CLIENT – TAMILNADU GENERATION & DISTRIBUTION CORPORATION LTD.

TB-400-553-124
Rev. 01
CONSULTANT- TATA CONSULTING ENGINEERS LIMITED BEGALURU
PROJECT: 2X660MW UDANGUDI STPP – (STAGE-1) Page | 1
TECHNICAL SPECIFICATION FOR VENTILATION SYSTEM

SECTION-1
INTENT, SYSTEM REQUIREMENT, DESIGN CRITERIA & SCOPE

1.0 INTENT OF SPECIFICATION

1.1 This specification covers the design, manufacture, inspection and testing at bidder's and/ or his sub
vendor’s work(s), proper packing, transportation & delivery, storage and handling at site, erection, testing
and commissioning, final painting and carrying out acceptance tests at site of Ventilation System as
detailed in this section and in various other sections of this specification for different rooms located inside
the 400KV Gas Insulated switchyard (GIS) control Building and GIS Hall of 2X660MW UDANGUDI STPP
– (Stage-1).

1.2 The requirement(s) specified under 'SECTION 2, SECTION 3, SECTION 4' and 'SECTION 5' of this
specification shall be considered as part of this section. In case of variance between sections, the
requirement of Section-1 shall prevail. Customer specification in annexure to section-2 shall be adhered
to by the bidder.

1.3 It is not the intent to specify herein all the details of design and manufacture. However, the equipment
shall conform in all respects to high standards of design, engineering and workmanship and shall be
capable of performing the required duties in a manner acceptable to Purchaser/ Owner, who will interpret
the meaning of drawings and specifications and shall be entitled to reject any work or material, which in
his judgment is not in full accordance herewith.

1.4 The bidder shall be deemed to have understood completely all the tender drawings and documents
and quoted accordingly.

1.5 The bidder has to note carefully the parameters, estimated capacities of equipment indicated and the
tender drawing in the specification are only for guidance of the bidder. The system shall be designed as
per relevant standards / codes and exact capacities and quantities are to be estimated by the bidder. All
such estimations and design calculations shall be submitted for Purchaser’s approval.

1.6 Deviation: In case of any deviation, the bidder shall indicate separately the deviations clause-wise
with respect to the specification in the ‘Schedule of Deviation’ given in schedule 1 of section-5. Deviations
in any other form including clarifications / assumptions / etc. will not be considered and it will be construed
that the bid conforms strictly to the specification.

1.7 The Contract shall be on Unit Rate basis for the quantities furnished by BHEL. The quantities
furnished in Price bid (BOQ) are as per preliminary design only. BHEL reserves the right for quantity
variation (upward/ downward) due to any reason upto ±30% of total contract value at same unit rate and
terms & conditions during execution of contract.

1.8 The Purchaser, Consultant and Customer in this specification stand for BHEL, TCE and TANGEDCO
respectively. The successful bidder shall be referred to as Contractor.

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 CLIENT – TAMILNADU GENERATION & DISTRIBUTION CORPORATION LTD. TB-400-553-124
Rev. 01
CONSULTANT- TATA CONSULTING ENGINEERS LIMITED BEGALURU
PROJECT: 2X660MW UDANGUDI STPP – (STAGE-1) Page | 2
TECHNICAL SPECIFICATION FOR VENTILATION SYSTEM

2.0 VENTILATION SYSTEM

This system shall be designed with the objective of providing Ventilation in different rooms located inside
the 400KV Gas Insulated switchyard (GIS) Control Building and GIS Hall of 2X660MW UDANGUDI
SUPERCRITICAL THERMAL POWER PROJECT STAGE-1.

2.1. CODES AND STANDARDS

The design, manufacture, inspection and testing of Ventilation system shall comply with all currently
applicable statutes, regulations and safety codes in the locality where the equipment is to be installed.
The equipment shall also conform to the latest applicable Indian/ British/American standards.

The equipment shall conform to the latest edition to the following standards:

IS: 659 - Safety Code for Air-Conditioning

IS: 655 - Specification of metal Air-Ducts
IS: 4999 (Part-51) - Noise Level
IS: 3588 - Specifications of Electrical Axial Flow Fans
IS: 2312 - Propeller type Ventilation fans
BS: 6540 Part I - Air Filters used in Air-Conditioning & General Ventilation
IS: 4671 - Expanded polystyrene for Thermal Insulation purpose
IS: 8183 - Bonded Mineral wool

2.2. SYSTEM DESCRIPTION

Design and Technical Requirement

Sl. Area Basis of Airflow rate: Equipment heat Illumination

No. Air changes per hour dissipation Load (kW) Heat load
01 Cable Vault 15 10 2 Watt per sq. ft.
02 LV Switchgear Room 15 15 or actual
03 Transformer Room 15 12 whichever is
04 GIS Hall 15 171 higher
05 Battery Room 30 7

Summary- Supply Air Ventilation System

Area to be ventilated Supply air system Exhaust air system

Cable Vault Wall mounted supply fans with pre filters Gravity dampers
LV Switchgear Room Wall mounted supply fans with pre filters Gravity dampers
Transformer Room Wall mounted supply fans with pre filters Gravity dampers
GIS Hall Centrifugal fan with pre filter and fine Gravity dampers.
filters along with ducting for supply air Exhaust fan (2x50% capacity) inter
system, exhaust by gravity dampers will linked with SF6 gas detector shall be
be provided for GIS building to maintain provided for emergency purpose.
positive pressure and to prevent ingress Capacity of exhaust fan shall be

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 CLIENT – TAMILNADU GENERATION & DISTRIBUTION CORPORATION LTD. TB-400-553-124
Rev. 01
CONSULTANT- TATA CONSULTING ENGINEERS LIMITED BEGALURU
PROJECT: 2X660MW UDANGUDI STPP – (STAGE-1) Page | 3
TECHNICAL SPECIFICATION FOR VENTILATION SYSTEM

of dust particles inside GIS building. arrived based on 1ACPH of GIS Hall.

Summary-Simple Exhaust Ventilation System

Area to be ventilated Supply air system Exhaust air system

Battery Room (2x50% capacity Fresh air through intake louvers Wall mounted exhaust fans
axial flow belt driven) and duct.
Pantry Through door undercuts/door louvers
Wall mounted Propeller type
exhaust fans
Note: Supply and exhaust fans of above mentioned areas shall be provided with their local
starter/push button (3 phase DOL starter).

a) Supply and exhaust fans of above mentioned areas shall be in multiplicity minimum 2X50%.

b) All the areas served by means of dry mechanical ventilation shall be designed for a maximum inside
temperature of 5 deg. Celsius above the design ambient (DBT) condition during summer or according to
suitable air changes per hour. The criterion that gives the highest flow rate will be considered for design
& selection of the equipment.

c) All the ventilation fans shall operate on 100% fresh air considering 15 air changes per hour (ACPH)
for LV Switchgear, cable vault, transformer rooms, 15 ACPH for pantry rooms and 30 ACPH for
battery room of 400KV GIS control building.

d) All the equipments of ventilation system shall be designed for generally continuous duty for continuous
operation of 24 hours a day.

e) Heat dissipation from GIS bays shall also be considered for sizing of ventilation system of GIS
hall during detailed engineering stage.

f) Selection of size, rating & number of ventilation fans shall be done through proper calculation and the
same will be submitted for final approval during detailed engineering stage.

g) Wall mounted supply air fans of suitable capacity (CMH) & required static head (WC) shall be
provided for positive pressurization of the following rooms:

i. Cable Vault (In Control building of GIS)

ii. Transformer Room (In Control building of GIS)
iii. LV Switchgear Room (In Control building of GIS)

Directly driven axial flow fans with die cast aluminium impeller dynamically balanced, fitted with
three-phase induction motor.
The fan casing shall be of galvanized steel material. Fan shall be provided with rain protection inlet
cowl, filters, bird-screen, back-draft damper, (where necessary) grouting frame and cadmium plated
fixing bolts.

The pre filter section shall comprise of 50 mm thick washable filter panel suitably arranged in holding
frames. The pre filter shall have a minimum efficiency of 90% down to 10 microns size. Maximum
Velocity across pre filter shall be 2.5 m/s.

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CONSULTANT- TATA CONSULTING ENGINEERS LIMITED BEGALURU
PROJECT: 2X660MW UDANGUDI STPP – (STAGE-1) Page | 4
TECHNICAL SPECIFICATION FOR VENTILATION SYSTEM

h) Gravity dampers (self-acting dampers) are provided to ensure pressurization of above areas.
Dampers shall be of gravity type designed such as not to allow infiltration of air from outside. The
louvers of the dampers shall be freely mounted on Spindles to allow the damper to open freely with
the pressure developed in the premises. The damper shall be provided with flange at the inlet.

i) Wall mounted Exhaust fans of suitable capacity (CMH) each having rain protection cowl, bird screen
and mounting arrangement shall be envisaged for the Battery rooms of control building of GIS as per
following design criteria:

Battery rooms - The wall mounted axial flow fan shall be of FRP coated cast aluminium impeller with
blades of aerofoil design. The fan motor shall be externally mounted (outside the air path) on a bracket
fixed to the casing with necessary V-belt drive. The motor shall be of explosion proof type.
Redundancy for battery room exhaust fans shall be 2X50%. Exhaust air from battery room shall be
taken out through GSS ducting.

Supply of air to battery room shall be through intake louvers provided at suitable location in the room.

j) Pantry shall be provided with propeller type exhaust fans of suitable capacity (CMH) with rain
protection cowl, bird screen and mounting arrangement along with back draft damper. Single
phase power supply points to these ventilation fans will be provided by BHEL. Further wiring from the
power supply point to the fans with necessary switch control shall be under contractor scope.

2.3. Ventilation system for 400 kV GIS Hall

Ventilation system shall be provided to maintain positive pressure inside GIS building. The system shall
comprise of supply air fan assemblies with Pre & Fine filters, Gravity louvers, exhaust air fans, gravity
dampers or a suitable combination of these along with necessary filters, ducting, grilles etc. Fans and
accessories for this ventilation system shall be placed in separate ventilation room provided adjacent to
the GIS Hall. This dry mechanical ventilation system shall be designed for a maximum inside temperature
of 5 deg. Celsius above the design ambient (DBT) condition during summer or according to suitable air
changes per hour (minimum 15 ACPH). The criterion that gives the highest flow rate will be considered
for design & selection of the equipment. Ventilation system for GIS hall shall operate on 100% fresh air.

Plant shall mainly consist Supply air fans of DIDW type with pre and fine filters, Supply air ducting and
grills. Two (2) nos. DIDW supply air centrifugal fans on 2x50 % (all working) basis shall be provided for
the collective requirement of GIS Hall. It shall also have GSS intake louvers with wire mesh, frame and
bird protection screen and HDPE filters of min. 99% arrestance down to 5 micron. The vibration level of
fans shall be within limits and vibration isolation shall be achieved by providing suitable spring type or pad
type (or combination) vibration isolators for ventilation system equipment (centrifugal fans).

There shall be 18 gauge G.I. common plenum chamber after centrifugal fans outlet provided with
necessary maintenance windows, water tube manometer across air filter, one pressure switch and pilot
light on panel to indicate dirty condition of filter.

These filters shall be arranged in a panel formation with filter module mounting frame on the downstream
side. Wall cut outs for mounting of intake louvers shall be made available in ventilation room. Two Supply
air duct shall be taken from plenum chamber which shall run on the both walls along the length of the GIS

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Rev. 01
CONSULTANT- TATA CONSULTING ENGINEERS LIMITED BEGALURU
PROJECT: 2X660MW UDANGUDI STPP – (STAGE-1) Page | 5
TECHNICAL SPECIFICATION FOR VENTILATION SYSTEM

Hall with necessary grilles/ diffusers to make proper ventilation arrangement inside the hall to facilitate
proper mixing and avoid any hot spot.

Exhaust fan inter linked with SF6 gas detector shall be provided for emergency purpose. The
control of switching on this exhaust fan under emergency condition shall be done through GIS
supplier equipments (through PFC or any other contacts). However local control (push buttons)
shall also be provided. The contractor shall make all necessary provision including cabling
between fan switch board to GIS output contacts (under leakage condition) to enable automatic
switch control (on/off) of this exhaust fan from remote under SF6 leakage condition. GIS supplier
shall provide one free contact of SF6 stage 2 collective alarm for remote connection.

Gravity dampers (self-acting dampers) are provided to ensure pressurization of above areas. Dampers
shall be of gravity type designed such as not to allow infiltration of air from outside. The louvers of the
dampers shall be freely mounted on Spindles to allow the damper to open freely with the pressure
developed in the premises. The damper shall be provided with flange at the inlet. Spring actuated counter
weight operated Pressure relief dampers with frame & bird screen shall be provided of suitable size and
quantities on both walls of GIS hall at elevation above supply air ducts to release hot air & excessive
pressure inside the hall beyond design over pressure.

Ventilation duct running inside GIS Hall shall be suitably placed to avoid any fouling with GIS
incoming/outgoing ducts, LCC panels & EOT crane.

For fans and blowers, AC motors shall be squirrel cage three phase/single phase induction motors. All the
motor shall be designed for bi-directional rotation. All the motors shall be rated for S1 duty for continuous
operation. The motors shall be suitable for direct on-line starting on full load and shall be energy efficient
type. Maximum continuous motor rating shall be atleast 10% above the maximum load derived of the
driven equipment under entire operating range including voltage & frequency variation.

All the equipments of Ventilation system shall be designed for continuous duty for continuous operation of
24 hours a day.

✓ Notes:

Ventilation fan calculation sheet for different areas mentioned above of GIS control building & GIS
Hall shall be submitted for customer/ consultant approval during detailed engineering stage.

No monitoring and control of the ventilation system for switchyard area shall be done
through remote PLC/DDCMIS in main plant.

GENERAL

a. Centrifugal Fans:
Centrifugal fans for Ventilation System shall be DIDW non-overloading type designed. Fan shall be
driven with V-belt by a totally enclosed motor and the fan outlet velocity shall not exceed 11 m/sec.
Impeller shall be die formed aerofoil or laminar type of self-cleaning and non-overloading
characteristics. The impeller shall be statically and dynamically balanced according to ISO standard.
The fan casing shall be of welded construction and provided with flanges on inlet & outlet side for
duct connection.

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CONSULTANT- TATA CONSULTING ENGINEERS LIMITED BEGALURU
PROJECT: 2X660MW UDANGUDI STPP – (STAGE-1) Page | 6
TECHNICAL SPECIFICATION FOR VENTILATION SYSTEM

The fan impeller & casing etc. shall be protected by a suitable corrosion resistant.
Accessories like common base frame, anchor bolts, vibration isolators, V-belt guard, inlet guard and
outlet damper, canvas etc., shall be provided. Centrifugal fans and drive motors mounted on common
base frame to be mounted on spring type vibration isolators to prevent vibration transfer to floors as
well as to the downstream side of duct.

b. Air Distribution System

The ductwork inside the building shall be manufactured form hot-dip galvanized sheet metal,
complying with IS-277 Gr 275 or better.

All ductwork support ties to the structure shall be made resilient with the use of 12mm thick non-
intercellular neoprene strip, gaskets or washers. All ductwork connections to air handling equipment
shall be made via 15 cm long connections of rubber impregnated canvass material.

Maximum velocity in the duct shall be 11 m/s and velocity of air through supply air grilles shall be
maximum 5 m/s for ventilation system.

Supports for Ductwork: Supports shall generally comprise hot-dipped galvanized mild steel sections
and drop rods assembled in a suitable manner to permit adjustment for height and alignment of the
ducts, and to prevent the transmission of vibration and/or noise. Ducts shall be supported by the
stiffening angles or angle flanges but where this is impractical, supporting angles shall be fixed to the
ducts.

Supply and Exhaust Air Grilles: In conventional attractive design, lamellas adjustable, aerofoil
shape, broad front frame to allow airtight mounting. Frame and lamella made from steel with agreed
stove enamel finish, conserved in nature color. Covered screw mounting with use of mounting frame
shall be provided. Air-flow control shall be by means of counter-moving, coupled lamellas, with sets of
adjustable air deflection blades and an opposed blade damper located at the rear, adjustable from the
front side.

Fire Dampers: The main duct of ventilation system shall be provided with automatic motor-operated
fire dampers with fire rating of 120 minutes, at locations where ducts pass through wall/floors/ceiling
slabs for isolation/ maintenance/ fire-protection purpose. The operation of these automatic dampers
shall be interlocked with the fire alarm system and shall also be possible to operate manually from the
remote control panel. Required electrical contacts shall be provided in control panel of A/C plant for
further wiring up to fire alarm panels.
Fusible link fire dampers of 60 minutes fire rating shall be provided for all other areas excluding
electrical rooms where ducts pass through wall/floors/ceiling slabs for isolation/maintenance/ fire-
protection purpose.

Isolating Dampers: Consisting of frames of galvanized sheet metal, air foiled lamellas, adjustable
from the outside by a lever and positioning device.

Weather Louvers: Weather louvers shall be of hot-dipped galvanized angle-iron frame with built-in
rain-rejecting galvanised iron or aluminium lamellas as well as bird protection screen of galvanized
iron, Mounting frame of galvanized profile steel.

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TECHNICAL SPECIFICATION FOR VENTILATION SYSTEM

2.4. CONTROL & POWER SUPPLY REQUIREMENT

a. Four (4) nos. wall mounted fuse boards each for extending power supplies to 3 phase supply/exhaust
fans in Cable vault, LV Switchgear, Transformer Room & Battery rooms, shall be located in their
respective rooms. These fuse boards shall be supplied by contractor. Also necessary cabling shall be
done further from the fuse board to each fan’s 3-phase DOL local starter & motors by contractor.
BHEL shall provide 4 nos. incomer feeders (through MPCB) one no. of 32 A rating for fuse board of
cable vault and 3 nos. of 16A rating for fuse board of LV Switchgear, Transformer Room & Battery
rooms. These feeders shall be made available by BHEL from MCC cum PDB of Air Conditioning
System in AHU/AC Plant room (other’s scope) of control room building area.

b. One (1) no. dedicated MCC cum Power distribution board in ventilation room of 400 kV GIS Hall shall
be provided. This shall extend power supplies to centrifugal fan and other equipments of ventilation
system of GIS Hall including exhaust fans under emergency conditions as described in clause 2.3.
BHEL shall provide two incomers each of rating 200A from main ACDB board to feed this MCC cum
PDB. Contractor shall provide necessary arrangements accordingly. Two nos. incomers of 200A rating
(through MCCB) of cable size 3.5CX300 sqmm. (Al/XLPE) shall be provided from the main ACDB by
BHEL and the same will be terminated in MCC cum PDB. Lamps shall be provided for indicating the
status of each fan etc. in the panel. All annunciations related to failure of equipments, tripping of
equipments and source of failure/reason due to which the equipment is stopped/tripped, low & high
limits of parameters such as level, temp., pressure drop etc. as applicable details of which shall be
finalized during engineering stage shall be provided for each fan in the panel. Fully wired, 20% spare
annunciation windows shall be provided in the panel. Start/stop push buttons etc. shall also be
provided.

c. MCC shall be drawout type. Bidder shall refer the detailed panel specification annexed to section-2.

d. One no. spare feeder shall also to be provided of each type and rating in the MCC cum PDB. Spare
feeders shall be completely wired up.

e. No DC feeder shall be provided by BHEL and necessary convertor (AC/DC) shall be supplied by
contractor, if required.

f. Single phase power supply points to ventilation fan of pantry will be provided by BHEL.

Note: MCC cum PDB shall be of reputed make such as C&S Electric, L&T, BCH Electric, Schneider
Electric, Pyrotech Electronics etc. that will be finalized during detailed engineering. Make finalized
by customer shall be binding to contractor and there shall not be any price implication on account
of make considered by bidder at tender stage and during detailed engineering. Hence bidder may
prepare their estimate and quote accordingly to full fill above requirement.

3.0 Inspection & Testing requirement

Being standard equipment, no shop tests have been envisaged for ventilation fans. Test certificates for all
major equipments of ventilation system will be submitted to customer for verification and release of
dispatch instruction.

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CONSULTANT- TATA CONSULTING ENGINEERS LIMITED BEGALURU
PROJECT: 2X660MW UDANGUDI STPP – (STAGE-1) Page | 8
TECHNICAL SPECIFICATION FOR VENTILATION SYSTEM

After the installation is over, the system will be subjected to performance guaranteed test in the presence
of customer.

“Performance Guarantee Test Procedure” will be submitted during detailed engineering for approval of
customer/consultant.

All the equipments shall be inspected prior to dispatch in line with relevant IS, approved GTP/ drawing and
technical specification, BHEL/ customer approved QAP.

4.0 List of Mandatory Spares

Ventilation system
SL. NO. ITEM DESCRIPTION QUANTITY
A. Centrifugal Fans
1 V-Belts 2 sets of each type
2 Blower Bearing Sets 2 sets of each type
3 Blower Motor Bearings 2 sets of each type
4 Seal Gasket and other wear out parts in sets 2 sets of each type
5 Vibration Isolators 2 sets of each type
B. Axial Fans
1 Fan Bearings 2 sets of each type
2 Fan Motor Bearing 2 sets of each type
3 Dry Filters 2 sets of each type & size

4.0.1. Special Tools

Following tools and maintenance equipment shall be provided for repair and maintenance of
ventilation system.

For Ventilation System

1 RING SPANNER - 6 MM TO 32 MM (12 Pcs) 1 Set
2 OFFSET SCREW DRIVER 1 No.
3 LOCK WITH KEY FOR TOOL BOX 1 No.
4 MS TOOL BOX 1 No.
5 BOX WRENCHES ‐ 6 MM TO 22 MM (14 Pcs) 1 Set
6 FLAT D WRENCH ‐ 6 MM TO 32 MM (12 Pcs) 1 Set
7 ALLEN KEYS ‐ 2 MM TO 10 MM 1 No.
8 CRESCENT SCREW SPANNER 1 No.
9 SCREW DRIVER 1 No.
10 INSULATED PLIER 1 No.
11 TORCH LIGHT ( SUITABLE FOR 2 CELL) 1 No.
12 HAMMER 1 LB 1 No.
13 OIL CAN 1 No.
14 RATCHET 1/4" 1 No.

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TECHNICAL SPECIFICATION FOR VENTILATION SYSTEM

References:

i. Arch drawing- Control room building-TB-1-400-607-620-1 (Plan), TB-1-400-607-620-2 (Elevation),

TB-1-400-607-620-3 (Section) for 400kV (GIS) Switchyard at Udangudi.

ii. Arch drawing- GIS building- TB-1-400-607-640-1 (Plan), TB-1-400-607-640-2 (Elevation), TB-1-400-
607-640-3 (Section) for 400kV (GIS) Switchyard at Udangudi.

Notes:

❖ Ventilation system for different areas of Gas insulated switchyard control building shall be designed
as per the latest architecture drawings during detailed engineering stage.

❖ Customer/ consultant approval on all the technical data sheets of equipments /drawings/ documents
for this package will be obtained during the detailed engineering stage.

5.0 SCOPE OF SUPPLY & SERVICES

Exact requirements shall be worked out during detailed engineering after award of contract. The scope of
the work under the contract shall be deemed to include all such items, which although not specifically
mentioned in the bid documents and/or in the bidder’s proposal, but are required to make the
equipment/system complete for its safe, efficient, reliable and trouble free operation, unless the same is
specifically excluded from the Bidder’s scope of work under clause 6.0 of this section.

5.0.1. Bidder shall also consider the following while quoting for the system:

i) Power & Control cables including instrumentation and FO cable for Ventilation System will be supplied
on free issue basis to contractor. Contractor shall have to choose their cables from the available sizes
only and necessary modifications in their equipment for termination of these cables shall be made by
contractor.

ii) Since laying & termination of all cables is in contractor’s scope, supply of cable accessories such as
lugs, glands, cable tags & markers etc. shall be included by the bidders in their offers.

iii) Necessary cable trays will be supplied on free issue basis to the contractor, however necessary
hardware for fixing the same on walls or elsewhere shall be included by the bidders in their offers.

iv) Earthing material viz. GS flat & wire will also be supplied on free issue basis to contractor; however
requirement shall be given by the bidders in their respective bids.

v) Bidder shall ensure that sufficient quantities of commissioning spares are made available for timely
completion of commissioning of the system. The bidder shall furnish a list of Commissioning spares that
will be brought by him. The unused commissioning spares shall be returnable to the bidder.

vi) Conducting performance guarantee tests as per approved procedure to the satisfaction of Owner /
Purchaser and handing over an operational system to the owner. Procedure for performance guarantee
test shall be submitted by contractor for customer review and approval.

vii) Contractor shall submit valid Type test report for approval by owner. Fresh type test of equipment is
not envisaged. It is presumed that equipment offered is duly type tested.

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In case the type test reports are found un-satisfactory, tests shall be carried out afresh by
contractor without any additional cost implication to BHEL.

5.1.0. Scope of services

A. Erection, Testing & Commissioning (ETC) requirements

i) The scope of ETC shall include receipt of material at site, unloading, safe storage of material, handling
of equipment/ material at site, erection of equipment /material at site including fabrication, equipment and
system testing, commissioning of the entire system, conducting performance guarantee tests to the
satisfaction of Owner / Purchaser and final handing over to the owner of the entire system.

ii) Furnishing technical calculations in support of equipment selection or sizing as and when required.

B. Electrical System
i) Preparations of cable interconnection diagram for equipment supplied under this contract and
accordingly offer guidance to the purchaser for laying necessary cables. Termination details shall also be
furnished in the said interconnection table.

ii) Cables laying for incomers to the PDB panel shall be done by the purchaser while termination of the
same to the MCC panel end supplied under this contract is in bidder’s scope of works. The contractor has
to lay and terminate all the other power and control cables supplied under the present scope.

iii) Laying & Termination of Power/ Control cables/FO Cables for the equipment under the scope of this
specification. Bidders shall include all cable accessories like lugs, glands, cable tags, markers etc in their
respective bids.

iv) Earthing of all installations (to the nearest earth mat/ earthing pad) supplied under the scope of this
specification.

C. All machinery tools & tackles and consumables required for erection/testing / commissioning of the
system shall be arranged by the Bidder.

D. Minor modifications, alterations in system installation as per customer's specific requirements shall be
done without any extra cost to purchaser.

E. Painting of all the equipments shall be as per customer specification.

F. After completion of erection and commissioning of the system, the bidder shall train site engineers of
Purchaser/Owner so that they are fully conversant with both electrical and mechanical part of this
package.

G. Bidders to ensure that sufficient quantity of spares is made available for timely completion of
commissioning of the system. The bidder shall furnish a list of commissioning spares that will be brought
by him. The unused commissioning spares shall be returnable to the bidder.

H. Obtaining approval on documents & installations.

i) Obtaining, "As Built" certification from purchaser or owner on applicable drawings. Completing
documentation as per specification requirement.

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ii) Obtaining customer's written acceptance of satisfactory completion of job. (Acceptance of PG +

handing over of system and mandatory spares (if any)).

iii) Any other service not explicitly illustrated herein but which may be required to complete the system
with its desired functionality or in the spirit of contract shall also deemed to be under the scope of bidder.

L. Civil Works
Major civil works such as room & foundations for various Ventilation equipments shall be in purchaser’s
scope. However, following shall be in contractor scope of services:

a. Wall openings at suitable locations for duct & ventilation fans shall be made by the contractor.
Associated civil works such as grouting, filling up crevices/cut outs etc during installations of equipments
shall also be in contractor’s scope. Any other damage caused to civil works during ETC work of the
equipment/system shall be made good to the original finish by the contractor at no extra cost to the
purchaser.

b. Providing necessary guidance to / coordination with civil contractor so that appropriate sized / correctly
located cut outs are made (by civil contractor).
However, in case wall openings / cut outs have not been provided for either duct laying, louver fixing,
ventilation fan(s), the same shall have to be made by the Contractor.

Minor modifications, alterations in system installation as per customer's specific requirements shall be
done without any extra cost to purchaser. The Bidder shall however supply foundation bolts & hardware
and undertake minor civil works such as grouting, filling up of crevices/ cut outs etc. Any damage caused
to civil works during ETC work of the equipment/system shall have to be made good to the original finish
by the Contractor at no extra cost to the Purchaser.

6.0 Exclusions

a) Supply of power & control cables, Instrumentation and FO cable are excluded. However, laying
and termination of these cables shall be in contractor’s scope. The bidder shall furnish quantity and
type of cables required for complete system in their respective bids. Laying & termination is in contractor
scope.

b) Supply of necessary cable trays for laying cables, however hardware for fixing the same on wall
trenches or elsewhere shall be included by the bidder in his bid.

c) Supply of GI flat for earthing of equipments.

d) Major civil works such as room & foundations for various Ventilation equipments.

7.0 Utilities Available

Construction water and electricity shall be available at one point each. Contractor shall be required to
make own arrangement for taking supplies from there.
However the final terms & conditions mentioned in work order shall prevail and contractual obligation to
successful bidder.

8.0 Engineering Drawings/ Documents

Engineering shall start immediately after the award of the contract.

Page 11 of 18
 CLIENT – TAMILNADU GENERATION & DISTRIBUTION CORPORATION LTD. TB-400-553-124
Rev. 01
CONSULTANT- TATA CONSULTING ENGINEERS LIMITED BEGALURU
PROJECT: 2X660MW UDANGUDI STPP – (STAGE-1) Page | 12
TECHNICAL SPECIFICATION FOR VENTILATION SYSTEM

Submission & approval of all drg. / data sheet – as per tender requirement.

8.1 OPERATION & MAINTENANCE (O&M) MANUAL

Operation and Maintenance manuals shall be specifically compiled for the project by the bidders. The
draft O&M manual shall be submitted along with the supply of the items. The O&M manual shall contain
the following information:
a. Description of the system and equipment with design particulars.
b. Instruction for erection.
c. Instruction for operation, maintenance and repair.
d. Recommended inspection practices and inspection schedule.
e. Ordering information for all replaceable parts.
f. Recommendation for type of lubricants and frequency of lubrication.

9.0 Handing & Taking Over

It is the responsibility of the contractor to maintain the Ventilation system for switchyard till PG test
conducted successfully and it is handed over to customer. Any defect noted during the period shall be
rectified by the contractor without any price implication to BHEL. Also suitable PG tests shall be
conducted by the contractor to show the achievement of guaranteed parameters in line with the
requirements of specification/ standards/ codes and to the satisfaction of Purchaser/ Owner.

10.0 Various Heads to be quoted for

10.1.1 Based on the above input it is recommended that the bidders shall submit their offers in the
prescribed format only.

Sl. Unit Tota Ex- Unit Total

Item Description Unit Quantity Remarks
No. Rate Works ETC ETC
Supply air type Centrifugal
fan (2W+0S) with 55
mmwc static pressure with
CENTRIFUGAL FAN - motor minimum rating
1 Nos. 2
200000 CMH 55kW, V-belt drive, pulley,
casing alongwith fixing
hardware and all
accessories - GIS Hall
Each filter of size 610X610
sqmm. (132 nos at air
intake of GIS Ventilation
2 Pre Filter Nos. 136
room, 4 nos. at air intake
of Battery
room)
Each filter of size 610X610
sqmm. (132 nos at air
3 Fine Filter Nos. 132
intake of GIS Ventilation
room)
Exhaust type axial flow fan
(2W+0S) with 10mmwc
AXIAL FLOW static pressure to exhaust
4 EXHAUST FANS - Nos. 2 SF6 Gas in case of
15000 CMH emergency along with the
connection to the alarm
alongwith fixing hardware,

Page 12 of 18
 CLIENT – TAMILNADU GENERATION & DISTRIBUTION CORPORATION LTD. TB-400-553-124
Rev. 01
CONSULTANT- TATA CONSULTING ENGINEERS LIMITED BEGALURU
PROJECT: 2X660MW UDANGUDI STPP – (STAGE-1) Page | 13
TECHNICAL SPECIFICATION FOR VENTILATION SYSTEM

with motor minimum rating

1.1kW - GIS Hall
Supply Air type Axial flow
fan (2W+0S) with 15mmwc
static pressure with motor
AXIAL FLOW SUPPLY minimum rating 2.2kW, rail
5 Nos. 2
FANS - 15000 CMH protection cowl, filters, bird
screen & gravity back draft
damper alongwith fixing
hardware - Cable Vault
Supply Air type Axial flow
fan with 15mmwc static
pressure with motor
minimum rating 1.1kW, rail
protection cowl, filters, bird
AXIAL FLOW SUPPLY
6 Nos. 5 screen & gravity back draft
FANS - 6000 CMH
damper alongwith fixing
hardware- 2nos. (2W+0S)
in LV Switchgear room & 3
nos. (3W+0S) in
Transformer Room
Axial flow Exhaust fan
(2W+0S) with 15mmwc
AXIAL FLOW static pressure with belt
EXHAUST FANS WITH driven flame proof motor
7 Nos. 2
FLP MOTOR - 6000 minimum rating 1.1kW,
CMH with fresh air intake louver
alongwith fixing hardware -
Battery Room
Wall mounted propeller
PROPELLER exhaust fan alongwith
8 EXHAUST AIR FANS - Nos. 1 fixing hardware for pantry
2000 CMH with mi imum motor ratimg
0.1kW
As per IS-277 Gr 275
GSS DUCT SHEET -
alongwith supporting
9 24 G - VENTILATION [Link] 82
structure and fixing
SYSTEM
hardware.
As per IS-277 Gr 275
GSS DUCT SHEET -
alongwith supporting
10 22 G - VENTILATION [Link] 270
structure and fixing
SYSTEM
hardware.
As per IS-277 Gr 275
GSS DUCT SHEET -
alongwith supporting
11 20 G - VENTILATION [Link] 646
structure and fixing
SYSTEM
hardware.
As per IS-277 Gr 275
GSS DUCT SHEET -
alongwith supporting
12 18 G - VENTILATION [Link] 695
structure and fixing
SYSTEM
hardware.
VOLUME CONTROL Size 3250x1850,
13 SqMtr 11
DAMPER 2500x1600, 1000x550
Motorized Fire Damper
MOTORIZED FIRE with fire rating of 120
14 SqMtr 11
DAMPER minutes. Size 2500x1600,
3250x1850
MOTORISED
Actuators for Fire Dampers
15 ACTUATOR FOR FIRE Nos. 2
with control panels
DAMPER

Page 13 of 18
 CLIENT – TAMILNADU GENERATION & DISTRIBUTION CORPORATION LTD. TB-400-553-124
Rev. 01
CONSULTANT- TATA CONSULTING ENGINEERS LIMITED BEGALURU
PROJECT: 2X660MW UDANGUDI STPP – (STAGE-1) Page | 14
TECHNICAL SPECIFICATION FOR VENTILATION SYSTEM

181 nos. of size 600x300

16 GRILLS/ DIFFUSERS [Link] 35 in GIS hall, 8 nos. of size
1000x200 in battery room.
Each of size 600x450 (40
PRESSURE RELIEF
17 [Link] 13 nos. in GIS Hall, 6 nos. in
DAMPER
control building)
At air intake of GIS
18 AIR INTAKE LOUVER [Link] 50 Ventilation room and
battery room
MCC CUM POWER
19 DISTRIBUTION No. 1
BOARD
WALL MOUNTED
20 No. 1 For Cable vault room
FUSE BOARD 32A
For LV SWGR room,
WALL MOUNTED
21 Nos. 3 Transformer room &
FUSE BOARD 16A
Battery room

9 Nos. for all ventilation

fans in cable vault, LV
Switchgear room,
Transformer room &
LOCAL STARTER / Battery room. 2 Nos. for
PUSH BUTTON Exhaust fans in GIS hall
22 Nos. 11
STATIONS (3-PHASE under emergency
DOL STARTER) condition of SF6 leakage
with sufficient contact
multiplier and other
necessary items required
to it's automatic operation.

As per clause 4.0.1 of

MAINTENANCE
23 Set 1 Section-1 of Technical
TOOLS & TACKLES
Specification
24 Mandatory spares
V-Belts of each type for One set = one no. of each
i. Sets 2
Centrifugal fans type
Blower Bearing Sets of
One set = one no. of each
ii. each type for Sets 2
type
Centrifugal fans
Blower Motor Bearings
One set = one no. of each
iii. of each type for Sets 2
NA type
Centrifugal fans
Seal Gasket and other
wear out parts in sets One set = one no. of each
iv. Sets 2
of each type for type
Centrifugal fans
Vibration Isolators of
One set = one no. of each
v. each type for Sets 2
type
Centrifugal fans
Fan Bearings of each One set = one no. of each
vi. Sets 2
type for axial fans type
Fan Motor Bearing of One set = one no. of each
vii. Sets 2
each type for axial fans type

Page 14 of 18
 CLIENT – TAMILNADU GENERATION & DISTRIBUTION CORPORATION LTD. TB-400-553-124
Rev. 01
CONSULTANT- TATA CONSULTING ENGINEERS LIMITED BEGALURU
PROJECT: 2X660MW UDANGUDI STPP – (STAGE-1) Page | 15
TECHNICAL SPECIFICATION FOR VENTILATION SYSTEM

Dry Filters of each type One set = one no. of each

viii. Sets 2
& size for axial fans type and size
For ETC Scope

Cable Laying along

25 Meter 300 NA ETC scope only
with accessories

** Remarks: Bidder should go through the technical specification TB-400-553-124-Rev01 for detailing of all
equipments.

a) The equipments and services to be furnished under this contract are detailed here under Cl. No. 10.0
of this section is for reference. Bidders shall work out the actual requirement based on the building &
switchyard layout enclosed with this specification during detailed engineering stage.

b) The Bill of Quantities shall be read in conjunction with the Instructions to Bidders, General and
Special Conditions of Contract, Technical Specifications, and Drawings.

c) The quantities given in the Bill of Quantities are estimated and provisional, and are given to provide a
common basis for bidding. The basis of payment will be the actual quantities of work ordered and
carried out, as measured by the Contractor and verified by the Purchaser and valued at the rates and
prices bid in the priced Bill of Quantities.

d) A rate or price shall be entered against each item in the priced Bill of Quantities. The cost of Items
against which the Contractor has failed to enter a rate or price shall be deemed to be covered by
other rates and prices entered in the Bill of Quantities.

e) The whole cost of complying with the provisions of the Contract shall be included in the Items
provided in the priced Bill of Quantities, and where no Items are provided, the cost shall be deemed
to be distributed among the rates and prices entered for the related Items of Work.

f) General directions and descriptions of work and materials are not necessarily repeated nor
summarized in the Bill of Quantities. References to the relevant sections of the Contract
documentation shall be made before entering prices against each item in the priced Bill of Quantities.

g) Miscellaneous items like hardware, fixtures, fittings etc. shall be deemed to be included under the
relevant BOQ items and bidders shall consider the same while quoting for BOQ items.

h) Exact requirements shall be worked out during detailed engineering after award of contract.

i) Bidders shall consider makes for various equipments as per Annexure A, which shall be subjected to
Owner’s approval during design engineering stage. Price implication to BHEL later on account of non-
acceptance of proposed vendors by Owner shall not be considered.

Page 15 of 18
 CLIENT – TAMILNADU GENERATION & DISTRIBUTION CORPORATION LTD. TB-400-553-124
Rev. 01
CONSULTANT- TATA CONSULTING ENGINEERS LIMITED BEGALURU
PROJECT: 2X660MW UDANGUDI STPP – (STAGE-1) Page | 16
TECHNICAL SPECIFICATION FOR VENTILATION SYSTEM

ANNEXURE-A

SUB VENDOR LIST FOR VENTILATION SYSTEMS

Project : 2x660 MW UNITS UDANGUDI, STPP

SL. NO. Item Proposed Subvendor

FLAKT
KRUGER
DRAFT AIR
HYDERABAD POLUTION CONTROL
PATEL AIR
1 CENTRIFUGAL FAN NIKOTRA
SK SYSTEM
MARATHON
CB DOCTOR
SARLA
COMEFRI
Parker Haniffin (John Fowler - India)
2 AIR FILTERS Puromatic
Spectrum
INTAKE LOUVER / GRILLS / AIR FLOW
VOLUME CONTROL DAMPER / TSC
FILTER FRAME / AIR INTAKE
3 AIR MASTER
LOUVER BASE FRAME/ COWL
CONNECTION PIECE SUPPLY AIR CARRYAIRE
GRILL/ GRAVITY DAMPER ETC. RAVISTER (SYSTEM AIR)
HYDERABAD POLUTION CONTROL
SK SYSTEM
KRUGER
NIKOTRA
FRESH AIR/ SUPPLY/ MARATHON
4
EXHAUST FANS FLAKT
CB DOCTOR
SARLA (SITAL)
PATEL AIR
KHAITAN
EXHAUST FANS (PROPELLER Marathon
5
TYPE) WITH MOTOR Khaitan
SAIL
6 GI SHEET
Tata

Page 16 of 18
 CLIENT – TAMILNADU GENERATION & DISTRIBUTION CORPORATION LTD. TB-400-553-124
Rev. 01
CONSULTANT- TATA CONSULTING ENGINEERS LIMITED BEGALURU
PROJECT: 2X660MW UDANGUDI STPP – (STAGE-1) Page | 17
TECHNICAL SPECIFICATION FOR VENTILATION SYSTEM

RASHTRIYA ISPAT NIGAM LTD.

Essar
Jindal
JSW
System Air
FIRE DAMPER (MOTOR
7 Caryaire
OPERATED)
TSC

ABB

BBL
8 INDUCTION MOTOR (LT) MARATHON
CGL
KEC
LHP
Pyrotech
9 CONTROL PANEL
Positronics

Page 17 of 18
 CLIENT – TAMILNADU GENERATION & DISTRIBUTION CORPORATION LTD. TB-400-553-124
Rev. 01
CONSULTANT- TATA CONSULTING ENGINEERS LIMITED BEGALURU
PROJECT: 2X660MW UDANGUDI STPP – (STAGE-1) Page | 18
TECHNICAL SPECIFICATION FOR VENTILATION SYSTEM

ANNEXURE-‘B’
Cable Sizes being procured by BHEL for Sub-Station

2C x 2.5 sq mm PVC/Copper, Armoured Control Cable

5C x 4 sq mm PVC/Copper, Armoured Control Cable
5C x 2.5 sq mm PVC/Copper, Armoured Control Cable
7C x 2.5 sq mm PVC/Copper, Armoured Control Cable
10C x 2.5sqmm PVC/Copper, Armoured Control Cable
14C x 2.5 sq mm PVC/Copper, Armoured Control Cable
19C x 2.5 sq mm PVC/Copper, Armoured Control Cable
2C x 6 [Link] XLPE/Aluminium, Armoured Auxiliary Power Cable
4C x 16 [Link] XLPE/Aluminium, Armoured Auxiliary Power Cable
4C x 6 [Link] XLPE/Aluminium, Armoured Auxiliary Power Cable
3.5C x 70 [Link] XLPE/Aluminium, Armoured Auxiliary Power Cable
3.5C x 150 [Link] XLPE/Aluminium, Armoured Auxiliary Power Cable
3.5C x 300 [Link] XLPE/Aluminium, Armoured Auxiliary Power Cable
1C x 630 [Link] XLPE/Aluminium, Armoured Auxiliary Power Cable

Page 18 of 18
 CLIENT – TAMILNADU GENERATION & DISTRIBUTION CORPORATION LTD. TB-400-553-124
CONSULTANT- TATA CONSULTING ENGINEERS LMITED BENGALURU
Rev. 01
PROJECT: 2X660MW UDANGUDI STPP (STATE-1)
TECHNICAL SPECIFICATION FOR VENTILATION SYSTEM
Page | 1

SECTION-2
CUSTOMER SPECIFICATION

Customer contract document is enclosed as part of this specification. Only equipment specification
pertaining to Section-1 shall be referred. Regarding quantities and type of Ventilation System
equipment, Section-1 shall be referred.

2.1. PANEL SPECIFICATION

Refer Annexure-1 to Section-2

2.2. MOTOR SPECIFICATION

2.2.1 Duty

• All AC motors shall be squirrel cage three phase/single phase induction motors. All the motor
shall be designed for bi-directional rotation.
• All the motors shall be rated for S1 duty for continuous operation. Motors of crane and hoist
application shall be intermittent duty.
• Motors shall be suitable for installation in hot, humid and tropical atmosphere and polluted at
places with coal ash and or fly ash.

2.2.2 Design margin

Whenever the basis for motor rating are not specified in the corresponding mechanical
specification section maximum continuous motor rating shall be atleast 10% above the maximum
load derived of the driven equipment under entire operating range including voltage & frequency
variation.
The motor characteristics shall match the requirements of the driven equipment so that adequate
starting, accelerating; pull up, breakdown and full load torques are available for the intended
service.
Service shall be considered as 1.0 only.

2.2.3 Efficiency

All the duty motors shall be energy efficient type. For HT and LT motors, it shall be IE3 class as
per IS 12615.

2.2.4 Temperature rise

• Winding Insulation shall be Class F.

• Temperature rise of air cooled motors shall not exceed 70 0C over air temperature of 500C by
resistance method, while delivering its maximum rated output.
• Temperature rise of water cooled motors shall not exceed 80 0C over inlet cooling water
temperature by resistance method, while delivering its maximum rated output.

2.2.5 Enclosure

a) Motors shall have IP 55 degree of protection.

b) For hazardous location, the enclosure of motors shall following have flame proof construction
conforming to applicable standard.
• Fuel oil area Group – IIB
• Hydrogen generation plant area: Group – IIC

Page 1 of 3
 CLIENT – TAMILNADU GENERATION & DISTRIBUTION CORPORATION LTD. TB-400-553-124
CONSULTANT- TATA CONSULTING ENGINEERS LMITED BENGALURU
Rev. 01
PROJECT: 2X660MW UDANGUDI STPP (STATE-1)
TECHNICAL SPECIFICATION FOR VENTILATION SYSTEM
Page | 2

2.2.6 Cooling

LT motors shall be totally enclosed fan cooled (TEFC), type IC411. The cooling shall be effected
by self-driven bi-directional centrifugal fan protected by fan cover.

2.2.7 Winding

Winding shall be class F insulation with temperature limited to class B. Insulation shall be Non-
hygroscopic, oil resistant, and flame resistant. Winding, fittings and hardware shall be corrosion
resistant. Winding shall be tropicalized and suitably varnished, baked and treated for operating
satisfactorily in humid and corrosive atmosphere.

2.2.8 Bearings

• Motor shall be provided with antifriction bearings, unless sleeve bearings are required by the
motor application. Bearings shall be provided with seals to prevent leakage of lubricant or
entrance of foreign matters like dirt, water etc. into the bearing area.
• Sleeve bearings shall be split type, ring oiled with permanently aligned, close running shaft
sleeves. Grease lubricated bearings shall be pre-lubricated and shall have provisions for inservice
positive lubrication with grease nipple and relief holes. For sleeve bearings, the bearing housing
shall be preferably in end shield itself.
• Vertical shaft motors shall be provided with thrust and guide bearings. Thrust bearing of tilting pad
type is preferred. However, if anti-friction bearings can take vertical thrust, thrust and guide
bearings are not required.
• Lubricant shall not deteriorate under all service conditions. The lubricants shall be limited to
normally available types. For motors rated 30 kW and above re-lubrication facility shall be
provided.
• All the motors rated <15 kW shall be provided with sealed ZZ bearings.

2.2.9 Terminal Boxes

• Separate terminal boxes of IP 55 degree of protection shall be provided for stator leads. For
single core cables, gland plate shall be non-magnetic material. Terminal box of LT motors shall be
capable of being turned 360° in steps of 90°. The terminal boxes shall be split type with
removable cover with access to connections.
• Terminals for motors shall be stud type, thoroughly insulated from the frame. The terminals shall
be clearly identified by phase markings, with corresponding direction of rotation marked on the
non-driving end of the motor.
• The terminal box shall be capable of withstanding maximum system fault current for 0.2 sec for all
breaker operated motors and shall be provided with explosion vent.
• For contactor operated LT motors, the terminal box shall be capable of withstanding the fault
current for 0.2 sec minimum and operating time of MPCB/MCCB.
• Removable gland plates of thickness not less than 2.5 mm sheet steel or 3 mm aluminium (for
single core cables) shall be provided for cable boxes.
• Cable spreader box shall be provided for larger cable sizes.

2.2.10 Earthing Terminals

The frame of each motor shall be provided with two separate and distinct grounding pads
complete with tapped hole, GI bolts and washer. The terminal box shall have a separate
grounding terminal.

2.2.11 Noise and Vibration

• Motors shall be selected with low noise levels in accordance with IS 12065.
• The peak amplitude of the vibration shall also be within the specified limits of IS: 12075.
• All HT motors shall be provided with vibration pads for mounting vibration detectors.

Page 2 of 3
 CLIENT – TAMILNADU GENERATION & DISTRIBUTION CORPORATION LTD. TB-400-553-124
CONSULTANT- TATA CONSULTING ENGINEERS LMITED BENGALURU
Rev. 01
PROJECT: 2X660MW UDANGUDI STPP (STATE-1)
TECHNICAL SPECIFICATION FOR VENTILATION SYSTEM
Page | 3

2.2.12 Name Plates

Motor shall have stainless steel nameplate(s) showing diagram of connections, all particulars as
per IS: 325 / IS: 12615 and shall also have ‘BEE’ marking.
In addition to the minimum information required by IEC/IS, the following information shall be
shown on motor rating plate:
- Temperature rise in ºC under rated condition and method of measurement.
- Degree of protection.
- Bearing identification no. and recommended lubricant.
- Location of insulated bearings.

2.2.13 PAINTING

Painting shall be carried out by an approved process. Pretreatment shall conform to applicable
standard. The equipment shall be subject to a coat of red oxide primer paint. All inside and
outside surface shall be painted with epoxy based paint. The final thickness of paint film on steel
shall not be less than 100 microns. Finish shade shall be 631 of IS: 5 (smoke grey).

Page 3 of 3
 Annexure-1 to Section-2 of Technical Specification
2 X 660 MW Udangudi Supercritical Thermal Power Project – Stage-1

Tender Enquiry Document for EPC Contract

VOLUME II
SUB-SECTION - 2.17
AIR CONDITIONING AND VENTILATION SYSTEM

1.0.0 GENERAL

This section covers minimum requirements for design, engineering, fabrication, manufacture
& assembly, inspection, erection, testing and commissioning of Air Conditioning and
Ventilation System and associated equipment to be provided by the Contractor.

2.0.0 SCOPE OF SUPPLY

This section sets out the scope of the installations covered by this specification as well as
required supplies and services but without excluding other necessary components and
services not mentioned.

2.1.0 Air Conditioning System

Air conditioning system shall be provided for all buildings or rooms as specified below:
• In which waste heat occurs which is not removed by other means and where, due to the
installed equipment temperature limitations exist

• Intended for human habitation

and all other areas where equipment requires air conditioned atmosphere.

2.1.1 Water Cooled Chiller unit type Air conditioning system

Independent Water Cooled Chiller shall be provided for TG building and Service building air
conditioned areas

• TG Building

• Central Control Room

• Electronic Equipment Room
• Computer Room
• Printer Room
• UPS Room
• Record Room
• Shift In-charge room
• Relay room
• I & C Laboratories
• Engineers room

• Service Building

2.1.2 Water Cooled Package Type Air conditioning System

Water Cooled Package unit shall be provided for the following areas:

• ESP Control Room

• Switch Yard Control room
• Coal Handling System Control Room
• Ash Handling System Control Room
• Administration building

Spec. No. SE/C/UP/EE/E/OT No. 01/2015-16 FICHTNER INDIA Vol. II, Section 2 Page : 1 of 20
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2.1.3 Water Cooled Package Type/Split Type Air conditioning System

• For auxiliary buildings, if AC load is less than 5 TR, multiple split units shall be provided
considering one number of standby unit.
• For areas having AC load more than 5 TR or equal to 5TR, Water cooled package units
shall be provided

Depending on the capacity criteria mentioned above, either water cooled package unit or split
type air conditioning system shall be followed for the following areas

• DM plant control room

• CW pump house control room
• Fire water pump house control room
• Fuel oil unloading/forwarding pump house control room
• SWAS Room (Dry Panel)
• Electro chlorination control room
• Hydrogen generation plant control room
• Road weigh bridge control room
• Sea water intake pump house control room
• Stack emission monitoring system control room
• Air compressor control room
• Fire water booster pump house control room
• Ash slurry pump house control room
• Ash water recovery pump house control room
• Elevator M/c room
• Operator cabin in crusher house
• Field maintenance Office
• HT Switch gear operator room
• Turbine control room at EL(+) 0.00 m,
• ETP control room
• STP control room
• Stores – maintenance officer room
• Storage shed for electronic items like PLC panels, DCS panels, cards etc,.
• Fire station control room
• Dormitory and dispensary

Any other areas if required air conditioned environment shall be provided with suitable AC
plant

2.2.0 Ventilation System

Ventilation system shall be provided for all the buildings or rooms as specified below

• In which waste heat occurs which has to be removed but where temperature ranges do
not necessitate air conditioning and all other areas which requires ventilation.

2.2.1 Evaporative type Ventilation System

[Link] Air Washer System

The Evaporative type system shall be provided in the following locations within the TG
Building by air washers. A dedicated plant room shall be provided for air washer unit.

• TG Hall
• HT Switchgear Rooms

Spec. No. SE/C/UP/EE/E/OT No. 01/2015-16 FICHTNER INDIA Vol. II, Section 2 Page : 2 of 20
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• LT Switchgear Rooms
• Electrical Rooms
• Cable Spreader Rooms
• Battery charger room
• SWAS room (wet panel)

[Link] Unitary Air Filtration System

Sheet metal type Unitary Air Filtration unit (UAF) of suitable capacity shall be envisaged for
each unit of ESP Building non AC areas. A dedicated plant room shall be provided for UAF
unit.

2.2.2 Dry type Ventilation system

[Link] Supply Ventilation System

The supply ventilation system shall be provided for the following areas

• All switchgear rooms/MCC rooms ( Except TG and ESP building)

• Cable spreader rooms ( Except TG and ESP building)

[Link] Simple Exhaust Ventilation System

The simple exhaust ventilation system shall be provided for the following areas

• Diesel generator room

• Air Compressor room
• Electro chlorination room
• Battery Room
• All Pump Rooms
• DM plant room
• Chemical House
• Hydrogen generation plant room
• Workshop
• Stores
• Elevator machine room
• AC plant room
• Toilets

2.2.3 Common equipment

• All controls, measuring and monitoring equipment, to an extent as well as additional

instrumentation necessary for matching to specific designs of equipment and units.

• Hot dip galvanized duct work.

3.0.0 DESIGN REQUIREMENTS

3.1.0 Air Conditioning

Indoor / Outdoor Design Conditions

• Inside design conditions to be maintained in Air-conditioned area

Dry bulb temperature Relative humidity

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Occupied Area : 24.0°C ± 1.0°C 50 ± 5%

Equipment Room : 21.0°C ± 1.0°C 50± 5%

• The outdoor design data shall be taken from ISHRAE/ASHRAE Hand book
3
• Fresh air for air conditioned area shall be provided with 1 AC/hr or 35 m /hr/person which
ever is higher
• Bidder shall collect the actual data from the meteorological department pertaining to site
location and design for plant accordingly
• Bidder shall adopt the Thoothukudi Metrological data (No. Of years shall be minimum of
20 years ) and design condition shall be arrived based on the guidelines mentioned in
ASHRAE .The design condition subject to the owner’s approval

3.2.0 Ventilation System

Design & Technical Requirements

Basis of Airflow
rate:
Room
Air changes per
hour
Evaporative cooled areas - T.G building operating floor, mezzanine 6
floor, ground floor , MCC room / Switch gear room, Electrical room
and Cable spreader room
MCC room / Switch gear room/ GIS room 15
Battery Rooms 30
Chemical house 20
Air Compressor building 15
Diesel generator room 30
Sea water intake pump house, CW pump house, Fuel Oil unloading / 15
Forwarding pump house and all other pump houses
SWAS room ( Non-AC areas) 15
AC Plant room 15
Workshop and Stores 6
Toilets in all buildings 15
Pantry in all buildings 15
Elevator machine room 15
Hydrogen generation plant room 20
Electro chlorination plant room 20

Supply and Exhaust Ventilation System

Area to be ventilated Supply air system Exhaust air system

TG Hall Filtered Supply air Roof exhaust fans
ventilation system from air
washer through ducting

Supply Air Ventilation System

Area to be ventilated Supply air system Exhaust air system

Various rooms like cable Filtered Supply air Gravity dampers
spreader room, switchgear room, ventilation system from air
battery charger room, SWAS washer through ducting
room (Non AC) etc, in TG

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Area to be ventilated Supply air system Exhaust air system

Building.
ESP Switchgear Building Filtered Supply air Gravity dampers
ventilation system from UAF
through ducting
All other MCC Wall mounted supply fans Gravity dampers
rooms/Switchgear, cable with pre filters
spreader rooms,
GIS Building Centrifugal fan with pre filter Gravity dampers.
and fine filters along with Exhaust fan inter linked
ducting for supply air with SF6 gas detector
system, exhaust by gravity shall be provied for
dampers will be provided for emergency purpose.
GIS building to maintain
positive pressure and to
prevent ingress of duct
particles inside GIS building.

Simple Exhaust Ventilation System

Area to be ventilated Supply air system Exhaust air system
DM Plant Room Fresh air through intake Wall mounted
louvers exhaust fans
Battery Room (2x50% capacity Fresh air through intake Wall mounted
axial flow belt driven) louvers exhaust fans

Chemical house of PT Plant, Fresh air through intake Wall mounted

workshop and stores, pantry in louvers exhaust fans
all buildings, Hydrogen
generation plant room, Electro
chlorination plant room
All Pump houses Fresh air through intake Wall mounted /Roof
louvers exhaust fans
Elevator machine room/ AC Fresh air through intake Wall mounted
Plant room/ Compressor building louvers exhaust fans

Diesel generator room Fresh air through Roof/Wall mounted

acoustically treated intake exhaust fans
louvers

Toilets in all buildings Through door Wall mounted

undercuts/door louvers Propeller type
exhaust fans

3.3.0 General Design Requirement

3.3.1 Relevant Indian/International standards such as ISHRAE, ASHRAE SMACNA, etc., as

applicable to HVAC system and latest issues of these applicable codes and standards shall
be adopted.

3.3.2 10% margin in equipment capacity over peak heat load calculated considering solar load and
all internal loads due to equipment, lighting, fresh air, occupants, etc have to be considered
for air conditioning and ventilation system.

3.3.3 For sensible and latent heat load, 5% factor of safety shall be considered. .

3.3.4 All windows in the air-conditioned area shall be provided with light coloured venetian blind.

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3.3.5 False-ceiling shall be provided in all air conditioning areas.

3.3.6 All the AC areas and air handling unit room, shall be provided with insulation on the under
side of the roof.

3.3.7 i) The evaporative type ventilation system for each area shall be sized based on either air
flow rate calculated considering a room temperature of 3°C (Maximum) below ambient
DBT during peak summer considering all heat loads or air flow rate calculated
considering minimum number of air changes / hour as mentioned above, whichever
results in higher air flow rate.

ii) The saturation efficiency of 90% and 70% shall be considered for air washer and UAF
system

iii) The dry type ventilation system for each area shall be sized based on either air flow rate
calculated considering a room temperature of 5°C (Maximum) above ambient DBT
during peak summer considering all heat loads or air flow rate calculated considering
minimum number of air changes / hour as mentioned above, whichever results in higher
air flow rate.

iv) Exhaust air quantity from TG hall shall be estimated a 65%-70% of supply air quantity.

3.3.8 For switchgear and cable vault rooms, the supply air flow rate shall be maintained higher than
that of exhaust air flow rate to prevent the ingress of dust into the room from outside.

3.3.9 If, as per manufacturer’s requirements, any switchgear requires air-conditioning, the same
shall be provided by the Tenderer.

3.3.10 The battery room shall be maintained at negative pressure to prevent leakage of fumes to
outside from the battery rooms.

3.3.11 All equipment, ducts, pipes, controls, etc. shall be fully treated against corrosion and sealed
against moisture, sand and dust ingress.

3.3.12 All plant including ducts and pipes as well as machines shall be vibration isolated or otherwise
treated that:

• No excessive vibration is felt in the floors or walls of the rooms served by any machine.

• The mechanically induced vibration levels in floors, walls and ceilings of rooms are
sufficiently small as to limit the radiation of sound levels to the rooms within acceptable
levels.

4.0.0 CONSTRUCTION REQUIREMENT

4.1.0 Water Cooled Chiller unit

The capacity of chilling unit shall be based on the following:

• Chilled water In / Out temperature : 12 deg C / 7 deg C

• Condenser water In/out temp : 33 deg C/ 38 deg C

Each Water Cooled Screw chilling unit comprises of the following:

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• Microprocessor controlled water cooled chiller package unit suitable for R 134a having
one no. of Rotary screw Compressor (Semi hermetic type) with motor, unit mounted
starter, automatic capacity control etc.,

• One no. of Shell & tube water cooled condenser with hot gas inlet, liquid outlet, relief and
purge connection for refrigerant, water inlet and outlet connection, drain connection with
valve.

• One no. of Shell & tube flooded type chiller with liquid inlet, vapour outlet, connection for
refrigerant, water inlet and outlet connection, drain connection with valve and chiller
insulation.

• Thermostatic expansion valve, Refrigerant piping, valves and fittings interconnecting

compressor, condenser, chiller and expansion device and refrigerant piping including
insulation etc,

• Chilled water pumps, condenser water pumps including all interconnecting pipe lines,
valves and necessary accessories.

• Induced draft cooling towers with valves and accessories

• Initial charge of Refrigerant Gas & Oil lubricants, base frames, vibration isolation pad,
integral wiring and unit mounted isolator/fuse switch.

• Flexible connection (corirubber with retainer rods and flanges suitable to operate at the
design pressure) between chilling unit and piping.

• Vibration isolators for chillers & Cooling towers.

• Necessary instruments for safe and reliable operation of the system

4.2.0 WATER cooled Package Air Conditioners

Each water cooled Package Air Conditioners comprises of the following:

• Scroll type refrigerant compressor (R 134a) with motor and drive package

• One no of Water cooled condenser

• One no DX cooling coil with air handling fan.

• Interconnecting refrigerant pipes to connect the compressor, condenser, and expansion

device.

• Condenser water pumps including all interconnecting pipe lines, valves and necessary
accessories.

• Induced draft cooling towers with valves and accessories

• Initial charge of Refrigerant Gas & Oil, lubricants.

• Necessary instruments for safe and reliable operation of the system.

4.3.0 Split type air-conditioning system

The major components of split type air–conditioner system is:

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i) Indoor unit comprising of:

DX -Cooling coil
Blower
Coarse filter

ii) Outdoor unit comprising of:

Compressor
Condenser.

DX Dehumidifying & coil unit: The DX coil shall be standard staggered tube arrangement with
seamless copper tube and aluminum plate fin mechanically bonded to copper shall be sized
with following specification:

Face velocity : 2.5 m/sec

Tube OD minimum : 10mm

Wall thickness : 0.5mm

Blower : The Blower shall be DIDW forward curved belt driven

fan of suitable capacity and static pressure.

Coarse Filter : Coarse filter shall be washable dry panel filter having
an efficiency of 90 % down to 20 microns and
suitable for handling the units air quantity
Compressor : The compressor of split unit shall be Scroll type
compressor ( R 134a/407c/R410a).
Condenser : Condensers shall be fin-tube type seamless copper
tubes and aluminum plate fin mechanically bonded
to copper and shall be sized with following
specification:

Face velocity : 2.5 m/sec

Tube OD minimum : 10mm

Wall thickness : 0.5mm

The Condenser fan shall be of high efficiency propeller type

4.4.0 Centrifugal Pump

Each centrifugal pump set shall be either horizontal split casing/End suction top discharge
pumps for chilled water and condenser water re-circulation. It shall comprise of the following:
• One no. horizontal split casing/ End suction top discharge centrifugal pump with
adequately sized induction motor suitable for 415V, 3 phase, 50 Hz supply.
• Common base plate for the pump and motor, coupling with guard, anti vibration pads,
foundation bolts etc.
• Chilled water pump set shall include thermal insulation of pump.
• Flexible connection (Corirubber with retainer rods and flanges suitable to operate at the
design pressure) shall be provided between pump and piping.
• Drain piping from pump to nearest floor drain.

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4.5.0 Cooling Tower

The cooling tower shall be induced draft (Single cell) FRP cooling tower with fan and motor,
drive package, FRP basin, FRP air inlet louvers, fills, drift eliminators, nozzles, make-up
connection, over flow connection, drain connection, ladder and supporting structure. The
capacity of the cooling tower shall be equal to the condenser cooling capacity and designed
for the following conditions:
0

Approach : 5 C

4.6.0 Air Handling Unit

Air handling unit (AHU) shall be double skinned, draw through re-circulating type handling an
air quantity equal to the dehumidified air quantity. The system shall consist of the following
items:

AHU Casing

Inlet louvers

Coarse filters section

Cooling and dehumidifying coil section

Fans Section (DIDW centrifugal type)

Vibration isolators ( minimum efficiency of 85%)

AHU casing

The AHU casing shall be in sectionalized construction with modules for dampers, filters,
cooling coil, and fan section all housed in a galvanized sheet metal casing. The casing of
AHU shall be double skin construction. Double skin sandwich panel (inside and outside) shall
be fabricated using minimum 0.8mm (22g) galvanized steel sheet with 25mm thick
3
polyurethane foam [PUF] insulation of minimum 38kg /m density in between the two skins.
The skin shall be suitably stiffened and braced to eliminate distortion and drumming.

Pre-Filter

The pre-filter section shall be washable type filter panels suitably arranged in holding frames
having a minimum efficiency of 90% down to 10 micron size. A differential pressure gauge
shall be fitted across the filter.

Cooling coil unit

The cooling coil with capacity equal to the units refrigeration capacity shall be standard
staggered tube arrangement fabricated from continuous aluminum fins mechanically bonded
to seamless copper tubes sized with a face velocity of 2.5 m/sec.

Centrifugal Fan
The centrifugal fan shall be double inlet double width centrifugal forward curved V-belt driven
fan by a totally enclosed motor of suitable capacity and static pressure. The blower / fan
discharge velocity shall not exceed 10 m/s.

4.7.0 Plenum mounted Fine filter

The fine filter section shall be synthetic non-woven washable filter panels, suitably arranged in
holding frames having a minimum efficiency of 99.9% down to 5 micron size. A differential
pressure switch shall be fitted across the filter. The fine filter area shall be designed for a face
velocity of not exceeding 1.75 m/sec.

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4.8.0 Electric duct heaters

Electric air heater shall be finned tubular element sheathed type construction of either
ductable or slip-on installation type. The electric heater shall be UL approved design & be
provided with the following accessories conforming to NEC Article - 424.

• Step controller of either silicon control rectifier or SCR-vernier type for system requiring
close RH tolerance.
• Program controller - with multiple humidistat’s / thermostat energizing heater in steps-
minimum 4-steps for areas requiring relatively higher RH tolerance.
• High temperature cutout with manual reset facility
• Fan circuit interlocking contacts
• Over current protection
• Safety disconnect switch (Interlocking with panel door).

All heater capacity shall be sized for winter heating load also and where heater are used as
reheater for humidity control, facility shall also be provided to control room dry bulb
temperature during winter.

4.9.0 Pan type Humidifier

Electric humidifier, shall be pan type steam humidifier. The humidifier shall consist of stainless
steel basin insulated on outside with 25 mm resin bonded fiber glass thermal insulation of
25 kg/ cm. density covered with 20 SWG GI sheet on outside.

4.10.0 Fresh air unit

Each fresh air unit shall comprise of :

a) One (1) no. Tube axial fan with motor

b) Pre filter with HDPE media having 18 G GSS frame. The efficiency of the filters shall be
90% down to 10 microns. Maximum Velocity across pre filter shall be 2.5 m/s.

c) Fine filter with HDPE media having 18 G GSS frame. The efficiency of the filters shall be
99.9% down to 5 microns. Maximum Velocity across Fine filter shall be 1.75 m/s.

d) Fresh air Louver, Volume control damper and connecting duct

4.11.0 Make-Up Water Tank and softening plant

The Make-up water tank shall be made of G.I or FRP and shall be of adequate thickness and
suitably reinforced. It shall be complete with make-up connection with float valve, quick fill
connection, overflow connection and drain connection with valve. The tank shall be provided
with level gauge glass. This tank shall supply make-up water to Cooling towers, Expansion
tank and humidifiers. The tank size is to be designed based on capacity to hold water for
15 minutes of make-up water requirement. This make up water shall be treated through the
Non-Chemical Water Softening Equipment (if required) installed in the common header of
Condenser water pump outlets. Conductivity type level switches low, low low, high high shall
be provided.

4.12.0 Expansion Tank

MS Expansion tank shall be insulated. The tank shall be complete with all the accessories,
float valve, drain, overflow, makeup connection and vent connection. Conductivity type level
switches low, low low, high high shall be provided.

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4.13.0 Air Washer Unit

Air washer chamber housing the Air Intake Louver with bird screen, pre filter, air distribution
plates, Stainless Steel Filters continuously flooded with water through spray nozzles, Die-
extruded PVC Eliminators, Water tanks, marine light shall be manufactured of steel sheet in
sections to facilitate easy dismantling and erection. The unit shall be fabricated from minimum
3 mm thick M.S. sheet duly painted with epoxy resin based paint from inside and outside with
adequate stiffeners, bracings etc. The air washer tank also shall be made from minimum 6
mm thick MS sheet duly painted with epoxy resin based paint.

The various sections of the unit shall be bolted with suitable gasket to avoid leakage of water.
All the sections of the units shall be Epoxy painted from inside and outside to prevent
corrosion/ weathering damage. The nuts and bolts used for jointing the sections shall also be
galvanized. All inside and outside parts of the fan shall be spray galvanized except the fan
shaft that shall be of epoxy painted.

Properly hinged air tight epoxy painted inspection doors of suitable sizes shall have to be
provided in filter and spray sections of each sheet metal Air Washer units.

The water shall be collected in a MS (6mm) fabricated tank and shall be re-circulated by
means of the pump. This tank shall be shall be complete with make-up connection with float
valve, quick fill connection, drain connection with valve, water low level switch and overflow
connection with siphon. Water from the washer chamber tank shall be taken through a
primary screen type water strainer fitted in an accessible position in the tank. The strainer
screen shall be manufactured of S.S netting in a S.S. Frame.

4.14.0 Unitary Air filtration unit

Unitary Air Filtration Unit shall consist of intake louvers with bird screen, pre filter, air
distribution plates, one set of automatically cleanable type Stainless Steel mesh Filters with
continuous water spraying arrangement over the surface of it to clean the filters, PVC die-
extruded Moisture Eliminator sets after the above water flooded filters to eliminate the carry
over of moisture, sump tank, circulating water pumps, piping and valves, centrifugal fans,
outlet damper and plenum section. The entire components shall be neatly arranged and skid
mounted and shall be self-enclosed by 3 mm thick MS casing duly painted with epoxy resin
based paint. The casing front shall be provided with the air intake louvers with bird screen of
GI construction. Each section i.e., filters, evaporative pad and pump section etc. shall be
provided with access door for maintenance. All parts of the fan for this system coming in
contact with moist air shall be epoxy painted. The fan section shall be designed to limit the
noise level to 85 dBA within 1.0 m of the fan enclosure. On the whole, the assembly of UAF
shall be designed so as to be structurally sound, air tight and also aesthetically pleasing.

The water shall be collected in a MS (6mm) fabricated tank and shall be re-circulated by
means of the pump. This tank shall be shall be complete with make-up connection with float
valve, quick fill connection, drain connection with valve, water low level switch and overflow
connection with siphon. Water from the washer chamber tank shall be taken through a
primary screen type water strainer fitted in an accessible position in the tank. The strainer
screen shall be manufactured of S.S netting in a S.S. Frame.

4.15.0 Centrifugal Fans

Centrifugal fans for Ventilation System shall be DIDW/SISW non-overloading type designed.
Fan shall be driven with V-belt by a totally enclosed motor and the fan outlet velocity shall not
exceed 11 m/sec.

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Impeller shall be die formed aerofoil or laminar type of self cleaning and non-overloading
characteristics. The impeller shall be statically and dynamically balanced according to ISO
standard.

The fan casing shall be of welded construction and provided with flanges on inlet & outlet side
for duct connection.

The fan impeller & casing etc. shall be protected by a suitable corrosion resistant.

Accessories like common base frame, anchor bolts, vibration isolators, V-belt guard, inlet
guard and outlet damper, canvas etc., shall be provided. Centrifugal fans and drive motors
mounted on common base frame to be mounted on spring type vibration isolators to prevent
vibration transfer to floors as well as to the downstream side of duct.

4.16.0 Roof Extractors

Power roof extractor’s impeller shall be of axial type. Casing shall be made of MS and
impeller shall be made of aluminum. Hood of the roof ventilator shall be of hinged type
providing easy access to motor and impeller. Mounting frame for mounting the roof ventilators
shall be provided. Weather proof lockable type disconnect switch shall be provided such that,
the hood can be opened only when the disconnect switch is in “OFF” position.

4.17.0 Axial Flow Fan

Directly driven axial flow fans with die cast aluminium impeller dynamically balanced, fitted
with three-phase induction motor.

The fan casing shall be of galvanized steel material. Fan shall be provided with rain protection
hood (for roof exhausted) / inlet cowl, filters (supply air fans), bird-screen, back-draft damper,
(where necessary) grouting frame and cadmium plated fixing bolts.

For battery rooms, the wall mounted axial flow fan shall be of FRP coated cast aluminium
impeller with blades of aerofoil design. The fan motor shall be externally mounted (outside the
air path) on a bracket fixed to the casing with necessary V-belt drive. The motor shall be of
explosion proof type.

4.18.0 Pre Filter

The pre filter section shall comprise of 50 mm thick washable filter panel suitably arranged in
holding frames. The pre filter shall have a minimum efficiency of 90% down to 10 microns
size. Maximum Velocity across pre filter shall be 2.5 m/s.

4.19.0 Air Distribution System (common for both air conditioning and ventilation
Ductwork

The ductwork inside the building shall be manufactured form hot-dip galvanized sheet metal,
complying with IS-277 Gr 275 or better.

All ductwork support ties to the structure shall be made resilient with the use of 12mm thick
non-intercellular neoprene strip, gaskets or washers. All ductwork connections to air handling
equipment shall be made via 15 cm long connections of rubber impregnated canvass
material.

Entire AC ducting shall be designed based on equal friction method and maximum velocity in
the ducting shall be 7.5 m/s.

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Maximum velocity in the duct shall be 11 m/s and velocity of air through supply air grilles shall
be maximum 5 m/s for ventilation system.

Supports for Ductwork

Supports shall generally comprise hot-dipped galvanized mild steel sections and drop rods
assembled in a suitable manner to permit adjustment for height and alignment of the ducts,
and to prevent the transmission of vibration and/or noise.

Ducts shall be supported by the stiffening angles or angle flanges but where this is
impractical, supporting angles shall be fixed to the ducts

Supply and Exhaust Air Grilles

In conventional attractive design, lamellas adjustable, aerofoil shape, broad front frame to
allow airtight mounting. Frame and lamella made from steel with agreed stove enamel finish,
conserved in nature color. Covered screw mounting with use of mounting frame shall be
provided.

Air-flow control shall be by means of counter-moving, coupled lamellas, with sets of

adjustable air deflection blades and an opposed blade damper located at the rear, adjustable
from the front side.

Supply and Exhaust Air Diffusers

Square construction diffusers for mounting in false ceilings shall be provided. Air vanes in
lamella form for air distribution to all sides, made from powder coated extruded aluminium
with agreed finish, Connection boxes in air-foiled construction made of galvanized sheet
metal with built-in throttling device and connecting piece.

Ceiling diffusers shall be of the adjustable eyelash deflection blade type and shall have an
opposed blade damper located at the rear. The diffuser shall be fixed to the ductwork by a
purpose-made sub-frame assembly.

Fire Dampers

The supply and return air ducts of air conditioning system and main duct of ventilation system
shall be provided with automatic motor-operated fire dampers with fire rating of 120 minutes,
at locations where ducts pass through wall/floors/ceiling slabs of electrical rooms in TG
building & ESP building, for isolation/ maintenance/ fire-protection purpose. The operation of
these automatic dampers shall be interlocked with the fire alarm system and shall also be
possible to operate manually from the remote control panel. Required electrical contacts shall
be provided in control panel of A/C plant for further wiring up to fire alarm panels.

Fusible link fire dampers of 60 minutes fire rating shall be provided for all other areas
excluding electrical rooms where ducts pass through wall/floors/ceiling slabs for isolation/
maintenance/ fire-protection purpose.

Isolating Dampers

Consisting of frames of galvanized sheet metal, air foiled lamellas, adjustable from the
outside by a lever and positioning device.

Lamella clutches by aluminium cogs mounted inside, bearing sleeves closed to the outside,
including mounting flange for connection to an air-duct or mounting into an A/C-chamber.

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Air Quantity Regulating Flaps

Air quantity regulating flaps for balancing, during first step of operation, of the mathematically-
-determined air quantities in each duct branch. These throttling devices shall be arranged in
supply air ducts as well as in return air ducts.

Weather Louvers

Weather louvers shall be of hot-dipped galvanized angle-iron frame with built-in rain-rejecting
galvanised iron or aluminium lamellas as well as bird protection screen of galvanized iron,
Mounting frame of galvanized profile steel.

4.20.0 Insulation

4.20.1 Thermal Insulation

The entire supply / return air ducting shall be thermally insulated with 25 mm thk. fibre glass
of 32 kg/cu.m. The exposed roofing also shall be thermally insulated.

The exposed roof slabs (Including beams and column etc.) of air- conditioning areas , air
handling units room and Packaged Air conditioners (PAC) rooms will be insulated with 50 mm
3
thickness fibre glass insulation of density 48 kg/m finished with 26 SWG aluminium cladding.
For the portion ventilation system ducting exposed to outdoor ambient, thermal insulation of
25 mm fiber glass wool with aluminium cladding finished with sand cement plaster shall be
provided.

4.20.2 Acoustic Insulation

The supply air ducting from each AHU outlet upto 5 meters shall be acoustically insulated with
12 mm thick resin bonded fibre glass of density 48 kg/cu.m covered with 30 G perforated
aluminum sheets.
4.20.3 Chilled water pipe insulation

Chilled water piping shall be thermally insulated with expanded polystyrene of density
20 kg/cu.m and finished with sand cement plaster. The thickness of piping insulation shall be
as follow.

Sl. No. Pipe Diameter in mm Insulation Thickness in mm

1 Upto 25 NB 40 mm
2 Above 25 NB to 125 NB 50 mm
3 150 NB 75 mm

5.0.0 CONTROL PHILOSOPHY

It is envisaged that primary operations including control and monitoring of TG building A/C
system and monitoring of ventilation system shall be carried out from the AC and ventilation
system local control room through the remote I/Os with the redundant Processor, power
supply, communication module, redundant communication link with the main plant DCS. Apart
from the DCS controls, selector switches and push buttons shall be provided for manual
operation of all air-conditioning equipment.

Control, operation and monitoring of service building A/C system and monitoring of ventilation
system shall be carried out from the PLC system located in the A/C control room of Service
Building. Apart from the PLC controls, push buttons, selector switch shall be provided for
manual operation of all air-conditioning equipment.

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Control, operation and monitoring of CHP, AHP, ESP & Switch yard building A/C system shall
be carried out from the respective air-conditioning equipment.

Operations of the ventilation equipment in TG building and ESP building shall be carried out
from the respective ventilation LCP
Operation of the ventilation fans in other areas like AHP building, switchyard buildings,
Compressor room, WTP room and all other buildings shall be carried out from the respective
MCC.

One no. Local starter Panel shall be installed in each AHU room which will feed power to all
the AHU fans, motors of 3-way mixing valves of AHUs, Fresh air fans (wherever applicable),
Smoke Exhaust fans (wherever applicable) and their motorized isolating dampers, Fire
damper motors, Electric heaters and Humidifiers. These equipment located in each AHU
room shall be operated and controlled from the DCS operator stations located in the AC
Plant Room as well as from this Local Starter Panel.

The Screw Chilling units shall incorporate microprocessor based control panel, which will also
be interfaced with the DCS system.

The Screw Chilling units can be started only when its associated cooling tower fan, condenser
& chilled water pumps are in operation.
All the drives of the AC system shall be manually started / restarted through DCS operator
stations after any trip.

The chilled water system shall be provided with the following safety & operating controls:

(i) Operating Control

Room temperature control with the help of modulating 3-way chilled water flow
regulating valve with the cooling coil of AHUs through the PLC system, getting sense
from the temperature sensor and associated transmitter placed in the return air path.

Chilled water temperature shall be controlled based on the room load with the help of
operating temperature sensor and through compressor’s automatic unloading
mechanism for screw chillers through the built-in Microprocessor based control panel
of Screw Chiller. This control shall also be possible through the PLC system

One common PLC for Air-Conditioning System & Ventilation System shall be provided to
control the followings.

a) AC system for control building.

b) AC system for ESP building.
c) AC system for service building.
d) Ventilation system (Air washers) for TG building.
e) Ventilation system (UAF) for ESP building.

Further it may be noted that Control of auxiliaries buildings provided with split AC / package
Units shall be independent of common PLC Control of auxiliaries buildings provided with dry
ventilation system shall be independent of common PLC.

Room RH control with the help of humidifiers (if required) & duct mounted re-heaters
through the DCS, getting sense from the RH & Temperature sensors and their
associated transmitters placed in the return air path inside AHU rooms.

(ii) Safety Control

The chilled water system shall be incorporated with the following safety controls and
interlocks:

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- High discharge pressure cutout (HP).

- Low suction pressure cutout (LP).
- Low oil level cutout
- High winding temperature cutout through PTC sensors

Low chilled water temperature cutout by anti-freeze thermostat /temperature

sensor for Screw chiller.

Cutout due to low flow of chilled water & condenser water by flow switches.

Cutout due to overload of all drive motors. High air temperature cutout by safety
thermostat / temperature sensor for duct mounted electric heaters.

Safety controls of Screw chillers will also include Over/Under voltage and voltage
unbalance protection, Single phase & Phase reversal preventer, over/under current
and current unbalance protection and others as per manufacturer’s standard.

Low cooling tower sump water level cutout for Condenser pumps. (Alarm for low
water level in expansion tank & humidifier as applicable shall be provided).

Stopping of AHU fans in case of fire in the respective zone through the PLC.

Closing of fire dampers at the air supply duct from AHUs in case of fire with the sense
from room mounted fire/smoke detector through zonal fire panel and the PLC.

(iii) Interlocks

The system components shall be interlocked with one another in the following way:

The Screw Compressor shall not start unless:

At least one cooling tower fan is running.
At least one condenser water pump is running.
At least one chilled water pump is running.

The duct mounted electric strip heater shall not be energized unless the respective AHU fans
are running.

All the above Interlocking and the complete controls will be implemented in the respective
control system mentioned above.. Whereas the chilled water temperature controls and the
safety interlocks of the screw chillers shall be realized in the microprocessor based control
panel as per the manufacturer’s standard

On-Off-trip status for all the drives, electric heaters & humidifiers (if required) shall be
available at the DCS operator stations located in the local control room of the AC and
ventilation system

Motors of fire dampers provided in supply air duct of AHU shall remain energized in normal
condition to effect opening of dampers. In the event of fire, the motors of fire dampers will be
de-energized and the damper will close due to spring action, the relevant AHU fan motors will
be tripped at the same time. These dampers shall be operated through the PLC getting signal
from relevant duct mounted smoke detectors / fire alarm panel.

Provision for one common audio annunciation for any kind of malfunctioning in AC plant shall
be kept through a hooter located in the AC Plant Control Room and suitably interfaced with
the respective control system.

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The DCS system shall be interfaced with:

• The Air Conditioning MCC cum PDB.

• The Microprocessor based control panels of Screw Chiller.
• The LCPs located in each AHU rooms.
• The Temperature and RH sensors and their associated transmitters located in the
AHU rooms.
• The zone fire panels/ duct mounted smoke detectors.

6.0.0 DRAWINGS & DOCUMENTS TO BE SUBMITTED ALONG WITH THE PROPOSAL

• Technical data sheet to be filled by Bidder.

7.0.0 DRAWINGS & DOCUMENTS TO BE SUBMITTED AFTER AWARD OF CONTRACT

• P&I Diagram Air conditioning System

• P&I Diagram Ventilation System
• DBR for Air Conditioning System
• DBR for Ventilation System
• Air conditioning System calculations
• Ventilation System calculations
• Specification for Air Conditioning System
• Specification for Ventilation System
• Equipment layout for Air conditioning plant room and AHU room
• Equipment layout for Air washer room and UAF room
• Ducting layout for AC and Ventilation system
• GA and data sheet for equipment for AC and Ventilation system
• Schematic duct layout for AC and Ventilation system

Any other drawings required for review during the detailed engineering stage, same shall also
be submitted by contractor.

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ANNEX – 2.17.1
SPECIFIED DESIGN DATA
[Link] Description Unit Data
A) Chillers unit
Type Water cooled Screw chillers
No of units 3 x 50 %
Flow To suit system requirement
Compressor
Type Semi hermetic/
Refrigerant R134a
Evaporator
Type Flooded type shell & tube
Condenser
Type Shell & Tube
B) Chilled /Condenser Water
Pumps
Horizontal split casing end suction top
Type
discharge Centrifugal pump
3 x 50 % for chiller system and 2 x 100% for
No of units
package air conditioning system
Flow To suit system requirement
C) Air Handling Units
Double skinned, horizontal floor mounted,
Type
draw through re-circulating type
No of units 3 x 50 %
Capacity To suit system requirement
Coil type Chilled water type
Copper tube with aluminum fins mechanically
Coil construction
bounded
Coil face velocity 2.5 m/s
Fan
Fan Type DIDW forward curved centrifugal fan
No of fans per AHU One
Fan Outlet Velocity < 10m/s
Filter
Type Pre Filter
Filter material Non Woven synthetic type, washable
Filter efficiency 90% down to 10 microns
D) Packaged Air Conditioners
Type Water cooled type
Area served Refer clause 2.1.2
Capacity To suit system requirement
N + 1, where N - no of working units, 1 no of
No of units
standby unit
Indoor unit
Cooling coil Internally grooved copper tubing with slit fins
Fan type Centrifugal
Compressor Hermetically sealed Scroll
Filters
Non woven polyester media enclosed by
Filter media
HDPE mesh
Efficiency 90% down to 10 microns
E) Cooling Towers
Casing FRP
3 x 50 % for chiller system and 2 x 100% for
Redundancy
package air conditioning system

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[Link] Description Unit Data

Air inlet louver FRP
Fill PVC
Nozzles Bronze / Polypropylene
Cold water basin FRP
F) Split Air Conditioners
Type Air cooled type with 5 Star Rating inverter AC
Area served Refer clause 2.1.3
Capacity To suit system requirement
N + 1, where N - no of working units, 1 no of
No of units
standby unit
Indoor unit
Cooling coil Internally grooved copper tubing with slit fins
Filters
Non woven polyester media enclosed by
Filter media
HDPE mesh
Efficiency 90% down to 10 microns
Outdoor unit
Condenser coil Copper coil with aluminum fins
Compressor Hermetically sealed rotary type
Fan type Propeller
G) Air washer unit
Areas Served Power house building
Type Spray type (Double bank)
Flow To suit system requirement
Redundancy All working
Construction type Sheet Metal type
Casing 3 mm MS Sheet
Tank Minimum 6 mm MS Sheet
Air Distribution Plate 18 - 24G GS Sheet
Nozzle Stainless steel/ Brass / PVC, Spray Nozzle
Eliminator PVC
Spray Set Header MS to IS 1239 / IS 3589
Air intake louver 22 G GS Sheet with MS Angle Frame
Filter Flooded type stainless steel filter.
H) Unitary Air filtration Unit
Areas Served ESP building
All Working.
Redundancy
2X50% UAF for each ESP building
Type Spray type ( Single bank)
Flow To suit system requirement
Construction type Sheet Metal type
Casing 3 mm MS Sheet
Tank Minimum 6 mm MS Sheet
Air Distribution Plate 18 - 24G GS Sheet
Nozzle Stainless steel/ Brass / PVC, Spray Nozzle
Eliminator PVC
Spray Set Header MS to IS 1239 / IS 3589
Air intake louver 22 G GS Sheet with MS Angle Frame
Filter Flooded type stainless steel filter.
I) Air Washer/UAF Fan
Areas Served Power house building
Redundancy 2 nos of fan for each air washer and UAF
Centrifugal Fan, DIDW for Air Washer / SISW
Type
for UAF
Casing 3.15 mm MS Sheet with spray galvanization
Fan Shaft EN8

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[Link] Description Unit Data

Fan Impeller Mild steel spray galvanized
Motor driven, coupled with fan through V-belt
Drive
and Pulleys
Outlet damper 18 G GS Sheet with 16 G Frame
Base Frame, Slide Rail, Belt Guard, Inlet
Other Accessories
Screen and Vibration Isolator to be provided
J) Pumps for Air washer / UAF
Horizontal split casing end suction top
Type
discharge Centrifugal pump
3 x 50 % for air washer system and 2 x 100%
No of units
for UAF system
Flow To suit system requirement
K) Axial Flow Fan
Service Supply/Exhaust
Mounting Wall/Roof/Duct
Type Tube axial/Propeller
Capacity To suit system requirement
Redundancy for battery room
2x50%
exhaust fans
Material of construction
Casing Mild steel plate to IS 2062
Impeller Cast Aluminium
Shaft EN 8
Inlet Cone / Outlet cone Mild steel
L) Roof Extractor Fan
Service Exhaust
Mounting Roof
Type Axial
Capacity To suit system requirement
Material of construction
Casing Mild steel plate to IS 2062
Impeller Cast Aluminium
Shaft EN 8
Hood MS

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SECTION-3.10: LOW VOLTAGE (LV) SWITCHGEAR

1.0.0 INTENT OF SPECIFICATION

This section covers the technical requirements of low voltage switchgear.

2.0.0 SCOPE OF WORK

The scope of work shall include supply, installation, testing and commissioning of the following:
a) 415 V, AC intelligent Power control centres (PCC) for units, station, auxiliary plant and non
plant buildings.
b) 415 V, AC intelligent Motor control centres (MCC) for units, station, auxiliary plant and non
plant buildings.
c) 415 V, AC distribution boards for units, station, auxiliary plant and non plant buildings.
d) 415 V, AC Emergency PCC and emergency MCC for each unit.
e) 220 V DC distribution boards for units, station and auxiliary plants.
f) 415 V heater control panels for electrical heat tracing of fuel pipe lines
g) Local starters for units, station and auxiliary plants.
h) Local panels for units, station and auxiliary plants.
i) Local push button stations for various units, station and auxiliary plants.
j) Commissioning spares and consumables
k) Mandatory spares
l) Tools & tackles
m) Any other equipment required for the system

3.0.0 CODES AND STANDARDS

The equipment to be furnished under this specification shall be in accordance with the
applicable section of the latest version of the relevant IS/IEC standards including amendments,
if any, except where modified and/or supplemented by this specification. Some of the
applicable standards are listed below:

a) IS 8623 Specification for low voltage switchgear and control gear Assemblies
b) IS 10118 Code of practice for selection, installation and maintenance of switchgear
and control gear
c) IS/IEC 60715 Dimensions of low-voltage switchgear and control gear - standardized
mounting on rails of mechanical support of electrical devices in switchgear
and control gear installations
d) IS 12021 Specification for control transformers for switchgear and control gear for
voltages not exceeding 1000 V
e) IS 13032 Miniature circuit breaker boards for voltages not exceeding 1000 V
f) IS/IEC60947 Specification for low voltage switchgear and control gear
g) IS 694 Specification for PVC insulated cables for working voltage up to and
including 1100 V
h) IS 5 Colour for ready mixed paints and enamels
i) IS 14372 Specification for volt-ampere hour meters for full power factor range
j) IS 14415 Specification for volt-ampere hour meters for restricted power factor range
k) IS 1248 Direct acting indicating analogue electrical measuring instruments and their
accessories

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l) IS 2705 Specification for current transformers

m) IS 3156 Specification for voltage transformers
n) IS 3231 Specification for electrical relays for power system protection
o) IS 6005 Code of practice for phosphate of iron and steel
p) IS 11353 Guide for uniform system of marking and identification of conductors and
apparatus terminals
q) IS/IEC 60529 Degrees of protection provided by enclosures (IP code)

r) IEC 60439 Low voltage switchgear and control gear assemblies

s) IEC 60947 Low voltage switchgear and control gear
t) IEC/TR 61641 Enclosed low-voltage switchgear and control gear assemblies – Guide for
testing under conditions of arcing due to internal fault

4.0.0 TECHNICAL REQUIREMENTS

4.1.0 Power supply voltage shall be considered as follows:

• Motors rated > 0.2 kW and up to 200 kW : 415 V, 50 Hz, 3 Phase

• Motors rated up to 0.2 kW : 240 V, 50 Hz, Single Phase
• Panel lighting & Space Heater : 240 V, 50 Hz, Single Phase
• Control Supply : 220 V DC

4.2.0 Current Rating

4.2.1 Ambient temperature prevailing inside the switchgear while carrying rated current, when the
outside air ambient temperature is 50˚C shall be considered as design ambient temperature for
sizing the equipment/device/bus rating. Continuous current rating shall be such that the
temperature does not exceed 90˚C. For silver plated joints the temperature shall not exceed
105˚C.

4.2.2 The continuous current rating of the feeders shall be based on the name plate current rating of
the connected equipment with 10% margin at design ambient condition, rounded off to next
higher standard rating unless specified otherwise.

4.2.3 The continuous current rating of the incomers/tie feeders/main bus bars of PCC shall be based
on the name plate rating of the upstream transformer with 10% margin at design ambient
condition, rounded off to next higher standard rating unless specified otherwise.

4.2.4 The continuous current rating of the incomers/tie feeders/main bus bars of other switchgear
shall be based on the continuous current rating of the all the connected loads with 10% margin
at design ambient condition, rounded off to next higher standard rating unless specified
otherwise.

4.2.5 For switchgear having two bus sections, each bus section, bus coupler and incomer shall be
rated for the combined load requirements of both the bus sections.

4.2.6 Similar equipment and components shall be of same make. Equipment / Module of same type
and rating shall be interchangeable.

4.2.7 The design of the LV Switchgear shall include all devices required for remote control &
monitoring from DCS. It shall be monitored from the EMS system also.

4.2.8 The power control centres and motor control centres shall be intelligent type.

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4.3.0 Protection

4.3.1 The Contractor shall be responsible for selection of protective devices so as to provide optimum
protection and discrimination of various circuits and equipment including the safety of the
devices. For motor feeders, coordination of overload relay and MPCB/MCCB with the thermal
characteristics of the motor shall be ensured.

4.3.2 MCCB / MPCB, contactor and Electronic overload relay for motor feeders shall meet type-2
coordination as per applicable standard.

4.3.3 The incomer modules shall be interlocked with their upstream breaker such that they can be
closed only when upstream breaker is closed and trip automatically when upstream breaker is
tripped.

4.3.4 Each breaker module shall be provided with multifunction numerical relay for protection. Relays
shall have built in protection, control & metering and communication modules suitable for IEC-
61850 protocol.

4.4.0 Control

4.4.1 Incomers and bus coupler of PCCs shall have air circuit breaker (ACB). PCC refers to LV
switchgear connected to load center transformer which consists of outgoing power feeders and
outgoing motors feeders.

4.4.2 Outgoing feeders of PCC shall be controlled by ACB / moulded case circuit breakers (MCCBs)
depending on their ratings / applications.

4.4.3 Incomers and bus couplers of MCCs shall be breaker controlled. Outgoing feeders of MCCs
shall be controlled by MCCBs / Motor protection circuit breakers (MPCBs) and contactors
depending on their ratings / applications.

4.4.4 Feeders rated above 630 A shall be controlled by ACBs, unless specified otherwise. Feeders
rated up to 630 A may be controlled by MCCBs. However ACB shall be used for 400 A and 630
A feeders where auto changeover is envisaged at incomer / bus coupler.

4.4.5 ACBs shall be used for motor feeders rated above 125 kW for direct-on-line (DOL) starting.

4.4.6 MCCB/MPCB Contactor starter units shall be used for motor feeders rated up to 125 kW for
DOL starting.

4.4.7 Feeders of 415 V PCC/MCC shall be controlled from DCS or Respective control system and
Local Push Button (LPB) Station as per scheme requirement.

4.4.8 Remote selection shall enable control from DCS/Respective control system.

4.4.9 The control/interlock schemes for various types of feeders shall be commensurate with their
applications.

4.4.10 Local start push button shall be hardwired to DCS/Respective control system so as to check the
process permissive for starting the drives, whereas local stop push button shall be directly hard
wired to concerned switch gear for tripping.

4.5.0 Changeover Scheme

4.5.1 All PCCs and ACB operated MCCs shall be normally operated with the bus coupler breaker
open. Auto-changeover facility shall be provided such that if there is a prolonged under voltage
on any one of the bus sections, the respective incoming breaker shall trip and the bus coupler
breaker shall close, provided on the other bus section is healthy. This auto-changeover shall be

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blocked if the incoming breaker had tripped either on a bus fault or manually. Changeover back
to the normal source of supply shall be done manually.

4.5.2 Planned changeover facility shall be provided for PCC and ACB operated MCC. When planned
outage of one of the normal incoming supplies is required, the respective incomers shall be
tripped automatically after the bus coupler breaker is closed manually through synchro-check
relay. For this purpose, a trip selection shall be provided in DCS/Respective control system for
selecting the incomer to be tripped. Thus, depending on the selection made incomer A or
incomer B shall be tripped once bus coupler breaker is closed manually, thus maintaining
continuity of supply. A timer for annunciation of the running breaker failing to trip within a pre-
set time, (i.e. if the two sources remain paralleled for more than a pre-set time) shall be
provided. When the normal supply is to be brought back into operation, the incomer breaker
shall be closed through synchro-check relay whereupon the bus section breaker shall trip
automatically. All hardware required for meeting the functional requirements stated above, shall
be included.

4.6.0 Emergency MCC

4.6.1 Emergency MCC to supply power to important emergency loads/motors for safe shut-down of
unit shall be provided for each unit. It shall have two bus sections (A&B) with a bus coupler.
Bus section-A shall have two incomers, one from Unit PCC and the other from emergency
PCC. Bus section-B shall have one incomer from station PCC. All the incomer breakers in the
emergency MCC shall be 4 Pole. Bus coupler shall be normally closed.

4.6.2 In case of failure of unit supply to the Emergency MCC, the station supply shall be switched ON
automatically and in case of total failure of AC supply of the power station, the supply from
emergency PCC shall be switched ON automatically.

4.6.3 DG PCC shall have two incomers, one incomer fed from respective Unit DG set and second
incomer fed from standby DG set. In case of failure of unit DG set, the stand-by DG set shall be
switched ON.

4.6.4 All service like essential motors for safe shutdown of the unit, UPS incomers, battery charger
AC supply, lighting, etc. shall be connected to this MCC. DG supply shall be extended to
emergency MCC in less than 15 sec from loss of power.

4.6.5 On restoration of normal supply, the changeover of DG supply to normal supply at Emergency
MCC shall be done with synchronizing facility to avoid interruption of supply.

4.6.6 For DG paralleling / load testing, separate breaker shall be provided in main plant AC MCC &
Emergency MCC. Load test of DG set can be carried out using connected loads on the AC
MCC switchgear.

4.7.0 Essential Service Modules

During auto changeover of the supply, the contactors in the affected bus would have dropped
off. The services, which shall be restarted immediately without time lapse to keep unit
running, are considered essential service. (For e.g. seal oil pumps, lube oil pumps, auxiliary
cooling water pumps etc.) Such auxiliaries shall restart automatically without any action by
the operator after an auto change over. These modules shall have additional hardware like
timer, aux contactors and associated circuitry in the module or shall have restart feature
programmed in DCS. Such essential services shall be identified during the detailed
engineering stage and suitable module / scheme shall be provided.

The modules of some of the critical application motors like barring gear motor, air heater
motor, lube oil pump, jacking oil pump etc. irrespective of their kW rating shall be provided
with a CT, ammeter and a current transducer with remote metering in DCS.

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5.0.0 CONSTRUCTIONAL FEATURES

5.1.0 General

5.1.1 PCC/MCC/DB shall be metal enclosed, indoor, floor mounted and free standing type.
Switchgear frames, load bearing members, doors and covers and gland plates shall be
fabricated using CRCA sheet steel. The thickness of sheet shall be not less than 1.6 mm for
non-load bearing members and 2.0 mm for load bearing members. Gland plate thickness shall
be minimum 3.0 mm.

5.1.2 PCC / MCC shall be drawout type and distribution boards can be fixed type with
compartmentalized construction.

5.1.3 Suitable synthetic rubber gaskets shall be provided to make switchgear completely dust-proof
and vermin-proof with a degree of protection of IP 52 for all switchgear. However, degree of
protection for bus bar chamber where the bus bar is rated above 1600 A can be IP 42.

5.1.4 All switchgear shall be compartmentalized (conforming to Form 4b of IEC 60439-1) with uniform
height not exceeding 2450 mm. Module size of switchgear shall not be less than 200 mm.

5.1.5 The switchgear shall be arc proof tested. In the event of an internal fault in a functional unit, the
damage shall be confined to that unit alone, so that the busbar system and all other functional
units remain fit for further service. Switchgear assemblies shall comply with IEC 61641 with
regard to internal arc testing.

5.1.6 The arrangement of feeders in the switchgear shall take into consideration the number and size
of cables required for the feeders. Incomer and bus section ACB shall be limited to one per
panel. ACB outgoing feeders shall be limited to two per panel for ratings up to 1000 A. For
ratings 1250 A and above, the number of outgoing feeders shall be limited to one per panel.

5.1.7 Bus duct entry shall be from top and cable entry shall be from bottom for PCCs/MCCs/DBs.
Switchgear shall be divided into distinct vertical sections (panels), each comprising of the
following compartments:
• Main bus bar compartment
• Switchgear/feeder compartment
• Cable alley of at least 300 mm width
• Auxiliary bus bar compartment
• Control compartment for relays for ACB feeder

5.1.8 Switchgear shall be of modular design, consisting of modules, segregated into single or multi-
tier compartments. Each module shall be placed in individual compartment. All module grouped
together shall form the complete switchgear. Completed switchgear shall be of flush-fronted
design having a neat appearance and shall be readily extensible.

Door shall be provided at the front of each compartment to give full access to all the
components and the compartment.

Switchgear covers (including doors without interlock) shall be bolted type and shall be designed
to give access to individual circuits without exposing other circuits, which may be live. Alter-
natively, circuits exposed by the removal of the cover shall be individually shrouded.

5.1.9 The switchgear shall be designed to prevent contact with live parts both within the modules and
in the cable alley. Following are the minimum segregations to be provided amongst the different
parts of the switchgear:

a) Main horizontal bus bar chamber and vertical bus bar chamber

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b) Between different modules

c) Between modules and cable chamber
d) Between auxiliary bus bars and the rest of the switchgear
e) Between vertical bus bars and modules

All insulating materials used as partitions guards and shrouds shall be non-hygroscopic and
flame retardant.

5.1.10 Interlock between compartment door and modules shall be provided such that the door cannot
be opened without switching off the power supply to the module. Defeat interlock shall be
provided for the module comprising of MCCB/MPCB as a means of isolation, such that it is
possible to open the door with device ON and the module in ‘SERVICE’ position. The following
shall apply under these conditions:

a) It shall not be possible to close the door till the interlock has been reinstated
b) Attempted withdrawal of the module under such conditions shall be cautioned against by
providing warning label affixed at an appropriate place

5.1.11 Switchgear shall be equipped with thermostatically controlled space heaters in each panel
(separate for front and rear in case of double front panels having separate cable alleys) so as
to maintain interior temperature 5˚C above the ambient. They shall have MCB for protection.

5.1.12 All LT switchgear modules shall be provided with lock and Key arrangement with key rack
located in respective control room.

5.1.13 At least 20% of feeder modules covering the range of motors/ outgoing feeders used subject to
minimum of one module in each bus section shall be provided as spare. Spare modules shall
be completely wired up.

5.1.14 20% of control terminals in each module shall be provided as spare subject to a minimum of 2
terminals.

5.2.0 Feeder Modules

5.2.1 Drawout modules shall have the following features:

a) Withdrawal of module shall be possible without disconnecting wires.

b) Drawout units of similar type and rating shall be interchangeable.
c) Secondary connections to the drawout module shall be through self-aligning and self-
isolating contacts. In case of circuit breakers, easily disconnecting type plug and socket shall
be acceptable in place of self-aligning and self-isolating type contacts.
d) With the drawout module fully removed from its housing, live parts exposed shall either be
finger proof or shall have means to shroud them totally to prevent contact. Suitable add-on
type shrouds shall be provided where automatic shutters or in-built shrouds are not
provided.

5.2.2 All single front switchgear shall be provided with single leaf, hinged or bolted covers at the rear.
The bolts shall be of captive type. The covers shall be provided with ‘DANGER’ labels.

5.2.3 Drawout modules shall have distinct ‘SERVICE’ and ‘TEST’ positions. The equipment
pertaining to a drawout type module shall be mounted on a fully withdrawable chassis, which
can be drawn out without having to unscrew any wire or cable connection. Suitable
arrangement with cradle/rollers and guides shall be provided for smooth movement of the
chassis.

5.2.4 Each switchgear shall be provided with removable type gland plate, which shall cover the entire
cable alley. For all single core cables, gland plate shall be of non-magnetic material.

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5.2.5 The arrangement of the feeders shall ensure that operating handle of the switch/breaker shall
be above 350 mm but below 1800 mm from finished floor level.

5.3.0 Bus Bars and Insulators

5.3.1 Each PCC/MCC/DB shall be provided with three phase bus bars and one neutral bus bar. DC
distribution boards shall have two bus bars.

5.3.2 Bus bars (including neutral bus bar) shall be capable of carrying the short time current for the
duration as specified, without any damage. Current carrying capacity of neutral bus bar shall be
minimum half that of the phase bus bar.

5.3.3 For double front type of board, separate vertical bus bars for each front shall be used.

5.3.4 All bus bars shall be made of high conductivity copper/aluminium alloy. They shall be supported
on insulators of material such as fiber reinforced polyester or epoxy cast resin.

5.3.5 Minimum air clearance for horizontal and vertical bus bar termination shall be 25 mm between
phases and 20 mm between phase and earth. For all other components the clearance shall be
10 mm minimum.

5.3.6 All bus bars shall be adequately supported by non-hygroscopic, non-combustible, track-
resistant and high strength insulators. All bus bar joints shall be provided with high tensile steel
bolts, belleville/spring washers and nuts. All bus bars and bus taps shall have HRPVC sleeves,
colour coded as follows:
• Red, yellow & blue for R, Y & B phases respectively
• Black for neutral
• Grey & white for positive and negative respectively

5.3.7 All horizontal and vertical bus bars and joints shall be covered by insulating shrouds.

5.3.8 Contact surfaces at all joints shall be silver plated or properly cleaned and anti-oxide grease
applied to ensure an efficient and trouble free connection. In case of dissimilar metal
connections (copper to aluminium), proper treatment shall be given to minimize bimetallic
effect. All such joints shall be silver/tin plated or suitable bimetallic washers shall be provided.

5.3.9 Auxiliary bus bars each of minimum 25 [Link] thick electrolytic tough pitch copper shall be
provided for the following applications.

• 240 V AC supply for panel space heater/motor space heater/panel illumination

• 220 V DC control supply for breaker tripping and closing, spring charging motors, indication
circuits
• 110 V AC control supply for contactor operated motor starter control circuits as applicable

5.4.0 Control Supply and Space Heater Supply

5.4.1 PCC and ACB operated MCC shall have redundant 220 V DC control supply and shall have
diode auctioneering. Each panel shall receive control supply through bus wires tapped off from
auxiliary copper bus bar through MCBs provided in the respective panel. It shall be possible to
isolate any panel without disturbing the power supply to other panels. Each sub-circuit shall
have separate MCB.

5.4.2 An under voltage relay to monitor control supply shall be provided. A contact of the relay shall
be wired to the terminal for external use. Control Supply Failed’ indication shall be provided.

5.4.3 PCC/MCC shall derive 110 V AC control supply through 2X100% rated 415 /110 V transformer
and shall be provided with changeover arrangement. Changeover shall be blocked for control

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bus bar fault. The control transformers shall be of insulation class ‘B’ or better. The sizing of
control transformers shall be carried out considering the load of power contactors, auxiliary
contactors, indicating lamps and other equipment including remote auxiliary relays and lamps in
the circuit with 20% design margin. One pole of secondary winding shall be earthed.

5.4.4 For PCC and MCC 240 V AC Space heater supply shall be derived from 415/230 V control
supply transformer located one in each bus section. Necessary MCB to isolate and distribute
the supply shall be provided. For DB, 240 V AC space heater supply can be derived from
incoming supply itself.

5.4.5 All motors rated 30 kW and above shall be provided with power supply for space heater. Circuit
for motor space heater shall be wired through auxiliary NC contact of breaker/contactor and
MCB.

5.4.6 Each panel of PCC/MCC/DB shall be equipped with the following as required:

o Thermostatically controlled space heater(s).

o Illumination lamp with door switch
o 5 Amp 3 pin socket with MCB protection.

5.5.0 Air Circuit Breakers

5.5.1 Air circuit breakers shall be stored energy, trip free, air break and horizontal drawout type and
shall have fault making and breaking capacities as specified. There shall be ‘SERVICE’, ‘TEST’
and ‘ISOLATED’ positions for the breakers. In ‘TEST’ position the circuit breaker shall be
capable of being tested for operation without energizing the power circuits i.e. the power
contacts shall be disconnected, while the control circuits shall remain undisturbed. Locking
facilities shall be provided so as to prevent movement of the circuit breaker from the
‘SERVICE’, ‘TEST’ or ‘ISOLATED’ position. It shall be possible to close the door in ‘TEST’
position.

5.5.2 Breakers of different ratings shall not be interchangeable. Front fascia cut-outs for all ratings of
breakers shall be identical.

5.5.3 The spring charging mechanism of the circuit breaker shall be motor operated. The close/trip
control switch shall be interlocked to trip before close. The closing and tripping circuits shall be
self-opening on completion of their respective functions irrespective of the position of the
control switch. Manual closing devices shall also be provided. The circuit breaker shall be
electrically and mechanically trip free. For all circuit breakers electrical anti-pumping device
shall be provided.

5.5.4 The fixed portion of the circuit breaker shall have rail arrangement over which the chassis can
move smoothly. Proper mechanical indication shall be provided for the three positions
(‘SERVICE’, ‘TEST’ and ‘ISOLATED’) without opening the compartment door. It shall be
possible to bring the circuit breaker to isolated position with the help of external lever without
opening the compartment door. The circuit breaker can be padlocked in OFF position with door
interlock defeat facility.

5.5.5 The following interlocks shall be provided on the circuit breaker:

• It shall not be possible to withdraw the circuit breaker from the service position with the
contacts of the breaker closed
• It shall not be possible to close the circuit breaker unless any one of the three positions is
located
• It shall not be possible to open the compartment door when the circuit breaker is ON

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5.5.6 It shall not be possible to close the breaker under following conditions:

• Stored energy mechanism is not charged

• Shunt release is energized
• OFF push button is locked in OFF position

5.5.7 The circuit breaker shall be provided with mechanical ON/OFF, ‘TRIP’, ‘SPRING
CHARGED/DISCHARGED’, ‘READY TO CLOSE’ and breaker position indications and
mechanical trip push button. An operating handle shall also be provided to charge the spring
manually.

5.5.8 The circuit breaker shall be provided with automatic safety shutters, so that before the breaker
reaches ‘ISOLATED’ position the main isolating contacts are completely shrouded. In the
drawout condition, it shall be possible to inspect the breaker fixed contacts condition by lifting
the shutters.

5.5.9 When the circuit breaker compartment door is open, it shall not be possible to touch the live
parts. All removable covers protecting live parts shall be clearly labeled with warning notices
reading ‘LIVE PARTS. ISOLATE ELSEWHERE BEFORE REMOVING COVER’. It shall be
possible to readily remove the arc chutes for routine inspection of the contacts with the circuit
breaker in the withdrawn position. Contact erosion indicator shall be provided on moving
contacts of breaker for visual indication of contact life.

5.5.10 Each breaker feeder shall be provided with the following:

• An anti-pumping relay
• Motor charged spring operating mechanism
• Manual spring charging and manual closing mechanism
• Mechanical indication of spring charge
• Mechanical position indicator ( to show whether the breaker is in the ‘ON’ or ‘OFF’ positions
and in the ‘SERVICE’, ‘TEST’ or ‘ISOLATED’ positions)
• Closing coil
• Shunt trip coil
• CTs for protection
• Manual trip push button
• Phase barriers
• Shutter assembly
• Door interlock kit
• Operation counter
• Intelligent control unit
5.5.11 The closing coil and spring charging motor shall operate satisfactorily for all values of control
supply voltage between 80% and 110% of the rated voltage. But, the shunt trip coil shall be
designed such that it shall operate satisfactorily for all values of control supply voltage between
70% and 110% of the rated voltage. One open-close-open operation of the circuit breaker shall
be possible after failure of power supply to motor.

5.5.12 Telescopic trolley or suitable arrangement shall be provided for maintenance of circuit-breaker
module in a cubicle. The trolley shall be such that the topmost breaker module can be
withdrawn on the trolley and can be lowered for maintenance purpose. Also, it shall be such
that all types, sizes and ratings of breakers can be withdrawn / inserted in the switchgear.

5.6.0 Contactor Starter Unit

5.6.1 All motors rated up to 125 kW shall be controlled by direct-on-line contactor starters. MPCB
shall be used for motor feeders rated up to 15 kW. For feeders rated above 15 kW and up to
125 kW, MCCB shall be used. The starting circuit shall consist of the following:

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- Isolating device (MCCB/MPCB)

- Contactor as main means of starting and stopping of motor
- A short circuit protective device (Inbuilt feature of MPCB/MCCB)
- Electronic overload protection relay with current display unit & built-in single phasing
prevention feature
- CT operated numerical relay for motor feeders rated 75 kW and above
- Intelligent control unit

5.6.2 Withdrawable contactor starter units shall be provided with means for mechanically indicating
the ‘SERVICE’ and other positions.

5.7.0 Moulded case Circuit Breakers (MCCB) / Motor Protection Circuit Breakers (MPCB)

5.7.1 MCCBs shall be of three / four pole construction for panel mounting. The MCCBs shall be
provided with front operating handles and mechanical ON / OFF indicators.

5.7.2 MCCB shall be provided with spring assisted quick-make, quick-break, current limiting type
manually operated trip free mechanism, mechanical ON/OFF/TRIP position indicators, thermal
tripping devices of inverse characteristics, instantaneous short circuit tripping devices and
necessary auxiliary and alarm contacts. The MCCB module shall be provided with service, test
and isolated position. The thermal and short circuit tripping device shall be adjustable type.

5.7.3 The MPCB’s shall be in general similar to that of MCCB’s in all the features mentioned above.

5.7.4 MCCBs/MPCBs shall be provided with overload thermal release setting range of 50% to 100%
of rated current and adjustable short circuit magnetic release of 5 to 10 times rated current.

5.7.5 MCCBs/MPCBs shall be capable of withstanding the thermal stresses caused by overloads and
locked rotor currents of values associated with protective relay settings of the motor starting
equipment and the mechanical stress caused by the peak short circuit current of value
associated with the switchgear rating. The maximum tripping time under short circuit shall not
exceed 20 m. Second. When used for motor circuit, shunt trip devices shall be provided and the
let through power of controlling MCCB/MPCB shall be lower than the respective contactor,
Contactor and overload relays shall be selected so as to withstand the let-through energy of the
connected MCCB/MPCB in the feeder and consequent thermal and dynamic effects. All power
feeder module MCCBs shall be equipped with earth fault release.

5.7.6 The DC circuits shall be provided with DC rated MCCB / MCBs.

5.7.7 MCCBs/MPCBs shall have following accessories and features:

a) Shunt trip release

b) Under voltage release
c) Auxiliary contact for ON/OFF/ trip position
d) Fault signaling contact
e) Insulation shields to isolate the connection between each pole
f) Finger protection plate to prevent accidental contact
g) The compartment door shall be interlocked with handle of MCCB/MPCB.

5.8.0 Control and Selector Switches

5.8.1 All circuit breaker operating switches shall be of the pistol grip type, spring return to neutral and
lockable in that position. The trip, neutral and close positions shall be clearly indicated.

5.8.2 Ammeter and voltmeter selector switches shall have four stay put positions with adequate
number of contacts for 3 phase 4 wire system. These shall have oval handles. Ammeter

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selector switches shall have make before break type contacts to prevent open circuiting of CT
secondary

5.8.3 Local/Remote selector switch shall be provided as per control requirement.

5.9.0 Contactors

5.9.1 Contactors shall be of air break, electromagnetic type rated for uninterrupted duty. Contactors
shall be double-break, non-gravity type and their main contacts shall be silver faced copper.
Direct-on-line contactors shall be of utilization category AC3. Full voltage reversing starters
shall comprise of forward and reverse contactors mechanically and electrically interlocked with
each other. These contactors shall be of utilization category AC4. DC contactor shall be of
utilization category DC3. The contactor rating shall be chosen to provide type-2 discrimination.
However, the minimum rating shall be 16 A.

5.9.2 Electronic over load relay shall have selectable setting, self-powered, ambient temperature
compensated, sensitive to phase loss/unbalance, trip free mechanism, with trip indication, test
and stop function, current display etc. Type-2 coordination shall be ensured between
MCCB/MPCB, contactor and overload relay.

5.10.0 Miniature Circuit Breaker (MCB)

MCB shall be rated for atleast 10 kA short circuit rating. It shall be quick make, quick break, and
independent manual type with trip free feature. MCB shall have overcurrent protection, ON/OFF
position indicators and auxiliary contact block for ON/OFF/Trip positions.

5.11.0 Instrument Transformers

All current and voltage transformers shall be completely encapsulated, cast resin insulated type
suitable for continuous operation at the temperature prevailing inside the switchgear enclosure,
when the switchgear is operating at its rated condition and the specified ambient temperature.
The class of insulation shall be ‘B’ or better.
Current Transformers shall be cast-resin type with 1 A secondary. Separate cores shall be used
for metering and protection. Accuracy class of the current transformers shall be class 5P20
for relaying and Class 0.5 and ISF<5 for metering.
Voltage transformers shall be cast-resin drawout type and shall have an accuracy class of
0.5/3P for metering & protection. Voltage transformer mounted on breaker carriage is not
acceptable. It shall have a continuous voltage factor of 1.2 with short time over voltage factor of
1.5 for 30 seconds. The VT shall be provided with MCCB on the primary side and MCBs on
secondary side.

5.12.0 Relays and Timers

5.12.1 Relays and timers in protective circuits shall be flush mounted on panel front with connections
from the inside. They shall have transparent and dust tight covers removable from the front.
They shall either have built-in test facilities, or shall be provided with necessary test blocks and
test switches located immediately below each relay.

5.12.2 Relays shall have lock-out facility with manual reset. Each circuit breaker feeder shall be
provided with separate latched lockout relay (86), trip circuit supervision relay, necessary
auxiliary relays, timers, etc. to meet circuit requirements. In addition self-reset type lockout relay
to be provided on Bus PT Panel for Under voltage tripping the motor feeders.

5.12.3 Lock out relay contacts shall only be provided for protection trip & reset status for use in close
and trip interlocks of the circuit breaker.

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5.12.4 Auxiliary supply voltage for relays and transducers shall be 220 V DC. Relays shall be capable
of satisfactory continuous operation between 80-120% of the rated voltage.

5.12.5 Failure of a control or auxiliary supply and de-energisation of a relay shall not initiate any circuit
breaker operation. All relays shall withstand a minimum test voltage of 2 KV AC Rms for one
minute.

5.12.6 The relays shall have provision of both current and voltage inputs. The current operated relay
shall have provision for 5 sets of CT inputs, 3 nos. for phase fault and 1 CT input for earth fault
& 1 CT input for CBCT. Relay shall be suitable for both residually connected CT input as well
as CBCT input. Relays shall be suitable for CT secondary current of 1 A / 5 A selectable at site.
The voltage-operated relay shall have provision for 3 PT inputs. Relays shall be rated for
operation on 110 V, VT secondary voltage. Relays used in Incomers and bus couplers shall
have provision of two sets of voltage signal inputs for the purpose of synchronization.

5.12.7 All CT and PT terminals shall be provided as fixed type terminals on the relay to avoid any
hazard due to loose connection leading to CT opening or any other loose connection. In no
circumstances Plug In type connectors shall be used for CT/ PT connections.

5.12.8 All numerical relays shall have key pad / keys to allow relay settings from relay front. All hand
reset relays shall have reset button on the relay front. Relay to be self or hand reset shall be
software selectable. Manual resetting shall be possible from remote. Relays shall have suitable
output contact for breaker failure protection.

5.12.9 Relays shall have self-diagnostic feature with self-check for power failure, programmable
routines, memory and main CPU failures.

5.12.10 The numerical relay shall be able to provide supervisory functions such as, circuit breaker state
monitoring, PT and CT supervisions and recording facilities with Post fault analysis

5.12.11 The numerical processor shall be capable of measuring and storing values of a wide range of
quantities, all events, faults and disturbance recordings with a time stamping using the internal
real time clock. Battery backup for real time clock in the event of power supply failure shall be
provided.

5.12.12 Relays shall have event recording feature, recording of abnormalities and operating parameters
with time stamping.

5.12.13 Numerical relays shall be capable of storing Minimum of 150 time tagged events/ records with
time stamping. The numerical relays shall be able to store last 5 faults including the indication,
waveforms, protection operated, fault location relay and operating time, currents, voltage and
time. All Setting parameters, Fault data, waveforms & event logs shall be stored in Non-volatile
memory only.

5.12.14 Sequence of events shall have 1 ms resolution at device level.

5.12.15 Measurement accuracy shall be 1 % for RMS Current and voltage.

5.12.16 Relay shall be immune to capacitance effect due to long length of connected control cables.
Any external hardware, if required for avoiding mal operation of the relay due to cable
capacitance shall be included as a standard feature. All IOs shall have optical isolation. Analog
inputs shall be protected against switching surges, harmonics etc.

5.12.17 The alarm/status of each individual protection function and trip operation shall be
communicated to DCS/Respective control system. The numerical relay system shall have built-
in features/hardware interface to provide such inputs to Respective control system for
analog/digital values.

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5.12.18 Relays shall have at least two sets or groups of two different sets of adaptable settings. Relays
shall have multiple IEC/ ANSI programmable characteristics.

5.12.19 Numerical relays shall have two level pass word protections, one for read only and other for
authorization for modifying the setting etc.

5.12.20 Timer functions shall be programmable for on/off delays.

5.12.21 The protective relays shall have at least 10 nos. potential free contacts (Programmable)
Auxiliary relays shall have contacts as required. Relay output contacts shall be suitable for
directly wiring in the breaker closing and trip circuit operating from 220 V DC control voltage.

5.12.22 Making, carrying and breaking current ratings of their contacts shall be adequate for the circuits
in which they are used. Interrogation voltage for the binary inputs shall be suitably selected to
ensure avoidance of mal operation due to stray voltages.

5.12.23 No separate earth bus shall be required for the relays. It shall be possible to connect the relay
earth to the common earth bus in the switchgear panel which shall be connected to the plant
earth mat.

5.12.24 All protective relays shall be latest numerical type, having following features/functions:

• Protection functions as required

• IEC IDMT characteristics
• Measurements
• Event/fault/disturbance recording
• Binary input/output relays as required
• LEDs to indicate status of the relay
• LCD display for measurements, settings, faults etc.
• Key pad on the front of the relay
• Communication ports for transmitting settings, measurements, alarms, faults, events,
disturbance records to DCS/Respective control system/SAS (Substation Automation
System)
• Communication port for software setting/access measurements/maintenance/fault analysis
• Self-monitoring

5.12.25 All protective relays shall be latest numerical type with one USB port at the front for connecting
to Laptop and one port (RJ45/FO port) at rear suitable for communication on IEC 61850
protocols.

5.12.26 The Numerical relays shall be networked through Ethernet switch, Gateway/Data Concentrators
and shall be further integrated with SCADA based electrical monitoring system (for monitoring,
measuring, fault data analysis & relay parameterization).

5.12.27 All necessary hardware including Managed Ethernet switches, accessories and licensed
software shall be supplied by the vendor.

5.12.28 Ethernet switches shall be ‘substation hardened’ and shall comply with IEC61850-3 for
communications and environment requirements. The Ethernet switches shall be of managed
type with two (2) no. of fibre optic cable ports for ring network and Fourteen/Sixteen of Copper
ports to achieve the LAN configuration. These switches shall be mounted inside the switchgear
Panel.

5.12.29 The switchgear shall be provided with DC fail relay and DC fail indication lamp.

5.12.30 Breaker auxiliary contacts used for interlocking purposes shall be multiplied using electrically
latched relay.

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5.12.31 Protection relays shall include, protection functions but not limited to the following:

a) Incomer feeder from transformers:

• IDMT & DMT overcurrent protection (50/51)
• IDMT & DMT Earth fault protection (50N/51N)
• Under voltage relay (27)

b) Normal Incomer feeder ( Direct from Upstream switchgear):

• IDMT & DMT overcurrent protection (50/51)
• IDMT & DMT Earth fault protection (50N/51N)
• Under voltage relay (27)

c) Bus Coupler feeder:

• IDMT & DMT overcurrent protection (50/51)
• IDMT & DMT Earth fault protection (50N/51N)
• Check Synchronizing relay (25C)

d) Outgoing ACB operated Motor feeder:

• IDMT & DMT overcurrent protection (50/51)
• IDMT & DMT Earth fault protection (50N/51N)
• Over load (49)
• Negative sequence (46)
• Phase Reversal (46 R)
• Restart inhibit with startup counter (37)
• Locked rotor (48-LR)
• Under current (66)

e) Other Outgoing feeder:

• IDMT & DMT overcurrent protection (50/51)
• IDMT & DMT Earth fault protection (50N/51N)

f) Bus PT:
• 3 phase Under voltage relay

5.13.0 Indicating Instruments

5.13.1 All indicating instruments and meters shall be capable of carrying continuously their full load
currents and full voltage across their coils. They shall not be damaged by the passage of fault
currents or the existence of over voltage on the primary side of their instrument transformers for
the maximum permitted duration of fault conditions which may occur during normal operation.
All instruments and meters shall be back connected.

5.13.2 Meters and transducers for 415 Volts PCCs

For incomers feeders following Meters and transducers shall be provided:

• Current transducer on ‘Y’ phase
• Voltage transducer on ‘Y-B’ phase
• 1.0S class energy accounting and audit meter
• 1.0 class digital multi-function meter

For Bus Coupler following Meters and transducers shall be provided:

• Current transducer on ‘Y’ phase
• 1.0 class digital multi-function meter

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For ACB outgoing feeders following Meters and transducers shall be provided:
• Current transducer on ‘Y’ phase
• 1.0 class digital multi-function meter

For ACB motor feeders following Meters and transducers shall be provided:
• Current transducer on ‘Y’ phase
• 1.0 class Analog meter on ‘Y’ phase

For contactor motor feeders 15 kW & above following Meters and transducers shall be provided:
• Current transducer on ‘Y’ phase
• 1.0 class Analog meter on ‘Y’ phase
• Electronic overload relay with current display in switchgear.

For contactor motor feeders less than 15 kW following Meters and transducers shall be provided:
• Electronic overload relay with current display in switchgear.

For Bus PT following Meters and transducers shall be provided:

• Digital Voltmeter measuring all three phases
• Voltage transducer on three phases
• Power factor transducer

5.13.3 Meters and Transducers for 415 Volts MCCs

For incomers feeders following Meters and transducers shall be provided:

• Current transducer on ‘Y’ phase
• Voltage transducer on ‘Y-B’ phase
• 1.0 class digital multi-function Meter.

For Bus Coupler following Meters and transducers shall be provided:

• Current transducer on ‘Y’ phase
• 1.0 class digital multi-function Meter.

For Bus PT following Meters and transducers shall be provided:

• Digital Voltmeter measuring all three phases
• Voltage transducer on three phases

For contactor motor feeders 15 kW & above following Meters and transducers shall be provided:
• Current transducer on ‘Y’ phase
• 1.0 class Analog meter on ‘Y’ phase
• Electronic overload relay with current display in switchgear.

For contactor motor feeders less than 15 kW following Meters and transducers shall be provided:
• Electronic overload relay with current display in switchgear.

5.13.4 Meters and Transducers for 415 Volts DBs

For incomers feeders following Meters shall be provided:

• Digital voltmeter measuring all three phases
• Digital ammeter measuring all three phases

For Bus PT following Meters shall be provided:

• Digital Voltmeter measuring all three phases

5.13.5 Energy accounting and audit meters shall meet CEA regulation. It shall be integrated with
integrated energy management system. The energy audit meters shall be suitable for
measurement, recording and display of cumulative active energy with date and time. It shall

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have data storage capacity for at least 35 days in a non-volatile memory. It shall have facility to
download the parameters through meter reading instruments as well as remote transmission of
data over communication network. It shall also have the facility to measure, record and display
the following parameters. All parameters excluding instantaneous electrical parameters shall
also be stored in memory.
(a) Apparent power
(b) Phase wise kilowatt at peak KVA
(c) Phase wise KVA(reactive) at peak KVA
(d) Phase wise voltage at peak KVA
(e) Power down time
(f) Average power factor
(g) Line currents
(h) Phase voltages
(i) Date and time
(j) Tamper events

5.13.6 Digital Multifunction Meters shall be provided with bright LED/LCD display for local indication
and shall be provided with communication port suitable for communicating on MODBUS
protocol to EMS/DCS. It shall display various parameters like 3 phase currents, voltages, PF,
MD, KW, KVA, etc. for local indication and shall be provided with minimum 8 nos. of user
programmable registers for communicating any of the displayed parameters to the remote.

5.13.7 For motor feeder, analog ammeter with accuracy class 1.0, of 96x96 [Link] square with 240°
scale. Shall be provided. It shall have cramped scale above 2 times to 8 times the rated current
for indicating the starting current.

5.13.8 Transducers shall be of dual output type, class 0.5, 4-20 mA DC linear output & 750 ohm load.

5.13.9 Transducers shall be provided in all the buses so that algebraic summation in electrical system
shall be Zero.

5.14.0 Push Buttons

5.14.1 Push buttons shall be of heavy duty, spring return and push-to-actuate type. Their contacts
shall be rated to make, continuously carry and break 10 A at 240 V AC and 1 A (inductive) at
220 V DC.

5.14.2 All push buttons shall have two nos. NO and two nos. NC contacts, unless specified otherwise.
The contact faces shall be of silver alloy. All push buttons shall be provided with integral
escutcheon plates marked with their functions.

5.14.3 The colour of the button shall be as follows:

• Green for motor START and breaker CLOSE

• Red for motor STOP and breaker OPEN
• Black for valve/damper OPEN/CLOSE commands
• Black for all annunciation functions, overloads, reset and miscellaneous commands

5.14.4 All push buttons on panels shall be located in such a way that red push buttons shall always be
to the left of green push buttons. All emergency push buttons shall have mushroom knobs.

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5.15.0 Indicating Lamps

5.15.1 Indicating lamps shall be of the panel mounting clustered LED type. The lamps shall have
escutcheon plates marked with their functions, wherever necessary. Bulbs and lamp covers
shall be easily replaceable from the front of the cubicles. Low Voltage Glow Prevention (LVGP)
feature shall be provided for indicating lamps. Lamps shall have translucent lamp covers of the
following colour, as warranted by the application :

• Red for motor ON, valve/damper OPEN and breaker CLOSE

• Green for motor OFF, valve/damper CLOSE and breaker OPEN
• Amber for TRIP
• Blue for ‘SERVICE’ position indications
• White for all healthy conditions (e.g. control supply, lockout relay healthy, spring charged
condition etc.)
• White for ‘TEST’ position indications
• Red, yellow, blue for R, Y and B phases respectively

5.15.2 Indicating lamps shall be located just above the associated push button/control switch. Red
lamps shall invariably be located to the right of green lamps. When associated with push
buttons, red lamps shall be directly above the green push button and green lamp shall be
directly above the red push button.

5.15.3 All indicating lamps shall be suitable for continuous operation at 85% to 110% of their rated
voltage.

5.15.4 For incomer and bus, indicating lamps for R, Y and B phases shall be provided.

5.16.0 Wiring

5.16.1 Wiring shall be by 1100 volt grade multi-stranded PVC insulated copper wire having a cross-
sectional area of not less than 1.5 [Link]. All connections from CT leads up to instruments,
relays and terminal board shall be made by copper wires of minimum 2.5 [Link] size. The
cables shall be tested for flammability test as per applicable standards and shall also withstand
service temperature without deterioration.

All wiring shall use the colour codes specified below:

• 3 phase AC connections Red, yellow & blue for R, Y & B phases respectively
• 1 phase AC connections Red and black for phase and neutral respectively
• DC connections Grey & white for positive and negative respectively
• Earth connection Yellow-Green

5.16.2 Wiring shall be run mostly clear of all metal parts in insulated cleats, properly routed and neatly
bunched. However, PVC wire holders and channels shall be preferred for running of wiring.
Where wiring passes from one compartment to another, the aperture shall be ‘bushed’ to
prevent damage of wires against sheet metal edges. Bushes may comprise of good quality
rubber grommets.

5.16.3 Where single phase conductors are associated with the 3 phase system from which they are
derived, the phase conductor shall use the same colour as the phase from which it is derived.

5.16.4 Inter-module bus wires shall be kept separate from all other wiring. AC or DC terminations shall
be grouped function-wise as far as possible and labels of the function shall be affixed.

5.16.5 Terminal boards shall have separate terminals for incoming and outgoing wires with not more
than two wires connected to any one terminal. Terminal boards shall be mounted vertically at
the side of the cubicle or in horizontal rows and properly spaced to have clean wiring

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arrangement, adequate access for putting ferrules, making terminations etc. It shall be possible
to read the ferrule numbers when the wiring is complete. Where terminals may be live when the
equipment is isolated from the main supply, these shall be clearly marked on the panel.

5.16.6 Extra flexible wires shall be used for wiring to devices mounted on moving parts such as hinged
doors. The wire bunches from the panel inside to the doors shall be properly sleeved or taped.
All internal wiring terminations shall be made with solder less crimping type heavy duty tinned
copper lugs. Insulation sleeves shall be provided over the exposed parts of lugs.

5.16.7 Engraved core identification plastic ferrules marked to correspond with panel wiring diagrams
shall be fitted at both ends of each wire.

5.16.8 Control terminal blocks shall be of 650 V grade, rated for 10 A and in one piece molding. It
shall be complete with insulating barriers, clip-on type terminals and identification strips.
Marking on terminal strip shall correspond to the terminal numbering on wiring diagrams.
Terminal blocks for CT and VT secondary leads shall be provided with test links and isolating
facilities. CT secondary leads shall be provided with short circuiting and earthing facilities.

5.16.9 In all the panels, at least 20% spare terminals for external connections shall be provided and
these spare terminals shall be uniformly distributed on all terminal blocks.

5.16.10 All interlocks shall be hardwired in the switchgear itself.

5.16.11 The wiring shall be complete in all aspects so as to ensure proper functioning of control,
protection and interlocking scheme. All the wiring shall be complete up to terminal blocks on the
side of each unit/module.

5.16.12 Adjacent rows of terminal blocks shall be spaced not less than 100 mm apart.

5.16.13 The terminal blocks shall be mounted inside the module (and not in cable way) in a manner so
as to provide easy access to terminals and to enable ferrule numbers to be read without
difficulty.

5.16.14 All inter-panel wiring shall be carried out within the switchgear before dispatching the panel.

5.16.15 A typed circuit directory, card holder and card with clear plastic covering shall be provided on
the inside of each cabinet door. The directory card shall provide space to identify each circuit in
the panel board. An electronic copy of the circuit directory shall be provided to the Owner.

5.17.0 Cable/Busduct Termination

a) PMCC/MCC/DB shall be designed for cable entry from the bottom. Sufficient space shall be
provided for ease of termination and connection. Add-on panels shall be considered for
cables, if any.
b) Cable termination compartment and arrangement for power cables shall be suitable for
heavy duty, 1.1 kV grade, stranded aluminium conductor, XLPE insulated, armoured and
FRLS PVC sheathed cables.
c) Sufficient space and support arrangement shall be provided in the cubicles to accommodate
cables.
d) Cables shall be PVC insulated, armoured, extruded FRLS PVC overall sheathed with 2.5
[Link] for control & current circuits and 1.5 [Link] for voltage circuits and PVC insulated,
armoured, extruded FRLS PVC overall sheathed with stranded copper / aluminium
conductor for power circuits.
e) All provisions and accessories shall be furnished for termination and connection of cables,
including removable gland plates, cable supports, crimp type tinned copper lugs, brass
compression glands with tapped washer and terminals blocks.

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f) The gland plates and supporting arrangement for 1/C power cable shall be such as to
minimize flow of eddy current.
g) For all DG sets & service transformers rated 1000 KVA and above shall be connected
through bus ducts to the respective switchgear panel. Busduct entry shall be from the top.

5.18.0 Name plates and labels

5.18.1 Nameplates shall be of 3 ply laminate with black lettering on white background. The following
shall be provided with nameplates/warning labels as described below:

• Main name plate for PCC/MCC/DB on front and back sides

• All incomers and outgoing feeders indicating description, rating, equipment no., feeder no.,
etc.
• All door mounted components
• Panel numbers on front and rear
• Warning labels for interlocks
All name plates shall be fastened by means of screws to the panel.
Danger labels shall be provided for the following:
• MCC as per statutory regulations
• Bus bar chamber
• Cable alley housing live terminals

5.18.2 Name plate or polyester adhesive stickers shall be provided inside the panel for all equipment
(lamps, push buttons, switches, relays, auxiliary contactors etc.) mounted on the switchgear.

5.18.3 Special warning plates, one each on each front of a shipping section, shall be provided on
removable covers of doors giving access to cable terminals and bus bars. Special warning
labels shall be provided inside the switchgear also, wherever considered necessary.
Identification tags shall be provided inside the panels matching with those shown on the circuit
diagram.

5.18.4 All major components such as breakers, switches, contactors, CTs etc. shall be provided with
labels indicating their ratings.

5.18.5 For single front switchgears, similar panel and board identification labels shall be provided at
the rear also.

5.19.0 Earthing

5.19.1 Two earth terminals shall be provided on each switch cubicle, at the rear side. An earth bar of
at least 50 x 10 mm aluminium shall be fixed to these terminals. The earth bar shall be
electrically continuous and shall run the full extent of each board. This earth bar shall be on the
same side as the cable entry and shall be extended on both sides of the panel.

5.19.2 Each unit shall be constructed to ensure satisfactory electrical continuity between all metal
parts not intended to be alive and earth terminals of the unit. Suitable holes with bolts and nuts
shall be provided at each end of earth bar of switchgear for connection to a main earthing grid.

5.19.3 The earth bar shall be accessible in each cable entering compartment either directly or through
a branch extension to earth the cable armour and shields. 10 mm diameter holes shall be
drilled and hardware for connection provided through the earth bus.

5.19.4 The cores of transformer (bus voltage transformer, control transformer, heating transformer
etc.) shall also be earthed through copper wire. Doors shall have a copper wire for earth

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connection to fixed unit. VT and CT secondary neutral point earthing shall be at one place only
on the terminal block.

5.19.5 All non-current carrying metal work of the switchgear/panel shall be effectively bonded to the
earth bus. All metallic cases of relays, instruments and other panel mounted equipment shall be
connected to earth bus by independent stranded copper wires of size not less than 2.5 [Link].
Insulation colour code of earthing wires shall be green. Earthing wires shall be connected to
terminals with suitable clamp connectors and soldering shall not be acceptable. All hinged
doors shall be earthed through flexible earthing braid.

5.20.0 Wall Mounted Distribution Boards

5.20.1 Wall mounted distribution boards shall be metal enclosed, suitable for outdoor mounting on
wall or steel structures with suitable hood on the top. The enclosure shall be cold rolled sheet
steel of at least 1.6 mm thickness. Gland plate shall be of 2 mm thick. The board shall be dust
and vermin-proof and shall have a degree of protection of IP-55. MCB/motor protection circuit
breaker (MPCB) shall be rated for 10 kA short circuit rating. MPCB shall have adjustable
overload setting and short circuit release.

5.20.2 Wall mounted distribution boards shall comprise the following as a minimum:

• Adequately rated TPN MCB isolator as incomer

• 3 phase & neutral bus bar
• Required number of TPN/SP MCBs or MPCBs with contactor and start/stop PBs for outgoing
feeders
• R,Y, B indicating lamps (LED)

5.21.0 Local Motor Starters

5.21.1 Local motor starters shall be metal enclosed, suitable for outdoor mounting on wall or steel
structures with suitable hood on top. The enclosure shall be cold rolled sheet steel of at least
1.6 mm thickness. The local motor starters shall be dust and vermin-proof and shall have a
degree of protection of IP-55.

5.21.2 Local motor starters shall comprise of the following:

• A 3-pole contactor, mechanically latched type

• Start push button, coloured green
• Stop push button, coloured red
• ‘ON’ indicating lamp
• Electronic overload relay with single phasing protection

5.22.0 Local Push Button (LPB) Stations

5.22.1 The local push buttons station enclosure shall be with hood on top suitable for outdoor
mounting on wall or steel structures. The enclosure shall be provided with a protective guard,
to avoid inadvertent operation of push buttons. The local push button stations shall be dust and
vermin-proof and shall have a degree of protection of IP-55 as per IS 13947.

5.22.2 LPB shall be of following types:

• Type-A: With Stop Push Button in FRP enclosure

• Type-B: With Start & Stop Push Buttons in FRP enclosure
• Type-C: With Forward, Reverse & Stop Push Buttons in FRP enclosure
• Type-D: With Stop Push Button in flame-proof enclosure
• Type-E: With Start & Stop Push Buttons in flame-proof enclosure
• Type-F: With Forward, Reverse & Stop Push Buttons in flame-proof enclosure

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5.22.3 Push buttons shall be with two NO and two NC contacts. Emergency stop push buttons shall be
mushroom, latched type. Start push button shall be self-reset type.

6.0.0 PAINTING

Painting shall be carried out by approved process. After preparation of the under surface the
equipment shall be painted with epoxy based paint by powder coating. The final thickness of
paint film on sheet steel shall not be less than 85 microns. Final shade shall be RAL-7035.

7.0.0 TESTS

7.1.0 All tests shall be conducted as per relevant IS/IEC standards and shall be performed in the
presence of Owner’s representative, if so desired by the Owner. All equipment/
components/materials shall be of type tested and proven type.

7.2.0 Type test reports shall be submitted for switchgear panel and breaker of each current rating as
per applicable standard. The switchgear panel shall be subjected to routine tests in accordance
with the relevant IS/IEC standards. Test reports shall be submitted to the Owner for approval.

7.3.0 Type Tests

7.3.1 Type test reports for the following shall be submitted for switchgear panel of each current
rating:
• Power frequency withstand test on power circuit and auxiliary and control circuits
• Temperature rise test
• Measurement of resistance of the main circuit
• Short time withstand current and peak withstand current test
• Degree of protection test

7.3.2 Type test reports shall be submitted for circuit breaker as per applicable standard by the Bidder
for Owner’s review. The list of type tests shall include the following:

• Dielectric tests
• Measurement of the resistance of the main circuit
• Temperature rise tests
• Short time withstand current and peak withstand current tests
• Electromagnetic compatibility tests
• Mechanical and environmental tests including mechanical operation test
• Short circuit current making and breaking tests
• Mechanical endurance test
• Electrical endurance test

7.3.3 The contactors, relays, switches, breakers, local push buttons, local motor starters,
instruments, VTs, CTs and control transformers shall be subjected to type tests in accordance
with the relevant IS/IEC standards.

7.4.0 Routine Tests

7.4.1 The switchgear panel shall be subjected to routine tests in accordance with the relevant IS/IEC
standards. The tests shall include the following:

• Power frequency voltage dry test on the main circuit

• Voltage test on control and auxiliary circuits
• Measurement of resistance of the main circuit
• Mechanical operating tests

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7.4.2 The circuit breakers, contactors, switches, local push buttons, local motor starters, VTs, CTs
and control transformers shall be subjected to routine tests in accordance with the relevant
IS/IEC standards. Routine test reports shall be furnished by the Vendor for Owner’s review.

7.4.3 For circuit breaker, the list of routine tests shall include the following:

• Dielectric tests on the main circuit

• Dielectric tests on the control circuit & auxiliary circuit
• Measurement of the resistance of the main circuit
• Mechanical operating tests
• Design and visual checks

7.5.0 Site Tests

The following minimum tests/ checks shall be conducted at site. Any other tests/ checks as per
the manufacturer’s recommendation shall also be carried out.

a) General
• Check name plate details according to specification
• Check for physical damage
• Check tightness of all bolts, clamps and connecting terminals
• Check earth connections
• Check cleanliness of insulators and bushings
• Check heaters are provided
• HV test on complete switchgear with CT and breaker/ contactor in position
• Check all moving parts are properly lubricated
• Check for alignment of busbar with the insulators to ensure alignment and fitness of
insulators
• Check for interchange ability of breakers/ contactors
• Check continuity and IR value of space heater
• Check earth continuity for the complete switchgear board

b) Circuit Breaker/ Contactors

• Check alignment of trucks for free movement
• Check correct operation of shutters
• Check slow closing operation (if provided)
• Check control wiring for correctness of connections, continuity and IR values
• Manual operation of breakers completely assembled
• Power closing/ opening operation, manually and electrically at extreme condition of control
supply voltage
• Closing and tripping time
• Trip free and anti-pumping operation
• IR values, resistance and minimum pick up voltage of coils
• Simultaneous closing of all the three phases
• Check electrical and mechanical interlocks provided
• Checks on spring charging motor, correct operation of limit switches and time of charging
• Check SF6 pressure/ vacuum (as applicable)
• All functional checks

c) Current Transformers
• Insulation resistance between windings and winding terminals to body
• Polarity tests
• Ratio identification checking of all ratios on all cores by primary
• injection of current
• Magnetisation characteristics and secondary winding resistance
• Spare CT cores, if any to be shorted and earthed

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d) Voltage Transformers
• Insulation resistance test
• Ratio test on all cores
• Polarity test
• Line connections as per connection diagram

e) Cubicle Wiring
• Check all switch developments
• It should be made sure that the wiring is as per relevant drawings. All interconnections
between panels shall similarly be checked
• Insulation resistance of all wires with respect to earth
• Functional checking of all control circuit e.g. closing, tripping interlock, supervision and
alarm circuit including proper functioning of component/ equipment
• Check terminations and connections
• Wire ducting
• Gap sealing and cable bunching

f) Relays
• Check internal wiring
• Insulation resistance between all terminals and body
• Insulation resistance between AC and DC terminals
• Check operating characteristics by secondary injection
• Check minimum pick up voltage of DC coils
• Check operation of electrical/ mechanical targets
• Check CT connections with particular reference to their polarities for differential type relays
• Relay settings

g) Meters
• Insulation resistance of all insulated portions
• Check CT and VT connections with particular reference to their polarities for power type
meter

8.0.0 TECHNICAL PARAMETERS OF LV SWITCHGEAR

Sloe. Description Unit Parameters

1.0 LV Switchgear – General

a) Type Metal clad, Form 4b

b) Type of cooling Natural air cooled

One minute power frequency withstand
voltage
c) kV 2.5
• Main circuit
kV 2.0
• Auxiliary circuit
d) Rated voltage V 415 ±10%, 3 phase, 4 wire

2.0 PCC/MCC
Short circuit withstand current rating for 65 kA (rms) for 1 sec &
a)
switchgear fed from 2500 kVA transformer 137 kA (peak)
Short circuit withstand current rating for all 50 kA (rms) for 1 sec &
b)
other switchgear 105 kA (peak)
Degree of protection of switchgear with IP-52
c)
modules in service and all doors closed

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Sloe. Description Unit Parameters

Degree of protection for bus bar chambers IP-42
d)
(above1600 A)
3.0 AC Distribution Board
50 kA (rms) for 1 sec
a) Short circuit withstand current rating kA
105 kA (peak)
b) Degree of protection IP-52
4.0 Air Circuit Breaker
a) Type ACB
b) No. of poles TPN/TP/4P
c) Short circuit performance category P2
d) Rated operating duty O-3min-CO-3min-CO
Short time current for 1 sec. for 2500 kVA
e) kA(rms) 65
transformer
Rated short circuit breaking current for 2500
f) kVA kA(rms) 65
transformer
Rated short circuit making current for 2500
g) kVA kA(peak) 137
transformer
Short time current for 1 sec. for all other
h) kA(rms) 50
breakers
Rated short circuit breaking current for all
i) kA(rms) 50
other breakers
Rated short circuit making current for all
j) kA(peak) 105
other breakers
Control supply voltage
k) • Closing coil, spring charging motor V 220 V DC, (80-110%)
• Tripping coil 220 V DC, (70-110%)
4.0 Moulded Case Circuit Breaker (MCCB)
a) No. of poles TPN/TP
b) Short time current for 1 sec. kA(rms) 50/65
c) Rated short circuit breaking current kA(rms) 50/65

d) Rated short circuit making current kA(peak) 105/137

e) Overload release setting Yes

f) Short circuit release setting Yes

g) Undervoltage release Yes

h) Shunt trip Yes

4.0 Motor Protection Circuit Breaker (MPCB)
a) No. of poles TP
b) Rated short circuit breaking current kA(rms) 50/65

c) Overload release setting Yes

d) Short circuit release setting Yes

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Sloe. Description Unit Parameters

e) Undervoltage release Yes

f) Shunt trip Yes

5.0 Bus Bar

Temperature rise over design ambient of

50°C
a) 40°C
(i) Bus bars
55°C
(ii) Silver plated joints
65 kA (rms) for 1 sec with
Short-time current for PCC with incomer
b) kA 137 kA (peak) dynamic
from 2500 kVA transformer
rating
50 kA (rms) for 1 sec with
c) Short-time current for other PCC/MCC/DB kA 105 kA (peak) dynamic
rating
Bus bar clearance in air (minimum )
d) • Phase to phase mm 25
• Phase to earth mm 20

9.0.0 DRAWINGS & DOCUMENTS

The following drawings and documents shall be submitted for approval during detail
engineering stage.
• Technical data sheet
• General arrangement and section drawing
• Single line diagram & Schematic wiring diagrams
• Sizing Calculation for busbar
• Short circuit withstand calculation for busbar (Thermal & dynamic)
• Component list & Bill of Quantities for all the boards
• Panel cutout details
• Foundation Plan & loading details
• Erection and commissioning procedures
• CT / VT sizing calculation
• Relay setting calculation
• Catalogues / drawings / leaflets for all items
• Operation and maintenance manual
• Test reports
• Sub-vendor list
• Manufacturing quality plan
• Field quality plan

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 CLIENT – TAMILNADU GENERATION & DISTRIBUTION CORPORATION LTD. TB-400-553-124
CONSULTANT- TATA CONSULTING ENGINEERS LMITED BENGALURU
Rev. 01
PROJECT: 2X660MW UDANGUDI STPP (STATE-1)
TECHNICAL SPECIFICATION FOR VENTILATION SYSTEM Page | 1

SECTION-3
PROJECT DETAILS AND GENERAL SPECIFICATIONS

3.0 GENERAL

This section stipulates the General Technical Requirements under the contract and
will form an integral part of the Technical Specification.

The provisions under this section are intended to supplement general requirements for
the materials, equipment and services covered under other sections and are not
exclusive. However in case of conflict between the requirements specified in this
section and requirements specified under other sections, the requirements specified
under respective sections shall hold good.

3.1 SITE INFORMATION

[Link]. DESCRIPTION
3.1 PROJECT INFORMATION
a) Customer Tamil Nadu Generation
and Distribution
Corporation
(TANGEDCO)
b) Project 400kV GIS at 2 x 660
MW Udangudi STPP
(Stage-I)
c) Project location
i) Country India
ii) State Tamil Nadu
iii) Administrative district Thoothukudi
iv)Next Big cities to site Thoothukudi (approx..
45 kms from site)
v) Road access East Coast Road- State
high way (176)
vi) Nearest Railway Station Thiruchendur
(approx.. 12 kms from
site)
vii) Nearest Airport Vagaikulam (approx..
60 kms from site)
viii) Nearest Harbour Tuticorin (approx.. 45
kms from site)

Page 1 of 16
 CLIENT – TAMILNADU GENERATION & DISTRIBUTION CORPORATION LTD. TB-400-553-124
CONSULTANT- TATA CONSULTING ENGINEERS LMITED BENGALURU
Rev. 01
PROJECT: 2X660MW UDANGUDI STPP (STATE-1)
TECHNICAL SPECIFICATION FOR VENTILATION SYSTEM Page | 2

3.2 SITE CONDITIONS

3.2.1 Ambient Air Temp.
a) Maximum dry bulb 410C
temp. (max.) °C
b) Minimum dry bulb temp. 170C
(min.) °C
Design ambient temperature 500C
3.2.2 Relative humidity
Mean Maximum humidity (Summer) 84 %
Mean Minimum humidity (Summer) 62 %
Maximum humidity (Monsoon) 97%
Minimum humidity (Monsoon) 45%

3.2.3 Rain fall

Annual rainfall (Maximum) 718.2 mm
Annual rainfall (Minimum) 384.1 mm
Twenty four (24) Hour max 138.2 mm

3.2.4 High Flood Level

High Flood Level for site RL 2.450 m

3.2.5 Wind
Mean Wind Speed (max) 39 m/sec (As per IS:
875)
Wind direction North, North east, North
west, East
3.3 Seismic intensity
Seismic Intensity As per IS:1893 Latest
Zone II

3.2 INSTRUCTION TO BIDDERS

The bidders shall submit the technical requirements, data and information as per the
technical data sheets, provided in Section-4.

The bidders shall furnish catalogues, engineering data, technical information, design
documents, drawings etc fully in conformity with the technical specification.

It is recognized that the Manufacturer may have standardized on the use of certain
components, materials, processes or procedures different than those specified herein.
Alternate proposals offering similar equipment based on the manufacturer's standard

Page 2 of 16
 CLIENT – TAMILNADU GENERATION & DISTRIBUTION CORPORATION LTD. TB-400-553-124
CONSULTANT- TATA CONSULTING ENGINEERS LMITED BENGALURU
Rev. 01
PROJECT: 2X660MW UDANGUDI STPP (STATE-1)
TECHNICAL SPECIFICATION FOR VENTILATION SYSTEM Page | 3

practice will also be considered provided such proposals meet the specified designs,
standard and performance requirements and are acceptable to the Purchaser. Unless
brought out clearly, the Bidder shall be deemed to conform to this specification
scrupulously.

3.3 STANDARDS
The works covered by the specification shall be designed, engineered, manufactured,
built, tested and commissioned in accordance with the Acts, Rules, Laws and
Regulations of India.

The equipment to be furnished under this specification shall conform to latest issue
(with all amendments) of specified standards.

In addition to meeting the specific requirement called for in Sections 1 and 2 of the
Technical Specification, the equipment shall also conform to the general requirement
of the applicable standards, which shall form an integral part of the specification.

The Bidder shall note that standards mentioned in the specification are not mutually
exclusive or complete in themselves, but intended to complement each other.

When the specific requirements stipulated in the specifications exceed or differ from
those required by the applicable standards, the stipulation of the specification shall
take precedence.

Other internationally accepted standards, which ensure equivalent or better

performance than that specified in the standards referred, shall also be accepted. The
bidder shall submit copies of such standards.

In case governing standard for the equipment is different from IS or IEC, the salient
points of difference shall be clearly brought out in the offer along with English
language version of standard or relevant extract of the same. The equipment
conforming to standards other than IS/IEC shall be subject to Purchaser's / owner’s
approval.

The bidder shall clearly indicate in his bid the specific standards in accordance with
which the works will be carried out.

3.4 SERVICES TO BE PERFORMED BY THE EQUIPMENT BEING

FURNISHED

All equipment shall also perform satisfactorily under various other electrical, electro
mechanical and meteorological conditions of the site of installation All equipment

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shall be able to withstand all external and internal mechanical, thermal and electro
mechanical forces due to various factors like wind load, temperature variation, ice &
snow, (wherever applicable) short circuit etc for the equipment.

3.5 ENGINEERING DATA

3.5.1 Drawings
The Supplier shall necessarily submit all the drawings/ documents unless anything is
waived. The Supplier shall submit drawings/ design documents/ data/ test
reports/manuals as may be required for the approval of the purchaser. All drawings
submitted by the Manufacturer including those submitted at the time of bid shall be in
sufficient detail to indicate the type, size, arrangement, material description, Bill of
Materials, weight of each component, break-up for packing and shipment, the
external connections, fixing arrangement required. The dimensions required for
installation and interconnections with other equipment and materials, clearances and
spaces required for installation and interconnections between various portions of
equipment and any other information specifically requested in the specifications.

Each drawing submitted by the Manufacturer shall be clearly marked with the name
of the Purchaser, the unit designation, the specifications title, the specification
number and the name of the Project. If standard catalogue pages are submitted, the
applicable items shall be indicated therein. All titles, noting, markings and writings
on the drawing shall be in English. All the dimensions should be in metric units.

Further work by the Manufacturer shall be in strict accordance with these drawings
and no deviation shall be permitted without the written approval of the Purchaser, if
so required.

The review of these data by the Owner will cover only general conformance of the
data to the specifications and documents, interfaces with the equipment provided
under the specifications, external connections and of the dimensions which might
affect substation layout. Owner may not indicate a thorough review of all dimensions,
quantities and details of the equipment, material, any devices or items indicated or the
accuracy of the information submitted. This review and /or approval by the Owner
shall not be considered by the Manufacturer, as limiting any of his responsibilities
and liabilities for mistakes and deviations from the requirements, specified under
these specifications and documents.

All manufacturing and fabrication work in connection with the equipment prior to the
approval of the drawings shall be at the Manufacturer's risk. The Manufacturer may
make any changes in the design which are necessary to make the equipment conform
to the provisions and intent of the Contract and such changes will again be subject to

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approval by the Purchaser. Approval of Manufacturer’s drawing or work by the

Purchaser shall not relieve the manufacturer of any of his responsibilities and
liabilities under the Contract.

All engineering data submitted by the Manufacturer after final process including
review and approval by the Owner shall form part of the Contract Document and the
entire works performed under these specifications shall be performed in strict
conformity, unless otherwise expressly requested by the Owner in Writing.
The title block of drawings shall contain the following information incorporated in all
contract drawings

Title block for project:

1. Customer : Tamil Nadu Generation and Distribution Corporation (TANGEDCO)

2. Consultant : DESEIN PRIVATE LIMITED, DESEIN HOUSE, NEW DELHI
3. Project : 400kV GIS at 2 x 660 MW Udangudi STPP (Stage-I)
4. Contract No./LOA No. : [Link]/[Link]/SE/C/UTPP/EE/E/LOI/D.179/2017,
dt.07.12.2017
5. Main Contractor : Bharat Heavy Electricals Limited
6. BHEL Order No. & Date :

3.5.2 Documentation

Document Distribution Schedule - After Placement of Order:

S. Stage No. of
No. copies

i) Submission of Data sheets 13 As per agreed schedule

Datasheet, drawings,
documents,
write-ups, calculation, test
reports, Preliminary
ii) Resubmission of above, if 13 As per agreed schedule
required
iii) Final approved documents 13 As per agreed schedule

iv) Instruction manuals for 6 As per agreed schedule

erection and O&M
v) As built drawings including As per agreed schedule
O &M manual

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-Hard copy 13
-Soft copy in CD/Pendrive 6

NOTES:

a) The manufacturer may note that all re-submissions must incorporate all comments
given in the prior submission by the Purchaser. Adequate justification for not
incorporating the same must be submitted, failing which the submitted documents
may be returned.

3.5.3 Format of Documentation

a) All engineering documents and drawings shall be of international “A” series sizes, that is,
A0, A1, A2, A3 and A4.
b) Two set of CD/ pendrive containing all the drawings in Auto CAD shall also be supplied in
addition to hard copies. Soft copy of all documents shall be supplied in a CD/pendrive in
PDF format.
c) Grouped documents shall be provided by size A4, with the inclusion of bigger size
drawings which, however, have to be folded as Size A4.

3.5.4 Instruction manuals and operating manuals

The Supplier shall provide Instruction & Maintenance Manuals for each part of the
Plant and Equipment included in the Works and Operating Manuals for each Station.

The Instruction Manuals and Operating Manuals shall be arranged in an organized

library adequately cross referenced to facilitate issuing clauses of the manuals as
required by the work i.e. erection instructions shall be required before operating &
maintenance instructions.

All Manuals provided by the Supplier shall be fully detailed and specifically prepared
for the Works and equipment provided. General manuals not specifically required for
the work shall not be acceptable.

The instruction manuals shall at least contain:

a) A general description of all components

b) Storage instructions
c) Erection instructions
d) Pre-commissioning Instruction:
e) Material and part list.
f) Design clearances and settings
g) Complete sets of drawings as finally issued

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h) Operating Instructions:
i) Routine and Preventive Maintenance instructions with material requirement for
each site
j) Preventive Maintenance Schedule.
k) Replacement instruction for all equipment

The operation manuals shall at least contain:

a) Operator oriented functional descriptions of the equipment.
b) Operator oriented description of the protection and control systems
c) Description of the equipment auxiliary systems
d) Fault finding and diagnostic tools
e) User software interface tools for modification/augmentation etc.

Notes:

The supplier may please note that all resubmissions must incorporate all comments
given in the earlier submission by the Owner/Purchaser or adequate justification for not
incorporating the same must be submitted failing which the submission of documents is
likely to be returned.

If after the commissioning and initial operation of the substation, the instruction
manuals require any modifications/ additions/changes, the same shall be incorporated
and the updated final instruction manuals shall be submitted by the Supplier to the
Owner/Purchaser.

The Supplier shall furnish to the Owner/Purchaser, catalogues of spare parts also.

3.6 QUALITY ASSURANCE PROGRAMME

This section contains general requirements for inspection of material, parts, equipment
and workmanship during manufacture, assembling to demonstrate compliance with
specification, codes and standards to ensure overall reliability of product operation and
performance.
The Owner and/or authorized Representatives shall, at any time, be allowed free and
ready access to the Contractor's premises and those of his suppliers as well as to the
site installation and the Contractor has to make the items available for the purpose of
inspection of the specified equipment components and obtaining information as to the
progress of the work. Failure on the part of the Owner, at this or any other time, to
discover or reject materials or work which do not meet specified requirements shall
not be deemed an acceptance thereof nor a waiver of defects therein.

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The approval of the Owner shall not prejudice the right to reject equipment if it does
not give complete satisfaction in service.

To ensure that the equipment and services under the scope of this Contract, whether
manufactured or performed within the Manufacturer's Works or at his Sub-
manufacturer's premises or at the Purchaser's site or at any other place of Work, are in
accordance with the specifications, the Manufacturer shall adopt a suitable quality
assurance programme to control such activities at all points, as necessary.
Before manufacture commences and not later than 45 days after award of contract, the
Contractor shall submit an outline of his proposed inspection program, which shall
include all major stages during manufacturing. The inspection and test program shall
include for the various items the designation No., name of equipment, part of
equipment, the kind of test, test standard, company which carries out the test, place,
date and witnesses by the Contractor, third party or Owner's Representative. The
detailed manufacturer’s quality assurance plan shall be subject to approval after award
of contract.
The Owner will return a copy of the Contractor's proposed inspection program
indicating those inspection stages for which notification is required. Notification shall
be by Fax or email in a format to be agreed and shall be sent prior to the intended test.
If the Owner intends to be represented at the test he will provide at least 24 hours'
notice and if his representative does not attend on the notified date, an alternative date
has to be informed by the Owner.
A quality assurance programme of the manufacturer shall generally cover the
following:

(a) Manufacturer's organisation structure for the management and implementation of

the proposed quality assurance programme:
(b) Documentation control system;
(c) Qualification data of bidder's key personnel;
(d) The procedure for purchases of materials, parts components and selection of sub-
Manufacturer's services including vendor analysis, source inspection, incoming raw
material inspection, verification of material purchases etc.
(e) System for shop manufacturing and site erection controls including process
controls and fabrication and assembly control;
(f) Control of non-conforming items and system for corrective actions;
(g) Inspection and test procedure both for manufacture and field activities;
(h) Control of calibration and testing of measuring instruments and field activities;
(i) System for indication and appraisal of inspection status;
(j) System for quality audits;
(k) System for authorising release of manufactured product to the Purchaser
(1) System for maintenance of records;
(m) System for handling storage and delivery; and

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(n) A quality plan detailing out the specific quality control measures and Procedures
adopted for controlling the quality characteristics relevant to each item of equipment
furnished and/or services rendered. The Purchaser or his duly authorised
representative reserves the right to carry out quality audit and quality surveillance of
the system and Procedure of the Manufacturer/his vendors quality management and
control activities.

3.7 Quality Assurance Documents

The Manufacturer shall be required to submit all Quality Assurance Documents as

stipulated in the quality plan at the time of purchaser’s inspection of equipment/
material.

3.8 TYPE TESTING, INSPECTION, TESTING & INSPECTION CERTIFICATE

All equipment being supplied shall conform to type tests and shall be subject to
routine and acceptance tests in accordance with requirements stipulated under
respective sections. Purchaser reserves the right to witness any or all the tests. The
Manufacturer shall intimate the Purchaser the detailed programme about the tests at
least three (3) weeks in advance in case of domestic supplies & six (6) weeks in
advance in case of foreign supplies. The Manufacturer shall also submit type test
procedure for approval of the Purchaser.

In the event of any discrepancy in the test reports i.e. any test report not acceptable
due to any design/manufacturing changes (including substitution of components) or
due to non-compliance with the requirement stipulated in the technical specification
or any/all additional type tests not carried out, Such test shall be conducted fresh
without any additional cost implication to the Purchaser.

The price of conducting all tests and additional type tests is deemed to be included in
Bid price. In case any bidder indicates that he shall not carry out a particular test, his
offer shall be considered incomplete and shall be liable to be rejected.

Inspection may be made at any stage of manufacture, dispatch or at site at the option
of the Purchaser and the equipment if found unsatisfactory due to bad workmanship
or quality, material is liable to be rejected.

The Purchaser or Inspector shall, within fifteen (15) days from the date of inspection
as defined herein, give notice in writing to the Manufacturer, of any objection to any
drawings and all or any equipment and workmanship which in his opinion is not in
accordance with the Contract. The Manufacturer shall give due consideration to such
objections and shall either make the modifications that may be necessary to meet the

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said objections or shall confirm in writing to the Purchaser/ inspector giving reasons
therein, that no modifications are necessary to comply with the Contract.

When the factory tests have been completed at the Manufacturer's works, the
Purchaser/inspector shall issue a certificate to this effect within fifteen (15) days after
completion of tests but if the tests are not witnessed by the Purchaser/inspector, the
certificate shall be issued within fifteen (15) days of receipt of the Manufacturer’s
Test certificate by the Engineer/ Inspector. Failure of the Purchaser/inspector to issue
such a certificate shall not prevent the Manufacturer from proceeding with the Works.
The completion of these tests or the issue of the certificate shall not bind the
Purchaser to accept the equipment should it, on further tests/ after erection, be found
not to comply with the Contract. The equipment shall be dispatched to site only after
approval of test reports and issuance of MICC by the Purchaser.

In all cases where the Contract provides for tests whether at the premises or at the
works of the Manufacturer or of any Sub-Contractor, the Manufacturer except where
otherwise specified shall provide free of charge such items as labour, materials,
electricity, fuel, water, stores, apparatus and instruments as may be reasonably
demanded by the Purchaser /Inspector or his authorised representative to carry out
effectively such tests of the equipment in accordance with the Contract and shall give
facilities to the Purchaser Inspector or to his authorised representative to accomplish
testing.

The inspection by Purchaser and issue of Inspection Certificate thereon shall in no

way limit the liabilities and responsibilities of the Manufacturer in respect of the
agreed quality assurance programme forming a part of the Contract.

The Purchaser reserves the right for getting any field tests not specified in respective
sections of the technical specification conducted on the completely assembled
equipment at site. The testing equipment for these tests shall be provided by the
Purchaser.

3.9 MATERIALS AND WORKMANSHIP

Equipment materials and components shall be new, of high grade and good quality
and be to the latest engineering practice. The material and workmanship throughout
shall be in accordance with the purpose for which they are intended. Each component
shall be designed to be consistent with its duty.

All the information concerning materials or components to be used in manufacturing,

machinery, equipment, materials and components supplied, installed or used shall be
submitted for approval. Without such approval the supplier shall run risk of

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subsequent rejection. The cost as well as time delay associated with such rejection
shall be borne by the supplier.

3.10 COLOUR SCHEME

The Supplier shall propose a colour scheme for the equipment for the approval of the
Employer. The decision of the Employer shall be final. However, the finishing colour
shall be RAL 7035 for all Control panels/ MCC/ Switchgear panels. The scheme shall
include:

- Finishing colour of Indoor equipment

- Finishing colour of Outdoor equipment
- Finishing colour of various auxiliary system equipment including piping
- Finishing colour of various building items.
- Finishing colour of all cubicles.

All steel structures, plates etc shall be painted with non-corrosive paint on a suitable
primer. The galvanised structures in the switchyard shall not be painted. However
galvanised structures in other areas may require painting for aesthetic reasons.

3.11 PACKING AND STORAGE

Packing specification shall be submitted for BHEL/customer approval after award of

contract.
All the equipment shall be suitably protected, coated, covered or boxed and crated to
prevent damage or deterioration during transit, handling and storage at site till the
time of erection. On request of the purchaser, the manufacturer shall also submit
packing details/associated drawing for any equipment/ material at a later ate, in case
the need arises. While packing all the materials, the limitation from the point of view
of availability of Railway wagon sizes in India should be taken into account. The
manufacturer shall be responsible for any loss or damage during transportation,
handling and storage due to improper packing. Any demurrage, wharf age and other
such charges claimed by the transporters, railways etc shall be to the account of the
manufacturer. Purchaser takes no responsibility of the availability of the wagons.

All coated surfaces shall be protected against abrasions, impact, discoloration and any
other damages. All exposed threaded portions shall be suitably protected with either a
metallic or a non-metallic protecting device.

Supplier shall ensure that equipment shall be properly packed, blocked, padded,
coated and protected so that it is not damaged due to possible mishandling. Storage
requirements shall be clearly defined by the supplier. Packing shall be such that if

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required, long time storage (at least 1 year) at site should not deteriorate the
performance of the equipment.

3.12 NAME PLATE

Name plates which are to be firmly fixed on all the equipment, buildings and
structures shall be provided. For equipment of small size, these are to be fixed on the
piping or structure adjacent to the equipment. The contents of nameplate are to
include the designation and principal parameters of the equipment.
The nameplate within the field shall be made of a high temperature - resistant metallic
sheets, with designation permanently engraved on them. Indoor installed equipments
(e.g., panels, cabinets, switchgear, etc.) shall also be labelled by appropriate name
plate.
The form, size, base colour and colour of contents of the name plates and prompting
plates will be agreed between the Contractor and the Owner. It shall be possible for
these to be readily seen by the operator. The designation of warning tags shall be
different from that of other tags.

The Equipment identification shall be finalized by vendor in consultation with

BHEL/TANGEDCO and should be included in name plates.

3.13 CLAMPS & CONNECTORS

i) All power clamps and connectors shall conform to lS: 5561, and/or IEC standard
and shall be made of materials listed below:

a) For connecting ACSR Aluminium alloy casting, conforming to

conductors designation A6 of IS: 617 and shall be tested
for all tests as per IS:617

b) For connecting equipment Bimetallic connectors made from

terminals made of copper with aluminium alloy casting, conforming to
ACSR conductors designation A6 of IS 617 with 2 mm thick
Bimetallic liner and shall be tested as per IS: 617.
c) For connecting G.I. Shield wire Galvanised mild steel

d).1 Bolts, nuts & Plain washers. Electro galvanized for sizes below
M12, for others hot dip galvanised
d).2 Spring washers for items 'a' to Electro-galvanised mild steel suitable for at least
'c’ service condition-3 as per lS: 1573

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ii) Equipment shall be supplied with the necessary terminals and connectors, as
required by the ultimate design for the particular installation. The conductor
terminations of equipment shall be either expansion, sliding or rigid type. The
requirements regarding external corona and RIV as specified for any equipment
shall include its terminal fittings and the equipment shall be factory tested with the
connectors in position. In case the connector is not available then equivalent
connector may be used. If corona rings are required to meet these requirements
they shall be considered as part of that equipment and included in the scope of
Work.

iii) Where copper to aluminium connections are required, bi-metallic clamps shall be
used, which have been properly designed to ensure that any deterioration of the
connection is kept to a minimum and restricted to parts which are not current t
shall be furnished to the Employer.

iv) Low voltage connectors, grounding connectors and accessories for grounding all
equipment as specified are also included in the scope of Work.

v) No current carrying part of any clamp shall be less than 10 mm thick. All ferrous
parts shall be hot dip galvanised. Copper alloy liner of minimum 2mm thickness
shall be cast integral with aluminium body for Bi-metallic clamps. When copper
alloy is not cast integral with aluminium body, a bimetallic washer or strip shall be
used to meet the functional requirement.

vi) All casting shall be free from blow holes, surface blisters, cracks and cavities. All
sharp edges and corners shall be blurred and rounded off.

vii) Flexible connectors, braids or laminated straps made for the terminal clamps for
bus posts shall be suitable for both expansion or through (fixed/sliding) type
connection of IPS Aluminium tube as required. In both the cases the clamp height
(top of the mounting pad to centre line of the tube) should be same.

viii) Clamp shall be designed to carry the same current as the conductor and the
temperature rise shall be equal or less than that of the conductor at the specified
ambient temperature. The rated current for which the clamp/connector is designed
with respect to the specified reference ambient temperature, shall also be indelibly
marked on each component of the clamp/connector, except on the hardware.

ix) All current carrying parts shall be designed and manufactured to have minimum
contact resistance.

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x) TESTS

The following is the list of type tests.

a) Temperature rise test (maximum temperature rise allowed is 35deg C over 50
deg C ambient)
b) Short time current test
c) Dry corona and RIV test as per annexure-A
d) Resistance test and tensile test

3.14 GALVANIZING

Galvanizing works shall conform in all respect to B.S. 729, B.S. 3083 and B.S.C.P.
2008 and to DIN 50976 whatever requires the higher quality and shall be performed
by the hot dip process, unless otherwise specified. It is essential that details of steel
members and assemblies which are to be hot-dip galvanized should be designed in
accordance with B.S 4479.
Vent-holes and drain-holes should be provided to avoid high internal pressures and
air-locks during immersion, which may cause explosions, and to ensure that molten
zinc is not retained in pockets during withdrawal.
Careful cleaning of welds is necessary before welded assemblies are dipped. The
welds and the surrounding metal should be cleaned separately, preferably be blast-
cleaning, because the usual preliminary pickling cannot be relied on to remove the
welding slag.
All defects of the steel surface including cracks, surface laminations, laps and folds
shall be removed in accordance with B.S. 4360. All drilling, cutting, welding,
forming and final fabrication of unit members and assemblies shall be completed,
where feasible, before the structures are galvanized. The surface of the steelwork to
be galvanized shall be free from paint, oil, grease and similar contaminants in
accordance with DIN 55928, part 4 and DIN 50976. The weight of zinc coating per
unit area has to be noted in the manufacturing documents in accordance with DIN
50976.
The minimum average coating weight shall be as specified in Table 1 of B.S. 729 or
Table 2, DIN 50976, whatever requires higher quality.
Structural steel items shall be initially grit-blasted to B.S. 4232, second quality, (Sa
21/2) or by pickling in a bath and the minimum average coating weight on steel
sections 5 mm thick and over shall be 610 g/m2 (DFT = 85μ) .
On removal from the galvanizing bath, the resultant coating shall be smooth,
continuous, free from gross surface imperfections such as bare spots, lumps, blisters
and inclusions of flux, ash or dross.

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Galvanized contact surfaces to be joined by high-tensile friction-grip bolts shall be

roughened before assembly so that the required slip factor (defined in B.S. 3294, part
1 and B.S. 4604,
part 1) is achieved. Care shall be taken to ensure that the roughening is confined to
the area of the mating faces.
Bolts, nuts and washers, including general grade high-tensile friction grip bolts
(referred to in B.S. 3139, and B.S.4395 part 1) shall be hot dip galvanized and
subsequently centrifuged (according to B.S. 729). Nuts shall be tapped up to 0.4 mm
oversize after galvanizing and the threads oiled to permit the nuts to be finger-turned
on the bolt for the full depth of the nut. No lubricant, applied to the projecting threads
of galvanized high-tensile friction-grip bolt after the bolt has been inserted through
the steelwork, must be allowed to come into contact with the mating faces of the
steelwork,. A local remelting of the galvanized parts to achieve the nuts to be finger
turned on the bolt is possible in accordance with DIN 50976.
Protected slings must be used for offloading and erection. Galvanized work which is
to be stored at the works or on site shall be stacked so as to provide adequate
ventilation to all surfaces to avoid wet storage staining (white rust).

Small areas of the galvanized coating damaged in any way shall be restored in
accordance with DIN 55928, part A and DIN 50976 by:
• Cleaning the area of any weld slag rust and other impurities and by thorough
wire brushing to give a metallic clean surface.
• Application of suitable number of coats of zinc-rich paint containing more
than 90 % w/w of zinc in dried film. The dry film thickness shall exceed at
least 50 % the thickness of the desired galvanization. In case of application of
a low melting point zinc alloy repair rod, the rods shall be in accordance with
DIN1707, the thickness of the alloy shall be at least as of the desired
galvanization.
The restored area is not to exceed 1 % of the galvanized surface. Surface restoration
of parts in contact with drinking water is not allowed and the quality of the
galvanization is to be in accordance with DIN 2444.
After fixing, bolt heads, washers and nuts shall receive two coats of zinc-rich paint.
Connections between galvanized surfaces and copper, copper alloy or aluminum
surfaces shall be protected by suitable preferably hydrophobe tape wrappings to the
owner’s approval.

3.15 DEGREE OF PROTECTION

The enclosures of the control cabinets, Junction boxes and Marshalling boxes, panels
etc. to be installed as detailed here under:

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The minimum requirements for panels are as follows:

• Installed out door: IP- 55

• Installed indoors in air-conditioned area: IP-32
• Installed in covered area: IP-52
• Installed indoors in non air-conditioned area where possibility of entry of
water is limited: IP-41.
• For LT Switchgear (AC & DC distribution Boards): IP-52.

The degree of protection shall be in accordance with IS:13947 (Part-I) / IEC-947

(Part-I) / IS 12063 / IEC 529. Type test report for degree of protection test, on each
type of the box shall be submitted for approval.

Page 16 of 16
 CLIENT – TAMILNADU GENERATION & DISTRIBUTION CORPORATION LTD. TB-400-553-124
CONSULTANT- TATA CONSULTING ENGINEERS LMITED BENGALURU
Rev. 01
PROJECT: 2X660MW UDANGUDI STPP (STATE-1)
TECHNICAL SPECIFICATION FOR VENTILAION SYSTEM
Page | 1

SECTION-4
LIST OF DRAWINGS & DOCUMENTS

Bidder shall submit the drawings & data sheets as per the following list:

DRAWING NO. DRAWING NAME

TB-400-553-123-03 Ventilation equipment & Ducting layout for GIS building
TB-400-553-123-04 Schematic, GA & SLD for Ventilation PDB in GIS building
TB-400-553-123-05 Ventilation Equipment & Ducting layout for Control Building
TB-400-553-123-06 Schematic, GA & SLD for wall mounted fuse board for ventilation fans in
control building
DATA SHEETS DATA SHEETS NAME
TB-400-553-124-03 TDS For Supply Air Fans / Exhaust Fans
TB-400-553-124-04 TDS for Centrifugal Fan
TB-400-553-124-09 Ventilation Fan Calculation
TB-400-553-124-11 TDS For Ventilation Duct
TB-400-553-124-12 BOQ- Ventilation System
TB-400-553-124-13 O&M Manual for Ventilation System
TB-400-553-124-14 TDS For Ventilation Grills
TB-400-553-124-15 TDS For Ventilation VCD & PRD
TB-400-553-124-16 TDS For Ventilation System Fire Damper
TB-400-553-124-17 TDS For Ventilation System Pre-filter & Fine filter
TB-400-553-124-18 TDS For Propeller Exhaust Fan
TB-400-553-124-19 TDS For Ventilation Louvers

Page 1 of 1
 CLIENT – TAMILNADU GENERATION & DISTRIBUTION CORPORATION LTD. TB-400-553-124
CONSULTANT- TATA CONSULTING ENGINEERS LMITED BENGALURU
Rev. 01
PROJECT: 2X660MW UDANGUDI STPP (STATE-1)
TECHNICAL SPECIFICATION FOR VENTILATION SYSTEM
Page | 1

SECTION-5
ENCLOSURES TO SPECIFICATION

SCHEDULES TO BE FILLED UP BY THE BIDDER

Schedule 1 Schedules of Deviations

Schedule 2 Details of contact persons (technical & commercial)

Schedule 3 Enclosures to Specification

Annexure-A: Drawings

Page 1 of 4
 CLIENT – TAMILNADU GENERATION & DISTRIBUTION CORPORATION LTD. TB-400-553-124
CONSULTANT- TATA CONSULTING ENGINEERS LMITED BENGALURU
Rev. 01
PROJECT: 2X660MW UDANGUDI STPP (STATE-1)
TECHNICAL SPECIFICATION FOR VENTILATION SYSTEM
Page | 2

SCHEDULE-1

SCHEDULE OF TECHNICAL DEVIATION

The following are the deviations / variations / exceptions from the specification:

Section Clause No. / Statement of deviation/

Page No. Variations/Exceptions

1) In case, this schedule is not submitted, it will be presumed that the equipment
/material to be supplied under this contract are deemed to be in compliance with the
specification.

2) If there is NIL deviation, even then the format to be filled as NIL DEVIATION

3) Continuation sheets of like size and format may be used as per the Bidder’s Requirement
and shall be annexed to this schedule.

Place Signature of the authorized representative of Bidder

Name -------------------------------------

Date Designation----------------------------------------

Company seal--------------------------------------

Page 2 of 4
 CLIENT – TAMILNADU GENERATION & DISTRIBUTION CORPORATION LTD. TB-400-553-124
CONSULTANT- TATA CONSULTING ENGINEERS LMITED BENGALURU
Rev. 01
PROJECT: 2X660MW UDANGUDI STPP (STATE-1)
TECHNICAL SPECIFICATION FOR VENTILATION SYSTEM
Page | 3

SCHEDULE-2

DETAILS OF CONTACT PERSON BOTH TECHNICAL AND COMMERCIAL

Name

Address for correspondence

Phone No.

Fax No.

Email

Place Signature of the authorized representative of Bidder

Name-----------------------------------------------
Date
Designation----------------------------------------

Company seal -------------------------------------

Note: Continuation sheets of like size and format may be used as per the Bidder’s
Requirement and shall be annexed to this schedule.

Page 3 of 4
 CLIENT – TAMILNADU GENERATION & DISTRIBUTION CORPORATION LTD. TB-400-553-124
CONSULTANT- TATA CONSULTING ENGINEERS LMITED BENGALURU
Rev. 01
PROJECT: 2X660MW UDANGUDI STPP (STATE-1)
TECHNICAL SPECIFICATION FOR VENTILATION SYSTEM
Page | 4

SCHEDULE –3

ENCLOSURES TO SPECIFICATION

(ANNEXURE-A)

DRAWINGS

1. Architectural drawing Control Room Building

DRG. NO. TB-1-400-607-620-1/2/2

2. Architectural drawing GIS Building

DRG. NO. TB-1-400-607-640-1/2/3

Page 4 of 4
 7 2 .50S
2 48 .4 5W

RE A CT OR-2

00.00E
00.00N
UP
 B6 B7 B8 B6 B7 B8
B4 B5 B4 B5
B1 B2 B3 B1 B2 B3

W1

W1
W2

W2
V2

V2
V1

V1
U2

U2
U1

U1
A1 A2 A3 A1 A2 A3

A4 A5 A4 A5
A6 A7 A8 A6 A7 A8

00.00N
00.00E
ST # 2
ST # 1

AIR WASHER

AIR WASHER
UAT-2CAT01 UAT-2CAT02 UAT-1CAT01 UAT-1CAT02

ROOM

ROOM
UT # 1A UT # 1B

UT # 2A
UT # 2B

1.1

1.1 1.1 1.1 1.1 1.1 1.1

GT-2A GT-2B GT-2C STANDBY GT-1A GT-1B GT-1C SPARE GT

MAINTENANCE TR
# SBT

R Y B R Y B R Y B

248.45W
72.50S

R Y B R Y B R Y B
227.95W

REACTOR-1

REACTOR-2
67a 67a

135.50S

VENTILATION
BUILDING
15000X8000 STORE
5000X5000

850
RACK
1610
1 RACK
1610
1
48V BATTERY-1 48V BATTERY-2

1330
850 850 1000 850 850

220V BATTERY-1

220V BATTERY-2
400KV GIS BUILDING

RACK 1

RACK 2

RACK 1

RACK 2
3220
3580
EYE WASH AREA

800
200

800
1000

R Y B

B B
R Y R Y R Y B R Y B R Y B R Y B

VIRUDUNAGAR-2

VIRUDUNAGAR-1
SPARE EQUIPED
SPARE UNEQUIPED

SPARE UNEQUIPED

NGAPURAM-1
NGAPURAM-2

SAMUGARE-
SAMUGARE-

DARAM-1
DARAM-2

OTTAPI-
OTTAPI-
BAY
BAY-2

BAY-1
SECTIONALIZER SECTIONALIZER

MAIN BUS-2B

SECTIONALIZER SECTIONALIZER

196.64W
187.89S
 112.14W
169.89S

MAIN BUS-1A

FOR FINISHING SCHEDULE REFER DRAWING NO TB1-400-607-641

MAIN BUS-2A
UP
SLOPE