars for the switchgears as per the table below :

TECHNICAL REQUIREMENTS – 415V SWITCHGEAR

The 415V switchgear shall comply with the particulars indicated below and Contractor shall
furnish the details in respective columns given below :

Sl. No. VALUES / CONTRACTOR

DESCRIPTION UNITS
REQUIREMENTS S DATA

1.0 Switchboard & Bus bars

1.1 Rated voltage, phases & V/P/Hz 415, 3, 50, 3 wire

frequency
1.2 System neutral earthing Solidly earthed

1.3 One minute power

frequency voltage
withstand

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SYSTEM 1050 MW MAITHON RIGHT BANK TPP
ELECTRICAL 415 V SWITCHGEAR

a Power circuits V 2500

b Control circuits V 1500

c Auxiliary circuits V 2000

0
1.4 Reference ambient air C 50
temperature
1.5 Material of bus bars Aluminium, with Colour
coded PVC sleeves.
0
1.6 Maximum temperature of C 105
bus bars contacts,
droppers at site reference
ambient of 500C
1.7 Short circuit withstand

a Short time current (1 sec.) rms 50kA for 1 Sec.

b Momentary current Peak 125kA

1.8 Switchboard / MCC Switchboard / MCC

Construction
a Fully draw out Yes

b Double front / single front Single front / Double

front
c Cable entry (Power & Bottom
Control)
d Modular construction Yes

1.9 Degree of protection for as IP 55

per IS : 2147
1.10 Thickness of sheet steel Frame Door Cover

a Cold rolled mm 2.5 1.6 1.6

b Gland plate thickness mm 3

1.11 Clearances in air for live

parts
a Phase to phase mm 25.4

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SYSTEM 1050 MW MAITHON RIGHT BANK TPP
ELECTRICAL 415 V SWITCHGEAR

b Phase to earth mm 19.4

c All other compartments mm 10

1.12 Paint shade RAL 7032

2.0 Contactors & O/L relay

2.1 Utilisation category for AC3 for non-reversible &

contactors AC4 for reversible
2.2 Contactor rated duty Uninterrupted

2.3 Reset feature for thermal Hand

O/L relay
2.4 Starter type DOL

3.0 Circuit breakers

3.1 Circuit breaker type Air break, three pole with

shunt trip
3.2 Rated operated duty B-3min-MB-3min-MB

3.3 Type of operating Motor wound spring

mechanism charged
3.4 Short circuit rating 50kA for 1 sec.

3.5 Control voltage for spring V/DC 220V +10% & -15%
charging motor and
tripping & closing
3.6 Emergency manual
operation required in
addition to electrical
operating devices
a For spring charging & Required
closing
b For tripping Required

3.7 Anti-pumping feature Required

4.0 CTs and VTs

4.1 Short time withstand 50kA for 1 sec.

current and duration for CT

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SYSTEM 1050 MW MAITHON RIGHT BANK TPP
ELECTRICAL 415 V SWITCHGEAR

a Breaker controlled Based on breaker short

circuit current rating and
duration
b Switch fuse controlled To match with fuse
withstand
4.2 Over voltage withstand
capacity for VT
a Continuous pu 1.2

b 30 seconds pu 1.9

5.0 Meters Digital

5.1 Class of accuracy 0.5 for energy meters

and 1.0 for others
6.0 Applicable Standards

6.1 Switchboard general IS : 4237

requirements
6.2 AC circuit breakers IS : 13118

6.3 Air break switches IS : 4064 & IEC 60947-3

6.4 Miniature circuit breakers IS : 8828

6.5 HRC cartridge fuses IS : 9224

6.6 D type fuses IS : 8187

6.7 Contactors IS : 29259

6.8 Starters IS : 8544

6.9 Control switches / push IS : 6875

buttons and maintenance
of switchboard
6.10 Code of practice for IS : 6005
phosphating iron and steel
6.11 Wrought aluminium & IS : 5082
aluminium alloys for
electrical purposes

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SYSTEM 1050 MW MAITHON RIGHT BANK TPP
ELECTRICAL 415 V SWITCHGEAR

6.12 Control transformer for IS : 12021

switchboard and control
gear for voltages not
exceeding 1000V AC
6.13 Factory built assemblies of IS : 8623
switchboard and control
gear for voltages upto &
including 1000V AC &
1200 V DC
7.0 Technical requirements
Table for 415V AC
Distribution Boards /
Control Panels
7.1 Location / mounting Indoor/Outdoor / floor
mounted
7.2 Current rating Max. expected load
current + 20% margin
7.3 Cable entry Bottom

0
7.4 Design ambient C 50
temperature
7.5 Codes and standards As indicated for 415V
switchboards / MCCs.

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SYSTEM 1050 MW MAITHON RIGHT BANK TPP
ELECTRICAL BUS DUCTS

1.0 SEGREGATED PHASE BUS DUCTS

1.1 Segregated phase bus duct and accessories shall be provided for connections
as required.
1.2 The short time and momentary current ratings of the bus ducts shall be same as that
of associated 6.6kV switchgear.
2.0 NON-SEGREGATED PHASE BUS DUCTS (NSPBD)
2.1 1.1 kV class non-segregated phase bus duct (NSPBD) and accessories shall be
provided for connection between all service transformers and their 415V switchgear
supplied as a part of Coal Handling System Package scope. NSPBD shall also be
considered for connection between other switchgear/MCCs to suit the layout.
2.2 The continuous rating of the bus duct shall be same as the rated current of
respective switchgear bus.
2.3 The short time and momentary current ratings of the bus ducts shall be same as that
of associated 415V switchgear.
2.4 The bus bars in the bus duct shall be sleeved with FRLS heat shrinkable, colour
coded XLPE sleeves.
3.0 SPECIFIC REQUIREMENTS
3.1 Bus Enclosure: The enclosure shall be rectangular and shall be made of aluminium
alloy sheets for SPBD and for NSPBD the same shall be of mild steel.
3.2 Bus Conductor: The bus conductor shall be of Aluminium alloy grade 63401 as per
IS: 5082.
3.3 Phase Barriers: In case of segregated phase bus duct, the phase segregation shall
be of aluminium or non-hygroscopic insulating material like fibreglass.
3.4 Flexible expansion joints shall be provided for the conductor and enclosure along
the run of the busduct length to take care of expansion. Also flexible joints shall be
provided at the termination points.
3.5 Inspection covers for periodic inspection of the insulators shall be provided. There
shall be no joints or fixing bolts on top of the enclosure through which water can
seep.
3.6 The outdoor portion of the bus duct shall be provided with a continuous rain hood of
non-magnetic material suitably supported from the busduct support structure.
3.7 The bus conductors shall be given a coat of matt black paint to facilitate heat
dissipation. However the sizing of bus conductor shall consider the conductor as
bare.
3.8 The adjacent section of the bus conductor shall be welded or bolted.
3.9 The joints along the conductors shall be of highest quality and the temperature rise
test shall be conducted including the joints.
3.10 The bus support insulators shall be of 2 KV class (as required) for segregated phase
bus ducts and 1.1 KV class for non-segregated phase bus ducts and shall be

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ELECTRICAL BUS DUCTS

mounted on resilient pads.

3.11 The material of insulator shall be porcelain or epoxy cast resin.
3.12 The spacing of the bus support insulators shall be considered by giving due factor of
safety to withstand the forces due to the momentary short circuit current assigned
for the bus duct.
3.13 Wall frame assembly and seal off bushings shall be provided where the bus duct
passes through walls (indoor to indoor). These shall be fabricated out of Aluminium
angles and sheets. Wall frame assemblies with seal off bushing shall be provided
where bus ducts pass through walls (outdoor to indoor).
3.14 The bus duct supports shall be fabricated from standard steel sections. The support
structures shall be hot dip galvanised.
3.15 Thermostatically controlled space heaters shall be provided along the run of
Bus duct.
3.16 Silica gel breathers shall be provided both in indoor and outdoor portions of Bus duct
for absorption of moisture.
3.17 At the factory, on one typical section of SPBD containing bends, joints etc.,
Following type tests shall be conducted
(a) Air tightness test.
(b) Water tightness test.
(c) Temperature rise test.
(d) Short circuit current withstand
(e) Impulse withstand test.
For NSPBD, type test certificates shall be furnished.
3.18 On all the pieces of SPBD & NSPBD applicable routine tests shall be conducted.
Also, test certificates shall be furnished for bought out items.
3.19 HV voltage test, air tightness test and water tightness tests shall be conducted on
site on fully assembled bus duct.
4.0 TECHNICAL REQUIREMENTS
4.1 Segregated/non-segregated phase bus ducts shall comply with the particulars
indicated in the following table.

Sl. Description Requirement for

Segregated Phase Non-segregated

Bus duct Phase Bus
duct

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(a) Type of cooling Natural air Natural air

o
(b) Maximum temperature 40 C 40oC
rise of conductor
over 50oC
ambient
(c) Maximum temperature 20oC 20oC
rise of enclosure
over 50oC
ambient
Data to be furnished with the bid:
5.1 Technical particulars for the segregated/non-segregated phase bus duct as per table
given below.
5.2 Calculations for arriving at the size of the conductor and the insulator spacing.
5.3 Experience list of the make of bus duct proposed.
5.4 Type test report (short circuit, impulse withstand, temperature rise test for similar
bus duct manufactured by the proposed manufacturer)
1.0 BUS DUCT
1.1 Manufacturer/ Country
1.2 Bus Conductor
(a) Busbar grade
(b) Shape of busbar
(c) Size of busbar mm2
1.3 Barriers
(a) Thickness of phase barrier mm
1.4 Phase to phase spacing mm
1.5 Size of enclosure W x H or Diameter if Mm x mm/ mm
circular
1.6 Resistance/meter/Phase at 20qC of Ohm
conductor
1.7 Inductive reactance/meter/phase at 20qC Ohm
1.8 Capacitive reactance/meter/phase at 20qC Ohm
1.9 Heat loss in the bus duct at full rated current Watts/ ph/ m
1.10 Weight of 3-phase duct Kg/meter
1.11 Standard section length m
1.12 Minimum required clearances from the
periphery of the bus duct

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i) To structural steel work parallel to the mm

duct
ii) To structural steel work perpendicular mm
to the duct
2.0 INSULATORS
2.1 Manufacturer/ Country
2.2 Type
2.3 Cantilever strength
i) Upright Kg.
ii) Underhung Kg.
2.4 Weight of each insulator Kg.
3.0 SEAL OFF BUSHINGS
3.1 Manufacturer/ Country
3.2 Type
3.3 Mechanical Strength
i) Compression Kg.
ii) Tension Kg.
3.4 Weight of each bushing Kg.

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ELECTRICAL DC SYSTEM

1.0 220V DC SYSTEM

1.1 220V DC power supply is the most reliable source of power supply for control,
protection, interlock and annunciation requirements of the Coal Handling System
Package during the normal running of the CH plant as well as for a safe shut
down at the time of the total power supply failure. For arranging the 220V DC
supply for the above, the following shall be provided.
Two (2) 100% rated tubular high discharge type stationary lead acid battery with
associated 2 x 100% float and boost charger and DC switchboard for the Coal
Handling System’s loads. The scheme shall be subject to approval by
Purchaser. Suitable capacity, schemes etc. to achieve same shall be included in
Vendors scope.
If separate battery bank and chargers, DCDBs are required for remote
pumphouses included in CHP package, same shall be included in Vendor’s
scope of supply.
1.2 Sizing

1.2.1 The 220V DC Battery shall be sized to cater for the following loads with minimum
duration as indicated. The voltage at the end of duty cycle shall be 1.85 V / cell
for lead acid type battery.
a) Momentary Load (For duration upto 1 minute)
(i) Tripping load of 6.6kV, & 415V breakers
(ii) Starting current of all automatically started DC drives(if applicable).
(iii) Solenoid valves.
(iv) Indicating lamps on switchgear and control & relay panels.
b) Emergency load (For 2 hours duration)
(i) Running currents of essential DC motors(if applicable).
(ii) Emergency lighting.
c) Continuous Load (For 10 hours duration)
(i) Indicating lamps on switchgear and control & relay panels.
(ii) Control room (For Coal Handling System) emergency lighting.
(iii) Auxiliary relays.
d) Spring Charging Motor load for 6.6kV and 415V Breakers, closing coil
of main incoming breakers and buscouplers (as applicable) shall be
considered as part of the last minute load at the end of the duty cycle.
1.2.2 The battery shall be sized in accordance with the IEEE 485-1983 considering
temperature correction factor, contingency and ageing factors (aging factor to be
25% as per IEEE). A design margin of minimum 10% shall be considered for
battery rating.
1.2.3 Float charger will be rated to cater the following:

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(a) Trickle charging current of the battery

(b) Continuous load on the DC bus with 25% margin.
(c) Full load current of the largest DC motor (for 220V DC battery
only) (if applicable).
1.2.4 The boost charger unit shall be rated such that the battery can be charged from
fully discharged condition within 10 hours.
1.3 Under normal conditions, the float charger connected to the DC switchboard and
battery shall cater to the continuous load of DC system plus trickle charging
current of battery. In case of AC supply failure in the plant/to charger, battery
shall meet the DC load. After restoration of power supply, the float charger will
continue to supply the loads as well as trickle charge the battery. If required,
depending on the battery condition, same will be put to boost charge. If during
boost charging, should the main supply fail, the battery shall supply the DC loads
through the tap cell of the battery.
2.0 Specific Requirements
2.1 Batteries
2.1.1 The batteries shall be stationary lead acid High discharge tubular type capable of
high discharge performance of IS : 1651
2.1.2 The battery shall be closed top or sealed in type. Open type cells are not
acceptable.
2.1.3 The batteries shall be provided with aquagen recombination plugs. The batteries
shall be complete with all accessories such as battery stand, cell connectors, etc.
All the accessories required for testing and maintenance shall be supplied with
the batteries along with electrolyte for first filling. These shall also include + 3
volts DC voltmeter with suitable leads for measuring cell voltage and hydrometer
for measuring specific gravity of electrolyte in steps of 0.005. The batteries shall
be sized for a discharge rate with end cell voltage as 1.85V per cell.
2.2 Battery Charger
2.2.1 The float and boost charger offered shall be static type with silicon controlled
rectifiers and diodes, complete with resistor/capacitor network for surge
protection, connected in three phase full wave bridge circuit.
2.2.2 Charger shall have provision for manual control if the auto mode fails. Load
limiting features shall be provided. The charger shall be designed for adequate
short time over load to take care of the starting of the largest DC motor/testing of
lamps, etc. with other DC loads connected to bus.
2.2.3 The chargers shall be provided with automatic voltage regulation in float mode
and automatic constant current regulation in boost mode.
2.2.4 The charger shall essentially comprise the following items:
x One (1) moving coil DC voltmeter and ammeter of size 96x96 mm of
suitable range for float and boost chargers. Necessary shunts for
local and remote metering shall be provided.

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x One (1) moving coil centre zero ammeter, with shunt, size 96 x 96
mm to read discharge / charge current of the battery.
2.2.5 Fault indicating lamps shall be provided on the charger cubicle and following
initiating contacts shall be provided for remote alarm for each of the float and
boost chargers. The following alarms shall be considered for remote
annunciation.
x Main AC failure
x AC input fuse blown
x DC output fuse blown
x U/V and current limit protection
x Over voltage protection
x Overcurrent protection
x Filter condenser fuse blown
x Rectifier fuse blown
2.2.6 In addition to the above, any additional indication/alarms considered necessary
during the detailed engineering shall also be provided.
2.2.7 For all the above alarms, a group alarm for each charger shall be provided for
remote annunciation.
2.2.8 The charger shall be natural air cooled and no external fans shall be provided to
dissipate the heat developed within the panel.
3.0 Tests for Batteries
3.1 All type, routine and acceptance tests shall be conducted as per the relevant
standards.
3.2 Capacity test and test for voltage during discharge shall be carried out at site on
completion of installation and commissioning and immediately prior to putting the
battery in service.
4.0 Tests for Battery Chargers
4.1 The following routine tests shall be conducted at Vendor’s works :
(a) Visual checks for dimensions and general arrangement.
(b) Wiring checks
(c) Functional checks
(d) Voltage regulation for rated input supply for loads from 0-100%.
(e) Load test to show the charger can deliver the rated duty without
the current limiter device operating.
(f) Ripple measurement by oscilloscope at different loads.
(g) Demonstration of guaranteed efficiency and power factor

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(h) Insulation test (with 500 V megger).

(i) High voltage test, excluding electronic controller, at 2 kV AC for
one min.
4.2 Heat run test shall be conducted as a type test at the factory.
4.3 Test certificates shall be submitted for all bought out items.

TECHNICAL REQUIREMENTS TABLE (APPLICABLE FOR 220V DC SYSTEM)

(a) General
(i) DC system voltage (Nominal) : 220V
(ii) DC System earthing :Unearthed for 220V
(b) Battery Charger Details
(i) DC voltage setting : + 10% of nominal
adjustment of AVR for voltage
float charging
(ii) Voltage stabilisation for : (i) + 1% of set DC
constant voltage voltage with + 10%
regulator variation in supply
voltage.
(ii)+5% during
transients
(iii) DC current adjustment : 30% to 100% of max.
for boost charger boost charger current.
(iv) Current stabilisation for : + 2%
constant current
regulator for boost
charger
(v) Min. Permissible p.f. at : 0.8
rated continuous load
(vi) Permissible ripple : 1% max.
content at rated
continuous load

5.0 Data / Documents to be furnished along with the bid

5.1 Battery sizing calculations indicating relevant assumptions & characteristic
curves.
5.2 Schematic drawings of charger showing main components and basic schemes
5.3 Data as per Technical particulars table given below
5.4 Experience list of battery and battery charges offered.

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5.5 Battery stand / Rack General Arrangement details.

6.0 DC Switchboards
6.1 For feeding the 220V DC loads, following DC switchboards shall be provided.
(a) 220V DC Coal Handling System switchboard.
(b) Any other remote loads coming in CHP that requires a dedicated
switchboard to be provided near the load center.
6.2 The switchboards shall be provided with suitably rated incomers (two incomers
with bus coupler), required quantity and type of outgoing feeders for the
auxiliaries, control supplies to various panels/systems included in Coal Handling
System. In addition, the following feeders shall be provided in each switchboard.
(a) Minimum of two nos. feeders of each type and rating as spare.
The same is the minimum quantity at the time of handing over the
plant. Any additional quantity required for increase / adjustment
during detailed engineering stage shall also be duly considered.
(b) 240V space heating module (This can be part of a separate Space
heater DB also).
(c) 1 No. Alarm module for common alarm of outgoing feeder fault.
6.3 Current Ratings
6.3.1 The short circuit current rating of the switchboard shall be arrived considering the
contribution from charger and battery with 10% margin.
6.3.2 The continuous current rating of the bus bars, incomers, ties for 220V DC
switchboards shall be the maximum DC load (excluding the momentary load) on
the bus due to any operating condition plus 20% margin rounded off to the next
higher standard rating.
6.4 Specific Requirements
6.4.1 The constructional features of all DC switchboards shall comply with the
requirements of 415V AC switchgears in this specification as applicable.
6.4.2 Positive and negative bus bars in the DC switchgear shall be completely
segregated from each other by partitions.
6.4.3 Module details
(a) Incomer
The incomer modules shall be breaker controlled. Each incomer shall be
provided with:
x Ammeter & voltmeter
x Earth fault relay (only for 220V DC switchboards)
x Under voltage relay with timer
x Indicating lamps for ON, OFF, EARTH FAULT, UNDER VOLTAGE
conditions

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x Current and voltage transducers for remote indication

x Necessary hardware and circuitry for fault alarm, lamp test and alarm test.
(b) Outgoing switch fuse feeders and tie feeders/bus coupler
(i) These feeders shall be provided with suitably rated switch-fuses on positive
and negative sides with feeder on and fault indicating lamps.
(ii) The feeders rated 200 Amps and above (if applicable for Coal Handling
System) shall be provided with a shunt and ammeter
(c) Motor modules (If applicable)
(i) For DC motors, starters shall be preferably housed within the DC
switchboard. However, the resistors can be separately mounted in
boxes/panels, which may be located adjacent to DC switchboard.
(ii) The motor modules shall be provided with :
x Switch, fuses, air break contactors
x Thermal overload relays
x Starting resistors with associated timers
x ON, OFF, FAULT indicating lamps
x Necessary auxiliary contactors for fault alarm circuit
x 240V space heating circuit
x ON, OFF PBs for testing purposes
x One shunt with ammeter and one shunt for remote indication
x Appropriate circuitry for receiving the ON, OFF commands from remote
panels/systems, interlocks, etc.
x MCB for space heating circuit
(d) Space Heating Module
240V, 1 space heating shall be obtained through a dedicated space heater
distribution board or from the 415V Coal Handling System Switchgear by
providing a suitable 415/240V cast resin transformer of adequate rating.
Vendor shall decide the mode of power supply for space heating, during
detailed engineering.
(e) Alarm module
(i) Alarm module for outgoing feeder faults shall be provided with switch fuse,
alarm accept, reset PBs, ‘supply ON’ lamp, ‘fault detected’ lamp, hooter,
necessary auxiliary contactors, control circuit for detecting, annunciating,
accepting, resetting the fault in any module of the particular bus section.
Contacts from this module for common feeder fault and its own module
supply failure shall be provided and used for annunciation in control desk.
(ii) Alarm module for incomers/bus coupler faults shall be similar to the above

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except that it shall work on 240V AC supply.

6.5 Control room alarms/indications/SER points
(a) Following indications/alarms shall be available for remote annunciations
(i) Incomer, bus coupler, ties – ON & OFF
(ii) Incomer current
(iii) Alarm module supply failed
(iv) Outgoing feeder fault
(v) Incomer alarm supply fail
(vi) Bus under voltage
(vii) Bus earth fault
(viii) Bus voltage
(b) For the annunciation, alarms of a particular bus shall be grouped as one
window. The requirement of contacts to SER shall be duly considered and
provided.
6.6 Data to be furnished with BID
Technical particulars for the switchboard as indicated under (220V switchgear)
shall be furnished.
6.6.1 Descriptive literature/pamphlets on switchboard.
6.6.2 Write up on switchboard construction
6.6.3 Single line diagram showing ratings of all the buses, incomers, ties etc.
TECHNICAL PARTICULARS TABLE
Battery Chargers
(a) Manufacturer’s Name
(b) Type
(c) Rated output in kW
(d) Guaranteed efficiency @ rated load
(e) Maximum permissible temperature rise over ambient
(f) Rectifier transformer : deg.C
(ii) Rectifier cells : deg.C
(iii) Smoothing reactor : deg.C
(g) Class of insulation
(i) Rectifier transformer
(ii) Smoothing reactor
(h) Method of cooling

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(i) Rectifier cells

(ii) Transformer
(i) Degree of protection IP

Batteries
(a) Manufacturer’s name
(b) Standards to which battery is manufactured
(c) Capacity at 270C
(d) Expected life of battery in years
(e) No. of cells required to give rated DC voltage
(f) Type of cell

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ELECTRICAL LOCAL CONTROL PANELS, PUSH BUTTONS & JB’S

1.0 CONTROL PANELS & CABINETS AND MISCELLANEOUS ELECTRICAL

EQUIPMENT
1.1 Indoor control panels provided for control of miscellaneous systems in the Coal
Handling System viz., cooling control system, Electrics for ventilation, air-
conditioning, etc. in Coal Handling System scope shall comply with the
requirements as specified in this section.
1.2 All the meters provided on the panel shall be multifunction digital type.
1.3 The facia annunciation windows if provided on the panel shall conform to
requirements latest national and international standards.
1.4 The required 240 V, 1 phase AC supply required for panel illumination and
receptacle shall be derived in the control panel itself. However 240V, 1 Phase AC
supply for space heating of panel shall be fed from a separate ACDB.
1.5 Technical Requirements
SL. DESCRIPTION REQUIREMENTS
NO.
1 Location Indoor/Outdoor depending
on location

2 Type of mounting Wall/Floor

3 Cable entry Top/bottom depending on
layout
4 Paint Finish: Outside/Inside Grey shade no.631
(epoxy) as per IS-5/Glossy
white.
5 Supply voltage 415V, 3 phase, 3 wire
6 Control transformer Required to derive 110V
control supply (to be
decided by Vendor).
7 Space heater, lighting supply voltage 240V, 1 phase AC
8 Degree of protection of Enclosure for IP 54 class for Indoor & IP
Electrical panels/cabinet enclosure 65 class with canopy for
outdoor of polycarbonate /
FRP / Die cast aluminium.
(See Cl.3.2. below)
2.0 Following miscellaneous equipment shall be included in Contractor’s scope as
required.
2.1 Local push button stations.
2.2 Junction boxes (JBs)
2.3 Danger boards
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ELECTRICAL LOCAL CONTROL PANELS, PUSH BUTTONS & JB’S

2.4 Rubber mats with suitable insulation levels as per IS and application.
2.5 Welding Sockets
3.0 LOCAL PUSH BUTTON STATIONS (LPB)
3.1 Local push button station shall be provided for all the drive motors of the plant
(415V motors and 6.6 kV motors) (start / stop push buttons for unidirectional
motors, start/stop/reverse push buttons for bi-directional motors & only start push
button for emergency motors) as per scheme requirement.
3.2 The degree of protection of LPBs shall be IP65 with canopy for outdoor and IP54
for indoor applications. All outdoor PBs, LPBs and JBs shall be of
polycarbonate / FRP / die cast aluminium.
3.3 All PBs shall be push to actuate type and the stop PB shall be lockable in off
position as per the scheme requirement.
3.4 Emergency local stop push button should not be lockable. For critical loads, two
stop push buttons connected in series shall be provided as per the scheme
requirement.
3.5 All push buttons shall be provided with 2 nos. NO and 2 nos. NC contacts for
various interlocking purposes. One contact of stop PB shall be directly wired to
the switchgear module for direct tripping and another contact to control system.
3.6 Terminals to be suitable for 2 cores of 2.5 sq mm conductors with 20% spare
terminals.

4.0 JUNCTION BOXES (JBs)

4.1 Junction boxes as required for the power plant shall be supplied :
4.2 The JBs used in outdoor areas shall be weatherproof type with IP-65 degree of
protection.
4.3 Junction boxes/marshallng boxes (JBs/MB) shall be provided to enable running a
large core cables from (JB/MB) to control panels, terminal cabinets, etc.
4.4 All JBs, shall be of polycarbonate /FRP/Dye-cast aluminium.
5.0 Danger boards shall be provided in line with the statutory requirements.
6.0 Rubber mats shall be provided to meet the safety and other statutory
requirements.
7.0 WELDING SOCKETS
7.1 Industrial type 63A and 100A (welding purpose) sockets shall be provided in
sufficient number to facilitate extension of power supply to various machine tools,
welding sets etc at strategic locations in the CHP system. The exact locations and
qty shall be decided by CHP vendor during detailed engineering and shall be
subject to Purchaser/Engineer’s approval.
7.2 Welding switch socket outlets shall be provided at an average distance of 60m
distance. The number of welding socket outlets for Coal Handling System areas
shall be decided based on requirement, approach etc. Generally the socket outlets
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ELECTRICAL LOCAL CONTROL PANELS, PUSH BUTTONS & JB’S

shall be provided in such a manner so that using 30m flexible cable with welding
set, total CHP and yard / conveyor belt and Junction tower / pumphouse areas can
be covered. Upto three switch socket outlets shall be looped per feeder circuit.
Sheet metal clad switch fuse units shall be provided for feeding power.
7.3 The welding switch socket outlets and switch units shall be fed from separate
distribution board.
8.0 TESTING
The following testing shall be conducted on all equipments at works.
a. IR Test before and after HV Test
b. HV Test with 2.5 KV megger.
SNO DESCRIPTION REQUIREMENTS
Applicable standards (Latest Issues as on date of order
are applicable.)
1 Switchgear general requirements IS 4237
2 Factory built assemblies of switchgear and IS 8623
control gear for voltages upto and
including 1000 V AC & 1200 V sDC
3 Air break switches IS 13947 pt 1 & 2
4 Miniature circuit breakers IS 8828
5 HRC cartridge fuses IS 9224
6 Contactors IS 2959
7 Control switches/push buttons IS 6875
8 Current transformers IS 2705
9 Voltage transformers IS 3156
10 Relays IS 3231
11 Indicating instruments IS 1248
12 Arrangement for bus bars, main IS 375
connections and accessories
13 Degree of Protection IS 2147
14 Climate proofing of electrical equipment IS 3202
15 Code of practice for phosphating iron & IS 6005
steel
16 Wrought aluminium and aluminium alloys IS 5082
for electrical purposes

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ELECTRICAL MOTORS

1.0 A.C. Motors

1.1 All LV motors shall be suitable for 415V, 3 Phase, 3-wire, 50 Hz power supply.
Motor of rating upto and including 200kW shall be supplied from LT switchgear /
MCCs through SFU/MCCB and contactors or ACBs.
All MV motors shall be suitable for 6600V, 3 Phase, 3-wire, 50 Hz power supply.
Motor of rating above 200kW shall be supplied from CHP 6.6kV switchgear
through SF6 / Vacuum CBs.
1.2 The drive motor rating shall have atleast 15% margin over the duty point input of
10% over the maximum power requirement of driven equipment. Motors shall be
capable of starting and accelerating the load with the applicable method of
starting without exceeding acceptable winding temperatures when supply voltage
is 85% for LV motors.
1.3 Motors shall be capable of developing the rated full load torque even if the supply
voltage drops to 70% of the rated voltage. If such operation is envisaged for a
period of one second, the pull out torque of the motor shall be atleast 205% of full
load torque.
1.4 Motors shall withstand for 1 second the voltage and torque stresses developed
due to the vector difference between the motor residual voltage and the incoming
supply voltage equal to 150% of the rated voltage during fast change over of
buses.
1.5 Locked rotor current of the LV motor shall not exceed 600% of full load current
inclusive of 20% tolerance allowed by the IS/IEC.
1.6 The locked rotor withstand time under hot condition at 110% rated voltage shall
be more than the starting time at minimum permissible voltage specified above
by atleast three seconds or 15% of the accelerating time whichever is greater.
Provision of speed switch shall be avoided to the extent possible.
1.7 The degree of protection for the motor enclosure shall be IP-55. The terminal
boxes shall be provided with atleast IP-55 degree of protection. For single core
cable termination, gland plates shall be of non-magnetic material. All motors
located in hazardous area shall have flame proof design.
1.8 All MV motors shall be provided with vibration pads for mounting vibration
detectors.
1.9 For 415V motors, maximum double amplitude vibrations upto 1500 rpm shall be
40 microns and 15 microns upto 3000 rpm.
1.10 Maximum noise level measured at a distance of 1.0 meter from the outer surface
of the motor shall not exceed 85 db (A).
1.11 Variable frequency controller shall be provided for motors requiring speed
control.

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ELECTRICAL MOTORS

1.12 Terminal boxes shall have fault withstand capacity equal to at least rated short
circuit level of the system voltage for 0.25 sec. The terminal boxes shall be
reversible to suit cable entry from bottom or top. Terminal boxes shall be suitable
for termination of FRLS, XLPE armoured cables.
1.13 Separate terminal box to be provided for space heater. All terminal boxes shall be
provided with two earthing studs for termination of protective earth conductor.
Double compression type brass cable glands and crimping type tinned copper
lugs shall be provided for termination.
1.14 Type of cooling for LT motors shall be TEFC and Continuous duty motors shall
be capable of three equally spread starts per hour under normal condition or two
starts in quick succession from cold or one hot start, under rated load condition.
1.15 LT motors shall have insulation class ‘F’ with temperature rise limited to class ‘B’
i.e. 70 deg.C over the ambient of 50 deg.C.
1.16 Space heaters shall be provided for all LT motors of rating equal to or more than
30 kW. Heaters to be automatically ‘OFF’ when the motor is switched ‘ON’
1.17 All motors for outdoor duty shall have detachable metal/FRP/Polycarbonate
canopy.
1.18 Each motor shall have two Earthing terminals.
1.19 All motors above 37KW shall have minimum 92% efficiency at full load
conditions.
1.20 All motors shall be suitable for DOL starting.
2.0 D.C. Motors
2.1 DC motors shall be suitable for the DC system voltage available in the plant.
Motor shall be capable of starting and accelerating the load with the applicable
method of starting, without exceeding acceptable winding temperatures, when
the supply voltage is in the range of 85% to 110% of rated motor voltage.
2.2 DC motors shall have insulation class ‘F’ with temperature rise limited to class ‘B’
i.e., 70°C over an ambient of 50°C.
3.0 Actuator
General Technical Requirement
3.1 Actuator shall be weatherproof type with enclosure conforming to IP-67 degree of
protection. It should be suitable for out-door use without the need for canopy. If
the IP-68 degree of protection is required due to occasional submergence, the
Owner / Project Manager will specify the depth and duration of such
submergence.
The actuator shall be suitable for installation in any position without lubrication
leakage or other operational difficulty.
The main gearbox of the actuator shall be special grease filled.

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ELECTRICAL MOTORS

Each actuator should have a hand wheel for emergency manual operation.
Clockwise operation of hand wheel shall cause clockwise movement of the
output drive. The hand wheel shall be clearly marked with an arrow and the word
CLOSE.
The hand wheel shall automatically disengage when the power to the motor is
restored i.e. power drive shall have a preference over manual drive.
3.2 The manual effort should not exceed 400 N (push / pull). A top bevel gear set
(side mounted hand wheel) shall be employed to reduce the manual effort.
Each actuator shall have a local mechanical position indicator. It should be
suitable to indicate 0 - 100% position of the valve (continuous type).
In order to minimise the amount of spare parts required, parts and sub-
assemblies limit / torque switches, limit switch counter gear assembly, torque
switch drive assembly, mechanical position indicator assembly etc. individually
interchangeable / replaceable throughout the models selected.
The actuator shall be painted with corrosion resistant epoxy resin paint. Paint
shade shall be Grey as per IS-631 grade 5.
In order to prevent condensation, a space heater shall be provided in the switch
compartment, suitable for continuous operation.
Actuator mounting dimensions shall be according to ISO-5210.
For rising stem applications, the design must allow the removal of actuator from
the output drive without disturbing the function of valve.
Limit and Torque Switches
Independent torque and limit switches shall be provided in the actuator. A
minimum of two position limit switches and two torque switches, one each for
each direction of travel, having 2 NO + 2 NC potential free contacts, shall be
supplied. If called for in the data sheet, two additional limit switches shall be
provided for intermediate positions.
Torque switch dial shall be graduated directly in “kg-m” for easy setting to desired
value within the range specified. Separate dials shall be provided for CLOSE and
OPEN torque switches.
The rating of both torque and limit switches shall be 250 V, 5 Amps. AC/ 250V,
0.46 Amps DC.
The switches shall individually be enclosed to a minimum of IP-66 protection
class.
Torque and limit switches shall have only stainless steel flaps for better
protection against environmental condition.
Limit switches shall be operated by gear driven cams, which are mechanically
linked to the driving devices. The counter gear used for counting and tripping the
limit switches shall be of metallic construction like brass etc. No plastic gearing
shall be allowed.

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ELECTRICAL MOTORS

To guarantee proper function under high ambient temperatures, torque and limit
switch sensing shall be of mechanical type.
If specified in data sheet, two additional limit switches of 2NO + 2NC contact,
each adjustable at any intermediate position, shall be provided in the actuator.
3.3 Electric Drive for Actuator (Motor)
All motors shall be specifically designed for valve actuator operation, which is
characterised by high starting torque, low stall torque & low inertia. All motors
shall be high starting torque type to facilitate ‘unseating’ of valve.
Motor shall be suitable for power supply of 415 V, 3 ph, 50 Hz, AC.
Motor shall be squirrel cage induction type and shall generally conform to IS-325.
Motor shall have minimum class 'F' insulation with temperature rise restricted to
class 'B'.
Motor shall be of totally enclosed surface cooled (TESC) type with IP-67
protection class after mounting on actuator.
Motor shall have three thermostats connected in series, one in each phase of
stator winding, for protection against overheating.
Motor shall be suitable for operation under voltage variation of + 10%, frequency
variation of + 5% and combined voltage & frequency variation of 10% absolute.
Motor shall be suitable for direct on-line (DOL) starting and starter shall be
integral to the motor.
It should be possible to separate the motor from the lubricant filled gearing of the
actuator allowing easy replacement of motor without loosing any lubricant
regardless of mounting position.
Fins shall be provided on the motor body to ensure better heat dissipation.
It shall be possible to change the output rpm of the actuator, if required, at the
site at a later date, without hampering the mounting arrangement and loss of any
lubricant.
Other Requirements of Actuator
Common potential free contact shall be available to annunciate the following
faults to the remote control station :
- Thermo switch tripped.
- Thermal overload relay tripped.
- Torque and limit switch contacts.

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ELECTRICAL MOTORS

The following individual relay / potential free contacts shall be provided for the
remote annunciation :
- Actuator running in OPEN direction.
- Actuator running in CLOSE direction.
- Torque switch OPEN tripped.
- Torque switch CLOSE tripped.
Thermal overload relay shall be provided to trip the actuator in case of overload.
The DC and AC actuator shall be provided with accessories viz., Torque limit
switch, end of travel switch, adjustable limit switch, hand wheel motor,
thermostat, etc. Complete actuator shall be tested at factory as per IS 9334. All
actuators should have minimum 2 limit switches for each position, and should
have position transmitters wherever required.
4.0 Tests
4.1 Tests on all types of motors shall be conducted as per relevant standard.
4.2 For 415V motors and DC motors, if type test certificates are available for the
same rating of the motors offered, the same shall be furnished, else they shall be
conducted. However, all routine and acceptance tests shall be conducted on all
415V motors as per relevant standards.
4.3 Noise level measurement test shall be conducted on one motor of each type.
4.4 Di-electric tests to establish the insulation withstand level of motors shall be
performed on a sample coil (identical to those to be used in the motor quoted for)
for each type of motor. These tested sample coils shall not be used in the motors
to be supplied.
5.0 Technical Requirements
5.1 The motors shall comply with the particulars indicated below and Contractor shall
furnish the details in respective column given below (to be separately submitted
for different type & rating of the motor).

Sl. Specification Contractor’s

Description Unit
No. Requirement Details

I AC Motors
1.0 Application/Designation *
2.0 Manufacturer *

3.0 Type of motors Squirrel cage

4.0 Rated voltage kV *

5.0 Rated

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ELECTRICAL MOTORS

(a) Output kW *
(b) Load factor *
(c) Speed rpm *
6.0 Duty
Type of Duty (IS-325 or
6.1 *
equivalent)
Duty designation (IS-325
6.2 *
or equivalent)
7.0 Supply Conditions
Allowable variations in
(i) Voltage % + 10
(ii) Frequency % +5
(iii) Combined % 10
8.0 Efficiency *
9.0 Rated power factor *
Power factor during
10.0 *
starting
11.0 Current
(a) Full load Amps *
(b) Starting % FL *
12.0 Method of starting DOL
13.0 Insulation
14.1 Class of insulation Class F
Temperature rise by Deg. C Temp. rise limited to
14.2
Resistance method Class B

15.0 Type of cooling TEFC for LV motors

Degree of protection
16.0 *
(IS:4691 or equivalent)
Suitable for outdoor Yes / No
17.0 *
operation
Normal winding Star /
18.0 *
connection Delta

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Permissible No. of equally

spread starts per hour
19.0 Sec *
under normal service
conditions
Hot thermal withstand
20.0 time at 110% of the rated Sec *
voltage.
Starting time at 80% of
21.0 Sec *
the rated voltage.
Thermal characteristics,
starting characteristics
22.0 and negative sequence **
characteristics to be
furnished
II DC MOTORS
23.0 Class of Insulation : F
24.0 Temperature rise : Temp. rise limited to
class B
25.0 Method of starting : *
Information against all items listed above under AC as applicable shall be furnished for
DC motors also.
Note: ‘*’ indicated above shall be filled by the Contractor.
‘**’ Contractor shall furnish the data after placement of order.

6.0 Data to be furnished with the Bid

6.1 Technical particulars as per Data Sheet indicated above.

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SYSTEM 1050 MW MAITHON RIGHT BANK TPP
ELECTRICAL LIGHTING SYSTEM

1.0 LIGHTING SYSTEMS

Complete Lighting System shall be provided for Coal Handling System building and
areas including indoor lighting, outdoor lighting, yard lighting, road lighting,
emergency lighting at strategic points in Coal Handling areas etc. but not limited to
the following:
x Buildings and structures (e.g., coal handling control room, CHP switchgear
building, transformer yard, pump houses, skid lighting, crusher house,
junction towers, conveyor route lighting, street lighting, yard lighting etc.,)
associated with and included in the scope of Coal Handling systems scope.
x Lighting of all equipments supplied as a part of Coal Handling systems
package.
x Aviation warning lighting where required as per Airports Authority and
international standards. Aviation warning lights shall be high intensity
flashing type with varying intensity for day and night.
2.0 CATEGORIES OF LIGHTING
2.1 The plant lighting system shall comprise the following four (4) categories :
(a) Normal 240V AC Lighting System.
(b) 220V DC Lighting System for the CHP Control room (and any other
control room coming in this package).
(c) Emergency & Exit Lighting using Installite (Normally fed from AC supply
and having 3 hour built in battery backup).
(d) Maintenance 24V AC Lighting and power receptacles(Portable lights)
2.1.1 Normal 240V AC Lighting System
In this system, the lighting circuits shall be fed by the 3 phase, 4 wire normal AC
supply from the normal lighting distribution boards. All the lighting fixtures connected
to this system shall be available as long as supply is available from normal source
through lighting transformer.
2.1.2 220V DC Lighting System
This shall be provided for the Coal Handling control rooms from the CHP DC System.
These lights shall be switched ON automatically in the event of loss of normal AC
supply. These lights shall be energised from a separate 220V DC Lighting Panel
which will be located in the Coal Handling System control room.
2.1.3 Emergency Lighting System (AC/DC Installite type fixtures)
This shall be provided by emergency A.C/D.C lighting fixtures located strategically in
critical operating area and exit lighting in buildings and other places. These lights
shall be ON all the time, normally from the CHP normal LDB/emergency LDB(if
available). In case of failure of both normal AC system and D.G set, these lights shall
be energised from built in battery packs having 3 hour backup. All equipment/cabling
required to achieve above shall be in the Contractor’s scope.

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2.1.4 Maintenance 24V AC Lighting System & Power receptacles.

For lighting facilities comprising portable hand lamps and/or connection of portable
hand tools etc., required during the routine maintenance work, 24V single phase 3 pin
sockets with switches shall be provided at selected points in the areas listed below.
Such sockets for routine maintenance shall be clearly identified by colour coding in
order to distinguish them from the normal 240V power outlets. Necessary outlets shall
be made on the inside walls of the building near equipments.
The areas to be considered for locating the maintenance 24V AC lighting shall be
decided during the detailed engineering stage as necessary by CONTRACTOR /
OWNER.
3.0 The area wise distribution of lighting fixtures connected to the three systems covered
under Clause 2.1.1 to 2.1.3 is indicated below:
Area-wise Distribution of Lighting System in the Plant

Area/building Percentage Distribution of Lighting

Normal Normal & 220V DC through
Emergency (if dedicated DC LP.
dedicated DG is
provided for
Coal Handling
System)
Coal Handling System 70% 20% 10%
Control room
Service buildings / other 80% 20% -
buildings for CH Package.
Various pump houses and 80% 20% -
electrical switchgear rooms
such as CHP switchgear
room, etc.
4.0 LIGHTING SUPPLY DISTRIBUTION SYSTEM
Separate lighting transformers and CHP Main Lighting Distribution Board (CHP MLDB)
shall be provided for feeding the CHP System lighting loads. Sub-lighting distribution
boards and Lighting Panels as per site requirement shall be provided by vendor.
Lighting distribution system shall be distinct and separate from the LT main distribution.
Main and Sub LDBs shall have three-phase, 4 wire, TPN MCB/MCCB controlled
feeders. LPs shall have TPN ELCB incomers and number of single phase, SPN MCB
outgoing circuits. Lighting panels feeding the yard area / other remote / inaccessible
areas coming under Coal Handling System shall be provided with contactors for control
from a remote point. The outdoor area and street lights shall be ‘ON’ automatically
through photocell. Provision shall be made for switching ‘ON’ the rest of the lights.
Lighting fixtures in indoor areas shall be controlled from the respective lighting panels.
4.1 Normal 240V AC Lighting System
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SYSTEM 1050 MW MAITHON RIGHT BANK TPP
ELECTRICAL LIGHTING SYSTEM

For this system, lighting points shall be supplied at 240V AC through 415V, 3-phase, 4-
wire, 50 Hz system for Coal Handling Package. The whole lighting fixtures and power
receptacle loads shall be distributed evenly on all the three phases to the maximum
possible extent.
In unmanned premises housing some equipment or system which could require
occasional inspection or maintenance, normally few of the lights shall be ‘ON’ with
separate control and complete darkness in this area shall be avoided. All other lights
shall be made ‘ON’ or ‘OFF’, whenever required.
4.2 220 V DC Lighting System
Emergency DC lighting supply distribution shall be on 220 V DC, 2-wire unearthed
system. This power supply shall be obtained from the Coal Handling System 220V DC
switchboard. DC lighting panel shall be provided for distribution of lighting supply.
This panel shall have an incoming switch, under voltage relay and number of outgoing
circuits controlled by switch fuses/ MCB feeders of adequate rating. On failure of AC
supply the battery shall supply to the DCLP through the DCDB. Spare outgoing feeders
for purchaser’s use shall be provided and quantity will be decided during detailed
engineering.
4.3 Distribution of 24 V AC Maintenance Lighting System
24 V AC supply for maintenance purposes (for hand lamps and/or hand operated tools)
shall be supplied from 24 V AC distribution panel, which receives 240 V power supply
from 415 V/240V transformer modules of N/E switchgear. 24 V AC distribution panel
consists of one incoming double pole switch with fuses and MCBs, one 240/26.5 V dry
type transformer of adequate rating and HRC fuses on 26.5 V side of the transformer.
This shall be strategically located and suitable circuits shall be formed. This panel shall
be wall / column mounting type.
ILLUMINATION LEVELS AND CHOICE OF LIGHTING FIXTURES
5.0 The area-wise distribution of average illumination levels and type of luminaries shall be
as indicated below

Sl. Area/Structure Average Type of Fixture Type of Luminaire

No. Illumination
Level in Lux
(Minimum)
A- COAL HANDLING
SYSTEM AREAS
1. Cable vault 100 Industrial type FTL Energy Efficient FTL
2. CHP switchgear room 250 Industrial type with Energy Efficient FTL.
area vitreous enamel Incandescent lamps
reflector. for DC Lighting.
3. CHP control room 300 Decorative Energy Efficient FTL
recessed with wide
angle mirror optic
anti-glare type
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ELECTRICAL LIGHTING SYSTEM

Sl. Area/Structure Average Type of Fixture Type of Luminaire

No. Illumination
Level in Lux
(Minimum)
4. Battery room 150 Corrosion-proof Energy Efficient FTL
5. Air washer room and 200 Totally enclosed Energy Efficient FTL
A/C plant room (as vapour proof with
applicable) clear acrylic cover
6. Unloading and 300 Industrial high bay 250 W HPSV/ HPMV/
maintenance bay(as with anodised MH lamp (for mounting
applicable) aluminium reflector height >9m)
7. Electrical laboratory, 250 Decorative Energy Efficient FTL
chemical laboratory recessed with wide
(air-conditioned) (as angle mirror optic
applicable) anti-glare type
9. Chemical laboratory 250 Industrial type with Energy Efficient FTL
(non-airconditioned) vitreous enamel
(as applicable) reflector
B- VARIOUS OFF-SITE
BUILDING
1. Equipment room (pump 200 Industrial type with
house) vitreous enamel
150 / 250 W HPSV
reflector upto
lamp
mounting height of
8M
2. Switchgear room 250 Industrial high bay Energy Efficient FTL
for mounting
heights above 8M
3. Outside working areas 70 Flood light medium 250 W HPSV lamp
beam
4. Stores 100 Industrial type with Energy Efficient FTL
vitreous enamel
reflector
C- GENERAL
1. Corridors, walkways, 100 Industrial type with Energy Efficient FTL
staircase, etc. vitreous enamel
reflectors/channel
mounted box type
2. Lockers, toilets, wash 100 Channel mounted Energy Efficient FTL
rooms, etc. box type

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ELECTRICAL LIGHTING SYSTEM

Sl. Area/Structure Average Type of Fixture Type of Luminaire

No. Illumination
Level in Lux
(Minimum)
3. Building periphery 50 Industrial well glass 70 W HPSV lamp / 400
lighting & Yard lighting with integral W HPSV lamp
mounted control
gear/industrial bulk
head with integral
mounted control
gear/ flood light
fittings (Photo cell
control to be
provided).
4. Office Rooms 400 Decorative Energy Efficient FTL
recessed type FTL
5. Road Lighting 15 By Vendor. 70 W HPSV lamp
D DC LIGHT FITTINGS
1. Control room For Decorative 1x100 W incandescent
emergency recessed type with lamp
condition. cylindrical reflector
2. Other areas (as - Industrial bulk head 1x100 W incandescent
required) or industrial well lamp
glass with reflector
Note:
1. Energy efficient FTL – T5 type energy efficient tube light fittings (or equivalent type
from reputed manufacturers acceptable to purchaser) shall be used.
2. CONTRACTOR may propose alternate type of fixtures/lamps to be used in areas
against indicated above, provided minimum illumination level as indicated above is
maintained. Lighting shall appear aesthetically good and shall ensure comfort of
the person’s working in that particular area. Also, lighting for a particular area or
equipment shall be selected suitably taking into consideration the type of work to be
carried out in that particular area (considering glare, colour rendering, Visual
Comfort, indoor/outdoor, type of atmosphere etc). CONTRACTOR shall measure
the lux levels in the above areas (measured at the working plane) as per relevant
standards to prove that the specified values are being met.

6.0 LIGHTING SYSTEM DESIGN

6.1 The lighting system design shall comply with the acceptable norms and the best
engineering practices. The system design shall consider principles of lighting
specified in following paragraph. The lighting layout shall be designed to provide
uniform illumination with minimum glare, visual comfort for the operator and good
aesthetic appearance. The layout design shall meet all the statutory requirements,

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local rules etc.

6.2 Indoor Lighting
The recommended values of illumination level for various areas in the plant are
indicated in the Table above. Following factors shall be considered while arriving at
the utilisation factor to determine the number of fixtures for each area/buildings in the
plant.
6.2.1 Maintenance Factor:
(a) Air conditioned clean interiors like office rooms,
Laboratories, Auditorium : 0.8
(b) Industrial areas with normal interiors such
as workshops, stores : 0.7
(c) Industrial areas with dusty interiors : 0.6
(d) Industrial areas with very dusty interiors such as crusher house and junction
towers : 0.5
6.2.2 Reflection factor for wall/ceiling
(a) White and very light colours : 0.7
(b) Light colours : 0.5
(c) Middle tints : 0.3
(d) Dark colours : 0.1
6.2.3 Utilisation factor considering the room index at applicable surface reflection factors.
The working plane shall be considered at 0.85 m from the floor level.
6.2.4 The value of the ratio of spacing (S) to mounting height (H) shall be commensurate
with the type of fittings selected and uniformity of illumination. The suspension height
for suspended fixtures shall not exceed 1 meter.
6.3 Outdoor Lighting
6.3.1 The recommended illumination levels for outdoor areas are indicated in the above
table.
6.3.2 Mounting height, spacing of flood lights shall be based on lamp wattage, uniformity of
illumination and vertical angles. Ratio of minimum to average illumination shall not
be less than 0.3 and for minimum to maximum shall not be less than 0.05.
6.3.3 Maintenance factor shall be generally 0.6 under average conditions.
6.3.4 Flood lights for area lighting shall be mounted on building structures or dedicated
lighting poles of adequate height shall be proposed.
6.3.5 Automatic switching ON/OFF shall be through timers/photo cells. For road
illumination inside the battery limit lighting poles shall be provided every 30m
6.3.6 Aviation obstruction lights shall be provided on tall installations as per regulation.
7.0 SWITCHES, RECEPTACLES & CEILING FANS

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ELECTRICAL LIGHTING SYSTEM

7.1 In the Coal Handling plant areas, the lighting circuits shall be controlled directly from
the MCBs in the lighting panels. Wherever the lighting panel is not in the same area,
separate switches shall be provided. For cabins, rooms, etc., separate switches shall
be provided for each point. Similarly for entrances, building periphery lighting
separate switches shall be provided.
7.2 240V, 50 Hz, 3 pin Power Receptacles (5A and 15A) shall be provided suitably in all
building/areas of the Coal Handling System. Inside a building, receptacles shall be
provided at interval of 30m or part there of for hand tools, water coolers, exhaust fans
etc. Inside each cabins atleast two receptacles shall be provided and the same shall
be indoor/outdoor/flameproof as per the location. Minimum 2 nos of 5A and 1 no 15A
receptacles shall be provided in each room. 20A sockets shall be used for AC &
ventilation and shall be controlled through MCBs.
7.3 Ceiling fans/Exhaust fans
1200mm sweep ceiling fans shall be provided for office rooms, store rooms and other
social buildings. Atleast one no of fan shall be provided for every 10 sq metre area.
The ceiling fans shall be complete with electronic regulator.
Exhaust fans for toilets, battery rooms etc shall be provided with their control devices
(MCBs) & louvers as per good engineering practise.
8.0 LIGHTING DISTRIBUTION BOARDS (LDB) & LIGHTING PANELS (LP)
8.1 The Main Lighting Distribution board shall be fed through 415V/433V lighting
transformers with off circuit taps ± 5% in steps of 2.5%. The lighting transformer shall
be cast resin dry type and shall be housed in a suitable enclosure
The main lighting distribution boards shall consist of two incoming ACB/MCCB of
adequate rating and required number of out going triple pole and neutral
SFUs/MCCBs. The MLDB shall be designed for the minimum short circuit level of 20
kA for 1 second. All the distribution boards shall be sheet steel clad, dust and vermin
proof, cubicle type with degree of protection conforming to IP-52. Outdoor panels
shall be weather proof type with IP-54 protection. The thickness of sheet steel
enclosures shall be 2 mm minimum for load bearing and 1.6 mm for other members.
In main lighting, feeders for Purchaser’s use and spare feeders shall be provided as
required during detailed engineering.
8.2 Number of outgoing feeders in MLDB’s, SLDB’s and LPs shall be provided as per
requirement including the spare feeders and feeders for “PURCHASER’S USE”.
Loading per circuit per phase shall be limited to a maximum of 2kW. One feeder shall
control a maximum of 10 fixtures in a given area.
8.3 Individual control in office buildings shall be through single pole flush type
switches/MCBs. In those areas where group controls are required, rotary switches
shall be provided.
8.4 External area lighting shall be fed from separate boards located at suitable places.
Automatic switching ON/OFF of these circuits shall be done through timers/photo cell.
In high bays, walkway shall be provided for maintaining light fittings. At other places
suitable ladder / platform / approach shall be provided for maintaining / replacement
of light fittings.

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ELECTRICAL LIGHTING SYSTEM

8.5 Each of the LDBs shall be provided with voltmeter and ammeter along with selector
switches, ‘SUPPLY ON” indicating lamps, etc. The switch boxes, receptacle boxes
etc. shall be made up of 18 SWG sheet steel.
8.6 Two ground pads with bolts and nuts shall be provided on each board for connection
to 50x6/25x3 mm GS flat.
8.7 Painting: All sheet steel enclosures of panels, switchboards & receptacles shall be
chemically cleaned & rinsed, phosphated & dried. After the treatment steel surfaces
shall be given two coats of primer and two coats of finished enamel paint of approved
shade. Vendor shall submit the painting procedure for purchaser’s approval.
8.8 Bus and Busbar Connection
Panel busbar shall be adequately sized, electrolytic grade hard drawn aluminium
busbar with colour coding for easy identification of phase conductors and neutral.

9.0 CABLES AND WIRING

9.1 Heavy duty AYWY cables with FRLS, PVC inner sheath and outer sheath shall be
provided for the following connections:
a) Incoming feeders to all LDBs, receptacles, lighting panels and emergency DC
lighting panels.
b) Feeders connecting area lighting panels to outdoor lighting panels, etc. shall be
of 3 core x 2.5 sq.mm, 1100 V grade FRLS, PVC stranded cable of copper.
9.2 Wiring from lighting DBs/panels to individual fixtures, plug points, fans, etc. shall be
of single core, 2.5 sq.mm, 650 V grade PVC stranded copper conductors through
surface mounted or concealed medium duty GI conduits confirming to IS 1239 with
earth wire. The wires shall occupy 60% of the conduit area.
9.3 650 V / 440 V grade stranded copper conductor, PVC insulated, colour coded, wires
laid in GI conduits shall be used for lighting in non-hazardous area. In the hazardous
area, outdoor areas like transformer yard and road lighting, cable wiring shall be
adopted. The specification of cable shall conform to the details indicated in “Cabling
System” (D2.10) section.
9.4 Minimum size of wires in case of conduit wiring shall be 2.5 sq.mm. copper in case of
lighting and 4 sq.mm. copper in case of receptacle wiring.
9.5 Wires of different phases shall be run in separate conduits. However, wires of same
phase but having different circuit nos. can be run in same conduit. Wires of lighting
and power receptacles shall be carried out in separate conduits and on separate
circuits. Wires of AC and DC lighting system shall be carried out in separate
conduits.
9.6 For outdoor lighting, the cable shall be buried at a minimum depth of 750 mm from
ground level or run in cable trays. The buried cables shall have suitable bedding,
protective covers and markers.
9.7 Material used for saddles, clamps, JBs, etc. shall be galvanised.
9.8 Office buildings, laboratory buildings shall have concealed wiring with 2.5 sqmm

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ELECTRICAL LIGHTING SYSTEM

cable using PVC conduits. In heat zones, i.e. in the areas where ambient
temperature is 60oC and above, heat resistant control cables shall be used in hot dip
galvanised rigid steel surface mounted conduits.
10.0 LIGHTING CIRCUIT DESIGN
10.1 In an area, the lighting fixtures shall be arranged in different phase / LPs such that
even in case one lighting panel is faulty complete lighting is not affected. In case of
any location the lighting shall be arranged from two phases.
10.2 The circuit loading on each circuit shall be restricted to 80% of the MCB rating.
10.3 The voltage drop from LDB and any fixture shall not exceed 3%.
11.0 TESTS
Acceptance tests and routine tests for the lighting fixtures and accessories, LDBs
shall be carried out as per relevant standards.
Test to be carried out for LDB shall be as follows :

IR test before and after HT test.

HV test by HV megger.
Checking for functions of components for each module.
Checking for interchangeability of similar components.
Checking of tightness of earth connection.
Testing and calibration of all indicating meters.
Check output of each feeder after energisation.
12.0 DATA TO BE SUBMITTED WITH THE BID
Details as per Technical Particulars given below:

12.1 Indoor Lighting

12.1.1 Make of light fittings :
12.1.2 Make of main DB :
12.1.3 Make of sub-lighting DB :
12.1.4 Type of fitting for periphery lighting and :
control for same
12.1.5 Cable laying method :
12.1.6 Control operations :
12.1.7 Escape lighting :
12.1.8 Type of cable proposed :
12.1.9 Make of cables :

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ELECTRICAL LIGHTING SYSTEM

12.1.10 Type of fittings at various locations :

12.1.11 DC emergency lighting control board :
with necessary contactor
12.1.12 Type of incomer for main and sub-DBs :
12.1.13 Type of outgoing for main and sub-DBs :
12.1.14 Second source of supply considered :
for all the areas
12.1.15 a) Degree of protection for main and :
sub-DB enclosure
b) Mounting details for DBs :
12.1.16 Phase to phase and phase to earth :
clearances in main and sub-DBs
12.1.17 Busbar arrangement in Sub-DBs :
12.1.18 Make of ballast :
12.1.19 Make of switches :
12.1.20 Erection accessories such as junction :
boxes, clamps, saddles
12.1.21 Make of ceiling fans :
12.1.22 Make of exhaust fans :
12.1.23 Make of flame-proof fittings and :
catalogue numbers
12.1.24 Rating of exhaust fans :
12.1.25 Deviations, if any, on technical design :
data
12.2 OUTDOOR LIGHTING
12.2.1 Type of fittings envisaged :
12.2.2 Make of fittings :
12.2.3 Lux level to be obtained :
12.2.4 Provision of escape lighting :
12.2.5 Location of main and sub-DBs
12.2.6 Control of lighting :
12.2.7 Automatic :
12.2.8 Cable laying above ground :
12.2.9 Deviations, if any, on technical :
specification

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ELECTRICAL LIGHTING SYSTEM

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COAL HANDLING TITLE MAITHON POWER LIMITED

SHEET : 1 OF 1
SYSTEM 1050 MW MAITHON RIGHT BANK TPP
ELECTRICAL NEUTRAL EARTHING EQUIPMENT

1.0 Methods of Earthing

1.1 415V system shall be a solidly earthed system. The neutral of the
service transformers shall be independently connected to the earth.

1.2 240V systems for lighting and the space heating shall be a solidly earthed
system. The neutral of the transformers shall be connected to the earth
bus through a link in the respective board, which is in turn connected to
the Plant earth grid.

1.3 110V AC control supply shall be a solidly earthed system. The earth side
of the transformers shall be connected solidly through a link to the earth
bus in the respective modules of switchgear / control panels.

2.0 Specific Requirements

2.1 Cable boxes shall be provided for receiving the cables from the
transformers.

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ELECTRICAL SPARES, MAINTENANCE TOOLS & TACKLES

1.0 MAINTENANCE TOOLS AND TACKLES

1.1 The CONTRACTOR shall include all necessary maintenance tools in addition to
the minimum requirement given below. For some of the equipment/systems,
requirement of maintenance tools and tackles has been specified in Data
Sheets. CONTRACTOR shall necessarily supply these tools in addition to other
tools and tackles as required. Total price of all the maintenance tools and tackles
shall be included in the quoted lump sum price.

1.2 The CONTRACTOR shall note that if any other tools are found to be necessary
during the engineering and erection stage of the contract, the same shall be
supplied by the CONTRACTOR without any price implication.

1.3 In addition to above following minimum tools shall be provided

a) Breaker handling trolleys for all type of breakers - one Number.

b) Panel keys - 10 nos, each type.

c) Breaker rack in/out, spring charging handle – 3 nos.. each type.

d) Earthing rods/trucks (as per IS) – 2 sets.

e) Digital, 3 phase watt meter, with programmable CT/PT ratio and range up to
2000kW class 0.5(subject to Owner approval) – 1 nos..

f) Megger with selection of voltage from 200V to 5000V, battery operated (subject
to Owner approval) – 1 nos..

g) Programmable power system analyser (subject to approval of Owner) – 1 set.

h) Battery cell lifting and shifting tools – 1 set.

2.0 SPARES
2.1 START UP AND COMMISSIONING SPARES

The offer shall include the start up and commissioning spares as required till
handing over of the plant.

2.2 ESSENTIAL SPARES

The offer shall include essential spares required for the period of one year. The
items and quantity shall include all but not limited to the following. The quantity
indicated is for each type, size and rating and shall be 10% of the total quantity
being supplied.

3.1 6.6 kV & 415V Motors (quantities shall be applicable separately for each
rating, type and size)
Bearing temperature indicators

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ELECTRICAL SPARES, MAINTENANCE TOOLS & TACKLES

Bearing temperature detectors

Space heaters
Terminal bushing assembly
Cooling fan
Bearing housing

3.2 Relay Panels

Protective relays
Trip relays
Auxiliary relays
Timers
Set of 3 interposing CTs of each ratio
Set of 3 interposing PTs of each ratio
Power supply module for each type
Test terminal Blocks
Control & selector switches
Neutral links
Stabilising resistors and varistors .

3.3 Non-Segregated Phase Bus ducts

Bus support insulator
Seal-off bushing
Flexible connector (for equipment connection)
Gasket & Bellows

3.4 6600V Switchgear

Breaker complete with operating mechanism and truck mounted
Breaker Aux. Switches
Isolator/ Disconnector
Closing & tripping coils
Spring charging motors
Gaskets
Bus bar support insulators
Aux. switch assembly, limit
position switches, Local/Remote
selector switch, breaker control switches & other switches
Operating mechanism rods
Limit position switches
Local/remote selector switch (for equipment connection)
Breaker control switches
Relays
CTs of each ratio & type
VTs.of each ratio & type
HV Fuses
Castle Keys
3 pole vacuum contactor trolley complete with accessories
Closing & tripping coil set
Surge suppressor units
Power contactors
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ELECTRICAL SPARES, MAINTENANCE TOOLS & TACKLES

Panel space heaters

AC/DC switches
CT/VT Fuse blocks
Pressure Gauge & Switches.

3.5 415V Switchgear

Breaker complete with operating mechanism and truck mounted
Closing & tripping coils
Fixed and moving contact assemblies of each breaker
Spring charging motors
Set of gasket
Bus bar support insulators
Aux switch assembly, limit position switches, Local/ Remote selector switch,
breaker control switches & other switches
Relays
CTs. of each ratio & type
VTs. of each ratio & type
Meters. of each type & rating.
Fuses of each rating
Sliding Control connectors(Male & Female) 10% OR min 5 nos whichever is
higher
Horizontal and vertical drop out buses.
Control Transformers
Power transformer (Space heating etc.)
Sliding Power contacts

3.6 DC System
Battery
a) Battery Cell
b) Insulators
c) Connectors with Nuts & Bolts
d) Vent Plugs
e) PVC Spill Trays
f) Cell container empty .

3.7 Battery Chargers

a) Silicon Diodes/Thyristors
b) Power / Control/selector Switch
c) All type of card
e) Fuse of each type
f) Cooling Fans
g) Annunciation Window
h) Control Transformer
i) LC filter

3.8 Lighting Fixtures

Lighting fixtures along with bulbs

Lighting Panels
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ELECTRICAL SPARES, MAINTENANCE TOOLS & TACKLES

MCBs/MCCBs/SFUs of each type and rating

ELCB
Timers/Photo Cells

3.9 LT Motors (AC/DC)

Bearings
Cooling fan
Motor Terminal Plate
Complete motor for following
Coal Conveyors

3.10 Control Panels

(For Miscellaneous systems like Air conditioning, fire protection, evaporative air
cooling etc.)
Aux. relays, contactors
Push Buttons
Control/ selector switches

3.11 Electrically Operated Actuators

(a) Complete set of gaskets/ rings/oil seals

(b) Limit & Torque Switches
(c) Limit switch counter gear assembly
(d) Out put drive bush
(e) Motors
(f) Torque Switch Drive Assembly
(g) Clutch fork assembly
(h) Limit switch drive assembly

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SYSTEM 1050 MW MAITHON RIGHT BANK TPP
ELECTRICAL DATA TO BE FURNISHED WITH BID

DATA TO BE FURNISHED WITH THE BID

1. All the Data Sheets and Schedules duly filled up with soft copies of the same.

2. Proposed Coal Handling System switchgear building, Control Building and

any other building plan & sections.

3. Proposed Transformer locations, plan and sections.

4. Auxiliary System Single Line Diagram for Coal Handling System.

5. Protection and metering single line diagram.

6. Description literature / catalogues and write-ups for the offered

equipment/systems.

7. Technical requirements and data of Electrical works, Mechanical works, I&C

works and Civil works as called for in the specification.

8. Block diagram showing all the equipment/components and terminal points for
battery limit.

9. Project execution network schedule

10. Type test certificates/reports for the major equipment covered in the
specification.

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DOCUMENTS TO BE SUBMITTED AFTER AWARD OF
ELECTRICAL
CONTRACT

1.1 Concept note covering the equipment main parameters, design and A
operation philosophies, test certificate, sizing criteria, selection criteria,
sizing calculations, schemes proposed, operation, indication and alarm
philosophies for Service transformer of Coal Handling system, 6.6 kV
switchgear, 415V main switchboard, motor control centres, DC
system, cabling system (cable carriers, layout, installation), earthing
and lightning protection system, lighting system, electrical equipment
layouts, sizing calculations for all transformers, system studies for
largest motor starting etc. for all equipment covered under this
specification
1.2 A
Calculations for all CT and PT Parameters. Sizing calculations, fault
withstand capability for all equipment covered under this specification.

1.3 Fault calculation and voltage dip calculation. Fault calculation and A
voltage dip calculation shall be done considering all ties and for entire
station. Fault withstand capability (dynamic and thermal) calculations
for all power equipments like transformer, NSPBD, switchgear etc.

1.4 Main one line diagram, 6.6 kV system and 415V single line diagrams, A
indicating parameters of all electrical equipment, CTs, PTs, location of
meters, relays, etc.
1.5 Technical data sheet for all electrical equipment A

1.6 Block interlock diagrams showing the interlocks, control and indication A
at all the points for 6.6 kV switchgear, 415V switchgear incomers and
bus coupler, MCC incomers and bus coupler.
1.7 415V, 220 V DC system single line diagram. A

1.8 6.6 kV, 415V and DC module scheme drawings for various types / A
ratings of drives.
1.9 Standard / typical installation sketches for cabling, earthing, lightning A
protection and lighting
1.10 Cable layout (trench, tray layout), earthing layout, lighting layout, A
lightning protection layout for station building, outlying areas. The
exact list of areas will be finalised later.
1.11 (a) Control wiring diagram I

(b) Control wiring : Showing the complete details of the I

diagrams for switchgear module, external cable
each drive / connection to motors, devices, control
auxiliary panels, system cabinets, etc.,
interconnection between panels related to
the respective drives, cable nos., cable
core nos.
1.12 Transformer yard and electrical equipment layout drawings and layout I
of equipment as specified.
1.13 Relay settings along with calculation for entire Coal Handling system I
including relay and co-ordination calculations and curves.
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DOCUMENTS TO BE SUBMITTED AFTER AWARD OF
ELECTRICAL
CONTRACT

1.14 Cable interconnection schedules & diagrams for all the cables showing I
the cable no., core no., cable size, and terminal nos., on either side.
1.15 Cable schedule showing the cable number, size and type, emanating I
and terminating points, cable lengths, routing, etc., to facilitate cable
layout work and as a reference to monitor the work and later as a
maintenance reference
1.16 Contractor shall furnish the following drawings / data / information :

1.16.1 Switchgear (6.6 kV Switchboards, MCC and DCDB)

(a) Switchgear cubicles: Outline dimensions and general I

arrangement, including plan, front elevation, rear elevation, side
elevation and relevant cross-sectional views.
(b) Schematic control circuit diagrams A

© Detailed wiring diagrams including terminal block numbers, I

ferrule numbers and cable connections.
(d) Development diagrams of switches I

1.16.2 Motors (AC and DC)

(a) Dimensioned outline and general arrangement drawing of motor I

(b) Internal view of terminal boxes showing connection of motor i.e., I

star / delta terminal markings, clearance between phases,
disconnecting facilities and direction of cable entry and cable
glands.
© Motor characteristics curves I

1.16.3 Motor Operated Valve Actuators

(a) Drawing indicating overall dimensions and mounting details of I

valve actuator on the valve
(b) Detailed internal wiring diagram of the actuator I

1.16.4 Electrical Control and Relay Panels

(a) Outline dimensions including plan, front elevation including the I

mimic, rear elevation, side elevation and door opening sizes.
(b) Drawings showing foundation details, floor openings for cabling I
and weight of each panel
© Schematic control circuit and block logic diagrams. The latter A
shall indicate the location of all devices relays, sensors,
transducers, instruments and their interaction to serve as a basis
for developing elementary diagrams
(d) Layouts and cross section views of front / rear panels and desks I
complete with identification markings for all mounted devices and
complete material list giving ratings, make and type.
(e) Switch development diagrams I

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DOCUMENTS TO BE SUBMITTED AFTER AWARD OF
ELECTRICAL
CONTRACT

(f) One line diagrams of power circuits and control circuits I

arrangement and distribution.

(g) Detailed wiring drawings including identification of devices, I

terminal block numbers, ferrule numbers and cable connections.
(h) Inter panel interconnection diagrams indicating terminals and I
external connections between panel to panel and panel to field
devices. The interconnection diagrams shall indicate maximum
permissible external connection resistance to permit correct
operation of equipment at minimum voltage when such
resistance is less than 4.3 ohms (300 m, 1.5 sq. mm copper
control cable). If special cables are required for external
connections (co-axial, twisted pairs, shielded) they shall be used
and identified.

1.16.5 Batteries (220 V DC)

(a) Layout drawing indicating supporting arrangement for battery A

bank.
(b) Drawing showing constructional details of cell. I
© Battery characteristics / curves I

1.16.6 Battery Charger (220 V)

(a) Detailed schematic diagram of charger scheme including voltage A

/ current regulator electronic controller, under voltage / over
voltage / overload / earth fault relays, annunciation scheme, etc.
(b) General arrangement drawing showing main dimensions, type of A
mounting, location of various devices, etc.

1.16.7 Control Cabinets (For all services)

(a) Schematic diagram indicating terminal numbers for external I

connections and with a Bill of Material for all the equipment
(b) Control cabinet drawing showing outline dimensions, cable entry I
openings, floor / wall / pedestal fixing arrangement, padlocking
arrangement, weights

1.16.8 Lighting System

(a) Distribution boards and panels general arrangement I

dimensioned drawings showing front, side and plan views,
outline dimensions, floor openings, floor / wall / structure fixing
arrangements, earthing terminals and weights.
(b) Schematic wiring diagram of the distribution boards / panels, I
showing the terminal numbers.
© Inside view of distribution boards / panels showing mounting and I
wiring arrangement of various component equipment.
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DOCUMENTS TO BE SUBMITTED AFTER AWARD OF
ELECTRICAL
CONTRACT

1.16.9 Fire Proof Sealing for Cable Carrier Systems

(a) Detailed drawings including the constructional features, outline I

dimensions, general arrangement and cross-sectional views of
the Fire Proof Sealing System to be provided in the areas
specified in specification for each type of fire stop and fire break
supplied.
(b) Type test certificates as per this specification for all types of fire I
stop / fire breaks included in the order.
© Layout drawing indicating the location of FPS Systems proposed I

1.16.10 Neutral Grounding Cubicle

(a) General outline drawing with dimensions and weights I

(b) Detailed outline drawing showing plan, front elevation, end I

elevation, inner view, locating dimensions of cable entries,
terminal details, structure / floor fixing details and weights of the
cubicles
© Schematic diagrams with all the parameters for the cubicles I
1.16.11 Transformers
(a) General arrangements, bushing, wiring diagram, valve schedule, A
foundation details, rail gauge etc. drawing
(b) Short circuit with stand capability calculations A
1.16.12 Cables
(a) Constructional details A
1.16.13 UPS
(a) Constructional details I
(b) Sizing Calculations A
(c) Layout Arrangement I
(d) UPS Schematics A

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ELECTRICAL CODES AND STANDARDS

ANSI /
SL. NO APPLICABLE STANDARDS IS BS IEC
IEEE

1 Bus Ducts 8084 159

2 Bushing for > 1000V, AC 2099 223 60137

3 Bushing for < 1000V, AC 7421

4 Neutral earthing transformer 3151 171 / 60076

BSEN
60076

5 Electrical insulation classified by 1271 2757 60085

thermal stability

6 a) Bus bars (Aluminium) 5082 / 159 60105

2678

b) Bus bar (Copper) 282 125 /

1977

7 Bus bar support insulators 2544 3297 60273

8 Current transformers 2705 3938 60185

9 Potential transformers 3156 3491 60186

10 AC Electricity meters 722 2692

5685

11 Electrical indicating instruments 1248 89 60051

12 Electrical relays for power system 3231 142 60255

protection

13 High voltage fuses 9385

14 HRC Fuses 9224

15 Environmental requirements of 6553

semiconductor devices and
integrated circuits
16 Degree of protection for LV 2147 60144 /
Switchgear 60947

17 HRC cartridge fuse 13703 88

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CONSULTANTS: TCE CONSULTING ENGINEERS LIMITED TCE FORM 329 R3

 TCE 4891A-H-500-004 TCE CONSULTING ENGINEERS LIMITED SECTION: D2.16

COAL HANDLING TITLE MAITHON POWER LIMITED SHEET : 2 OF 6

SYSTEM 1050 MW MAITHON RIGHT BANK TPP
ELECTRICAL CODES AND STANDARDS

ANSI /
SL. NO APPLICABLE STANDARDS IS BS IEC
IEEE
18 Control switches / push buttons 6875

19 Starters 13947 EN- 60292

60947-4

20 Interconnecting bus bars for AC 8084

voltage above 1 kV upto and
including 36 kV

21 Specification for metal clad base 5921

materials for printed circuits for use in
electronic and telecommunication
equipment

22 Transformer and inductors (Power, 6297

audio pulse & switching) for
electronic equipment.

23 Thyristor Converters 6619

24 Semiconductor converters 60146

25 Semiconductor rectifier cells and 3895 / 4417 60146

stacks 4540

26 Electrical installation and wiring 732

installation

27 Environmental testing procedure for 9000

electronic and electrical items

28 Power Transformers 2026 171 60075

29 Pulse Transformer 60146

30 Wiring Rectifiers 2274

31 Safety code for semiconductors 6619
rectifier equipment

32 Printed wiring boards 7405

33 Single and double sided PCB with 61000 –

plain holes – Electromagnetic 1995
compatibility

34 Semiconductor rectifier assemblies 4417 60148

and thyristor converters
ISSUE
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 TCE 4891A-H-500-004 TCE CONSULTING ENGINEERS LIMITED SECTION: D2.16

COAL HANDLING TITLE MAITHON POWER LIMITED SHEET : 3 OF 6

SYSTEM 1050 MW MAITHON RIGHT BANK TPP
ELECTRICAL CODES AND STANDARDS

ANSI /
SL. NO APPLICABLE STANDARDS IS BS IEC
IEEE
35 Factory built assemblies of 8623 60947 60439
switchgear and control gear for
voltages upto and including 1000V
AC and 1200V DC

36 Indicating Instruments 1248

37 Three phase induction motors 325 4999 60034-1

38 Specifications for rotating electrical 4722 60034-1

machines – rating & performance

39 Specification for turbine type 5422 60034-3

generators

40 Methods of determination of 4889 60034-2

efficiency for rotating electrical
machines

41 Methods for determining 7306 60034-4

synchronous machine quantities from
tests

42 Single phase small AC and universal 996

electric motors

43 Three phase induction motors with 9628

type of protection ‘n’

44 Construction and testing of electrical 6381

apparatus with type of protection ‘e’

45 Designations for types of 2253 60034-7

construction and mounting
arrangement of rotating electrical
machines

46 Terminal marking and direction of 4728 4999 60034-8

rotation for rotating electrical
machinery

47 Designation of methods of cooling for 6362 4999 60034-6

rotation electrical machines

ISSUE
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CONSULTANTS: TCE CONSULTING ENGINEERS LIMITED TCE FORM 329 R3

 TCE 4891A-H-500-004 TCE CONSULTING ENGINEERS LIMITED SECTION: D2.16

COAL HANDLING TITLE MAITHON POWER LIMITED SHEET : 4 OF 6

SYSTEM 1050 MW MAITHON RIGHT BANK TPP
ELECTRICAL CODES AND STANDARDS

ANSI /
SL. NO APPLICABLE STANDARDS IS BS IEC
IEEE

48 Measurement and evaluation of 4999-142 60034-9

vibration of rotating electrical
machines

49 Degrees of protection provided by 4691 4999 60034-5

enclosure for rotating electrical
machinery
50 Guide for testing three phase 4029 60034-34
induction motors
51 Measurement and evaluation of 12075 4999 60034-14
Mechanical vibration of rotating
electrical machines

52 Classification of hazardous areas 5572 60079

53 Dimensions of slide rails for electric 2968 4999

motors

54 Permissible limits of noise level for 12065 60034

rotating electrical machines

55 Guide for testing insulation 7816

resistance of rotating machines

56 Procedure for measurement of loss 13508

of tangent angle for coils & bars

57 Impulse voltage withstand test 60034-15

58 Temperature rise measurement of 12802

rotating electrical machines

59 Type of duty and classes of rating 12824

assigned to rotating electrical
machines

60 Compression type tubular terminal 8309 4683

ends for aluminium conductors of
insulated cables

61 Code of practice for safety earthing 3043 1013

62 Lightning arrester 3070 BSEN- 60099

60099

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 TCE 4891A-H-500-004 TCE CONSULTING ENGINEERS LIMITED SECTION: D2.16

COAL HANDLING TITLE MAITHON POWER LIMITED SHEET : 5 OF 6

SYSTEM 1050 MW MAITHON RIGHT BANK TPP
ELECTRICAL CODES AND STANDARDS

ANSI /
SL. NO APPLICABLE STANDARDS IS BS IEC
IEEE
63 Code of practice for Installation and 900
maintenance of induction motors

64 Protection of buildings and allied 2309 6651

structures against lightning

65 Emergency Standard Power Systems IEEE 446

66 Stationary cells and batteries

67 Lead acid type

- With Plante positive plate 1652 6290-2 60896

68 Quality tolerances for water for 1069 4974

storage battery

69 Sulphuric acid 266 3031

70 Rubber and plastic containers for 1146

lead acid storage battery

71 Sealing compound for lead acid 3116

batteries

72 Synthetic separators for lead acid 6071

batteries

73 General requirements and methods 8320

of test for lead acid storage batteries

74 Recommended practice for sizing IEEE 485

large lead acid storage batteries for
generating stations and sub-stations

75 Containers and Vent Plugs UL 924

76 Battery enclosures UL 1778

77 Climate proofing CP:1014

78 Code and practice for installation, 14665

operation and maintenance of
Electric passenger and goods lifts

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 TCE 4891A-H-500-004 TCE CONSULTING ENGINEERS LIMITED SECTION: D2.16

COAL HANDLING TITLE MAITHON POWER LIMITED SHEET : 6 OF 6

SYSTEM 1050 MW MAITHON RIGHT BANK TPP
ELECTRICAL CODES AND STANDARDS

ANSI /
SL. NO APPLICABLE STANDARDS IS BS IEC
IEEE
79 Harmonic limits in power systems IEEE-519

Indian Electricity Act

80 Indian Electricity Act 1910

81 Electricity Supply Act, 1948

82 Indian Electricity Rules,

83 Indian Electricity Act 2003

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CONSULTANTS: TCE CONSULTING ENGINEERS LIMITED TCE FORM 329 R3

TCE 4891A-H-500-004
TCE CONSULTING ENGINEERS LIMITED SECTION :

COAL HANDLING MAITHON POWER LIMITED

SYSTEM 1050 MW MAITHON RIGHT BANK TPP SHEET 1 of 3
ELECTRICAL
SUB VENDOR LIST FOR BIDDERS

SUB VENDOR LIST FOR BIDDERS

"List of makes / vendors for various equipment / materials / systems furnished herein
is applicable to both Indian and Foreign Bidders. However in the case of Foreign
Bidders if they are unable to comply with the makes listed herein, they may suggest
alternative foreign makes / vendors along with the Technical Bid. Acceptability of
such alternative makes / vendors which will be reviewed by Owner, and coveyed to
bidders prior to opening of Price bids".

S.No. Equipment Vendor

1. Bus duct including CTs & • Control & Switchgear Co. Ltd., New
PTs as applicable
Delhi
• Bharat Heavy Electricals Limited,
Bhopal
• Powergear Ltd., Bangalore
2. Power and Distribution • Asea Brown Boveri Ltd.,
Transformers
• Areva T & D India Ltd
• CGL
• Voltamp
3. 6.6 kV Switchgear • Asea Brown Boveri Ltd., Mumbai
• Areva T & D India Ltd., Kolkata
• Siemens Limited, Mumbai
• Bharat Heavy Electricals Limited,
Bhopal
4. 415 V Switchgear & 220 V • Larsen & Toubro Limited, Mumbai
DC Switchgear
• Siemens Limited, Mumbai
• Schneider Electric India Pvt.
Limited, New Delhi
• Asea Brown Boveri Ltd., Bangalore
• GE Power Controls, Bangalore
5. HVAC • ABB
• Voltas
• Blue Star
• Carrier Aircon
ISSUE
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TCE 4891A-H-500-004
TCE CONSULTING ENGINEERS LIMITED SECTION :

COAL HANDLING MAITHON POWER LIMITED

SYSTEM 1050 MW MAITHON RIGHT BANK TPP SHEET 2 of 3
ELECTRICAL
SUB VENDOR LIST FOR BIDDERS

6. MV and LV Motors and • ABB

Drive Systems
• CGL
• L&T
7. Other Electrical
Equipment/Systems
including CH Plant
Equipment Erection
6a) DC System • Caldyne Automatics Limited,
Kolkata
• Chhabi Electricals Pvt. Limited,
Mumbai
• Emerson Network Power (India)
Pvt. Limited
• Masstech Controls Pvt. Limited,
Mumbai
6b) Batteries • Exide Batteries, Kolkata
• Hoppecke Batteries GmbH & Co.,
Germany
• Amara Raja Batteries
6c) UPS System • Hi-Rel Electronics Pvt. Limited,
Mumbai
• Emerson Network Power (India)
Pvt. Limited
• Siemens Limited, New Delhi
• Gutor Electronics Limited, New
Delhi
6d) Lighting System for CHS • Philips Lighting
Package
• Bajaj Electricals
• Crompton Greaves Limited
• GE Lighting
• Wipro Lighting
6e) Power cables- 6.6kV • Universal Cables Ltd.
• Nicco Corporation Ltd.
• Polycab Wires Pvt.Ltd.
• RPG Cables Ltd.
ISSUE
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TCE 4891A-H-500-004
TCE CONSULTING ENGINEERS LIMITED SECTION :

COAL HANDLING MAITHON POWER LIMITED

SYSTEM 1050 MW MAITHON RIGHT BANK TPP SHEET 3 of 3
ELECTRICAL
SUB VENDOR LIST FOR BIDDERS

6f) 1.1 kV Power cables • RPG Cables Limited

• Universal Cables Limited
• Finolex
• Nicco Corporation Limited
• Industrial cables
• Polycab
• Ravin Cables
• Gemscab Industries
6g) Control cables • RPG Cables Limited
• Universal Cables Limited
• Finolex
• Torrent
• Nicco Corporation Limited
• Ravin Cables
• Reliance Engineers, Bangalore
• Gemscab Industries
6h) Instrumentation Cables • Reliance Engineers, Bangalore
• Associated Cables
• Uday Pyrocables
• Cosmotec Communication Products
Pvt. Ltd. (for Belden make)
• Lapp
• Cords Cables Industries Ltd.

ISSUE
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TCE 4891A-H-500-004 TCE CONSULTING ENGINEERS LIMITED SECTION: D3.0
TITLE MAITHON POWER LIMITED
COAL HANDLING SHEET 1 OF 15
SYSTEM
1050 MW MAITHON RIGHT BANK TPP
INSTRUMENTATION & CONTROL SYSTEM

9.0 INSTRUMENTATION & CONTROL SYSTEM

The Instrumentation & Control System shall cater to the requirements of coal
handling system (CHS) consisting of the following major components:-

a) Coal Unloading System

b) Coal transport /storage/reclaim System
c) Dust Control System
d) Electrical controls related to CHS

9.1 Coal Unloading System (Track Hopper Complex)

9.1.1 Coal unloading operation of track hopper shall be operated/ managed from
"Track Hopper Control Room" located adjacent to the Track Hopper.

9.1.2 Track Hopper control room having MMI of the PLC , mimic panel, etc shall be
air conditioned with false ceiling and glass panels all around and duly
sound proofed. Control room wall facing the track shall be provided with
glass panels to have full view of the coal unloading operation.
.
9.1.3 A central Weigh bridge terminal complete with its computer, printer etc shall
be located in the weigh bridge control room. This weighbridge terminal shall
be suitably connected to individual weighbridge terminals located at entry to
the plant. The weigh bridge control room shall be air conditioned.

9.1.5 One number of ‘In motion weigh bridge for measurement of gross weight
and tare weight shall be provided. Each weighbridge shall have its computer
with built-in diagnostics and suitable weight management software. The
system shall be provided with explosion protection and lightning protection
system. All cabling shall be armoured with braided stainless steel to protect
against corrosion and rodents. The railway track shall be straight and leveled
up to at least 50 meters at upstream and downstream of each weighbridge.
The weighbridge shall be designed to operate in dusty environment.

9.2 Coal Handling System (Storage / Transport/ Reclaimer)

9.2.1 Belt weighing system, Metal detector and In-line magnetic separator shall be
provided on belt conveyors. Inline Magnetic Separator shall be provided on
conveyors as indicated in the flow diagram.

9.2.2 Stacker- re-claimer shall have its independent microprocessor based control
system with MMI located in the operator’s cabin with suitable interface with
the main CHS PLC.

9.3 DUST EXTRACTION SYSTEM (DES) & DUST SUPPRESSION SYSTEM

(DSS)

9.3.1 The control & monitoring requirements of DES & DSS shall be implemented in

REV. NO. PPD BY: JOB NO. OWNER: Maithon Power Ltd TPP 2 x 525MW
DATE CKD BY: KJP 4891A
REV. BY DATE: AUG PROJECT: 2 x 525MW TPP
07
TCE 4891A-H-500-004 TCE CONSULTING ENGINEERS LIMITED SECTION: D3.0
TITLE MAITHON POWER LIMITED
COAL HANDLING SHEET 2 OF 15
SYSTEM
1050 MW MAITHON RIGHT BANK TPP
INSTRUMENTATION & CONTROL SYSTEM

main PLC of CHS. Necessary local control / starting panel shall be provided.
Indication of DES operation shall be provided in the HMI in the central CHP
control room.

9.4 Belt conveyer protection

9.4.1 Pull-Cord Switches - Pull Cord (manual reset type) emergency stop
switches shall be located along both the sides of entire length of all
conveyors. Adequate length of PVC coated wire rope with all
accessories shall be furnished. From either end of conveyor, pull cord
switches should not be more than 15M. A special canopy made of 5mm M.S.
plate shall be provided over the lever of each pull cord switch so that spilled
over coal lumps do not trip the belt by actuating the lever. Also a local trip
indication (Cluster of LEDs) shall be provided for each pull cord switch. Pull
chord switch shall have C.I. body with enclosure protection class IP-65.

9.4.2 Belt-Sway Switches - Belt Sway limit switches (auto reset type) shall be
furnished in pairs at head and tail part of each conveyor to limit belt sway to
permissible extent. However, each conveyor shall be provided with minimum
two pairs of switches. These switches shall be placed not more than 15 M
from either end of conveyor.

9.4.3 Zero speed switches - Each conveyor shall be provided with a zero speed
switch (auto reset type) at the tail end for sequential operation of the system.
In case of belt speed falling below the tolerable limit, the switch shall stop the
conveyor. The speed setting should be adjustable. Necessary provision
shall be provided in the control system to by-pass the switch during starting.

9.4.4 All the above switches shall be provided with enclosure protection to minimum
IP-65. Canopy shall be provided for pull cord and belt sway switches.
9.5 Control & instrumentation- specific requirements

9.5.1 The Control and Instrumentation shall be through microprocessor based

Programmable Logic Controller (PLC) System covering the total functional
requirements of measurement, sequence control, interlock & protection,
monitoring, alarm, data logging, fault analysis etc. The system will also
consists of Microprocessor based PLC ,Control desk cum panel, local control
panel ,Local Instruments, I &C Cables & erection Hardware.

9.5.2 The proposed PLC control system shall comprise of the following sub systems
/ features operating in a completely integrated manner:-

i) Processor: The processor shall be configured as hot redundant

and should not be loaded more than 60%.The processor shall be 32
bit with 8 MB RAM and shall be 100% redundant. The loop cycle
time shall be less than 500 msec for closed loops and 120 m sec
for open loops. The switchover from main controller to redundant
controller shall be bump-less; and shall be within one cycle time i.e.
REV. NO. PPD BY: JOB NO. OWNER: Maithon Power Ltd TPP 2 x 525MW
DATE CKD BY: KJP 4891A
REV. BY DATE: AUG PROJECT: 2 x 525MW TPP
07
TCE 4891A-H-500-004 TCE CONSULTING ENGINEERS LIMITED SECTION: D3.0
TITLE MAITHON POWER LIMITED
COAL HANDLING SHEET 3 OF 15
SYSTEM
1050 MW MAITHON RIGHT BANK TPP
INSTRUMENTATION & CONTROL SYSTEM

within 50 milliseconds.

ii) Input/Output Cards: The I/O cards for control & interlock shall be
non redundant. However, sensor redundancy shall be provide for
critical loops. The redundant sensors shall be wired to two different
I/O Cards. The I/O racks & I/O cards shall be Non Redundant.
AI/AO cards shall be 16 channel & DI/DO cards shall be 32 channel
type

iii) The scan time for digital inputs shall not be more than 60msec and
loop execution time not more than 120 m sec.

iv) Communication: The communication shall be redundant between

control processors and HMI as well as across control processors
and also between control processors and I/O if field bus is used.

v) Power Supply: Power supply shall be redundant and shall be

derived from a redundant UPS ( included in the scope) with battery
back up time of 60 minutes.

vi) Interface with station DCS: Redundant serial interface shall be

provided between PLC of CHS and Station DCS of each unit.
The hardware and software ( including engineering) for
configuring and dumping on demand approximately 60 Analog
points and 200 digital points on to station DCS in Central control
room shall be provided. Also Bidder shall supply test software to
check the implementation of the serial link duly configured
during the FAT of purchaser’s DCS.

vii) Human Machine Interface (HMI): The HMI (Operator station)

shall have TFT monitors with keyboard and mouse. Two nos. of
operator cum engineering work stations having minimum 21”
high resolution monitors (1280 x 1024 dots min.); min. 80 GB
hard disk, DVD R/W drive, mouse and keyboard shall be offered
. One (1) No. colour graphic printer, connected to both OS/ES
shall be offered. Both operating software & engineering software
shall be loaded in each of these stations with a selection facility.
The display update time for the monitor shall be 1 to 2 sec. Graphic
Trends call up time shall be better than 4 sec.
The HMI shall have a mimic diagram displaying the status of each
component of the PLC System up to card level and shall indicate
failures.

viii) All process mimics, alarms, control graphics, trends, plots, logs
etc as required for the process and operation.

The system shall be provided with the following as required.

REV. NO. PPD BY: JOB NO. OWNER: Maithon Power Ltd TPP 2 x 525MW
DATE CKD BY: KJP 4891A
REV. BY DATE: AUG PROJECT: 2 x 525MW TPP
07
TCE 4891A-H-500-004 TCE CONSULTING ENGINEERS LIMITED SECTION: D3.0
TITLE MAITHON POWER LIMITED
COAL HANDLING SHEET 4 OF 15
SYSTEM
1050 MW MAITHON RIGHT BANK TPP
INSTRUMENTATION & CONTROL SYSTEM

System Cabinets / Interposing relay cabinet

Input/Output Cards
Signal conditioning cards
Power supply cards (Redundant)
Processor cards (redundant)
Any other associated hardware to make the system
complete.
Each Processor shall not be loaded more than 60% of its
capacity.
Each I/O card shall be provided with 10% of channel
capacity as spare.
Adequate spare terminals shall be provided.

ix) One(1) dot-matrix printer shall also be provided.

x) Mimics of the entire Coal handling system shall be available on

Operator station monitor. In addition, the mimic shall include the
power supply arrangement for the complete Coal handling system.

xi) Operator station and peripherals shall be capable of handling

minimum 75 displays, 30 real time trends, 50 historical trends,
20 standard, 20 free formatted logs and 100 current and 300
logged alarms. Historical storage back up should be at least one
month or better for complete data base. Compact disc drive for
permanent storage & retrieval shall be offered.

xii) The hardware of the PLC system shall support the following
design features

i) Optical isolation for all digital inputs & outputs

ii) Galvanic isolation/optical isolation for all analog inputs
& outputs.
iii) Power supply to sensor transmitter at +24V DC from
the PLC
iv) In rush current limiter to driving circuit
v) All circuits shall be short and voltage surge proof.
vi) Modular type of cards.
vii) PCB shall be epoxy fibre class, plug in type with gold
plated contacts
viii) All cards shall be tropicalised
xii) The processors and the input/output system racks shall be
connected by redundant communication cables physically laid
separately in separate conduits and supply of these cables shall
also be included in Bidder’s offer. The distance between the
central control room and Coal handling system control room
shall be about 500 m. The Bidder shall furnish the unit price for
10 meters of the communication cable for additions/deletions.

REV. NO. PPD BY: JOB NO. OWNER: Maithon Power Ltd TPP 2 x 525MW
DATE CKD BY: KJP 4891A
REV. BY DATE: AUG PROJECT: 2 x 525MW TPP
07
TCE 4891A-H-500-004 TCE CONSULTING ENGINEERS LIMITED SECTION: D3.0
TITLE MAITHON POWER LIMITED
COAL HANDLING SHEET 5 OF 15
SYSTEM
1050 MW MAITHON RIGHT BANK TPP
INSTRUMENTATION & CONTROL SYSTEM

9.5.3 The PLC system availability shall be 99.7% or better and the same shall be
demonstrated based on a procedure to be submitted by the bidder during
detailed engineering stage.

9.5.4 All systems and accessories furnished shall be from the latest proven
product range of a qualified manufacturer whose successful
performance has been established by a considerable record of
satisfactory operation in material handling plants of similar or bigger size.

9.6 The bidder shall be responsible for engineering, selection and connection
of all components and sub systems to form a fully complete system whose
performance is in accordance with functional, parametric and other
requirements of this specification. It is not the intent to specify all individual
system components since the bidder has full responsibility for engineering
and furnishing of a complete system meeting the control and monitoring
requirements of all equipment associated with the coal Handling System.

9.7 Further, bidder may note that in case at any stage during the contract,
it is considered necessary by the Purchaser that some additional (over
and above those indicated by the bidder in the proposal) devices /
instrumentation are required for safe and efficient operation of the Coal
Handling plant, the same shall be provided without any cost or schedule
implications.

9.8 Bidder's proposal shall be based on types and quantities of

instrumentation and control equipment as required basis. However, the bidder
shall furnish the plant equipment and services as per actual requirements to
be finalized during detailed engineering stage, in accordance with the
approved drawings / documents.

9.9 All the necessary field instruments like Pull cord switches, Belt Speed
Switches, Zero Speed Switches, RTDs, T/Cs, Ultrasonic Level Indicators,
Level Switches, Pressure Switches etc., and Instruments required for
auxiliary systems like Compressed Air System, Dust Suppression system
etc., shall be included in Bidder’s scope.

9.10 Panels/Cabinets/Desks/Relay panels shall be totally enclosed dust and

vermin proof with IP-42 protection as per IS: 2147. These shall be made of at
least 10 SWG ( 2mm) sheet steel, reinforced to provide rigid flat level
surfaces, resistant to vibration during transportation and installation. No
welds, revert hinges or bolt threads shall appear from outside.

9.11 The belt weigher shall have dual 4-20 mA output for connection to the
purchasers DCS system.

9.12 General guidelines for selection of field instrumentation is given in Table-1

below.

REV. NO. PPD BY: JOB NO. OWNER: Maithon Power Ltd TPP 2 x 525MW
DATE CKD BY: KJP 4891A
REV. BY DATE: AUG PROJECT: 2 x 525MW TPP
07
TCE 4891A-H-500-004 TCE CONSULTING ENGINEERS LIMITED SECTION: D3.0
TITLE MAITHON POWER LIMITED
COAL HANDLING SHEET 6 OF 15
SYSTEM
1050 MW MAITHON RIGHT BANK TPP
INSTRUMENTATION & CONTROL SYSTEM

The table below is for general guidance only and may not cover all the
instruments. Vendor shall submit data sheets for all instruments for approval
by the Purchaser / Consultant during detailed engineering stage.

9.13 The data sheet for PLC system is as given in Table-2.

9.11 The Essential Spares shall be supplied as detailed below.

a. For all field Instruments ,a min of one (1) or 10% of the quantity of
each type or range ,Which ever is higher is provided

b) For all Modules of PLC ,a min of one (1) or 10% of the quantity
of each type Module ,Which ever is higher is provided

REV. NO. PPD BY: JOB NO. OWNER: Maithon Power Ltd TPP 2 x 525MW
DATE CKD BY: KJP 4891A
REV. BY DATE: AUG PROJECT: 2 x 525MW TPP
07
 DATE
REV. BY
REV. NO.
SL. INSTRUMNET TYPE ACCURACY ENCL. SPECIFIC APPLICATIONS
SYSTEM

NO REQUIREMENTS
TCE 4891A-H-500-004

COAL HANDLING

1. Pressure Direct + 1.0% IP65 6" dial, 316 SS Bourdon • Suction/Discharge of

TITLE

Indicator Tube, Micrometer Pumps/Fans

adjustable pointer Epoxy • Common Header of
coated, Die cast Pumps/Fans, etc.
aluminium casing • Inlets/outlets of Heat

DATE:
Exchangers

PPD BY:
CKD BY:
2. Pressure Non- + 1.0% IP65 Epoxy Coated Diecast • Suction pressure for

07
Switches Indicating / (+0.5% Aluminium Casing, 316 permissive and trip of

KJP
AUG
Indicating Repeatability SS Element, 2 SPDT pumps/Fans, etc.
Type ) contacts rated for 0.2A • Discharge pressure low
at 220V DC for auto start of Standby
TABLE-1

pump

4891A
JOB NO.
• Pre-trip alarm conditions

3. Pressure SMART + 0.02% IP65

MAITHON POWER LIMITED

Epoxy coated Diecast • Suction and Discharge of

Transmitters with LCD Aluminium / Fibre glass Main Process/Pumps
Indicator + casing 4-20mA DC • For all controlled
1050 MW MAITHON RIGHT BANK TPP
INSTRUMENTATION & CONTROL SYSTEM
TCE CONSULTING ENGINEERS LIMITED

HART output. Zero span and parameters

range adjustement

PROJECT: 2 x 525MW TPP

4. Differential Direct + 1.0% IP65 Epoxy coated casing, 6" • Across filters/strainers
Pressure dial, 316 SS diaphragm/
Indicator bellows; with 3-way
SECTION: D3.0

manifold
SHEET 7 OF 15

OWNER: Maithon Power Ltd TPP 2 x 525MW

 DATE
REV. BY
REV. NO.
SL. INSTRUMNET TYPE ACCURACY ENCL. SPECIFIC APPLICATIONS
SYSTEM

NO REQUIREMENTS
TCE 4891A-H-500-004

COAL HANDLING

5. Differential Non- +1.0% (+0.5% IP65 Epoxy Coated Diecast • Across filters/strainers
TITLE

Pressure indicating Repeatability) Aluminium Casing, 316 for high alarm and trip on
Switches SS Element, 2 SPDT very high value
contacts rated for 0.2A
at 220V DC

DATE:
PPD BY:
CKD BY:
6. Differential SMART +0.02% IP65 Epoxy coated Diecast • Flow measurements and
Pressure with LCD Aluminium / Fibre glass • Level measuement
Transmitters Indicator + casing 4-20mA DC • Differential pressure

07
KJP
HART

AUG
output. Zero span and measurement
range adjustement
7. Thermometers Direct +1% (Response IP65 Vapour filled system • Main process pump
(TI) time of 2-4 with 10 M, SS316 discharge

4891A
Seconds)

JOB NO.
armoured capillary, with • Wherever there is a
316SS Thermowell change of temperature in
(Barstock) the process
MAITHON POWER LIMITED

• Inlet/out of Heat Exchan-

gers,
1050 MW MAITHON RIGHT BANK TPP
INSTRUMENTATION & CONTROL SYSTEM
TCE CONSULTING ENGINEERS LIMITED

8. Temperature Non- +1% IP65 Vapour filled system • For bearing temperature
Switch (TS) indicating with 10 M, SS316 alarm and interlock/
armoured capillary, with protection
316SS Thermowell • Wherever temperature

PROJECT: 2 x 525MW TPP

(Barstock) abnormality to be alarmed
(non-critical applications)
• Wherever
equipment/system to be
tripped on high tempera-
SECTION: D3.0

SHEET 8 OF 15

ture

OWNER: Maithon Power Ltd TPP 2 x 525MW

 DATE
REV. BY
REV. NO.
SL. INSTRUMNET TYPE ACCURACY ENCL. SPECIFIC APPLICATIONS
SYSTEM

NO REQUIREMENTS
TCE 4891A-H-500-004

COAL HANDLING

9. Temperature SMART +0.05% IP-65 4-20mA DC output • All control

TITLE

Transmitters with LCD linearised, configurable applications

Indication +
HART

10. Resistance - Response time IP-65 Platinum, 3-wire, duplex • For all temperature

DATE:
PPD BY:
Temperature for bare RTD 15 with 316 SS measurement not

CKD BY:
Detector (RTD) Sec. and with Thermowell, ANSI, DIN, exceeding 150oC for
assembly T/W 30 Sec. IEC Standard. remote display.

07
Spring loaded for • For all control

KJP
AUG
bearing temperature applications and
measurement. monitoring points where
major temperature
11. Thermocouple Cr. Response time IP-65

4891A
Material selection as per • For all temperature

JOB NO.
(Tc/s) assembly Aluminium bare with T/W ISA, ANSI, Duplex with measurement not
K-Type of 5 to 6 sec. 316SS Thermowell exceeding 150oC for
packed with Mgo remote display.
MAITHON POWER LIMITED

insulation, and spring • For all control

loaded high speed of applications and
1050 MW MAITHON RIGHT BANK TPP
INSTRUMENTATION & CONTROL SYSTEM

response. monitoring points where

TCE CONSULTING ENGINEERS LIMITED

major temperature
changes occur
12. Thermowells - - - 316SS, design as per • For performance test
ANSI, DIN, Bar stock

PROJECT: 2 x 525MW TPP

• Across all Heat
Exchangers,
• For RTD, TC/S, TS,
TI,TW
SECTION: D3.0

SHEET 9 OF 15

OWNER: Maithon Power Ltd TPP 2 x 525MW

 DATE
REV. BY
REV. NO.
SL. INSTRUMNET TYPE ACCURACY ENCL. SPECIFIC APPLICATIONS
SYSTEM

NO REQUIREMENTS
TCE 4891A-H-500-004

COAL HANDLING

13. Flow • On-line - - Rotary type with Pyrex • Coolant from the
TITLE

Glass • Bypass tempered glass. The equipment

body material shall be • On-line upto 4 inch pipe
carbon steel with bronze and bypass type above 4
wetted parts inch pipes

DATE:
PPD BY:
CKD BY:
14. Flow Indicators Variable +/- 1% - CS body with 316 SS • Common outlet header
Area float and scale of identical equipment

07
KJP
AUG
• On-line meters upto 4
inch size
• Bypass type above 4
inch size

4891A
JOB NO.
15. Flow Switches On-line +2% IP-65 CS body with 316 SS • Common outlet header,
element with contacts of identical equipment for
low alarm
MAITHON POWER LIMITED
1050 MW MAITHON RIGHT BANK TPP
INSTRUMENTATION & CONTROL SYSTEM
TCE CONSULTING ENGINEERS LIMITED

16. Flow Indicators Positive +0.5% of rate IP-65 CS body with 316 SS • Measurement of flow on
displaceme of flow wetted parts oil lines(wherever
nt type applicable )

PROJECT: 2 x 525MW TPP

17. Flow Dp type +0.02% IP-65 - • Refer under "Differential
Transmitters SMART+ Pressure Transmitters"
HART
SECTION: D3.0

SHEET 10 OF 15

OWNER: Maithon Power Ltd TPP 2 x 525MW

 DATE
REV. BY
REV. NO.
SL. INSTRUMNET TYPE ACCURACY ENC SPECIFIC APPLICATIONS
SYSTEM

NO L. REQUIREMENTS
TCE 4891A-H-500-004

COAL HANDLING

18. Flow Elements Orifice +1% URV - Flange Taps with 3 pairs • For liquid metering
TITLE

assembly of connections or as • Upto 300 lbs ANSI rating

required, Designed as • 316 SS orifice plate
per ANSI, BS, DIN assembly
Standard, 316 SS orifice
plate

DATE:
PPD BY:
CKD BY:

07
KJP
AUG
19. Level gauges Mechanical - IP-65 Complete with automatic • All surface mounted/
ball check valve, guard overhead tanks, and any
rods, micashield and storage tanks

4891A
illumination where plant • Reflex type for two

JOB NO.
illumination is not phase applications
adequate • Tubular type for liquid
applications
MAITHON POWER LIMITED
1050 MW MAITHON RIGHT BANK TPP
INSTRUMENTATION & CONTROL SYSTEM
TCE CONSULTING ENGINEERS LIMITED

PROJECT: 2 x 525MW TPP

SECTION: D3.0

SHEET 11 OF 15

OWNER: Maithon Power Ltd TPP 2 x 525MW

 DATE
REV. BY
REV. NO.
SL. INSTRUMNET TYPE ACCURAC ENCL. SPECIFIC APPLICATIONS
SYSTEM

NO Y REQUIREMENTS
TCE 4891A-H-500-004

COAL HANDLING

20. Level Switches Mechanical - IP-65 • CS body, 316 SS • For all tanks/sumps for
TITLE

Float Type float external cage with low and high alarm
SPDT contact rated for • For all tanks/sumps for
0.2A, 224 V DC, for very low for pump
surface mounted tanks protection and very high to

DATE:
• Top mounted for trip supply pump

PPD BY:
CKD BY:
sumps • For all tanks/sumps for
normal for starting of the
pump

07
KJP
AUG
21. Level - +0.5% IP-65 External cage with CS • For all level
Transmitters body and SS wetted measurement with two

4891A
JOB NO.
parts, 4-20 mA DC phase fluids and not
output exceeding 800 mm length
for both monitoring and
MAITHON POWER LIMITED

control applications

22. Digital Dew Microproce +/- 2 deg IP-65 Dew point sensor shall At the outlet of each air
1050 MW MAITHON RIGHT BANK TPP
INSTRUMENTATION & CONTROL SYSTEM
TCE CONSULTING ENGINEERS LIMITED

Point Meter ssor based C Dew be Aluminium oxide dryer ( if applicable)

point type with sintered
Repeatabil bronze sensor guard
ity & 0.3 suitable for on line

PROJECT: 2 x 525MW TPP

deg C of measurement
dew point
SECTION: D3.0

SHEET 12 OF 15

OWNER: Maithon Power Ltd TPP 2 x 525MW

TCE 4891A-H-500-004 TCE CONSULTING ENGINEERS LIMITED SECTION: D3.0
TITLE MAITHON POWER LIMITED
COAL HANDLING SHEET 13 OF 15
SYSTEM
1050 MW MAITHON RIGHT BANK TPP
INSTRUMENTATION & CONTROL SYSTEM

TABLE-2
Data Sheet for PLC:

S. No DESCRIPTION REQUIREMENT
1.0 Type of Control system Programmable Logic Controller (PLC)
1.1 Offered PLC System Latest system available / being marketed in
the international market by the vendor/
collaborator with minimum 3 years of proven
performance record.
1.2 Operating System Windows -XP
1.3 Hierarchical protection for At least 3 levels of security is required
operator & engineer functions
1.4 Standalone UPS – Required.
240 V AC, 1Ø, 50 Hz Any other voltage required for the PLC shall
be derived from the UPS. Similarly, 24 V DC
derived from the UPS shall have redundant
power packs
1.5 No of UPS feeders Two(2)
1.6 Response time (Maximum) for
Analog input 250 m sec
RTD input 1 sec
Digital Input / output 60 m sec
Loop cycle time inclusive of 250 m sec (Analog); 100 m sec (Digital)
controller processing time
1.7 Auto switchover time to
backup/redundant component Instantaneous and bump-less
at (Bidder to indicate the time)
a) Processor level
b) Communication level
c) Power supply level

1.8 Display Call up time in HMI 1-2 sec

monitor
1.9 Dynamic update time of
parameters in the HMI monitor 1-2 sec
for measurement and control
1.10 Spare capacity required in the
control processor considering
spare I/O channels and future Minimum 40 %
I/O modules to be located in the
spare I/o slots
1.11 Output status on controller
failure Configurable in Engineering station

S. No DESCRIPTION REQUIREMENT
1.12 Output status on power supply
failure Configurable for switching to fail safe mode

REV. NO. PPD BY: JOB NO. OWNER: Maithon Power Ltd TPP 2 x 525MW
DATE CKD BY: KJP 4891A
REV. BY DATE: AUG PROJECT: 2 x 525MW TPP
07
TCE 4891A-H-500-004 TCE CONSULTING ENGINEERS LIMITED SECTION: D3.0
TITLE MAITHON POWER LIMITED
COAL HANDLING SHEET 14 OF 15
SYSTEM
1050 MW MAITHON RIGHT BANK TPP
INSTRUMENTATION & CONTROL SYSTEM

1.13 Status indication for each LED indication required

channel in DI / DO card
1.14 Power supply healthiness LED indication required
status in all modules
1.15 Optical Isolation for DI / DO Required
1.16 Galvanic isolation for AI / AO Required
1.17 Control processor with floating 32 bit processor , RISC based
point arithmetic capability
Capacity of RAM 256 MB minimum
Spare capacity in RAM Minimum 40 % including spare I/O
Processor Redundancy Dual redundant hot stand-by
Battery back up for RAM Rechargeable Ni.Cd
Duration of battery back up for 50 hrs
dynamic memory
1.18 Closed Loop Control Non-redundant I/O modules

1.19 Open loop control ( Logic , Non-redundant I/O modules

Protection & Interlock)
1.20 Maximum number of channels
in I/O modules -
Analog I/O modules 8 Channel
RTD, Thermocouple 16 Channel
Digital I/O modules 16 Channel
1.21 Power supply to the field Analog input module shall drive the
trasmitters connected field transmitter on 2 wire loop
1.21 Interrogation voltage for Digital 24 V DC
signals
1.22 Concept of I/O grouping a) No two identical / similar equipment
shall be grouped in the same I/O
module
b) I/Os related to equipment and I/Os
related to its associated auxiliaries
shall be connected to different
modules.
c) Inputs and outputs shall not be
combined in a single module.
d) Where ever 2oo3 logic is involved, the
redundant inputs shall be connected
to different modules.
1.23 USB ports on the operator 4nos
station
1.24 DVD R/W drives on Operator One(1)
Station
1.25 Displays on HMI monitor Process mimic displays, trend displays,
system status, alarm displays, logs / reports
etc

REV. NO. PPD BY: JOB NO. OWNER: Maithon Power Ltd TPP 2 x 525MW
DATE CKD BY: KJP 4891A
REV. BY DATE: AUG PROJECT: 2 x 525MW TPP
07
TCE 4891A-H-500-004 TCE CONSULTING ENGINEERS LIMITED SECTION: D3.0
TITLE MAITHON POWER LIMITED
COAL HANDLING SHEET 15 OF 15
SYSTEM
1050 MW MAITHON RIGHT BANK TPP
INSTRUMENTATION & CONTROL SYSTEM

1.26 Minimum no of plant mimics 50

configurable
1.27 Time activated logs Periodic logs, shift report, daily report, status
change log, Control system fault log
1.28 Operator Station: - Pentium IV , Minimum 1.8 GHz processor
- 21” LCD Monitor
- 512 MB RAM
- 80 GB HDD
- DVD R/W Drive
- QWERTY Keyboard
1.29 Engineering Station Operator Station having Engineering
capability and pass word protection.
1.30 Annunciation System Integral to the PLC
In addition, a window based annunciation
driven by the PLC
1.31 Printer On line Dot matrix printer – Min 300 CPS
A3 size – B/W –for reports, alarm and logs
printing
1.32 Interface with plant DCS Through– RS485 on Modbus RTU protocol
1.33 Spare Channels in I/O Modules 20 % (wired up ) spare channels over the
entire population of each type of module.
1.34 Spare slots in the I/O rack 20% additional slots in each rack
1.35 Fuse for I/O channels - Individual for analog signals
- Group of max 8 for digital channels
2.0 Interposing Relays 24 V DC with free wheeling diode across the
coil – Relay contact rating 5A at 240 V AC
3.0 Panels / Cabinets Self Standing type with maximum height of
2200mm
3.1 Mechanical features a) Minimum 2mm thick CRCA
b) 3mm removable gland plate
c) 2.5 mm thickness for double doors
d) Panel; door switch
e) Fans
f) Paint to IS-5 Shade 692 – Glossy
white interior
g) Illuminated lamp push buttons
h) Enclosure Protection IP-42
4.0 Panel Earthing Safety earth for enclosure and Electronic
earth for PLC system.
5.0 Control room Air Conditioned.
6.0 Quality Assurance As per quality plan to be approved by the
Purchaser / Consultant
7.0 Inspection Requirements Factory Acceptance Test as per procedure
approved by the Purchaser / Consultant.

REV. NO. PPD BY: JOB NO. OWNER: Maithon Power Ltd TPP 2 x 525MW
DATE CKD BY: KJP 4891A
REV. BY DATE: AUG PROJECT: 2 x 525MW TPP
07