Bhel Isg Spec

NMDC LIMITEDHYDERABAD

KUMARASWAMY IRON ORE PROJECT BELLARY DIST - KARNATAKA

TENDER DOCUMENT FOR

PACKAGE - II DOWNHILL CONVEYOR SYSTEM

VOLUME IV OF V

MECON LIMITED BANGALORE

MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD REV. 0

JANUARY 2010

NMDC LIMITED

MECON LIMITED

KUMARASWAMY IRON ORE PROJECT PACKAGE NO II VOLUME I of V Chapter No 1. 2. 3. 4. 5. 6. Description Check list Notice Inviting Tender (NIT) Instructions to Tenderers (ITT) General Conditions of Contract (GCC) Special Conditions of Contract (SCC) Erection Conditions Of Contract (ECC) DOWN HILL CONVEYOR SYSTEM CONTENTS

VOLUME II of V 1. Preamble, Summary of Prices, Price for exemptions / variations and Price Format

VOLUME III of V Chapter No A B C D E F G H I J K L M Description Brief on the Project and Intent Of Tender General technical conditions General site information Scope of work and battery limit Performance guarantee and warranty Surface preparation and painting Quality assurance, inspection and testing Construction, erection, testing and commissioning Engineering services Project management services Site services List of Tender Drawings Part/1 - Documents/ drawings to be submitted along with the tender Part/2 Questionnaire and design data sheets to be filled and submitted along with the tender

NMDC LIMITED

MECON LIMITED

KUMARASWAMY IRON ORE PROJECT PACKAGE NO II N O P Q1 Q2 DOWN HILL CONVEYOR SYSTEM

Documents /drawings to be submitted by successful Tenderer Spares, Special tools & Tackles List of Preferred makes of equipment Technical specification Mechanical Technical specification Environmental

Enclosures: 1. 2. 3. 4. Tender drawings as per the list under chapter-L Specimen QAP format for Structural & Mechanical equipment Specimen QAP format for Electrical equipment Specimen Inspection call format.

VOLUME IV of V Chapter No Q3 Q4 Q5 Description Technical specification Electrical Technical specification Automation and Control Technical specification Plant Communication System

VOLUME V of V Chapter No Q6 Q7 Q8 Q9 Description Technical specification Civil Technical specification Structural Technical specification Hydro Engineering

Technical specification Fire Detection and Suppression System for Down Hill Conveyor Q10 Technical specification General Layout, Roads and Fire Fighting Enclosures:- One Compact disc containing soft copy of the following: 1. 2.3.

Soft copy of Questionnaire and design data sheet Chapter-M (Part-2 of 2) Soil investigation report (for reference only) Waste Dump Locations - Sketch dated 14.09.07

NMDC LIMITED

MECON LIMITED

KUMARASWAMY IRON ORE PROJECTPACKAGE NO - II CHAPTER NO. Q3 VOLUME - IV of V PAGE No. 1 of 272

CHAPTER-Q3 ELECTRICALINDEXSl. No. 1.0 2.0 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13 2.14 2.15 3.0 4.0 5.0 Description SCOPE OF WORK EQUIPMENT SPECIFICATION 11kV & 6.6kV HT SWITCHGEAR & 11kV CICO OUTDOOR PANEL 11kV & 6.6kV HT CAPACITOR WITH SERIES REACTORS BATTERY, BATTERY CHARGER & D.C. DISTRIBUTION BOARD TRANSFORMERS VARIABLE VOLTAGE VARIABLE FREQUENCY DRIVES LT MOTORS LT SWITCHGEAR PANEL /LT PMCC /MCC CABLES (HT, LT & CONTROL) POWER DISTRIBUTION BOARDS / MAIN LIGHTING DISTRIBUTION BOARD AND SUB DISTRIBUTION BOARDS ILLUMINATION EQUIPMENT SPECIFICATION MISCELLANEOUS ELECTRICAL ITEMS EARTHING AND LIGHTNING PROTECTION OVERHEAD LINES (11kV ) EQUIPMENT SIZING & SELECTION APPLICABLE STANDARDS AND CODES ERECTION, TESTING & COMMISSIONING DRAWINGS AND DOCUMENTATION MAJOR EQUIPMENT LIST (INDICATIVE)

MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD 2010, MECON Limited. All rights reserved.

Rev. 0

NMDC LIMITED

MECON LIMITED

KUMARASWAMY IRON ORE PROJECTPACKAGE NO - II CHAPTER NO. Q3 1.0 1.1 SCOPE OF WORK GENERAL The scope of work includes but not limited to Design, Basic and detailed Engineering, Manufacture, Shop Testing, Inspection, Supply, Transportation to site, Unloading, Storage and Stores Management at site, Shifting of equipment / materials to erection site, erection, testing during erection, preliminary acceptance tests, liquidating defects after preliminary acceptance tests and commissioning, final acceptance tests, liquidating defects after final acceptance tests, performance guarantee tests, obtaining all permissions and approvals from statutory bodies (CEA, DGMS etc.), handing over of Power distribution , electrics, and illumination required for Down Hill Conveyor System. Battery Limits for Power supply Power supply shall be made available at the following two points: i. At DHC Tail End: Client's 6.6kV switchgear at 33/6.6kV substation near the Crushing Plant building. The Tenderer shall supply, lay & terminate 2 runs of 6.6 kV cables (Each rated for the full load of the plant, approximately 450 meters per run) directly in prepared cable trench and through Hume pipes at road crossings/ wherever required up to Tenderers 6.6kV switchgear inside the electrical building and terminate the cables at both ends. Further distribution of power to all the equipment in scope of this package, at all voltage levels, is also included in the scope. At DHC Head End: Tenderer scope shall starts from outgoing terminals of 11kV Outdoor Cable In Cable Out (CICO) panel at Donimalai 11kV switchyard. The tenderer scope also included the supply of 11kV CICO panel. From out going of CICO panel power supply shall be fed to 11kV DP structure-1 through cable which is nearer/ adjacent to the CICO panel. However, Incoming 11kV power supply and 110v DC Rev. 0 VOLUME - IV of V PAGE No. 2 of 272

ii.


NMDC LIMITED

MECON LIMITED


to the CICO panel shall be provided by client form existing substation. From the DP structure-1, 11 KV OH line will start which is 3 kilometer length. Double pole structures with all accessories shall be provided at both ends of the Overhead line. From the DP structure-2 (at TH3) power shall be fed to the tenderers 11kV switchgear through cable. The 11kV switchgear shall cater power to all motors, lighting loads, belt feeder, reversible conveyor, various facilities at Transfer House TH-3, and all downstream equipment covered under this package. The following substations shall be foreseen by the tenderer: i. At tail end of the DHC, tenderer shall plan a substation to accommodate 6.6kV HT switchgear, Distribution transformer, lighting transformers, VFDs, and other electrical equipment. At head end of the DHC two numbers of substation buildings (ie. One near TH5 and another near TH3) shall be provided. At substation near TH5,, 11kV HT switchgear, Distribution transformer, lighting transformers, VFD drive for reversible conveyor, etc shall be located. At substation near TH3, VFD panel for belt feeder (725) shall be provided in a separate AC room with other electrical equipment as per requirement.

ii.

1.2

The major equipment / services covered in this tender shall include but not limited to the following: Equipment at Downhill conveyor system tail end:

1.2.1

One number single incomer 6.6 kV Switchboard to cater to the 6.6 kV loads, 690V loads, 415V LT & Lighting loads (230V phase to phase) of the Down hill conveyor system tail end comprising of required feeders and spare feeders of minimum of one number for each type as per enclosed typical drawing. For protections of each feeders refer tender drawing no. MEC/01/Q6DH/KIOP/II/214/TS


Rev. 0

NMDC LIMITED

MECON LIMITED

KUMARASWAMY IRON ORE PROJECTPACKAGE NO - II CHAPTER NO. Q3 1.2.2 VOLUME - IV of V PAGE No. 4 of 272

HT capacitor banks with current limiting reactor, RVT, to ensure a power factor of not less than 0.95 at the tenderers 6.6kV incomer. SICAP construction (In a closed container) shall be considered. 110 VDC, 200AH (Minimum),, Plante' type Lead Acid battery bank, dual redundant Float Cum Boost Charger, DCDB for control supply to HT switchboard Transformers: 6.6/0.433 kV, required Distribution Transformer kVAR, 3 phase, ONAN,

1.2.3

1.2.4

6.6/0.72 kV, required kVAR, 3 phase, ONAN, converter duty transformer for Down hill regenerative conveyor. 6.6/0.230 kV, required transformer for lighting kVAR, 3 phase ONAN

Dry type Booster transformers to cater to welding power receptacles and lighting loads as required. 1.2.5 690V VVVF Drive (with Active Front end) for the downhill conveyor (723), & 415V VVVF Drive for the Belt feeder (720) 415 V, TPN, PMCC with bus sectionaliser to feed repair loads one side and all process related loads on other side, with required feeders including capacitor bank feeder. Rotor resistance boxes / control panel for Slip ring motors as required. HT, LT (energy efficient-eff2) motors & 690V Inverter duty motors Electrics for Belt feeders, EOT cranes, Hoists, magnetic separators and other equipment covered under this package. Local Control stations for drives and equipment for local control with indications, Junction boxes of different sizes (For Power, control, instrument, Lighting). Rev. 0

1.2.6

1.2.7 1.2.8 1.2.9

1.2.10


NMDC LIMITED

MECON LIMITED


In-line Magnet separator, Metal detector and control panel etc as required. Equipment at Head end side of Downhill conveyor:

1.2.12 1.2.13

One Number 11kV Outdoor CICO VCB panel (at Donimalai 11kV switchyard) One number 11 kV Switchboard (with single incomer) to cater to loads of the Down hill conveyor system head end, comprising of required feeders and spare feeders of minimum of one number for each type as per enclosed typical drawing. For protections refer tender MEC/01/Q6DH/KIOP/II/214/TS. drawing no.

1.2.14

HT capacitor banks with current limiting reactor, RVT, to ensure a power factor of not less than 0.95 at tenderers 11kV incomer. SICAP construction (In a closed container) shall be considered. 110 VDC, 200AH (Minimum), Plante' type Lead Acid battery bank, dual redundant Float Cum Boost Charger, DCDB for control supply to 11kV HT switchboard . Transformers: 11/0.433 kV, required Distribution Transformer kVAR, 3 phase, ONAN,

1.2.15

1.2.16

11/0.72 kV, required kVAR, 3 phase, ONAN, converter duty transformer for downhill regenerative conveyor. 11/0.230 kV, required transformer for lighting kVAR, 3 phase ONAN

Dry type Booster transformers to cater to welding power receptacles and lighting loads as required.

1.2.17

690V reversible regenerative VVVF Drive for the reversible conveyor (727) system & 415V VVVF Drive for the Belt feeder (725) Rev. 0


NMDC LIMITED

MECON LIMITED


1.2.18

11 kV over-head line with Squirrel ASCR conductors from Donimalai 11kV switchyard Double pole structure to Downhill conveyor head end near TH3. (Line length is 3.0 Kilometers). OH line shall include one number DP structure at both ends and minimum 2nos. cut off points shall be provided. DP structure-1 & 2 shall have horizontal GOS switch with earth-switch, Dropout fuses, Lightning arrestors, stay sets, earthing, earth pits, fencing etc as per specification. Secondhand rail poles (9 Meter long, 90lb/yard) shall be used for 11 kV OH lines. Minimum 13Mtrs long rail poles shall be used for DP structures & OH line road crossings. Earth conductor shall be run along with OH line. Earth conductor shall be provided on the top of the phase conductors (ie. Y type conductor spacing shall be planned for phase conductors) . Rail poles and bracings for OH line and DP structures shall be de-rusted and painted with two coats of red oxide followed by two coats of epoxy silver paint 415 V, TPN, PMCC with bus sectionaliser to feed repair loads one side and all process related loads on other side, with required feeders including capacitor bank feeder. Rotor resistance boxes / control panel for Slip ring motors as required. LT (energy efficient-eff2) motors and 690V Inverter duty Motors. Electrics for Belt feeders, EOT cranes, Hoists and other equipment covered under this package. Local Control stations for drives and equipment for local control with indications, Junction boxes of different

1.2.19

1.2.20 1.2.21 1.2.22 1.2.23

Other Items: Modifications to the existing tripper conveyor equipment 122 developing and hooking up all hardware /software at owners existing system / power & control cabling from/to owners existing system and at the system being provided under this package for smooth operation, effective control and monitoring of both systems in an integrated manner. MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD Rev. 0 2010, MECON Limited. All rights reserved. 1.2.24

NMDC LIMITED

MECON LIMITED


MCCB in shop floor for cranes / hoists and power supply arrangement (Shrouded Bus Bar Power supply system) to cranes / hoists. Complete mounted Electrics for cranes, hoists, etc. Main lighting distribution boards, Lighting distribution boards, Sub-distribution boards, etc. with suitable provision for switching ON/OFF from PLC in control room including necessary control wiring, push button station, indicating lamps etc. Lighting for 200 meters of every approach road to buildings and to conveyor Gallery coming under this package. Light fixtures, lamps, switches, sockets, ceiling fan, and sirens etc. Industrial type (for plant buildings) & Decorative type (Control room, VVVF drives rooms, non-plant buildings etc.). Portable, rechargeable emergency lights with converter/inverter to be considered for control rooms, transfer houses etc., Light fixtures as required for equipment lighting, focus/flood lighting for chutes, external lighting around the buildings, approach roads. Neon type Aviation obstruction lamps with photocell control for buildings more than 30m height, to cover the profile of the building. Monorail with manual hoist for panel lifting (If required) The following additional information may be noted and taken care about lighting. i. Lighting shall be carried out using High Pressure Sodium Vapor (HPSV) lamps, Metal Halide (MH) lamps, fluorescent tube light and compact fluorescent lamps depending on the mounting height / aesthetics Integral type control gearbox shall be considered for well glass fittings, High bay, Medium bay, Streetlight etc. Rev. 0

1.2.26

1.2.27 1.2.28

1.2.29

1.2.30

1.2.31

1.2.32 1.2.33

ii.


NMDC LIMITED

MECON LIMITED

KUMARASWAMY IRON ORE PROJECTPACKAGE NO - II CHAPTER NO. Q3 iii. VOLUME - IV of V PAGE No. 8 of 272

Timer and contactor control for streetlights, outdoor lights, and other area lights with suitable provision for switching ON/OFF from PLC in control room / PLC room along with provision to switch ON/OFF locally. 20% spare feeders / starters with at least one of each type and rating shall also be provided in PMCC / MCC / PDB / MLDB / LDB / SLDB / DCDB / other distribution boards Galvanized Flood light poles / street light poles including foundations and earthwork for buried pipes, cable trenches, earth pits etc. Surface wiring in GI conduits in Transfer Houses, Conveyor galleries, etc., and concealed PVC conduit wiring for office buildings, Electrical switchgear, control room etc. (civil buildings).

iv.

v.

vi.

1.2.34 1.2.35

63A TPNE, 32A TPN & 20A 1 phase power socket outlets as required. All required sizes of cable trays with cable tray supports, HT termination kits, cable accessories, cable duct, structural supports, road crossing pipes1000mm below road, lugs, glands, clamps, tags, route marker etc. Cable trays shall be laid horizontally only. Conveyor structural supports should not be used as cable tray supports. All interface hardware, software, power monitors / multifunction meters, control, communication & signaling cables etc., required for connecting I/Os from relevant incoming, power feeders, motor feeders of HT, MT & LT, LT switchgear/ MCCs, PDBs, LDBs field devices (whether explicitly specified in detail or not) required for: i. ii. Control and operation of plant including illumination in a safe manner in automated and other modes. Monitoring the status and parameters (ON, OFF, trip, voltage, current, frequency, MD, power, power factor etc), from the PLC in the central control room.

1.2.36

Addressable type Pull cord switches, Addressable type Belt sway switches, zero speed switches with contacts for MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD Rev. 0 2010, MECON Limited. All rights reserved.

1.2.37

NMDC LIMITED

MECON LIMITED


connections to PLC and for interlocking with drive with status display of each switch for conveyors at local and remote in PLC monitors. Pull cord switches shall be hardwired to switchgear also. 1.2.38 Limit switches, proximity switches, level switches / transmitters, pressure switches / transmitters, DP switches, speed sensors, encoders, Hooters / Bells etc. as required for the various equipment operation and safety. All Cables (HT, LT, power, control, Optical fiber cable, illumination, and other special cables, wires for illumination) supply laying and termination including accessories and consumables accessories (Viz HT Cable termination kits, Terminal / Junction boxes, double compression brass cable glands, crimping type lugs etc. as required for laying and termination of cable. Complete Earthing & Lightning protection system for the plant, buildings, equipment and electrical works carried out under the scope of this tender including. Air-lock room with airtight door arrangement shall be provided for control room & Air-condition rooms. Minimum 2 entry / exits should be provided for all Electrical / Switchgear rooms & control rooms. Ventilation systems for HT & LT switchgear rooms, Battery room, MCC room, Electrical rooms & cable cellars etc. with Pressurized ventilation system with Multiple TA Fans without duct. Exhaust fans ventilation for Battery room shall be provided. Air conditioning system for Control rooms and rooms where PLC, VVVF drive rooms & Shift in-charge room are installed. Wall mounted / pedestal fan shall also be provided for PLC control rooms / office rooms. Detailed specification for A/C and ventilation system are covered in chapter Q2 of this tender document Battery room shall be provided with acid resistant flooring, wall tiles and acid proof lighting fixtures/exhaust fans. Wash facility shall also be provided in battery room Rev. 0

1.2.39

1.2.40

1.2.41

1.2.42

1.2.43

1.2.44 1.2.45


NMDC LIMITED

MECON LIMITED


GI cable trays (ladder and perforated type) with coupler plates and electro-galvanised hardware etc. with painted supporting brackets and cable structures nylon cable ties, saddles, aluminium clamps, punched aluminium cable tags, route markers, cable tray separators, ferrules insulating tapes, sealing compound, etc., Mainly overhead cable laying shall be considered. GI pipes of different sizes as per site requirement for cable protection, for cable laying in ground / floor / through concrete etc. and cable entering / leaving buildings / rooms/ walls / floors, cable duct / structural supports / pipes 1000mm below road for road crossing. Fabricated steel structures, checkered plates, MS plates and Anchor fasteners for supporting/ mounting of electrical equipment viz. Cable trays, Panels / boards, light fixtures, local control stations etc. All structures shall be de-rusted and two coats of epoxy-based paint over one coat of primer shall be applied. Chequered plates of 6mm thick with stiffeners and collapsible handles shall be provided for closing floor cutouts after fixing the panels. Checkered plates shall be provided with one coat of primer and one coat of epoxy based paint of black colour. All accessories like branch/pull/junction boxes, cross arms brackets for supporting light fixtures, distribution board etc., saddle / clamps, single core cable and other miscellaneous items required for the completeness and efficient working of the system whether explicitly specified or not in this specification. RCC cable trenches / ducts with removable RCC cover wherever approved by the owner/consultant. Excavations of earth trenches and back filling (with bricks / concrete slabs over sand above and below cables, soil over bricks / concrete slabs etc.) only in special locations, as approved during detail engineering. Fire barriers / fire partition & pressure seals wherever cables enter /exit pressurized areas. Rev. 0

1.2.47

1.2.48

1.2.49

1.2.50

1.2.51

1.2.52


NMDC LIMITED

MECON LIMITED


Safety items for electrical systems such as fire extinguishers, safety charts, first aid box, hand gloves, fire buckets with stand, danger boards, rubber mats, Key boxes, Digital clock etc. Switchgear rooms & Control room furniture. Tools and Tackles. First fill of grease, lubricant, insulating oil, electrolyte etc. and other consumables necessary for commissioning and operation of the equipment. Any other requirement, whether specifically mentioned herein or not but required for completion of works and satisfactory performance of the plant is included in the scope The scope mentioned for instrumentation and automation and Plant communication system under different Chapters shall also be complementary to the scope mentioned herein Commissioning spares. 2 years operational spares as specified. Successful Tenderer shall have to arrange his own arrangement for construction power supply. SERVICES

1.2.54 1.2.55 1.2.56

1.2.57

1.2.58

1.2.59 1.2.60 1.2.61

1.2.62 1.2.63

Soil resistivity test shall be conducted by the successful tenderer. Co-ordination with all agencies for inspection of work / installation, pre-commissioning (no load / load) tests, integrated (no load /load) testing & commissioning, handing over, conducting PAT / FAT and liquidating defects etc. till handing over of the installations and performance guarantee. Documentation (preparation and submission in requisite copies of all drawings, test certificates, O & M manuals and any other drawings/documents required for the erection of the plant and installation). Rev. 0

1.2.64


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MECON LIMITED


Liaison with statutory bodies on behalf of the Owner and obtaining all necessary clearances / approvals including modifications to be carried out, if any, as per their specific requirement without commercial/contractual implications to the owner. Submission of all necessary documents and drawings, paying the required inspection fees (fees to be reimbursed by owner on production of receipts) and liaisoning with the statutory bodies for inspection of installation as and when required and make all arrangements for the same. Obtaining of approvals for drawings, prior permission to energize, all HT and other electrical installations from DGMS. STANDARDS, CODES AND REGULATIONS Design supply and installation of electrical system & equipment under this package shall conform to the requirements of latest revisions of IEC, Indian Standards, DGMS standards IE Rules, local rules and regulations. IE rules. IE Rule No.45, clause 1. No electrical installation work including additions, alterations, repairs and adjustments to existing installations, except such replacement of lamps, fans, fuses, switches, low voltage domestic appliances and fittings as in no way alters its capacity or character, shall be carried out upon the premises of or on behalf of any consumer/owner/ or occupier for the purpose of supply to such consumer, owner, except by an electrical contractor licensed in this behalf by the state government and under the direct supervision of a person holding a certificate of competency and by a person holding a permit | issued or recognized by the state government. IE Rule No.45, clause 2.No electrical installation work which has been carried out in contravention of clause (1.3.2) shall either be energized or connected to the works of any supplier. IE Rule No.63, clause 1.Before making an application to the inspector for permission to commence or re-commence supply after an installation has been disconnected for one Rev. 0

1.2.66

1.3 1.3.1

1.3.2

1.3.3

1.3.4


NMDC LIMITED

MECON LIMITED


year and above at high or extra high voltage to any person, the supplier shall ensure that the high or extra high voltage electric supply lines or apparatus belonging to him are placed in position properly joined and duly completed and examined. The supply of energy shall not be commenced by the suppliers unless and until the inspector is satisfied that the provisions of rules 65 and 69 (both inclusive) have been complied with and approval in writing of the inspector has been obtained by him. 1.3.5 All linemen, wiremen, electricians, supervisors and engineers engaged by the contractor or his sub-contractor shall posses valid license & the same shall be submitted for verification if called for. In view of the above, along with bid, the Tenderer shall furnish, the list of sub-contractors having valid electrical contractors license of appropriate category in Karnataka whom he proposes to engage for electrical erection / testing & commissioning and for obtaining statutory approval. VOLTAGE LEVELS 1 2 3 4 5 6 7 1.4.1 VVVF Drives : controlled motors Motors (DOL start : up to and including 160 kW) Control voltage : Control voltage (for : HT switchboard) Lighting fixtures : Small Power sockets : Welding switch : socket outlets 415 /690 Volts, 3 Ph (as per requirement) 415V +/- 10%, 50Hz +/5%, 3Ph, 4 wire AC 110V AC obtained through control transformers & protection device. 110V DC obtained by providing suitable batteries and battery charger 230V AC (phase to phase) 230V AC TPNE, 415V AC, 50 Hz

1.3.6

1.4

DC control, if required during detailed engineering, due to longer control cable lengths provided in place of AC controls. In this case provision of suitable control gear and rectifier units with protections / annunciations etc. in Switchgear / PMCC / MCC panel is also included in the Rev. 0


NMDC LIMITED

MECON LIMITED


scope. This aspect shall be kept in view while submitting the offer. 1.5 SUPPLY VOLTAGE VARIATIONS AND FAULT LEVEL a) POWER SUPPLY VARIATIONS Voltage level Voltage Variation Frequency Variation 5% 5% 5% 5% 10 %

230 V 10 % 415 V 10 % 6.6 kV 10 % 11kV 10 % Combined voltage and frequency variation b) FAULT LEVELS Voltage level 230 V 415 V 6.6 kV 11 kV System earthing 1.6

In KA 25 40 25 25 Resistance earthing on 6.6kV side Solid earthing on 11kV & 415V

CLIMATE CONDITIONS The climate of area is mild and pleasant during summer months and moderately cold during winter. Max. Ambient Temperature Min. Ambient temperature Rain fall Relative humidity Height above Mean sea level : 450C : 150C to 80C : 600mm to 800mm per annum during monsoon : 100% not occurring Simultaneously with maximum temperature : More than 1000M above MSL


Rev. 0

NMDC LIMITED

MECON LIMITED

KUMARASWAMY IRON ORE PROJECTPACKAGE NO - II CHAPTER NO. Q3 1.7 1.7.1 NOISE POLLUTION CONTROL Noise control measures shall be adopted to restrict noise levels in and around the plant. Maximum noise level tolerable in rooms & offices, work areas and within the plant boundary, have been specified herein. The equipment and the services shall be designed such that these levels are not exceeded. The maximum noise level guaranteed for each equipment and system with detailed description of noise control measures adopted. The maximum noise levels for rooms and offices must permit a good understanding of speech. Limiting exposure values of sound pressure levels for different areas are given below: Office/conference rooms Control rooms, Computer rooms Factory and shop area - General Where telephone conversation is Required - Plant boundary 1.7.4 : : : : : 65 dB (A) 55 dB (A) 85 dB (A) 65 dB (A) 65 dB (A) VOLUME - IV of V PAGE No. 15 of 272

1.7.2

1.7.3

The plant and machinery shall be designed such that the continuous exposure noise level of 85 dB (A) is not exceeded. Adequate numbers of suitable earplugs shall be supplied for operating people to approach the areas with higher noise levels. MAKE AND INTERCHANGEABILITY The makes of equipment shall be limited to preferred makes indicated in technical specification and such of those equipment for which preferred makes are not indicated, makes of such equipment shall be subject to prior approval by Owner / Consultant. Similar equipment and components shall be of same make. Equipment of same type and rating shall be interchangeable. Rev. 0

1.8 1.8.1

1.8.2


NMDC LIMITED

MECON LIMITED


All materials used and all equipment supplied shall be new and the best of their respective kinds and shall be of the class most suitable for the purpose for which they are intended. The quality of material and installations shall be to the highest standard of Indian and international practices. The decision of owner/consultant with in this regard is final and binding. When quality of work is not satisfactory in the opinion of consultant/owner, and when so directed the work shall be redone including supply of required equipment and material at no extra cost to the owner and without affecting the agreed milestones. MODE OF CONTROL FOR ILLUMINATION Conveyor gallery illumination (especially of long conveyors) is designed to provide graded levels of illumination so that either one in every three luminaries OR two in every three luminaries can be switched ON based on requirement. If required all the lights in the conveyor gallery can be made ON. For achieving this 2 Nos. four core power cables shall be laid from junction houses where corresponding LDBs are located and terminated / looped in junction boxes. For conveyor gallery lighting / Outdoor area and street lighting the LDB's, DBs and Feeder pillars shall have contactors for each of the incoming /outgoing circuits. Number of contactors shall be decided as per requirement of owner / consultant and shall also include internal wiring. However any other specific requirements will be finalized during detailed engineering / approval of drawings and the same shall be provided without any cost implications. The control from PLC shall also be done apart from local (panel / DB). Contactors on the incoming side of each LDB's / Feeder pillars shall be provided for switching ON / OFF the whole board and also for few feeders on outgoing side of the LDB's / SDIs, as desired by owner/consultant, to control the lighting of limited areas. Contactor coil shall be rated for 230V, tapped from the main busbars of LDB for switching ON from remote. ON /OFF controls from PLC shall also be done apart from local DB. Exact requirement shall be indicated at the time of approval of the drawings. ON Rev. 0

1.8.4

1.9 1.9.1

1.9.2


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MECON LIMITED


/OFF switches or pushbutton stations shall be located in the plant control rooms (if required). 1.9.3 Outdoor lighting (i.e. Street lighting, area lighting, peripheral lighting etc.) shall have provision for control of fitting in auto and manual modes. In auto mode the lights shall be switched ON by sensing natural light by adjustable photo cells with relay unit (Timers with relay are not acceptable) and the manual mode of operation shall be from near the board or from PLC monitor. INSCRIPTION All equipment shall be provided with indelible / permanent type inscription plates identifying the equipment as per approved drawing. All components, terminal blocks, relays, indicating lamps, control switches shall be provided with permanent inscription plates with inscriptions as per approved drawings. Identification plates of the equipment shall have letters of 15-mm size. 5 mm characters shall be used for panelmounted components. PAINTING Metal parts of all equipment shall be protected against corrosion. The sheet steel parts shall be cleaned by sand blasting (wherever required) and shall undergo rust removal by seven-tank process consisting of alkaline, degreasing, de-scaling, pickling and phosphating. Two final coats of epoxy spray painting shall be applied over two coats of primer. The colour of finished painting shall be as per the approval of owner/ consultant TYPES OF STARTER/ CONTROLS FOR DRIVES

1.10 1.10.1

1.10.2

1.11 1.11.1

1.11.2

1.12 1.12.1

The braking system and controls of the downhill conveyor shall be latest state of art technology so that the braking system takes care of all safety requirements and ensures no undue tension, lifting & slackening in the belt under varying conditions (normal / emergency) of loading pattern on the belt. This shall also ensure material stability on the belt (i.e. if the braking or starting is too rapid the material MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD Rev. 0 2010, MECON Limited. All rights reserved.

NMDC LIMITED

MECON LIMITED


doesnt avalanche Down the hill). The requirements specified in detail in mechanical equipment specification shall be considered. 1.12.2 1.12.3 Mechanical brakes shall also be provided for conveyors /crane / hoists, as required. DOL / RDOL starters shall be adopted for all other motors in the project as per the requirement. The motors envisaged are mainly squirrel cage motors. Energy efficient motors shall be used preferably for continuous running applications. Dust suppression system pump and the solenoids shall also be fed from the MCC. The solenoids shall be suitable for 240V DC. Pump shall be continuously working when the plant is in operation but when plant is not operating for some time the pump shall continue to run and re-circulate in tank automatically. If plant is stopped for long time then the system can be switched off. Atomized water spray shall work till the material presence is sensed by switch to be provided below the conveyor for that purpose or equipment is in operation. EQUIPMENT SPECIFICATION 11kV & 6.6kV HT switchgear & 11kV CICO Outdoor Panel DESIGN CRITERIA 11 & 6.6kV HT 11kV CICO switchgears (Outdoor) (Indoor) Fully compartmentalized metal clad horizontal draw out sheet steel enclosed conforming to IP4X (for indoor panel) & IP 55 with canopy (for Outdoor panel). Fully type tested as per IEC 62271.Inter compartmental partitions as per IP 2X or as per manufacturers standard practice Rev. 0

1.12.4

2.0 2.1 2.1.1 I) Cubicle

1. Type

:


NMDC LIMITED

MECON LIMITED


2. Thickness of sheet steel

(Minimum thickness) : 2.5 mm hot rolled sheet steel or as per manufacturers standard practice 2 mm cold rolled sheet steel as per manufacturers standard practice 6.6kV & 11kV, 11kV, 3 phase, 3 3 phase, 50 Hz, wire, 50Hz 3 Wire As per Requirement

a) Sides/bottom/partition between panelsb) Front & rear hinged door &

:

covers3. Rated voltage 4. Continuous rated current at 450C 5. Short circuit withstand capability of switchboard including busbars a) Short time rating b) Dynamic rating 6. Insulation level a) Impulse withstand value b) 1 min. PF withstand value 7. Busbars a) Material of busbars b) Temperature rise of busbars at rated current over 450Cambient c) Inter panel busbar chamber partition d) Busbar joints e) Insulation f) Phase identification g) Support insulators 8. Auxiliary connections 9. Safety shutters : :

: : : :

25 KA (RMS), 1 sec 63 KA peak 60 KVP for 6.6kV & 75 kVP for 11kV 20 KV (RMS) for 6.6kV & 28 kVP for 11kV Aluminium Alloy As per IEC Not applicable Zinc passivated bolts Encapsulation of Main & feeder Busbars joints to full insulation Colour tapes Non-hygroscopic, non-tracking, resin cast insulator. Silver-plated, 16A plug and socket with necessary interlocks. Automatically operated shutters with facility to lock the busbar and cable side shutters independently. Rev. 0 75 kVP 28 kV (RMS)

: : : : : : : : :


NMDC LIMITED

MECON LIMITED


10. Locking facility

:

Special door locking with Integral locking facility carriage position lock

key for

11. Accessories with each cubiclea) Panel illumination lamp with switch b) Space heater c) 3 pin power socket with switch d) Base channel e) Termination accessories : : : : : CFL To be provided in metering compartment 240V, AC, 50 Hz heater with thermostat & control switch To be provided Base channels as required shall be supplied as part of cubicle HT cable sealing kit, compression type brass cable glands and tinned copper lugs for HT power, LT power and control cables to be terminated in the panels. As Specified

f) Name plates, inscription plates for components, switches, feeder identification. g) Flexible copper connections between hinged doors and cubicle for earthing h) Breaker accessories visible and accessible from outside, with the cubicle door closed.

:

: :

To be provided Breaker position TEST/ SERVICE Breaker ON/OFF, spring charged Mechanical trip push button accessible from outside with panel door closed Mechanical close push button accessible only after opening the door To be provided as per manufacturers standard practice To be provided on front and rear To be provided

i) Removable welded wire mesh behind the panel j) Danger notice boards and instruction plates k) Breaker operation counter

: : :


Rev. 0

NMDC LIMITED

MECON LIMITED


l) Components to be mounted on the front door of cubicle

:

Push buttons, control & selector switches (operating height shall not exceed 1800 mm), lamps, meters, relays Bottom LT power, control, CT, D.C, A.C terminals shall be segregated and identified. CT terminal shall be CATD-m4 type Earthing trucks for bus earthing and cable earthing for each panel type with safety interlocks and audiovisual indication. IP4X Front ON/OFF/TRIP/Trip circuit Healthy, breaker test position, breaker service condition & Spring charged .All lamps to be LED type. Annunciation windows shall be considered for all feeders VAJHM23

m) Outgoing Entry for power and control cable n) Terminals

: :

o) Earthing trucks

:

p) Enclosure q) Indicating lamps

: :

r) Annunciator

:

s) Master trip relay : 12. Operational clearances a) In front for withdrawal of : To be indicated by Tenderer truck b) At the back of the panel : To be indicated by Tenderer 13. Minimum safety clearances in : air a) Between phases in mm : as per IEC as per IEC b) Between phase & earth in : as per IEC as per IEC mm 14. Control Schemes : As per approved drawings II) Breaker for I/C, Transformers & capacitor feeders/Vacuum contactor with fuse for 6.6kV motor feeders (if required) 1. System : 6.6 kV & 11kV 50 Hz, 3 phase 3 wire 2. Highest system voltage : 7.2 KV for 6.6kV & 12kV for 11kV

3. Design ambient : 450C MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD 2010, MECON Limited. All rights reserved.

Rev. 0

NMDC LIMITED

MECON LIMITED


4. Ratings a) Rated current in IP4X enclosure at 450C ambient b) Symmetrical breaking capacity c) Making capacity & dynamic stability rating d) Short time current rating

: : : : : : : : : : : : : : : : :

As per Requirement 25 KA (RMS) for VCBs 63 KA peak for VCBs 25 KA (RMS), 1 sec for VCBs 20 KV (RMS) 28kV (RMS) for 6.6kV & 28 kVP for 11kV 60 KVP for 75 kVP 6.6kV & 75 kVP for 11kV Auto re-closure duty not required Less than 5 cycles Shall be re-strike free Vacuum 1.3 Spring charged stored energymanual independent closing Manual and motor drive 110 V DC 80-110% of rated voltage 110 V DC 80-110% of rated voltage Both AC and DC to be provided DC trip coil AC trip coil 110 V DC 240 V AC 70-110% of rated voltage One One 8 No + 8 NC (Silver plated contacts) 10A at 240 V AC 4A at 110 / 220 V DC Rev. 0

5. Insulation levela) One min. P.F withstand value KV RMS b) 1.2/50 microsecond impulse withstand value KV (peak) 6. Operating duty 7. Total break time 8. Critical current 9. Arc extinction medium 10. First pole to clear factor 11. Operating mechanism a) Type of closing b) Method of closing c) Spring charging motor 1) Rated voltage 2) Operating voltage range d) Closing Coil 1) Rated voltage 2) Operating voltage range e) Shunt trip coil 1) Rated voltage 2) Operating voltage range 12. No. of poles/ phase 13. No. of breaks / pole 14. Auxiliary contacts 15. Rating of auxiliary contacts

: : : : : :


NMDC LIMITED

MECON LIMITED


16. Wiring of auxiliary contacts

:

All auxiliary contacts shall be wired contacts to terminal block, external to draw out truck Without opening the door Silver plated copper moving contacts, contacts with selfaligning feature having sufficient contact pressure. IEC- 62271 To be provided for Motor feeders, capacitor feeders & dry type transformer feeders to suit the insulation level of connected equipment. Resin cast, bar primary As per requirement (sizing calculations shall be submitted for approval) Same as for switchboard Same as for switchboard Same as for switchboard Same as for switchboard IS 2705, 1992 Resin cast, natural air cooled, enclosed in cubicle 6.6KV/11kV/0.110 KV / 0.110KV 3 3 3 1 phase, star/ star/ star 50VA each Class 1.0 core for metering and class 3P for protection

17. Test, service position of breaker 18. Material of fixed & moving contacts

: :

19. Breaker fully type tested as per. 20. Surge diverters in case of VCBs / Vacuum Contactors

: :

III) Current transformer 1. Type 2. Ratio, burden, accuracy class cores 3. a) Short time rating b) Dynamic stability current 4. Insulation level a) Impulse withstand voltage b) PF withstand voltage 5. Applicable standard IV) Potential transformers 1. Type 2. Ratio 3. Connection 4. Rated burden

: : : : : : : : : : :


Rev. 0

NMDC LIMITED

MECON LIMITED


5. Voltage factor

:

1.1 Continuous & 1.9 for 8 hours for noneffectively earthed system

1.2 Continuous & 1.5 for 30 seconds for effectively earthed system

6. Neutrals 7. Insulation level a) Impulse withstand voltage & peak b) PF withstand voltage KV (RMS) 8. Protection a) HV side b) LV side 9. Mounting of BUS PT Line PT 10. Applicable standard V) Metering System A) Indicating Meters 1. Type of meters 2. Type of movement 3. Size 4. Dial finish 5. 6. 7. 8. 9. Mounting Accuracy class Voltage / current Range Applicable standard

:

Neutrals to be brought out for earthing on HV & LV side Same as switchboard Same as switchboard

: :

: : :

HRC fuse for each phase MCB with auxiliary contact N.A. part of incomer N.A. Separate draw cubicle side out

:

IS: 3156 1992

: : : : : : : : :

Ammeters, voltmeters, PF meter, frequency meter, watt meter with MDI Taut band 144 sq for I/C, 144 sq. mm 96 sq for O/G feeders White painted dial with pointer type needle Flush mounting 1.0 110 V PT, 1A CT sec. current As specified IS: 1248-2003 Rev. 0


NMDC LIMITED

MECON LIMITED


B) Integrating meters 1. Type

:

2. Features

:

3. Accuracy class 4. Coil rating a) Current b) Voltage 5. Mounting VI) Auxiliary equipment 1. Protection relays 2. Control switches

: : : :

Microprocessor based metering system to read phase & line voltages, line currents, 3 phase MW, MVAR, MVA, MWH, MVARH, MVAH, Max. demand in MW, MVA & MVAR with adjustable integrating period Metering system shall also have Max. demand controller, a serial port (RS 485) for connecting the metering to PLC system. The system shall be supplied with interconnecting cable, terminal accessories, software for data logging & management. 0.5 1A CT sec 110 V AC, PT sec. Flush mounting

: :

Numerical protection relays with adequate binary I/Os. 16A, 440 V AC 10A, 110 V DC Quick make, quick break, flush mounted, stay-put/ spring return, IS: 13947 2A, 110 V DC 10A, 440 V AC 1 No +1 NC Flush mounted, IS: 13947 LED type suitable for flush mounting. Assembly for bulb is from the front. By MCBs

3. Push buttons

:

4. Indicating lamps

:

5. Control circuit protection

:


Rev. 0

NMDC LIMITED

MECON LIMITED

KUMARASWAMY IRON ORE PROJECTPACKAGE NO - II CHAPTER NO. Q3 2.1.2 2.1.2.1 VOLUME - IV of V PAGE No. 26 TECHNICAL SPECIFICATION for both 11kV, 6.6kV boards & Outdoor CICO panel GENERAL The switchgear shall comply with list of applicable codes and standards and enclosed specification and drawings. The switchgear shall be factory assembled and fully type tested as per IEC . 2.1.2.2 2.1.2.2.1 TYPE OF GEAR The switchgear shall be metal clad, dead front, air insulated, natural air cooled, fully compartmentalized, fully draw-out, self standing indoor cubicle conforming to IP4X for 6.6kV & 11kV panels and IP 55 with canopy for 11kV CICO panel. Each cubicle shall be constructed on unit principle. Each switchboard shall comprise of number of cubicles forming a single continuous board. It shall be possible to perform all switching operations with door closed. Interlocks required for safe switching, operation and maintenance shall be provided. Wherever possible, mechanical interlocks shall be provided in addition to electrical interlocks. CUBICLE Each cubicle shall be fully compartmentalized with metallic partitions having separate chambers for main busbars, CTs and cable terminations, switching device, LV chamber for metering, protection and control equipment. The metallic partitions shall be earthed and compartments thus formed shall be dust and vermin proof. This state of the compartments shall be maintained while switching device is in service position. Pressure relief flaps, which cannot be opened from outside shall be provided to vent upwards in case of arcing faults inside the cubicle. To ensure personnel safety, the following conditions shall be met for internal arcing faults: i. ii. Correctly secured doors, covers etc., must not open. Parts, which may cause hazard to personnel, must not fly-off. Rev. 0 of 272

2.1.2.2.2

2.1.2.3 2.1.2.3.1

2.1.2.3.2


NMDC LIMITED

MECON LIMITED

KUMARASWAMY IRON ORE PROJECTPACKAGE NO - II CHAPTER NO. Q3 iii. 2.1.2.3.3 VOLUME - IV of V PAGE No. 27 Earthing connections must remain effective. of 272

LV compartment, switching device & termination compartments shall be segregated from those of adjacent cubicles. Busbars chamber shall be provided preferably with seal-off bushings to segregate busbar chambers of adjacent panels. Lockable lift-off type front door shall be provided for switching device compartment. LV compartment shall have independent hinged door with locking facility. Rear side of cubicle shall be provided with hinged doors with locking provision. Inspection window of clear glass / polycarbonate shall be provided in cable termination chamber for viewing the cable termination. All mechanical indications of breaker truck / carriage positions, Breaker ON/OFF/ Trip conditions, spring charged/ discharged indications shall be freely visible from outside. Emergency trip push button shall be accessible from outside. The mechanical close pushbuttons for incomers and bus-coupler panels shall be rendered ineffective. All control switches, indication lamps, meters, protection and auxiliary relays shall be flush mounted on the swing panel of respective LV compartment. Height of operating handles of control switches, push buttons, reset rods of relays shall be less than 1800 mm from floor level of switchgear room. BUSBARS Busbars shall be made electrolytic grade Aluminium alloy. Maximum temperature of busbars including joints at rated current shall not exceed the limits specified in IEC 60694. Provision shall be made for taking up changes in length of busbars due to change in temperature. Short time thermal withstand capability and dynamic stability of busbars shall as applicable to the switchboard.

2.1.2.3.4

2.1.2.3.5

2.1.2.3.6

2.1.2.3.7

2.1.2.4 2.1.2.4.1


Rev. 0

NMDC LIMITED

MECON LIMITED

KUMARASWAMY IRON ORE PROJECTPACKAGE NO - II CHAPTER NO. Q3 2.1.2.4.2 VOLUME - IV of V PAGE No. 28 of 272

Bus bar cross-section shall be selected based on the temperature rise indicated. Main busbars shall have same cross sectional area throughout its length and feeder busbars shall be rated corresponding to breaker rating. Main & feeder busbars shall be fully insulated and busbar joints shall be provided with removable insulation shrouds. Entire bus work, CTs shall be supported on resin cast insulators of adequate creepage distance. CIRCUIT BREAKER/ CONTACTOR WITH FUSES The circuit breaker shall be three pole vacuum break, horizontal draw-out type with stored energy, spring charged operating mechanism. The circuit breaker design shall ensure re-strike free operation and have very low value of chopping current under all switching duties. Switching surge voltages while switching ON or OFF of low inductive currents, locked motor currents, capacitor currents etc. shall not exceed 2.5 PU (Max.). In case switching voltage is more than 2.5 PU, the value shall be indicated in the offer. In case of possibility of high transient voltage, more than 2.5 PU, metal oxide, gapless surge arrestors shall be provided. The breaker with its operating mechanism and surge arrestors shall be suitable for high frequency of operation (switching On and OFF) and shall be able to operate reliably with a long period of interval between maintenance. Further the surge arrestors shall be provided with pressure relief vents preferably. Provision of mechanical indication for the arrestors failure is preferred. The air clearance between phases and between phase to earth shall be adequate to meet the dielectric strength requirements/BIL specified.. Breakers of same rating shall be identical and interchangeable at site. Parts of the breaker required for maintenance, inspection or replacement shall be easily accessible. Surge arrestor should be provided for capacitor feeders & Dry transformer feeders. Rev. 0

2.1.2.4.3

2.1.2.5 2.1.2.5.1

2.1.2.5.2

2.1.2.5.3

2.1.2.5.4

2.1.2.5.5


NMDC LIMITED

MECON LIMITED

KUMARASWAMY IRON ORE PROJECTPACKAGE NO - II CHAPTER NO. Q3 2.1.2.5.6 2.1.2.6 2.1.2.6.1 VOLUME - IV of V PAGE No. 29 AC & DC trip circuit supervision relay shall be considered Operating mechanism All circuit breakers shall be provided with motor operated stored energy, manual independent closing and shunt trip mechanism with built in anti-pumping feature and trip free operating mechanism conforming to IEC. The shunt trip and closing coil and spring charging motor shall be suitable for AC or DC control supply indicated in design criteria. In case of circuit breakers serving as motor feeders or substation incoming and bus coupler feeders, both AC & DC shunt trip coils shall be provided. In case of circuit breakers with more than one operating spring, they shall be so interlocked that the springs are charged to the same extent and the breaker can be closed only if all the springs are charged to the required values. In the event of manual charging of springs, means shall be provided through a limit switch in the operating mechanism to cut off the electrical circuit of spring charging motor on insertion of the operating lever. In order to ensure the reliability and long operating life for the mechanism, the mechanism shall be light, with a high mechanical strength and abrasion resistance to avoid high rate of wear and tear and with few components. The number of components in the breaker and operating mechanism shall be kept to a minimum and they shall be designed to be free of undue stresses during normal or short circuit operations. Further they shall ensure a high frequency of operations indicated in technical particulars. All the moving parts of the mechanism requiring inspection, maintenance and lubrication shall be easily accessible. The life of the operating mechanism shall not be less than 30, 000 operations in case of vacuum breakers. Trip coil shall operate satisfactorily between 70% and 110% of rated voltage while closing coil and spring charging motor shall operate satisfactorily between 80% and 110% of rated voltage. Rev. 0 of 272

2.1.2.6.2

2.1.2.6.3

2.1.2.6.4

2.1.2.6.5

2.1.2.6.6 2.1.2.6.7


NMDC LIMITED

MECON LIMITED


The closing and tripping circuits shall be self-opening on completion of their respective functions, irrespective of position of the breaker ON/OFF switch. Mechanical breaker ON/OFF and spring charged indication shall be provided positively coupled to the operating mechanism and visible from the front with cubicle door closed. Each breaker shall be provided with mechanical trip push button, accessible with door closed. Auxiliary contacts Each circuit breaker shall have required number of auxiliary contacts to control circuit changes for indication, protection, interlocking, supervision, metering and others. All auxiliary contacts shall be positively operated by the main apparatus and all contacts shall be adequate to make, carry and interrupt the currents in their circuits. Minimum of 4 NO + 4NC auxiliary contacts shall be available for owners exclusive use at site. Multiplication of breaker auxiliary contacts shall be avoided. However in case of necessity, electrically reset latched relays shall be used. Further these contacts shall be available in both test and service positions. i. ii. iii. iv. v. vi. Breaker auxiliary contacts available in test and service position and those available in service position only shall be clearly indicated. Normally open and normally closed contacts shall be interchangeable at site. All the contacts for customers use shall be wired up to the terminal block. Advance and retard contacts as required by the control circuits shall be provided. Contact sequence diagram shall be provided. Interlock with door limit switch shall be provided to ensure that the breaker cannot be closed in Service. Additional Breaker aux. contacts as scheme requirement shall be multiplied by using mechanically latched electrically reset type relay only. Rev. 0

2.1.2.6.9

2.1.2.6.10 2.1.2.7 2.1.2.7.1

2.1.2.7.2

2.1.2.7.3


NMDC LIMITED

MECON LIMITED


2.1.2.7.4

A readily identifiable mechanical emergency trip device as well as provision for manual charging of springs through the cubicle door shall be provided for each breaker. Breaker truck/ carriage The circuit breaker with its control units, operating mechanism, isolating and interlocking gears, auxiliary switches, isolating contacts and wiring shall be carried on a horizontally with-drawable, sheet steel, dead front truck / carriage on wheels / guide channels. The truck / carriage shall be provided with handles for maneuvering the breaker into position. All Circuit breaker trucks / carriages of same rating shall be identical in all respects and shall be interchangeable at site. The circuit breaker truck / carriage shall have three clear position viz. the service position where the control and power terminals of the circuit breaker are engaged; the test position, where the power terminals of the circuit breaker are isolated, while the control terminals remain engaged; maintenance position where both power and control terminals of the circuit breaker are isolated. The service and test position of the circuit breaker shall be within the cubicle and it should be possible to keep the door closed, with the breaker truck. Carriage in either test or service position. However the maintenance position can be with door open. The truck movement inside the cubicle shall be within guide ways, on metal / nylon roller and the movement of the truck shall be smooth and reasonably effortless. At the end of the travel i.e. in service position or in test position it shall be ensured that the breaker terminals engage positively. Further, mechanical indications shall be provided to be visible from the front of cubicle door for the position of the truck / carriage. The truck / carriage shall be provided with locking arrangement for locking them in either test or service position, to prevent movement due to short circuit forces. Rev. 0

2.1.2.8 2.1.2.8.1

2.1.2.8.2

2.1.2.8.3

2.1.2.8.4

2.1.2.8.5


NMDC LIMITED

MECON LIMITED


Spring loaded, sliding earth terminals shall be provided on both sides of the truck/ carriage, making positive connection with the earth strip provided with cubicle to ensure that all non conducting metal parts are securely earthed before moving the breaker truck / carriage to test and service positions. The location of the earth terminal shall be such that, it should be first to make and last to break to ensure personal safety. All the non-conducting metals parts shall be bonded together and connected to the earth terminal by means of a separate connection. Bolted connections of the framework of the truck / carriage shall not be used as earth continuity conductors. Interlocks Mechanical interlocks shall be provided on each truck/ carriage to prevent mal-operation and in particular to ensure that: i. ii. The truck cannot be moved in or out of its cubicle with the circuit breaker closed. The circuit breaker can only be closed when the truck is in one of the positions i.e. the service position, a definitely located test position or fully out of the cubicle in the maintenance position. The necessary contacts for the same shall be provided on the truck / carriage at these locations. The truck cannot be pushed to service position, if either set of safety shutters is not free and not in its normal closed position. The truck cannot be pushed to service position without making the connections of control isolating contacts. In case of plug and socket connections for isolating contacts, it shall be ensured that the correct sequence of connections is maintained.

2.1.2.9 2.1.2.9.1

iii. iv. v.

2.1.2.10 2.1.2.10.1

Isolating contacts and shutters Power isolating contact assembly shall have self-aligning silver faced contacts with replaceable fingers or equivalent construction. The moving contact shall engage with the fixed contacts through opening in the bus bar and current transformer chambers. Each opening shall be covered by Rev. 0


NMDC LIMITED

MECON LIMITED


vermin proof spring-loaded automatic safety shutters. With the safety shutter closed, it shall not be possible to introduce even small tools such as screwdrivers and complete protection shall be offered against accidental contact with live terminal, in line with protection class of enclosure specified in the design criteria. 2.1.2.10.2 Independently operable, bus bar and cable end shutters shall be provided, operated by the movement of the truck/ carriage, so that when the breaker truck is moved out of service position, the shutters shall enclose the live terminals to prevent inadvertent access to these terminals. The shutters shall be provided with independent locking arrangement. The shutters shall preferably be of transparent polycarbonate material to enable visual inspection of bus bar terminals and finger contacts with the shutters closed. Shutters shall be positively operated by the travel of the truck/ carriage, each shutter independently of the other. Bus bar shutters shall be labeled to distinguish them from feeder shutters and both shutters shall be independently lockable in the closed position. Auxiliary control connections The wiring on each truck/ carriage shall be connected to the wiring on its cubicle by means of plug and socket connections or by means of spring loaded sliding finger contacts. In case of plug and socket arrangement interlock shall be provided so that plug is removed before the breaker is withdrawn to maintenance position and breaker cannot be moved into service position without inserting the plug into the socket. Further there shall be an interlock to prevent improper connections. In case of finger contact arrangement, perfect alignment of male and female contacts shall be ensured and the contacts shall be of high conductivity, electrical grade copper with silver facing. Clear distinction shall be made between the Rev. 0

2.1.2.10.3

2.1.2.10.4 2.1.2.10.5

2.1.2.11 2.1.2.11.1

2.1.2.11.2

2.1.2.11.3


NMDC LIMITED

MECON LIMITED


contacts, those available in test and service position and those available in service position only. 2.1.2.12 2.1.2.12.1 Cable Termination The cubicle shall be suitable for terminating cables or bus trunkings as specified. Sufficient space and support arrangements shall be provided for terminating specified number of power cables with bottom entry as specified. If the required number of cable terminations cannot be accommodated in the respective cubicle, additional dummy panel with necessary bus-work shall be provided. Required no. of compression type cable glands and tinned copper lugs shall be provided. Where cable terminations are specified, HT cable sealing kits shall form part of cubicle. Where core balance types CTs are specified, the same shall also be enclosed inside the cubicle. Blank G.I plates, gasketed and bolted to the cubicle, for glanding and terminating low voltage control and power cables shall be provided. Compression type brass cable glands shall be supplied for LT cables and control cables of specified type and size. Heavy duty tinned copper lugs of crimping type shall be provided. INSTRUMENT TRANSFORMERS Current transformers The instrument and protection transformers shall be supplied as specified and shall have the ratings, outputs and accuracies as specified or required. The current transformers ratio specified are provisional and are subject to alteration and confirmation later. Where outputs and accuracies are not specified, these shall be such as may be required by the metering or protective circuit in which they are used. Separate cores shall be used for metering & protection.

2.1.2.12.2

2.1.2.12.3

2.1.3 2.1.3.1 2.1.3.1.1

2.1.3.1.2 2.1.3.1.3

All current transformers shall be designed to have over current factors to withstand the fault currents of the associated system as applicable to the switchboard. MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD Rev. 0 2010, MECON Limited. All rights reserved.

NMDC LIMITED

MECON LIMITED


Current transformers used for protection shall have an accuracy limit factor not less than 10. Those used for metering shall have a saturation factor 5. All current transformers shall have 1Amp. secondaries and shall be of the air insulated, plain ring type, encapsulated in thermal setting resin and with bar primary. All CTs shall be mounted in a separate chamber on the fixed portion of the cubicle, on the outgoing side of the circuit breakers, so that circuit breaker trucks of same rating and of different circuits having different C.T ratios are interchangeable. Polarity of primary and secondaries of all the CTs shall be clearly marked. Short time thermal rating & dynamic fault current withstand rating of CTs shall match with the switchboard rating. Voltage transformer (PT) Voltage transformers shall be built-up of CRGO electrical steel. The voltage transformers shall be resin cast dry type, mounted on draw-out trucks. The PTs shall be single phase or three-phase type as specified. When 3 phase PTs are offered they shall be star/ star/star or star/star/open delta type as specified, fully insulated with neutral points brought out for earthing on both sides. Basic features of draw-out truck/ carriage specified for breaker shall also applicable for draw-out truck of PT including safety shutters. HT side of PTs shall be protected by HRC fuses, mounted on draw-out truck. LT terminals shall be terminated on separate power terminal block located in the same panel. When PTs form part of non effectively earthed system, it shall have a voltage factor of 1.9 for 8 hours. Primary side neutral point shall be earthed through a removable link and one phase shall be earthed on the secondary side, through a removable link.

2.1.3.1.5

2.1.3.1.6 2.1.3.1.7 2.1.3.2 2.1.3.2.1

2.1.3.2.2

2.1.3.2.3

2.1.3.2.4 2.1.3.2.5


Rev. 0

NMDC LIMITED

MECON LIMITED


Where line PTs are specified, they shall be offered in independent cubicle in a draw-out truck unless agreed otherwise. ACCESSORIES Relays All relays specified shall be flush mounted in dust proof cases and shall match the appearance of the instruments mounted on the same panel. Each relay shall be identified with relay number indicated in the approved control schemes both on its case and on drawout part. Protective relays shall be of the easy with-drawable type. Trip circuits shall be automatically broken and current transformer secondary circuits shorted, when a relay is withdrawn from its case. A marking strip shall be provided in front of each terminal block and a diagram plate at the back of each case to identify connections. Relay contacts shall withstand repeated operation and shall make or break the maximum currents in their circuit without deterioration. All spare contacts shall also be wired upto external terminal blocks in the cubicle. Relay coils shall carry their normal currents, indefinitely and such currents as can occur under fault conditions. Relay mechanism shall not be affected by vibration or external magnetic fields, which may occur in normal operation. All relays in tripping circuits shall have mechanically operated flag indicators. Indicators, mechanical or electrical, shall also be provided on other relays to identify the type of fault that may have occurred. Indicators shall be capable of being reset without opening the relay case. It shall not be possible to operate the relay by hand or to alter is settling, without opening the case. All relays shall operate satisfactorily from 50 to 120% of rated voltage.

2.1.4 2.1.4.1 2.1.4.1.1

2.1.4.1.2

2.1.4.1.3

2.1.4.1.4

2.1.4.1.5


Rev. 0

NMDC LIMITED

MECON LIMITED

KUMARASWAMY IRON ORE PROJECTPACKAGE NO - II CHAPTER NO. Q3 2.1.4.2 2.1.4.2.1 Numerical Relays: General requirements Protection relays shall be fully type tested, of approved types and shall comply with the relevant IEC255 standards. Relays of numerical technology including monitoring and control shall be preferred. They shall be designed for flush mounting in relay panels or in the doors of the low voltage compartments of the switchgear units. The cases shall be dust and moisture proof to IP 51 according to IEC 529. The connection terminals shall be allocated at the case rear side and shall allow alternatively screw or crimp-snap-in connection. 2.1.4.2.2 The relays shall satisfy the following requirements: i. EMC: the relay shall be type-tested w.r.t. interference suppression, 1 MHz Burst disturbance, immunity to Electrostatic discharge, immunity to radiated electromagnetic energy, electrical fast transient or burst, current/voltage surge immunity, immunity to conducted disturbances induced by radio frequency fields, power frequency magnetic field immunity. The relay shall withstand one-minute power frequency voltage of 2 kV RMS and impulse voltage (1.2/50 micro second) of 6 kV. The relays shall be suitable for operation in a tropical climate and for the ambient temperature and humidity levels specified. Relays, whether mounted in panels or not, shall be provided with clearly inscribed labels describing their application and rating in addition to the general purpose labels. The protection measuring relays shall be numerical type. The analogue to digital converted measuring qualities shall be processed in microprocessor-based hardware units according to proven protection algorithms. VOLUME - IV of V PAGE No. 37 of 272

ii.

iii.

iv.


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MECON LIMITED

KUMARASWAMY IRON ORE PROJECTPACKAGE NO - II CHAPTER NO. Q3 v. VOLUME - IV of V PAGE No. 38 of 272

The sampling frequency shall not be less than 12 times rated power system frequency. Reliable shielding against electromagnetic interference shall be assisted by the following measures: a. b. c. d. e. Metal relay case Shielded input-transformers Opto-Coupled/ galvanically inputs DC/DC converter supply Relay outputs

isolated

binary

2.1.4.2.3 2.1.4.2.4

The complete relay shall be according to IEC255-22-1to 4. The relays shall have an integrated setting keypad and an alphanumeric display the setting shall be menu-guided and setting values shall be entered as numbers. The setting ranges shall be limited and checked for plausibility. Setting shall be possible on-line without restart of the microprocessor system. The setting values shall only be valid after a final code word cheek. The display shall normally indicate selectable load values, such as currents or voltages, and shall automatically change over to fault indications, such as faulted phase, tripping time, etc., when system faults occurs. The function assignment of binary inputs, relay outputs and indications shall be freely programmable. The functions shall be selectable from a library in the relay manual. It shall also be possible to build group alarms or group indications. It shall further be possible to store up to four setting groups in impedance and 11 over current relays. The required setting -group can be enabled by digital inputs. A lockable control switch must be provided for each circuit breaker allowing the auto re-closure to be switched on or off. Displays on the Relays The following important information must be displayed without operator action: i. Protection information disturbances. arising from network Rev. 0

2.1.4.2.5

2.1.4.2.6

2.1.4.2.7


NMDC LIMITED

MECON LIMITED

KUMARASWAMY IRON ORE PROJECTPACKAGE NO - II CHAPTER NO. Q3 ii. iii. 2.1.4.2.8 Information about internal possibly group indications. Status indications VOLUME - IV of V PAGE No. 39 faults and of 272

monitors,

These indications may be by LED or displays or a combination of both. Display shall be in English language and shall be textual. Protection information about network disturbances, internal faults and monitors shall be indicated with red LEDs. Ready for operation shall be indicated with green LEDS. Fresh optional shall be indicated with red LEDS. For graded protection (e.g. d.m.t. and i.d.m.t), run-time indication must be available. Range 0-approx. 6s with 10 ms resolution. Run-time indication must be started by the general pick-up signal and stopped by dropout. Protective relays must be designed as to show the last eight event. Information must be retained for 24 hours if the power supply fails and displayed when power is restored. Further, it shall be possible to display further information on request (e.g. fault impedance, fault current at instant of TRIP command, line values as primary values). The software version must be displayed on request. Contacts Potential free, freely assignable output contacts shall be provided. In addition, one dedicated output contact indicating relay healthiness shall be provided.

2.1.4.2.9

2.1.4.2.10

2.1.4.2.11

2.1.4.2.12

2.1.4.2.13

2.1.4.2.14

Remote interrogation via serial ports Provision must be available, which will allow information to be interrogated from serial ports (for off-line PC's and online central units). Scope of data dependent on protection type and application, e.g.: i. ii. System fault reporting Fault records (currents and voltages, time resolution 1 to 2 ms). Rev. 0


NMDC LIMITED

MECON LIMITED

KUMARASWAMY IRON ORE PROJECTPACKAGE NO - II CHAPTER NO. Q3 iii. iv. v. vi. 2.1.4.2.15 Status indications Relay monitor Line parameters. Setting values. VOLUME - IV of V PAGE No. 40 of 272

The protection relay shall also used for detection and storage of protection information and for fault record. In such a case the requirements are: i. Fault reporting data shall be stored for at least the last three events (three general start signals). The memory shall be arranged in a first-in, first-out manner. The memory capacity shall cover sequences up to 3 sec. in transmission systems and approx. 1.5 sec in sub transmission and distribution systems. Fault record must be started by the general pick-up signal and the preceding 100msec must also be recorded. When the memory is full, always the earliest record shall be erased. The relationship between protection information and analogue disturbance values must be definitive. For the use of numerical relays without a central unit, models must be available which correlate date and time to the protection functions. Time recording accuracy of 1 minute in 1 month is adequate. Date and time settings must be possible both via the serial port and keyboard on the relay. Power failure reserve of at least 24 hours is required.

ii.

iii.

iv. v.

2.1.4.3

External signal inputs The relays shall have required binary inputs to receive individual signals from other relays (e.g. a buchholz signal to a numeric relay) or from devices located in the field.


Rev. 0

NMDC LIMITED

MECON LIMITED

KUMARASWAMY IRON ORE PROJECTPACKAGE NO - II CHAPTER NO. Q3 2.1.4.3.1 Fault reporting Numerical relays shall be interrogated both from an integral keypad and from a serial port. 2.1.4.3.2 2.1.4.3.3 Operation from keypad Resetting indicators Resetting must be possible at the relay but must only affect the indications and not the memory content. The same applies for remote reset. For relays in individual housings, reset must be possible without opening the case. A reset button must be provided on the front of relays built into cabinets 2.1.4.3.4 Erasure of stored information in memory It must be possible to erase data stored in memory (e.g. after testing), but the method must be such that accidental erasure is prevented. 2.1.4.3.5 Selection of indications Selection of indications in the display must be possible, on the relay, and from remote. 2.1.4.3.6 Setting and interrogation i. For setting and interrogation of the set values, relays must have integral operating elements. These functions must be possible without reference to the handbook - menu guided or sufficient instructions on the relay. Inputs, which are outside the design range, must be rejected. Design must prevent accidental or careless alteration of set values. e.g. a password. Input of parameters must be in secondary values. VOLUME - IV of V PAGE No. 41 of 272

ii.

2.1.4.3.7

Serial Communication Interfaces i. It shall be possible via a serial port (RS 432), to set and interrogate relays, using an external device. Operation and setting of the various makes and Rev. 0


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types of relays must be possible with common PC hardware. Communication shall be based on approved standard. This serial port shall be located in relay front. ii. For integration into a numerical, co-ordinated protection and control system or a substation automation system, relays must be provided with an additional serial interface located at the back of the relay. Unless agreed otherwise, this port shall be RS 485 port; where specifically indicated a fibre optic interface shall be provided. Communication wise this port shall use approved protocol to suit the substation automation system envisaged.

2.1.4.3.8

Self-monitoring and failure annunciation. i. The protection systems must provide the best possible level of self-monitoring. Failure of the selfmonitoring function must be indicated and signaled. The occurrence of a failure (in hardware or software) shall not lead to nuisance trip of the relay. A separate, potential-free contact shall be provided for DC supply monitoring. The contact must be reset and the relay automatically made ready for service when the supply returns.

ii.

2.1.4.3.9

Auxiliary Power supply and battery i. Relays, which rely, for there operation, on an external DC supply shall be catered to from the station battery at 110V DC. The relay shall be suitable for a ripple content of 12% in the auxiliary source. DC/DC converters shall provide galvanic isolation between the internal static circuits and the external station battery. The relay shall be provided with an internal battery back up to ensure back up to the internal clock, switching statistics, fault/status record, values of parameters such as voltage/current/time at fault. The battery condition shall be monitored and a message shall be generated in case of weak battery. Rev. 0

ii.


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MECON LIMITED

KUMARASWAMY IRON ORE PROJECTPACKAGE NO - II CHAPTER NO. Q3 iii. VOLUME - IV of V PAGE No. 43 of 272

An integral DC voltage buffer shall ensure uninterrupted performance of the relay in case of DC voltage interruptions