20100719233500

FOR AUTHORISED USE ONLY
GOVERNMENT OF MAHARASHTRA WATER RESOURCES DEPARTMENT KUMBHE HYDRO ELECTRIC PROJECT (1 X 10 MW)
BIDDING DOCUMENT NO. SEGEMC/KUMBHE/E & M/TGP/1/2010 FOR

DESIGN, DETAILED ENGINEERING, MANUFACTURING, SUPPLY, ERECTION, TESTING, COMMISSIONING OF TURBINE, GENERATOR AND ASSOCIATED EQUIPMENT. VOLUME-I COMMERCIAL TERMS AND CONDITIONS OF CONTRACT VOLUME-II TECHNICAL SPECIFICATIONS OF TURBINE, GENERATOR & ASSOCIATED EQUIPMENTS
VOLUME-II
OFFICE OF THE CHIEF ENGINEER (ELECT.) HYDRO PROJECTS, HSBC BANK BUILDING, 4TH FLOOR, M.G.ROAD, FORT, MUMBAI-400 001. TEL. (022) 22670074, 22674867 FAX. (022) 22674996
INDEX SECTION NO. I II III IV INTENT OF THE SPECIFICATIONS GENERAL REQUIREMENT SCHEDULE OF REQUIREMENTS TECHNICAL SPECIFICATION OF GENERATOR V VI TECHNICAL SPECIFICATIONS OF TURBINE TECHNICAL SPECIFICATION OF SPHERICAL VALVE VII TECHNICAL SPECIFICATIONS OF STATION AUXILIARIES VIII TECHNICAL SPECIFICATION OF PROTECTION AND METERING IX TECHNICAL SPECIFICATION OF SUPERVISORY CONTROL AND DATA ACQUISITION SYSTEM X DRAWING 6 NOS. 272-298 261-271 236-260 164-214 215-235 1-18 19-59 60-82 83-163 DESCRIPTION PAGE NO.
SECTION- I INTENT OF THE SPECIFICATIONS
SECTION- I INTENT OF THE SPECIFICATIONS INDEX Sr.no. 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 1.9 1.10 1.11 1.12 Description Intent of the specifications Hydraulic data Climatic and other conditions Seismicity Approach and transport limitation Operational requirements Rating requirements Other design requirements Layout constraints Designs studies/calculations Data sheets Drawings and data to be submitted with bid Annexure I-1 Page no. 3 5 5 6 6 6 7 8 10 10 13 13 14
Signature of Bidder
Signature of Purchaser
SECTION- I
INTENT OF THE SPECIFICATIONS 1.1 INTENT OF THE SPECIFICATIONS: The scope of work comprises of the following: To undertake the complete engineering, design, manufacture, supply, onsite erection, testing and commissioning, putting into commercial use and trail run for 90 days of the following hydro power plant and equipment. The brief details of the power plant equipment shall be as follows: Mechanical Lot One no.: Horizontal Shaft Pelton Turbine directly coupled to Generator with
nozzle spear head, servo motor and deflector assembly etc. Turbine designed for net rated head of 402.00 mtr. and discharge 3.12 m3/sec at rated head and rated output capacity of 10.42 MW, 500 rpm, comprising of electronic Governor with oil pressure unit, high pressure oil & water piping, valves, strainers, flow meters, relays, limit switches, temperature gauges etc., complete. One no.: Main O.P.U. type spherical valve of suitable size for 1000mm dia. Penstock along with operating system, inlet/outlet pipes, control cabinet etc., complete. Valve shall be designed for a pressure of 700 m of water column. One lot : Penstock pipes:-Matching pipes between i) penstock end and Spherical valve( i.e. Penstock specials) ii) Spherical valve and Distributor pipe and Branch pipes. Further lot shall comprise of stiffeners, supports and anchors for proper embedment. Lot :
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i) Compressed air system for Governor, M.I.V., generator breaking and other purpose shall include adequate nos. of compressors, air tanks and piping etc., complete. ii)Drainage & dewatering system shall include adequate nos. of pumps, strainers, valves, and piping etc. iii) Cooling water system shall include adequate nos. of pumps, pressure reducers, strainers, valves, and piping etc., complete. Electrical lot: One no.: Horizontal shaft synchronous generator salient pole, 3 ph, 50 Hz, 0.9 pf, 12.5 MVA, 11 kV rated voltage suitable for coupling to above mentioned turbine with fully static excitation system including excitation transformer, grounding cubicle, power cable for interconnection, DVR etc. Complete. One Lot : Generator auxiliaries : comprising of S.S.G. unit, Local control boards , fire protection system, H.S. lubrication, LAVT, Bus Duct, 11 kV XLPE cable, isolator, earthing switch, 11kV junction bus panel, power, control & measurement cables, coolers, heaters, etc., complete. One Lot: Protection:-Software based protection relay panels covering all required electrical protections with back up protections of Turbine, Generator, step up transformer, auxiliaries etc., complete One no. SCADA system with Unit control board: SCADA system and Unit control board for the operation of plant. This includes PLC based control system of turbine generator unit, Synchronizing unit, alarm window, annunciation window. Auto as well as manual control of the plant. Lot : Mandatory Spares for above items. Lot : Special Tools and Plants for erection, testing and commissioning.
Signature of Bidder
The above work shall be carried out on totality basis including the incidental services mentioned in clause No.3.15 and 4.7 of vol.1. Further the said work shall be carried out in co-operation with the purchaser and suppliers of other equipment in a business like manner with utmost speed so as to achieve overall economy and efficiency. 1.2 HYDRAULIC DATA The hydraulic data and the other data regarding water conductor system is as follows: LEVELS A B C D E F G H Minimum Draw Down level (m) Full Reservoir water level (m) Maximum tail water level Minimum tail water level Design discharge Nozzle level (m) Total Head loss (m) Rated head (Design) (m) 579.11 EL 602.00 EL 190.00 EL (tentative) 189.00 EL (tentative) 3.12 m3/sec 190.00 EL 1.91 402
The turbine shall be designed based on the hydraulic data mentioned above. 1.3 CLIMATIC AND OTHER CONDITIONS
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Kumbhe HEP is situated in hilly terrain of Sahyadri ranges. The general climatic and isoseismic conditions are as stated under Section VII Annexure I of Volume-1. 1.4 SEISMICITY : Entire plant and equipment shall be designed to withstand forces due to gravitational acceleration as stipulated in Section-VII Annexure I of Volume I i.e. Commercial Terms and Conditions of Contract. 1.5 APPROACH AND TRANSPORT LIMITATION: Bidders are requested to verify and ascertain limitations given under section VII Annexure I of Volume I i.e. Commercial Terms and Conditions of Contract. The limitations are indicative and the bidder has to ascertain the actual limitation and design the plant accordingly. 1.6 OPERATIONAL REQUIREMENTS: The whole of the plant and equipment including auxiliaries shall be suitable for trouble-free operations under varying operational conditions. The anticipated operational requirements of the turbine and generator unit and associated equipment are given below: A. Operating mode: Power generation at any load in the range between 9000 kW of power and maximum power of 11000kW B. Operating Duty: 1. No. of starts and stops per year 2. Total time for starting From standstill to Synchronising (Max.) 3. Rate of loading < 300 Sec 800 starts and 800 stops
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a) Normal loading b) Fast loading c) Emergency loading 4. The frequency and voltage range under which the units shall be capable of performing satisfactorily.
a) About 2.0% of P max/sec b) About 6.25% of P max/sec. c) About 6.25% of Pmax/sec. 47.5 to 51.5 Hz. 0.9 Un to 1,1 Un
where Un means rated voltage of Turbine generator unit.
5. Load range 6. Network condition: The voltage and frequency variations in system with which the unit shall be synchronised and able to deliver rated power continuously. 1.7 1) RATING REQUIREMENTS: Output :
between 9000 kW to 11000 kW 220kV10% 47.5 Hz to 51.5 Hz
The Turbine shall be so designed that rated output of 10000 kW is developed under the rated net head of 402mtr. 2) Turbine setting: Turbine setting and other key dimensions of unit is the sole responsibility of the bidder. The bidder shall design the turbine setting based on the hydraulic data mentioned above. The Purchaser has tentatively chosen (Shown in study drawing) the turbine setting as 0.375 m above the penstock center level. This is only for study purpose. Further, the key dimensions / levels of the power house
Signature of Bidder
are tentatively fixed based on the dimensions of turbine and generator. The bidder shall examine this aspect and give his recommendations about the precise requirements. The proposed setting shall provide adequate allowance under all operating conditions considering power swing, shaft pressure pulsation, cavitationless performance, minimum vibration and minimum noise, flooding level of river etc.
3)
Moment of inertia (GD) The moment of inertia shall be calculated and furnished. It shall includes the maximum momentary speed rise, and maximum momentary pressure rise specified under clause No.1.8 of this section (other design requirement).
1.8
OTHER DESIGN REQUIREMENTS In addition to the operational requirement, mentioned in Clause no.1.6 of this section, the following requirements shall be kept in view. i) The whole of the plant including all auxiliaries shall be designed to give satisfactory service with designed availability for a period of 50 (fifty) years. ii) iii) Number of tripping (max.) : Number of turbine : Runway condition iv) Closing of Spherical : valve (MIV) Ten (10) nos. per year One (1) no. in five years life on an average. Every time the unit is stopped and brought to position. v) The rotating parts of the unit shall be mechanically designed so as to allow the continuous operation and the stresses included in any part at maximum runway condition shall not exceed 67% of the yield point of the material of that part or 30% of the ultimate strength. standstill
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vi)
The pressure containing parts of the unit for example the Spherical valve, the Distributor and branch pipes, penstock specials, the nozzles, deflectors, governing assembly, runner, buckets shall be designed from consideration of fatigue stresses induced due to cyclic changes in
vii)
pressure conditions. The nozzles, deflectors, regulating mechanism shall be designed to have closing tendency and minimum of lost motion and friction.
viii)
The pulsation in power output in turbine operation shall not exceed 1.5% at full load output and 5% at partial loads of actual rated power output.
ix)
The maximum momentary pressure rise under most unfavorable transient conditions accordingly to Clause 2.3.5.7 of IEC 41 shall not exceed 700 m.
x)
The maximum momentary over speed under most unfavorable transient conditions according to IEC 41(1991), sub-clause 2.3.4.14 will not exceed 1.50 times the rated operating speed.
xi)
Whole of plant and equipment including the control and protective equipment shall remain operative when maximum credible earthquake occurs at site. Further, the plant should trip and safely come to standstill when earthquake of large magnitude occurs. Entire plant and equipment to operate without malfunctioning upto seismic conditions as project area is situated in earthquake zone. Entire plant and equipment to to shut-off at seismic conditions : Horizontal direction aH = 0.375g : Vertical direction aV=0.25g : Horizontal direction aH = 0.3g :Vertical direction aV=0.2g
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xii)
The plant and auxiliaries shall be designed to operate continuously for 12 months period without any off-load maintenance and to achieve a high start-up reliability.
xiii)
The control scheme shall be so designed that in the event of a collapse of the state grid system, The Kumbhe HEP shall be disconnected automatically.
xiii)
When unit is in operation, the noise level in the turbine housing 1 m away from shaft measured shall not exceed 90 dB (A) .
xiv)
The generator and turbine bearing shall be so designed to allow the unit to be frequently and quickly started. Besides, the bearing shall be liberally designed such that full power output is available even if oil cooler of any bearing is blocked continuously. In addition, the volume of oil provided and circulating system shall be such that none of the bearing would suffer any damage during shutdown process in the event the unit is tripped due to stoppage of cooling water / oil supply.
xv)
Entire equipment shall be designed for maximum runaway speed for 15 minutes.
1.9
LAYOUT CONSTRAINTS : The layout of power station is prepared with a view achieving over all economy. The major layout constraints are given below: i) ii) Width of the power station Overall length of power station DESIGNS STUDIES/CALCULATIONS: The bidder and eventually the supplier shall have to undertake/conduct special studies and calculation in order to establish that the design requirements are achieved. The cost of such studies and calculations shall 24.00m 25.60m
1.10
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be deemed to be included in the contract price. The following studies and/or calculations are required to be completed. A) 1) Studies prior to bid submission. Study of hydraulic Transients. The study must be conducted considering worst operating conditions and the results thereof must be submitted in the form of graphs, tables etc. giving the values of maximum momentary pressure rise, maximum momentary speed rise, water levels in the approach channel, surge well, and tail race channel. The purchaser desires that the following conditions are to be studied by the bidder. i) Unit generating maximum power is tripped on mechanical fault. ii) Unit generating maximum power is tripped and then attempt is made to restart the unit in emergency. iii) Unit generating maximum power and generator circuit breaker is tripped due to electric fault. The bidder may consider any other condition which may induce/provoke more dangerous situation. In addition, the bidder should provide specific comments regarding settings of intake and outfall structures. 2) B) Studies regarding critical speed of the shaft system. After award of Contract:The Successful bidder (Supplier) shall be required to undertake the following studies and / or calculations: 1. Optimisation of the turbine runner and the hydraulic passages. 2. Review studies and/or calculation mentioned above on the basis of data obtained on completion of detailed design and supply the result. 3. Conduct FEM study to determine the stresses induced and the pattern of concentration of stresses in major components of the unit such as turbine runner, nozzles, Deflectors, Distribution pipes, generator stator frame and the bearing brackets, shaft etc. 4. Computations of forces on overhangs, generator foundations, Bearings supports etc. under most unfavorable conditions.
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5. Dynamic analysis: Studies to determine the dynamic behavior of the unit rotating parts, bearing brackets and the forces which would be induced and transferred to civil foundations shall be undertaken by computer simulations. The studies should demonstrate the unit and the foundations are capable of withstanding without damage the abnormal conditions during trip-outs and during runaway conditions. Dynamic analysis by computer simulation of the unit vibratory characteristics should be carried out to determine the amplitude and frequency of the hydraulically and mechanically excited vibrations originating within turbine, generator and entire water passage system. The frequency of these vibrations should be compared with each other and the natural frequency of related components to determine whether or not there would be resonance. The comparison should include critical speeds of major machinery components, frequency and magnitude of vortex shedding from runner, runner buckets, nozzles, deflectors, the unit dynamic imbalance, runner hydraulic imbalance etc. All these natural frequencies shall be checked for adequate margin against predominant frequencies to avoid resonance. Studies carried out in this regard shall be furnished. The supplier shall duly analyse all cases of possible interferences of different resonance frequencies and must ensure that abnormal vibration shall not occur when the unit operating at any load from 90% to 110% load turbine. Besides, such an operation shall not provoke power pulsations at generator terminals. 6. Dynamic analysis by computer simulations of the entire rotating system should be carried out and determine the dynamic stability of the unit, main shaft and bearings. These analyses should be sensitive to running clearances, bearings spring constants, magnetic and hydraulic imbalances, runaway speed, component centrifugal growth and critical speeds. These analyses should demonstrate that the critical speeds, shaft run-outs, unit bearings supports and bearing oil film are within safe limits for normal and transient operating conditions. The maximum stresses induced under worst conditions shall not exceed 2/3rd of yield point strength of material.
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7. Dynamic stability studies both for large disturbances as well as small perturbances shall be carried out to determine excitation characteristics and determine necessity and type of damping, feedback signal for static excitation system.
8. All the designs as per above requirements shall be validated on the basis of studies carried out by the supplier and by mere calculations. 9. Model Test of Turbine: The supplier shall manufacture a homologous model of the turbine and perform the various tests to predict the performance and other operational behavior of the prototype turbine. The tests to be conducted on the model turbine are detailed in clause 5.5 of section V of this volume. Only after the model tests are successfully performed and test report is approved by purchaser, the manufacture of turbine shall be commenced. The model must include geometrically similar water passages from the inlet of the turbine up to end of hydraulic upto exit section. Besides, the model must be sensitive to the running clearances. 10. EOT Crane: One no. of electricaly operated overhead traveling crane will be provided in power house for handling the parts of the turbine and generator and other equipment such as Spherical valve etc. Maximum load to be lifted by EOT crane shall be given by bidder. Hook approaches, reaches end clearances etc. of crane should be calculated by bidder and submit to the Purchaser for necessary provisions.
1.11
DATA SHEETS All data sheets appended to bidding documents must be completely filled in by the bidder. The bidder shall specifically note that incomplete information or non supply of important information may result in rejection of his bid.
1.12
DRAWINGS AND DATA TO BE SUBMITTED WITH BID
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All drawing and data as per enclosed Annexure-I.1 shall be submitted along with the bid. The drawing and data shall be sufficient enough to prove technical compatibility of the bid and shall not be limited to the list of Annexure I.1.
ANNEXURE I-1 LIST OF DRAWING AND DATA TO BE SUBMITTED WITH BID I- MECHANICAL LOT DRAWING (Power Station layout drawing specially prepared to scale and large enough to give clear understanding regarding the provision of space for mounting various equipment, cable galleries, pipe gallery etc.) A) 1. LAYOUT DRAWINGS Cross section of Power Station. The drawing must shown the limit of supply on the upstream side and on the downstream side, the turbine Setting, the excavation level, turbine level and generator level, Spherical Valve gallery level, the hook lift requirement above the service bay PREFERRED SCALE
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level and the required capacity of the power station crane .1: 100
2.
Plan of the station at Service bay level showing the of equipment proposed provision .1:100
3.
Cross section of power station at turbine generator level .1:100
4.
Cross section of power station showing station auxiliaries.
.1:100
5.
Power station Control room Layout
.1:100
6.
L section of power station at turbine generator level 1.100
B) 6.
MACHINE DRAWING Cross section of the turbine showing clearly arrangement of shaft seal, bearing, turbine housing and the access to these part during maintenance / operation; the running clearance between labyrinths on the runner , runner and discharge , the position of nozzles, deflectors, servomotors. The height of shaft flange above the centre line of turbine and any other details desirable. ..1:20
L section of the turbine showing clearly arrangement of shaft seal, bearing, turbine housing and the access to these part during maintenance / operation; the
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running clearance between labyrinths on the runner , runner and discharge , the position of nozzles, deflectors, servomotors. The height of shaft flange above the centre line of turbine and any other details desirable 8. Nozzle and Deflectors assembly: Plan and sectional assembly drawing showing the important dimension. The method of construction and field welding joints. ..1:20 ..1:20
9.
Bearings The drawing should shown in sufficient details, the arrangement of supporting the pads; method of adjusting the pad clearance; The minimum and maximum level of oil, arrangement of cooling the oil etc. .1:20
10.
Arrangement drawing of Spherical valve & matching piece. .1:20
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Arrangement drawing of Distribution pipe, branch pipe. .1:20
C)
LIFTING ARRANGEMENT DRAWING FOR Turbine runner and shaft,
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Turbine housing, Spherical Valve Stator and Rotor Bearings
D)
SCHEMATIC DIAGRAMS OF -Cooling water system -Compressed air system -Drainage system and Dewatering system -Penstock dewatering system -Pressure oil system of Governor and MIV
D. DESIGN CALCULATION /RESULT OF DESIGN STUDIES 1. Transient behavior 2. Adequacy of cooling water 3. Adequacy of dewatering and drainage pit. 4. Details of pump capacity, rating etc. for drainage & dewatering system. 5. Details of water pressure reducer set with pressure reducer valve, stop valve, safety valve and strainer etc. for cooling water system. 6. Requirement of DC supply voltage, Ampere capacity etc.
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7. Requirement of AC Supply, voltage capacity etc.
II A. 1. 2.
ELECTRICAL LOT LAYOUT DRAWINGS: Generator-turbine cross section showing important dimensions, levels etc. General arrangement and overall dimensions of Turbine generator showing position of main and neutral leads, bearing and bearings supporting arrangements etc.
3. 4. 5. B. 1. 2. 3.
Excitation system Protection scheme: single line diagram showing CT, PT, LAVT etc. and its rating. 11 kV XLPE cable arrangement drawing. Graphs, tables and charts Graph showing the no load, short circuit and air gap line curves. Excitation currents for 105%, 100%, 95% of rated output. Power generation charts at 0.91.01.1 Un.
4. Table giving the various losses and calculated efficiency at various loads and power factors.
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SECTION II GENERAL REQUIREMENT
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SECTION II GENERAL REQUIREMENT INDEX Sr.no. 2.1 2.2 2.3 2.4 2.5 2.6 2.7 Description General requirements Limits of contract Project information Interchangeability Engineering data Quality assurance plan Safety and Compliance with rules regulations & obtaining statutory approval 2.8 2.9 2.10 2.11 2.12 2.13 2.14 2.15 2.16 2.17 2.18 2.19 2.20 2.21 2.22 2.23 2.24 2.25 Inspection of works Drawings Supply of oils, grease/lubricants and other consumable Manufacturing schedule and the progress reports Design improvements Erection-tools and tackles and spanners Foundations and fixtures Material and workmanship Balancing Electrical equipment Earthing Units Protective guards Storage at site Rating plates, name plates and labels Tests Report of chemical analysis of water Applicable standards 24 24 26 26 27 27 27 27 41 42 48 48 49 49 49 49 55 55 Page no. 21 21 21 21 21 22 23
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SECTION II GENERAL REQUIREMENT 2.1 GENERAL REQUIREMENTS : The general requirements explained hereafter shall be applicable to the equipment to be supplied. 2.2 LIMITS OF CONTRACT: Equipment furnished shall be complete in every respect with all mountings, fittings, fixtures provided with such equipments needed for erection, completion and safe operation of the equipments and are deemed to have been included. Further, these fittings, fixtures and accessories shall be of the best standards and proven for use. 2.3 PROJECT INFORMATION The data and information given in Bid Document are based on the information available from project site authority. The Bidder shall satisfy himself about the adequacy of the said data/information and interpretation there-of and if necessary, carry out further investigation. 2.4 INTERCHANGEABILITY: All parts shall be made to standard gauge in accordance with the normal practice for the class of equipment concerned. All corresponding parts of similar apparatus including spare parts shall be interchangeable. 2.5 ENGINEERING DATA: The furnishing of engineering data by bidder shall be in accordance with the provisions mentioned in the Technical specifications and the Data Sheets annexed thereto. The review of these data by the purchaser will cover only general conformity of the data to the specifications and documents interfaces with the equipments provided under the specifications, external connections and of the dimensions which might affect plant layout. This review by the purchaser shall not be construed by the supplier, as limiting any of his responsibilities and liabilities for mistakes, omissions and deviations from the
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requirements, specified under these specifications. All engineering data submitted by the supplier after final design including review shall form part of the contract documents and the entire work covered under these specifications shall be performed in strict conformity. If the provisions made for the unit (e.g. jacks for rotor lifting, lifting beam for rotor lifting, H.S. lubrication etc.,) by the Purchaser is not required, the bidder shall clarify for the same in his bid. 2.6 QUALITY ASSURANCE PLAN
2.6.1 Quality Assurance Plan for Manufacturing Works Four copies of Quality Assurance Plan giving details of inspection, tests and customer witness / hold points shall be submitted with the bids. The quality plan shall contain the details of inspection and tests to be carried out for each major component of each functional assembly as recommended by the manufacturer as per their standard practice. The tests will include material composition and its properties, NDT, X-ray, hydraulic tests, leakage tests, insulation, high voltage tests and functional tests etc. along with the applicable standards and acceptance criteria. The Supplier shall get the quality plans finalised and approved after the award of the Contract. The approved quality plan shall form the basis for inspection and acceptance of the equipment. The Engineer shall have the right to ask for more relevant tests if the same could not be included in the quality assurance plan at the time of their approval due to non availability of final design drawings. 2.6.2 Quality Assurance Plan for Site Installation & Commissioning Four copies of Quality Assurance Plan giving details of stage inspection during installation, pre-commissioning and commissioning tests and customer witness / hold points shall be submitted with the bids. The quality plan shall contain the details of inspection and tests to be carried out for each major component of each functional assembly as recommended by the manufacturer as per their standard practice. Test Procedure shall be specified giving for each test item (kind of test) a description, test method / standards,
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used instruments, sample/routine test, test judgement.The tests will necessarily include NDT, X-ray, hydraulic tests, leakage tests, insulation, high voltage tests and functional tests etc. along with the applicable standards and acceptance criteria.
The Supplier shall get the quality plans finalised and approved after the award of the Contract. The approved quality plan shall form the basis for inspection and acceptance of the equipment at site. The Engineer shall have the right to ask for more relevant tests if the same could not be included in the quality assurance plan at the time of their approval due to oversight and/or non availability of final design drawings.
2.7
SAFETY AND COMPLIANCE WITH RULES REGULATIONS & OBTAINING STATUTORY APPROVAL A Unit with respect to their location, layout, general arrangement and design and equipment, structural design, etc. shall be safe to the personnel and conform to the relevant safety rules and regulations / statutory requirement issued by Government and the Central Government as well as to the following Indian Electricity Rules Indian Electricity Act Indian Explosives Manual Fire Protection Manual issued by Tariff Advisory Committee (India). All equipment / materials shall be installed in accordance with the requirement of relevant Standards, Indian Electricity Rules and Acts. The successful bidder shall ensure that the electrical installation supplied and erected by him shall be to the entire satisfaction of Chief Electrical Inspector, Central Electricity Authority or any other statutory body having Jurisdiction in the area and also to the purchaser / his authorized representative. Electrical Inspectorates approval for the installation and commissioning shall be the responsibility of the bidder. Preparation and submission of all necessary drawings, calculations, tests certificate and relevant details to the Electrical inspectorate and obtaining prior approval for commencing the work and for the complete installation work done shall be done by the bidder. Any statutory fee for inspection charge by Electrical inspectorate, shall be borne by the bidder.
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2.8
INSPECTION OF WORKS During erection, re-assembly, commissioning and trial operation, the Successful bidder shall perform at suitable intervals all inspections and tests in the presence of the Engineer in order to prove the orderly execution of the works in accordance with the Contract. Unless otherwise specified, all costs for testing at site and of works and charges associated with it shall be borne by the Bidder. Thus includes the measuring devices properly calibrated, and any pertinent accessories which shall be made available by the Successful bidder for the entire duration of the tests. The successful bidder shall delegate his experts to perform the tests at site. In case of disagreement between the Engineer and Successful bidder on the test result, an independent expert shall be appointed by Purchaser to whom both parties shall agree. If no amicable settlement can be reached, the Arbitration Clause shall be applied.
2.9
DRAWINGS:
2.9.1 DRAWINGS AND DATA TO BE SUBMITTED WITH BID: Drawings and other data which is required to be submitted with the bid is stated in the Annexure-I-1 of section I of this Volume. These drawing shall include sufficient details to demonstrate fully that the apparatus furnished shall conform to the provision and intent of these specifications. Detail drawings or design data for the purpose of checking the adequacy of the suppliers design by calculations shall not ordinarily be required but the purchaser reserves the right to call for these in certain cases at his discretion. These drawing shall show sufficient overall dimensions clearance etc. required for assembling and dismantling and furnishing the space requirements of all apparatus to enable the purchaser to determine the design and layout of the installation and to decide the compatibility of the bid. 2.9.2 DRAWINGS AND DATA TO BE SUBMITTED AFTER AWARD OF CONTRACT : A) Drawings for approval : The supplier shall furnish eight (8) copies of each of the drawings, the list of which is given in respective specifications, for approval of the Signature of Bidder 24 Signature of Purchaser
purchaser. The methodology of submitting these drawings to the officers of purchaser and or to consultants etc. shall be mutually agreed after award of contract. The Purchaser and consultants as far as possible will review the drawings submitted by the supplier within eight (8) weeks of their receipt. During the process the purchaser shall have the right to call for additional clarification or to suggest changes, which in the purchasers opinion, are required to conform the equipment to the provision of the specification. The drawings shall then be returned to the supplier along with comments and/or modified drawing. The supplier shall account for the comments and the suggested modifications and submit the revised drawings for approval. The delay arising out of revision of drawings by the supplier shall not cause any hold-ups related to site work or the manufacturing schedule and eventually the completion of contract. All the drawings pertaining to the plant and goods of ElectroMechanical works shall preferably be worked out on computers using latest version of AutoCAD on maximum A1 size. Electrical drawings including schematic drawings, block diagrams, flow diagrams, terminal details, panel outline drawings, circuit diagrams etc. shall be worked out on A3 size. All drawings shall have a uniform title-block as approved by the Engineer. Beginning with the very first submittal to the Engineer, the successful bidders drawings shall bear a serial number corresponding to a drawing classification plan to be agreed upon by the Successful bidder and the engineer. The drawings of bought out items shall also be preferred in AutoCAD version, however, their scanned version will be allowed. Catalogue sheets, illustration, printed specifications, etc., shall be checked and prepared by the Successful bidder in such a way that the figures, statements and data valid for the delivered sizes and types of the works concerned are clearly marked. These documents also shall be stored on CD and supplied to Department. B) Revised drawings : When revised drawings are submitted for approval, the changes for the previous submissions shall be clearly identified on the drawings including changes affected by supplier on his own from previous experience. Each revision made shall be identified by revision number and the date and the Signature of Bidder 25 Signature of Purchaser
brief description of the revision. The drawings shall be clear and legible in all respects. The revised drawings shall be again examined and if all the comments are accounted, the drawing shall be Approved and copy will be returned to supplier. Further work by the supplier shall be in strict accordance with such approved drawings and no deviation shall be permitted without the written approval of the purchaser. All manufacturing and fabrication works in connection with the equipment prior to the approval of the drawings shall be at the suppliers risk and cost. Approval of suppliers drawing or work by the purchaser shall not relieve the supplier of any of his responsibilities and liabilities under the contract. C) As Built Drawings : After the completion of the onsite erection work, the supplier shall furnish ten (10) sets (including one copy on tracing cloth or in velograph i.e. reproducible film) of the As Built drawings showing changes, if made, during erection for reference and record of the purchaser. These Drawings also shall be stored on CD and supplied to purchaser. 2.10 SUPPLY OF OILS, GREASE/LUBRICANTS AND OTHER CONSUMABLE: Sufficient quantity of oil, grease, lubricants and other consumable required to put the whole of the plant including auxiliaries into successful operation shall be supplied (i.e. deemed to be included in scope) without extra charges. The quality and the grade of the oils, grease and / or lubricants and other consumable to be used shall be from the locally available suppliers. 2.11 MANUFACTURING SCHEDULE AND THE PROGRESS REPORTS: The supplier shall submit to the purchaser his confirmed manufacturing and delivery schedules for all equipments within thirty (30) days from the date of Notification of award of contract. This schedule will not relieve the supplier of the delivery and work completion obligations as offered by him with the bid. The schedule shall be such as to meet the requirement of onsite construction. This schedule may be updated, if required, and the changes, if Signature of Bidder 26 Signature of Purchaser
any, must be informed to the purchaser every quarter. The schedules shall also include the materials and equipments purchased from outside. Every quarter a report highlighting the delays, if any, and the actual progress achieved shall be submitted. For substantiating the progress report, video films and copies of the photographs (in duplicate) shall be supplied. 2.12 DESIGN IMPROVEMENTS: The purchaser or the supplier may propose changes in the specifications of the equipment or the quality thereof and if the parties agree upon any such changes, the specification shall be modified accordingly. 2.13 ERECTION-TOOLS AND TACKLES AND SPANNERS: A complete outfit of erection tools and tackles, gauges, slings, other lifting devices, instruments and all other appliances required for the assembly, erection, dismantling and maintenance of the plant shall be supplied. Spanners and wrenches shall fit the nuts and bolts used in the plant. 2.14 FOUNDATION AND FIXTURES : Foundations related to various equipment shall be prepared by the purchaser on the basis of design data furnished by the supplier in line with civil construction schedule. However, the supplier shall supply all fixtures necessary for proper erection of embedded parts shall be supplied by the supplier. If requested by the purchaser, the supplier shall assist the purchaser involving special designs and criteria for civil foundation works of the turbine and generator unit. All supports, fixtures etc. needed for assembly, erection, testing and commissioning including that for field tests shall be prepared by supplier at his cost. 2.15 MATERIAL AND WORKMANSHIP : 2.15.1 GENERAL All parts shall be manufactured true to drawing dimensions. All tolerance shall be designed on the suppliers drawings for both manufacturing and installation purposes. Holes shall be drilled full size or under size and reamed during shop assembly. Punched holes will only be permitted in plates 20 mm or less Signature of Bidder 27 Signature of Purchaser
in thickness provided all such holes are subsequently reamed full size during shop assembly. The materials used in the construction of the plan shall be new of high quality and selected particularly to meet the duties required of them. The material specification shall be indicated in suppliers detailed drawings. The use of materials liable to be attacked by termites or other insects shall not be allowed. All workmanship shall be of the highest quality throughout to ensure running smooth without vibration and noise under all possible operating conditions. The design, dimensions and materials of all parts, shall be so chosen that the stresses to which they may be subjected shall not render them liable to distortion or damage under the most severe conditions encountered in actual services. Materials and workmanship shall conform to the latest editions of the relevant standards. 2.15.2 PIPING : All pipes and fittings (adequate number to be approved by the purchaser), valves, drain plugs/cocks, test plugs, sight flow indicators, meters etc. shall be provided so as to allow the operation and maintenance of the system with ease. All piping shall be clean inside and where ending in open connections for other works, the piping shall have the ends capped for protection. Valves shall be easily accessible and gauges and other operating or indicating devices shall be located so that they can be conveniently operated or read from the floor walkways. Valves shall be suitable for the services intended. Either a blind end flange or a pipe shall be provided wherever necessary to protect valves. Where piping systems must be disconnected for servicing, flanges or unions shall be provided and the piping, valves and joints shall be arranged for minimum disturbance or interference with other parts during operation. As far as possible, the pipes shall not be embedded but shall run in trenches or shall be suitably supported by hangers, brackets, hooks, pedestals, or any other support suited to the requirements, care being taken to avoid vibration at the supports. An adequate allowance for the expansion of pipes under service conditions shall be made. Each Signature of Bidder 28 drain pipe shall be laid with suitable Signature of Purchaser
slope to facilitate drainage. End pipe shall be suitably tagged or painted with anticondensation paints where necessary. The material of piping for different services shall be stated in the bid. Flexible pipe connections to apparatus shall be provided wherever necessary. For ready identification or different piping systems and their functions, each piping system shall be painted in code colour (to be provided by the supplier and approved by the purchaser). All operating points and also each separate section shall be painted with two bands of approved code colours, the wide band twice the width or the narrow one. An arrow showing the direction of flow shall also be marked. All operating valves on a piping shall also be painted with the same code colour. Each valve shall have, fitted to it, a suitable name plate indicating the function of the valve. 2.15.3 FASTENINGS :Nuts, bolts, studs and washers for incorporation of plant shall conform to the requirements of the appropriate standards. Where the contract includes nuts and bolts of different standards, then the tools shall be provided in compliance with that specification and shall be provided in compliance with that specification and shall include spanners, taps and dies for these nuts and bolts. Nuts and bolts for pressure parts shall be of the best quality bright steel, machined on the shank. All washers shall be included under the contract, including locking devices and antivibration arrangements. Taper washers shall be fitted, wherever necessary. Where there is a risk of corrosion, bolts and studs shall be finished flush with the surface of the nuts. Bolts except for high strength friction grip bolts shall be designed so that with the nuts fully tightened, the stress intensity at the bottom of the thread shall not exceed half the yield point of the material under all conditions. All bolts, nuts, and screws, which shall be subjected to frequent adjustment on frequent removal in the course of operation, shall be made of corrosion resistant steel or bronze. Spring type washers will not be permitted where they may damage any protective castings. Special tools, wrenches and devices found to be necessary for the completion of the work shall also be provided under this contract.
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2.15.4 FORGING :All highly stressed forgings shall be subjected to examination internally for the detection of the purchaser. 2.15.5 CASTINGS :The casting shall not contain damaging defects and shall be satisfactorily cleared before use. The surfaces which are not machine finished and which will be exposed after their final installation shall be such that grinding at the site will not be required before painting. The presence of defective material shall be determined and it shall be removed down to sound metal. The cast parts shall be homogeneous and free from excessive non-metallic inclusion. An excessive concentration of impurities or a separation of the alloy elements in the critical points of a cast part shall be sufficient reason for its rejection. The casting of the main parts, including all those subject to hydraulic pressure and all castings which undergo a major repair, shall be tested using radiographic, ultrasonic, dye penetration, magnetic particle or any other standard non-destructive test method. The expenses incurred on such tests shall be to the suppliers account. In case of bus duct only 10 % radiography of enclosure shall be done. Minor defects or imperfections which definitely do not affect the strength or utilization of the cast parts, may be repaired by welding, according to the accepted practice for the repair of such parts. Thickness and other dimensions of the cast parts shall agree substantially with the dimensions shown on the drawing and shall not be reduced by shop or casting practices to such extent that the effective strength of the cast parts shall not be less than the stressed allowed by these specifications. Use of cast iron for parts subjected to tension or impact shall not be permitted without the approval of the purchaser. flaw and heat treatment for the relief of residual stresses. Particulars of the heat treatment proposed for all forging shall be submitted to
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2.15.6 WELDING :Supplier shall specify clearly on all relevant drawings, the amount and type of material for each type of weld, supplier shall also provide detailed drawings showing joint preparation required for each type of welding to be carried out on site and at suppliers works. The parts to be joined by electric welding shall be cut precisely to the correct size by methods suitable for the type of weld to be used and to allow proper penetration and good fusion on the weld with the base metal. The cut surface shall not have visible defects such as scales, superficial defects caused by shearing or torch cutting operation or any other damaging defects. The surfaces of the edge to be welded shall be free from rust, oil, grease and other foreign matter. All welds exposed to water flow shall be ground to a smooth and even surface flush with the adjacent plate. Supplier shall indicate on the detailed drawings, the type, sizes and material of electrodes he proposes to use for shop and / or field welding. Unless otherwise stated, all non destructive tests shall be carried out. All major welding and all welding carried out on tanks and vessels, which will contain liquid under pressure or compressed air shall subjected to 100 % radiographic examination. In those cases where it is impossible to carryout radiographic inspection, or otherwise state in specifications, it may be replaced by ultrasonic examinations or any other non- destructive test systems. 2.15.7 SURFACE TREATMENT AND PAINTING : 1 GENERAL : Where necessary the work shall be painted or treated with protective coating to protect them from corrosion and to a neat and pleasing appearances. This work shall comprise the surface treatment, priming and application of paint or metallic coatings in the suppliers workshops and at the site including all paint repair work becoming possibly necessary. Every possible attempt shall be made that the design of the equipment is such that all surfaces can be finish coated or recoated after erection at the site. Unless otherwise specified, the coating and painting shall be carried out in accordance with the latest International Standard (Protective coatings for steel structures, directions) or another equivalent approved standard. All priming and painting material shall Signature of Bidder 31 Signature of Purchaser
satisfactorily fulfill the requirements imposed by the site conditions (considering also possibility extended periods of storage at site) as well as the stresses to which the respective equipment is subjected during operation of the works, Shades of the finishing coatings shall be as per the standard colour tables at the choice of the purchaser. Each coat of primer and paintings shall be compatible with the previous and subsequent coats. All pigmented primers and paints, which will be used for priming and painting at the site shall be delivered in original and sealed containers packed by the supplier. The supplier shall supply full details regarding the extent by which sand blasting, priming will be carried out in his workshops (or his sub-suppliers as the case may be), at the site and after erection. 2 SURFACE PREPARATION : Before the application of primers and paints the surfaces of steel or ferrous equipment shall be properly cleaned up to the base metal in accordance with ISO 8501-1 : 1988 or Swedish Standard SIS- SS05, 59.00. Wherever practicable scale, rust and dirt shall be removed by abrasive blast cleaning with quartz sand or corundum. The blast cleaned surfaces shall correspond to standard gauges and the average surface roughness after sand blasting shall not exceed 40 micrometers or minimum blast cleaning guide to BSA 2 (ISO 8501 1 : 1988). All water passages, turbine and spherical valve shall be prepared as follows: Sand blasting to a minimum surface cleanliness or finish corresponding to standard recommended grade. Sand shall be quartz sand, washed, clean and dry and be gypsum and salt free. The practical size shall be between 0.7 mm and 2.00 mm and the average peak to valley profile obtained shall be 40-60 micrometers. If grit blasting is used, it shall have good angularity of form with sharp cutting edges and be free from half rounds. It shall be chilled iron on hard steel grit with a particle size not greater than 0.9 mm. The maximum peak to valley height thus obtained shall not normally exceed 100 micrometers. It is accepted that there will generally be isolated rogue peaks where the amplitude is abnormal, but no where shall these be greater than 150 micrometers. Parts, which cannot be blast-cleaned, shall be cleaned free from rust and scale by power tool cleaning to the highest possible degree, according to the above standards. The surface preparation for non-ferrous Signature of Bidder 32 Signature of Purchaser
materials shall be to the approval of the purchaser and or consultant and will generally be required to conform to the recommendation of the coating manufacturer. All working of the material (e.g. welding, drilling, grinding) shall be completed and surface defects (e.g. weld splatter, burns, cracks, surface laminations and pitting), likely to be detrimental to the protective coating shall be removed before surface preparation begins. As regards welding joints, these shall be covered with one coat of appropriate primer shortly after welding wherever possible. Otherwise they must be cleaned with a steel brush before applying the first primer coat. 3 PRIMER, FINISHER AND PAINT APPLICATION: Before the application of the primer all sand blasted or otherwise mechanically created surfaces shall be subject to thorough cleaning process during which all dirt, dust, grease, moisture etc. is removed so that the primer is applied on suitable surfaces. Clean cloth and pure dissolvent shall be used for this process. The primer may be applied by airless spray gun, roller or by brush. All subsequent coats of paint shall be applied using airless spray equipment, unless otherwise recommended by the paint supplier or approved by the purchaser and or consultant. Where the use of airless spray equipment is found impracticable, the supplier must be prepared to use brush application at no additional cost to the purchaser, such application being to the approval of the paint supplier and the purchaser. The paint suppliers instructions shall be followed implicitly with respect to the method of application of the paints, the drying time between coats and the temperature of the material being painted, where ambient temperature, relative humidity or dew point will affect the drying or curing of paint, the manufacturers recommendations shall be followed. Unless specifically recommended otherwise by the paint supplier or approved by the purchaser, not less than 24 hours, not more than five days shall lapse between priming and successive coats of paint. Each coat shall be free from runs, drops, pin holes, waves, lops, sag and unnecessary brush marks. Particular care shall be taken to provide adequate paint film cover on corners and edges, nuts and bolt heads. Equipment contained in cubicles, cabinets or similar enclosures shall be painted as if is exposed to view and the inside surface of the enclosures shall Signature of Bidder 33 Signature of Purchaser
be painted semi-gloss white. In sheet metal enclosures where otherwise the surface would not be protected against corrosion (e.g. between the surfaces of spot welded joints and behind stiffening channels), such surfaces shall be quoted before assembly with an approved spot welding primer after preparation of the surface in accordance with the paint suppliers instructions. All paint shall be delivered to the point of use in unopened containers bearing the manufacturers label which shall include, where appropriate for special systems, date of manufacture, batch number and instructions. All paint shall be supplied in the ready mixed condition and except to comply with the suppliers direction, mixing of paints by the supplier shall not be permitted. Machinery paint may be thinned, if necessary to permit satisfactory application, but the amount of thinner shall be kept to a minimum. Special attention has to be given to the two pack coating. The application of these materials is no problem if the specification is strictly followed. For a perfect application the following important and generally valid conditions apply. The prime coating should be applied immediately after or at least on the day of blasting (exception only in air conditioned rooms). After the mechanical treatment but before the top coating is applied, the prime coating has to be cleaned (grease, oil and other impurities) with solvents and / or hot stream. Application temperature for two pack epoxy resin coating at least 5 degrees C Surface temperature minimum 5 degrees C above dew point. Maximum atmospheric humidity: not higher than 75 %. The proportion of mixture for two component products are to be strictly followed. Waiting times between coatings to be observed according to specification. For multilayer it is advisable to change the shade of colour (for later abrasion). Otherwise abrasions have to be checked by measuring film thickness. Edges have to be pre coated. Not to prime a strip of 150 mm beside the planned site welds (especially important for zinc rich primers) Prior to the top coating, the prime coating has to be repaired carefully. 4 GALVANISING: All drilling, punching, tapping, cutting and bending of the parts shall be completed and all burrs removed prior to galvanizing. Galvanising shall be applied by the hot dipped process and shall consist of the smooth clean zinc coating free from defects and of uniform thickness. Original blast furnace raw Signature of Bidder 34 Signature of Purchaser
zinc ( minimum purity 98%) shall be used. The zinc coating shall weight not less than 600 g/m2 of area covered. Sheardizing or other alternative process shall not be used without the approval of the purchaser and / or consultant. Material on which galvanizing has been damaged shall re-dipped unless, in the opinion of the purchaser, the damage is local and can be repaired by applying a coat of galvanizing repair paint where such repair is authorized the damaged area shall be cleaned by wiping with clean rags saturated with mineral spirits or xylene followed by wire brushing. After wire brushing, the area shall be re-cleaned with solvent to remove residue and shall be given a minimum of two coats of zinc primer containing not less than 98% (by weight) of metallic zinc in the dry film which shall have a total thickness of not less than 60 micrometers. Galvanised surfaces should be kept apart in storage and transport. If this is impossible, they should be treated by dipping in a 10 to 18% solution of chromic acid, which should produce a coating of 12 micrometers. This coating must be removed before any painting is attempted. 5 METAL SPRAYING : Subject to the approval of the purchaser where an item is of a size or shape to render hot-dip galvanizing impracticable, zinc spraying or other approved method of coating may be adopted. Metal spraying of surfaces shall comply with the following procedure: Surface preparation prior to spraying shall be dry grit blasting to a standard approved by the purchaser and/or consultant. Immediately after grit blasting, the surface shall be cleaned of any traces of blast products on the surface and in pockets, pits and corners by brushing with clean brush, blowing with compressed air or vacuum cleaning. The surface shall be coated with the metal spray before discoloration occurs. In the event of the surface becoming contaminated e.g. with rust, oil or dirt between blast cleaning and applying the metal spray, it shall be recleaned by repeating the above procedures. Care shall be taken to have as little roughness as possible on the sprayed surface.
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NON METALLIC COATINGS : Coatings in this category include sprayed or sheet linings, as applied to tanks, vessels and pipes carrying aggressive fluids and wrappings as applied to buried or immersed pipe work. The materials employed may be rubber, PVC sheet, glass reinforced resin or plastic. Surface preparation and application of the coating shall be strict in accordance with the approved instructions of the coating supplier.
WETTED SURFACES CORROSIVE MATERIALS : The material to be protected is usually under water and exposed to constant flow. Erosion through water with a more or less high sand content is one of the main strains for these parts. Therefore the coating has to be of high quality, epoxy resin is best suited. In order to endure chemical aggression of soiled water, the coating material is mixed with coal tar, which is also resistant against bacteria, fungi and algae. The coating system is set up as follows: Prime coating: One layer of two pack high zinc pigmented epoxy primer. This primer is an active corrosion protection, above all to avoid under rusting if the top coat is damaged or porous. Film thickness: 60 micrometers. Top coating: Two pack modified epoxy coal tar. Depending on the application place or the suitability of the part, there will be distinguish between two layers of two pack modified epoxy coal tar containing solvents of 100-150 micrometers . Colour : black or red. This material can be applied by brushing or by airless spraying or the normal use more than one coat is necessary. Total film thickness: 260-360 micrometers. Or one layer of two coat modified epoxy coal tar solvent free material of 300 micrometers. Colour : black. The material can only be applied with a special machine. Standard applications are one coat. Because of the lack of solvents in the painting material, there is no danger of pores. Total film thickness: 360 micrometers.
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REMARK: Condensation zones where the colour is not visible from outside, may be coated with epoxy coal tar. 8 NON-CORROSIVE MATERIALS: Normally highly alloyed stainless steels, Ni : Cr, 4 : 13 (can be corrosive if soiled) and bronze e.g. red brass are not to be coated. It is important, however, that the contact areas stainless steel / normal steel are carefully protected by coating, also a stripe of the non- corrosive material, otherwise an amplified corrosion may occur (Contact corrosion). Machine with long rest periods (e.g. pumps) are exposed to increased localised corrosion similar to pitting (localised corrosion) usually on the base materials when the coating is porous and damaged. EXCEPTION: If a stainless steel part required a coating due to reasons such as photographing or decoration, a water and oil resistant synthetic resin primer should be applied. Such a coating has to be especially required by the purchaser. 9 ZONES WETTED BY CONDENSATION : The main strain for zones wetted by condensation is the permanent rewetting, i.e. interchange : wetting drying. The visible surfaces are less stressed. However, surface quality and appearance (shade of colour) require a high standard of material. Gloss and semi gloss finishes facilities cleaning. Due to practical reasons visible and invisible (dry) surfaces are not differentiated. The same applies for visible surface of stainless materials. The coating system is set up as follows : Prime coating : One layer of two pack zinc rich epoxy primer to avoid under rustings if the top coat is damaged or porous. Film thickness 60 micrometers. Intermediate Coating : One layer of two pack micaceous iron oxide epoxy paint (two coats if exposed to condensation). The micaceous iron oxide in lamellar from embedded in the epoxy oxide is a perfect pore protection and has excellent adherence properties for the top coating. Signature of Bidder 37 Signature of Purchaser
Film thickness : 60 micrometers, Top coating : One coat : Either polyurethane acrylpoiyol micaceous iron oxide coat of 60 micrometers (recommended for outdoor coating providing a mat glossy surface ). Or polyurethane top coating of 60 micrometers with a glossy surface, usually applied for indoor coatings. The polyurethane based top coats have very good abrasion and mechanical resistance in addition to a proven corrosion protection and an excellent colour retention. Total film thickness : 180-240 micrometers. REMARK : Parts covered with epoxy coal tar on the water side should be coated with the same material on the condensation water side if the shade of colour is not important. 10. OIL WETTED SURFACES : For oil tanks, bearing casings, servomotors etc. As a standard coat as a one pack synthetic resin primer is sufficient. This coat is oil and water resistant upto 150 degree C. The first primer is applied before the tightness test and the second coat is applied after assembly. The total film thickness : 80 micrometers. 11 COATING OF MACHINED SURFACES : Machined surfaces require a two pack epoxy resin zinc chromate or zinc phosphate pigmented prime coat to improve adhesion to the base material. A standard top coating may then be applied, depending on the strain the parts are exposed to total film thickness : 120-160 micrometers. REMARK : Generally sand blasting after machining (if possible) is preferred because of the adhesion of the paint. Sand blast surfaces may then be coated in the normal manner. 12 BLANK SURFACES : These surfaces are only to be protected for transportation and temporary storage with a soluble lacquer. Signature of Bidder 38 Signature of Purchaser
13.
PIPEWORK WATER PIPES All such pipes, except those of corrosion resistant material shall be blast cleaned and be coated by dipping in acid free hot bituminous compound to give an acceptable finished coating thickness. Ends of pipes and tubes subject to weld joining at the site shall be left uncoated over a distance of approx. 100 mm. After site welding the erection welds shall be coated with 2 layers of zinc rich primer containing not less than 95 % (by weight) of metallic zinc in the dry film, which shall have a total thickness of not less than 60 micrometers. Finishing of the ends of pipes and tubes interior shall be by a layer of zinc rich chlorinated rubber paint. The exterior of small pipes shall be carefully cleaned and pickled and coated with 2 layers of zinc-rich chlorinated rubber paint. Exterior surfaces of pipes and tubes, except those of corrosion resistant materials shall be primed with three layers of red lead paint on chlorinated rubber / synthetic resin basis (total minimum thickness of the dry film : 100 micrometers) .. Uninsulated and unwrapped pipes and tubes shall receive two subsequent layer of finishing paint on the same basis (total minimum thickness of the dried finishing coats : 60 micrometers) OIL PIPES Both the interior and exterior shall be thoroughly cleaned and pickled and rinsed very carefully to an approved method. The exterior surfaces shall subsequently receive two layers each of oil resistant priming and finishing varnish or enamel. The interior of fuel carrying pipes shall be protected by a corrosion prevention compound. AIR PIPES Same treatment and painting as for the water carrying pipes. The purchaser will decide on the finishing shades at a later date. AIR DUCTS External surfaces shall be coated with 2 layers each of priming and finishing paint.
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CUBICLES AND CABINETS FOR INDOOR INSTALLATION After careful sand blasting all cubicles and cabinets shall be given two priming and two finishing coats of varnish or enamel which in case of those carrying oil or liable to oil vapour exposition shall be oil resisting. A minimum dry film thickness shall be 100 micrometers in total. The insides of cubicles and cabinets where condensation is liable to occur shall be coated with four layers of an approved anti condensation composition. Other inside surfaces shall be coated with at least two layers of varnish of semi glass white. External surfaces of cubicles and cabinets shall be given to suppliers standard primer and machinery enamel or appropriate enamel for cubicles being used indoors for electrical equipment. All cubicles being located in one row must be painted with the same shade. FOR OUTDOOR INSTALLATION These cubicles and cabinets shall be given after careful sand blasting and hot dip galvanizing coat inside and outside. After etching these should receive two layers each weather resisting varnish or enamel.
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STEEL CONSTRUCTIONS INDOOR Same shall be thoroughly sand-blasted and provided with (two hours later) three layers of red lead primer on chlorinated rubber / synthetic resin basis (total minimum dry film thickness : 100 micrometers). Finishing shall be by 2 respective coatings on the same basis (total minimum dry Film thickness of finishers : 60 micrometers) Areas subject to oil and grease shall receive four layers of oil resistant priming and finishing varnish or enamel). This shall apply in particular to all transformers. OUTDOOR After careful blast cleaning with an approved method and cleaning of the surface after this process, all steel structures shall be heavily hot dip galvanized.
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WORKSHOP EQUIPMENTS, PUMPS, COMPRESSORS ETC. Treatment as per the suppliers practice and coating with the suppliers standard primer and machinery plant.
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PLATFORMS, HANDRAILS, COVER PLATES, TRENCH COVERS, ACCESS LADDERS ETC. All gratings shall be heavily hot-dip galvanized. Aluminum alloy chequered plates need no treatment and protection. Ferrous chequered plates shall be heavily hot dip galvanized. Handrails shall be heavily hot dip galvanized. These should after etching receive 2 layers of oil resisting varnish or enamel.
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PARTS IN CONCRETE The surfaces shall be cleaned from mill scale, dirt, oil, greace and other residues and shall be covered before leaving suppliers premises with a substantial coating of Portland cement wash or other proprietary coating. For parts in concerete, it is important that the zone between visible surface and zone in concrete a stripe of approx . 0.5 m of the concrete be coated, along the visible surface. Components under high pressure (penstocks or spiral cases) touching in concerete should be sealed additionally.
2.16
BALANCING For small rotating machinery all rotating parts and assemblies shall be well balanced both statically and dynamically at the suppliers works. The supplier shall rectify any out of balance that may occur during erection at site. Over dimensioned and heavy rotating machinery shall be statically and accurately balanced at the point of installation.
2.16.1 DOWELLING At all stages of assembly, where accuracy of fit has to be assured on site, dowel holes shall be provided with dowels to assist reassembly and load resisting if needed.
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2.17
ELECTRICAL EQUIPMENT
2.17.1 GENERAL The various auxiliaries and controls shall be suitable for operation on following power supply mains. i) ii) iii) 400 V, 3 phase, 50 Hz, A.C. 230 V, single phase, 50 Hz, A.C. 220 V D.C
The above power supply will be available with 10 % for AC voltage and + 10% and 15% for DC voltage and + 3% and -5% frequency variations for AC supply. If any other voltage is needed, the supplier shall make his own arrangement with suitable power converters, transformers etc. to derive the required supply. The cost thereon is deemed to have been included in the bid. Electricity for construction work will be supplied free of charge by purchaser. 2.17.2 PUMPS AND MOTORS: Unless otherwise specified, oil pumps shall be directly coupled to driving motors and their type, capacity and performances shall be best suited to the requirements. The efficiency of the pumps shall be as high as practicable consistent with good design. As far as possible, the pumps shall be of standard size to facilitate replacement of parts. The pump shall be of the self priming type, if however any external means of priming are employed these shall be stated in bid and shall be subject to the approval of the purchaser. Driving motors to which pumps are coupled shall confirm to the general standards laid down in this specification. Gear motors, if employed shall be subject to the purchasers approval. The alternating current (A.C) motors of rating 120 kW shall be provided with direct on line starter at supply voltage of 400 V and those of rating > 120 kW shall be provided with star / delta starter. Rated power of motors shall be guaranteed at 85 % rated voltage and 95 % of rated frequency with closed air cooling according to IEC standard with interchangeable possibility. The pump capacities and the rating of the driving motors shall have liberal margin over the requirements. Motors shall be drip proof.
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All pumps shall be designed and constructed to ensure quiet and satisfactory operation without undue noise or vibration under all condition of discharge and pressure. Centrifugal pump casings shall be designed to produce smooth flow with gradual changes in velocities. In addition, the pumps shall be easily removable and replaceable. Suitable gaskets shall be provided for all pipe joints to ensure that they are leak proof. If any strainers are required with the pumps, these shall be included in the bid and be duplex type or by pass to enable periodic cleaning. All pumps shall be complete with the necessary piping, both on the suction and delivery sides and with all fitting suited to the size and duty of the pump. Adequate number of valves as stated earlier shall be furnished with each pumping units to suit its operation and maintenance. Where ever necessary, pumps shall be provided with suitable flow meters or flow indicators and pressure gauges to measure the discharge and the pressure delivered by the pumps. Suitable eye bolts or lifting lugs shall be provided on each pumping set to facilitate handling. 2.17.3 ELECTRIC MOTORS AND MOTOR CONTROL GEAR :
All motors furnished by the supplier, for driving the unit auxiliaries and other apparatus shall be directly coupled to the apparatus driven and shall be suitable for operation on purchasers power supply. All motors to be supplied shall be energy efficient motors. The enclosure of each motor shall be of the type best suited to the service conditions of the motor and shall be subject to the approval of the purchaser in every case. The motor shall generally conform to the relevant Indian or IEC or other equivalent standards. The insulation shall be moisture, oil, oil vapour, drip proof and the motors shall be entirely suitable for the operation in the tropical climate conditions prevailing at site with 100 % humidity (degree of protection IP 54 or as applicable). Motor shall be provided with varnish cambric or glass insulation class F and shall be used for connections from the windings to the terminals. All motor terminals shall be of stud type and totally enclosed. The capacity, speed and torque characteristic of the motors shall be suitable for the starting and operating requirements of the associated apparatus. Signature of Bidder 43 Signature of Purchaser
Necessary starting, protective and control gear shall be furnished by the supplier with each motor. Instantaneous and thermal overload protection shall be provided for the motors together with remote indication of the operation of the protective gear, wherever necessary. In the case of essential motors stoppage of which would result in serious damage the thermal overload protection devices shall be arranged give alarm only, without disconnecting the motors. Red and green indicating lamps shall be furnished for indication of the closed and open positions respectively of motor contacts The control and indication equipment shall be suitable for operation with 220 V DC supply. Special type of motors, not adequately covered by the specification may be offered for any special application, but these shall be subject to the approval of the purchaser. 2.17.4 SMALL WIRING:
All small electrical wiring of various equipments, panels, etc. shall be completed at the suppliers work as far as possible. All small wiring shall be arranged neatly into flat or rectangular groups and shall be adequately supported with cleats etc. The small wiring shall be so arranged as to reduce the number of bends or crossing to a minimum. There shall be no splices in the wire and all connections shall made at the terminal studs or terminal blocks. Similar circuit shall be arranged to terminate as far as possible on adjacent terminals to facilitate grouping and to minimise the number of interconnecting cables. Secondary or control wiring including leads from the current transformers, temperature detectors, alarm contracts, speed and pressure switches etc., shall be enclosed in conduits and shall be carried to dust and water proof and oil tight cabinets located conveniently for connection to the control cables. Pressure circuits shall be suitably protected so that failure of one circuit shall not cause the progressive failure of adjacent circuits. Alternating current circuits, direct current circuits, shall be grouped separately and the wiring of each of these group shall preferably be segregated. For the purpose of easy identification, tracing and reconnection the wiring shall be colour coded according to relevant international or IS standards and shall be fitted near the terminals with ferrules or such other cup indelibly Signature of Bidder 44 Signature of Purchaser
marked with the identification number corresponding
with that of the
associated terminal blocks. When an electrical circuit is extended to several pieces of equipment necessitating sectionalising of circuit wiring at the terminal blocks of the corresponding equipments common identification numbers shall be used for the designation of the circuit at all the terminal blocks and connections. The terminals and circuit designation for all wiring shall be subject to the approval of the purchaser. All small wiring shall be switchboard type, single conductor, tinned annealed copper wire, PVC insulated cables as per relevant Indian or International standards, insulated with varnished cambric, which has proved its utility in tropical region against hot damp and moist climatic conditions and wiring complying with the relevant international standards. All small wiring shall have oil and oil vapour proof insulation. The sizes of the wiring for different circuits shall be so chosen as to provide ample margin for the purposes intended and shall subject to the approval of the purchaser. 2.17.5 TERMINAL BLOCKS: Terminal blocks shall preferably be made of suitable moulded plastic material and shall be provided with brass stud inserts for terminating the outgoing end of the cubicle wiring and the corresponding wiring of the incoming end. Provision shall be made on each block for holding 15% extra connections. All blocks shall be shrouded by easily removable shrouds moulded from transparent dielectric material. The terminal block shall be of disconnecting type and suitable for max. 1000 V service and dielectric test of 2000 V. Sufficient space for receiving the control cables inside the switch board at the bottom of the switchboard cubicles and mounting arrangements for the terminal glands shall be provided. Terminal block compartment shall be separated from the remainder of the equipment by oil and oil vapour proof barriers and scale, wherever necessary. 2.17.6 MEASURING INSTRUMENTS: All instruments and meters shall be suitable for operation under the climatic conditions prevailing at site. The instrument cases shall be dust proof, water tight, vermin proof and specially constructed to adequately protect the instruments against damages for deterioration due to high ambient Signature of Bidder 45 Signature of Purchaser
temperature and humidity, special care being taken in the protection of instruments for indoor and outdoor services also. The dials, pointers etc., shall be designed to facilitate glare from instrument window and by providing clear, bold, dial markings. The size of dial and length of the scales of indicating instruments shall be subject to the approval of the purchaser in each case. The scale of the indicating instruments which are to be mounted on main control panel shall cover approximately size 48 x 48 mm. Supplier can follow his standard practice for other instruments. The scale plates of panel mounted indicating instruments shall have a permanent white matt finish with black graduation. The pointer or the pointer indicating and contact setting (in contact working instruments) shall be distinguished from the main pointer by a distinct colour and/or shapes. Instruments mounted on panels shall be of the semi-flush finish type and shall be back connected. All instruments on a switchboard or instrument panel shall be of matching pattern, shape and finish so as to present a pleasing appearance consistent with the functional requirements. The finish of the instrument case shall be subject to the approval of the purchaser. All instruments shall be designed for accurate measurements of the quantity or state under all conditions of operations and any error due to change in the ambient temperature, over the entire range of temperatures obtainable at site, shall be kept to a minimum. The instruments shall be provided with all the auxiliary appliances and any special tools required for their maintenance. MKS (meter-kilogram-seconds) units shall be used for marking the instrument dials. The range shall generally be such that the normal operating values are indicated in the middle third of the scale. All electrical instrument coils shall be designed for continuous operation on at least 120 percent of the full rated current and voltage of the instruments. The instrument coil rating shall be coordinated with those of the associated instrument transformers. The VA burden of instrument coils shall be as low as possible, consistent with the best modern design. Electrical indicating instruments shall comply generally with the requirements of the Indian/IEC or any other International Standards and shall be of the accuracy specified in relevant sections. Recording instruments shall be of the strip chart type with chart scales having a suitable width. The chart shall be gear driven by a self-starting synchronous Signature of Bidder 46 Signature of Purchaser
motor wound spring device having ample torque even at reduced voltage and with at-least 8 hours spring reserve under all normal conditions of operation. The recording instruments shall be of withdrawal type for easy access to maintenance work. Sufficient number of chart rolls, recording ink for five years of operation and any special tools required for the maintenance of the instruments shall be furnished with each recorder. Integrating watt and VAR hour meters shall comply generally with the requirements of the international standards. Instruments provided with contacts shall have contacts suitable for 230V, A.C. or 220 V D.C. circuits. All instruments shall have as high accuracy as possible consistent with best modern design. The construction of instruments shall be mechanically sound and shall ensure permanence in the accuracy. The limits of error for different instruments shall be stated in the bid and their accuracy classification, where otherwise not specified, shall be subject to the approval of the purchaser. All instruments shall be tested in accordance with the requirements of the standard, wherever specified. In cases where no specific standards are mentioned, the supplier shall submit the list of the standards in accordance with which the instruments are proposed to be manufactured and tested and these shall be subject to the approval of the purchaser in every case. The instruments shall be capable of withstanding the following tests viz., effect of shock, effect of vibration, effect of humidity and dielectric tests of 2000 V to ground for one minute in accordance with relevant standards. 2.17.7 FLOW RELAYS Flow controllers, used throughout the works shall be equipped with adjustable contacts suitable for 220V D.C.System designed to change position on a decrease in flow below predetermined value. 2.17.8 LIMIT SWITCHES Any limit switch shall be entirely suitable for its specific application. Particular attention shall be paid to potentially harmful environmental conditions, including water, oil, dust, dirt, temperature variations and differential expansions, where switches operate through linkages. Precautions shall be
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taken to eliminate variations of setting and incorrect operations resulting from wear or tolerance. Operating voltage shall be 220V D.C. 2.17.9 CONSTRUCTIONAL REQUIREMENTS FOR CUBICLES AND PANEL BOARDS Switch boards, control, relay and metering panel shall be of robust, industrial type design and manufacture, formed of a steel frame and covered with smooth steel plate. The steel plate shall be sufficiently thick and properly stiffened to prevent distortion. If required, flush mounted hinged steel doors with latches shall be provided; doors shall be of the lockable type by means of approved key locks. The key lock shall be of the same type for all panels. All cubicles shall be fully enclosed and protected according to the protection class given in the specification. The lowest degree of protection shall be IP 44. The frames of the cubicles shall be designed to permit firm anchoring on the floor. The frames shall permit easy erection and allowance shall be made for extension of the cubicles by additional similar ones. Suppliers supply shall include all necessary mounting brackets, framing, foundation bolts and respective embedded metal to permit proper installation of the cubicles. 2.18 EARTHING The Supplier shall provide earthing terminals on all the equipments supplied under the contract and shall connect the earthing conductors (95-120mm copper) to these terminals as approved or directed by the purchaser. The Supplier will provide the earthing conductors from the station earthing bus to the equipment. Supplier shall do equipment earthing. The Supplier shall provide suitable test terminals at convenient points of the equipments being supplied to enable periodic testing of the receptivity and insulation level of the equipments. Purchaser will provide earth mat and mild steel flats. Supplier shall provide suitable earthing terminals with bimetal clamps, washers, nut bolts, lug etc. suitable for both connections. 2.19 UNITS According to the latest edition of the relevant Indian and/or IEC publications shall be used for this contract. For the purpose of design/calculations, SI Units shall be used. Signature of Bidder 48 Signature of Purchaser
2.20
PROTECTIVE GUARDS Suitable guards shall be provided for protection of personnel on all exposed rotating and/or moving machine parts. All such guards with necessary spares and accessories shall be designed for easy installation and removal for maintenance purpose.
2.21
STORAGE AT SITE The supplier shall furnish complete instructions regarding the storage of the equipment at site. If at any time after the receipt of equipment at site, supplier or his representative desires to draw the attention of the purchaser to the conditions of storage, which in his opinion might affect the state of the equipment stored, he shall do so in writing to the purchaser. Periodical inspection of stored items shall be the responsibility of supplier.
2.22
RATING PLATES, NAME PLATES AND LABELS A rating plate of non-corrodible material metal sheets shall be attached to major and auxiliary item of equipment supplied. This plate shall be permanently engraved with the designed full load ratings, serial number, type, number, date of manufacture and other identification deemed necessary. Where necessary, diagram plates shall also be supplied. A name plate shall be provided to identify the service of major items of plant supplied. The purchaser shall approve the identifying description. Devices shall be identified by name plate on both front and rear of all desks, panels, cubicles etc. Names plates or labels shall be manufactured of stainless steel or aluminum alloy with engraving of contrasting colour or alternatively for indoor use of transparent plastic material with lettering engraved on the back and filled with enamel. These shall be in English language only.
2.23
TESTS In accordance with stipulations of General Conditions of Contract and Special Conditions of Contract the test shall be performed. Brief details of tests are as follows but shall not be limited to the same.
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2.23.1 GENERAL Inspection and testing of the equipment shall include all inspections, tests, checks, procedures etc. technical specifications. The tests include, but are not limited to the following. Turbine model test Chemical analysis of materials Destructive and non-destructive tests of materials Check and examination of welds Check of fits and assemblies Dimensional checks Inspection of paints and coatings (thickness and porosity) Hydrostatic pressure and tightness tests Balancing tests Shaft run-out tests Electrical tests Running tests (inclusive measurements of vibration and noise levels). Functional tests Performance tests Load and overload tests Load rejection and load taking-up tests Acceptance tests (prototype output and efficiency tests) Type tests if specially required The technique, equipment and instrumentation to be used for these tests, checks, inspections, examinations etc. shall generally be in accordance with the relevant internationally accepted standards, rules or codes mentioned in except where specifically mentioned in the technical specification. If in the purchasers and/or consultants opinion instruments, apparatus, devices etc. used by the supplier (or sub supplier) need calibration or recalibration then such instruments, apparatus, devices etc. shall be calibrated at the suppliers cost by an independent authority or institute subject to approval by the purchaser. Whether mechanical, hydraulic or electrical as required to ensure that the equipment supplied meets the requirements of the
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2.23.2 RANDOM SAMPLE TESTS These tests are to be carried out on random samples from a lot of equipment, parts or material. The purchaser and/or consultant shall do the choosing of samples to be tested, parts etc. and the complete lot of equipment be presented for this purpose. The number of samples taken will be either at the discretion of the purchaser and/or consultant particularly for small lots, or shall conform to the generally accepted rules and standards of statistical testing. The whole lot, of which the samples have been taken, shall be considered satisfactory if none of the sample tested has failed. Should any one of the samples fail, even in any one test, the following shall apply. a) b) SMALL LOTS: All pieces shall be fully tested. LARGE LOTS: A second set of samples, identical in number to the first one, shall be chosen and tested. If the set passes all tests satisfactorily, the lot shall be considered to be accepted. If again one or more sample fails in the tests, either the whole lot shall be rejected of all pieces of the lot be fully tested individually. The decision as to which of the two alternatives shall be adopted shall be with the purchaser. Pieces of lots which have been declared non acceptable and samples which have failed in test must be marked immediately and must not be presented for test again. 2.23.3 TESTS AT SUPPLIERS WORK Before any material, equipment, aggregate, apparatus etc. is packed or dispatched from the supplier or sub-suppliers works, all tests, inspections, checks, examinations etc. required by the relevant and international accepted standards, rules or codes shall be carried out as far as practicable and agreed in the specifications. All equipment, materials, aggregates, apparatus and other parts of components of the works to be tested, inspected, checked, examined, etc. at the suppliers or sub-suppliers works shall be properly accessible for testing and inspection work. There shall be no interference or disturbance from other shop activities when conducting the tests and inspections. It shall be understood that all equipment materials, aggregates, apparatus and other parts or components will be adequately shielded and protected against weather whilst being tested, inspected, checked and examined. Signature of Bidder 51 Signature of Purchaser
Parts and components shall be assembled to the fairest possible and agreed extent and dimensional checks shall be performed on all major assemblies, sub-assemblies, parts and components especially when close tolerance and fits are being involved (tolerance of shafts, clearance between stationery and moving parts, connecting dimensions for the assembly with other elements and supplies, combined functioning of electrical equipment etc.) Components and parts to be weld assembled at the site, shall be tag welded in the shops to permit visual and dimensional check of the fits and transmissions. All such components and parts shall be match marked properly to ensure correct assembly and welding at the site. If dimensional checks show discrepancies in measurements, which may affect the fit transition clearance, assembly or dismantling of the respective part or component, immediate, proper, and workman like correction or modification is a must. Such correction or modification shall, however, in no way lead to sacrifice with respect to reliability of operation or inter-changeability and shall be performed only after the agreement of the purchaser and/or consultant has been obtained. If the correction or modification can not be carried out in accordance with the terms mentioned above, the part or component concerned may be subject to rejection. Doubtful, used, weak and faulty materials or products will also become automatically liable for rejection. Shop testing shall also cover the hydrostatic pressure testing of equipment which can be finish assembled in the suppliers or his sub Suppliers premises. Pumps, fans, compressors and apparatus shall be tested at the manufacturers works. If two or more identical pumps, fans, compressors and apparatus etc. are supplied a complete performance test is to be carried out on the first unit only. Such performance test shall comprise the verification of the discharge capacity against discharge pressure, power input and efficiency and other performance data requested in the specification. The respective test diagrams shall be provided. Subsequent units need to be tested only if test results obtained from the first unit prove doubtful or unsatisfactory. Evidence and diagrams of previous type tests undertaken on identical design of pumps, fans, compressors and apparatus may be acceptable Signature of Bidder 52 Signature of Purchaser
instead of further complete performance tests, but the purchasers approval must be sought in each case. A test at the duty point will, however, in any event be required. Particular requirements have also been set out in the specifications. As far as possible tests on pumps in the manufacturers works shall be carried out with suction conditions as those after installation at the site. Cubicles, cabinets and control boards shall, prior to their inspection and testing, be completely definitely assembled, equipped and wired internally in the suppliers or his sub Suppliers shops. Shop testing shall include functional tests as the case may be part or complete assemblies to the extent practicable and agreed. Such tests shall be performed under, as far as possible in operation like conditions. When requested by the purchaser the functional tests shall be repeated or extended until proof has been obtained that the functioning of the assemblies will comply with the requirements of the specification. 2.23.4 TESTS AT SITE During erection and installation work at site, the equipment shall be subject to tests which may include but not be limited to the testing, checking, inspection and examination of all equipment assembled/welded and set up at the site. The procedure may be confirmed upto final acceptance of the works. The supplier shall provide at his cost, all competent personnel (including those from sub-supplier) as well as all equipment, material and other services required for the proper and the complete testing and putting into commercial service of all equipment. If in the opinion of the Purchaser not sufficient competent personnel have been delegated, the Purchaser may request the Supplier to send additional appropriate competent personnel to the site. Further to the tests, checks, examinations etc, stipulated in technical specifications, the tests at the site shall comprise but not be limited to: Checks and examination of welds Hydrostatic pressure tests Tightness tests Dielectric tests
Dry rotation tests (with clearance and run out checks)
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Functional checks (on protective devices, automatic and manual controls, monitoring, supervisory equipment etc.) Running tests Reliability tests
Performance tests and determination of characteristic data and tests in particulars of the turbine and generator. Turbine acceptance tests (in accordance with IEC-Publication for field acceptance tests to determine the hydraulic performance of hydraulic turbine)
Regulator acceptance tests (in accordance with the IEC Publication 308, 1970, International Code for testing of speed governing systems for hydraulic turbine)
2.23.5
RELIABILITY TESTS After the supplier has notified the purchaser and received his agreement that the equipment is ready for commercial services, the generating units may be operated continuously at rated speed and maximum output for a maximum period compatible with site conditions. After successful completion of such tests, the unit shall be operated under the various conditions envisaged within the limits of maximum output either continuously or intermittently, for a period of ninety (90) days with a view of obtaining useful information and to verify if the interest of specifications are met or otherwise. The equipment will be operated by the purchasers staff with the assistance and as per the advice of the suppliers staff during the reliability test period. The supplier may request any minor adjustments, which may be necessary provided that such adjustments do not in any way, interfere with or prevent the use of the equipment by the purchaser or result in reducing the output or decreasing the efficiency. If any failure or interruption occurs in any portion of the equipment covered by the contract due to, or arising from faulty design or materials, or workmanship (including construction at site) sufficient to prevent full use of the equipment, all the reliability tests shall be repeated after the supplier has remedied the cause of failure or interruption.
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2.24
REPORT OF CHEMICAL ANALYSIS OF WATER Source of water sample : Nirabai River , Date of sampling : 24/05/2010.
Sr. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 2.25
Parameters Colour Odour pH Suspended Solids Dissolved Solids Total Solids Turbidity Alkalinity Chiorides (as Cl) Sulphate(as SO4) Flurides (as F ) Calcium (as Ca) Total Hardness (as CaCO3) Iron (as Fe) Magnesium (as Mg)
Results Clear Odour Free 6.7 34 mg/lit. 96 mg/lit. 130 mg/lit. 5.0 NTU 66 mg/lit. 8.5 mg/lit. 9.5 mg/lit. 0.4 mg/lit. 12 mg/lit. 76 mg/lit. 0.044 mg/lit. 11.18 mg/lit.
APPLICABLE STANDARDS Unless otherwise specifically stated, the applicable standards would be the latest revisions of the relevant IEC standards/codes or other standards, which are equivalent to IS or IEC. The supplier is requested to get himself acquainted with Indian Electricity Acts and Rules and follow those. Generally applicable standards are as under but not limited to: IEC standard for main turbine
IEC 193(1963) IEC 193A (1972)
International code for model acceptance tests of hydraulic turbines (code X) Amendment No.1 (1977) (code K) First supplement (code P)
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IEC 308(1970) IEC 497(1976) IEC 41(1991) IEC 545(1976) IEC 609(1978) IEC 994(1991)
International code for testing of speed governing system to hydraulic turbine (code X) International code for model acceptance tests of storage pumps (code X B) Field acceptance test to determine the hydraulic performance of hydraulic turbine storage pumps and pump-turbines.(code XK) Guide for commissioning, operation and maintenance of hydraulic turbines (Code S) Cavitations pitting & valuation in hydraulic turbines, storage pumps & pump turbines (Code P) Guide for field measurement of vibration and pulsation in hydraulic machines (turbine, storage pumps and pump-turbines) (Code XB)
IEC 995(1991)
Determination of prototype performance from model acceptance tests of hydraulic machines with consideration of scale effects. (Code V)
Note: IEC 198(1966) acceptance tests of pump turbines and IEC 609 (1978) Thermodynamic measurement are replaces to IEC 41 (1991) IEC standard for accessories of turbine. ASME VIII, ASME V ASTMA 435 ASTMA 609, ASTMA 709 IEC 404 ASME Boiler and pressure vessel code section VIII, Dim 2 Low cycle fatigue. IEC- 34.9 ISO- 1996 VDI-2056 IEC 298(1990) Noise limits for electrical machines. Noise measuring. Vibration limit. . ASTMA A 388 and Welding materials
A.C. metal enclosed switchgear and control gear for rated voltage above 1 KV and up to and including 52 kV (code XA) Amendment No.1 (1994) (Code K)
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IEC 264
Packaging of winding wires 264.1, 264.2, 264.2.1, 264.2.2, 264.2.3, 264.3, 264.3.1, 264.3.2, 264.3.3, 264.3.4, 264.4, 264.4.1, 264.4.2.
IEC 502(1994) IEC 227
Extruded solid dielectric insulated power cables for rated voltage from 1 kV up to 30 kV (code XA) Polyvinyl chloride insulated cables of rated voltage up to and including 450/750 V, 227.1(1993) (code S), 227.2(1979)(code K), 227.3(1993) (code Q), 227.4(1992) (code H)-227.5(1979) (code P), Amendment No.1 (1987) (code B), Amendment No.2 (1994) (code D), 227-6(1985) (code L).
IEC 228(1978) IEC 228 A (1992)
Conductors of insulated cables (code M) Amendment No. 1(1993) (code D) First supplement, Guide to the dimensional limits of circular conductors (code E)
IEC 287(1982)
Calculations of the continuous current rating of cables (100% load factor) (code XB) Amendment No. 1 (1988) (code G) Amendment No.2 (1991) Amendment No 3(1993) (code E) (code L)
IEC 287.1.2(1993) Part 1:
Correct rating equations (100% load factor) and
calculations of losses - Section 2 Sheath eddy current loss factor for two circuit in flat formation. (Code U) IEC 287.2-1(1994) Part 2: Thermal resistance section 1: thermal IEC 947-2(1989) (Code XB) Amendment No.1 (1992) (code U) Amendment No.2 (1993) (code S) IEC 947-4-1(1990) Part 4 contactors and motor starters Section 1 Electro mechanical Suppliers and motor - starter (code XD) (This publication supersets IEC 158-1(1970) and its Amendment (1983) and 158-1c. IEC 269 Low voltage fuses resistance.(Code V) and calculation of
Part 2: Circuit breaker (This publication Supersedes IEC 157-1
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269-1
(1966)Part
General
requirements
(code
XB)
Amendments No.1 (1994) (code B) 269-2(1986) Part 2 Supplementary requirements for fuses for use 269.2.1. (1987) by authorized persons (fuses mainly for industrial application) (code G) Part2 Supplementary requirements for fuses for use by authorised persons (code D) Amendment No. 1 (1993) (code F) Amendment No.2 (1994) (code B) 269-3 Part 3 269-3.1Part 3 Supplementary requirements for fuses for uses by unskilled persons (code L) Supplementary requirements for fuses for uses by unskilled persons (code XD)269-4 (1986) Part - 4 Supplementary requirements for fuse links for protection of semiconductor devices (code U) IEC 357 IEC 364 IEC 508 IEC 408 IEC 439 IEC - 51 IEC 145(1963) IEC 52(1988) IEC 255 IEC 72 IEC 404 IEC 947 - 5 - 1 Electrical installation of buildings Methods for measuring the performance/electric ironing machines for semi conductor IEC 147 IEC 947 - 3 Low voltage switchgear and control gear assemblies. 439 - 1, 439-2, 439-3, 439-4. Direct acting indicating analogue electrical measuring I instruments and their acessories.51-1 to 51-9 VAR hour meters. (Code R) Class 0.5.1 and 2 alternating current watt hour meter (code w) Electrical relays 255 - 1.00 to 255-23. Dimensions and output series for rotating electrical machines 72 -1 to 72 -3. Magnetic materials 404-1, 404-2, 404-3, 404-4, 404-5, 404-6, 404-7, 404-8, 404 8.1, 404-8.2, 404-8.3, 404-8.4, 404-8.5, 404-8.6, 404-8.7, 404.8.8, 404-8.9, 404-8.10, 404-9, 404-10, 404-11, 404-12. IEC 34-9(1990) Part 9 Noise limit for rotating, electrical machines (code K)
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IEC 34
Rotating electrical machines
34-1, 34-2A, 34-3, 34-4, 34-5,
34-6, 34-7, 34-8, 34-9, 34-10, 34-11, 34-11-2, 34-11-3, 34-12, 34-13, 14-14, 14-15, 34-16-1, 34-16-2, 34-17, 34-18-1, 34-18-2, 34-183. IEC 76 IEC 56(1987) Power transformers 76-1 (1993) - 76-2 (1993), 76-3 (1980), 763-1 (1987), 76-5 (1976). High voltage alternating current circuit breakers (code XH) Amendments No.1 (1992) (Code M)831,871,931
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SECTION III SCHEDULE OF REQUIREMENTS
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SECTION III SCHEDULE OF REQUIREMENTS INDEX Sr.no. I 3.1 3.2 3.3 3.4 3.5 II 3.6 3.7 3.8 Description MECHANICAL LOT Turbine Governor Spherical valve Station auxiliaries Spares ELECTRICAL LOT Generator and static excitation equipment 11 kV XLPE cable and 12 kV Bus Duct Isolator, earthing switch, magnetic voltage transformer, current transformer 3.9 3.10 3.11 Protective and Metering System Supervisory control and data acquisition system Spares 75 76 79 70 72 73 62 64 65 65 66 Page no.
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SECTION III SCHEDULE OF REQUIREMENTS I 3.1 MECHANICAL LOT TURBINE 1 No. Horizontal shaft Pelton turbine. Turbine shall be capable of developing maximum continuous output of at least 11000 kW at rated net head of 402 m. Turbine shall consist of: 1 No. Pipes between Penstock and Spherical valve (i.e. penstock special), between Spherical valve and Distribution pipes of the turbine including stiffeners. installation material etc. complete with pipes, duplex valve systems. Valve shall be suitable for operations from Spherical valve gallery. 1No. 1No. 1No. Turbine housing Pelton runner with adequate no. of buckets Turbine shaft (Runner mounting on extended generator shaft may be allowed, if offered by bidder) 1No. Turbine bearing (Drive end side) with H. S. lubrication (if required), oil coolers, Resistance temperature detector (R.T.D.s), Dial type thermometers (D.T.T.s) etc. with piping, valves etc. 2Nos Jet deflectors (interlinked) with deflector servomotor
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2Nos.
Nozzles each with needle servomotor and needle operating device, regulating apparatus, servomotor double acting type etc. complete with locking device, oil pipelines, valves, pressure gauges, limit switches etc.
1Set 1Set. 1 Set 1 Set. Lot
Brake jet assembly including necessary piping, valves etc. Oil pressure unit and oil pipe lines Penstock drainage system Expansion joint, air release valve Thermometers, thermal relays, all level gauges and relays, water pressure gauges and relays etc. Gauges, temperature indicators etc. to be mounted on unit control board covered under electrical lot. Supplier of Mechanical and Electrical lot shall co-ordinate to include all interfaces suitable for local/remote and auto operations of the system.
1 Set
Oil leakage system if needed (requirement shall be justified at bidding stage) complete with tank, motor-pump sets, pipes, valves, level switches, gauges etc.
1 Set 1 Set 1 Set Lot
Velocity measuring devices before Spherical valve. Water level measuring devices. Mechanical over speed device Control and Power Cables Power cables for local control board to equipment, local control board to unit control boards and up to distribution board shall be provided by the Supplier. Control cables, racks, dressing of cables by nylon /plastic belts, ferrule, glands, copper lugs etc. for entire system of equipment covered under the
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scope of supply shall also be provided by the supplier. All cables shall be FRLS, HRPVC insulated copper conductor stranded type. Lot Lot Oil, grease, lubricants sufficient for first filling and 25% spare quantities. All accessories viz. sole plates, foundation and anchor bolts, platforms, ladders, guards, hand rail, bolts, nuts, turn buckles etc. complete 1 Set 1 Set 1 Set including requirement during installation and of permanent nature. Turbine junction box. Runner inspection & maintenance platform (if required) Necessary instrumentation, control, safety devices etc. along with the spares and special tools and plants required for erection, operation & maintenance including the following. Runner removal tools complete. Hydraulic jacks for pre-stressing of the shaft coupling bolts, Hydraulic jacks for pre-stressing of the Turbine cover and bottom ring. Tools and Tackles required for handling of bearings. All tools for assembling and dismantling guide bearing, shaft seal, nozzles, deflectors, nozzle pin, runner, turbine shaft support collar etc. 1 Set 1 Set All test kits, instruments, meters etc. for commissioning, routine and special tests at site. Slings for handling the bearing, runner, shaft head cover, servomotor etc. 3.2 GOVERNOR 1Set Governing system including digital governor, speed signal generator, over speed trip device, emergency shut down device, restoring mechanism, Oil pressure Unit etc.
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3.3.
SPHERICAL VALVE 1 No. Spherical valve (to suit for 1000mm dia. Penstock ) with service and maintenance seals complete with oil hydraulic drive, Oil pressure Unit, main and stand-by pump-motor unit for servomotor for opening operation, air valve, counter weight or pressurised water piping with valves for closing operation, draining system, all accessories, gauges, meters, indicators etc. complete. 1 Set Erection and maintenance tools for Spherical valve.
3.4
STATION AUXILIARIES Compressed air system is required for Governor OPU, MIV OPU, Generator Braking and service air and consists of : 2 nos. 2 nos. 1 no. 1 no. 1 no. 1 lot 3 Stage Reciprocating Compressors Moisture Separators High Pressure Air receiver Pressure reducer Low Pressure Air receiver (for Generator Braking and service air) Pipes, valves, instruments & fittings.
3.4.1 COMPRESSED AIR SYSTEM
3.4.2 COOLING WATER SUPPLY SYSTEM Cooling water required for unit operation shall be tapped from penstock before Spherical valve. The exhaust water shall be led down in to the tail race. Cooling water system shall cater for the cooling water requirements of entire power plant i.e. turbine and generator and shall comprise of : Water Pressure reducer set Stop Valves, safety valves, strainer duplex filters and piping with control devices, instruments etc., complete. The piping shall be complete from penstock tap upto discharge point. Signature of Bidder 65 Signature of Purchaser
3.4.3 DRAINAGE & DEWATERING SYSTEM Comprising of adequate no. of submersible type pump-motor units, complete with control, protection and switchgear panels, level control devices, piping, valves, check valves, clamps, supports, anchors etc. The piping shall be complete from pump room up to discharge point. 3.5 SPARES
MANDATORY SPARES FOR MECHANICAL LOT
Item No. I A) 1 2 3 4 5 6 7 8 9 10 11 12 13
Description
Quantity
MACHANICAL LOT TURBINE Needle Nozzle Bush of needle assembly Deflector Bush of Deflector assembly Seals of nozzle assembly Springs (each type) Bearing segments/pads Piston rings for servomotor Bearings for regulating mechanism 1 No. 1 No. 2 Sets 1 Set 2 Sets 2 Sets 2 Sets 1 Set 1 Set 1 Set
Shaft gland/ seal assemblies finished with fixing 1 Set elements. Shaft seal water filter elements (If filters are 1 Set required) Removable protective bush of shaft 1 No. 66 Signature of Purchaser
Signature of Bidder
Item No. 14 15 16 17 18 19 20 21
Description
Quantity
Solenoid coils per solenoid used Flow relay of each type used Annunciator lamps of each type used Mercury thermometer of each type used Resistance thermometer of each type used Limit switch of each type used Necessary recording charts for one year operation. Consumables such as all packing, gasket and jointing material used throughout the turbine, including those for the servomotors and for the man doors. Ten per cent (10%) of all bolts, screws nuts and washers used up to and including M30 size. FOR GOVERNOR AND OIL PRESSURE SYSTEM Oil Pump complete with motor Hydraulic amplifier Pilot and control valve complete Transducers Equipment for checking turbine speed Equipment for limiting the opening of nozzle Oil pump for pumping leakage oil
1 Set 1 Set 1 Set 1 Set 1 Set 1 Set Lot 1 Set
22 B) 1 2 3 4 5 6 7 8 9 10 11
1 Set
1 Set 1 Set 1Set 1 Set 1 Set 1 Set 1 Set
Printed circuit boards used for speed and limit 1 Set setting. Safety relief valve 1 Set Setting Potentiometer of each type used. 1 Set
Float switches, pressure, flow and temperature 1 Set relays of each 67 Signature of Purchaser
Signature of Bidder
Item No. 12 13 14 15 16 C) 1 2 3 4 5 6 7 8 D) a)
Description
Quantity
Solenoids for each type of solenoid valve used Fuses of each type used Each kind of filter used
1 Set 1 Set 1 Set
Com Complete set of all packing, gasket and jointing 1 Set material used. percent (10%) of all bolts, screws, nuts and 1 Set washers up to and including M 30 FOR INLET VALVES (MIV) Service seal with all fixing Maintenance seal with all fixing Servomotor piston rings and packing Instrument and indicator of each type used. Control solenoid of each type used. Flow relay and man stat of each type used Limit switch of each type used Necessary recording charts for operation. FOR STATION AUXILIARIES DEWATERING EQUIPMENT Completely assembled submersible pump-motor 1 No. set DRAINAGE EQUIPMENT Completely assembled submersible pump-motor set COOLING WATER EQUIPMENT Pressure Reducer set 1 No. one 1 Set 1 Set 1 Set 1 Set 2 Set 1 Set 1 Set year 1 Set
b)
c)
1 No. 68 Signature of Purchaser
Signature of Bidder
Item No. d) 1 2 3 4 5 6 e) 1 2 3 4 5 E 1 2 3 5 6 7
Description
Quantity
COMPRESSED AIR SYSTEMS Piston Rings Unloader valves Bolts Gasket Oil filter elements All types of valves CONTROL AND SAFETY DEVICES Limit Switches Level Switches Float Switches Pressure Switch Flow Relays WATER LEVEL MEASURING DEVICE Printed circuit card Converter Surge Protector Water level detector Recorder Chart Digital indicator One (1) of each kind One (1) of each kind One (1) of each kind One (1) set of each kind Fifty (50) rolls One (1) of each kind 1 Set 1 Set 1 Set 1 Set 1 Set 1 Set 1 Set 1 Set 1 Set 1 Set 1 Set
Signature of Bidder
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ll 3.6
ELECTRICAL LOT GENERATOR AND STATIC EXCITATION EQUIPMENT. One No. One No. One No. One No. Horizontal shaft generator suitable for direct coupling with the turbine. Generator shall comprise of: Ventilation system air-cooled type Stator assembly complete with frame, core and winding. Rotor assembly complete with spider rim, brakes, jacks, field winding etc. One No. Terminal cubicle for machine housing surge capacitor, potential transformers, current transformers, lightning arresters, cable boxes, etc., complete. Neutral grounding cubicle consisting of grounding transformer, secondary loading resistor, current transformer, cable boxes, etc. One No. One No. Shaft with coupling flanges and bolts etc. complete. Generator bearing (Non-drive end side) with H. S. lubrication (if required), oil coolers, Resistance temperature detector (R.T.D.s), Dial type thermometers (D.T.T.s) etc. with piping, valves etc. One No. Forced/self lubrication system for bearings with externally mounted oil coolers complete with all the oil and water piping with valves, flow relays.(if required)
One No.
Signature of Bidder
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One Set
Air coolers (Air/Water heat exchangers) with valves, connecting piping, flow meter, thermometers and other fittings for generator cooling. (if required)
One Set.
Sole plates, foundation bolts, dowels and other fittings required for proper erection, leveling and alignment of stator, bearings, Turbine housing etc.
One Set. One Set.
Air guide cum air seal assembly. (if required) Brake and jack (if necessary) cylinders complete with all the necessary internal and external pipe work, valves, electrical remote switches with contacts and with brake dust collector.
One No.
Speed signal sensing device. Signal sensing device shall be complete with casing suitable to cover over speed device also.
One Set. One Set
Brush gear system with slip rings and brushes. Static excitation system complete with excitation transformer, thyristor cubicles, field flashing system, battery field flashing provision, field suppression cubicle with field breaker and discharge resistor, etc. complete.
One No. One No.
Digital voltage regulator. 11 kV Junction Bus panel with copper bus and necessary provisions of tapping for UAT etc.
One Set
All instruments and devices such as dial type thermometers, pressure gauges, resistance temperature detectors, thermostats, flow relays, oil level switches etc. complete shall be provided.
Signature of Bidder
71
One Set.
Turbine, generator gauge panel containing temperature gauge both of turbine and generator
One Set. One Lot
Temperature scanner Local control boards for equipment wherever necessary for control indication and alarm of the system shall be provided.
One No.
415 volt A.C. Power Distribution Panel required for motors of unit and auxiliaries.
One Set One Set One Lot
Rotor lifting device (if required) Complete erection tools required for unit. Testing equipment comprising the following I) 5kV megger, mains operated. II) Lubricating oil filter III) 10kV, tan-delta measuring kit 1No. 1No. 1No.
One Lot: One Set: 3.7
Mulsifire system for generator Operation and maintenance tools
11/11 kV, 1 X630 SQ.MM, COPPER CONDUCTOR UNARMOURED XLPE INSULATED POWER CABLE AND 12 kV BUS DUCT 11/11 kV, 1X630 sq. mm, copper conductor unarmoured XLPE insulated power cable for a machine shall comprise of :
Signature of Bidder
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Lot
11/11 kV, 1X630 sq. mm, copper conductor unarmoured XLPE cable from LAVT to isolator and from isolator to junction box bus panel to step-up transformer with one spare core. As shown in single line diagram.
Lot
11/11 kV, 1X630 sq. mm, copper conductor unarmoured XLPE cable tap run from 11kV Junction bus panel to unit auxiliary transformer with one spare core
Lot Lot Lot
12 kV, segregated 3 phases, 3 cores, Aluminum Bus Duct from Generator terminal to LAVT cubicle. 12 kV, segregated 3 phase, 3 core, Aluminum Bus Duct tap run to the cubicle of voltage transformers and disconnecting switches. 12 kV, segregated 3 phase, 3 core, Aluminum Bus Duct run to the cubicle of excitation transformer, disconnecting switches and current transformers.
Lot
12 kV, segregated 3 phase, 3 core, Aluminum Bus Duct tap run to the cubicle of surge absorber, voltage transformers and current transformers.
Lot Lot One Set One Set 3.8
12 kV, segregated 3 phase, 3 core, Aluminum Bus Duct cable tap run from generator neutral connection to neutral grounding cubicle. Support steel structure, hardware, trays, fixing belts etc. for entire XLPE cable run. Shorting Links for dry out and short circuit test All special tools required for erection and maintenance.
ISOLATOR, EARTHING SWITCH, MAGNETIC VOLTAGE TRANSFORMER, CURRENT TRANSFORMER 12 kV, 5 kA rating isolator as follows for each unit : One No. Isolator having own operating mechanism (before Unit Auxiliary transformer tapping in 11 kV junction bus panel and after LAVT
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panel) for back charging of step up transformer shown in single line diagram. One No. Earthing switch (after isolator and before 11kV junction bus panel) as per shown in single line diagram. One Set 3 nos. of Current transformer of two cores in Neutral Grounding Cubicle as per shown in single line diagram. One Set 3 nos. of Current transformer of four cores in LAVT cubicle for Protection and Metering as per shown in single line diagram. One Set 3 nos. of Current transformer of single core in LAVT cubicle for spare as per shown in single line diagram. One Set 3 nos. of Current transformer of two core in LAVT cubicle for excitation transformer ratio correction factor as per shown in single line diagram. One Set 3 nos. Current transformers of three cores in Junction Bus panel for differential protection of UAT and ratio correction factor of UAT for transformer and overall differential protection (as per shown in single line diagram ). One Set 3 nos. of Current transformer of two cores in Excitation cubicle for excitation transformer protection (as per shown in single line diagram). One Set 3 nos. of Current transformer of two cores in UAT cubicle for UAT protection and metering (as per shown in single line diagram).
Signature of Bidder
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One Set
Six nos. of Magnetic voltage transformers of two cores for Protection and Metering in LAVT Cubicle (as per shown in single line diagram).
One Set
Totally enclosed Surge protection capacitors and arrestors for connection in tap run of Bus Duct.
One set One set Lot One Set 3.9
Generator neutral Terminals Neutral grounding cubicle with grounding transformer/ resistor and voltage transformer. Fittings, accessories. Special tools required for erection and maintenance.
PROTECTIVE AND METERING SYSTEM 3.10.1 One set A) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Static protection system comprising of following protective relays: Generator, step-up Transformer Unit Protection Generator Differential Protection. Overall Differential Protection. Step-up transformer differential protection. Generator Stator Earth-fault protection. Generator-Rotor Earth-fault protection ( Two steps) Voltage controlled over-current protection. Loss of excitation (Minimum reactance protection) Reverse power protection. Under-impedance protection. Thermal over-load protection. Negative sequence phase current protection.
Signature of Bidder
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12. 13. 14. 15. 16. 17. 18. 19 20 21
Restricted earth-fault protection for star-connected secondary winding of step-up transformer. Over-frequency protection. Under-frequency protection Generator over-voltage protection. Generator under-voltage protection. Step-up transformer over-current protection. Over-current protection for Unit Auxiliary Transformer. Excitation transformer Over-current protection Unit auxiliary transformer differential protection Generator phase sequence check. Protection for D.C System * Under-voltage protection for 220 V D.C. * Under-voltage protection for 48V D.C. * Earth-fault protection for 220V D.C. * Earth-fault protection for 48V D.C.
B) One Set
In addition, the following static protective relays shall be provided i. ii. iii. Negative phase sequence relay (46) IDMT Over current relay (51) Stator earth fault protection (64G)
C)
One Set
Following mechanical protections shall be provided: a. Resistance temperature detectors (Pt-100) in stator core (12 no.) and in the bearings for indication, alarm and recording. RTDs are to be provided by Generator Suppliers.
Signature of Bidder
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b.
Turbine and generator bearing, metal and oil temperatures alarm/shutdown.
c.
Governor oil pressure low to block starting and very low for emergency tripping.
d. e. D) One Set
Over speed for normal and emergency shutdown depending upon its extent. Our speed relay-Mechanical And Electrical (12) The following protection shall be provided on the transformer.
(i) (a)
220 kV side of transformer Digital IDMT over current and earth fault relay with high set instantaneous element (50/51/64.)
(b) (c) (ii) (d)
T/F winding temp high alarm/trip control. T/F oil temperature high alarm/trip control. LV side of the transformer Digital IDMT over current and earth fault relay with high set instantaneous element (50/51/64.)
(e) (f)
T/F winding temp high alarm/trip control. T/F oil temperature high alarm/trip control.
Signature of Bidder
77
3.10.2
Metering System Lot Following metering equipments shall be provided on relevant panels. 1. kW meter 2. kWh meter 3. kVA meter 4. Ampere meter 5. Voltmeter 6. Power factor meter 7. Frequency/speed meter 8. Temperature meters.
3.10
SUPERVISORY CONTROL AND DATA ACQUISITION SYSTEM One set Microprocessor based control system comprising : 1. 2. 3. 4. 5. 6. 7. 8. 9. Integrated Operation Station (IOS) Integrated Data base station (IDS) Integrated Engineering Station (IES) Printer. Micro Controller (HDC) Power Distribution Equipment (CVCF). Main control board, 220 kV control & interface board and mosaic board Man machine Interface. (MMI) Computer system with main control board and function keyboard.
Signature of Bidder
78
3.11SPARES
MANDATORY SPARES FOR ELECTRICAL LOT
Item No. 3.11.1 1
Description FOR GENERATOR Stator upper and lower bar with insulating material to form 1/3 stator winding
Quantity
1 Set
2 3 4 5 6 7 8 9
Field coils. Generator bearing segment/ pads Brushes with brush holders Brake liners Generator air coolers Oil coolers for Generator bearing. Dial type thermometer Thermostat bearing etc. for air circuit,
1 set 1 set 1 set 1 set set 1 set 1 set 1 set
10
Water flow relays for air coolers, bearings, etc.
1 set
12 13 14 15 16 3.11.2
Gaskets for brake cylinders Gasket/ washers for air water coolers Speed device equipment Fans with driving electrical motors Embedded detector for bearings EXCITATION AND DIGITAL VOLTAGE REGULATOR EQUIPMENT
1 set 1set 1 set set 1 No.
Parts of magnetic contactor a) Contactor b) Operating coils 1 piece of each kind of contactor 1 piece of each kind of contactor
Uninterrupted Power supply in DVR
1 set
Signature of Bidder
79
Item No. 4
Description Converting measuring and supervision units for slips stabilization
Quantity 1 set
5 6 7 8 9 10 11 12 13 14 15 16
Rotor angle limiter Rotor Current limiter Stator Current limiter
1 set 1 set 1 set 1 set 1 set 1 set 1 set 1 set 1 set 1 set 1 set 1 No..
Pulse Comparison units Digital Voltage Adjuster Digital potentiometer Feed back module Grid control unit Pulse Amplifier
Pulse Supervision unit Voltage supervision unit Over current relay for excitation transformer
17 18 19 20 21 22 23 24 25 26 27 28 1
Rotor earth fault relay Network filter Thyristor element and fuse
1 No. No. 1 piece of each type. 1 No. of each type 1 No. 1 set 1 set 1 set 1 No. 3 Nos. 2 Nos.
Thyristor bridge Field breaker De-excitation discharge resistor Tripping coil Closing Coil Field flashing rectifier Blocking diodes for field Ventilation fans Modules relating to DVR shall be digital Bus support insulators 80
3 nos.
Signature of Bidder
Item No. 3.11.3 2 3 3.11.4
Description
Quantity
11 kV JUNCTION BUS PANEL Flexible connectors Rubber bellows

3 nos of each 3nos.
SUPERVISORY CONTROL AND DATA ACQUISITION SYSTEM (POWER SYSTEM CONTROL AND MONITORING SYSTEM)
Relay *Protective Relay *Auxiliary Relay
One(1) of each kind.
Ten(10) of each kind One (1) of each kind One (1) of each kind Fifty (50) rolls Ten (10) bottles of ink and Ten (10) Pieces of pen Five (5) of each kind
2 3 4 5
Moulded case circuit breaker Meter Recording chart recorder Ink and pen for recording
Fault, operation and symbol indicator assembly.
7 8
Lens for symbol Indicating LED & Lamp
Five (5) of each kind 100% of installed quantity
Fuse Recording chart and ribbon for logging printer
Twenty (20) of each kind Fifty (50) rolls & chart and ten (10) strips of ribbon Fifty (50) rolls & chart and ten (10) strips of ribbon One (1) of each kind One (1) of each kind One (1) of each kind 10% of installed quantity
10
Recording chart and ribbon for line printer
11 12 13 14
Printer Circuit card Control selector and cut off switch. Transducer Wrapping label and marketing strip DVD drive
One plus one spare 81 Signature of Purchaser
Signature of Bidder
Item No.
Description
Quantity
COMPUTER
15 16
Power supply unit
One for each cubicle
Printed circuit cards used for C.P.U. Disc, One (1) of each kind drive, watch dog etc. SPECIAL TOOLS The following special tools shall be provided A/D converter checker for water level One (1) set measuring Portable controller set equipment One (1) set Printed circuit card Converter Surge Protector Fuse. Water level detector Recorder Chart Digital indicator PROTECTIVE GEAR 1.Printed Circuit Boards used for Numerical relay 2.Printed Circuit Boards used for static relay
17 18 19 20 21 22 23 24 25 3.11.5 1 2
One (1) Number of each type PCB. One (1) Number of each type PCB.
3.11.6
3. Other necessary parts (to be listed by the Recommended by the bidder bidder) Printed circuit cards used for C.P.U. Disc, drive, watch dog etc. SPECIAL TOOLS The following special tools shall be provided
1 2
A/D converter checker for water level One (1) set measuring Portable controller set equipment One (1) set
Signature of Bidder
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SECTION IV TECHNICAL SPECIFICATION OF GENERATOR
83
SECTION IV TECHNICAL SPECIFICATION OF GENERATOR
INDEX Sr.no. 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 Description
Scope Standards Type and main characteristics Particular mechanical design characteristics Particular electrical design considerations Performance guarantee Tolerances Technical specification of generator Technical specifications of static excitation system
4.11 4.12 4.13 4.14 4.15 4.16 4.17 4.18 4.19 4.20 4.21
11/11 kV,1 x 630 sq. mm , copper conductor unarmoured XLPE insulated power cable and 12 kV bus duct Current transformers and Potential transformers Lightning arrestor Surge capacitor Isolator and Earthing switch
Generator bearing 415 volts ac distribution board for utilities Factory tests for generator and related equipment Material test Site tests for generator and related equipment Drawings, designs, studies and manuals to be submitted after award of contract by the bidder. Spares Annexure IV-1 Annexure IV-2 Data Sheet E1 to 27
Page no. 85 85 86 86 87 89 89 90 105 113
114 114 115 115 115 117 118 120 126 129 130 131 135 136
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SECTION IV TECHNICAL SPECIFICATION OF GENERATOR 4.1 SCOPE: This section of the specification covers the complete engineering, design, manufacture, testing at factory, delivery to project site, onsite erection, testing, commissioning, putting into commercial use and giving satisfactory trial operation for a period of 90 days of one number of three phase horizontal shaft synchronous generator and related equipment including static excitation equipment, power & control cables, spares, tools and erection equipment as mentioned hereafter. The generator shall be capable of giving a continuous rated output of 10000 kW at 0.9 p.f. (over excited), unity p.f and 0.9 p.f (under excited). The generator shall be suitable for direct coupling to the turbine specified under Section V. Any fittings, accessories or apparatus which may not have been specifically mentioned in these specifications but which are indispensable for reliable operation of the plant shall be provided by the supplier at no extra cost to the Purchaser. 4.2 STANDARDS The applicable standards are as follows: 1) 2) 3) 4) 5) 6) 7) IEC 34/1991 VDE Standards of group 0530 IEC 85 (Insulation classes) ANSIB 49-1-1967 Shaft couplings, Integrally Forged Flange type for Hydro Electric units. V.D.I. 2056 for provisions regarding Radial Vibration Amplitudes. V.D.I . 2060 for provisions regarding Rotor balancing. Rathbone curves for provisions regarding Radial & Axial Vibration accelerations.
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8) 9) 10) 11) 12)
I.E.C. 287 - Calculation of continuous current rating (100% load factor). I.E.C. 38 - Standard Voltages I.E.C. 71 - Insulation co-ordination (Part 1,2, &3 ) I.E.C. 136 - Dimension of brushes & brush holders for electrical machinery. Please refer list of standards contained in Mechanical Lot. These are also applicable wherever relevant.
4.3
TYPE AND MAIN CHARACTERISTICS For the ratings and other parameters of the Hydro generator please refer Technical Data Sheet enclosed here with. The bidder shall fill in these Data Sheets and submit them in his bid. The bidders shall specifically note the requirements and fulfil it in all respect without fail.
4.4
PARTICULAR MECHANICAL DESIGN CHARACTERISTICS In addition to the provisions contained in section I of this volume regarding operational and other design requirements, the equipment specified in this section shall also comply with the following stipulations:
1)
All parts of the generator shall be designed to withstand safely the electrical, mechanical and other stresses which may be induced during abnormal conditions such as runaway speed, electrical faults and the machine shall shutdown and come to standstill position without damage. The electrical faults which shall be considered must include faulty synchronising, sudden three phase short circuit, two phase short circuit and terminal short circuit at normal voltage with simultaneous over-speed for 3 seconds. The design shall be such that stresses induced in any part under steady state runaway condition and electrical fault conditions shall not exceed two-thirds of yield point strength of the material used in that part.
2)
Static and Dynamic stability of the Mechanical Parts : Critical speed of the complete shaft line (generator + turbine) must be beyond 120% of maximum runaway speed during most unfavourable conditions.
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The rigidity of the entire shaft line must be such that asymmetries of the stator air gap will not be increased markedly. Oscillations of rotor and shaft line must not be initiated by pulsations of the torque or horizontal hydraulic thrust from the turbine or by sub-harmonic oscillations resulting from the stator winding or by pulsating torques originated by failures (e.g. sudden short circuits ) etc. The stator must be safe against core buckling. Its circular stability and the centricity of the shaft line must be safely secured. 3) Vibrations & Balancing : The relative locations of the generator bearing and the turbine bearing shall be so determined that vibrations shall be minimum and a smooth operation is ensured on the whole of the operating range i.e. at any load and at any head within the range specified in section I & Section V of this Volume . 4) Hydraulic Thrust : The unit and its bearings shall be designed to support the combined weight of the rotating parts of the generator and turbine including the maximum horizontal and vertical hydraulic thrust due to the turbine during transient conditions. 4.5 PARTICULAR ELECTRICAL DESIGN CONSIDERATIONS 1) Generator Rated Voltage (Un) : The rated voltage (Un) of Generator shall be 11kV. The continuous automatic voltage regulation shall be ensured within the range 0.9 Un to 1.10 Un (Un 10%). Rated frequency is 50 Hz. The supplier shall guarantee rated continuous output within the range of frequency from 47.5 Hz. to 51.5 Hz and voltage range of 0.9 Un to 1.1 Un. Supplier shall furnish information regarding outputs available below 47.5 Hz. (47 and 46 Hz) and duration of such output. Rated power factor is 0.90 (over excited) 1.0-0.90 (under excited). The most unfavourable conditions such as sudden two phase terminal short circuit at nominal voltage, 50% pole short-circuits with simultaneous over speed for 3 seconds shall be
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considered. No damage whatsoever must occur to the generator itself and the foundations in either case. 2) STATOR WINDING CONNECTION The stator winding shall be star connected and neutral point to be grounded through primary of power or voltage transformer and resistor. 3) Winding Insulation Class The stator and field windings shall be entirely insulated with class F materials (thermosetting type). 4) Wave form and Telephone Harmonic Factor ( THF) The wave form of the open-circuit terminal voltage shall not deviate from a true sine wave by more than 5%. The Telephone Harmonic Factor shall not exceed 1.5%. 5) Limits of Temperature and Temperature Rises: The rated output which should be available at its terminals at power factors cos 0.9(over excited)...1...0.90(under excited) shall be more than 11111 kVA. When the generator operates at rated output, rated power factors, speed and voltage, the stator and field winding temperature of generator measured by embedded thermostat temperature detector and resistance method shall not exceed 1250 C & 1300 C respectively. When the generator operates at maximum output, rated power factors, speed and voltage, the stator and field winding temperature of generator measured by embedded thermostat temperature detection and resistance method of generator shall not exceed 1350 C and 1400 C respectively. 6) Short Circuit Ratio of the generator shall not be less than 1.00. Direct synchronous reactance shall not be higher than 1.10 p.u. Direct - axis transient reactance (unsaturated value) shall not be higher than 0.45 p.u. 7) Dielectric strength: a) The stator and rotor windings shall withstand the following power frequency test voltages for 1 minute: 2.75 times of rated voltage (11 kV) before coil insertion
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2.25 times of rated voltage (11 kV) after coil insertion and at the time of completion of coil assembly. b) The rotor winding shall withstand 10 times of rated field voltage for 1 minute. 4.6 PERFORMANCE GUARANTEE: The output and efficiency guarantees shall be subject to verification and therefore applications of liquidated damages are stated in clause No 3.25 of Vol. I. In addition, the supplier shall guarantee that the performance values in respect of vibrations, operation. If during site tests, it is observed that any one or all these values are not within guaranteed values, the supplier shall take corrective steps so that guarantees are met / achieved. Absolute Temperature rise - Stator windings -Field windings ( by resistance method) The above temperature limits shall be reduced by the amounts as specified in clause 16.2 of IEC 34- 1. 4.7 TOLERANCES However, for a selected number of key characteristics given below, tolerances on the unfavourable side has been disallowed in this specification: i) ii) iii) iv) Guaranteed Voltage Range. Rated Power Factors. Moment of inertia. Stator Winding Temperature rise. 1250 C 1300 C 85 K 90 K power output, bearing temperature and direct axis synchronous reactance stated in Data sheet shall not actually exceed in
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vi) vii) viii) ix) x) xi) xii) xiii) 4.8
Field Winding Temperature rise. Bearings temperature Excitation rated Current. Excitation rated Voltage. Excitation Ceiling Voltage. Excitation response. De-excitation time from rated voltage to 10% of rated voltage. . Synchronous and transient direct-axis reactances.
TECHNICAL SPECIFICATION OF GENERATOR 1) All material to be used shall be suitable and adequate for the purpose intended and shall conform to the IEC standards. No patching, blocking, shimming or any other similar means of overcoming defects, discrepancies or errors shall be permitted without approval of Purchaser or/and Consultants. The generator design shall be such that the movements and deformations due to temperature variations are compensated and the loads and resulting forces, which would act on the foundation, are substantially reduced. It should further be ensured that: i) ii) No buckling of stator core laminations takes place. The concentricity and the size of air gap shall remain unchanged. The unit shall be designed for unit assembly during erection and for the removal of the complete assembled generator rotor during major maintenance programs. This design shall permit the assembly and dismantling operations to be performed as conveniently and quickly as possible with the facilities of the powerhouse crane. Proper stator and rotor lifting device (if required) for connecting to power house crane shall be provided. If lifting device is not used, the bidder shall give the reasons for not providing the lifting device. The necessary information regarding the shape of the hooks shall be taken into consideration.
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Supplier shall declare along with bid his work plan for stator and rotor building at site on service bay, built up in situ or partial building on service bay and situ. bid. Periods for such activities shall be distinctly shown and his proposal for execution of job shall be declared in the Considerations in the design shall be given to the following requirement for maintenance program. - Rotor field poles shall be arranged in such a manner as to permit
easy removal with the rotor in place. Field pole electrical connections shall be located in a position to facilitate ease in inspection, separation and reconnection. The neutral terminals of the phase shall be brought out separately to abominate current transformers before forming the star point of the winding . The two ends of field windings shall be connected to two slip rings mounted on shaft. 2. STATOR GENERAL The stator shall consist of a frame with air heat exchangers on its outer periphery, built-in laminated core with radial/axial air ducts and bar winding in slots. The stator frame shall also support the bushing of the phase bus bars and generator neutral connection. STATOR FRAME The stator frame shall be fabricated from steel plates and shall be of welded construction. The frame shall be sufficiently strong to Air coolers shall be withstand the most severe forces during the abnormal conditions e.g. sudden short circuit & faulty synchronisation. mounted around the outer periphery of stator frame. The frame shall be provided with adequate number of horizontal stiffeners. STATOR CORE The stator core shall be made of low loss, high grade, non-ageing, silicon magnetic steel laminations having a favourable bending
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co-efficient. The lamination shall be accurately punched and deburred so as to obtain very smooth surface at winding slots and keys slots. Each lamination shall be coated on both sides with class F insulating layer to eliminate inter lamination and eddy current circulation. The stator core shall be built up in stacks of equal height as far as possible, the bottom and top most stacks shall give a special treatment so as to form solid mass. While stacking the lamination, intermediate pressure treatment shall be given several times and the whole core should be pressed at both ends, by means of clamping rings with fingers pressing over teeth portion to ensure high tightness and mechanical strength of the core. The stack of laminations must be firmly anchored to the frame and pressed together in a firm and uniform way, which does not require readjustments after installation. In particular, vibration of stator as a whole is practically eliminated during any operating condition and stator migration phenomenon is avoided during life expectancy. The supplier shall describe in his bid the measures and means that will be provided by him totally to avoid the displacement of stator core punching. For cooling of the core and winding in the slots, the core shall be divided into several packets spacer punching provided with radial/axial air ducts of appropriate height and breadth shall be used between the packets. After completion of core building, a low induction core test with flux density of 1.0 T shall be conducted to find out if any laminations are short-circuited. The testing procedure shall be simple and efficient such that the same can be repeated on the core even at a later date. In case the design of core is such that neither a heating of the core nor an induction test of finished core with rated flux are necessary, the completed core shall be tested by means of non-destructive magnetizing test for detecting and locating short circuit faults in the core.
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STATOR WINDING The suitable stator winding type shall be designed by bidder. The insulation shall be of Class F material (Epoxy mica type). The slot portion of the coil shall be pressed to closed limits and the complete treatment shall ensure that the coil is fully thermoset and dimensionally stable. The overcharge portion of the coils will be insulated with flexible tapes. The end winding will be painted with suitable anti-tracking moisture resistant paint. The winding will be tightly wedged in the slots with non-shrinking epoxy glass laminate wedges. RTDs shall be permanently fitted in between coil of same slot at the centre of slot portion to measure the winding temperature. All RTDs in stator of the generator shall be wired to a terminal box mounted on the outside of generator frame. Each phase winding shall be so distributed around this stator as to minimize unbalanced magnetic pull and the circulating current between the parallel circuits. The two ends of each phase shall be brought out to terminals on the stator frame The main and neutral leads and associated current transformers in neutral leads shall be protected by suitable nonmagnetic enclosures to prevent accidental contact by personnel. Final details of the main and neutral lead termination at the unit shall be subject to approval by purchaser. All bolted main current carrying terminals shall be silver-plated. All neutral connections of the stator windings shall be parallel and all neutral current transformers shall be mounted beyond the generator housing and before the formation of neutral. The neutral lead shall terminate at the neutral cubicle, which shall contain the grounding transformer, supplied. All generator windings, connections between individual windings or between a winding and a related generator component as well as all resistor and accessories. The neutral grounding equipment, cubicle, interconnections, and ground connections shall be
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other primary connection and conductor shall be made of copper in accordance with applicable material standards. All bolted main current carrying terminals shall be silver-plated. The insulation of coils shall be continuous and of equal thickness along the entire coil. Insulation materials used shall be class F designed conforming to the requirements of IEC standards and manufactured in accordance with modern technology. Functional evaluation of insulation system shall be provided according to IEC 34-18-1/1992. The duro plastic insulation system used shall have excellent dielectric, thermal and mechanical properties with proven reliability to withstand high voltages not only under operational conditions but also under severe fault conditions. The insulation on the stator coils shall be sufficiently durable so that in case it is necessary to remove coils, removal and replacement may be effected without damage to the insulation of any of the other coils. The quality and life of the insulation shall not be impaired in attaining the above requirements. Class F insulation of proven design and which has shown no breakdown shall be used. The details of the installation where such insulation system is used shall be stated in the bid. The construction of winding bars and the winding in slots shall be fully explained with drawings and detailed description. The class F insulation system used shall be proven. The bidder must furnish examples where the same system is used and is in trouble free operation. Corona shielding applied to the fully insulated bar shall have the following structure. The straight part of the bar shall be covered with a conducting varnish (outer corona protection) in order to avoid potential differences between the surface of insulation and the core iron. The bend end portions of bars are covered with a semi-conducting varnish and in addition a special tape be wound over a certain portion to ensure the desired potential distribution (Capacitive control of potential distribution). These measures would avoid creeping discharges along
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the surface of insulation or even a breakdown. The bars shall be carefully inserted in slots and properly aligned. It shall be ensured that the wedges are firmly and permanently seated and there are no possibilities of damaging the core lamination edges in the slot. Rewedging should be virtually not necessary. The packing shall be effective in both the circumferential and radial directions. When installed, the coil sides shall be tight within the slot so that a 0.5 mm. filler gauge will not enter any gap between the coil and slot sides. The 0.5-mm. fillers gauge no-go standard shall apply to at least 90% of the stacked core length. The remaining 10% has individual go length of less than 0.80 mm. After final wedging, there shall be no measurable radial clearance between the coil and slot or wedge. Slot wedges shall be of phenolic or glass-reinforced polyester material, highly resistant to thermal ageing and designed to minimize any tendency to relax the radial pressure exerted on the coils. The stator coil insulation, wedging, packing, brazing and tying shall be such as to minimize the effect of thermal shock and of additional differential expansion which may occur as a result of the cyclic loading. End connections of the stator coils shall be made at the top of winding. The end portion of the winding shall be rigidly supported to prevent any movement and distortion even under the most unfavourable short circuit conditions. No metallic part, which does not correspond to class F, shall be used for this purpose. The slot portion of the bars must be manufactured to close tolerances. No grinding of insulation will be permitted to achieve required dimensions. The connections between half coils shall be covered in the ends by glass fibre insulation caps. Bracing shall make all connections in end windings. The strands of corresponding upper and lower layers bars shall be soldered at the connecting end using copper clips to ensure adequate mechanical strength and conductivity. A fibreglass-insulating cap shall be placed over each connection and filled with an epoxy
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compound to secure it to the ground insulation. The winding overhang portion shall be rigidly supported, lashed together by impregnated glass cords so as to form a rigid cone, which can withstand the forces due to a sudden short circuit. The system must be described in bid. Circulating primary split-phase current under normal operating conditions shall be less than 2.5% of total rated phase current. Each winding bar shall be subjected to tangent delta measuring kV test in shop and the dielectric losses of each coil shall be measured in the factory and also after assembly at site. Resistance elements for temperature recorder shall be mounted at 6 positions in the portions where the stator coils of each phase are presumed to show the highest temperature. 3) ROTOR GENERAL The rotor shall consist of a spider, laminated rims with brake ring at the bottom, salient poles with field coils and damper winding cage as well as shaft. ROTOR SPIDER The rotor spider shall be of fabricated structure. High strength high yield steel shall be used in the construction of the central hub and the radial arms. The attachment of laminated rotor rim with the spider arms shall be designed to withstand the maximum forces induced in the runaway condition of the unit. The arrangement of arms shall not only compensate the expansion and contractions during operation of generator but also those due to welding. Approved tests for material and welds such as X-ray and ultrasonic tests and/or liquid penetration tests to ensure the reliability of the whole spider shall be conducted. ROTOR RIM The rotor rim shall be of laminated floating type i.e. it should be attached to the spider by means of wedges driven in between the key
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supports on spider arms and the slots on the inner periphery of the rim. The rotor rim shall be made up of circular segmental punching from sheet steel, stacked overlapped layer by layer around the outer periphery of the spider. The laminated rims shall be clamped to a compacted ring of solid segmented end plates by means of high tensile axial bolts so as to ensure firm mechanical connection between the adjacent segments of any two layers for transmission of tensile forces. The shape and geometry of laminations and the pattern of stacking shall be such that the completed rim corresponds to an ideal homogenous cylinder as the uniform distribution of mass. The brake ring shall be provided at the bottom of rim. The brake ring may be constructed in segments so as to allow any replacement. ROTOR POLES The pole body shall be made up of steel laminations made of same material as is used in construction of rim laminations. number of bolts. The poles shall be secured to the rim by means of wedges in such a way as to allow the removal of poles in the horizontal direction without requiring removal of the rotor out of the stator bore. FIELD COILS AND DAMPER WINDING Each pole will carry a field coil fabricated from straight lengths of copper strip dovetailed and brazed at corner. The insulation between turns shall be of specially treated asbestos paper. Insulation to ground (Pole body) shall be a epoxy glass laminates and rectangular insulation washers shall be placed at the top and bottom of the coil. The completed coils will be electrically heated & pressed while not to a pressure greater than the maximum centrifugal force which would be experienced in service. The field poles shall be provided with adequate damper windings to insure stability under fault conditions and to meet I2t value of 40. The pole laminations shall be held tight between end plates by means of suitable
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The insulation system of class F shall be used to ensure compact assembly with excellent electrical and mechanical properties. The turn insulation should be thoroughly cemented to adjacent turns to permit removal of field pole coil as a unit. The pole core insulation must be separate from the coil. Special attention shall be paid to ensure prevention of end turns of a coil from deforming or slipping due to centrifugal forces on the inter-connections. End turn insulations must be reinforced if necessary. The field coils of poles shall be connected by means of flexible copper plates to form as field winding whose ends are brought out for connection with slip rings. The coils shall be tested at medium frequency test voltage or impulse voltage test on the terminals. During this test, the magnetising current must be measured and this current shall not differ by more than 10% between various coils. Low resistance damper winding of fully caged construction shall be provided to improve stability under fault conditions and specially to reduce voltage disruption under conditions of single-phase fault. 4) BRAKES Brakes shall be provided for bringing the unit to stop when the speed is reduced to approximately 10% of rated speed. The brakes will be operated by air pressure The brake shoes shall bear on a brake which is an annular ring attached to the rotor. The brakes shall be liberally designed keeping in view the frequent stops of the unit (2/3 times per day) and with margins to allow for emergency conditions. mechanical brake shall be effective for either forward or reverse rotating direction and shall be automatically released after the generator stops. The brakes shall be capable of operating, without appreciable wear and tear of the brake shoes from 50% rated speed in emergencies. The brake shoes liners must be able to withstand at least 3 years operations. The braking system shall be so interlocked that application The
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of brakes will not be possible at speeds exceeding 50% of rated speed. A brake dust extraction system ( if necessary ) shall be provided by the supplier. A position switch having two sets of contacts shall be provided for each brake shoe. One set of open contacts (when brakes OFF) shall be wired in parallel and will be used for brakes ON indication. The set of closed contacts (when brakes OFF) shall be wired in series and will be used in the unit start interlock circuit. Wires from both sets of contacts shall be brought out and terminated in the generator terminal box. The equipment shall be complete with necessary control cabinet, piping, valves, fixtures etc. 5) SOLE PLATES AND FOUNDATION BOLTS The supplier shall provide adequate number of soleplates, anchor bolts etc., for fixing stator frame to foundation. The whole anchorage shall be designed and constructed to resist the forces under most abnormal condition, resulting from sudden short circuit or faulty synchronising. The supplier shall furnish the detailed drawings & calculations to the Purchaser for his consent and approval. 6) VENTILATION : The generator shall be provided with screen protected enclosure. The air shall be drawn from both the ends. The combined action of the rotor poles and axial fans shall be sufficient to extract the heat generated in the generator. The generator shall be forced air cooled, self-ventilated type. Air passage in the stator, rotor, fans etc. shall be designed to give a smooth quite flow of air. 7) HEATERS : Space heaters of black heat type of adequate rating shall be provided inside the protection caps on the stator frame for maintaining stator surrounding air temperature above ambient during prolonged shut down period. At each end of the generator heating elements of suitable
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capacity shall be installed to avoid condensation when the unit is under shutdown. The temperature to be maintained shall be 50 C above the surrounding temperature. Necessary thermostat be provided for auto on / off of the heating elements. 8) GENERATOR TERMINAL BOX, ELECTRICAL ITEMS AND WIRING & PIPINGS. All electrical items supplied by supplier shall comply with the appropriate sections of the relevant IEC standards. They shall be arranged in a manner approved by the Purchaser. The supplier shall provide and install terminal boxes in locations approved by Purchaser, and shall provide and install all wiring and conduit from its electrical components to these terminal boxes. All wiring shall be standard wire, with oil proof insulation. Further a common marshalling box shall be provided. Wiring from all individual terminal boxes shall be brought by the supplier up to this marshalling box. Leads for all auxiliary electrical circuits such as current transformers, resistance elements, limit switches; various kinds of relays shall be supplied up to the terminal blocks installed in the generator housing. All wiring within the generator housing, including main field leads, lighting, resistance temperature detectors leads and control and indicating leads shall be adequately clipped or otherwise supported and protected. The wiring shall be bundled and tied together, where possible, to provide a neat arrangement. The wiring passing through openings in metal members of the generator, or otherwise passing over or near metal edges, shall be carefully protected against abrasion. In general, close attention shall be given in order to prevent failures or shutdowns occurring as a result of generator vibration. The wire insulation shall be resistant to flow and abrasion under the conditions to which it may be exposed. Liquid type flexible conduit shall be used where wiring may be exposed to oil or water leakage. All piping shall be supplied such as feed / drain oil pipes of the generator bearing oil tank, oil jacks, piping of oil level relays and oil
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level gauges, feed / drain water pipes for bearing coolers and air coolers, connecting pipes between respective coolers, drain pipes of leakage oil and leakage water at respective positions and other piping installed in the generator air housing including valves and flanges. 9) TEMPERATURE DETECTORS The Supplier shall provide six resistance temperature detectors (pt. 100 ohm at 0 degrees C) per parallel circuit per phase, embedded in the various parts of the stator winding in accordance with relevant IEC standards. Twelve resistance temperature detectors (pt. 100 ohm at 0 degrees C) shall be embedded in a suitable location, six at each end of the stator core for temperature measurement for the detection of end iron heating. One at each teeth location in the stator core for temperature measurement of teeth. RTDs and hotspot temperature indicator shall be furnished. Requirements of temperatures to be measured have been described; however supplier shall decide number of scanners required. The exact location of the temperature detectors in the stator winding and core shall be subject to the approval of purchaser. All temperature detectors in and around the generator shall be wired to the terminal box mounted on the outside of the generator air housing. This terminal box shall be separated from other terminal boxes. All connections from the temperature detectors to the terminal box shall consist of twisted leads in shielded cables. The leads from each stator bearings, water and air temperature detectors shall be brought in a neat and substantial manner to suitable terminal blocks located in a terminal box on the generator housing. This box shall be used exclusively for resistance temperature detectors. The terminal box, to be provided by supplier shall have provision for connection to external conduit and wiring. The leads shall be supplied as twisted three wire leads suitably shielded and otherwise protected to minimize stray pickup. The insulated leads shall be capable of with-standing an applied
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potential test of 2000V to ground for 1 min. Separate terminals shall be provided for terminating the shields of individual Resistance Temperature Detector (RTD) leads. The resistance temperature detectors shall be platinum type and have a resistance of 100 ohms at 00C. Resistance ratio between 00C and 1000C shall be 1.3926. All temperature measuring equipment and its connections supplied by supplier shall be accurately calibrated against accepted standards. 10) OIL GAUGES AND OIL LEVEL RELAYS The following oil gauges and oil relays shall be provided. a) i) ii) b) i) ii) Oil gauges : For generator bearing oil tank For turbine bearing oil tank Oil level relays For generator bearing oil tank For turbine bearing oil tank : 1No. : 1 No. : 1No. : 1No. : 1 No.
Oil gauge : The oil gauge shall be of gauge type or float type and free from oil leakage. The oil gauges shall be mounted on a convenient position for inspection. The gauge shall be clearly marked on the surface with standard oil level, the upper limit and lower limit of oil level. Oil level relay:The relays shall be accurate in operation and mounted on a convenient position for inspection and shall be provided with alarm contacts for rising and lowering of oil level and provided with automatic reset mechanism when the oil level is restored within the normal range. Sufficient lubrication oil for the generator shall be supplied by the supplier. The supplier shall recommend the suitable lubricating oil for the generator.
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11)
FIRE PROTECTION A dry type deluge fire protection system shall be provided by supplier complete with deluge valve, control unit and sprinkler rings with atomising nozzles. The atomising nozzles shall be so placed that the streams of water will be directed on the top and bottom coil ends and connections of the stator winding. The exact direction of flow shall be subject to approval by purchaser. The fire fighting system shall be of emulsifier water jet system and shall be designed to inject sufficient quantity of water in the form of jets to extinguish the fire in minimum possible time. The fire extinguishments shall be achieved by a combination of cooling and smoothening effects. SAFE DISTANCE FROM LIVE EQUIPMENT The ring headers, smoke / heat detectors etc. shall be provided in the generator such that the clearance between un-insulated live parts of generator and any portion of water spray system is not less than the minimum clearances stipulated. TESTING OF THE SYSTEM Suitable provisions for testing the system without discharging water into the generator shall be made. WATER DRAINAGE: Supplier shall prepare a scheme for drainage of the water from generator housing to dewatering pit from where water will be pumped out into the tail race channel.
12)
LINE TERMINAL AND NEUTRAL GROUNDING CUBICLES The generator suppliers shall supply 1 no. terminal cubicle for surge capacitor, magnetic voltage transformers, current transformers, lightning arresters, cable boxes, etc., The cubicle shall be complete with necessary tappings for excitation system, etc. The rating of the
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CTs for DVR shall be decided by the supplier taking into account the requirements of DVR. The supplier shall supply one no. neutral grounding cubicle consist of grounding transformer, secondary loading resistor, current transformer, cable boxes, etc. The cubicles shall be sheet suitably compartmentalized with doors and shall be furnished complete with base mounting arrangement, foundation bolts, etc. The internal illumination for cubicles shall be provided with guarded lamps with on/off switches. Copper/Aluminium conductors of appropriate size shall be used for bus bars and connections in the cubicles. The bus bar and main connecting conductors shall be suitably insulated to make them compatible with generator temperature rise and insulation. The support insulators for the bus connection will be provided as necessary. GI earth bus of adequate cross section will be provided in the cubicle. 13) CABLE SCHEDULES AND WIRING DAIGRAMS The supplier shall prepare cable schedule and wiring diagrams of the station equipment as a whole. Terminal wiring diagrams for the equipment and plant not covered by this package will be furnished by purchaser to the bidder of this tender and he shall prepare consolidated wiring and cabling schedule for the entire power station.
14)
11kV JUNCTION BUS PANEL 11kV Junction Bus panel shall be provided at suitable location in power house for tapings of 11 kV XLPE cable. Tap for Unit Auxiliary Transformer is provided at this panel. Copper Bus with necessary insulators is provided for tapings. Fault calculation of bus bar shall be carried out by bidder and accordingly panel is to be designed. 11kV, 3 phase, single core, 630 sq. mm, XLPE cable with one spare core from junction Bus panel to step-up transformer is to be provided by bidder. Other XLPE cables as
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per Section III of this volume shall also be provided by bidder. 15) Temperature scanners: Temperature scanner with built in datalogging and printing facility to be mounted on unit control board and for monitoring temperatures of bearings, stator and field windings, cold and hot air temperature of generator cooling air with 3 sets of contacts. Each set consisting of two potential free normal/open contacts operating at two different levels of temperatures to be used for external annunciation scheme. The scanner shall be suitable to operate on the inputs from RTD (Resistance Temperature Detectors).
4.9 4.9.1 1) TECHNICAL SPECIFICATIONS OF STATIC EXCITATION SYSTEM GENERAL TYPE, CHARACTERISTICS AND PERFORMANCE The generator excitation system shall be of the solid- state controlled rectifier (static thyristors) type, complete with excitation transformer and solid-state type of digital voltage regulator (DVR) and rectifier controls, capable of providing negative exciter voltage and extremely rapid changes in generator excitation voltages. The excitation system shall take out the power from terminal voltage of generator through a power supply transformer and supply it to the field winding of generator. The field flashing circuits shall be supplied from an auxiliary transformer / rectifier assembly suitable for connection to a 400-V, 50-Hz., 3- phase supply of a capacity to be specified by supplier. Provisions shall also be made for field flashing from the station battery in emergency with manually deployed connections, preferably transfer links. The field flashing equipment shall be rated to supply approximately rated excitation current continuously for test purposes and shall be capable of adjustment in 10% steps from 10% up to 100% rated
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voltage. Excitation supply shall hold during break period of change over of supply from Station Auxiliary Transformer / D.C. supply to Unit Auxiliary Transformer, acceptable break period shall be indicated by the Bidder. The thyristors shall be used for the rectifier of excitation system. The supplier shall supply forced cooled type 110% duty thyristor cubicle so that the excitation system shall be capable without exceeding the temperature limit of the thyristor with one thyristor per phase out of service. Indicator lights to indicate and locate the thyristor failure shall be provided. A suitable protection shall be provided to protect the thyristor from the surge, which might enter from the generator field and power supply transformer. Connections between the secondary of the transformers, air circuit breaker, and static excitation equipment shall be made with cables. The air circuit breaker shall be draw-out type individually enclosed and electrically operated. All controls, protection and operations of the equipment shall be either automatically or electrically operated, suitable for operation through remote control panels located at the unit control board. Remote control shall be limited to as few controls as possible, and shall include only such functions as stop-start and a raise-lower. The excitation equipment shall be designed to be capable of starting and running at reduced capacity and independent of a separate station service A.C. supply. Components and wiring shall be suitably designed and shielded to prevent excessive noise. The design of the excitation system shall be such that the effect on the balanced and/or residual Telephone Influence Factor (TIF) of the associated Generator is minimal and shall not cause the TIF to exceed the limits specified in applicable IEC standards. The final parameters for performance, capability, system response, etc., shall be confirmed by supplier and approved by Purchaser. Voltage regulator shall have dual channels consisting of two identical electronic control circuits plus a common voltage matching, fixed
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excitation, output selection and relay circuit. Usually both the main and stand by channels shall be energised and functional. However, only output selection circuit to control the converter will switch the output of main channels. If this channel fails then the controls shall be automatically switched to standby channel. The normal mode of operation shall be auto-control. Additionally, manual control of the excitation shall be available for testing and setting up purposes or in unlikely event of failure of the auto control of both channels. The auto-control circuits shall consists of two interdependent feed back control loops (Voltage and Current) with limiting circuits for underexcited MVAR, rotor heating, current and power system stabilisers. The excitation system shall be capable of switching from 25% of rated generator voltage and at 60% of voltage it shall be capable of supplying rated excitation current. system shall be less than 0.10 sec. 2) CAPABILITY With rated generator voltage, the excitation system shall be capable of delivering continuously, within rated temperature rise, any value from 0 to 120% of the field current required when the generator is operating at 110% of rated voltage, and rated power factors at 0.90 (over-excited). With rated generator voltage, the excitation system shall be capable of providing a ceiling current to the field of not less than 1.5 times rated field current for at least 30 seconds. De- excitation time between rated voltage and 10% of voltage shall not be more than 10 sec. 3) SYSTEM RESPONSE With the generator initially at rated apparent output power, rated voltage, power factor and speed, the excitation system shall be capable of changing from rated field voltage to 100% of ceiling voltage within 25 to 30 ms. for a sustained drop in generator terminal voltage of 10 %. The rated voltage shall be calculated assuming that at rated The time constant of excitation
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apparent power, field winding is operating at rated field current. Response in the negative (reverse) direction to suppress terminal voltage shall be similar. The small signal gain, defined below, shall be variable from 25 to 300 and should be lockable to prevent tampering. Excitation response shall be guaranteed with 4s. 4) CEILING VOLTAGE The exciter ceiling voltage with rated generator voltage and rated field voltage and current shall not initially be less than 1.5 times the excitation voltage required for rated field current with the operational field temperature. The exciter ceiling voltage with rated supply voltage and 1.5 times rated field current shall not be less than 2.0 times rated field voltage with the field windings temperature 1250C. With supply voltage less than rated value, the ceiling voltage may be reduced approximately in proportion to the reduction in supply voltage. With positive field current flowing, the excitation system shall be capable of providing a negative ceiling voltage of no less than 75% of the positive ceiling voltage for forcing the field current to zero. 5) OVER VOLTAGES The excitation system may be subjected to lightning and switching surges and dynamic over voltages, and shall be able to withstand them without damage to equipment or loss of life. The static excitation equipment shall comprise of: Microprocessor based Digital Voltage Regulator cubicles. Thyristor cubicles. Switchgear cubicle (Field breaker, de-excitation resistor, field flashing etc.). Excitation Transformer connected directly to the thyristor cubicle.
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Power supply to cubicles shall be duplicated and no interruption shall be allowed during changeover.
4.9.2) 1)
DIGITAL VOLTAGE REGULATOR Micro-processor based voltage regulator shall be digital type. It shall be liberally designed so as to be as reliable as possible and shall incorporate sufficient redundancy so that failure of any control equipment will not cause mal-operation of the system. 2) The digital voltage regulator should periodically calculate the control signal from measured and reference values. Calculation should be repeated at every short time intervals where by an apparently continuous regulator output characteristic is produced. 3) Calculation is to be carried out in binary system. The analog measured values of generator voltage and current as well as field current must be transformed in an Analog / Digital converter into binary signals. From the calculated control signals, pulses should be generated for firing the thyristor. 4) Various control functions like voltage regulation, limitations of field current, rotor angle, stator current, slip stabilising etc. shall be stored as programs to be executed in a cyclic pre-programmed manner. 5) 6) 7) 8) 9) 10) Control to maximum converter voltage shall be achieved in less than 10 milliseconds thus ensuring fast reaction to network disturbances. Internal conditions monitoring of devices with light emitting diode (LED) indication be provided which means short failure detection times. Set values shall be digital, absolutely reproducible and not vulnerable to changes ensuring long term stability Number of different units shall be small so that spare parts stock could be kept to a minimum. Low sensitivity to external electro-magnetic influences shall be ensured which means high noise immunity. Electrical control points shall be bare minimum to reduce potential trouble sources.
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11)
Comprehensive measuring and setting shall be possible, which should enable direct setting of characteristics values without the necessity of calibration instruments.
12)
The Digital Voltage Regulator shall perform following functions: Regulation of generator voltage. Limitation of field current. Limitation of stator current. Stabilization of power pulsations. Power factor control.
13)
A local control, input and display unit shall be provided for communication with the processing unit during operation. It should be
possible, from this control unit, to call up the stored parameters, measured values etc. and to change control parameters such as limit values or characteristics values of the control algorithms. 14) It should be exceptionally reliable with no changes in operating performances. If even a failure should occur, it should announce itself so that it can be removed fast. 15) 16) Frequency drop compensation shall be provided to ensure over excitation compensation of transformer in the event of low frequency. Automatic reactive power compensation or power factor regulation should be provided. The power factor regulating range shall be manually adjustable from lagging power factor 90% to leading power factor 90% rated output and rated voltage. 17) Current regulating equipment The current regulating equipment shall be provided in order to approach the operating power factors to unity when the generator current exceeds 105% of the rated current due to a voltage drop during generating operation. 18) In case the load is rejected due to any external fault during generating operation at the rated output, rated voltage and rated power factor, the voltage rise of the generator shall be less than 20% with speed regulation of 35% without opening the field circuit breaker. 19) Emergency demagnetising device
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Emergency demagnetising device shall be provided so as to perform quick demagnetisation of generator in the event of electrical internal fault of the generator. 20) Two independent modes of operation are envisaged. i) ii) Automatic mode with automatic channel in service. Emergency manual mode with the help of manual channel. Voltage adjusting device shall preferably, not be potentiometer but a solid-state device for example, push button controlled analog registor etc. In the automatic channel, the control shall be through DVR, DVR should derive its sensing signal through Voltage Transformers and Current Transformers in the generator main terminal circuit. This shall be compared with a highly stabilised auto reference value. Correction pulse generated shall be fed to the gate of thyristors. Output of DVR should thus control the firing angle of thyristors thereby adjusting the excitation current to the required level. In the manual channel, the voltage variation and excitation current shall be changed manually, while in auto mode also, the manual channel shall follow the auto channel so that all resistances of manual channel are at the correct positions corresponding to those of auto channel so that, if due to a minor fault the channel changes to manual the unit will not trip. DVR shall have two auto channels i.e. one main, one stand-by together with one manual channel only. Each channel shall be fully independent with separate pulse control unit, pulse amplifier and power supply units. 4.9.3 THYRISTOR CUBICLE 1) This cubicle contains full three phase thyristor bridges with its associated equipment. The design should be modular in such a way that changing of a thyristor or part of a bridge shall be easily possible. In case forced ventilation system is adopted, noise level outside the panel shall be negligible.
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2)
Number of thyristor cubicles provided shall be such that, even with failure of one Thyristor Bridge, the generator should be able to supply rated output and with failure of two bridges, the generator should trip.
3)
All thyristors shall be fuse protected. Voltage safety factor for thyristor, defined as the ratio between the maximum operating voltage and the rated peak cut-off voltage shall be more than 2.5. Excitation response shall not be less than 4.0 s.
4) 5)
Suitable protection shall be provided for thyristor to prevent voltage spikes from reaching them and damaging them. Over voltage protection to protect the thyristor bridges and the field circuit shall be provided.
4.9.4 1)
EXCITATION TRANSFORMERS Three phase, dry type, Excitation Transformers shall be of indoor type cast resin or equivalent dry insulated for direct connection to the bus ducts and cable connection to the thyristor cubicle. Transformers shall conform to IEC 726. 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) They shall be totally moisture proof They must be free from partial discharge up to 150% of the rated high voltage. They have to be resistant against sudden temperature changes. The insulation must cease fire and must not contain any PVC material. The cores shall be built up of high grade oriented crystal magnetic steel sheets, insulated on both sides. The cores shall be compressed sufficiently to avoid any undue noise generation and vibration. All metal parts shall be amply protected against corrosion. Coil casting or impregnating process must be conducted under vacuum and pressure. High voltage and low voltage windings shall be separated by a high grade insulating material cylinder. Adequate consideration shall be given to thermal coil dilation. Transformers must be able to withstand a short circuit on their low
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voltage terminals without suffering any damage. The time for which the transformer should withstand such short circuit should not be less than the longest fault clearing time for generator. 12) 13) 14) 15) 16) Cooling system of the transformers shall be as far as possible natural or shall occupy minimum space available on the floor. Suitable built-in over-heating protection device shall be provided. Transformers shall be impulse voltage tested according to IEC. Short circuit impedance shall be according to choice of design for excitation system. Total losses at rated load should be at minimum.
4.10
11/11 kV,1 X630 SQ.MM , COPPER CONDUCTOR UNARMOURED XLPE INSULATED POWER CABLE AND 12 kV BUS DUCT The supplier shall be responsible for complete job which will involve design, manufacture, testing at manufactures works before dispatch, supply to project site including loading, transport, insurance , unloading, laying, fixing, both end termination with necessary lugs, cable glands, fixing ties/belts, cable trays, supporting structures, testing before charging etc. complete. 11/11 kV, 1 x 630 sq. mm , copper conductor unarmoured XLPE insulated power cable one spare core and for a machine shall comprise of cable from cable tap run to the cubicle of unit auxiliary LAVT cubicle to junction box Bus panel to step-up transformer with transformer with one spare core. Cable termination at both ends shall be done by supplier. Eventhough the total length of cable is mentioned as 250 mtr. in price schedule, Supplier is required to ensure the actual length of cable as per site condition. The supplier shall supply 12 kV, segregated 3 phases, 3 cores, Aluminium Bus Duct of suitable size for following: i) ii) Tap run from Generator line Terminal to LAVT cubicle. Tap run to the cubicle of excitation transformer, disconnecting switches and current transformers. Signature of Bidder 113 Signature of Purchaser
iii)
Tap run to the cubicle of surge absorber, voltage transformers and current transformers and disconnecting switches.
iv)
Tap run from generator neutral connection to neutral grounding cubicle.
Supplier shall also supply the necessary Support steel structure, hardware, trays, fixing belts etc. and one Set of Shorting Links for dry out and short circuit test.
4.11
CURRENT TRANSFORMERS AND POTENTIAL TRANSFORMERS The current transformer will be epoxy cast, dry type unit conforming IS:2705. The current transformer shall be designed to withstand the thermal and magnetic stresses resulting from the maximum short circuit current. Detailed design and quantity shall be as per plant requirements. The current transformers shall be suitable for metering and protection. The protections specified in section VIII of this volume shall be provided. Inter posing CTs The potential transformers will be single phase, epoxy cast, dry type units. Potential transformer will be protected on primary and secondary side by current limiting fuses. The PT shall conform to IS:3156. The potential transformers shall be designed to withstand the thermal and magnetic stresses resulting from the maximum short circuit current. Detailed design and quantity shall be as per plant requirements
4.12
LIGHTNING ARRESTOR The lightning arrestors shall be heavy duty indoor station class nonlinear resistor type suitable for repeated operation to limit voltage surges on alternating current power circuits and to interrupt power follow current. The arrestors shall conform to IS:3070 (latest edition) Part-I. The nominal discharge current of lightning arrestor shall not be less than 10kA. Signature of Bidder 114 Signature of Purchaser
4.13
SURGE CAPACITOR The surge capacitors shall conform to the latest edition of IS:2834 The capacitors shall be connected in parallel with lightning arrestors and shall be provided with a built-in discharge resistor. The capacitor shall be suitable for indoor mounting.
4.14
ISOLATOR AND EARTHING SWITCH One No. Isolator with own operating mechanism before Unit Auxiliary transformer tapping in 11 kV junction bus panel and after LAVT panel shall be provided by bidder . Isolator shall have control switch in unit control board in control room and also included in sequence of unit starting and stopping. This isolator is provided for back charging of step up transformer and uninterrupted power supply from UAT. Earthing switch shall be provided after Isolator and before Junction Bus panel for discharging step up transformer and UAT in case of maintenance and shut down. Earthing switch shall be controlled in local position only. Isolator and earthing switch shall be provided as per shown in single line diagram. Isolator and earthing switch shall be as per requirement and conform latest relevant IS.
4.15
GENERATOR BEARING The Generator bearing at Non drive end side shall be pad / segment type, oil lubricated either selflubrication or forced lubrication type. The bearings shall be provided with a dial type or resistance type thermometer and a pressure gauge with provision for alarm annunciation/shut down on excessive bearing temperatures. The generator bearing shall be provided with H.S. Lubrication (if required). The number and type of bearings shall be stated in the bid. These bearings shall be guaranteed for a minimum continuous operation of 100,000 (One Hundred Thousand) hours and the design and performance shall be well proven and established. Further the bearing shall be designed to operate satisfactory (i.e. without any
Signature of Bidder
115
damage) under following conditions: * * * Continuous operation at any speed between 30% and 110% of rated speed at no load and maximum load. For 15 minutes at maximum runaway speed. For 15 minutes, upon sudden rejection of maximum power and in continuation thereafter till the unit comes to standstill as a result of tripping and interruption of cooling water supply. The bearing area and the bearing oil reservoir capacity shall be such that temperature shall not exceed 70oC under worst conditions of operations. The bearing shall be located as near to generator as possible consistent with the distance assumed in shaft system analysis and keeping in view the space required for accessibility and maintenance. The mechanical design of the bearing shall take into account the abnormal radial forces during starting, stopping, trip-outs and running at runaway speed of the unit and also provide axial movement of the shaft. The method of construction shall be fully described in the bid. The bearing design shall prevent the leakage of oil down along the shaft. Piping for filling oil in the bearing and reservoir shall be separate from the drain piping. The supplier shall supply and install the following indicating and protection devices for bearing. One dial type thermometer to indicate the hottest part of the bearing. The thermometer shall have two (2) sets of separately adjustable contact suitable for operating alarm and tripping circuits at 220 V D.C. The thermometer indicator shall be mounted in governor panel. The resistance temperature detectors R.T.D (Pt 100 Ohms at 0oC). One for bearing segment and one for oil indication and recording the temperatures at unit control board. One direct reading water flow meter with two electrical contacts (suitable for operation at 220V D.C. for signalling low cooling water supply / stoppage of cooling water supply. One oil level gauge properly graduated marked in litres and high and low level adjustable alarm contacts with 220V D.C. contact rating. All thermometer bulbs and detectors shall be installed in dry walls.
Signature of Bidder
116
4.16
415 VOLTS AC DISTRIBUTION BOARD FOR UTILITIES
The supplier shall be responsible for complete job which will involve design, manufacture, testing at manufactures works before dispatch, supply to project site including loading, transport, insurance , unloading , laying, fixing, termination with necessary lugs, cable glands, testing before charging etc. complete of 415 V AC Distribution board for machine utilities. This includes all pump-motors, motors and auxiliaries supply required for machine. The detailed Design of panel and provision of out going feeders, capacity, nos. etc. shall be as per requirement. Provision for spare feeders shall be made. Necessary indicating and
metering instruments including indication lamps, any other item / equipment required to make the system complete (KW meter, Voltmeter, Ampere meter) shall be provided. The distribution board shall be completely wired. The scope of power and control cables is also included. This distribution boards shall be attractive in design, mechanically strong, robust in construction and shall be totally enclosed in a mild steel cabinet of 3 mm. thickness. It shall have specified sets of MCBs and shall be vermin and dust proof complete with double door, lock and key arrangement. The doors shall be properly hinged. Cable entry shall be through suitable conduit pipe. The interior and exterior shall be painted with two coats of red oxide primer after 7 tank treatment and two coats of approved colour paint as per IS: with a minimum thickness of 60 microns. This distribution board shall be suitable to be mounted on concrete wall/columns or it may be mounted on floor. Suitable fixing arrangement such as nuts, bolts, washer, anchors shall be provided at suitable places for its proper fixing. The isolator / MCBs units shall be of reputed make only and shall be complete and fully comply with latest edition of IS:2516-1977, IEC 157-1983. The operating handle shall be properly insulated from the live portion of MCCBs / MCBs and shall always be easily accessible. The MCCBs/MCBs used for A.C. supply and D.C. supply shall be designed for a fault level of 10 KA for 1 second. These S.D.B.'s shall be suitable for voltage variations as per latest relevant I.S.S. Suitable earthing arrangement shall also be provided
Signature of Bidder
117
with sub distribution boards. The above description is a broad outline of the control, metering and protection system. 4.17 FACTORY TESTS FOR GENERATOR AND RELATED EQUIPMENT Tests to be conducted in factory on various material, assemblies etc. statements. legends of the nomenclature of tests is as below LEGEND FOR FACTORY TESTS OF ELECTRICAL LOT 1) 2) 3) 4) 5) 6) 7) 8) 9) 10) 11) Test at shop on random sample of raw material. Test at shop on random sample of raw material and on semi or fully finished part. Test at shop on 5% of consignment. Check straightness of bolts taking random sample of 10 bolts per machine. Test at shop in the presence of Purchasers representative. Test at shop on each piece. Spot check at shop of brazed parts of semi or fully finished parts. Test at shop on random sample of one per sheet. Test at shop on complete sheet. Test at shop - once per item. Test to be conducted by manufacturer and Test Certificates given to Purchaser. on generator at different stages of manufacture are indicated in the enclosed
Signature of Bidder
118
SUBMISSION OF TEST CERTIFICATES The Supplier shall submit 6 copies of test certificates to the Purchaser as per the procedure given below : i) FOR INSPECTION AND TESTING TO BE DONE IN PRESENCE OF PURCHASERS REPRESENTATIVE. Test certificates shall be submitted for approval. ii) FOR ALL OTHER INSPECTION AND TESTS Test certificates showing that the specified tests / inspection has been carried out reference. successfully by the Supplier shall be submitted for
Signature of Bidder
119
4.18
MATERIAL TEST Sr.No . 1) ROTOR RIM SHEETS: Tensile Test Chemical analysis Visual check Dimensional check 2) ROTOR RIM BOLTS Tensile Test Chemical analysis Visual check Dimensional check 3) FIELD WINDING (POLE COIL) FINISHED Tensile Test Visual check Dimensional check Test for short circuited turns Acceptance test of each piece Insulation Simulation Test 4) POLE FINISHED Visual check Dimensional check High voltage test Test for short circuited turns Weight check Acceptance Test of each piece (H.V.Test) 5) DAMPER BAR Hardness Test Particular of Test 1 2 3 4 5 6 7 8 9 10 11
Signature of Bidder
120
Sr.No .
Particular of Test
10 11
Visual check Dimensional check Electric conductivity Test Acceptance consignment 6) DAMPER SEGMENT RAW Hardness Test Visual check Dimensional check Acceptance consignment 7) POLE LAMINATION SHEETS Tensile Test Chemical Analysis Visual check Dimensional check Induction Test 8) POLE AND PLATE RAW Tensile Test Notched Bar Impact Test Chemical Analysis Ultrasonic Test Visual Test Dimensional Test Acceptance Test of each piece 9) POLE END PLATE MACHINING Visual check Test on 5% of Test on 5% of
Signature of Bidder
121
Sr.No .
Particular of Test
10 11
Dimensional check Acceptance Test of each piece 10) POLE BOLTS Tensile Test Chemical analysis Visual check Dimensional check 11) ROTOR LAMINATION Tensile Test Notched Bar Impact Test Chemical Analysis Ultrasonic Test Aging characteristic Acceptance Test of each piece 12) STATOR LAMINATION SHEETS Tensile Test Chemical analysis Visual check Dimensional check
Induction Test with determination of specific losses at 1.0 and 1.5 t 13) STATOR PUNCHING Tensile Test Chemical analysis Visual check Dimensional check 14) STATOR RIM BOLTS Tensile Test Chemical analysis
Signature of Bidder
122
Sr.No .
Particular of Test
10 11
Visual check Dimensional check 15) STATOR FRAME Tensile Test Notched Bar Impact Test Chemical Analysis Ultrasonic Test Aging characteristic Acceptance Test of each piece Trial Assembly 16) STATOR FINISHED Tensile Test Visual Test Dimensional check Test for short circuited Turns Acceptance piece(H.V. Test Test) of with each Tangent WINDING BARS
delta measurement Insulation simulation Test
17)
WATER/AIRHEAT (EACH) Tensile Test Visual Test Dimensional check Hydrostatic Test
EXCHANGER
18)
OIL COOLERS (EACH)
Signature of Bidder
123
Sr.No .
Particular of Test
10 11
Tensile Test Visual Test Dimensional check Hydrostatic Test 19) GENERATOR SHAFT Material Analysis Tensile Test Notch Impact Test Visual Inspection Magnetic particles Examination Ultrasonic Test Dimensional check Roughness Test Baroscopic Inspection Matching with Turbine shaft 20) BRAKE Visual Test Dimensional check Measurement of Stroke
Hydrostatic Test 21) E.T.D.THERMOMETER THERMAL SWITCH Calibration Test Check and setting of switches and relays 22) VARIOUS RELAYS Check and setting of pressure, SWITCHES AND
Signature of Bidder
124
Sr.No .
Particular of Test
10 11
Level, Flow Temperature switches and Relays 23) STATIC EXCITATION EQUIPMENT A) FOR EACH SET H.V. Test Functional Check of modules by simulation Control sequence interlock Test Load Test and current sharing Test on thyristor bridge Heat run test on thyristor bridges Heat run and Impulse test on excitation transformer
Signature of Bidder
125
4.19
SITE TESTS FOR GENERATOR AND RELATEEQUIPMENT Site tests to be conducted on various assemblies in presence of Purchaser are as below but shall not be limited to. DURING ERECTION STATOR WINDING : D.C. Resistance. Insulation Resistance. H.V. Test Dielectric Test.
ROTOR WINDING : D.C. Resistance Insulation Resistance. H.V. Test Rotor Impedance. Dielectric Test High frequency induced voltage test on poles.
MEASUREMENT OF CENTERING AND LEVELLING BEARING Insulation Resistance Check of vibration response Check of setting of oil level switches.
SHAFT : Check of shaft alignment together with Turbine Shaft. Check of vibration response. Check of slip ring deflection.
BRAKE AND SYSTEM Check of setting of pressure switch, limit switches,
Signature of Bidder
126
relays etc. check of pumps. Operation pump check in all mode.
STATOR FINISHED Magnetic flux test Di-electric Test. Measurement of stator winding D.C. resistance. Measurement of stator winding insulation resistance. Measurement of stator winding impedance. H.V. Test Check of concentricity of core. Check of core height.
ROTOR FINISHED Measurement of Rotor winding D.C. resistance. Measurement of rotor winding impedance. Measurement of rotor winding insulation resistance. H.V. Test Check of concentricity.
DURING PRECOMMISSIONING AND POST COMMISSIONING AUXILIARIES Auto/Manual operation of all auxiliary system connected with Generator . OTHER GENERATOR TESTS NO LOAD TESTS : Initial run Check of smooth run at gradually increased speed from zero to rated speed
Signature of Bidder
127
Vibration and noise level measurement Running test of bearings Recording of bearing metal and oil temperature at rated speed no load until all bearings reach stable temperature.
BEARING HEAT RUN
OVER SPEED TESTS Functional check of vibration & seismic monitor Run for 2 minutes at 150% over speed.
EXCITATION SYSTEM Commissioning test . SYNCHRONISING TEST Auto / Manual synchronising.
LOAD REJECTION TESTS Load rejection at 1/4, 1/2, 3/4 and 1.0 of rated output at rated power factor. Oscillograph measuring of voltage rise at each rejection. SHUT DOWN TESTS Normal stopping operation of generator Quick shut down tests. Emergency shut down test. Vibration and noise level measurement.
LOAD TESTS Check of operation of various controlling and `regulating. Temperature recording of windings and bearings.
Signature of Bidder
128
Vibration and noise level measurement. Measurement of Turbine and generator bearing bracket deflection.
STATIC EXCITATION SYSTEM Measurement of insulation resistance. H.V. Test. . Functional test of system component. Loading characteristic test. Measurement of range of voltage regulation. Measurement of range of power factor regulation. Test of generator current limiter and exciting current limiter. GENERATOR CHARACTERISTIC AND PERFORMANCE TESTS : Open circuit characteristic (without step-up power transformer). Three phase sustained short circuit condition characteristic. Line to line sustained short circuit condition (without step-up transformer) Various Reactances Measurement of Air gap Measurement of Noise level. Measurement of Moment of Inertia. Determination of balanced and residual component of telephone harmonic factor (THF) Measurement of following losses (according Calorimetric method) i) ii) iii) iv) Losses in active iron and additional no load losses in metal parts. Losses due to friction and windage Stator winding copper losses at 750 C Additional load losses to IEC 34-2A power
Signature of Bidder
129
v) vi) vii) -
Field winding copper losses at 750 C Excitation system losses + ac/dc link) Electrical losses in brushes. (Excitation transformer + thyristors
Measurement of vibration and noise level at rated output Measurement of all bearing temperatures at rated output. Measurement of reactive power Determination of generator guaranteed output with reference to guaranteed temperature rise.
4.20
DRAWINGS,
DESIGNS,
STUDIES
AND
MANUALS
TO
BE
SUBMITTED AFTER AWARD OF CONTRACT BY THE BIDDER. The list of drawings, designs, studies, data needed and manuals etc. required to be submitted by the supplier is enclosed with this section (Please refer Annexure IV - I). Mode of submission of designs and drawings will be intimated to the successful bidder in due course. 4.21 SPARES Spares shall be supplied as per the list under Section - III of this volume.
Signature of Bidder
130
ANNEXURE IV-1 DRAWINGS, DESIGNS AND MANUALS TO BE FURNISHED AFTER AWARD OF CONTRACT. Sr. No . 1 I 1. 2 GENERATOR Arrangement drawings describing 3 and illustrating the information of: * General layout drawing * Combined turbine and For approval Brief description within months from Remarks the date of award of contract 3 4
Generator cross section * General arrangement and overall dimensions of generator showing position and marking of main and neutral leads, important elevations etc Bearing Assembly * Air circulation arrangement * Excitation system * Description of bearings and data regarding construction, adjustment, accessibility and method. * Description and section of
stator and rotor insulation
Signature of Bidder
131
2. Installation, assembly drawings of : 1 2 Generator coupling Rotor Stator Foundation Stator windings Rotor arrangement including poles Slip ring arrangement Generator brakes 4 4 4 4 4 4 For approval For approval For approval For approval For approval For approval For approval and 3 turbine shaft 4 4 For approval
Assembly of stator and rotor with 4 lifting arrangement Speed arrangement Lifting and attachment drawing 4 sensing element 4
For approval
For approval
3. Drawings illustrating dimensional details with schematics for : 1 2 Lubrication and cooling of bearings Generator cooling Schematic diagram of air, and water piping Schematic diagram of brake 4 6 For approval For approval For approval 4 oil 4 For approval For approval 3 system 4 4 For approval
Thermometers, R.T.Ds etc General scheme giving of excitation system,
details 8 D.V.R.
Thyristors, field breaker, field discharge resistance, etc. Arrangement heaters of generator 8 For approval
Signature of Bidder
132
Arrangement of rotor service bay, Rim stools and bay floor. Arrangement withdrawal 4 of oil
on 4 building
For approval
loading on service
cooler 8
For reference
Layout, plan and cross sections 4 of floor openings for piping, cables etc. for units for: Trenches Block- out / cut- out etc Opening in housing
For approval
Sole plate, stator and bracket 18 fixing
For approval
8 9 10
Layout of cooling water piping Layout of oil piping and air piping Drainage arrangement
4 4
For approval For approval For approval
for 4
mulsifire water jet system 11 Layout protection schematics details. 12 Cable schedules of for all 10 power For approval of Mulsifire, system and fire 10 with For approval
equipment
equipments
entire
station as a whole and covering all equipment under i) Electrical lot. ii) Mechanical lot 13 Detailed wiring schedules for 10 interconnection of equipment stated in (12) above For approval
Signature of Bidder
133
MANUALS.
1 1
4 For reference
Manual for storage, preservation 12 and handling goods of the supplied
Manual dismantling, goods
for
erection testing
/ 12 and
For reference
commissioning of the supplied
Manual DONTs
giving
operating 18
For reference
instructions for all the DOs and
Manual
giving
detailed 18
For reference
maintenance schedule
Signature of Bidder
134
ANNEXURE IV-2 DEPARTURE FROM SPECIFICATION (To be filled in by Bidder) ---------------------------------------------------------------------------------------------------Item. Description of departure. Reference to clause in the specification. ----------------------------------------------------------------------------------------------------
Signature of Bidder
135
DATA SHEETS
DATA SHEETS E 1 TO E24 FOR TECHNICAL SPECIFICATIONS OF GENERATOR AND RELATED EQUIPMENT (THE BIDDER MUST FILL IN THIS DATA SHEETS COMPLETELY) Note : The indicated sign and the assigned meaning shall be as follows: > < (r). (d) (o) (*) no negative tolerance allowed no positive tolerance allowed required value desired value offered value guaranteed values inclusive of tolerance.
Signature of Bidder
136
DATA SHEET E1 Bidder's Remarks (if any) DATA SHEETS E 1 TO E 24
A
A1.
GENERATOR
GENERAL TECHNICAL DATA Direction of Rotation Seen from generator end Counter Clockwise(d) Rated Speed nn = 500 rpm (d)
------ (o)
A2.
------
rpm(o)
A3.
Maximum momentary over speed under most unfavourable transient conditions (according to turbine designer and IEC 41/1991 ) (nn max. < 1.5 nn (d)] nn max.------ rpm(o) Maximum steady state runaway speed at Qmax = 4.00 m/sec and Hnmax = 410 m and suddenly load removed according to turbine designer and IEC (1/1991-11 subclause 2.3.1.15) [nRmax. < 1.70 nn (r)] : nRmax = . rpm (o) Rated voltage and range of voltage regulation. Un = 11 kV Un = +10%kV (r) -----(o)
A4.
A5.
A6.
Rated frequency and range of frequency regulation for continuous operation fn =+3% & -5% (d) : fn = .-Hz(o) Telephone harmonic factor on open-circuit and rated speed and rated voltage:THF < 1.5% (r) Insulation class of stator and Field winding : Class F (r) -----(o)
A7.
A8.
------
(o)
A9.
Degree of protection (according to IEC 34.5/1991) : IP 44 (r) A10. Method of cooling of generator (according to IEC 34-6/ 1969) Signature of Bidder 137
------
(o)
------ (o)
DATA SHEET E2 Bidder's Remarks (if any) B. B1. GENERATION OUTPUT : Rated continuous apparent power output under entire zone A operation according to IEC-34-1 amend 2/1989 and temperature rise not higher than according to insulation class B (according to IEC 34-1) and rated power factor. [SN1 11.11MVA (r)] : SN1 = . (o) Rated continuous apparent power output under entire zone B operation according to IEC-34-1 amend 2/1989 and temperature rise not exceeding 95 K (and sub-clause 16.2 of IEC-34-1 embedded thermostat temperature detector method for stator windings and 100 K by Resistance method for field windings respectively with cooling water temperature at 300C and primary coolant maximum temperature 400C and rated power factor. SN2 11.11 MVA (r) : SN2 = . (o) Maximum permissible continuous apparent power output at Un + 10% fn+3% ,-5% and temperature rise according to IEC-34.1 amend 2/1989 at rated power factor. Exceeding 95 K (and sub-clause 16.2 of I.E.C. 34.1) by embedded thermostat temperature detector method for stator windings & 100 K by resistance method for field windings respectively with cooling water temperature at 300C and primary coolant maximum temp. 400C and rated power factor. SN3 > 11.11 MVA (r) : SN3 = . (o) Rated Power factor : cosn = 0.9 (overex) ..1.0..0.9(underex.) (r) ----- (o) Rated current at rated voltage UN and : SN1 = ------- MVA : IN1= .. A (o) SN2=-------MVA :IN2= .A(o) Smax=.MVA :Imax=. A(o) Occasional excess of the rated current < 1.5 times (r) armature current. (not less than 30 s) 138 ------ A (o)
B2.
B3.
B4. B5.
B6.
Signature of Bidder
DATA SHEET E 3 Bidder's Remarks (if any) B7. Apparent output for operating Conditions of rated voltage Un+ 10% and Hz 47.5 5051.5 at Temperature rise of stator winding 85K and field winding 90 K (Primary coolant temperature 40-degree C.) : MVA (o) Remark: Time for which generator can be run at rated apparent power output without fans in operation (if any) and without cooling water flow > 15 minutes without exceeding an additional temperature rise of 10 K. Bidders shall indicate permissible continuous apparent power for temperature rise not higher than insulation class F at Un + 10% Cos = 0.9 over excited) . 1.0 . 0.9 (under excited) for following frequency decreasing range. F net w = 46 Hz .. adm . KVA (o) Duration . Hrs (o) F net w = 47 Hz .. adm . KVA (o) Duration . Hrs (o) ELECTROMAGNETIC VALUES Electric loading (armature Ampere conductors per length) At rated current. Maximum magnetic flux Density of the air gap Surface at Un and no-load Average magnetic flux Density of the stator core Teeth at Un and no load Average magnetic flux Density of the pole core at Un and no load
C. C1.
A1 = . kA/m (o)
C2
:B 1 = . T (o)
C3.
: Bzl= . T (o)
C4.
:Bp=.T(o)
Signature of Bidder
139
DATA SHEET E4 Bidder's Remarks (if any) C5. Utilization factor Sn C = --------------------ds2. 1 nn Current density of armature windings at rated current kVA :C=------------------ (o) m3 x rpm A : S1------------- (o) mm2
C6.
C7.
Current density of field windings at rated excitation current for rated apparent power. Un and cos = 0.9 (over excited)
A : S2 =................ (o) mm2
C8 .
Maximum permissible continuous negative sequence component current [ 12 / IN > 0.1 p.u (d). ] : 12 / IN =..... p.u. (p) Maximum permissible value of (12 / IN) 2 x t for operation under fault conditions (12 / IN) 2 x t > 20 (d)
C9.
:( 12 / IN)2x t =.... p.u. (o)
D.
PERMISSIBLE LIMITS OF TEMPERATURE RISE PERMISSIBLE LIMITS OF TEMPERATURE RISE AT RATED APPARENT POWER OUTPUT OF SN2 OF DATA SHEET El-2 and Un cos <n = 0.9 ( over excited ) .... 1.0 0.9. ( under excited )with MAXIMUM PRIMARYCOOLANT TEMPERATURE 40 C.
D1
Stator ( by embedded thermostat temperature detectors ETD ) [AD a < 95 K (r) according to class B and subclause 16.2 of IEC 34- l] :Aoa < .... K (o)
D2.
Field windings [ Auf < 100K (r) ]
: Auf < ....... K (o)
Signature of Bidder
140
DATA SHEET E5 Bidder's Remarks (if any) D3. Permanently short-circuit insulated damper bars ( by thermometer ) [Aud<60K(d)] Magnetic core and parts not in contact with windings (by thermometer) [AuFe< 6 0 K ( d ) ] Magnetic core and parts in contact with windings (by thermometer) [Ao'Fe < 60 K (d)] Slip- rings enclosed (by thermometer) [Aosr<60K (d)] :Ausr< K (o)
: A o d < ..... K(o)
D4.
: A o F e < ..... K (o)
D5.
: Au'Fe <......K (o)
D6.
Signature of Bidder
141
DATA SHEET E6 Bidder's Remarks (if any)

E DESIGN AND GEOMETRIC DIMENSIONS (QUANTITIES ACCORDING TO IEC PUBL.27-4/1985) E1 Stator design a) Construction of core segments b) Inner diameter of stator core c) Length of one ventilation duct d) Number of ventilation duct e) Iron Length (1Fe = 1-nv.1V) f) Overall length of the core (Including ventilation duct) g) Outer diameter of the stator core (excluding heat exchangers and frame h) Air gap (maximum / minimum) i) Equivalent air gap (including slotting) j) Number of armature slots k) Armature slot dimensions (depth x width) l) Copper section per each Armature bar m) Total number of conductors n) Number of parallel paths o) Estimated maximum current circulating between the parallel circuits p) Number of conductors in a slot q) Number of slots per pole and phase r) Gap between coil & slot sides g = <0.5 mm (d) s) Number of armature windings per phase (turns in series in a coil) t) Stator slot pitch S = . mm (o) ZQ = . (o) q = . (o) g= mm (0) max/min = ../ mm (o) = ./.mm (o) Q = . mm (o) hs x bs = ..X..mm (o) Ss = . mm2 (o) z = . (o) a = . (o) A = . Amp (o) (o) ds = . mm (o) Iv = . mm (o) nv = . (o) IFe = . mm (o) 1 = . mm (o) dso = . mm (o)
Nc = . (o)
Signature of Bidder
142

u) Pole pitch v) Pitch factor (chording factor) w) Winding factor x) Carter factor due to slotting of the stator y) Thickness of material for core laminations. z) Specific losses of materials for laminations at 1.0 T & 50Hz aa) Class of armature windings insulation ab) Number of partial stator parts ac) Maximum mass of one stator part for transport ad) Maximum mass of the stator to be lifted during erection ae) Total mass of finished stator (Without coolers) af) Is winding fully insulated from line to neutral ? (yes / no) Yes (r) (r) (o) G1 tot.= . t(o) F (r) n = . (o) G1 = . t (o) Ger = . t (o) P = . mm (o) Kp = .. (o) Kw = . (o) Kc = .(o) t1 =.mm (o) c = . W/Kg (o)
ag) Anti corona protection (yes/no) Yes ah) Stator slot wedge material
ai) Necessary dimensions of Generator Housing Diameter of generator Housing i) inner Dp = mm (o) Dp = mm (o) Hp = mm (o)
- ii) Outer - total length of generator Housing E2 Rotor design a) Construction of rotor - laminated rotor or other construction type
(o) (o)
Signature of Bidder
143

- material for laminated rotor - thickness of material for laminations - material for shaft - material for body - material of pole core - material of pole shoe - material of field windings insulation - material of slip ring - class of field windings insulation b) Outer diameter of rotor c) Height of pole body d) Height of pole shoe e) Width of pole body f) Width of pole shoe g) Maximum stress in rotor Pole body at :- rated speed - max. steady state runaway speed h) Number of field windings i) Section of field windings j) Total number of damper bars k) Diameter for damper bars l) Section of dampers ring (if any) m) Total number of slip ring brushes n) Brush coverage ratio B = . Mpa B'' = . Mpa Nf = (o) Sf = mm2 (o) nb = (o) db = mm (o) Sdr = . mm2 (o) nbr =- . (o) (o) (o) F (r) dr = . mm (o) hp1 = . mm (o) hp2 . mm (o) bp1 = . mm (o) bp2 . mm (o) (o) t2= mm (o) (o) (o) (o) (o) (o) (o)
= (o)
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o) Can brushes be replaced on load (Yes / No) Yes (r) p) Maximum mass of rotor part and description to transport q) Maximum mass be to lifted during erection (complete rotor) E3 Terminals bushings and connections Ur = . kV (o) In = . A (o) G2= t (o)
G2 tot = t (o)
- Rated voltage level of terminals bushing - Rated current of terminals bushings E4 Mechanical braking design
a) At which speed are mechanical brakes applied for normal shutdown b) How long to stop of unit c) At which speed are brakes applied for emergency shutdown d) How long to emergency stop of unit e) Operating rated air pressure for braking system F SYNCHRONOUS MACHINE QUANTITIES (According to IEC Publ. 34-4/1985) F1 Rectances a) Short-circuit ratio (clause 4.5 ) b) Direct-axis synchronous reactance (unsaturated) (clause 4.5 ) c) Quadrature-axis synchronous reactance (unsaturated, tolerance + 5%)
nbr = . rpm (o)
tbr = s (o) n'br rpm (o)
t'br s (o) Pbr MPa (o)
Kc > p.u (o) Xd = p.u (o)
X'q = p.u. (o)
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d) Direct-axis transient reactance (clause 4.5 ) - At In - at Un e) Direct-axis substransient reactance - At In - at Un f) Quadrature axis substransient reactance - At In - at Un g) Negative sequence reactance - At In - at Un h) Zero sequence reactance - At In - at Un i) Potier reactance F2 Resistances a) Positive-sequence resistance b) Negative sequence resistance c) Zero-sequence resistance d) Armature windings direct current resistance at 75 degree C e) Field windings direct current resistance at 75 degree C r1 = p.u (o) r2 = p.u (o) r0 = p.u (o) Ra = /Ph (o) ra = p.u. (o) Rf = (o) rf = p.u. (o) XoIn = p.u. (o) XoUn = p.u. (o) Xp = p.u. (o) XzIn = p.u. (o) XzUn = p.u. (o) X'dIn = . p.u. (o) X'dUn = . p.u. (o) X'dIn = . p.u. (o) X'dUn > . p.u. (o) X'dIn < . p.u. (o) X'dUn < . p.u. (o)
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F3 Generator moment of inertia, acceleration time and stored energy constant a) Generator moment of inertia for rated speed. b) Generator acceleration time constant reported at rated active power Pn= 10 MW and rated speed c) Generator stored energy constant reported rated apparent power output Sn2 = 11.60 MVA and rated speed F4 Short-circuit currents at rated speed a) Sudden short-circuit currents at no-load and rated voltage : - initial symmetrical three phase short-circuit current (rms-value) - initial symmetrical line- short- circuit current (rms-value) - initial symmetrical line neutral- short- circuit current (rms-value) - initial symmetrical three phase short - circuit current (d.c. -value) b) Sustained short-circuit currents at no-load and rated voltage : - at three phase short-circuit (rms value) - at line-line phase short-circuit (rms value) - at line neutral phase short-circuit (rms-value) c) Sudden short-circuit at rated apparent power output, Un and cos = 0.9 (over excited) - initial symmetrical three phase short-circuit current (rms-value) I" K3= p.u. (o) IK3= p.u. (o) IK2 = p.u. (o) IK1= p.u. (o) I" Ka = p.u. (o) I" K2= p.u. (o) I" K1= p.u. (o) I" K3= p.u. (o) H=.s(o) J > . (o) J = s (o)
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- initial symmetrical line line short-circuit current (rmsvalue) - initial symmetrical line neutral short-circuit current (rms-value) - initial symmetrical three phase short-circuit current (d.c.value) d) Sustained short-circuit currents at rayed apparent power output, Un and cos = 0.9 (over excited - at three phase short-circuit (rms value) - at line-line phase short-circuit (rms value) - at line neutral phase short-circuit (rms-value) IK3= p.u. (o) I K2= p.u. (o) I K1= p.u. (o) I" Ka= p.u. (o) I" K1= p.u. (o) I" K2 = p.u. (o)
G. EXCITATION SYSTEM I. DATA FOR RATED SPEED (According to IEC 34-16-1/1991 and 34-16-2/1991) 1. No-load field current at rated voltage 2. No-load field voltage at rated voltage 3. Rated field current at rated apparent power output, Un and - Cos = 0.9 (overexcited) - Cos = 1.0 - Cos = 0.9 (underexcited) 4. Rated filed voltage at rated apparent power output Un and - Cos = 0.9 (overexcited) Ufn = V (o) Ifn = A (o) I'fn = A (o) I"fn = A (o) Ifo = A (o) Ufo = V (o)
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- Cos = 1.0 - Cos = 0.9 (underexcited) 5. Telephone harmonic factor < 1.5% (d) II. EXCITATION SYSTEM GENERAL (According to IEC 34-16-1 and 34-16-2) 1. General a) Preferred system Static excitation system with thyristors supply of excitation transformer from generator terminals (d) b) System offered c) Excitation system nominal response (VE > 4.0 s-1 (r)] d) Rated field voltage and current at rated output power, rated voltage and rated power factor 0.9 (overexcited) - Rated field voltage - Rated field current e) Maximum field forcing d.c output - Excitation system ceiling voltage [Up > 2.V fn (r)] - Excitation system ceiling voltage [Ip > 1.5. In (r)] III Main excitation transformer (Rectifier transformer) a) Manufacturer b) Type [1 three phase excitation dry transformers (d)] c) Standard specification with which the transformers comply ................. (o) ................. (o) ................. (o) Up > V (r) IP > A (r) Ufn = V (o) Ifn = V (o) (o) VE > s-1 (r) U'fn = V (o) U"fn = V(o) (o)
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d) Rating i) Continuous maximum output ii)Rated Voltage * high voltage side * low voltage side e) Type of cooling f) Cooling medium g) Connection group h) Short-circuit impedance at 750 C and 50 Hz i) No-load losses per phase j) Load losses per phase (I2R + stray losses) at 750 C and 50 Hz k) Magnetizing current at rated voltage and 50 Hz IV) Main excitation rectifier (Controlled rectifier) a) Input i) Maximum continuous A.C.voltage ii) Frequency iii) Number of phases iv) Power at maximum permissible continuous apparent power b) Output i) maximum continuous direct voltage ii) maximum continuous direct current iii) maximum direction current during 10 seconds . V (o) . A (o) . A (o) V (o) Hz (o) ................. (o) % In (o) kVA (o) Kv(o) kV (o) kV (o) ................. (o) ................. (o) ................. (o) % (o) .. kW (o) kW (o)
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c) Configuration i) Is rectified built in sections which can be individually removed and replaced with the machine at full load ? ii) How many such sections per phase are there in the complete rectifier ? iii) How many such sections per phase are required to maintain excitation on the generator max. permissible continuous apparent power d) Main diodes i) Number used in complete rectifier ii) Make iii) Type iv) Maximum permissible continuous direct current v) Maximum permissible continuous direct current during 10 seconds vi) Peak inverse voltage e) Rectifier main diode fuses i) Number used in complete rectifier ii) Make iii) Type iv) Current Rating v) Rating of fuse failure alarm contacts * Voltage * Current f) Cooling medium i) Rectifiers ii) D.C. busbars (o) (o) ......... V (o) ......... A (o) ......... (o) ......... (o) ......... (o) ......... A (o) ......... V (o) ......... (o) ......... (o) ......... (o) ......... A (o) ......... A (o) ......... (o) ......... (o) ......... (o)
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g) Power consumption of i) all fan motors on complete rectifier ii) all pump motors on complete rectifier (if any) V) Automatic Digital Voltage Regulator (DVR) a) Make b) Type c) Adjustment range of generator reference level for automatic control d) Adjustment range of generator voltage for hand control (at rated speed) i) Increasing Voltage ii) Decreasing Voltage e) Provision for remote electrical selection and setting of automatic and hand control f) Provision of automatic follow up of voltage setting by ......... (o) hand voltage setting g) Ratings of limit switches on automatic and hand remote setting devices i) Voltage ii) Current h) Provision for under-excitation monitor ......... V (o) ......... A (o) ......... (o) ......... % (o) ......... % (o) ......... (o) ......... (o) ......... (o) ......... % (o) kW (o)
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i) Method of preventing excitation boosting if voltage transformer fails j) Operating frequency range [45 to 55 Hz (d) k) Auxillary power required i) Voltage ii) Current iii) Supplied from m) Current transformers for automatic voltage regulator if Required i) Burden ii) Accuracy class iii) Current Ratio iv) Number per regulator v) Provided by NOTE : i) Tolerance shall be guaranteed along with Bidders remarks, if any. ii) Location of Excitation transformer. V.T. cubicles, dynamic brake cubicle, field suppression cubicle etc. shall be proposed by generator supplier and shall be coordinated with other supplier. ......... V A (o) (o) A/A (o) (o) (o) ......... V (o) ......... A (o) ......... (o) ......... to . Hz (o) .........
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..................DATA SHEET E18 ..................Bidder's Remarks (if any) H) GENERATOR BEARING Type of bearing [adjustable pad/segmental type self lubricated bearing ( d ) ] Diameter of generator bearing Number of pads/segments Total effective surface of all segments Circumferential length of pads/segments Axial length of pads/segments Dynamic viscosity of oil Maximum temperature for oil film Maximum temperature for Segment ( < 70 0C ( r ) Whether H.S. Lubrication is used (yes/no) Quantity of lubricated oil reservoir Quantity of cooling water (if required) Total losses in bearing at rated load Permissible duration of operation of the unit at rated load without supply of cooling water. Vibration limit of generator bearing for complete range of operation <75m (r) : =.. .m3 (o) : =. 1/s (o) : = . .Kw (o) : = : d =mm (o) : N =...(o) : A =.m2 (o) : L = .mm (o) : b =.mm (o) : v =.m/s2 (o) : =..0C (o) : =..0C (o) : .(o)
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..................
CURRENT TRANSFORMERS (To be supplied for each core separately in tubular form) a) CT Number/Location b) Qty. c) Application d) Name of manufacturer e) Type f) Winding of connection g) Rated burden of earth secondary winding per phase h) Insulation level i) Insulation class j) Impulse withstand voltage of primary winding k) (1.2/50 micro second wave) kV (peak) l) One minute power frequency dry withstand voltage (kV) m) Primary winding n) Secondary winding o) Characteristic enclosed (Yes/No) p) Accuracy class
POTENTIAL TRANSFORMER
(To be supplied for each core separately in tubular form) (a) Type (b) (c) (d) (e) (f) (g) (h) (i) Name of manufacturer Standard to which it conforms Manufacturers type design Volts Rated primary voltage Rated secondary voltage Rated burden Accuracy class Temperature rise at 1.1 times rated voltage with rated burden and frequency kV (rms)
(j) One minute power frequency withstand test voltage on primary
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DATA SHEET E20

Bidder's Remarks (if any)
LIGHTNING ARRESTER a) Make b) Type c) Rated voltage d) Max. system voltage across arrestor e) Power frequency spark over voltage (kV) f) Impulse spark over kV (peak) g) Max. front of wave impulse Spark over kV (P) h) Rated discharge current i) Max. discharge voltage in kV crest for discharge Current 8/20 micro sec. Wave j) Leakage current at rated voltage insulator (kV) k) One minute dry withstand voltage of arrestor external insulator (kV)
SURGE CAPACITOR l) Make m) Type n) Nominal voltage o) Max. voltage p) Insulation class q) Phase r) Frequency s) Capacitance t) impulse withstand voltage (1.2/ 50 micro second wave) u) Qty. v) Applicable standard w) Residual voltage after 5 minute of disconnection Signature of Bidder 156 Signature of Purchaser
DATA SHEET E21

INSULATORS (in junction bus panel) a. Make b. Type c. Material of insulator d. Colour e. Insulation level: f. Dry (PF) g. Wet (PF) h. Impulse
N (i)
Neutral Grounding Equipment Distribution Transformer and secondary Resistor (a) Type (b) Name of manufacturer (c) Voltage ratio (d) Continuous rating (e) One minute rating (f) Secondary load resistance (ohms) (g) Current rating of resistor (h) Duty cycle of resistor and cooling medium Neutral Isolation Switch (a) Type (b) Name of manufacturer (c) Voltage rating, frequency (d) Normal current (e) Short time rating (f) 1.2/50 Micro Second impulse level (g) 1 minute power frequency dry withstand voltage
(ii)
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11 kV XLPE CABLE General i. Name of the manufacturer Cable Type i. ii. iii. iv. Type and size of Cables Standard applicable Voltage rating Permissible variation in voltage, frequency and combined voltage and frequency. Suitable for earthed/ unearthed system
v.
Conductor i. ii. iii. iv. v. Material Nominal cross-sectional area. Form of conductor-circular/ shaped No. of strands Nominal dia. of each strand
Conductor Screen i. Material ii. Minimum thickness iii. Whether extruded Insulation i. Material (Mention type) ii. Minimum average thickness iii. Tolerance on the smallest of the measured values of thickness of insulation. iv. Dia of core over insulation. v. Specific insulation resistance at 27oC vi. Colour scheme of identification of cores. vii. Average dielectric strength viii. Suitability with regard to moisture zone, acid, oil and alkaline cup-roundings. Signature of Bidder 158 Signature of Purchaser
DATA SHEET E23

Electrical Properties i. ii. Conductor resistance at 20oC per km. Maximum permissible conductor temp. a. Under continuous full load b. Under transient conditions Loss tangent at normal frequency Reactance at 50 C/s per km. Capacitance at 50 C/s per km. Current rating. a. In air (continuous) b. In duct (continuous) c. Reference ambient temperature for the above d. Short circuit current rating for 1 sec. duration Impulse withstand voltage Power frequency withstand voltage (50 Hz) for 30 Minutes. Partial discharge Permissible Overload
iii. iv. v. vi.
vii viii ix x)
xi) Electrical stress (AC voltage) a) On conductor Average Maximum b) On Inner Semi conductor layer Average Maximum c) On Outer Semi conductor layer Average Maximum
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DATA SHEET E24

xii) Electrical stress ( Impulse withstand voltage) Average Maximum ( On Inner Semi conductor layer Mechanical Data i. ii. iii. iv. v. Overall dia. of the cable Dia. of the cable under the sheath Weight of cable per kg. Drum length Recommended minimum installation radius Maximum safe pulling force. P Heaviest package for shipment (a) (b) (c) Q Name Weight Dimensions (L x B x H)
Largest package for shipment (a) (b) (c) Name Weight Dimensions (L x B x H)
R.
Heaviest assembly to be lifted by power house crane (a) Name (b) Weight (c) Dimensions (L x B x H)
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TABLE NO.1
GUARANTEED VALUES OF GENERATOR LOSSES AND EFFICIENCY AT RATED VOLTAGE Un and cos -0.90 (overexcited) No. Losses (According to IEC 34-2) Symbol unit Apparent power at generator terminals Smax= 105 % SN = 100% SN =95% MVA MVA MVA Losses in active iron and additional no load Pfe kW Losses in metal parts 1 Constant Losses due to Turbine bearing losses Pu.g.b kW losses friction and windage (*) Generator bearing losses Pl.g.b. kW Windage and friction losses Pwi+f kW Brushes losses Pbr kW 2 Excitation Field voltage Uf V parameters Field current If A 3 Load losses Stator windings copper losses at 75 C Pcu 1 kW Additional load losses Padd. kW Field winding copper losses at 75 C Excitation system losses (excit trasf. + thyristors + ac/dc links) Electrical losses in brushes 4: 5 6 SUMMATION OF LOSSES CALCULATED GENERATOR EFFICIENCY GUARANTEED GENERATOR EFFICIENCY Pcu2 Pe.s Pe.br Ip f i G.c f jG.g kW kW kW kW
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TABLE NO.2
DATA SHEET E26

No. GUARANTEED VALUES OF GENERATOR LOSSES AND EFFICIENCY AT RATED VOLTAGE Un and cos -1.00 Losses (According to IEC 34-2) Symbol unit Apparent power at generator terminals Smax SN = 100% 95% 105 % MVA MVA SN MVA Losses in active iron and additional no load Pfe kW Losses in metal parts 1 Constant Losses due to Turbine bearing losses Pu.g.b kW losses friction and windage (*) Generator bearing losses Pl.g.b. kW Windage and friction losses Pwi+f kW Brushes losses Pbr kW 2 Excitation Field voltage Uf V parameters Field current If A 3 Load losses Stator windings copper losses at 75 C Pcu 1 kW Additional load losses Padd. kW Field winding copper losses at 75 C Excitation system losses (excit trasf. + thyristors + ac/dc links) Electrical losses in brushes 4: 5 6 SUMMATION OF LOSSES CALCULATED GENERATOR EFFICIENCY GUARANTEED GENERATOR EFFICIENCY Pcu2 Pe.s Pe.br Ip f i G.c f jG.g kW kW kW kW
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TABLE NO.3
GUARANTEED VALUES OF GENERATOR LOSSES AND EFFICIENCY AT RATED VOLTAGE Un and cos -0.90 (underexcited) No. Losses (According to IEC 34-2) Symbol unit Apparent power at generator terminals Smax SN = 100% 95% 105 % MVA MVA SN MVA Losses in active iron and additional no load Pfe kW Losses in metal parts 1 Constant Losses due to Turbine bearing losses Pu.g.b kW losses friction and windage (*) Generator bearing losses Pl.g.b. kW Windage and friction losses Pwi+f kW Brushes losses Pbr kW 2 Excitation Field voltage Uf V parameters Field current If A 3 Load losses Stator windings copper losses at 75 C Pcu 1 kW Additional load losses Padd. kW Field winding copper losses at 75 C Excitation system losses (excit trasf. + thyristors + ac/dc links) Electrical losses in brushes 4: 5 6 SUMMATION OF LOSSES CALCULATED GENERATOR EFFICIENCY GUARANTEED GENERATOR EFFICIENCY Pcu2 Pe.s Pe.br Ip f i G.c f jG.g kW kW kW kW
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SECTION V
TECHNICAL SPECIFICATIONS OF TURBINE
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SECTION V TECHNICAL SPECIFICATIONS OF TURBINE INDEX Sr.no. 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11 5.12 5.13 5.14 5.15 5.16 Description Scope Type and rating Guarantees vis--vis liquidated damages Liquidated damages for failure to meet performance guarantee Model test Field test and acceptance Detailed construction specifications of components of turbine Governing system Penstock drainage system Water level measuring & transmitting device Special tools, slings, consumables etc Spares Tests Guaranteed technical particulars Electrical equipment Standards Annexure V-1 Annexure V-2 Data sheet M1 to M13 Page no. 166 166 168 172 173 175 175 181 187 187 188 189 190 192 193 196 198 199 200
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SECTION V
TECHNICAL SPECIFICATIONS OF TURBINE
5.1
SCOPE works, supply, delivery at site, erection, testing at site and commissioning of 1 (One) No. horizontal Pelton type hydraulic turbine and associated auxiliary and ancillary equipment, main inlet valve, equipment for auxiliary systems such as compressed air system, Cooling water system, drainage & dewatering system, lubrication system, oil, water and air piping with valves and fittings, instrumentation, controls and safety devices(as required), necessary LT power, control, measurement & data cables, cable trays, tray supporting arrangement, Spares for five year operation of the plant, special tools etc., as described and detailed in the specification and listed in the schedule of requirements. The scope includes model testing including preparation of model and field efficiency tests of prototype in accordance with relevant IEC test code. The scope of supply shall include all parts, accessories, and spares etc., which are essential for construction, operation and maintenance of the complete prime mover even though these are not individually or specifically stated or enumerated. The turbine manufacturer shall co-ordinate with the generator supplier so that the generator to be coupled to the turbine is matched in respect of speed, runaway speed, moment of inertia, overload capacities, coupling and other relevant requirements.
5.1.1 This section of the specifications covers the design, manufacture, tests at
5.1.2 The turbine and generator unit shall match in respect of speed, overpressure, over-speed and runaway speed, moment of inertia, outputs, coupling and other requirements.
5.2
TYPE AND RATING: The turbine shall be of the Horizontal shaft Pelton type. The direction of rotation shall be counter clock-wise when viewed from generator/drive end. The turbine shall be capable of giving output higher than rated output to
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match the overload capability of the generator.. Number of units Type : : 1 No. Horizontal shaft single stage Pelton type turbine and suitable for direct coupling with the generator. The hydraulic data in respect of reservoir and the other data regarding water conductor system is as follows. LEVELS A B C D E G H I K Minimum Draw Down level (m) Full Reservoir water level (m) Maximum tail water level Minimum tail water level Design discharge Nozzle level (m) High Flood level of river (m) Total Head loss due to friction Rated head (Design) (m) 579.11 EL 602.00 EL 190.00 EL (tentative) 189.00 EL (tentative) 3.12 m3/sec 190.00 EL 187.52 EL 1.91 m 402 m
The specific speed of the turbine shall be as per the best modern practice and of proven design and operation. The tentative layouts of the powerhouse shall be given by the bidder. The turbine shall be designed to give a rated output of 12222 kW at rated head with nozzle opening of about 80-85 percent. The turbine shall have adequate
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capacity commensurate with the 10 % continuous overload capacity of the generator. The turbine would have output higher than the rated output when operating at heads higher than the rated head. During monsoon season more discharge will be available. The capacity of the turbine shall be suitable for smooth operation to give higher output at rated net head when higher discharges are available The supplier may offer his nearest standard design. The maximum output both at maximum and minimum heads shall be stated in the offer. In case of failure of governor or D.C.supply a positive device/arrangements shall be provided to cut off the water supply to turbine bring the machine immediately to stand still without any damage to generating unit or the foundation. The bidder should explain in his bid about the device/arrangement proposed by him to achieve the above special requirement along with write / up and the drawing of the same.
5.3
GUARANTEES VIS--VIS LIQUIDATED DAMAGES:GENERAL: The supplier shall guarantee that the turbine in its entirety, including all related equipment, material and structure furnished under this specification will be free from defects in design, material and workmanship. The Supplier shall warrant the successful operation of all such equipment.
i)
Performance guarantees: The meaning assigned to various performance guarantees shall be according to IEC 41(1991), IEC 193(1965), IEC 193A(1972), IEC308(1970), IEC 609(1978), IEC 545(1976), IEC 994(1991), and IEC 995(1991).
ii)
Turbine output and efficiency guarantee: The rated output of the turbine at rated head shall be stated and guaranteed. The efficiency of the turbine at rated head, maximum head, and minimum head for 105%, 100%, 95% rated output shall also be guaranteed. These figures shall be applicable for purpose of liquidated damages, rejection limits and bid evaluation. In addition, the output of the turbine at full nozzle opening
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at net head and rated head shall be stated in the bid. The supplier shall state and guarantee the weighted average efficiency value and shall furnish the estimated values of efficiency, nozzle opening and discharge in a tabular form enclosed in data sheets.
iii)
Weighted average efficiency The weighted average efficiency of the prototype turbine shall be determined from the field test or model test values of efficiency at rated head in accordance with the following formula for purpose of penalty and rejection limit and bid evaluation. Tav =k1 x T105 +k2 xT100+ k3 x T95 Where Tav Weighted average efficiency of the turbine, T105, T100 and T95 are efficiencies of turbine at 105%, 100% and 95% of rated output at rated head respectively. The value of k1, k2 and k3 are to be decided as per working table and discharge dependability.. The weighted average efficiency chart is given in data sheet. The bidder shall submit the values.
iv)
Rejection limit The purchaser has the right to reject the turbine if the test value of either weighted average efficiency or the rated output is less than the corresponding guaranteed value by 2(two) percent or more after allowing tolerance in computation of efficiency.
v)
Rectification to meet guarantees The contractor shall be given mutually agreed time to improve/modify the design of turbine or to carry out rectifications, etc., as may be required so that the guarantees are met in case the tests prove unsuccessful in meeting the guarantees. If the second meeting is also unsuccessful, penalty or rejection of the equipment, as the case may be, shall be applied. However, no delay in the original delivery schedule shall be allowed if the model test results do not meet the guarantees and rectifications are made by the contractor thereafter within a mutually agreed period as stated above.
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vi)
Pitting The bidder shall guarantee the runner against excessive pitting for 24 months from the date of commissioning or 5000 hours of operation, whichever is more. If the 24 months of guarantee period expires before completion of 5000 hours of operation, the guarantee shall apply to the actual hours of operation proportionately. Excessive pitting shall be defined as the removal of metal from the runner of a weight of W= 0.15 D per 1000 hours of operation, where, D = Discharge diameter of the runner and W = weight in Kg. Checking of this guarantee shall be as per IEC 609 In case of pitting exceeding the guarantee, the turbine supplier shall, at his cost, take corrective measures such as modification of design, finish, replacement, repair, etc., and the turbine after modification, etc. shall be subject to guarantee as for the original equipment. In determining whether or not excessive pitting has occurred metal removal by erosion, corrosion or by the presence of injurious elements in water, etc., shall be excluded.
vii)
Maximum momentary overspeed: The supplier shall guarantee that the maximum momentary over speed under most unfavourable transient conditions according to IEC 41(1991), sub-clause 2.3.4.14 will not exceed 1.50 times the rated operating speed.
viii)
Maximum steady state runaway speed : The Supplier shall guarantee that the maximum steady state runaway speed according to IEC 41(1991), sub-clause 2.3.4.15 will not exceed 1.70 times rated speed.
ix)
Maximum/minimum momentary pressure: The supplier shall guarantee that the maximum and the minimum momentary pressure under most unfavourable transient conditions according to IEC 41(1991), sub-clause 2.3.5.7 shall not exceed guaranteed values of data sheets.
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x)
Vibration amplitude: The amplitude (zero to peak) of vibration according to Rathbone chart shall be less than 75 m (microns). Should for any reason the above limit exceed, the supplier shall take at his own cost, all steps to remedy the situation and to reduce the vibration to the above-stated limits.
xi)
Noise level: When units are in operation at most unfavourable conditions in any mode, noise level measured in the turbine housing shall not exceed 90 dB(A). Further, the maximum noise level, on the turbine and generator floor levels at a point outside barrel shall not exceed 90 dB(A).
xii)
Resonance: The supplier shall guarantee that turbine is capable of operating continuously and smoothly without hunting in the entire operating range. The supplier shall confirm that the turbine design is such that the power pulsation at generator terminal is within 1.5% at full load and 5% at partial load of actual rated output.
5.4
Liquidated damages for failure to meet performance guarantee: The Supplier shall submit model test previously conducted for to ascertain guaranteed performance values, the model tests results would form basis for acceptance. The guarantees at the discretion of Purchaser shall be subject to verification by field tests. If the field tests are conducted for final acceptance and for arriving of liquidated damages non-conformity with guaranteed values, field tests will prevail. The testing protocol shall be as per IEC and the method of testing shall be Thermo-dynamic method and performance particulars would be established. The cost of performance of such tests shall be to the suppliers account. Charges for conducting field tests by thermodynamic method shall be indicated distinctly and separately in the price schedules of bid .The supplier shall account for the layout of water conductor system so that no arguments/disputes shall be raised. If the results obtained during these tests differ from those guaranteed by the supplier he shall pay the liquidated damages as per the provisions stipulated in Annexure III-2 of
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Volume I. The Supplier shall have to establish the data guaranteed by him in respect of energy generated. If the goods under the contract fail to meet the performance guarantees, the supplier shall agree to pay to purchaser as liquidated damages as per the provisions stipulated Annexure III-2 of Volume I of Commercial terms and conditions of contract . The liquidated damages for output and efficiency shall be computed separately and the total amount of penalty shall be the sum of these two. No tolerance shall be permissible over the test figures of rated output. In case of efficiency, tolerance will be allowed as per appropriate IEC test code. The ceiling on the total amount of penalty on account of shortfall in the weighted average efficiency and output shall be 10% of the total unit price of turbine and governing system
5.5
MODEL TEST Model test shall be carried out and the rates for model test as per relevant standards shall be quoted separately. The performance of the model tests shall be as per IEC standards 193 and 193A in all respects. The model shall be truly homologous and shall include the hydraulic parts from outlet of spherical valve including the connection pipes, nozzle and runner. Hydraulic performance tests shall be made at various nozzle openings percentage to determine machine characteristics including regimes of safe operations, zones of cavitation and vibration, etc. The phenomenon of cavitations and vibration shall be specially investigated. These tests shall include determination of capacity, cavitation limits, hydraulic thrust, runaway speed, etc., and such other details as covered in IEC 193 and 193A. Prototype efficiencies shall be derived from model tests as contained in IEC 193 for Pelton turbines. Model tests shall simulate all possible normal operating conditions of the prototype for entire range of forebay / reservoir and tailrace levels. The bidder shall clearly mention the time within which the model tests including manufacture of a new model, if required, will be completed. The delivery schedule given by the bidder shall be reckoned from the date of approval of model tests or model test report or from the time of permission to proceed with the prototype manufacture. The contract price shall include
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charges of model test and all expenses including to & fro air/first class Railway travel and accommodation of three (3) representatives of Purchaser for witnessing the test. MEASUREMENTS: Measurement of efficiency, power output and corresponding discharge for each of the nozzle opening position corresponding to 100%, 95%, 90%, 80%, 50%, 35%, 20% of the nozzle opening. * * * * Further, all these tests shall be conducted for operation at maximum net head, the rated net head and the minimum net head. Measurement of turbine runaway characteristics under most unfavourable conditions. Determination of the turbine cavitations characteristics i.e. efficiency Vs cavitations co-efficient relationship. Determination of the zone of stable operation in turbine mode between 35% and 100% of nozzle opening position at minimum net head, rated net head and maximum net head and the influence of air admission at part load operation. * * * * * Power pulsations at the shaft. Determination of axial hydraulic thrust and axial displacement of the shaft for various nozzle openings and different heads. Measurement of nozzle torque under abnormal transient conditions. Determination of the magnitude and frequency of radial forces on the turbine bearing during starting, stopping and running at runaway conditions. No load operation.
MODEL ACCEPTANCE Within two months after the receipt of the final model test report, the purchaser shall communicate his approval of the model to the supplier. Should the model fail to meet the guarantees and other requirements, the purchaser shall direct the supplier to modify the model until it complies with the requirements. The supplier shall make good the deficiencies and conduct (repeat) the model testing programme. All expenses involved for the modification and subsequent model tests shall be borne by the supplier.
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No delay, however shall be allowed in the original delivery schedule due to any reasons on account of model testing process. The rejection shall be applicable if the second attempt is also unsuccessful in meeting the guarantees.
5.6
FIELD TEST AND ACCEPTANCE Only the tests regarding output, vibration, noise, temperature-rise, stable operation, losses, over speed and over pressure, shall be conducted to verify the guaranteed performances. The guarantees at the discretion of the Purchaser shall be subject to verification of the prototype by field tests. Charges for field test shall be shown separately. If the field tests are decided to be done for final acceptance, for arriving at the liquidated damages for nonconformity with guaranteed values, field tests will prevail. Provisions for discharge measurements required to be adopted for field test shall be included in the cost of bid. No bonus will be given to supplier in case of better results however Purchaser reserve the rights to reject the equipment in case of failure to meet the guaranteed values in variation is more than 3 %.
5.7
DETAILED CONSTRUCTION SPECIFICATIONS OF COMPONENTS OF TURBINE The turbine shall be constructed as to allow all the removable parts to be dismantled conveniently. The design shall also permit removal of rotating parts without disturbing the deflector-nozzle assembles. The design shall also permit horizontal movement of runner shaft by an amount sufficient for adjustment of bearings and for clearing the joint at the coupling between the turbine and the generator.
i)
Runner The runner shall be of 13/4 chromium-nickel stainless steel. The composition of the material and the source of runner casting shall be stated in the bid. The runner shall be cast integrally of stainless steel. The runner will have adequate number of buckets which shall be polished and ground smooth and shall be free from roughness, cracks, high spots, etc. The
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finished machine and ground runner shall be dynamically balanced in the works before dispatch. Mounting of runner on extended generator shaft (if offered by any bidder) shall be allowed. The runner buckets shall be evenly and symmetrically spaced. The surface of the runner in contact with water shall be ground to a smooth finish so as to achieve surface without any humps or hollows. The runner band, the crown and shaft coupling surfaces shall be accurately machined and ground. If required these records shall be made available to purchaser on request. Runner and turbine shaft shall be connected by coupling. To facilitate replacement of runner in future and interchange ability, connecting parts shall be accurately finished and use of template and keys shall be provided. Connecting bolts shall be suitably covered to minimise resistance when rotating in water. The runner shall be designed to withstand safely the dynamic stresses at maximum runaway speed. The supplier shall provide complete arrangement of runner removal .
ii)
Shaft and Coupling Mounting of runner on extended generator shaft (if offered by any bidder) shall be allowed. The turbine shaft shall be forged carbon steel or alloy steel conforming to IS or other equivalent international standards. Wherever the flanges are integral with the shaft, the same should conform to American standard ANSI-49.1, 1967. The turbine shaft shall be connected to the runner on one side and to the generator shaft on the other side. It shall be of ample size to transmit torque at rated speed without excessive vibration or any distortion. It shall be provided with integrally forged coupling flanges for connecting to the generator shaft and to the runner. It shall be of ample size to operate at any speed up to the maximum runaway speed without detrimental vibration or distortion and to transmit the maximum output. The maximum stress induced under such abnormal condition shall not exceed 67% of the yield point stress. Besides, the shaft shall be designed to withstand safely the shocks and abnormal stress induced under conditions of line to line short circuit, faulty synchronising and turbine trip-outs without harmful vibrations or distortions.
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The shaft system shall be designed so that the first critical speed shall be at least 1.25 times the maximum steady state runaway speed, which may occur under most unfavourable transient conditions of turbine. The shaft shall be accurately machined all over and polished smooth in the portions where turbine bearing is fitted such that surface finish is within 0.4 microns. The amount of shaft run out shall be checked by rotating the finished turbine shaft in a lathe or lining device in factory. The turbine - generator shaft coupling shall be designed in accordance with ANSI B 49.1 The turbine supplier shall be responsible for the final reaming of the coupling bolt holes, aligning of the turbine and generator shaft and conducting the combined run-out to NEMA Standard No. MG-5.1-3.04 (R 1979). The field alignment procedure for shaft and bearings shall be approved by the Purchaser prior to the start of assembly. Under the conditions of rotational test, the run outs at the turbine bearing shall not exceed 0.10 microns per meter length of shaft between the generator bearing and the turbine bearing. Hydraulic jack for pre-stressing of shaft couplings bolts, head cover & bottom ring shall be provided.
iii)
Bearings The turbine bearings shall be pad / segment type, oil lubricated either selflubrication or forced lubrication type. The turbine shall be provided with adequate number of bearings. The bearings shall be provided with a dial type or resistance type thermometer and a pressure gauge with provision for alarm annunciation/shut down on excessive bearing temperatures. The turbine bearing shall be provided with H.S. Lubrication (if required). The number and type of bearings shall be stated in the bid. These bearings shall be guaranteed for a minimum continuous operation of 100,000 (One Hundred Thousand) hours and the design and performance shall be well proven and established. Further the bearing shall be designed to operate satisfactory (i.e. without any damage) under following conditions:
* *
Continuous operation at any speed between 30% and 110% of rated speed at no load and maximum load. For 15 minutes at maximum runaway speed.
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For 15 minutes, upon sudden rejection of maximum power and in continuation thereafter till the unit comes to standstill as a result of tripping and interruption of cooling water supply. The bearing area and the bearing oil reservoir capacity shall be such that temperature shall not exceed 70oC under worst conditions of operations. The bearing shall be located as near to runner as possible consistent with the distance assumed in shaft system analysis and keeping in view the space required for accessibility and maintenance. The mechanical design of the bearing shall take into account the abnormal radial forces during starting, stopping, trip-outs and running at runaway speed of the unit and also provide axial movement of the shaft. The method of construction shall be fully described in the bid. The bearing design shall prevent the leakage of oil down along the shaft. Piping for filling oil in the bearing and reservoir shall be separate from the drain piping. The supplier shall supply and install the following indicating and protection devices for bearing.
One dial type thermometer to indicate the hottest part of the bearing. The thermometer shall have two (2) sets of separately adjustable contact suitable for operating alarm and tripping circuits at 220 V D.C. The thermometer indicator shall be mounted in governor panel.
The resistance temperature detectors R.T.D (Pt 100 Ohms at 0oC). One for bearing segment and one for oil indication and recording the temperatures at unit control board.
One direct reading water flow meter with two electrical contacts (suitable for operation at 220V D.C. for signalling low cooling water supply / stoppage of cooling water supply.
One oil level gauge properly graduated marked in litres and high and low level adjustable alarm contacts with 220V D.C. contact rating. All thermometer bulbs and detectors shall be installed in dry walls.
iv)
Shaft Gland The shaft gland shall be of the stuffing box/carbon ring type with selflubricated packing and lantern ring. Any other suitable type of shaft gland will also be considered. The gland shall effectively prevent leakage of water along
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the shaft under all operating conditions and at standstill and prevent entry of air. A stainless steel sleeve shall be provided on the shaft where it passes through the gland. Arrangement for providing clean water supply to the gland, if required, shall be made by the contractor.
v)
Turbine housing The turbine housing shall be cast fabricated in low alloy Mn. Steel in two parts upper and lower. The wall thickness shall be sufficient to ensure adequate rigidity. Adequately sized air admittance piping enabling the turbine to draw air from atmosphere shall be provided. Turbine housing shall be equipped with the necessary lugs to facilitate easy handling by a hoist / crane. Necessary foundation shall be provided for securing the housing on turbine floor. Turbine housing and generator stator shall be supported on a common foundation frame. The bearings of turbine and generator shall be aligned in manufacturing shop. Brief description along with tolerances in location and plan, provisions for concrete placement and grouting, details of connections (e.g. turbine pit drain, test connections etc), erection support and handling devices etc. Type of material for its fabrication quoting relevant ISS. Brief description, design pressure, dismantling joint, material for fabrication quoting relevant Indian Standard, protective quoting, tolerance in plan & elevation, details of connection and erection support and handling devices shall be given
vi)
Branch pipes (including intake and nozzle pipe) General description of branch pipe, type of material for fabrication quoting relevant Indian Standard, no. of jets, design pressure, test pressure, protective quoting, erection supports and handling devices shall be given .Besides, details of turbine inlet connections and other connection (eg. Brake jet, cooling water etc.) with tolerances, access for inspection, description of all indications, test connections shall also be given.
vii)
Turbine cover Type of material for fabrication, its location on turbine housing or on pit floor. The cover should be strong but dismountable as it is meant for service access
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to the runner. Special loading conditions, if any protective coating shall be given.
viii)
Nozzle and deflector assembly Nozzles shall be of the straight-flow type with internal hydraulic servomotors. Adequate adjusting rings shall be provided for each nozzle to ensure correct alignment of the nozzles. The needles shall have self-closing tendency due to penstock pressure and spring action. Needle servomotors shall be double acting hydraulic jacks with spring assistance. The needle tips and seat ring will be made of erosion resistant stainless steel. Jet deflectors shall be provided on each nozzle and shall be regulated by governor. The nozzle body will be adequately reinforced to support the jet deflector. The deflector and the supports will be designed to prevent any harmful vibrations during operation, including complete load rejection and to ensure that no deflector can contact the runner in the event of operating mechanism breakdown. The deflectors will be of rigid design integrally cast or forged in 13 Cr 4 Ni, erosion and cavitations resistant stainless steel. Each deflector will turn on a shaft of stainless steel, supported in two self lubricating type bearings. All components of the deflector will be inside the turbine housing and shall be of corrosion resistant materials. Each deflector shall be provided with an external position indicator. The deflector servomotors will be double-acting, hydraulically operated on opening, but closed by spring action. The servomotors will have sufficient capacity to operate the deflectors under all conditions of operation and to move them through full opening or closing stroke in the minimum time specified. The servomotors will be equipped with a mechanical position feedback mechanism, for connecting to the governor restoring mechanism.
ix)
Brake jet assembly Turbine will be fitted with one nozzle intended to emit a brake jet, to be automatically operated during shutdown of the turbine. The brake nozzle will be fed from a pipe tapped from penstock upstream of the turbine inlet valve with a manual shutoff valve for maintenance. The operation of brake jet shall
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be controlled through a solenoid operated control valve with over riding manual operation facility.
x)
Speed Signal Generator (SSG) A toothed wheel type speed signal generator shall feed speed signal to the governor electronic circuits for speed regulation and operation of speed relays. The toothed wheel shall be mounted on the shaft and two magnetic pick-ups shall be mounted near the toothed wheel. One of the two pickups will work as redundant. The output signal of the magnetic pick-up shall be fed to the governor electronic cubicle.
xi)
Over Speed Device A centrifugal type over speed protection device with provisions for electrical/ mechanical tripping shall be mounted on the turbine shaft (outside the turbine housing). The tripping points shall be adjustable independently for speed higher than the maximum speed; the turbine can develop with loss of full load. The mechanical tripping device shall directly actuate the governor actuator shut-down valve through a hydraulic connection. The electrical tripping contact shall be wired to the turbine terminal cubicle. The rotating parts of the over speed protection shall be protected by a guard.
5.8
GOVERNING SYSTEM Turbine shall be provided with electronic PID governor to control the turbine during starting, stopping and operation at any load. The governor shall be of proven design capable of controlling speed / output under all operating conditions. The governing system shall comprise oil pressure system, governor actuator (Mechanical), governor electronic regulator, speed signal generator, oil pipe lines and deflector position restoring mechanism. The electronic regulating functions of governor i.e., speed / nozzle setting, deflector limit setting, start, stop, main circuit breaker position, shutdown etc. shall be operate the unit in manual mode in case governor electronic regulator is non-operative. Local control unit have the indicators for deflector position, speed of the unit and power generated by the unit.
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5.8.1
The governor system should have following qualities: i) ii) iii) iv) v) Fast acting Stable (No hunting). Reliable High sensitivity. Easy control. The governing system shall be designed to perform the following functions. 1) 2) 3) Unit start-up. Idling and synchronisation Normal stopping and emergency shut-down with necessary
monitoring and safety functions, and In addition the governing system must allow the operation of the unit either in frequency control (i.e. speed governing) function or in output control function. In frequency control function, the frequency (and therefore the operating speed) shall be maintained at set point, when the unit is in isolated operation or in idling mode. In output control function, the power output of the unit shall be maintained at set point. Configuration The governing system comprising of oil pressure system, the hydro mechanical cabinet (HMC) i.e. actuator and the electronics shall divide functionally so as to achieve, Local i.e. Manual Control or remote control of the unit. The manual control shall be directly from the HMC i.e. actuator cabinet. The remote control shall be from station control room by means of operator console and programmable logic controller. Speed and pressure regulations: The maximum momentary speed rise caused by sudden rejection of the rated output under the normal head shall not exceed 1.50 times of the normal speed, when coupled with the generator. The maximum momentary pressure caused by sudden rejection of any load at any operating head shall not exceed 700m.
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Performance The speed governor shall be of such structure that assures stable and reliable operation, high sensitivity and easy control operation. At any load it shall regulate the turbine to a uniform speed free from hunting or racing. The speed governor shall be so arranged that the speed adjusting and load limiting operations can be carried out by both the remote control by the operating handles provided to the control board in the control room and the local operation by the operating handles provided to the speed governor cabinet or regulator board. Pressure oil for operation of the speed governor shall be supplied from the oil pressure supply system described hereafter in this section. All hand controls shall be clearly and concisely marked as to purpose. The speed governor shall have the following facilities and performance. 1) 2) 3) 4) 5) 6) Speed adjusting range Adjusting range of permanent droop Adjusting range of incremental momentary speed droop Adjusting range of time constant of damping Governor dead band Nozzle setting operation 0 - 15 sec 0. 02% 0 - 50% 85 - 105% 0 - 6%
The speed governor shall be capable of nozzle setting operation by the load limiting device and will be capable of easily changing over from automatic operation to nozzle setting operation or vice versa. 7) Nozzle opening regulating device This device shall be capable of the following control. a) b) Starting control. Control of maximum output. The water level detector for the
upper reservoirs and tailrace required for the above shall be supplied by contractor. 8) Protective device: The protective device shall be capable of fully closing the nozzle in case that a trouble occurs in the speed governor and shall stop the turbine quickly.
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5.8.2 Both the speed control governor and power output governor shall actuate the same servo-positioner through the opening set point. 5.8.3 The electronic PID controllers behaviour shall be enhanced by special means such as disturbance super position and secondary variable super position. Speed sensing : The speed sensing for governor operation shall be taken from toothed disc method or via transducers using residual remainance.
5.8.4 MANUAL CONTROL Manual control of setting of turbine power directly via the actuators by-passing the governor control loop shall be provided. In that case, the safety of unit shall rest with over speed protection. 5.8.5 FOLLOW - UP CONTROLS To achieve bump-free transition from one operational mode to another following follow-up controls shall be provided: i) ii) The power output governor command signal shall follow the actual power output signal in the speed control mode. The speed command signal shall follow the actual frequency-signal in the power output control mode or during the start up phase (speed command signal pre-adjustment). iii) iv) v) The manual control set point shall follow the actual actuator position in the various control modes. In case of remote control, respective local control shall follow the respective command signals. It shall be possible to adjust the pre-opening of varying heads to minimise start up times.
a) GOVERNOR REGULATOR The speed sensing shall be achieved through speed signal generator and line PT. The governor shall control, with stability, the turbine at any speed between 85 and 105% of rated speed when operating isolated from the system and while connected to the system at any load between zero and the load corresponding to maximum opening of the nozzles with both nozzles
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operating. Partial Shutdown/Controlled Action Shutdown device shall be used for automatically shutting down the turbine to the speed-no-load position by the operation of certain protective devices. It should be possible to operate deflector position manually at the local control unit.
b) GOVERNOR ACTUATOR Governor actuator shall have the following provisions : Adequate capacity to operate the deflector servomotor and the needles through complete opening or closing strokes in desired time under all operating conditions. Hand control device for stroking of deflectors followed by needles so as to operate the machines manually even if electronic regulator is non-functional. Relationship between deflector position and needle stroke may be achieved through mechanical linkage utilizing a cam. Necessary data for relationship between deflector opening and needle stroke shall be given by turbine designer to the governor manufacturer. It should be possible to control the needles for off-cam position. Emergency shut down device, which can be operated manually at the actuator. Auto - clean double element filter to ensure that clean oil is supplied to control valves. The change over to standby filter and cleaning of clogged filter must be possible while unit is under operation. Means of independent adjustment of the opening and closing times of the deflectors and needles. The time for deflector closing under full load throw off shall be adjustable to limit the speed rise and pressure rise within guaranteed values.
c) SERVOMOTORS Turbine shall be provided with two (2) Nos. oil pressure operated hydraulic servomotors. The capacity of the servomotors shall be sufficient to supply the maximum force necessary to operate and hold the nozzles at any desired position at the minimum oil pressure. Further, the servomotors shall be rigidly supported and shall be capable of moving the nozzles from a completely closed position to a fully open position
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in one stroke and vice versa. Cushioning shall be provided in the last ten percent (10%) of the stroke in each direction. The servomotor cylinders shall be provided with flanges for connecting oil piping. Connection for pressure gauges shall be provided at each end of each cylinder. An air vent and a drain cock shall be provided on each servomotor for draining purpose. The inner surface of the cylinder shall be bored accurately to a uniform diameter. The surface finish shall be such that roughness shall be within 1.6 micron. The piston fitting shall be such as to allow the piston to travel, freely and smoothly but to reduce oil leakage past the piston to an absolute minimum. Chevron type packing shall be used for this purpose. Each piston shall be fitted with not less than three piston rings, suitably shaped to give close contact and uniform pressure on the cylinder walls. The servomotor piston rod shall be provided with lubricated bearings. Lubrication shall be arranged to ensure that lubricant is admitted to high pressure areas regardless of vane position. This piston rod shall be arranged for adjustment of stroke. The connecting rod shall be of forged steel and of uniform cross section. A specially designed and a strong joint using accurately ground pin of hardened steel shall be provided between piston rod and connecting rod. The joint shall be provided with greaseless bearings of self-lubricating type. Provision shall be made for adequate field alignment of the servomotors using levelling or dutchmen (shim) plates supplied by manufacturer. servomotor flange shall be dowelled in the field to its mounting flange. A manual locking device of a simple construction to permit locking in the fully open and closed positions and capable of withstanding safely the full operating force of the servomotors shall be provided at the servomotors. The device shall be such that it can be easily engaged and disengaged by one man. Besides, limit switches (with electrical contacts suitable for operating on 220 V D.C. system ) shall be provided, to indicate the fully open and fully closed positions of the nozzles and for using in the control circuit as interlocks for starting the unit. All contacts shall be wired up to terminal box . By-pass connections, equipped with orifices and/or adjustable needle valves, with a secure means of locking the adjustment, shall be provided on the The
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servomotors to retard connections shall be fitted with check valves to prevent sluggish movement during opening the nozzles from the fully closed position. A suitable pointer and graduated scale shall be provided to indicate the stroke of the servomotor (i.e. % opening from the closed position) in steps of 5 %. The scales shall be calibrated in the field and marked closed at one end of the scale and opened at the other end. The servomotor stroke must be capable of manual adjustment. Means for positively locking the adjustment must be provided. Servomotor cylinders and all the oil piping and valves in the system shall be shop tested to a pressure equal to 150% of the design pressure of the oil system.
5.9
PENSTOCK DRAINAGE SYSTEM Necessary piping with fittings and steel Nozzle valves shall be supplied for draining the penstock into tail race channel.
5.10
WATER LEVEL MEASURING & TRANSMITTING DEVICE Scope of Supply Water level measuring & transmitting device for intake and tail race channel shall comprise of the following : Level transducer with transmitting device for intake with complete mounting arrangement, Level transducer with transmitting device for tail race with complete mounting arrangement, Water level signals receiving and processing device with mounting arrangement, Interconnecting cables between sensors, transmitters and control unit. General Design and Constructional Requirements : i) For monitoring water level upstream of intake Nozzles, one set of suitable electronic level sensor ( strain gauge or capacitance type ) and transmitter unit shall be provided for transmitting the water level signal to controlling unit mounted in control & metering panels in control room. One set of identical level sensor and transmitter unit shall be provided for water level in tail race.
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The signals from both the units shall be analogue signals in the form of 4 to 20 mA. These signals shall be processed in centralized control unit. Necessary power supply to sensors and transmitting units shall be provided from control unit. ii) Output signals for Surge Tank level, tail race level and their difference shall be provided from the control unit for further utilization in Governor electronic cubicle and SCADA. Digital indictors shall be provided in the control unit for indicating fore-bay level, tail race level and their difference i.e. gross head. The device should be of reliable make. iii) The level sensors shall be mounted inside a pipe in such a way that oscillations in water level are damped out and pipe do not get clogged by floating materials or silt etc. complete with mounting accessories. iv) Level sensors should be hermitically sealed and it should be possible to take out and calibrate them easily.
5.11
SPECIAL TOOLS, SLINGS, CONSUMABLES ETC. * * Tools and tackles required for handling bearings shall be provided. All tools required for assembling and dismantling bearing, seals, rings, nozzles, links, shaft support collars etc shall be provided. * Test equipments of all kinds, which are necessary for erection, testing & commissioning at site shall be provided. * All kinds of slings, tools, pressure test equipments, spanners, O & M tools etc. shall be provided. * * metering for penstock water pressure Mechanical over speed device shall be provided by generator supplier. Turbine supplier shall co-ordinate with respect to his requirements. * Turbine junction boxes suitable for mounting on barrel wall outside.
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Control and power cables: Power cables for local control panels to equipment, local control panels to unit control boards and up to distribution centres provided by the purchaser shall be provided by the supplier, control cables racks, cleating, ferrule, glands etc for entire system of equipment covered under the scope of supply of the supplier shall also be provided by the supplier.
Oil, grease, lubricants sufficient for first filling and 25% spare quantities.
All accessories viz. sole plates, foundation & anchor bolts, platforms, ladders, guards, handrail, bolts, nuts, turn buckles etc complete including requirement for installation.
* *
Tools & Tackles for the turbine. Shaft seal with cooling water system complete including pressure reducers, strainers, filters and plant to provide clean water.
Turbine bearing of design with pads, oil coolers, Resistance temperature detector (RTDs) Dial type thermometers (DTTs) etc. with piping, valves etc.
Thermometers, thermal relays, oil level gauges and relays, water pressure gauges and relays etc. Gauges, temperature indicators etc. to be mounted on unit control board covered under Electrical Lot. Supplier of Mechanical and Electrical lot shall co-ordinate to include all interfaces suitable of local/remote and auto operations of the system.
Oil leakage system if needed (requirement shall be justified at bidding stage) complete with tank, motor-pump sets, pipes, valves, level switches, gauges etc. All special tools, slings, lifting devices, jacks, turn buckles, foundation plates/bolts, testing devices etc., required for erection and commissioning
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of the equipments shall be listed and supplied. First filling of oil and grease (if applicable) with 20% extra quantity shall be included in the offer and supplied along with equipment. Welding electrodes as required for site welding and paint for finishing coat shall be supplied by the contractor.
5.12
SPARES Spares shall be supplied as per the list under Section - III of this volume. .
5.13
TESTS
5.13.1 SHOP ASSEMBLY AND TESTS ( AT MANUFACTURING WORKS) The Bidder shall submit the quality assurance plan indicating the tests to be performed and witnessed by Purchaser and acceptance criteria for the same. The Contractor shall get the quality assurance plan approved from Purchaser as per Contract Conditions. For inspection and tests to be witnessed by Purchaser, requirements elaborated in Conditions of Contract shall be followed.
i) The following assembly and testing requirements in Contractors works shall essentially be included in quality assurance plan : Deflector and Needle Servomotors hydraulic testing, stroke checking, minimum oil pressure required for movement and oil leakage past piston and piston rod. Turbine Runner Dimensional checks, bucket profile checking, casting soundness tests, static and dynamic balancing. Deflector and Needle Assemblies: Free movement, minimum pressure required for movement, and stroke relationship Complete assembly of turbine in the shop for matching Oil Pressure System Performance testing of pumps, U/T of weld joints and hydrostatic testing of pressure vessels. Governor Assembly and complete performance testing as per relevant IEC code Turbine Inlet Valve : Assembly, hydraulic testing and Operational tests
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ii) Material Tests - Material tests for important components such as runner, turbine shaft, deflector, needles, nozzles, deflector bushes, turbine housing, bearing sleeve/shell and other important components shall be carried out as per agreed quality assurance plan. Purchasers Engineer shall review the test certificates during inspection. iii) Tests on Bought out Components: All motors, pumps and compressors etc. shall be tested as per relevant Indian Standards.
513.2 PRE-COMMISSIONING FIELD TESTS a) Following measurements/tests in addition to tests recommended by Contractor shall be included in quality plan for pre-commissioning tests : Characteristic - Servomotor stroke Vs Deflector Opening Characteristic Deflector opening Vs Needle stroke Deflector and Needle opening and closing times and servomotor cushioning time. Insulation Resistance Tests on all electrical motors as per relevant Indian Standards b) Operational tests on oil pressure system to verify : Setting of pressure relays for automatic control of pump Setting of pressure relay for emergency low pressure Test to verify pumps capacity Tests to verify number of close/open operations with oil pump not operating
c) The governor shall be assembled, adjusted and tested in the field for optimum performance. Specifically, the following tests/checks will be performed : Verify logic control scheme from local including start/stop, load control, emergency shutdown, controlled action shutdown, locking and other feature Verify stability and response of governor during 10% to 20% step change in load (acceptance and rejection or a combination of these). Verify setting range of permanent droop, on/off-line temporary speed droop, derivative time constants, frequency dead band, speed setting limits, Nozzle setting limits, no load Nozzle limit, speed relays etc.
5.13.3
COMMISSIONING TESTS
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Signature of Bidder
Following commissioning tests shall invariably be included in tests recommended by Supplier before putting the machine on 72 hours continuous trial run prior to handing over of equipment to Purchaser:
Logic control scheme from local/remote including start/stop, speed control, load control, level control, emergency shutdown, controlled action shutdown and other features,
Automatic starting, stopping, synchronizing, loading and emergency shut down by simulating emergency conditions,
Checking the setting of over speed trip device by actually over speeding the machine,
Checking speed rise and pressure rise at 100% sudden load rejection of generating unit. The Supplier shall carryout the commissioning test in accordance with the agreed procedures.
72 hours continuous operation test: The turbines shall be tested for 72 hours continuous operation to ensure trouble free from problems of leakage, overheating, failures, damages, etc.
5.13.4
FIELD ACCEPTANCE TESTS The turbines shall be tested at site for establishing fulfilment of guarantees in respect of turbine output and efficiencies including weighted average efficiency. The tests shall be carried out as per IEC 41 for Field Acceptance Tests of hydraulic turbines. The arrangements for these tests will be made, including the testing devices, by the Supplier.
5.13.5
Inspection for Pitting It is to be ensured that operating records during guarantee period are properly maintained. It is also to be verified that machines are operated within specified range of output head and discharge. After specified period of running of machine joint inspection is to be carried for pitting and establishing that pitting is within limits and provisions of pitting guarantee are met.
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5.14
GUARANTEED TECHNICAL PARTICULARS The bidder shall furnish all the data, information and other particulars called for in the sheets at the end of section under data sheets.
5.15
ELECTRICAL EQUIPMENT CABLES AND INTERFACES. Cables from each auxiliary system equipments to its control panel (both of which are included in suppliers scope) shall be supplied and erected; cables for interconnection between computers, computer based control panel shall also be supplied and installed. Turbine supplier shall co-ordinate with supplier of electrical lot in respect of interfaces and cables needed for the system. All interfaces cables, racks, formula glands, clamping and dressing arrangements for the equipment covered under scope is included in the scope of supply. Supplier of mechanical lot shall confirm that all these items are covered in scope of electrical lot or he shall provide the same without extra cost. FLOW METER CABLES. All flow meter cables required between the transducers and electronic converters shall be supplied. INSTALLATION. The flow meters, electronic converters and instruments shall be installed in an approved manner so that operation is satisfactory and the accuracy requirements are obtained. CONTROL AND MONITORING DEVICES. The instruments and devices shown for mounting other than local, shall be decided in consultation with the suppliers of the respective board/panel mentioned in the above said annexure. limited to following: 1. i) ii) iii) Automatic operation control devices a) Solenoid valves. For opening and closing of the inlet valve For starting and stopping of unit For the brake of the generator The control and monitoring devices shall include but not
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The solenoids shall be so arranged that they do not remain continuously energised in whichever case the unit is running or in standstill. b) c) d) e) 2. Turbine control Panel. The turbine control panel shall be of cubicle type of steel plates and shall be arranged in line with the speed governor cabinet. On the front of the turbine control board, a name plate shall be mounted. The turbine control board shall be capable of manual operation of the turbine and auxiliaries such as flowing of cooling water opening and closing of the inlet valve of the turbine, starting, stopping, and operation of the brake, etc. Manual operation shall be of such type as to actuate the solenoid by operation of the switches on the turbine control board individually. The control board shall house the solenoid valves etc., shall be provided with the measuring instruments, operation indicators, on the front surface and shall keep sufficient space so that inspection and adjustment can be carried out easily. The turbine control board shall comprise the following. a) Control switch change-over switch (local-remote) b) Manual operation switches for : i) Solenoid valves for opening and closing of the Spherical valve. ii) Solenoid valve for starting and stopping of turbine. iii) Solenoid valve for the brake of the generator iv) Other solenoid valves housed in turbine unit control board v) Limit switches vi) Auxiliary relay. 1 set 1 set. 1 set. 1 No 1 No. 1 No. 1 No. All necessary limit switches All necessary auxiliary relays All necessary relay valves All necessary piping and valves 1 set. 1 set. 1 set. 1 set.
Signature of Bidder
193
vii) Piping and valves. viii) Indicating lamps. c) Oil pressure relays : i) For starting condition of turbine.
1 set. 1 set.
(operates when oil pressure for nozzles operation is same as or higher than the specified value.) ii) iii) iv) v) vi) vii) . For alarm at oil pressure drop For quick stop at operating oil pressure drop For start and stop of the stand by oil pump For oil level control For Actuator pressure. Water pressure relay d) i) ii) iii) iv) v) vi) vii) Instruments : Water pressure gauge for steel lined shaft Pressure gauge for oil pressure tank. Dial thermometer for turbine bearing Dial thermometer for bearing of generator Dial thermometer for lower guide bearing of generator. Dial thermometer for inlet and outlet of each air cooler of generator. viii) Sequence indicators. 1 No. 1 set. 1 No. 1 No. 1 No. 1 No. 1 No. Water pressure gauge for Nozzle 1 No. 1 No. 1 No. 1 No. 1 No. 1 No. 1 No. 1 No.
Signature of Bidder
194
PUMP JUNCTION BOX AND ELECTRICAL ITEMS. Supplier shall supply all the necessary switches, contactors, magnetic starters and relays with the turbine and generator governor electrical auxiliaries according to this sub section and the electrical lot of these specifications. All electrical items supplied by supplier shall comply with the appropriate section of IEC- Standards. Supplier shall provide and install terminal boxes in locations to be approved by purchaser, and shall provide and install all wiring and conduit from his electrical components to these terminal boxes. All electrical wiring and conduit within the turbine housing, including wiring for pressure and flow switches, temperature relays and thermometer, alarms shall be supplied by the supplier, and shall terminate at terminal blocks in the turbine terminal box located in the turbine housing and supplied by supplier. All wiring shall be stranded wire, insulated with 1000 V oil proof insulation. For turbine a common junction box shall be provided. All controls, indications, alarms shall be brought by the supplier up to this junction box. Supplier shall supply schematic diagrams, wiring diagrams of connections, outlined drawings and catalogue numbers for all electrical components. All circuits of schematic , wiring diagram and equipment shall be properly identified and subject to approval by purchaser. Supplier shall provide data on all electrical motors being supplied. Alarm contacts shall be electrically separate and rated for a minimum interrupting capacity of 0.5A, non - inactive and be suitable for voltages up to 250 V D.C.
5.16
STANDARDS.
Turbine and governing system shall be designed, manufactured and commissioned to the latest I.E.C standard accepted standard practices. A few of the standards are listed below but not limited to. IEC-41/1991 IEC- 545 IEC-607 IEC-609 IEC-193/1965,193-A/1972 and 995/1991 IEC-994/1991 Scale model testing. Guide for field measurement. Field acceptance tests. Commissioning procedure. Thermodynamic method measuring. Cavitations pitting evaluation.
Signature of Bidder
195
ASME IEC- 308 ASME VIII, ASME V ASTMA 435 ASTMA 609, ASTMA 709 IEC 404 . ASTMA A 388 and
Tank and hydraulic cylinders. Governor testing.
Welding materials
ASME Boiler and pressure vessel code section VIII, Dim 2 Low cycle fatigue. IEC- 34.9 ISO- 1996 VDI-2056 Noise limits for electrical machines. Noise measuring. Vibration limit.
ANNEXURE V-1 DRAWINGS, DESIGNS AND MANUALS TO BE FURNISHED AFTER AWARD OF CONTRACT.
Signature of Bidder
196
Sr. No .
Brief description
within months Remarks from the date of award of contract
1 1.
2 Overall schematic arrangement drawings drawings, and
describing
illustrating the information of: i ii Turbine runner 3 For approval For approval
Nozzle assembly , Deflector assembly, 3 needle assembly, needle control device, Servomotors
iii iv v vi
Brake jet assembly Inlet valve Governor Emergency motion gear, closing device,
3 3 4 return 4
For approval For approval For approval For approval
vii
Speed signal generator, over speed trip 4 device
For approval
viii ix x xi xii xiii xiv xv xvi
Turbine Housing Turbine shaft & coupling Shaft Gland Penstock specials & branch pipes Turbine Bearing Compressed Air System Drainage and dewatering system Cooling water system Penstock drainage system
4 4 4 4 4 4 4 4 4
For approval For approval For approval For approval For approval For approval For approval For approval For approval For approval
xvii Schematic drawings of oil pressure 4 system of MIV & Governor 2 Foundation housing, drawing bearings, for and turbine 5 other
For approval
mechanical equipments used for unit
Signature of Bidder
197
3 4
Quality assurance plan
For approval For approval
Quality assurance plan for tests at 3 suppliers / vendors works indicating customer hold points and acceptance criteria.
Catalogues of pumps, valves and other 6 purchased items
For reference
Schedule of indicating and recording 4 instruments and safety devices
For approval
Tentative list of vendors for major 6 purchase items and instruments.
For reference
MANUALS.
1 1
4 For reference
Manual for storage, preservation 12 and handling goods of the supplied
Manual dismantling, goods
for
erection testing
/ 12 and
For reference
commissioning of the supplied
Manual DONTs
giving
operating 18
For reference
instructions for all the DOs and
Manual
giving
detailed 18
For reference
maintenance schedule
ANNEXURE V-2 DEPARTURE FROM SPECIFICATION (To be filled in by Bidder) Signature of Bidder
198
---------------------------------------------------------------------------------------------------Item. Description of departure. Reference to clause in the specification. ----------------------------------------------------------------------------------------------------
DATA SHEETS
DATA SHEETS M1 TO M13 FOR TECHNICAL SPECIFICATIONS OF
Signature of Bidder
199
PELTON TURBINE AND RELATED EQUIPMENT (THE BIDDER MUST FILL IN THIS DATA SHEETS COMPLETELY) Note : The indicated sign and the assigned meaning shall be as follows: > < (r). (d) (o) (*) no negative tolerance allowed no positive tolerance allowed required value desired value offered value guaranteed values inclusive of tolerance.
Bidders Remark (if any) Water Levels for reference of bidders/suppliers (I) Reservoir i) Full Reservoir Water Level - 602.00EL
200
Signature of Bidder
ii) (II)
Minimum Draw Down Level - 579.11 EL
Tail Race Channel i) ii) Maximum Water Level - 190.00 EL(Tentative) Minimum Water Level - 189.00 EL(Tentative)
(III) (IV)
Nozzle Level - 190.00EL Gross Heads i) Maximum Gross Head - 412.00 m (602.00 -190.00) ii) Minimum Gross Head(579.11 -190.00) 389.11m
(V)
Design Head i) Gross Rated Head = Min. Head + 2/3 (Max.head Min.head) = 389.11 + 2/3 (412 389.11) = 389.11 + 15.26 = 404. 37 Say ii) Net rated = 404.00 mtr
Head = Design Head head losses = 404 -1.91 = 402.09 Say = 402.00 mtr. 410.00 mtr. 387.00 mtr.
iii) Max. rated head iv) Min. rated Head-
DATA SHEET M1 Bidders Remark (if any)
A)
TURBINE SPEED, MECHANICAL OUTPUTS AND EFFICIENCIES:

201
Signature of Bidder
- Rated turbine speed
--------------(o)
nn = 500
2
rpm (d)
Direction of rotation (seen from generator end) Counter Clockwise(d) --------- (o)
3.
Guaranteed Output (a) Guaranteed rated output at rated head. (b) Guaranteed max. output at max. head. (c) Guaranteed max. output at min. head.
--------- (o) --------- (o) --------- (o)
4.
Efficiency Guaranteed efficiency at rated head for the following outputs:
(a) (b) (c)
105% 100% 95%
--------- (o) --------- (o) --------- (o)
Weighted Average Efficiency (clause 5.3.1 of this vol.) Tav =k1 x T105 +k2 xT100+ k3 x T95 Where K1=0.30, K2=0.60 & k3=0.10
--------- (o)
Signature of Bidder
202
Net head Load 105% m Output Efficiency Discharge 100% Output Efficiency Discharge 95% Output Efficiency Discharge 6 Speed (a) kW % % m3/sec kW % % m3/sec kW % % m3/sec
Max.
Rated
Minimum
Average Efficiency
Head m Head m Head m
Nozzle Opening
Nozzle Opening
Nozzle Opening
Specific speed in M.K.W. units.
(b)
(*) Maximum momentary over speed

under most unfavorable transient conditions [ nm max < 1.50 nn (d) ] : nm max =rpm( o)
(c)
(*) Maximum steady state runaway Speed at Qmax and Hg max 412 m and suddenly load removed [nR max < 1.70 nn ( r )
: nR max =rpm (o)
DATA SHEET M3 Bidders Remark (if any) 7. Time of nozzle closing for regulation
203
------- secs.
Signature of Bidder
in item (c) above 8. (a) Momentary drop in speed in increasing load from zero to full load ------% of rated speed.
(b) Time of nozzle opening for regulation at (a) above
----- secs.
B.
Factor of safety (a) Guaranteed minimum factor of safety under worst conditions based on yield point of the material. (b) Name and location of the part having the factor of safety in (a) above.
C.
Maximum water hammer pressure
---------
D.
MOMENT OF INERTIA (J= mr2 ) Moment of inertia of generator rotating parts (according to generator designer ): Moment of inertia of turbine rotaing parts : JT >.tm2 (o) : JG >. tm2 (o)
DATA SHEET M4 Bidders Remark (if any) E) CLOSING AND OPENING LAWS
204
Signature of Bidder
OF THE NOZZLE Closing law: 100 % to 0 % F) Opening law 0 % to 100 % Emergency closure AXIAL TURBINE HYDRAULIC THRUST ON RUNNER. : To =. s ( o ) : Te =..s ( o ) : Tc =. s ( o )
Maximum hydr. thrust on runner Nominal hydr. thrust on runner Minimum hydr. thrust on runner
: F max =kN ( o ) :Fn =kN ( o )
: F min =kN ( o )
G)
MASS OF ROTATION PARTS. Mass of rotation part of generator ( according to generator designer ) Mass of rotation part of turbine : G g.r =t ( o ) : G t.r =t ( o )
DATA SHEET M5 Bidders Remark (if any) H 1) TURBINE BEARINGS Type of bearing : .(o)
Signature of Bidder
205
[adjustable pad/segmental type self lubricated bearing ( d ) ] Diameter of turbine bearing Number of pads/segments Circumferential length of pads/segments Axial length of pads/segments Maximum temperature for oil film Maximum temperature for Segment ( < 70 0C ( r ) Whether H.S. Lubrication is used (yes/no) Quantity of lubricated oil reservoir Quantity of cooling water (if required) Total losses in bearing at rated load Permissible duration of operation of the unit at rated load without supply of cooling water. Vibration limit of turbine bearing for complete range of operation <75m (r) I : GEOMETRICAL DESIGN DATA OF TURBINE RUNNER. runner diameter Runner height Number of runner buckets Finished mass of runner Average surface roughness of runner buckets Note:-Please attach runner drawing with designed zones for roughness. : Dia =mm (o) : h2 =mm (o) : z2 =(o) : G2 =t(o) : : =.. .m3 (o) : =. 1/s (o) : = . .Kw (o) : = : d =mm (o) : N =...(o) : L = .mm (o) : b =.mm (o) : =..0C (o) : =..0C (o)
Signature of Bidder
206
DATA SHEET M6 Bidders Remark (if any) J Runner seal clearance in new condition runner crown seal ( clearance between the runner crown and the turbine cover) Material of runner (stainless steel ) Method of attachment to shaft Finished mass of one bucket Average surface roughness of buckets Material of Buckets (stainless steel) SERVOMOTORS Number of servomotors Design oil Pressure Operating oil pressure Rated operating oil pressure, Tripping oil pressure Minimum required oil pressure Volume per servomotor closing cylinder opening cylinder : Vc : Vo Ds : F : Y =.m3 (o) =.m3 (o) =mm (o) =kNm (o) =mm (o) : ns . (o) ; Pd =Mpa(o) : Pomax =..Mpa(o) : Pomin =..Mpa(o) ; Pn Ptr : PR =....Mpa (o) =....Mpa (o) =....Mpa(o) : : (o) : c =.mm (o)
: ... (o) : Go1 = .. kg (o) : Rou.o =..m (o) : ..(o)
Inside diameter servomotor Servomotor Force Stroke of servomotors Performance under major disturbances - minimum servomotor closing time - Minimum servomotor opening time - cushioning time of servomotor
:Tf :Tg : Th : Gs
=.s(o) =..s(o) =..s (o) =..s (o)
Mass of one servomotor
Signature of Bidder
207
DATA SHEET M7 Bidders Remark (if any) Material of servomotors -body -piston K Roughness of inner surface of cylinder < 1.6 micrometer TURBINE SHAFT AND SHAFT GLAND Total length of turbine shaft Shaft diameter at turbine bearing Hollow diameter Diameter of coupling flange , Type of coupling Mass of turbine shaft Type of shaft Quantity of cooling water for shaft gland Guaranteed life of shaft gland operating hours > 20,000 L STARTING TIMES Standstill to synchornising including start up of all auxiliaries and valves [< 300 s (d)] Standstill to rated speed No load to full load Total time from stand still to full load : : : <.s (o) <.s (o) <.s (o) : <.s (o) : Gs =.t (o) : . (o) : =1/s (o) : =..HRs (o) : LT =mm(o) : Ds =mm(o) : DH =mm(o) ; DC=.mm(o) : : : . (o) (o) (o)
Signature of Bidder
208
DATA SHEET M8 Bidders Remark (if any) M GOVERNING SYSTEM ( Hydraulic turbine control system ) (according to IEC- 308/1970) Control of rotation speed Setting range of speed range Setting range of permanent speed drop [bp =0 to 10% (d) ] Setting range of maximum stroke speed drop Setting range of temporary speed drop Proportional gain [Kp = 0.6 to 10 (d) ] Derivative gain Speed dead band Power output [ix /2< 2.10 (d) ] Admissible steady-state power output pulsation (in relation to actual generator output power [p < + 1.5% (d) ] N Penstock reflection time GOVERNOR PRESSURE OIL SYSTEM FOR TURBINE Oil tank volume Number of governor oil pumps Governor oil pump discharge Rated power of governor oil pump motor : v =.m3 : n = : Qoil =1/s : Pn = kW (o) (o) (o) (o) : p < +..% : Tr = s (o) (o)
-2
: : : : : : : :
. (o) n =.% (o) bp =% (o) bs =% (o) bt =% (o)
Kp =.. (o) Kv = ix = (o) (o) (o)
: ix/2 =
Signature of Bidder
209
DATA SHEET M9 Bidders Remark (if any) Rated speed of governor oil pump motor Number of pressure vessels per each turbine Total volume of pressure vessels Oil volume of pressure vessels Air volume of pressure vessels Maximum pressure in pressure vessel Rated pressure in pressure vessel Minimum pressure in pressure vessel Maximum oil leakage of pressure oil supply system Cooling water discharge for oil pressure vessel Rated power of motor to cooling oil pump Rated speed of motor to cooling oil pump : Pn =.kW (o) : Qoil =1/s (o) : Qw = 1/s (o) : v t =.m3 : Voil =.m
3.
: nn =.rpm : nt =.m3
(o) (o) (o) (o)
: Vair =.m3 . (o) : Pmax = Mpa (o) : Pn =.Mpa (o) : Pmin =..Mpa (o)
: nn =.rpm (o)
Signature of Bidder
210
PITTING (according to IEC 193/1965, 193/1972 and 609/1978) The Bidder shall complement the bid by charts with = f () showing distinctly 0 S and 1 defined in IEC publication 193A/1972 for the following net heads : 387 m 402 m 410 m Such charts shall be given for 11000kW,10000 kW and 90000 kW output of the turbines Plant sigma ( p) for these operations shall be fixed at min. 1.05 0 or min. 1.2 s (whichever is greater) and guaranteed as such. The Bidder shall guarantee the runner, and other hydraulic passages for cavitationless operation for 24 months from the date the plant is put to commercial use of 5000 hours of actual operation, whichever is earlier, considering IEC Publication 609/1978, sub-clause 8.1 " Reference duration of operation 5000 h (for machines operating with low load factor such as peak load turbines, storage pumps, pump-turbines during pumping operations)". Excluded from this guarantee is the removal of metal by erosion or damaging by the presence of injurious foreign elements in the water. Measurement must be done after 5000 hours but before 6000 operating hours. Evaluation will be done on the basis of IEC 609/1978 * Cavitation guarantee duration of operation [minimum 24 months or 5000 hours generator operation mode (d)] * Reference duration of operation in peak load mode [between 5000 and 6000 hours (d)] Expected annual duration of generator operation for 387 to 410 m NOTE : The partial load operations shall be considered for as below 95% output during 300 to 400 h/year Optimum output during 1400 to 1500 h/year Max. output during 700 to 800 h/year Material removal after tr = 5000 hours tR = . h (o) = (o)
Signature of Bidder
211
DATA SHEET M11 Bidders Remark (if any) * Absolute maximum depth of any pitted area measured from the original surface * * * * Total area damaged by pitting A < cm2 (o) Total volume of material removed by V < cm3 (o) pitting Total weight of material pitting [G < 0.15 D2 (r) ] D-outlet diameter in m G < Kg (o) The formula given is the required degree of pitting. The Supplier will be allowed to repair the runner for excessive pitting. Definition regarding area and depth shall be considered as per IEC 609. P MODEL DATA Model data to be supplied by the Bidder Model scale factor m = DM = (o)
D P
S < cm (o)
Gravitational constant at the place of gM = m/s2 model laboratory Acceleration due to gravity of the prototype Runner outlet reference diameter [Dm > 300 mm (d)] Water temperature during model test Kinematic viscosity of water at model test Kinematic viscosity of water at prototype (for tw = 300C according to IEC 995/991/08/table B3) Atmospheric Pressure Vapour Pressure VP = 0.8 x 10-6 m2/s gP = 9.783 m/s2 Dm = mm tw = 0C VM = m2/s
Pa = m.w.c. (o) ha = m.w.c. (o) Pva = m.w.c. (o) hva = m.w.c. (o) Hm = m (o)
Test net head
Signature of Bidder
212
DATA SHEET M12 Bidders Remark (if any) Prototype net head (387-402-410 m) Test rotational speed Cavitation coefficient Reference Reynolda number at optimum point Model Reynolds number at 10880 kW R output Prototype Reynolds number Hydraulic efficiency of the model at optimum point Relative scaleable losses at point Reuref Increase of hydraulic efficiency at kW output point hMA = (o) Hp = m nM = rpm M = ..
6
(o) (o) (o)
Reuref= . 7 x 10 (r) ReMA= .. x 106 (r) = x 106 Rep= . 7 x 106 (o) hMA = (o) refM = (o)
Hydraulic efficiency of the prototype nhp^ = (o) at kW output Total uncertainties for model [f < + Fn + % (o) 0.25% (d)] Real roughness of wetted surface FIELD TEST (According to IEC 41/1991) Pressure-time Method (Gibson method) ...... ...... days ..
1. 2. 3.
Method proposed by Bidder Detailed description and taps location for proposed method Time necessary for execution of the field test (incl. installation of instrumentation) Final tests reports after beginning of the field test Tolerance of measurement
4.
days .. (o)
Signature of Bidder
213
DATA SHEET M13 Bidders Remark (if any) R * VIBRATIONS AND NOISE LEVELS OF TURBINE Vibration limit of turbine for complete S1/max < / m operating range (max. bearing vibration) [double amplitude < 200 m (r)] maximum shaft displacement S2/max < / m Noise level of turbine for complete operating range in turbine housing 1 m. away from shaft [< 90 dB (S) (d) Vibration limit turbine bearing according to VD 12056 / 1964 for machine set up G Fig.6 S < 40 m (simple amplitude) NOTE : Tolerance shall be guaranteed along with Bidder's remark, if any Figures shown (*) shall be guaranteed and are inclusive of tolerances. S. Heaviest Package of Shipment (a) Name (b) Weight (c) Dimensions (L x W x H) Largest Package for Shipment (a) Name (b) Weight (c) Dimensions (L x W x H) Heaviest assembly to be lifted by power house crane (a) Name (b) Weight (c) Dimensions (L x W x H) < . d B (A) (o)
T.
Signature of Bidder
214
SECTION VI TECHNICAL SPECIFICATION OF SPHERICAL VALVE
215
SECTION VI TECHNICAL SPECIFICATION OF SPHERICAL VALVE INDEX Sr.no. 6.1 6.2 6.3 6.4 6.5 6.6 6.7 6.8 6.9 Description Scope and operational requirements Design requirements Design specifications and performance Construction Oil pressure system for spherical valves Accessories Tools and erection requirement Hydraulic pressure test at site Drawings, designs, manuals to be submitted after award of contract 6.10 6.11 6.12 Inspection and tests Miscellaneous Spares Annexure VI-1 Annexure VI-2 Data Sheet 226 229 229 230 232 233 Page no. 217 217 218 220 222 225 225 225 226
Signature of Bidder
216
SECTION VI TECHNICAL SPECIFICATION OF SPHERICAL VALVE 6.1 SCOPE AND OPERATIONAL REQUIREMENTS. This section of the specifications covers the complete engineering, design, manufacture, testing at factory before dispatch, supply, delivery to project sites, supervision of on site erection, testing, commissioning putting into commercial use and giving satisfactory trial operation for a period of 90 days of one number of turbine inlet spherical valve complete alongwith its associated control equipment, accessories, piping etc. and also supply and delivery at site of spares, tools and erection equipment as mentioned hereafter. Any fitting, accessories of apparatus which may not have been specifically mentioned in these specifications but which are required for reliable operation of the plant shall be provided by the supplier at no extra cost to the purchaser. For operational requirements relevant provisions from Section I of this volume shall be applicable. 6.2 DESIGN REQUIREMENTS For design requirements relevant provisions from section I shall be applicable. BASIC DESIGN DATA 1) ii) iii) Number of spherical valves purpose. Nominal diameter of inlet valve : One (1) : Turbine guard valve. :1000 mm Diameter (Should be same as that of Penstock diameter i.e.1000 mm) iv) v) vi) vii) viii) Design head. Test pressure. Rated discharge. Breakdown discharge, Operation. Opening Closing : 700mwc (6.85MPa) : 1050m.w.c. (10.27MPa) : 3.12 m 3 /sec. : 6.24 m 3 /sec. : : by oil pressure : closing by counter weights / water pressure
Signature of Bidder
217
ix)
Closing time of spherical valve -at still water -at rated discharge -under breakdown discharge
: : : : : <40 sec. <40 sec <30 sec <90 sec
x) xi) xii)
Opening time accumulator.
Spherical valve shall have its own pressure oil system with oil The spherical valve and its control system shall be suitable for frequent opening and closing. The minimum opening and closing operations per day shall be four.
xiii)
The head loss in spherical valve for rated discharge of 3.12 m 3 /sec shall be guaranteed.
6.3
DESIGN SPECIFICATIONS AND PERFORMANCE The spherical valve shall be free from vibration or other abnormality under steady- state operating conditions and under any possible transient conditions and shall have sufficient strength and rigidity against maximum transient water pressure.
. 6.3.1 REQUIRED SERVICE CONDITIONS It shall always be possible to close the spherical valve safely, without vibrations or pressure surges, particularly, 1) In normal service conditions with turbine nozzles closed. i.e. without significant water flow . 2) In case of emergency with turbine nozzles fully open i.e., with rated discharge and with full pressure on one side of the closing element near the end of closure. 3) In case of an accidental rupture of the pipe between the spherical valve and the turbine inlet (i.e. with the breakdown discharge and the whole pressure on one side already at the beginning of closure.) 6.3.2 GUARANTEES Guarantees for spherical valves must be given by the Bidders for: 1) 2) Low level of vibration and noise during closing . Strong construction and adequate design of housing.
Signature of Bidder
218
3) 4) 5) 6.3.3
Proved design of rotative parts. High level of water sealing. Minimum losses in the opened position. CONTROL
Control of spherical valve shall be hydraulically by means of its own oil pressure unit. Following modes of control shall be provided. Manual local from the respective control cabinet near spherical valve location. Manual remote from the unit control board located in power Station control room. As a part of automatic control sequence of turbine generating unit, the control shall be so arranged that the motion of spherical valve can be reversed at any time during the opening and closing cycle stroke. The spherical valve shall have automatic interlock devices. 6.3.4 DISCHARGE SHUTDOWN PERFORMANCE Inlet valve shall be capable of shutting down rated discharge of turbine at
all heads safely and reliably under unbalanced conditions. Also spherical valve shall be capable of closing during emergency conditions, safely and completely against full unbalanced flow occurring as a result of breakdown nozzle/Deflector assembly. Opening under balanced conditions or otherwise shall be decided in consultation with turbine manufacturer so as to achieve stipulated time for synchronizing of unit from stand still. 6.3.5 AMOUNT OF WATER LEAKAGE. Amount of water leakage past downstream side seal shall be less than 0.5 litre per minute at the maximum static pressure of 700 m.w.c. Amount of water leakage past from upstream side seal at above mentioned water pressure shall not be more than 0.8 litre per minute.
Signature of Bidder
219
6.4
CONSTRUCTION. The spherical valve shall be provided with two seals One service Seal on downstream side and the other maintenance seal on the upstream side.
6.4.1
VALVE BODY Valve body shall be made of carbon steel casting or welded steel plates. It shall be suitably divided in maximum two pieces which shall be connected by a flange at site. Valve body shall be of sufficiently stiff structure to withstand the maximum water pressure during transient conditions of turbine and to cause no detrimental deformation. Valve rotor shall be provided with trunnions of forged steel at both ends. Valve trunnions shall have sufficient diameter and shall not cause excessive deflation. Trunnion bearing shall be greaseless self lubricating with bronze backing and with Teflon fabric liner. Trunnion bearing seals shall be on both ends of each bearing and shall be made of self lubricating PTFE compound with integrated rubber. Bearing shall be capable of safely supporting the weight of the valve rotor and force caused by water pressure and shall be capable of operating valve smoothly.
6.4.2
SERVICE SEAL AND MAINTENANCE SEAL. The sealing system one for normal service on downstream side of the spherical valve and the other on the upstream side for maintenance of the service seal shall be provided. The design and construction of the seals shall be such that a service life of about 50,000 hours is guaranteed i.e. the expected mean time between failure (MTBF) shall be about 50,000 hours. Further the sealing arrangement shall be such that when worn out, the service seals could be replaced without having to dismantle the valve proper or without having/ requiring dewatering of pressure shaft. The complete method and sequence of replacing the service seals shall be furnished in the bid with explanatory write- ups, sketches and drawings. The design and construction of the maintenance seals shall be similar to that of service seal.
Signature of Bidder
220
6.4.3. VALVE ROTOR Valve rotor shall be made in spherical shape by carbon steel casting or welded steel plates. The rotor shall have sufficient strength against all operating conditions so that it will not cause any detrimental deformation. Besides, the rotor shall not cause any abnormal vibration during full opened position or during opening and closing operations or fluttering during transport conditions. Arrangement for removal of air trapped in the dome of valve shall be made. No air shall accumulate inside valve body. 6.4.4 AIR VALVES Suitable capacity air admission valve shall be provided on down stream side of valve to protect Inlet piping and shall also act as air exhaust valve. However leakage of water shall not occur during operating conditions. Suitable air valve shall also be provided on the upstream of spherical valve to protect pressure shaft. 6.4.5 PENSTOCK SPECIAL A connecting pipe shall be provided between the inlet valve and the Penstock. The connecting pipe shall be made of same material as Penstock (ASTM 517 Gr. for equivalent). The inlet valve and connecting pipe shall be connected by rigid flanges and connecting bolts and nuts and packing shall be supplied. 6.4.6 PENSTOCK DRAINAGE SYSTEM Necessary piping with fittings shall be supplied for draining the penstock into tail race channel. (as per specified in section v cl. no. 5.9 of this volume.) 6.4.7. OPERATING MECHANISM Valve operating mechanism shall comprise of servomotor, operating rods, levers, interlocks and limit switches, counter weight (if closing operation by weight), pressurized water piping necessary for closing . Opening of the valve shall be achieved by oil pressure. Closing of the valve shall be achieved by counter weight / pressurised water of penstock. Necessary provisions for closing by water pressure shall be made as per requirement. The pipe dia.
Signature of Bidder
221
and its discharge shall be as per requirement. The Servomotors shall be of balancing type and heavy supporting plates with anchor bars, fastening etc. shall be provided to mount the same on foundation block. Main parts of the operating mechanism such as servomotor, operating rods, levers, and connecting part with the valve trunnions shall have strength and capacity sufficient for safely and reliably shutting down and opening full flow discharge under all operating conditions of turbine without causing any excessive vibration and other abnormality. Dimensioning of piston shall be so as to transmit all operational forces without deflections. All pivots shall be preferably of self lubricated type. Operating mechanism shall be provided with a locking device capable of manually locking both the main valve and by pass valve when they are closed. Parts which come in contact with water supply shall be made of stainless steel. Limit switches, for open /close, transmitters, contacts etc.for local / remote operation and indication of valves shall be provided. ACCESSORIES Following accessories shall be supplied. Position switch. Valve opening / closing indicator. Pressure gauge for inlet to spherical valve with relay. 6.5 OIL PRESSURE SYSTEM FOR SPHERICAL VALVES Spherical valve shall be provided with one independent oil pressure unit to supply oil under pressure to servomotors. 6.5.1 PURPOSE Oil pressure unit system shall be used for opening of the spherical Valve. Operation control devices for the valve system shall be independent of the governing system of turbine. 6.5.2. SYSTEM A complete oil pressure unit shall be provided for spherical Valve. Each system shall compromise of following: One sump tank located adjacent to each spherical valve and dimensioned for 120% of the combined oil volume in the servomotors in fully Signature of Bidder 222 Signature of Purchaser
open positions, oil piping valves and pumps. The tank shall be provided with a filling opening (with strainer and cover) breather, breather opening, sight oil gauge with cocks and drain with cock and one manhole for inspection. Dial type oil level gauge and oil level relays for oil level low / high warnings. Two screw type silent running and self priming oil pumping unit One each for normal and stand by, each with suction strainer and capable of continuous operation. The pumps shall be vertical rotary type coupled directly with their drip proof alternating current electric induction motors. Both pumping units shall be identical and equipped with complete control system permitting the selection of either unit acting as stand-by and starting automatically when other pumping unit fails. Each pressure oil pump shall be a vertical shaft rotary pump. The oil flow rate per pump at the maximum delivery pressure will be sufficient for operating the spherical valve from the fully closed state to the fully opened state without supply of pressure oil from the pressure tank. The normal operating oil pressure shall be suitable to meet the stipulated operational requirements. Each of the normal and stand by pumps shall be provided with the Following accessories. 1 set Safety valve. 1 set Non-return valve. 2 set Strainer. One small pressure oil accumulator in parallel arrangement between the oil pumps and servomotor and located near the valve. This accumulator shall act as buffer and pressure oil holding means to prevent the oil pump from frequent starting. One hand operated double acting oil pump mounted in the sump tank shall be provided. Control valves for spherical valve drives and seal applications shall be as follows:All valves : such as safety valves, non-return valves etc. All oil piping and isolating valve within the oil pump tank and between the oil pumping set and servomotors. Control cabinet containing following instruments and switches: Two pressure gauges with contacts for indication of upstream and downstream water pressure of valve with recording facilities.
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One pressure gauge for indication of oil pressure with contacts. Selector switches for local / pumps. Control switches for pumps. One pump selector switch for main and stand by. Three push selector switch for opening, stop and closing of spherical valve. One selector switch for local / remote and auto / manual control of spherical valve. One switch with ON and OFF position for testing of oil pumping units. One electric heating element. All necessary relays, fuses, signal lamps, terminal blocks and other equipment for a complete and safe local and remote control of the spherical valve. The cabinet shall be of self standing sheet metal type, moisture, vapour and dust proof, with locable front door. All wiring shall be in the most efficient manner from point to point. There shall no jointing or teeing of wires between terminals. All control cabling between individual devices, instruments, switches etc. upto local control cabinet of spherical valve shall be provided. Control of pumps shall also be possible from the unit control board in addition to local control and shall operate in conjunction with turbine controls. Operation of the pressure oil pump shall be controlled by pressure switches when the normal oil pump fails, the stand by pump shall start automatically. Change over between the normal operation and stand-by pump will be carried out through the change over switch provided on the control cabinet. Provisions in the control scheme for shutting off the unit be provided in case of valve closure. Besides, starting and stopping shall be carried out not only automatically and remotely but also manually from control cabinet .All position indicators annunciations and control shall be suitable for local and remote operations. First filling plus 25% extra quantity for each unit of pressure system oil, required for each Sp. valve and its pressure oil system shall be supplied by remote and auto / manual control of
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the supplier. Supplier shall suggest the oil equivalent available in India for future maintenance and operation of the plant. 6.6 ACCESSORIES Following shall be supplied but shall not be limited to All necessary sole plates, foundation bolts, anchors etc. for Sp. valve and servomotor. All platforms, ladders, stairs, handrails, plate coverings, hooks, pulley blocks etc. necessary for obtaining easy and safe access to parts and item which are fitted with equipment. The name plate for each equipment showing manufacturers name, serial number, year of manufacture, type, rating, capacity etc. for valve assembly and servomotor shall be provided. All necessary washers, bolts, nuts etc. of high quality steel. All necessary turn buckles and pipe jacks needed for erection, operation and maintenance. 6.7 TOOLS AND ERECTION REQUIRMENT One (1) complete set of ordinary and special spanners, wrenches, special tools, slings, shackles, ropes etc. for the proper erection and maintenance of the valve shall be supplied. One complete set of smaller and standard tools and equipment shall be furnished with a sheet metal lockable toolbox, fitted internally so that the tools may be stored in a proper manner. 6.8 HYDRAULIC PRESSURE TEST AT SITE If the transport limitations permit, the spherical valve shall be dispatched in one piece duly assembled in workshop. In case, it is not possible to transport assemble valve to project site, it shall be pressure tested at site at 1050 m.w.c. (10.27 MPa) for 60 minutes after its erection. To carry out the pressure testing at site, the supplier shall provide one set of bulkheads for spherical valve together with all necessary pickings and jointly material and test equipment.
Signature of Bidder
225
6.9
DRAWINGS, DESIGNS, MANUALS TO BE SUBMITTED AFTER AWARD OF CONTRACT. These shall be supplied as per the list given in the Annexure VI - 1 to this section. Mode of submission of designs and drawings will be intimated to the successful bidder in due course.
6.10
INSPECTION AND TESTS Inspection and tests at factory shall be carried out by the supplier in respect of the spherical valve as per the list given below: LEGEND 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Material analysis. Tensile test. Notch impact test. Bending test. Visual inspection. Magnetic particle examination. Liquid penetrant examination. Ultrasonic test. Radiographic test.. Pressure Test Leakage test . Dimensional check. Erection check. Welding procedure approved by purchaser. Corrosion protection.
(Suffix - A) Test at workshop in the presence of purchaser and / or Consultants:
Signature of Bidder
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SUBMISSION OF TEST CERTIFICATES The supplier shall submit six (6) copies of test certificates to the purchaser as per the procedure given below: i) FOR INSPECTION & TESTING SPECIFIED TO BE DONE IN PRESENCE OF PURCHASERS REPRESENTATIVE. Test certificate shall be submitted for approval. ii) FOR ALL OTHER INSPECTION AND TESTING: Test certificate showing that the specified test / inspection has been carried out successfully by the supplier for reference. Following assembles will be inspected for tests under the item
Sr Particulars of
10
11
12
13
14 15
No. Assembly
BIPARTITION flanges
a) b)
CONNECTING flanges.
c) d) e) f) g)
BEARING HUBS Cylinder Shell
Valve body
8A
ROTOR Trunnions. ROTOR plates.
7A 8A
h) i)
ROTOR
8A
Assembled valve
10A
11A
13A
Signature of Bidder
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j)
Operating mechanism Cylinder flanges Cylinder shell Cylinder covers Welded cylinder Piston rod Piston rod heads 8A 9A
7A
k)
Assembled operating mechanism. Operating mechanical lever hub. Welded Lever Auxiliary valve.
10A
11A
13A
Air valve.
l)
Upstream pipe Connecting flange. Cylinder Shell. Welded pipe.
12A
8A
m)
Downstream pipe. Flange rings. Cylinder shell Welded pipe.
8A 10A 12A
Signature of Bidder
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Relevant commissioning tests of mechanical lot are listed under section-V of turbine and shall be followed but not be limited . 6.11 MISCELLANEOUS Relevant provisions wherever applicable needed for indicating, recordinginstruments, control switches, safety devices, gauges, flow meters etc. for normal operations and field tests shall be made by valve supplier in consultation with turbine supplier and facilities needed by supplier of control and protection system. 6.12 SPARES Spares shall be supplied as per the list under Section III of this volume.
Signature of Bidder
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ANNEXURE VI-1 List of drawings, designs and manuals to be submitted by the supplier after the award of contract.
Sr. no
Brief Description
Within award contract
months Remark of
from the date of
1. 1
2. DRAWINGS i) Arrangement of spherical valve. ii) Installation of spherical valve.
3.
4.
6 6 6
For Approval For Approval For reference For reference For Approval For Approval For Approval For Approval For Approval
2 3 4 5 6 7 8
Valve servometer valve. Arrangement of spherical valve piping. Outlet pipe with dismantling joint. Control gear diagram for spherical valve. Arrangement of air valve. loading on foundation under worst operating and earthquake condition.
Tools, tackles & erection devices of spherical 6 6 6 6 6
Foundation of valve and servomotor and 6
9 10 11 12
Arrangement of opening mechanism. Sealing arrangement. Pressure oil system with piping.
6 6
For Approval For Approval For Approval
Compressed air system with piping in co- 6 ordination with scope of pump-turbine manufacturer/auxiliaries supplier.
13 14 15
Layout with section of trenches, blackouts etc. 6 for piping & cables. Interconnection and wiring diagrams and 6 cable schedule. Arrangement of sp. Valve piping for closing the valve 6
For Approval For Approval For Approval
Signature of Bidder
230
DATA 1. Opening and closing characteristics. 2. Max. Efforts and Max. Toque on foundation & Steel shaft. 3. Considerations made in data about loading on foundations of inlet valve and servomotors. valve. 3 For Approval For Approval 4. Adequacy of oil pressure shaft unit for spherical 3 3 For Approval 3 For Approval
MANUALS 1. Manual for storage, preservation and handling of the supplied goods. 2. Manual for erection /dismantling, testing & Commissioning of the supplied goods. 3. Maintenance manuals. 4. Tolerance for assembly. 5. List of consumables, oils and spares. 12 18 12 12 For reference For reference For reference For reference 12 For reference
Signature of Bidder
231
ANNEXURE VI-2 DEPARTURE FROM SPECIFICATION (To be filled in by Bidder) ---------------------------------------------------------------------------------------------------Item. Description of departure. Reference to clause in the specification. ----------------------------------------------------------------------------------------------------
Signature of Bidder
232
DATA SHEETS
DATA SHEETS S1 to S2 FOR TECHNICAL SPECIFICATIONS OF MAIN SPHERICAL VALVE AND RELATED EQUIPMENT
DATA SHEETS SHALL BE FULFILLED OBLIGATORILY BY BIDDER Note: In all data sheets, the following signs have the indicated meanings :
No negative tolerance allowed. No positive tolerance allowed.
(r ) required value. (d) desired value (o) offered value. (*) guaranteed values.
Signature of Bidder
233
DATA SHEET 1 DATA SHEETS (To be filled by Bidder (obligatory) MAIN INLET SPHERIAL VALVES Preferable operation -Opening -Closing : with oil : with pressure counter weight / (0) =. mm = ............... = ...............mm = ............... MPa =................ m.w.c : PT = ............... MPa water pressure head - Nominal diameter of spherical valve same : D s v diameter as distributor pipe (nn= 500rpm) : D s = 1000mm(d) - Number of servomotors - Diameter of servomotors - Design head [HD = 6.85 MPa (=700 mwc) (d)] - Test pressure of SP.valve (1050 mwc) - Maximum gross head of Sp. valve in Normal operation. [Hg max. = 602190= 412 mwc - Maximum discharge of Sp. valve in Normal operation.[Qmax 4.00m3 /s (d) ] - Maximum discharge of Sp. valve in Breakdown discharge [Q max 8.00 m3/s (d) ] - Total loss of head in Sp. valve at [Qmax 4.00 m3/s) ] - Maximum allowable leakage through closed Valve. [ Qo 2 l / s (d) ] - Sp. valve opening time at still water [ to = 60-120s (adjustable) (d)] - Sp. valve closing time at still water [tc 90 s (d) ] - at discharge Qmax 4 m3/s [tc 30 (d) ]tc tc ......................s..... .................s to .......................s to .......................s Qo ...................l / s. Q max H FP .............. ...m3/s =.............m. w .c. Q max . ................ m3 /s Hg max = ............. m.w.c. FP : ns : Ds : HD opening and closing mode Bidders Remark (if any)
Signature of Bidder
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DATA SHEET 2 Bidders Remark (if at discharge Qmax 8 m3/s [tc 20 s (d)] - Maximum valve shaft torque during - Opening - Closing - Operating oil pressure - Total mass of Sp. table - Maximum transportation mass of Sp. Valve - Dimension of largest transportation single Piece - Total mass of completed Sp. valve - Material of Sp. valve * Valve body * Valve table - Shaft bearing housing - Bearing [self-lubricated Teflon type (d) ] - Counterweight - Servomotor - (*) Total loss of head in Sp. valve - Leakage past closed valve i) Upstream side ii) Downstream side - Vibrations transmitted to foundation i) Valve opening ii) Valve in operation iii) Valve closing - Noise level near 2 m. from valve during operation of unit .................dB ( A) ...........Micrometer ..Micrometer ..Micrometer ......................l / s ......................l / s .............. ............ .............. .............. ............. .............. ............................ ............................ ............................ ............................ ............................ ............................. H L3 =...................mm (o) G FP LxWx H = ...x....x...x mm = .......................t Mo Mc P G ft G Tr =.................. kN.m = .............. ...kN.m = ..................MPa = .............. .........t = ........................t any) ......................s
Signature of Bidder
235
SECTION VII
TECHNICAL SPECIFICATIONS OF STATION AUXILIARIES.
236
SECTION VII
TECHNICAL SPECIFICATIONS OF STATION AUXILIARIES. INDEX
Sr.no. 7.1 7.2 7.2.1 7.2.2 7.2.3 7.3 7.4 7.5 7.6
Description Scope and operational requirements Schedule of requirements Compressed air system Drainage and dewatering system Cooling water system Auxiliaries control board Standards Drawings and data to be submitted with bid Drawings, designs and manuals to be furnished after award of contract
Page no. 238 238 238 242 244 247 249 250 250
7.7
Spares Annexure VII - I Annexure VII- 2 Data sheets A1 to A6
250 251 254 255
Signature of Bidder
237
SECTION VII
TECHNICAL SPECIFICATIONS OF STATION AUXILIARIES.
7.1
SCOPE AND OPERATIONAL REQUIREMENTS. This section of the specifications covers the complete engineering, design, manufacture, testing at factory before despatch, supply, delivery at site, supervision of onsite erection, testing, commissioning, putting into commercial use and giving satisfactory trial operation for a period of 90 days of the station auxiliary system complete with associated piping, fittings, motor control board and also supply and delivery at site of spares as mentioned hereafter. Any fittings, accessories of apparatus which may not have been specifically mentioned in these specifications but which are indispensable for reliable operation of the plant shall be provided by supplier at no extra cost to the purchaser. The capacities and ratings mentioned for various auxiliaries in the scheme shall be designed by the supplier and these shall be subject to approval by the purchaser. Relevant provisions of sections No. I of this volume shall be applicable.
7.2
SCHEDULE OF REQUIREMENTS.
7.2.1 COMPRESSED AIR SYSTEM.
A centralized high pressure compressed air system for the unit shall be provided for charging the governor oil pressure unit, Main Inlet Valve O.P.U., Generator breaks and service system. The system shall comprise two numbers high pressure compressors of suitable capacity, one of them being a standby, a common air receiver and necessary pipes, fittings, valves, pressure switches, etc. One low pressure air receiver shall be provided for generator brakes and common service. Compressed air from high pressure air receiver shall be tapped and fed to low pressure air receiver through one pressure reducer. The capacity of the system shall be sufficient to cater to the generating unit. The
Signature of Bidder
238
compressed air system shall be of the automatic start-stop design operating under pressure switches control sensing the pressure in the receiver. Nitrogen filled cylinders as an alternative system for pressurizing the oil pressure unit shall not be accepted. Bidder shall have to give detailed design of the system. Equipment shall be as per relevant IS
7.2.1.1 Scope of Supply Compressed air system is required for Governor OPU, MIV OPU, Generator Braking and service air and consists of : 3 Stage Reciprocating Compressors, - 2 nos Moisture Separators - 2 nos High Pressure Air receiver -- 1 no Low Pressure Air receiver -- (for Generator Brakes) - 1 no. Pipes, valves, instruments & fittings. - 1 lot
7.2.1.2 General Design and Constructional Requirements : i). Two reciprocating multistage compressors driven by electric motors shall be provided to feed compressed air in the air receiver.. One of the compressors shall work as main and other as standby. Their operation shall be made automatic with the help of pressure switches. Compressed air after passing through air dryers shall be fed to one high pressure air receiver. One low pressure air receiver shall be provided for generator brakes. Compressed air from high pressure air receiver shall be tapped and fed to low pressure air receiver through one pressure reducer. ii) Pressure rating of each compressor shall match maximum pressure requirement of oil pressure unit of Governor, MIV OPU and generator brakes. The supplier shall check air requirement of the system and provide higher capacity, if required considering the compressor duty cycle in view. Design calculation regarding compressor capacity and strength calculation of air receivers shall be submitted for approval of the Purchaser. iii) The compressors will be driven by 3 phase, 415 VAC completely enclosed, fan cooled, squirrel cage induction motors with class F insulation through belt
Signature of Bidder
239
drive. Compressor and motor shall be mounted on a common base plate which shall be installed on floor with the help of foundation bolts. iv) Indian Standard IS 2825 shall be followed for design, manufacture and testing the air receivers. v) The motor starter panel housing contactors, switch fuse units and meters etc shall be mounted on the wall near the compressors and wired complete with leads labelled. The connections to each motor shall be arranged so that either compressor may be removed for repair or replacement without interfering with the continuous operation of the other. vi) System design shall be subject to approval of the Purchaser. LUBRICANTS. Sufficient quantity required for first fill of lubricant, grease, oil etc. plus 25% extra shall be supplied and included in bid cost. CABLES. Power supply cables and all control cabling from motor control board to compressors, receivers etc. shall be included in Bidders scope. Compressor starting shall be regulated from the pressure switches provided on air receivers. The motor control board shall be located near compressor. Cables from each auxiliary system equipment to its control panel (both of which are included in suppliers scope) shall be supplied. Cables for interconnection between computer and computer based control panel shall also be supplied.
7.2.1.3 Shop Tests The shop tests on compressed air system shall include : i) Dielectric and insulation tests on all electric motors, ii) Routine operational tests including starting current, output torque Vs current characteristics, noise, vibrations on electric motors as per Indian Standard or International standard, iii) Operational tests and tests for verification of Performance Characteristics of compressors as per Indian Standard/ International standard. Compressors will be tested with their respective motors. iv) Hydrostatic pressure tests on air receivers at 1.5 times the rated pressure. v) Hydrostatic and leakage tests on all valves at 1.5 times the rated pressure.
Signature of Bidder
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vi) Operational tests on pressure reducer.
7.2.1.4 Field Tests Following testes will be carried out at site after installation : i) Dielectrics and insulation tests on all electric motors, ii) Operational tests on compressors for minimum 8 hrs continuous operation to establish trouble free operation without abnormal vibrations and noise, iii) Operational tests on control panels and instruments.
7.2.1.5 Special tools, slings, consumables etc. All special tools, slings, lifting devices, jacks, turn buckles, foundation plates/bolts, testing devices etc., required for erection and commissioning of the equipment shall be listed and supplied. First filling of oil and grease (if applicable) with 20% extra quantity shall be included in the offer and supplied along with equipment. Welding electrodes as required for site welding and paint for finishing coat shall be supplied by the contractor.
7.2.2
DRAINAGE AND DEWATERING SYSTEM: One set of Dewatering and Drainage Equipment comprising three submersible pump motor sets for dewatering and drainage system with pump control cubicles duly wired with switchgear, instrumentation, control, automatic level control, float switches, associated valves, necessary piping and fitting and staff gauges in tail race sump. The arrangement of drainage and dewatering system shall be proposed by the bidder. The scopes of supply include all pipes, valves etc. required for the complete dewatering & drainage system. Bidder shall have to give detailed design of the system. Design of Dewatering and Drainage Equipment shall be as per relevant IS.(i.e. IS:1742.IS:1172,IS:4721)
7.2.2.1 Scope of Supply Dewatering of pressure shaft will be achieved by pressure shaft drain valve. Entire system is for free flow tailrace discharge and drainage is also arrange for gravity flow to tail race channels by gutter/pipe. Equipment comprising three submersible pump motor sets are to be provided for dewatering and drainage
Signature of Bidder
241
system. Dewatering system shall consist of two submersible pump, (one main & one stand by), one set of level controllers, pipe lines and valves. Level controllers shall be provided in the dewatering sump to start/stop the pumps automatically & to give alarm at a preset level. The pump shall discharge into tail race above the maximum tail water level. The drainage system shall consist of one submersible turbine pumps, one set of level controllers, pipe lines and valves. Automatic control of the pumps shall be arranged through level sensors. Provision for manual operation shall be made on the control panel. Control of the pumps shall be built in Unit Control Panels and their starter panels will be located near the pumps. These three pumps will be used as per leakages and dewatering requirement in power house.
7.2.2.3 Pump Motor Sets The impellors of pumps shall be manufactured from stainless steel and the casing of impellor from steel casting. The pump casing and impellors shall be provided with removable type of stainless steel liners. The electric motors shall be squirrel cage induction motors with hollow shaft and ratchet arrangement to prevent reverse rotation. The enclosure of the motors shall be drip proof type. LUBRICANTS. Sufficient quantity required for first fill of lubricant, grease, oil etc. plus 25% extra shall be supplied and included in bid cost. CABLES. Power supply cables and all control cablings from motor control centre to motors, load controllers etc. shall be included in Bidders scope. Cables from each auxiliary system equipment to its control panel (both of which are included in suppliers scope) shall be supplied. Cables for interconnection between computer and computer based control panel shall also be supplied.
7.2.2.4 Valves, Pipes and Fittings All Nozzle valves and non-return valves shall have housing in steel casting and valve seat in stainless steel. Piping shall be complete with sufficient number of bends, elbows, tees, clamps, flanges and fasteners.
Signature of Bidder
242
7.2.2.5 Shop Tests The shop tests on drainage / dewatering system shall include: i) Dielectrics and insulation tests on all electric motors, ii) Routine operational tests including starting current, torque/speed characteristics, output torque Vs current characteristics, noise, vibrations on electric motors as per Indian Standard or International standard, iii) Operational tests and tests for verification of Performance Characteristics offered of pumps as per Indian Standard/ International standard. Pumps will be tested with atleast one actual motor tested and supplied for each type of pump motor set iv) Hydrostatic and leakage tests on all valves at 1.5 times the rated pressure. v) Operational tests on level controllers
7.2.2.6 Field Tests Following testes will be carried out at site after installation: i) Dielectrics and insulation tests on all electric motors, ii) Operational tests on Pump Motor sets for determination of pump capacity, power drawn at full discharge, vibrations and noise, iii) Operational tests on Pump Motor sets for minimum 8 hrs continuous operation to establish trouble free operation, iv) Operational tests on control panels and instruments.
7.2.3 COOLING WATER SYSTEM The cooling water for generator air coolers (if applicable), generator and turbine bearing coolers, turbine shaft seal if applicable and for other equipment in the powerhouse is required. Cooling water shall be provided by tapping the penstock. As the pressure at the tapping is high, suitable pressure reducer shall be provided. The system shall be complete with required number of duplex strainers, pressure reducer valves, safety valves, stop valves, fine mesh filters, flow meters, flow indicators, flow relays, pressure gauges, etc. Bidder shall have to give detailed design of cooling water system. Equipment shall be as per relevant IS
Signature of Bidder
243
7.2.3.1 Scope of Supply Tapping arrangement from intake Water pressure reducer set with PRV, stop valve, safety valve etc. -sets Motorised self cleaning strainer (duplex) Servo operated hydro valve with solenoids Necessary flow meters, flow indicators, flow relays, pressure gauges, pipes, supports etc. lot - sets - sets
7.2.3.2 General Design & Constructional Requirements i) Cooling water will be tapped from penstock through embedded pipes and connected to a common header through isolating valves. Water pressure
reducer set with PRV, stop valve, safety valve etc. shall be used to supply adequate cooling water to generator air coolers and bearings of the unit. Cooling water after passing through strainers will be fed to a common header and distributed to unit. Motorized self cleaning strainer with discharge capacity 1 times the requirement shall be provided to various cooling circuits. The strainers shall be cleared off accumulated silt automatically through a motorised rotating arm mechanism. Cleaning operation will be operable through pressure differential switch and timers. Servo operated hydro valve controlled by 48 VDC solenoids or motor operated valve shall be provided on feeding line of unit to control cooling water supply during starting/shut down of unit. Valves, Pipes and Fittings: All Nozzle valves and non-return valves shall have housing in steel casting and valve seat in stainless steel. Piping shall be complete with sufficient number of bends, elbows, tees, clamps, flanges and fasteners. The duplex strainer (2 in nos.) shall be fitted with pressure switches to give alarm in case the pressure differential across it exceeds a pre-set value. Pressure gauges shall also be provided to indicate water pressure at its inlet and outlet. This cooling water supply scheme is of flexible type such that any combination of duplex strainer can be used for the unit in operation while the other is in shutdown.
Signature of Bidder
244
LUBRICANTS. Sufficient quantity required for first fill of lubricant, grease, oil etc. plus 25% extra shall be supplied and included in bid cost. CABLES. All power and control cables with clamps, trays, ferrules etc. (both of which are included in suppliers scope) shall be supplied. Cables for interconnection between computer and computer based control panel shall also be supplied.
7.2.3.3 Shop Tests The shop tests on cooling water system shall include : i. Operational tests and tests for verification of Performance Characteristics offered of valves as per Indian Standard/ International standard. ii. Hydrostatic and leakage tests on other valves at 2 times the rated pressure. iii) Operational tests of self cleaning strainers
7.2.3.4 Field Tests Following testes will be carried out at site after installation : i. Pressure reducer set shall be pressure tested at site at 1050 m.w.c.
(10.27 MPa) for 60 minutes after its erection.

ii. Operational tests on self cleaning strainers.
7.3
AUXILIARIES CONTROL BOARD. This board shall comprise of following: 1) CONTROL SWITCHES FOR
(a)
COOLING WATER PUMPS Strainer A/ B
(b)
DEWATERING PUMPS: Pump Selector Switch Pump Auto/ Manual switch Pmp1/ Pump2 Auto/ Manual.
Signature of Bidder
245
Pump A Pump B (c) COMPRESSED AIR SYSTEM Compressor Selector Switch Compressor Auto/ Manual switch Local/Remote switch Compressor A Compressor B
Start/ Stop Start/ Stop
Pmp1/ Pump2 Auto/ Manual. Local/Remote Start/ Stop Start/ Stop
(2)
INDICATOR LED LAMPS (a) COOLING WATER PUMPS Strainer Strainer A B ON/OFF/Trip. ON/OFF/Trip.
(b)
DRAINAGE & DEWATERING PUMPS: Pump Pump A B ON/OFF/Trip. ON/OFF/Trip.
(d)
COMPRESSED AIR SYSTEMS FOR
Compressor A Compressor B
ON/OFF/Trip. ON/OFF/Trip.
7.4
STANDARDS Equipment shall be in accordance with the latest IEC standards or equivalent internationally accepted standards. Some of the standards are listed below but shall not be limited to: IEC 298 IEC 264 IEC 227 IEC 287 - Cased equipment - Common clauses, IEC 502 - M.V. Cables - PVC Conductor and Cable. - Calculations and Dimensions.
Signature of Bidder
246
IEC 269 IEC 364 IEC 439
- Fuses. - Installation - Operating Mechanism, IEC 51-1 to 51-5
Measuring Devices. IEC 145 & 521 IEC 72 IEC 404 IEC 349 & ISO 1996 VDI 2056 Swedish Standard 515 ASTMA 435 ASME V ASTMA 609 & 709 ASTMA 388 - Counters, IEC 255 (1 to 22) - Relays - Motors - Magnetic Materials - Noise - Vibrations - Corrosion Protection - Steel Plate Testing - Welding Materials - Cast Part testing - Forged part testing
SUBMISSION OF TEST CERTIFICATES The supplier shall submit 6 copies of test certificates to the Purchaser as per the procedure given below: i) FOR INSPECTION AND TESTING SPECIFIED TO BE DONE IN PRESENCE OF PURCHASERS REPRESENTATIVE. Test certificates shall be submitted for approval. ii) FOR ALL OTHER INSPECTION AND TESTING Test certificates showing that the specified tests/inspection has been carried out successfully by the Supplier, shall be submitted for reference.
7.5
DRAWINGS AND DATA TO BE SUBMITTED WITH BID Bidder shall submit in his bid information and general drawings describing and illustrating the equipment he proposes to offer, in such a manner as to make possible a complete understanding of the equipment on which bid is based. The information shall include all essential dimensions, types of materials to be used in major parts with the chemical and physical properties of materials and the schematics, layout drawings, control schemes and data for the:
Signature of Bidder
247
1.
All Data Sheets enclosed with this section must be completely filled in by the Bidder. The Bidder shall specifically note this requirement and fulfil it in all respect without fail.
2. 3. 4.
Cooling water system Drainage and dewatering system Compressed air system
7.6
DRAWINGS, DESIGNS AND MANUALS TO BE FURNISHED AFTER AWARD OF CONTRACT These shall be submitted as per the list given in Annexure VII-I to this section. Mode of submission of drawings and designs will be intimated to the successful Bidder in due course.
7.7
SPARES Spares shall be supplied as per list under Section III of this Volume.
Signature of Bidder
248
ANNEXURE
VII - I
List of drawings, designs and manuals to be submitted by the Supplier after the award of contract.
Sr. No.
Brief Description
Within months from the date of award of contract
Remarks
DRAWINGS
1.
Layout and dimensional Drawings showing equipment for, * Cooling water station 4 For approval
* Drainage and dewatering Pump station
* Compressor station
* Trenches, blackouts etc. for pipe line and cables
* Support details of pipelines 2. Pipe layout of cooling water system 4 For approval
3.
Schematic of cooling water system. 4 For approval
4.
Control panel for cooling water system 4 For approval
5.
Arrangement diagram of compressed air system 4 For approval
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6.
Pipe layout of compressed air system 4 For approval
7.
Schematic of compressed air system 4 For approval
8.
Motor Control centre panel for compressed air system 4 For approval
9.
Arrangement of drainage and dewatering system. 4 For approval
10.
Pipe layout of drainage and dewatering system 4 For approval
11.
Schematic of drainage and dewatering system 4 For approval
12.
Motor Control centre panel for drainage and dewatering system 4 For approval
13
Interconnection and wiring diagram and cable schedules of equipment 6 For approval
14.
Foundation / support arrangement of, * Cooling water system 4 For approval
* Drainage/dewatering pumps
* Compressor air equipment,
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air receivers * All water piping, valves pump columns
* Switchgear panels of cooling water, drainage/dewatering and compressed air system.
DATA 1. Adequacy of cooling water system 2. Adequacy of dewatering and drainage pit size and volume 2 For approval 2 For approval
3.
Adequacy of pump capacity for cooling water, drainage and dewatering system 2 For approval
4.
Adequacy of compressed air systems including capacities of compressors and air receivers. 2 For approval
Signature of Bidder
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MANUALS
1.
Manual for storage, preservation and handling of the supplied goods. 8 For reference
2.
Manual for erection, dismantling, testing and commissioning of the supplied goods. 8 For reference
3. 4.
Maintenance manuals List of consumables, oils, grease, spares etc.
12
For reference
10
For reference
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ANNEXURE VIII- 2 DEPARTURE FROM SPECIFICATION (To be filled by Bidder)
Item
Description of departure
Reference to Clause in specification
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DATA SHEETS
DATA SHEETS A1 TO A5 FOR TECHNICAL SPECIFICATIONS OF 1. COMPRESSED AIR SYSTEM 2 COOLING WATER SYSTEM
3. DRAINAGE AND DEWATERING SYSTEM AND RELATED EQUIPMENT
*DATA SHEETS SHALL BE FULFILLED OBLIGATORILY BY BIDDER
Note: In all data sheets, the following signs have the indicated meaning: (r) (d) (o) No negative tolerance allowed No positive tolerance allowed Required value Desired value Offered value
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DATA SHEET A1 Bidders Remark (if any) DATA SHEETS COMPRESSED AIR SYSTEM FOR GOVERNOR, M.I.V., GENERATOR BRAKES AND GENERAL REQUIREMENT
-Total number of compressors
n c =................(o)
-Discharge of one compressor at working rated pressure Qc =.... N m3/s (o) =.........kg/s (o)
-Rated working pressure of compressor -Rated power of compressor motor
p = ... MPa
(o)
P =.........kW (o)
-Rated speed of compressor motor
nn =..........rpm (o)
-Total number of air tanks
nt =................ (o)
-Volume of one H.P. air tank for Governor and MIV -Air leakage during operation Vair=............ m3 (o)
Q=... ...kg/s (o)
-Volume of one air tank for generator brakes Vair=............ m3 (o) and general requirement
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DATA SHEET A2 Bidders Remark (if any) DRAINAGE AND DEWATERING SYSTEM TECHNICAL DATA SHEET FOR SUBMERSIBLE / VERTICAL MOTOR - PUMP UNITS -----------------------------------------------------------------------------------------------D&D PUMPS UNIT ASSIGNED VALUE OFFERED VALUE
-----------------------------------------------------------------------------------------------
Quantity Type of operation
............
Manufacture
.........
............
Type
Rated speed
rpm m3/sec
1480
.............
Discharge Heads Hn
... 10m
............. .............
Corresponding Discharges Qn (atHn) m3/sec
............. .............
Efficiency (Nominal point % >70 .............
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DATA SHEET A3 Bidders Remark (if any) Input power nominal Maximal kW kW ............. .............
Motor voltage
400 + /-10 %
.............
Net work frequency Hz
50
.............
Motor power
kW
.............
(With star/delta starting) Materials - body - Impeller Cast iron Cast iron or Phosphor Bronze - Shaft steel ............ ............ .............
Length of guide system
...........
Length of electrical cable Up to connection box Diameter of discharge Nozzle mm ........... m ...........
Weight of Pump + motor
kg
...........
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DATA SHEET A4 Bidders Remark (if any) COOLING WATER SYSTEM TECHNICAL DATA SHEET
COOLING WATER SYSTEM
UNIT
ASSIGNED VALUE
OFFERED VALUE
1) WATER PRESSURE REDVCER VALVE i) Type
ii) Manufacture
iii) Design Pilot / Piston operated (d)
iv) Material body seals & disc core, core plug nut core spring core tube v) Installation configuration Two stage serial reduction (d)
vi) Inlet pipe diameter
vii)Outlet pipe diameter
viii) Operating pressure differential
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DATA SHEET A5 Bidders Remark (if any)
ix) Maximum outlet pressure
x) Maximum flow rate
xi) Actuation method solenoid(d)
xii) Valve opening type normally closed(d)
2) SAFETY VALVE i. Type
ii.
Manufacturer
iii.
Minimum operating pressure
iv.
No. of safety valves used
v.
Material
3) STRAINERS
i.
Type
ii.
Manufacturer
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iii.
Designed flow rate

DATA SHEET A6 Bidders Remark (if any)
iv.
Material
v.
Motor capacity
vi.
No. of strainers used
Signature of Bidder
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SECTION VIII TECHNICAL SPECIFICATION OF PROTECTION AND METERING
261
SECTION VIII PROTECTION AND METERING DETAILS

INDEX
Sr.no. 8.1 8.2 8.3 8.4 8.5 8.6 8.7
Description
Page no. 263 263 263 264 266 266 266 267 268 269
Protection and Metering Scheme CTs / VTs Special Features of Proposed Protection System Generator And Transformer Protection Protection for D.C System Metering System Spares Annexure VIII - I Annexure VIII- 2 DATA SHEETS P1 to P3
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SECTION VIII PROTECTION AND METERING 8.1 Protection and Metering Scheme The following protection shall be provided by using integrated numerical generator protection relay for generator, generator transformer and auxiliaries. Back up electromagnetic relays with instrument transformers may be provided as mentioned cl.8.4.2 of this volume. All the protective relays will be housed in the control room of the Power Plant. The tentative locations of CTs and PTs housed in GT and NG cubicle for the protection and metering shown in single line diagram. Alternative arrangements may be proposed by the bidder. The final drawings for the protection & metering shall be submitted by the contractor and will be subject to the approval by the Purchaser. 8.2 CTs / VTs All current and voltage transformers required for protection system of the unit shall have adequate VA burdens, knee point voltage, saturation factor and characteristics suitable for the application, and shall be subject to approval of the purchaser. 8.3 Special Features of Proposed Protection System i. The protection system shall be built on latest technology and the bidder has to guarantee for supply of spares for at least 10 years. Moreover, the bidder should have full range of manufacture of the system offered. ii. Wide setting ranges with fine setting steps for each protection shall be available. iii. The protective relays shall preferably be housed in draw out type of cases with tropical finish.
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iv.
Common tripping relays (each for similar functions) will be provided with lockout facilities. All these relays shall have potential free contacts for trip and alarm purposes and externally hand reset type of flag indicators
8.4 8.4.1
Generator And Transformer Protection An integrated numerical protection relay incorporating the following functions shall be provided for generator and Transformer protection a) Generator, step-up Transformer Protection 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19 20 21 Generator Differential Protection. Overall Differential Protection. Step-up transformer differential protection. Generator Stator Earth-fault protection. Generator-Rotor Earth-fault protection. Voltage controlled over-current protection. Loss of excitation (Minimum reactance protection) Reverse power protection. Under-impedance protection. Thermal over-load protection. Negative sequence phase current protection. Restricted earth-fault protection for star-connected secondary winding of step-up transformer. Over-frequency protection. Under-frequency protection Generator over-voltage protection. Generator under-voltage protection. Step-up transformer over-current protection. Over-current protection for Unit Auxiliary Transformer. Excitation transformer Over-current protection Unit auxiliary transformer differential protection Generator phase sequence check.
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8.4.2 i. ii. iii.
In addition, the following static (analog) protective relays shall be provided Negative phase sequence relay (46) IDMT Over current relay (51) Stator earth fault protection (64G) The bidder may propose additional protection as an option.
8.4.3
Following protection provided on the generator transformers shall also be integrated with the main protection described above:
i. ii. iii. iv. 8.4.4
Oil temperature indicator with alarm and trip control. Buchholz relay with alarm and trip control. Winding temperature indicator with alarm and trip control Oil gauge with low-level alarm. Following mechanical protections shall be provided: a. b. c. d. e. Resistance temperature detectors (Pt-100) in stator core and in the bearings for indication, alarm and recording. Turbine and generator bearing, metal and oil temperatures alarm/shutdown. Governor oil pressure low to block starting and very low for emergency tripping. Over speed for normal and emergency shutdown depending upon its extent. Our speed relay-Mechanical And Electrical (12)
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8.5
Protection for D.C System i. Under-voltage protection for 220 V D.C. ii. Under-voltage protection for 48V D.C. iii. Earth-fault protection for 220V D.C. iv. Earth-fault protection for 48V D.C.
8.6
Metering System Power generated shall be metered at generator terminal through metering CT and PT. The power transferred to 220 kV feeder shall also be metered though CTs and PT. Following metering equipments shall be provided on relevant panels. 1. kW meter 2. kWh meter 3. kVA meter 4. Ampere meter 5. Voltmeter 6. Power factor meter 7. Frequency/speed meter 8. Temperature meters.
8.7
SPARES Spares shall be supplied as per the list under Section - III of this volume.
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ANNEXURE AWARD OF CONTRACT.
VIII - I
DRAWINGS, DESIGNS AND MANUALS TO BE FURNISHED AFTER
Sr. No .
Brief description
within months Remarks from the date of award of contract
1 1.
4 For approval
Circuit diagram/block diagram of all 6 protections listed in clause 8.4
Circuit diagram metering.
For reference
MANUALS. 1 1 2 Manual for storage, preservation handling of the supplied goods 2 Manual for erection / testing, setting and the supplied goods 3 Manual giving operating instructions 18 For reference dismantling, 12 For reference 3 and 12 4 For reference
commissioning of
for all the DOs and DONTs 4 Manual giving schedule 5 Manual for back up, loading software, data supplied system. detailed maintenance 18 For reference
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ANNEXURE VIII- 2 DEPARTURE FROM SPECIFICATION (To be filled by Bidder) Item Description of departure Reference to Clause in specification
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DATA SHEETS
DATA SHEET P1 Bidders Remark (if any) DATA SHEETS P1 TO P3 FOR TECHNICAL SPECIFICATIONS OF PROTECTION SYSTEM AND METERING *DATA SHEETS SHALL BE FULFILLED OBLIGATORILY BY BIDDER
D. PROTECTION SYSTEM
1 Make 2 Type of numerical relays their functions a. b. For Generators For transformers
3 Built in testing facility 4 Methodology to provide redundancy 5 Type of back-up protection in case of failure of numerical relays a. b. For generators For transformers
6 Parameter/command documentation 7 Maximum operating time 8 Sensitivity in %age of rated current 9

ANALOGUE INPUT VARIABLES
a. b. c. i. ii. iii. iv.
Rated frequency Rated current Thermal rating of current circuits Continuous For 10 seconds For 1 second Dynamic
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DATA SHEET P2 Bidders Remark (if any) 10 Rated Voltage 11 Thermal rating of voltage circuits (continuous) 12 Burden per phase a. b. 13 CURRENT TRANSFORMER REQUIREMENTS a. i. ii. iii. iv. b. i. ii. iii. iv. c. i. ii. Generator Protection VA burden Saturation factor Minimum knee point voltage Maximum excitation current Transformer Protection VA burden Saturation factor Minimum knee point voltage Maximum excitation current Feeder Protection VA burden Saturation factor At rated current At rated voltage
iii. Accuracy class C. ENERGY METERING SYSTEM 1 Make 2 Type 3 CT/PT connection direct or through transducers 5 Accuracy of meters 6 Accuracy of transducers, if any
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DATA SHEET P3 Bidders Remark (if any) 7 Parameters measured 8 Maximum current rating for 1 second 9 Service voltage range and tolerance 10 Service frequency range and tolerance 11 Service temperature range 12 Power consumption a. b. Current circuit Voltage circuit
13 Service life 14 Protection against electromagnetic/radio interference
Signature of Bidder
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SECTION IX
SUPERVISORY CONTROL AND DATA ACQUISITION SYSTEM
272
SECTION IX
SUPERVISORY CONTROL AND DATA ACQUISITION SYSTEM INDEX
Sr. no. 9.1 9.2 9.3 9.4 9.5 9.6 9.7 9.8 9.9 9.10
Description General requirement:Computer based SCADA system
Page no. 274 274 278 279 282 283 291 295 295 296 297 298
Physical and Environmental Requirements User and plant interfaces

Control parameters SCADA controllers Unit control board (UCB) Factory testing Site testing Spares Annexure VII - I Annexure VII- 2
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SECTION IX
SUPERVISORY CONTROL AND DATA ACQUISITION SYSTEM
9.1
GENERAL REQUIREMENT:1 Comprehensive system for automation of the power station complex as a whole shall be provided by the supplier. 2. The plant to be controlled shall consist of the following :i) One no. Turbine-Generator set including all connected auxiliaries. ii) iii) 3. Station service auxiliaries 220 kV switchyard equipments.
The system shall use the most upto date & proven technology based on microprocessors reliable transducers which require no, or little, maintenance and/or calibration during services, and the
communication link of optical fibre. 4. The system shall be arranged to provide (2) two levels of controls: -
i)
Remote plant Control in
automation mode from Unit Control board
(UCB) or from LCD console and manual mode from UCB. ii) Local Unit control, in manual mode from respective control cubicles (generator excitation cubicle, auxiliary equipment control board and generator voltage metal clad switchgear cubicle/etc.) 5. Normally, the plant control in remote automatic mode shall be used. When the communication link is not available, or when the equipment in central control room is being inspected and/or is under repairs, the control and monitoring functions of the unit can be performed in Unit Control in Manual Mode,.
9.2 9.2.1
COMPUTER BASED SCADA SYSTEM:Control scheme: The unit control scheme shall include following sequence: Starting and stopping of essential auxiliaries like governor oil
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pumps, cooling water, H.S. Lubricating pump and braking system manually. After manual/auto start of auxiliaries, automatic starting of the unit from stand still to speed no load condition. Synchronizing (Manual / Automatic) kVA / kVAR setting (Manual / Automatic) Control action shut down of the unit. Emergency shut down of the unit. Catastrophic shut down of the unit. Operation (Starting and stopping) of the unit from Unit Control Board from control room. While preparing the control scheme and providing controls, indications the bidder shall keep in view that the excitation equipment and the governor cubicle are proposed to be located in the control room. For Control panels arrangement bidder shall keep in view the power house layout. In addition to the protection signals, control action shut down and emergency shut down shall be initiated by normal stop command and emergency stop command respectively from control board. The indicating meters shall be 144 x 144 mm. size Annunciator of static type shall be provided. The scheme shall include auxiliary relays, timers, flags, relays, flicker relays, etc. complete.
9.2.2 System: Computer based SCADA system shall be used. Computer based SCADA system comprising of microprocessor based control technology physically distributed through out the power house. The separate microprocessor units are linked together by a number of digital communication paths to form a completely integrated control system.
Microprocessor based control system comprising: 1. 2. 3. 4. 5. Integrated Operation Station (IOS) Integrated Data base station (IDS) Integrated Engineering Station (IES) Printer. Micro Controller (HDC)
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6. 7. 8. 9.
Power Distribution Equipment (CVCF). Main control board Man machine Interface. Computer system with main control board and function keyboard
9.2.3 Specifying response time The bidder shall define response time speed of control system clearly. He shall define following times: Time duration required to update a graphical display from the instant a field contact changes state Time duration from the instant a control is activated at the operator station until the command is implemented at the field device; and Over all time duration to process and log an alarm once it is received at the computer. The specification shall define the acceptable time durations for each of the above events in both normal leading and high activity loading scenario. The computer system response times should be verified at the factory acceptance test to confirm the system will operate as required by specifications.
9.2.4 Software Requirements

The operating system: The software shall run in a priority interrupt driven, multitasking operating system. The system should provide each task with dedicated random access memory to allow pre-emptive scheduling of tasks without loss of information. Programming language The controlling programs shall be written in a high level compiled language whenever possible for ease in maintenance, with the exception of time critical tasks which shall be written in assembly language. The code shall be re-entrant and employ mutual exclusion techniques to prevent deadlock of resources. Standardization The software shall reside in non-volatile EPROM memory, which shall not require reloading for routine power interruptions to the controller.
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Configurability Configuring of the control software shall be accomplished via a menu driven user-friendly program that will be run on an PC or compatible computer. The configuring shall be able to be accomplished at an area remote from the controller and shall not prevent operation of the controller during configuring except during the transfer of the configuring information to the controller. Functions The software shall allow the operator to examine and modify those parameters of the control software that will specify the operating conditions and restrictions of a particular plant. These features shall include but are not limited to: - Timings - Decision paths - Set points - Equation coefficients - Enabling functions - Plant description information The software shall also allow for specifying particular contact inputs, analog inputs and analog outputs. The software shall allow user designation and titling of contact inputs. Analog scale factors shall be set via the configuring program. Communications The configuring information shall be communicable with the controller via standard RS-232C communications protocol. The communication shall have the ability to be via voice grade telephone communication as well as a direct connection with the controller. Security The configuring software shall provide a means of preventing unauthorized access to the configuring information. Further it shall provide a means of differentiating three or more security levels of configuring information to create three or more depths of configuring accessibility.
Man-Machine Interface (MMI) The operators station of the station controller (SCADA system) shall
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have an elaborate and friendly man-machine interface. A 19 or larger monitor shall be provided for the display. Provision shall be made for connecting a second colour monitor in parallel. The screen displays shall be suitably designed to provide information in most appropriate forms such as text, tables, curves, bar charts, dynamic mimic diagrams, graphic symbols, all in colour. An event printer shall be connected to PC of the SCADA system. Events shall be printed out spontaneously as they arrive. Provision shall be made to connect and use another printer simultaneously. Touch control screen, voice and other advanced modes of MMI are desired and shall be preferred. The entire customization of software for MMI and report generation shall be carried out. A windows based operating system shall be preferred. 9.3 Physical and Environmental Requirements
(i) Physical Requirements The equipment shall be constructed on a modular basis, using plug-in connection. The controller shall be suitable for mounting in a standard 19-inch rack with a minimum depth of 24 inches. Input/output termination cabinets shall be internally labelled, to permit ready identification of the incoming and outgoing wiring. The equipment shall be of self protecting against surges that may be generated on power supply bus by contact operation, circuit resonance, etc. External connections shall utilize modular screw terminal blocks which shall be shall be suitably mounted and readily accessible. Each terminal device shall suitably identify all conductors. All wiring shall be clearly marked and so designated on the drawing to permit identification for maintenance. Wire not colour coded shall be identified by a wire number marker on each end. All cables and jacketing material shall be oil, moisture, and heat resistance thermosetting compounds under operating conditions. Controller AC power connection shall be a standard NEMA PI5-5 plug configuration.
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(ii) Environmental Requirements The controller and video display shall be capable of withstanding the environmental conditions of the site of plant during air condition failure.
9.4
USER AND PLANT INTERFACES
9.4.1 User interfaces The look and feel of a personal computer shall be desirable to reduce special training. In order to make the system acceptable to the operations personnel, care must be taken in the selection of the hardware and software used. 9.4.2 Input devices Input devices are not mutually exclusive and may be combined to incorporate desired features. 9.4.3 Output devices As with input devices, various output devices may be combined to incorporate desired features. Some typical devices are as follows: a) Printers.. b) CRT screens. c) Mimic boards. 9.4.4 Plant Interfaces Types Plant interfaces include analog transducer signals, dry contacts (i.e., contacts without sensing voltages) and digital data. This clause covers several generic types, however, installations may have special application requirements to meet unique concerns. Digital, contact, and pulse inputs Digital or contact inputs shall meet minimum criteria for operations at the voltages and current loads anticipated. The current required to drive the input circuitry shall be adequate to ensure false indication changes do not occur due to noise. The current shall be as low as possible to conserve power and reduce heat generation. Wetting voltages (e.g.,
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those voltages required to sense the status of dry contacts) may be provided by the control system or the field device. Contact bounce in the input signal can cause erroneous data in the system. Digital inputs shall have filters to detect only sustained input signals. These filters may be in the hardware or the software. Filters must be selected in accordance with time tag accuracy. Simple lowpass filters can introduce undesirable delays. Voltage levels for logic detection shall be sufficient to prevent erroneous readings. Digital inputs may also serve the functions of pulse accumulators or counters. This function is normally in software or firmware at the I/O. Accuracy, counting, and pulse accumulation rates shall be sufficient for the intended use. Digital input status indicators, shall be provided. Digital and contact outputs Digital or Contact outputs provide data and control contacts for external circuits. These contacts must have sufficient current and voltage rating for the external load. These ratings must often be considered in total for a given card or group of I/O as well as for individual circuits. Wetting voltage is typically provided by the external circuit. The ability of the solid-state devices in the output circuitry of the I/O to absorb the required current (without thermal instability of the devices) is a function of temperature (heat generation). Where higher current ratings are required, interposing relays are typically installed. The current ratings are then those of the interposing relays. Digital outputs may be latched, momentary, or maintained. These functions may be implemented in software or in the output relay. Digital output status indicators shall be provided, similar to those on input I/Os. The failure state of digital outputs shall be defined and specified. Analog inputs Analog inputs shall be low-level (e.g., 0-1 mA dc, 4-20 mA dc, 1-5 V dc, etc.) current or voltage, resistance, or thermocouple signals. Resistance or millivolt (thermocouple) inputs may be scaled to engineering units by the I/O processor, or a separate RTD or
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thermocouple to current or voltage converter located with the I/O. The I/O is often capable of providing the loop power supply for analog inputs. Voltage, tolerance, stability, and loading shall be considered. Scaling accuracy, resolution, dead band, and thermal stability shall all be specified to meet the needs of the applications. Thermocouple and RTD replications shall meet the standard accuracy for these devices. Open thermocouple detection is desirable. Common and differential mode rejection ratios shall also be specified. When multiplexing technology is used, the multiplexing hardware shall be solid-state and not electromechanical. Multiplexing schemes must be fast enough to ensure that the most recent values are available when required for all control loops. Analog outputs Analog outputs are typically low-level voltage or current. Accuracy, resolution, dead band, and thermal stability shall all be specified. Analog-to-digital/digital-to-analog conversion The accuracy of any analog input or output depends on the conversion between the computer's digital data system and the analog information. The conversion is typically performed by multi-bit A/D converters. Conversion accuracy and resolution are a function of the number of A/D converter bits and I/O amplifier design. Further, the accuracy is affected by temperature-induced drift. Thus, A/D resolution, input accuracy, and temperature stability shall all be specified. 9.4.5 Field devices and field bus standards Another major source of interface signals are those originating from intelligent electronic devices (IED) and intelligent field devices (e.g., a field device capable of measuring more than one parameter and transmitting the measured parameters over one pair of wires 9.4.6 Input/output protection All inputs and outputs shall be specified to withstand the Surge Withstand Capability (SWC) test, -as described in IEEE C37.90.1-1989,
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without any false operations. The SWC test has proven to be a reliable means to identify noise problems similar to those found in a Hydroelectric powerhouse.
9.4.7
Grounding Each equipment rack in which automation system components are located shall be separately connected to the powerhouse ground mat by a large gauge wire. Shielded cables shall be used for analog signals between the transducers and the automation system. Each shield shall be tied to the signal common potential at the transducer end of the cable. If there is termination or junction boxes between the transducers and automation system, each shield circuit shall be maintained as a separate continuous circuit through such junction or termination boxes.
9.4.8 Static Control Equipment shall be immune to static problems in the normal operating configuration. Anti-static carpet and proper grounding for all devices that an operator may contact shall be provided.
9..5 Control Parameters: SCADA system shall be complete with primary sensors, cables
analysers/transmitters, monitors, system hardware/ software and peripherals etc. to monitor/control the following parameters. Generator stator and rotor winding temperatures Generator and turbine bearing temperature Lubrication oil temperatures Status of generator cooling system Governor control monitoring of turbine speed Generator terminal voltage current KW, KVAR, KVA, KWH, Hz, PF, field voltage and field current. Annunciation for violation of permissible limits of above parameter Turbine bearing temperature detector Generator bearing temperature detector Turbine bearings oil level indicator Signature of Bidder
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Generator bearing oil level indicator Generator winding temperature detector Turbine speed / Generator speed Governor oil pumps, oil pressure indicator and low pressure indicator Cooling water valves, section and discharge pressure switch/ gauge. Inlet pressure gauge at inlet of turbine SCADA shall provide monitoring of parameters listed above. The list may have additional parameters as per requirement and shall be finalised during design stage. 9.6 SCADA controllers: SCADA shall have following controlles: Unit controller Common plant controller/ supervisory control Remote supervisory control 9.6.1 Unit Controller: It shall be microprocessor based and is required to perform all functions as below. It is required to have capability to implement closed loop PID function for governing and to perform all monitoring, control, protection and recording functions that a power plant required independently. (a) It shall monitor and control items Turbine Nozzle opening/closing Turbine/ Generator RPM Generator power out put Generator excitation (b) Automatic unit control modes shall include following: Unit automatic start sequence Unit automatic shutdown sequence Unit automatic synchronizing Unit Nozzle opening/closing set point control Unit load set point control Unit flow control (c) The unit shall include digital governor with proportional, integral and derivative gains. The governor be with in a position loop controlled by speed
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loop and capable of 0-10% droop. A manual position control shall be provided. Following governing functions shall be provided. Speed evaluator Speed control Speed set point adjustment Nozzle opening/closing limiter Start up and shutdown control of turbine Position controller for Nozzle opening/closing with power amplifier for control of servo valve. (d) Unit Auto synchronisation The controller shall be capable of synchronizing the generator to the 220 kV bus by reading the slip frequency (generator-bus) and adjusting the governor speed set point until the correct slip frequency is obtained while sending voltage raise/lower pulses to the voltage regulator to match generator voltage to bus voltage. When the slip frequency is obtained and the generator and bus voltage are equal, the controller shall send a close breaker command to 220kV Circuit Breaker when the generator voltage and the bus are in phase. An additional external synchro check relay shall also be provided to supervise the controller close breaker command and the manual close breaker command. The controller shall follow synchronization limits in terms of breaker closing angle and voltage matching condition specified by generator manufacturer. (e) Shutdown sequence The shutdown sequence provided by controller shall be such that the turbine generator set from any moving state to a complete standstill with all auxiliaries correctly shutdown. The unit controller shall automatically shut down if the control system detects turbine mechanical system faults; generator electrical faults or specific shut down conditions are generated with in system. Following three types of shutdown to be performed on the turbine/generator set shall be provided by the controller. (i) Normal shutdown A normal shutdown shall be initiated by a shutdown command that has been issued by an operator either from the panel mosaic or the supervisory system locally or remotely. This sequence shall allow the plant to be shutdown in a
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standard orderly manner. After the plant has completely shutdown it shall return to a state in which it can be restarted again on the issuing of a start up command. (ii) Emergency shutdown An emergency shutdown shall be initiated if a failure occurs in a critical item of plant, which is likely to cause unsafe operation of plant such as an electrical trip. The plant shall quickly and safely shutdown with lockout to avoid damage to plant or injury to personnel. The plant shall be blocked from restarting again until the fault is rectified and acknowledged by the operator from either the UCB or the supervisory system. (iii) Rapid shutdown A rapid shutdown is initiated if a safety trip occurs on the plant. The plant is rapidly shutdown taking care not to cause unfavourable effects such as pulsations, backwater surges and suction waves. The plant is blocked from restart (iv) Unit start-up sequencing The controller shall allow the unit to be started manually (if all permissive are met) and bring generating unit speed to synchronous speed. Alternately if automatic start up mode is selected either locally or remotely then unit shall automatically start provided all the start up permissive are met. The unit controller shall allow parameters of the start-up sequence to be configured to match the turbine generator. (v) Lockout The controller shall include a generator lockout function. Whenever the lockout function is on it shall inhibit the generator from starting. Any alarm shall be configurable as a lockout alarm. The lockout shall be reset with a command entered on the keyboard. When the lockout is on, it shall be displayed on the screen annunciator. (vi) Auto restart The controller shall be capable of automatically restarting the turbine after certain shutdowns if so enabled and if the lockout is not set. The time to wait for a restart and the enabling of the restart function shall be configurable.
Signature of Bidder
285
(vii) Automatic power control modes The unit controller when the unit is not under plant control mode shall be capable of several forms of automatic power control. The operator shall be able to select automatic power control modes at any time and enter a new set point at any time. .The available power control modes shall meet the requirements of system. Nozzle opening/closing position shall be automatically controlled to match the nozzles to a position set point. Nozzle opening position shall be controlled to match the kW output of the generator to a kW set point. Regardless of the kW set point, the generator output shall be limited by a maximum kVA limit specified during configuration. Nozzle opening position shall be controlled to match a flow set point that is calculated by the controller from a flow versus gate Nozzle opening position curve for the operating head which is entered during the configuration process. (viii) Override control The controller shall provide at least two override controls that when enabled will take over turbine control from the Automatic Power Control mode when certain set point limits are reached. When these interim conditions return to normal, the controller shall automatically revert to the primary automatic power control mode. The controller shall modulate the turbine output so that the measured generator stator temperature (hottest of the three phases) does not exceed the Temperature Control set point. (ix) Reactive power control The controller shall have four reactive control modes, one manual and three automatic. The generator capability curve shall be entered into the controller during configuring. All automatic reactive power control modes shall be limited by the generator capability curves. If an operator enters a set point, that will take the generator outside its capability curves, the reactive power control program shall control reactive power to get as close to the set point as possible, but remain within the generator's capability.
Signature of Bidder
286
Manual: The controller shall provide operator capability, using "raise/lower" keys on the VDT keyboard and the "raise/lower" switch on the manual control panel to control voltage and reactive power. Automatic VAR control: The controller shall automatically control the generator output to that VAR set point set by operator. The generators voltage limit and capability curve shall not be exceeded regardless of the VAR set point. Automatic PF Control: The operator shall enter power factor set point from the keyboard and the controller shall automatically control the generator output to that power factor (leading or lagging) set point set by operator. The generator voltage limit and capability curve shall not be exceeded regardless of the power factor set point. Automatic voltage control: The controller shall automatically control the generator output to match that voltage set point set by operator. The generator's voltage limit and capability curve shall not be exceeded regardless of the voltage set point. Alarm Annunciation There shall be two types of alarms used by the controller. One type shall be the external alarms from contacts fed into the digital inputs of the controller and the second, the internal alarms generated by the controller. All alarms, whether internal or external, shall be capable of being configured to cause different sequences. Unit controller shall be capable of providing audible and visual alarms in the event of faults occurring in the power plants. The instant the fault occurs the relevant fault indicator is activated. All faults have to be acknowledged by the operators and can only be reset when the fault has been resolved. On the occurrence of faults audible warning shall be activated to attract the attention of the plant operators. (x) Unit Protection The protection system shall be based on the use of discrete Microprocessor based relays with the following features: Continuous self monitoring Online display of actual values
Signature of Bidder
287
Shall be capable to communicate with supervisory system through unit controller The bidder may also quote for multifunctional numerical relay.
9.6.2 Supervisory Controller It shall monitor and control the status of power plant, provide automatic unmanned operation, log data, display the process through a mimics, supervise water levels of reservoir, start up and shutdown of units, control manually control auxiliary and alarm monitoring. All such control shall subject to passward-bases security system. Depending on the station requirements, the operator shall be able to enter set points for power output, voltage and power factor. It shall also have online documentation and expert diagnostics, efficiency management and plant management.
(i)
Operating Regimes: The plant shall be controlled either manually or automatically under different operating regimes. Following operating regimes may be provided.
a)
Plant efficiency control mode: In this mode of operation, the automatic control system shall maximize the plant's energy production for a given headwater level. To achieve this, the system shall automatically select with the most efficient unit loading point to dispatch all available water for a particular gross operating head. The operator shall be able to specify the order in which unit is to be started and stopped by the control system.
b)
Reactive power control mode: In this mode of operation, the control system shall automatically adjust the excitation field current to maintain the output power factor or VARs within a defined range (i.e., leading or lagging). The operator shall be capable of entering a set range that the power factor or VARS must fall within for each unit. The control system shall maintain the unit's output power factor or VARs within this set range unless limited by the generator capability curve or the exciter output current capability. The system shall verify that the VAR set point is an identical percentage of rated output for all units when used in conjunction with automatic load sharing control.
Signature of Bidder
288
ii)
Operator Interface Requirements: The controller shall use a video display terminal or PC as the main operator console. It shall have powerful graphical user interface to the operators. The operator shall be able to completely operate the plant by typing commands/function key on the keyboard or by push button on control panel. All information required to operate the plant shall be shown on the screen. A printer shall be used to print out plant information. Symbols and colours specified in the international standard IEC 204 shall be used for display.
iii)
Screen display: The screen display shall include all metering, indication and annunciator information normally displayed on a typical power plant control panel. This shall include all metered data such as three phase generator volts and amps, generator watts, VARS, power factor, speed and frequency. This display shall also show generator stator and bearing temperatures, breaker status, line volts, line frequency, and kilowatt-hours. The time and date shall also be displayed with time to the minute. Screen data shall be updated promptly whenever actual data changes. Alarm and status information shall be updated within one second of actual changes. Analog data shall be updated within two seconds of a change. Calculated value such as temperature, watts, VARS, and power factor shall be updated within five seconds of an actual change. All DC analog readings on the screen display shall have configurable scale factors. All except speed shall have configurable labelling on the screen. The AC scaling shall be configurable by specifying WYE or DELTA and maximum AC voltage and current. Data shown on the display shall have the following minimum accuracies. AC Voltage 1% of full scale AC Current .1% of full scale Frequency .005 HZ DC Inputs .25% of full scale KW,KVAR, PF .25% of full scale Temperatures + .5 degrees C
Signature of Bidder
289
iv)
Annunciator display: A portion of the screen shall be dedicated for an annunciator. Alarms shall be displayed in order of occurrence with the oldest alarm at the top of the screen. The sequence of alarms shall be distinguishable if alarms are more than 1/60 th of a second apart. The display shall include space for a least 23 alarms. When 20 an alarm clears, the alarm below it shall move up to fill in the blank space keeping the sequence. No alarms shall be lost. Any alarms that do not fit on the screen shall be save until these is room. Alarms shall flash until the acknowledge key on the keyboard is presses. If the alarm is still on after it is acknowledged, it shall stop flashing but remain on the screen. If the alarm has cleared, it shall disappear from the screen when the acknowledge key is pressed. The annunciator shall display both alarms that are internally generated by the controller and alarms that are sensed external to the controller. The controller shall be capable of generating a contact closure (option) on selected alarms for use with a horn or telephone dialler.
v)
Control status display: The display shall include an indication of the status of the turbine i.e., starting, stopped, synchronizing, etc...
vi)
Automatic control status display: The display shall show the current automatic control mode, its set point, turbine nozzle opening limit, and any overriding control modes.
vii)
DT Keyboard: The keyboard shall be a standard keyboard with upper and lower cases, ten key numeric pad and at least ten function keys. The function keys shall be assigned important functions. The operator shall be able to start and stop the turbine from the keyboard using simple commands. The operator shall be able to enter set points via keyboard, select any one of automatic power control modes and select any one of reactive power control modes.
Signature of Bidder
290
viii)
External Interface Supervisory Controller shall have a number of protocol modules which shall provide connectivity to other devices including remote terminal units and programmable logic controllers.
ix)
Event Recording and Data Logging (a) Data logging Their shall be a provision for a data logging printer at the plant to provide data logging at adjustable intervals, trouble logs and operator comments entered manually at the keyboard. The data logging interval for each printers shall be adjustable by the operator in increments of one minute.
(b) Alarm and status logging All alarms annunciated on the screen shall be recorded on the data log, timetagged to 1/60 of a second resolution. Plant status or operational changes shall also be recorder on the data log, time-tagged to 1/60 of a second resolution. The operator shall be able to enter comments on the log manually through the keyboard.
(c) kWH logging Plant watthours shall be accumulated and recorded on the data log at both daily and monthly intervals. The integrated power generation controller shall have the capability to accumulate these data by one of two methods: internally, by a calculation method based on direct monitoring of generator CT and PT inputs, or externally, by receiving and totalizing counts from pulse initiator output from an external watthour meter.
9.7
UNIT CONTROL BOARD (UCB) Unit Control Board shall be installed in Control Room. Controls, Indications, Alarms etc. required on UCB are given below : 1. All control switches required for manual operation shall be mounted on this board. The following controls will be provided: Switches Emergency push button (mechanical).
Signature of Bidder
291
Generator anti-condensation heater ON & OFF switch. Panel heater ON and OFF switch. Alarm acknowledges push button. Healthy trip circuit test push button. Reset push button. Servomotor opening/ closing switches Breaker ON/OFF push buttons. Voltage raise/lower spring return switch. Any other control as deemed fit. 2. Following control switches for Auto operation of plant shall be provided on UCB a) b) c) Unit Start/Stop Auto Manual Emergency Stop
3. Three annunciation windows shall be provided. a) Operation indication window b) 30 window annunciator for Electrical fault c) 30 window annunciator for Mechanical fault 4. Digital clock for indication of time 5. Digital type temp. scanner (0-150oc) with selector switch for temperature indication of selective equipments of power plant such as stator, rotor, bearing etc. shall be provided. 6. Following meters shall be provided. - Nozzle opening Limiter Position Indicator (0-100%) Nozzle opening Position Indicator (0-100%) Runner Limiter Position Indicator (0-100%) Runner Position Indicator (0-100%) Generator Voltage Meter with Selector Switch (0-20 kV) Generator Current Meter with Selector Switch (0-1kA) Generator MW meter (MW-0-20 MW) Generator MVAR Meter Generator Power Factor Meter (0.9 over excited ....1.0 ...0.9 underexcited).
Signature of Bidder
292
Frequency Meter 45-55 Hz Field Voltage Meter 0-500 V Field Current Meter 0-200A Turbine Speed Indicator 0 to 500 rpm Speed/Load Setting Indicator. Running Hour Meter (Hours)
Indication Lamps The following indications will be provided on the control panel: Phase indication lamps on incoming and outgoing panels Unit circuit breaker on Unit circuit breaker off Auto trip-electrical fault Auto trip-mechanical fault Governor low oil pressure Healthy trip circuit DC supply fail Generator anti-condensation heater ON Any other indication as required 7. Dual channel AUTO/MANUAL Synchronizer shall be provided. Auto synchroniser shall consist of following modules :PHASE DETECTION MODULE : This module shall detect the phase difference between generator and grid voltage. Output of the module shall be a pulse train whose width shall vary as the phase difference. FREQUENCY DIFFERENCE MEASUREMENT MODULE : This shall measure the frequency difference between the generator and grid voltage in the frequency difference of 0.01Hz to 1.00 Hz. POLARITY MODULE : This module shall compare the frequency difference obtained with the set value. (The set value is the one which is set on the front plate of the module) The module shall then generate control signals for frequency matching. VOLTAGE DIFFERENCE MEASUREMENT MODULE : This shall measure the voltage difference between the generator voltage and grid voltage and generate control signals for voltage matching.
Signature of Bidder
293
VOLTAGE COMMAND MODULE: This shall issue final command to AVR for raising or lowering the generator voltage depending upon the measured condition. Interposing relays shall be provided for this purpose. FREQUENCY COMMAND MODULE : This shall issue the final command to the E.H.G for lowering or raising the generator frequency depending on the measured condition. Interposing relays shall be provided for this purpose. BREAKER COMMAND MODULE : After the voltage and frequency are matched this module shall issue the closing command to the breaker. It shall also take into account the breaker closing time which can be set on the front plate of the module. AUTOMATIC POWER OFF MODULE : After synchronisation, the feed back is received in this module which shall switch off the auto synchroniser. POWER SUPPLY MODULE: This module shall accept the input voltage of 230V A.C. and generate necessary voltage required for functioning of auto synchroniser. Synchronising Bracket The synchronizing bracket will be mounted on left hand side of the panel and shall be of swinging type and will have following provisions:
Quantity Description
1 Synchroscope 1 Double voltmeter 1 Double frequency meter 1 Synchronising check relay (25) with guard relay 1 Synchronising selector switch 1 set Auxiliary relays 1 Synchronising lamp
Signature of Bidder
294
9.8
FACTORY TESTING 9.8.1 Equipment Tests Each individual equipment shall be routine tested as per IEC/IS at the works of supplier in presence of Owner.
9.8.2 System Tests The contractor shall organize and execute a complete factory test of the system. The system shall be erected in his workshop in the engineered configuration and shall be tested for the following: i. Operation requirements ii. Operating characteristics iii. Response times iv. Software functions v. Deficiencies Various process signals shall be simulated for carrying out above system tests. The Supplier shall submit routine test reports of each equipment and the total system.
9.9
SITE TESTING The contractor shall carryout tests at site as per relevant IEC/IS standards as follows in the presence of and to the entire satisfaction of the owner: i. ii. Calibration checks (on sample basis) on all factory calibrated meters and transducers. Acceptance tests on all other devices fitted on the control panels and earlier tested in factory. IR tests on panels. Continuing and IR tests on external cablings. Calibration checks/acceptance tests on all devices and equipment connected to the control panels. Functional checks on each equipment/object controlled from unit controllers with control circuits de-energised. Functional checks on controllers with power circuits de-energised.
iii. iv. v. vi.
vii.
Signature of Bidder
295
viii. ix. x.
Verification of all manual control functions from unit control panels. Verification of all control sequences from unit controllers with power and control circuits energised. Watch up each generating unit and perform all start/stop sequences on it.
9.10
SPARES Spares shall be supplied as per the list under Section - III of this volume.
Signature of Bidder
296
ANNEXURE
VIII - I
List of drawings, designs and manuals to be submitted by the Supplier after the award of contract. DRAWINGS, DESIGNS AND MANUALS TO BE FURNISHED AFTER AWARD OF CONTRACT.
Sr. No .
Brief description
within months Remarks from the date of award of
contract 1 1. 2 3 4 For approval
Circuit diagram/block diagram of all 6 SCADA system
2 3
Circuit diagram of various controls Circuit diagram of Unit control Board
For approval For approval
MANUALS. 1 1 2 Manual for storage, preservation handling of the supplied goods 2 Manual for erection / testing, setting and the supplied goods 3 Manual giving operating instructions 18 For reference dismantling, 12 For reference 3 and 12 4 For reference
commissioning of
for all the DOs and DONTs 4 Manual giving schedule 5 Manual for back up, loading software, data supplied system. detailed maintenance 18 For reference
Signature of Bidder
297
ANNEXURE VIII- 2 DEPARTURE FROM SPECIFICATION (To be filled by Bidder)
Item
Description of departure
Reference to Clause in specification
Signature of Bidder
298

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FOR AUTHORISED USE ONLY

BIDDING DOCUMENT NO. SEGEMC/KUMBHE/E & M/TGP/1/2010 FOR

SECTION- I INTENT OF THE SPECIFICATIONS

where Un means rated voltage of Turbine generator unit.

between 9000 kW to 11000 kW 220kV10% 47.5 Hz to 51.5 Hz

DRAWINGS AND DATA TO BE SUBMITTED WITH BID

Cross section of power station at turbine generator level .1:100

Cross section of power station showing station auxiliaries.

Power station Control room Layout

L section of power station at turbine generator level 1.100

Arrangement drawing of Spherical valve & matching piece. .1:20

Arrangement drawing of Distribution pipe, branch pipe. .1:20

LIFTING ARRANGEMENT DRAWING FOR Turbine runner and shaft,

Turbine housing, Spherical Valve Stator and Rotor Bearings

7. Requirement of AC Supply, voltage capacity etc.

SECTION II GENERAL REQUIREMENT

marked with the identification number corresponding

with that of the

Dry rotation tests (with clearance and run out checks)

Sr. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 2.25

IEC 193(1963) IEC 193A (1972)

IEC 502(1994) IEC 227

IEC 228(1978) IEC 228 A (1992)

IEC 287.1.2(1993) Part 1:

Correct rating equations (100% load factor) and

Part 2: Circuit breaker (This publication Supersedes IEC 157-1

Rotating electrical machines

34-1, 34-2A, 34-3, 34-4, 34-5,

SECTION III SCHEDULE OF REQUIREMENTS

1Set 1Set. 1 Set 1 Set. Lot

1 Set 1 Set 1 Set Lot

3.4.1 COMPRESSED AIR SYSTEM

1 Set 1 Set 1 Set 1 Set 1 Set 1 Set Lot 1 Set

1 Set 1 Set 1Set 1 Set 1 Set 1 Set 1 Set

1 Set 1 Set 1 Set

1 No. 68 Signature of Purchaser

One Set. One Set.

One Set. One Set

One No. One No.

One Set. One Lot

One Set One Set One Lot

One Lot: One Set: 3.7

Mulsifire system for generator Operation and maintenance tools

Lot Lot Lot

Lot Lot One Set One Set 3.8

One set One set Lot One Set 3.9

12. 13. 14. 15. 16. 17. 18. 19 20 21

Turbine and generator bearing, metal and oil temperatures alarm/shutdown.

(b) (c) (ii) (d)

Item No. 3.11.1 1

1 set 1 set 1 set 1 set set 1 set 1 set 1 set

Water flow relays for air coolers, bearings, etc.

1 set 1set 1 set set 1 No.

Uninterrupted Power supply in DVR

Description Converting measuring and supervision units for slips stabilization

Rotor angle limiter Rotor Current limiter Stator Current limiter

Item No. 3.11.3 2 3 3.11.4

11 kV JUNCTION BUS PANEL Flexible connectors Rubber bellows

Relay *Protective Relay *Auxiliary Relay

One(1) of each kind.

Fault, operation and symbol indicator assembly.

Lens for symbol Indicating LED & Lamp

Five (5) of each kind 100% of installed quantity

Relay Protective Relay Auxiliary Relay