4 X 330 MW THERMAL POWER PLANT
Mundra – SEZ
Near Wandh Village, Kutchh District, Gujarat
TENDER DOCUMENT
PART – II : TECHNICAL
Title:TECHNICAL SPECIFICATION FOR
420 kV SHUNT REACTOR
Client:
ADANI POWER LIMITED
Mundra SEZ
(An Adani Group)
Mundra, Gujarat
REV DOC NO 2 8 2 0 - 7 1 0 0 0 1 - E L - S P C - 6 1 0 - 0 0 2 A
NO OF SHEETS
(INCLUDING COVER SHEET)
5 8 A.CODE
A 13/07/09 RM GS GS FIRST SUBMISSION
INITIALS SIGN INITIALS SIGN INITIALS SIGN DETAILS OF REVISION REV DATE
PREPARED CHECKED APPROVED
FICHTNER
Consulting Engineers (India) Private Limited
P A R T - I I
T A B L E O F C O N T E N T S
Section No. Description
1 TECHNICAL SPECIFICATION 23
2 ERECTION , TESTING & COMMISSIONING 06
3 TECHNICAL SCHEDULES 20
SECTION-1
CONTENTS
CLAUSE DESCRIPTION SHEET
NO. NO.
1.0.0 INTENT OF SPECIFICATION...2
2.0.0 SCOPE OF SUPPLY & SERVICES...2
3.0.0 TIME SHCEDULE ...3
4.0.0 CODES AND STANDARDS ...3
5.0.0 GENERAL REQUIREMENTS...4
6.0.0 PERFORMANCE REQUIREMENT ...ERROR! BOOKMARK NOT DEFINED. 7.0.0 CONSTRUCTIONAL FEATURES...4
8.0.0 SURGE ARRESTER...13
9.0.0 PAINTING ...13
10.0.0 PACKING & DELIVERY ...14
11.0.0 QUALITY ASSURANCE, TESTING & INSPECTION...14
12.0.0 DOCUMENTS ...17
ANNEXURE-A : PROJECT INFORMATION...19
ANNEXURE B: RECOMMENDED O&M SPARES ...21
1.0.0 INTENT OF SPECIFICATION
This specification covers Design, engineering, manufacture, assembly and testing at works, packing/dispatch, transportation to site, receipt, unloading/storage at site, erection, testing & commissioning of 2 nos of 63 MVAR, 420 kV Shunt Reactors as specified complete with all accessories for efficient and trouble-free operation of 4 x 330MW thermal power plant proposed at Mundra SEZ, Gujarat.
It is not the intent to specify completely herein all details of the 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 in continuous commercial operation up to bidder’s guarantee.
The general terms and conditions, instruction to bidders and other attachment referred to elsewhere be hereby made part of the technical specification. The bidder shall be responsible for and governed by all requirements stipulated in the specification.
Deviations if any, should be brought out very clearly on deviation sheet enclosed with the specification only. Otherwise it will be construed that the bidder’s offer is in line with what has been stated /asked for in this specification.
The offer should be complete with technical data, catalogue, brochures and drawings as applicable.
In order to be able to present the proven-ness of the equipment offered, the bidder is required to elaborate details of experience, capabilities, reference list etc in the offer.
2.0.0 SCOPE OF SUPPLY & SERVICES
2.1.0 The scope of supply shall cover Design, engineering, manufacture, assembly and testing at works, packing/dispatch, transportation to site, receipt, unloading/storage at site, erection, testing & commissioning of Two (2) nos of 63 MVAR , 420kV, 3 phase Shunt reactor complete with all fittings and accessories for 420 kV line feeders . (Bidder shall indicate optional price for 50 MVAR shunt reactor also.)
2.2.0 The scope of supply shall also include the following for the above shunt reactors: a) Bushing CTs.
b) Neutral grounding reactor. c) Surge Arrester.
2.3.0 Spares & Consumables
The scope of supply shall also include the following.: a) First fill of consumables.
b) Spare parts for three years trouble free operation & maintenance (O&M).
c) Special tools & tackles required for erection, testing, commissioning and maintenance of equipment
The item wise prices of these items shall be given by the bidder in the relevant schedule of Volume-II of the bidding documents. O&M spares shall be considered for evaluation of bid. It shall not be binding on the Owner to procure all of the O&M spares. The bidder is clarified that no O&M spares shall be used during the commissioning of the equipment. Any spares required for commissioning purpose shall be arranged by the Vendor. The unutilized spares if any brought for commissioning purpose shall be handed over to the Owner.
2.4.0 Scope of Services
• Preparation and submission of drawings & documents in soft and hard form as per the drawings / documents submission schedule.
• Unloading and safe storage at site
• Minor civil works associated with equipment erection, including welding, bolting, drilling, grouting, chipping, sealing, making openings, finishing etc., as required for satisfactory execution of the work.
• Erection, testing & commissioning. • Submission of progress report
• Participation in project review / Technical Coordination meetings. 2.5.0 Exclusion
a) Civil work such as foundation, rail, cable trench, etc. 2.6.0 Terminal Points
a) 400 kV bushing terminal. b) Earthing pads
3.0.0 TIME SHCEDULE
3.1.0 The following shall be the Schedule for completion of various milestone events for this package. • Design, Engineering, Manufacture, testing, transport and delivery at site : 6
months
• Erection , testing commissioning (from the date of foundation is handed over) : 1 month
4.0.0 CODES AND STANDARDS
4.1.0 The equipment to be furnished under this specification shall be in accordance with the applicable section of the latest version of the following Indian Standards, IEC publications and any other standards of latest edition including amendments, except where modified and /or supplemented by this specification.
Code No : Part No : Year : Description
• IS 335 : - : 1993 : Specification for New Insulating Oil(Fourth Revision) • IS 2099 : - : 1986 : Specification For Bushings for Alternating voltages above
1000V
• IS 3347 : : 1979 : Dimension for porcelain transformer bushings
• IS 1893 : - : 2004 : Criteria for earthquake Resistant Design of structures- : General Provision and Buildings (Fourth Revision)
• IS-5 : Painting
• IS-2705 : 1,2,3,4 :1992 : Specification for Current Transformers
• IEC-289 : Shunt Reactors
• IS-5553 (part-I) : Shunt Reactors • CBIP Manual on Switchyard
• Indian Electricity Act and rules framed there-under. • Fire Insurance Regulations
• Regulations laid by the office of the Chief Electrical Inspector to Government.
5.0.0 GENERAL REQUIREMENTS
5.1.0 Project information is given in Annexure-A.
5.2.0 The reactors shall be capable of operating continuously at its rated output without exceeding the specified temperature limits.
5.3.0 Shunt reactors shall be provided in 420 KV Lines of Power Station Switchyard to compensate capacitive generation from long lightly loaded overhead lines or extended cable systems and also for control of dynamic over voltages.
5.4.0 All the equipment shall be designed for design ambient temperature of 50°C unless otherwise specified.
5.5.0 The Shunt reactor shall be suitable for installation in Seismic Zone-4 as per UBC standard ( Zone 5 as per IS: 1893-2002).
5.6.0 Shunt reactors will be connected to the 420 kV transmission system for reactive load compensation and shall be capable of controlling the dynamic over voltage occurring in the system due to load rejection. Shunt reactors shall be capable of operating continuously at a voltage 5% higher than their rated voltage without exceeding hot spot temperature of 150 deg C at any part of the reactor. The typical line parameters of 420kV lines are given below.
Susceptance mhos/KM Sl.
No.
Line Positive Sequence Impedance Ohms/KM
Zero sequence Impedance
Ohms/Km Positive Zero
1. 420 kV DC Line
0.0265+j0.309 0.263+j1.1326 3.6x10-6 2.17 x 10-6
5.7.0 Temperature rise shall be guaranteed when shunt reactor is operating at 420kV.
5.8.0 The neutral grounding reactors are required for grounding of the neutral point of shunt reactors to limit the secondary arc current and the recovery voltage to a minimum value.
5.9.0 The reactor shall be subjected to switching surge over voltage of 2.5 p.u and temporary over voltage of the order of 2.3 p.u.for few cycles followed by power frequency over voltage up to 1.5p.u. The reactor must withstand the stress due to above transient dynamic conditions which may cause additional current flow as a result of changed saturation characteristics/slope beyond 1.5.p.u. voltage.
6.0.0 CONSTRUCTIONAL FEATURES 6.1.0 Tank & Tank Cover
a) Tank shall be of welded construction and fabricated from tested quality low carbon steel of adequate thickness. After completion of tank and before painting, dye penetration test shall be carried out on welded parts of jacking bosses, lifting lugs and all load bearing members. Tank stiffeners shall be provided for general rigidity and these shall be designed to prevent retention of water.
b) The reactor shall be of bell type tank with bolted joint at about 500 mm above the bottom of the tank. In case the joint is welded it shall be provided with flanges suitable for repeated welding. The joint shall be provided with a suitable gasket to prevent weld splatter inside the tank. Proper tank shielding shall be done to prevent excessive temperature rise of the joint. c) Each tank shall be provided with :
• Lifting lugs suitable for lifting the equipment complete with oil.
• A minimum of four jacking pads in accessible position to enable the reactor complete with oil to be raised or lowered using hydraulic jacks.
• Suitable haulage holes.
d) The tank shall be designed in such a way that it can be mounted on the plinth directly.
e) The base of each tank shall be so designed that it shall be possible to move the complete reactor unit by skidding in any direction without injury when using plates or rails.
f) The tank cover shall preferably be sloped to prevent retention of rainwater and shall not distort when lifted.
g) At least two adequately sized inspection openings one at each end of the tank, shall be provided for easy access to bushings and earth connections. The inspection covers shall not weigh more than 25 kg. Handles shall be provided on the inspection cover to facilitate lifting. h) The tank covers shall be fitted with pockets at the position of maximum oil temperature at
maximum continuous rating for bulbs of oil and winding temperature indicators. It shall be possible to remove these bulbs without lowering the oil in the tank. The thermometer shall be fitted with a captive screw to prevent the ingress of water.
i) Bushing turrets, covers of inspection openings, thermometer pockets etc. shall be designed to prevent ingress of water into or leakage of oil from the tank.
j) All bolted connections shall be fitted with weather proof, hot oil resistant, resilient gasket in between for complete oil tightness. If gasket is compressible, metallic stops/other suitable means shall be provided to prevent over-compression.
6.2.0 Core
a) The Shunt reactor shall be of gapped core type. Five limbed core construction shall be adopted to achieve high zero sequence impedance. In addition to the three gapped core limbs with windings, there shall be two continuous outer return limbs. The core sections between consecutive air gaps shall be moulded in epoxy resin to prevent movement between individual laminations. The spacers forming the air gaps shall be blocks of ceramics with a high modules of elasticity and the whole stacking of core modules shall be cemented together during the assembly to form a solid column without possibility of rocking , or rubbing between individual parts. The core segments shall be of radial laminated configuration. The radial laminations shall prevent fringing flux from entering flat surfaces of core steel which would result in eddy current overheating and hot spots.
b) The core shall be constructed from high grade, non-ageing, cold rolled, super grain oriented, silicon steel laminations.
c) The design of the magnetic circuit shall be such as to avoid static discharges, development of short circuit paths within itself or to the earthed clamping structure and production of flux component at right angles to the plane of laminations which may cause local heating.
d) The insulation of core to bolts and core to clamp plates shall be able to withstand a voltage of 2 kV (rms) for 1 minute.
e) Core and winding shall be capable of withstanding the shock during transport, installation and service. Adequate provision shall be made to prevent movement of core and winding relative to tank during these conditions.
f) All steel sections used for supporting the core shall be thoroughly sand blasted after cutting, drilling and welding.
g) Each core lamination shall be insulated with a material that will not deteriorate due to pressure and hot oil.
h) The supporting frame work of the core shall be so designed as to avoid presence of pockets which would prevent complete emptying of tank through drain valve or cause trapping of air during oil filling.
i) Adequate lifting lugs will be provided to enable the core and windings to be lifted. 6.3.0 Windings
a) The Contractor shall ensure that windings of all 420kV class reactors are made in dust proof and conditioned atmosphere.
b) The conductors shall be of electrolytic grade copper free from scales and burrs.
c) The insulation of reactor windings and connections shall be free from insulating compounds which are liable to soften, ooze out, shrink or collapse and be non-catalytic and chemically inactive in transformer oil during service.
d) Coil assembly and insulating spacers shall be so arranged as to ensure free circulation of oil and to reduce the hot spot of the winding.
e) The coils would be made up, shaped and braced to provide for expansion and contraction due to temperature changes.
f) The conductor shall be transposed at sufficient intervals in order to minimize eddy currents and to equalize the distribution of currents and temperature along the winding.
6.4.0 Conservator & Oil Preservation System
a) Main conservator shall have air cell type constant oil pressure system to prevent oxidation and contamination of oil due to contact with moisture, and shall be fitted with magnetic oil level gauge with low oil level potential free contacts. Air cell used shall be suitable for operating continuously at 100°C.
b) NGR shall have conventional type conservator with prismatic oil level gauge.
c) Conservator tank shall have adequate capacity with highest and lowest visible-levels to meet the requirements of expansion of total cold oil volume in the reactor and cooling equipment from minimum ambient temperature to 100°C.
d) The conservator shall be fitted in such a position so that it can be removed for cleaning purposes. Suitable provision shall be kept to replace air cell, wherever applicable. Conservator shall be positioned so as not to obstruct any electrical connection to reactor. The connection of
air cell to the top of the conservator is by air proof seal preventing entrance of air into the conservator.
e) Contact of the oil with atmosphere is prohibited by using a flexible air cell of Nitrile rubber reinforced with Nylon cloth.
f) Aircell type of conservator shall be able to withstand the vacuum during installation/maintenance periods. Otherwise provision shall be kept to isolate the conservator from the main tank when the latter is under vacuum by providing a vacuum sealing valve or other suitable means in the pipe connecting main tank with the conservator.
g) Conservator shall be fitted with a dehydrating filter breather. Passage of air shall be through Silicagel. Silicagel shall be isolated from atmosphere by an oil seal. Breather shall be mounted not more than 1200 mm above rail top level. To minimize the ingress of moisture, three breathers of identical size shall be connected in series for main tank conservator.
6.5.0 Pressure Relief Device
Adequate number of pressure relief devices shall be provided at suitable locations. These shall be of sufficient size for rapid release of any pressure that may be generated in the tank and which may result in damage to equipment. The device shall operate at a static pressure less than the hydraulic test pressure of the reactor tank. It shall be mounted directly on the tank. One set of electrically insulated contacts shall be provided for alarm/tripping. Discharge of pressure relief device shall be properly taken through pipes and directed away from the reactor/other equipment and this shall be prevented from spraying on the tank.
6.6.0 Buchholz Relay
Buchholz relay shall be double float reed type.. Any gas evolved in the reactor shall collect in this relay. The reed switch shall be magnetically operated type. The relay shall be provided with a test cock suitable for a flexible pipe connection for checking its operation and taking gas sample. A copper/stainless steel tube shall be connected from the gas collector to a valve located about 1200 mm above ground level to facilitate sampling with the reactor in service. The device shall be provided with two electrically independent ungrounded contacts, one for alarm on gas accumulation and the other for tripping on sudden rise of pressure.
6.7.0 Oil Temperature Indicators (OTI)
Reactors shall be provided with a 150 mm dial type thermometer for top oil temperature indication. The thermometer shall have adjustable, electrically independent ungrounded alarm and trip contacts, maximum reading pointer and resetting device shall be provided in the OTI. A temperature sensing element suitably located in a pocket on top oil shall be furnished. This shall be connected to the OTI by means of capillary tubing. Temperature indicator dials shall have linear gradations to clearly read atleast every 2°C. Accuracy class of OTI shall be 1.5% or better.
6.8.0 Winding Temperature Indicator (WTI)
a) A device for measuring the hot spot temperature of HV winding and LV winding shall be provided separately. It shall comprise the following:
• Temperature sensing element. • Image coil.
• Auxiliary CTs, if required to match the image coil, shall be furnished and mounted in the cooler control cabinet.
• 150 mm dia local indicating instrument with maximum reading pointer and two adjustable electrically independent, ungrounded contacts (one for high winding temperature alarm
and one for trip) besides that required for control of cooling equipment,. Temperature indicator dials shall have linear gradations to clearly read at least every 2°C. Accuracy class of WTI shall be 1.5% or better.
• Calibration device.
b) For Remote indication of winding temperature (RWTI), signal transmitter (RTD) for each winding shall be provided. Signal transmitter shall also transmit signal for recording winding temperature at ‘Owner’s ‘Data acquisition system’ (DAS). In lieu, separate RTD shall be provided for remote WTI and DAS.
c) RTD shall be duplex platinum with nominal resistance of 100 ohms at zero degree centigrade. The RTD shall be three wire ungrounded system.
d) Remote Winding Temperature Indicators (RWTI) for HV winding and LV winding shall be provided and suitable for flush mounting on Owner’s panel.
e) Shielded copper control cable required for connection between cooler control cabinet and remote WTI control circuit, shall be in scope of the bidder.
6.9.0 Axles and Wheels
a) The Shunt reactor shall be mounted on concrete plinth foundation directly.
b) The roller mounted reactors are to be provided with flanged bi-directional wheels and axles. This set of wheels and axles shall be suitable for fixing to the under carriage of reactor to facilitate its movement on rail track. Suitable locking arrangement along with foundation bolts shall be provided for the wheels to prevent accidental movement of reactor. The rail track gauge shall be 1676 mm.
c) To prevent reactor movement during earthquake, suitable clamping devices shall be provided for fixing the reactor to the foundation.
d) All Wheels shall be detachable and shall be made of cast iron and steel as required.
e) If wheels are required to swivel, they shall be arranged so that they can be turned through an angle of 90° when tank is jacked up clear of the rails or floor.
6.10.0 Earthing Terminals
a) Two (2) earthing pads (each complete with two (2) nos. holes, M10 bolts, plain and spring washers) suitable for connection to 75 x 10 mm galvanised steel grounding flat shall be provided each at position close to earth of the two (2) diagonally opposite bottom corners of the tank.
b) Two earthing terminals suitable for connection to 50 x 6 mm galvanised steel flat shall also be provided on cooler, Cooler control cabinet and any other equipment mounted separately. 6.11.0 Terminal Arrangements
a) The electrical and mechanical characteristics of bushings shall be in accordance with IS: 2099 and IS: 3347.
b) Bushing for voltage of 420 kV shall be of the oil filled condenser type.
c) Oil Filled condenser type bushing shall be provided with at least the following fittings: • Oil level gauge.
• Oil filling plug and drain valve if not hermetically sealed. • Tap for capacitance and tan delta test.
d) Line side bushing CTs and Neutral bushing CTs shall be provided as specified. Secondary leads of CTs shall be wired upto-marshalling box.
e) Where current transformers are specified, the bushings shall be removable without disturbing the current transformers.
f) Bushings of identical rating shall be interchangeable.
g) Porcelain used in bushing manufacture shall be homogenous, free from lamination, cavities and other flaws or imperfections that might affect the mechanical or dielectric quality and shall be thoroughly vitrified, tough and impervious to moisture.
h) Clamps and fittings shall be of hot dip galvanized steel.
i) Bushing turrets shall be provided with vent pipes, to route any gas collection through the Buchholz relay.
j) No arcing horns shall be provided on the bushings.
k) The terminal marking and their physical position shall be as per IS: 2026. 6.12.0 Neutral Earthing Arrangement
The neutral of shunt reactor connected to a line shall be grounded through a neutral grounding reactor. The contractor shall provide connections between neutral of the shunt reactor, surge arrestor and the neutral grounding reactor.
The neutral terminal of the shunt reactor and neutral grounding reactor shall be brought to the ground level by a tinned copper grounding bar, supported from the tank by using porcelain insulators. The end of the tinned copper bar shall be brought to the bottom of the tank, at a convenient point, for making bolted connection to two nos. 75 x 10 mm galvanized steel flats connected to Owner’s grounding mat.
6.13.0 Cooling Equipment
a) Oil immersed with natural cooling (ONAN)
b) The radiator bank of the shunt reactor shall be tank mounted or separately mounted. c) Radiators shall be made from pressed steel.
d) Each radiator bank shall be provided with the following accessories. • Top and bottom shut off valve
• Drain valve and sampling valve • Air release plug
• Two grounding terminals for termination of two(2) nos.75x12 mm galvanized steel flats. • Thermometer pockets with captive screw caps at cooler inlet and outlet.
• Lifting lugs
a) All valves upto and including 100 mm shall be of gun metal or of cast steel/cast iron. Larger valves may be of gun metal or may have cast iron bodies with gun metal fittings. They shall be of full way type with internal screw and shall open when turned counter clock wise when facing the hand wheel.
b) Suitable means shall be provided for locking the valves in the open and close positions. Provision is not required for locking individual radiator valves.
c) Each valve shall be provided with the indicator to show clearly the position of the valve. d) All valves flanges shall have machined faces.
e) All valves in oil line shall be suitable for continuous operation with Shunt reactor oil at 100 degree C.
f) The oil sampling point for main tank shall have two identical valves to be put in series .Oil sampling valve shall have provision to fix rubber hose of 10 mm size to facilitate oil sampling. g) A valve or other suitable means shall be provided to fix the on line dissolved gas monitoring
system to facilitate continuous dissolved gas analysis. The location & size of the same shall be finalised during detail engineering stage.
h) After testing, inside surface of all cast iron valves coming in contact with oil shall be applied with one coat of oil resisting paint/varnish with two coats of red oxide zinc chromate primer followed by two coats of fully glossy finishing paint of a shade (preferably red or yellow) distinct and different from that of main tank surface. Outside surface except gasket setting surface of butterfly valves shall be painted with two coats of red oxide zinc chromate followed by two coats of fully glossy finishing paint.
i) All hardware used shall be cadmium plated / electro galvanised. 6.15.0 Marshallig Box
a) A sheet steel marshalling box of a suitable construction shall be provided for the reactor ancillary apparatus and this shall be vermin. Dust & weather proof. All the terminals for remote indication shall be wired upto marshalling box from the reactor accessories. Necessary shorting of CT secondary terminals shall be done at the marshalling box.
b) The sheet steel used shall be atleast 2.5mm thick hot rolled or 2mm thick cold rolled. The degree of protection shall be IP-55 in accordance with IS-13947. The marshalling box shall be free standing floor mounted type or tank mounted type. In case of tank mounted type suitable antivibration pad shall be provided so that vibration from tank is not transferred to the marshalling box. The marshalling box shall have domed or sloping roof. It shall have double hinged doors and shall be provided with padlock and padlocking arrangement.
c) All doors, removable covers and plates shall be gasketed all round with neoprene gaskets. Louvers shall have screens and filters. The screens shall be of fine wire mesh made of brass and GI wire.
d) The marshalling box shall accommodate the following: • Temperature indicator for winding and oil,
e) Two set of potential free initiating contact for all the following conditions shall be wired independently to the terminal blocks of control cabinet, for connecting to Owner’s Panel and SAS system as a minimum requirement :
Buchholz relay Alarm/Trip
Winding Temperature Indicator Alarm/Trip Oil Temperature Indicator Alarm/Trip Pressure Relief Valve Operated (Trip ). Main tank Oil level low Alarm
Any other contacts as required. 6.16.0 Insulating Oil
The insulating oil shall be EHV grade mineral oil, and shall conform to all parameters specified below, while tested at supplier's premises. No inhibitors shall be used in oil. The Vendor shall furnish test certificates from the supplier against their acceptance norms as mentioned below, prior to dispatch of oil from refinery to site. Sufficient quantity of oil necessary for maintaining required oil level in tank, radiators, conservator etc till commissioning shall be supplied.
a. The oil shall be clear and transparent and free from suspended matter or sediment b. Density at 29.5°C(max.) : .89 gm/cm3
c. Kinematic Viscocity at 27°C (Max.) : 27 cSt d. Interfacial tension at 27°C (Min.) : 0.04 N/m e. Flash point Penskey-Marten (closed) (Min.) : 140°C
f. Pour point (Max.) : - 6°C
g. Neutralization value (total acidity) (Max.) : .03 mg KOH/gm h. Corrosive sulphur
(in classification of copper strip) : Non-Corrosive i. Electric strength(breakdown voltage)(Min.)
• New untreated oil : 30 kV (rms)
• After treatment : 60 kV (rms)
j. Dielectric dissipation factor (tan delta) at 90°C(Max.) : 0.002 k. Resistivity (Min.) (ohm cm)
• (a) at 90°C : 35x1012
• (b) at 27°C : 1500x1012
l. Oxidation stability
• Neutralization value after oxidation (Max.): 40 mg KOH/gm of oil • Total sludge after oxidation (Max) : 10 percent by weight
m. Presence of oxidation inhibitor : The oil shall not contain anti-oxidant additive
n. Water content (Max.)
• New untreated oil : 50 ppm
o. Ageing Characteristics after 96 hrs as per IS:12177 Method A with catalyst (copper) • Resistivity (Min) (ohm cm) at 27°C : 2.5x1012
• Resistivity (Min) (ohm cm)at 90°C : 0.2x1012 • Tan delta at 90°C (Max.) : 0.2
• Total acidity (Max.) : 0.05 mg KOH/gm of oil
6.17.0 The Shunt Reactor & neutral grounding reactor shall be supplied with the following accessories as a minimum :
a) Conservator for reactor main tank with filling hole and cap, drain valve, isolating valve, vent pipe and magnetic oil level gauge with low level alarm contacts.
b) Conservator for NGR main tank with drain valve, isolating valve, vent pipe and prismatic oil level gauge.
c) Air release devices
d) Dehydrating breather complete with first fill of activated silicagel. e) Inspection openings and covers.
f) Rating & diagram plate for reactors and current transformers. These plates shall be of material capable of withstanding continuous outdoor service.
g) Terminal marking plate conforming to IEC-289/IS:5553
h) Two earthing terminals each on shunt reactor tank, NGR tank, radiators & marshalling box, etc.
i) Suitable neutral bus connection
j) Reed type Buchholz relay with alarm and trip contacts. k) Bottom oil sampling valve and drain valves.
l) Filter valves at top and bottom.
m) Shut off valves on the pipe connection between radiator tank and radiator bank. n) Shut off valves on both sides of Buchholz relay at accessible height.
o) Sampling gas collectors for Buchholz relay at accessible height. p) Four jacking pads.
q) Lifting lugs or eyes for the cover.
r) Suitable terminal connectors on bushings
s) Under carriage with provision for flanged bidirectional wheels, set of flanged bi-directional rollers/Trolley for transportation.
t) Drain valves/Plug shall be provided in order that each section or pipe work can be drained independently.
u) Pressure relief device with contacts. v) Bushing with metal parts and gaskets.
w) Winding temperature indicator for local and remote mounting (only for shunt reactor) x) Oil temperature indicator.
y) Protected type mercury or alcohol in glass thermometer. z) Marshalling box
aa) Haulage lugs, bb) Bushing CT
The fittings listed above are only indicative and other fittings which generally are required for satisfactory operation of the reactor are deemed to be included. The Reactor fittings and accessories shall be of reputed make and shall be subject to approval of the Owner.
7.0.0 SURGE ARRESTER
7.1.0 The surge arresters shall conform in general to IS : 3070 (Part-I). It shall be gapless type without any series or shunt gap. Arresters shall be hermetically sealed units, of self supporting construction, suitable for mounting on structures.
7.2.0 The surge arresters shall be of heavy duty station class type. It shall be physically located between the neutral of 420 kV shunt reactor (brought out at 145 kV class bushing) and neutral grounding reactor and shall be electrically in parallel with the later.
7.3.0 The surge arresters shall be capable of discharging overvoltage occurring during switching of unloaded transformers and reactors. Surge arresters shall be capable of spark over on severe switching surges and multiple strokes.
7.4.0 The non linear blocks shall be of sintered metal oxide material. The surge arresters shall be fitted with pressure relief devices and arc diverting parts suitable for preventing shattering of porcelain housing and providing path for flow of rated fault currents in the event of arrester failure.
7.5.0 The arresters shall incorporate anti-contamination feature to prevent arrester failure consequent to uneven voltage gradient across the stack in the event of contamination of the arrester porcelain. 7.6.0 Seals shall be provided in such a way that these are always effectively maintained even when
discharging rated lightning current.
7.7.0 Outer insulator shall be porcelain used shall be homogenous, free from laminations, cavities and other flaws or imperfection that might affect the mechanical or dielectric quality and shall be thoroughly vitrified, tough and impersions to moisture. Glazing of porcelain shall be of uniform brown colour, free from blisters, burrs and other similar defects. Porcelain housing shall be so coordinated that external flashover will not occur due to application of any impulse or switching surge voltage upto the maximum design value for arrester.
7.8.0 The arrester shall be supplied with suitable support structure either of tubular GI pipe or lattice steel galvanised.
7.9.0 Each arrester shall be complete with insulating base, support structure and terminal connector. The height of the support structure shall not be less than 2500 mm. The structure would be made of galvanised steel generally conforming to IS:802. The surge arrester can also be mounted on the neutral grounding reactor in lieu of separate support structure.
7.10.0 Self contained discharge counter, suitably enclosed for outdoor use and requiring no auxiliary or battery supply for operation, shall be provided for each unit. The counter shall be visible through an inspection window from ground level. The counter terminals shall be robust and of adequate size and shall be so located that incoming and outgoing connections are made with minimum possible bends.
7.11.0 Suitable milliammeter on each arrester with appropriate connections shall be supplied to measure the resistor grading leakage current. The push buttons shall be mounted such that it can be operated from ground level. Discharge counter and milliammeter shall suitable for mounting on support structure of the arrester.
7.12.0 Grading / Corona rings shall be provided on each complete arrester unit as required for proper stress distribution.
a) Before painting or filling with oil or compound, all un-galvanized parts shall be completely clean and free from rust, scale and grease, and all external surface cavities on castings shall be filled by metal deposition.
b) The interior of reactor tanks and other oil filled chambers and internal structural steel work shall be cleaned of all scale and rust by shot-blasting or other approved method. These surfaces shall be painted with hot oil resisting varnish or paint. Unexposed welds need not be painted.
c) The external surface shall be given a coat of high quality red oxide or yellow chromite primer followed by filler coats. Except for nuts, bolts and washers, which may have to be removed for maintenance purposes, all external surfaces shall receive a minimum of three coats of paint. d) The primary coat shall be applied immediately after cleaning. The second coat shall be an oil
and weather resisting nature and preferably of a shade or colour easily distinguishable from the primary and final coats and shall be applied after the primary coat has been touched up where necessary. The final coat shall be of a glossy oil and weather resisting non-fading paint of shade Number 631 of IS:5 ( The same will be confirmed during detail engineering). The paint shall be suitable for coastal saline atmosphere. Primer paint shall be ready made zinc chrome as per IS:104;intermidiate and final coats of paint shall be as per IS:2932. The final thickness of paint film on steel shall not be less than 80 microns. Sufficient quantity of touch-up paint shall be furnished for application at site.
e) Nuts, bolts and washers which may have to be removed for maintenance purposes shall receive a minimum of one coat of paint after erection.
f) All interior surfaces of mechanism chambers and kiosks except those, which have received anti-corrosion treatment shall receive three coats of paint applied to the thoroughly cleaned metal surface. The final coat shall be of a light coloured anti-condensation mixture.
g) Any damage to paint work incurred during transport and erection shall be made good by the supplier by thoroughly cleaning the damage portion and applying the full number of coats of paint that had been applied before the damage was caused.
h) One coat of additional paint shall be given at site by the Owner. Supplier will supply the requisite quantity of paint.
9.0.0 PACKING & DELIVERY
The vendor shall arrange transportation of all equipment from the point of manufacture to the Site. The arrangements shall include, but not be limited to, hiring adequate capacity of Wagon, determination of routes, determination of required permits, payment of required taxes and duties, and notification to the Owner.
10.0.0 QUALITY ASSURANCE, TESTING & INSPECTION
10.1.0 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. The bidder shall give at least 15 days advance notice of the date when the tests are to be carried out.
10.2.0 Makes of all equipment/components shall be subjected to Owner’s approval without any cost implication.
10.3.0 Short circuit tests certificates for test conducted earlier on Shunt reactor of similar type and rating shall be furnished for the Owner’s review. Bidder shall also furnish test certificates of all type tests
as per relevant standard, already carried out by the bidder on similar type and rating of equipment along with the offer.
10.4.0 Type Tests
a) Following type tests shall be conducted on one reactor of each rating :
• Temperature rise test (As per IEC-289). Gas chromatographic analysis test on oil shall be conducted before and after this test..
• Measurement of zero-sequence reactance as per IS:2026 • Measurement of acoustic noise levels as per IS:2026. • Lighting impulse test on neutral as per IS:2026.
• Tank Vacuum and tank pressure tests on one reactor tank • Measurement of knee point voltage.
• Snap Back test on H.V. bushing.
• Measurement of capacitance and tan-delta to determine capacitance between winding and earth.
b) Impulse voltage withstand test (as per IEC-289) shall be conducted on one neutral grounding reactor.
10.5.0 Routine Tests
a) All the routine tests listed in IEC-289/IS-5553 (part-I) shall be carried out on all the reactors. In addition the following tests shall also be carried out on each reactor.
• Switching impulse on line terminals.
• Partial discharge measurement test (As per IS:2026,). • Oil leakage test on reactor tank
• Lightning impulse test on all phases. • Vibration and stress measurement test. • Frequency Response Analysis (FRA). b) Routine tests on neutral grounding reactor
All the routine tests listed in IEC-289/IS-5553 (part-I) shall be carried out. In addition the volt-current characteristics test shall also be carried out on each neutral grounding reactor . c) Surge arresters shall be subjected to routine tests as per IEC-99.1/IEC-99.4.
d) Routine tests on bushings
• Test for leakage on internal filling
• Measurement of creepage distance, dielectric dissipation factor and capacitance. • Dry power frequency test on terminal and tapping.
• Partial discharge test followed by dielectric dissipation factor and capacitance measurement.
10.6.0 Insulating oil shall be tested for BDV & moisture content as follows, at manufacturer's works (oil sample shall be drawn before and after heat run test) :
• BDV 60 kV (min.)
• Moisture content 15 ppm
10.7.1 During fabrication the following tests shall be carried out as per CBIP Manual:
a) The tank shall be tested for leakage by being completely filled with air at a pressure corresponding to twice the normal head of oil or to normal pressure plus 35 KN/Sq.m whichever is lower. The pressure shall be maintained for a period of minimum one hour during which time no leak shall occur. The equivalent air pressure corresponding to oil pressure calculated at the base of the tank to be considered for air pressure test. Permanent deflection of flat plates shall be measured on one tank of each design, after the excess pressure has been released and shall not exceed the figures specified below:
Horizontal Length Permanent deflection of flat plate (in mm) (in mm)
Upto and including 750 5.0
751 to 1250 6.5 1251 to 1750 8.0 1751 to 2000 9.0 2001 to 2250 11.0 2251 to 2500 12.5 2501 to 3000 16.0 Above 3000 19.0
b) The conservator shall be tested for leakage by being completely filled with air at 35 kN/ m2. The pressure shall be maintained for a period of minimum one hour during which time no leakage shall occur.
c) The radiators shall be tested for leakage by placing them horizontally in a tank filled with clean water and applying air pressure 2 kg/cm2m for atleast 15 minutes during which time no leakage shall occur.
d) The Pipes shall be tested for leakage by applying air pressure 4 kg/cm2m for atleast 15 minutes during which time no leakage shall occur.
10.7.2 During fabrication the Vacuum test shall be carried out as type test as per CBIP Manual as follows: Reactor tank of each design shall be subjected to vacuum of 100.64 kN/ m2 ( 760 mm of Hg). The tank designed for full vacuum shall be tested at an internal pressure of 3.33 KN/Sq.m absolute (25 torr) for one hour. The permanent deflection of flat plate after the vacuum has been released shall not exceed the values stated above in clause 11.7.1 a).
10.7.3 During fabrication the Pressure test shall be carried out as type test as per CBIP Manual as follows:
Reactor tank, its radiator, conservator vessel and other fittings together or separately shall be subjected to a pressure corresponding to twice the normal head of oil or to the normal pressure plus 35kN/m2 whichever is lower measured at the base of the tank and maintained for eight hours during which time no leakage shall occur.
10.7.4 Before conducting pressure test,the following shall be taken care of:
a) Pressure relief valve/relief vent shall be removed and opening shall be blanked. b) Oil should be completely filled and all trapped air released.
10.7.5 During assembly stage the following test shall be carried out as routine test.
Oil pressure test to be conducted on tank with turret and all other accessories as assembled by filling completely with oil at a pressure corresponding to twice the normal head of oil or to normal
pressure plus 35kN/m2 whichever is lower. The pressure shall be maintained for eight hours during which time no leakage shall occur
10.7.6 For the following fittings, type test & routine test reports shall be furnished by the Vendor for Owner’s approval.
Bushing Buchholz relay Cooler Control cabinet Pressure Relief device Test • Magnetic Oil Level gauge. • Air Cell
• OTI • WTI • Oil pump
• Bushing current transformers. • Axles & wheels
10.7.7 The Shunt reactors shall be subjected to switching surge overvoltage of 2.5 p.u. and temporary overvoltage of the order of 2.3 p.u. for few cycles followed by power frequency overvoltage upto
1.5 p.u. The reactor must withstand the stress due to above transient dynamic conditions which may cause additional current flow as a result of changed saturation characteristics/slope beyond 1.5 p.u. voltage.
10.7.8 The charges for carrying out all routine tests shall be deemed to be included in the Bid price. The charge of carrying out each type test/ special test shall be given separately in “ Unit Price Schedule” for price adjustment purpose, In case waival of any of the tests by the Owner at a later date.
11.0.0 DOCUMENTS
11.1.0 Drawings/Documents required along with the bid:
a. The bidder shall submit the following in separate envelopes marked as under: • Technical Offer for “420kV Shunt reactor ” (Unpriced) – 6 Copies.
• Price Offer for “420kV Shunt reactor” in sealed envelope.
b. Data sheet of Section-2 shall be duly filled up and stamped & signed on all the sheets. c. Type test certificate of similar type of comparable rating.
d. Measures adopted for Seismic Zone-4 (as per UBC standard) installation. e. Clause wise deviations, if any.
f. General arrangement drawing g. Experience list
h. Sub-Vendor List i. Quality Plan
11.2.0 Drawings/Documents to be submitted after award of contract:
a) Revised data sheet incorporating all the comments agreed during tender stage. b) List of deliverable items & packing list.
c) Measures adopted for Seismic Zone-4 (as per UBC standard) installation. d) Quality Plan
e) Dimensional General Arrangement drawing. f) Parts list
g) Bushing arrangement
h) Catalogues/drawings for bought out items. i) Transport /Shipping dimension drawing
j) Foundation Plan & loading details k) Properties of transformer oil
l) Valve diagram plate and list of valves indicating material & size. m) Name plate details
n) Design calculations for short circuit withstand capability.
o) Painting & surface preparation procedure for Owner’s acceptance. p) Test procedure
q) Test certificates
11.3.0 Schedule for submission of various documents shall will be finalized during award of contract.: 11.4.0 O&M MANUAL
O&M manual for installation, operation and maintenance of reactor shall be furnished before dispatch of the equipment. Draft O&M manual shall be submitted for Owner’s approval within two weeks of inspection. Manual shall contain minimum following details:
a) Description of the equipment b) Salient construction features c) Packing details
d) Instructions to be followed on receipt at site for storage e) Erection procedure & checks
f) Tests to be conducted at site g) Commissioning procedure h) Maintenance instructions i) List of spares
j) Approved GA drawing k) Approved Data Sheets
l) Technical leaflets of all important components
11.5.0 Drawing/Documents Distribution Schedule will be firmedup during finalization of the Contract. 11.6.0 For all technical tables and diagrams, calculation results, drawings, test data and scales adopted
in the design the Standard International unit system (SI) as per International Standardization Organization (ISO) shall be uniformly employed.
11.7.0 All engineering documents and drawings shall be of international “A” series sizes that is of A0, A1, A2, A3 & A4.
ANNEXURE-A : PROJECT INFORMATION
1.1.0 Owner : Adani Power Limited
Adani House, Near Mithakali Circle, Navrangpura, Ahmedabad – 380 009.
Fax: 079-2555 5627 Tel.: 079-2555 5555
1.2.0 Owner’s Engineer : FICHTNER Consulting Engineers(I)Pvt. Ltd
Ganesh Chambers, 64, Eldams Road, Chennai 600 018 Fax : 044 - 2434 4579, 2434 5611 Tel : 044 - 2435 9158 (5 lines) E-mail : fichtner@chn.fichtner.co.in
1.3.0 Project : Adani Power Limited.
4 x 330 MW Thermal Power Plant
1.4.0 Site Location : Tunda Village ,
Kutchh Dist.
Gujarat
1.5.0 Nearest Airport : Bhuj(65 Kms)
1.6.0 Approach Road : NH-8A(12 Kms) & SH - 6 (4 kms) 1.7.0 Nearest Railway Station : Adipur/Ghandhidham (63 kms)
1.8.0 Nearest Sea Port : Gujarat Adani Port (35 Kms)
1.9.0 Elevation above sea level (mean sea level) : 9.5 M
1.10.0 Seismic Zone : Zone 5 As per IS:1893 - 2002 : Zone 4 As per UBC Standard 2.0.0 Meteorological Information
2.1.0 Ambient Conditions
Design temperature for electrical
equipment / device : 50°C 2.2.0 Relative Humidity a. Maximum : 95% b. Minimum : 20% c. Average : 60% 2.3.0 Wind Data
a. Basic Wind speed : 50 m/sec b. Maximum wind velocity experienced : 65 km/hr
2.4.0 Soil Bearing Capacity : 15 Tons/sq.m. at 2M depth.
2.5.0 Tropicalisation : All equipment supplied against this
specification shall be given tropical and fungicidal treatment considering the saline climatic conditions prevailing at site as described.
3.0.0 Electrical Details 3.1.0 Electrical Voltage levels
a. EHV System : 420,000 V (±)5% volts , 3 phase, 50 (+)3% to (-)5% Hz, solidly grounded system.
b. EHV System : 220,000 V (±)10% volts , 3 phase, 50 (+)3% to (-)5% Hz, solidly grounded system.
c. MV System : 6600 V (±)10% volts, 3 phase, 50 Hz (+)3%
to (-)5% , low resistance grounded system. d. LV System : 415 V (±)10% volts, 3 phase, 50 Hz (+)3% to
(-)5% ,solidly grounded system.
e. AC Control Voltage : 110 V (±)10% volts, 1 phase, 50 Hz, (PH/N of 415 volt).
f. Auxiliary supply for lighting etc., : 240 V (±)10% volts, 1 phase, 50 Hz, (PH/N of 415 volt).
g. Combined voltage & frequency : 10% (Absolute sum) variation for MV & LV systems
h. DC Control Voltage : 220V (+)10% to (-) 15% volts (DC), ungrounded system
3.2.0 Electric Equipment Voltage Rating
a. For motors from 0.2 kW to <160 kW : 415 Volt, 3 phase, 50 Hz Solidly earthed b. For motors less than 0.2kW : 240 Volt, 1 phase, 50 Hz
3.3.0 Fault Level
a. 420,000 volts system : 40 kA for One second b. 220,000 volts system : 40 kA for Three second
c. 24 kV system : 175 kA for Three second
d. 6.6 kV system : 44 kA for Three second e. 415 volts system : 50 kA for one second
ANNEXURE B: RECOMMENDED O&M SPARES
SNO DESCRIPTION UNIT QTY
1) HV Bushings with metal parts ( 3 nos.) Set 1
2) HVN Bushings with metal parts ( 1 No..) Set 1
3) Oil Temperature Indicator Set 1
4) Set of Valves (1 No. of each type) Set 1
5) Dial Type Thermometer No. 1
6) Magnetic Oil Level Gauge No. 1
7) Silica Gel Breather No. 1
8) Winding Temperature Indicator with all accessories No. 1
9) Gaskets Sets 1
ANNEXURE-C : TECHNICAL PARAMETERS 1.1.0 Technical Parameters of Shunt reactors are as follows:
SL.NO. DESCRIPTION UNIT Shunt reactor
1. Rating MVAR 63/50
2. Quantity Nos. 2
3. Application Line Reactor
4. HV Side Voltage level 420 kV
5. Frequency & Variation 50 Hz, +3%, -5%
6. HV Side fault level kA 40
7. Short circuit withstand duration Sec 2
8. Type of cooling ONAN
9. Temp. rise above 50 °C amb. Temp.
a) In oil by thermometer measurement °C 50
b) In winding by resistance method °C 55
10. Lightning Impulse withstand level(1.2/50 micro sec) , Phase
KVp 1300 11. Switching surge impulse voltage KVp 1050
12. Ratio of zero sequence reactance to positive reactance (X0/X1)
Between 0.9 & 1.0.
13. Range of constant impedance Upto 1.5 p.u. voltage 14. Harmonic content in phase current The crest value of the third
harmonic component in phase current not to exceed 3% of the crest value of fundamental when
reactor is energised at rated voltage with sinusoidal wave form. 15. Permissible current unbalance
among different phases
+ 2%
16. Lightning Impulse withstand level(1.2/50 micro sec), Neutral
KVp 550 17. Switching surge impulse voltage,
Neutral
KVp 230 18. Neutral grounding reactor
a) Rated voltage kV 145
b) Rated frequency Hz 50
c) No. of Phases one
d) Type Outdoor
e) Insulation Graded
f) Max. continuous current A 10A (rms)
g) Rated short time current (10secs) rms 60A h) Rated impedance at rated short time
current
600 to 2500ohm(This is an indicative value, actual value will
SL.NO. DESCRIPTION UNIT Shunt reactor be confirmed during detail
engineering.) 19. Terminal arrangement
a) HV side Over head line
b) HV Neutral side Over head line
20. Phase Bushings
a) Rated Voltage kV 420
b) Bushings Creepage distance 31 mm /kV
c) Lightning Impulse withstand level(1.2/50 micro sec) , Phase
KVp 1425 d) Switching surge impulse voltage,
Phase
KVp 1050 e) One minute Power frequency
withstand voltage
kV 630 21. Neutral Bushings
a) Rated Voltage kV 145
b) Bushings Creepage distance 31 mm /kV
c) Lightning Impulse withstand level(1.2/50 micro sec) , Phase
KVp 650 e) One minute Power frequency
withstand voltage
kV 275 22. HV bushing CTs
a) CT ratio Amps 100/1A
b) Accuracy class PS class
23. HV Neutral bushing CTs
a) CT ratio Amps 100/1A
SECTION –2
SECTION-2 CONTENTS
CLAUSE DESCRIPTION SHEET
NO. NO.
1.0.0 GENERAL REQUIREMENTS ... 3 2.0.0 INSTALLATION ... 3 3.0.0 TESTING AND COMMISSIONING ... 5 4.0.0 ENERGISING: ... 6
SECTION –2
ERECTION, TESTING & COMMISSIONING
1.0.0 GENERAL REQUIREMENTS
1.1.0 The contractor shall furnish the organization chart of his site office indicating names, designation, experience of Site in-charge, supervising staff, etc. who will be posted at site for the following . a. Day to day execution of work and supervision
b. Testing and commissioning
c. For co-ordination with purchaser’s representative
1.2.0 The installation shall be carried out by electrical contractor, holding a valid license issued by relevant authorities for carrying out installation work of the reactor under the direct supervision and person holding valid certificate of competency for the same voltage classes, issued or recognized by the Government of India.
1.3.0 Equipment / item shall be installed in a neat work manner so that it is leveled, plumbed, squared and properly aligned and oriented.
1.4.0 The contractor shall effectively protect his work, equipment and material under his custody from theft, damage or tampering. Finished work where required shall be suitably covered to keep it clean and free from defacement or injury. Contractor shall be held responsible for any loss or damage to equipment and material issued to him until the same is taken over by the purchaser according to contract.
1.5.0 All safety rules and codes as applicable to work shall be followed without exception. All safety appliance and protective devices including belts, hand gloves, across, helmets, shields, goggles, safety shoes etc. shall be provided by the contractor for his personnel.
1.6.0 The contractor shall provide guards and prominently display caution notices if access to any equipment / area is considered unsafe and hazardous.
1.7.0 Special tools and tackles required for erection, testing and commissioning of equipment shall be in contractor’s scope.
1.8.0 All tools and tackles and other equipments required for erection shall be arranged by contractor at the site before the work in started.
2.0.0 INSTALLATION
The contractor shall prepare a schedule of the works to be carried out with specific periods for each item of work involved.
2.1.0 Precautions
2.1.1 The contractor shall take extreme care to prevent any foreign material from being dropped into the Reactor.
2.1.2 Fibrous cleaning materials shall not be used by contractor. The presence of loose fibres in suspension in reactor oil can reduce materially its insulating properties. All components shall be cleaned inside and outside before being fitted.
2.1.3 If any internal temporary transportation braces are provided, they are to be removed by contractor without disturbing any permanent internal arrangements such parts should be clearly marked on the transportation drawings.
2.2.0 Positioning of the Unit : The reactor shall be erected on a level foundation by contractor. The reactor tank contain the core and coil assembly should be first placed in position selected for assembly. The reactor shall then be jacked up and the roller fitted to the bottom frame.
2.3.0 OIL : The oil to be used for filling and topping up must comply with IS : 335 (Latest revision) as supplied. The oil sample from the reactor tank before commissioning shall meet the following specifications.
a. BDV - 60 kV
b. Water content - 10 ppm
c. Resistivity - 1 x 1012 ohm – cm d. Dielectric dissipation - 0.05
factor (tan δ) at 90°C max. 2.4.0 Oil Filling
a. For Shunt reactor dispatched with gas filled, the filling of oil inside the tank is done under vacuum. When filling a reactor with oil, it is preferable that the oil be pumped into the bottom of the tank and that a filter press or other reliable oil drying and cleaning device should be interposed between the pumps and the tank.
b. Before filling oil in the tank, it shall be tested to meet the requirements specified above. In case the oil does not meet the requirement, it should be processed and shall only be used when it meets the specification requirements.
c. Process of Drying : Before the drying out is started, all fittings except coolers and associated accessories shall be fitted. The coolers, etc shall be conveniently fitted after the successful dry out of windings and insulation. In no case shall a reactor be left unattended during any part of the dry-out period. Reactor should be carefully watched throughout the dry-out process and also observations shall be carefully recorded.
2.5.0 Gaskets : Whenever blanking plates are removed to fix detached parts such as bushing turrets etc. a new gasket shall be used while fixing the same.
2.6.0 Bushings : The bushings shall be checked for any damage at the oil end as well as the porcelains before fixing bushings shall be cleaned thoroughly. The bushings shall be lifted by using the lifting eyes and soft mainila ropes. The line lead of HV winding if coiled inside the reactor is drawn through the bushing using a string when the bushings is lowered into position. The cable ferrule is fixed in position at the top of the bushing brass tube. The lower end of the bushing shall be inspected through the inspection cover for proper sealing. The line connection should be tight and should not strain the terminals. Sufficient flexibility in the connecting leads should also be provided to avoid mechanical stress on the bushing.
2.7.0 Cooling Equipments
a. The cooling equipment and associated pipe work and fittings are to be thoroughly cleaned and flushed with clean dry reactor oil before assembly The cooler and associated pipe work is then filled with clean dry oil keeping all the cooler circuit open, except the reactor inlet and outlet valves. Air is released from all the pipe work during filling. The oil is circulated through a filter press using the filter valves provided in the cooler inlet and outlet branches. The cooler control circuit is to be checked for correct operation in all positions of the selector switch. The cooler system is then connected to the main tank by opening the tank inlet and outlet valves.
b. There will be a header each at top and bottom which are supported on frames. Flanges are provided on these headers for fixing the radiators. Radiator valves are fitted to the headers and dispatched. The end frames are to be erected first. The frames should be positioned correctly with respect to the reactor. After erecting the end frames the top and bottom header are mounted. The headers will have to be properly leveled so that the connecting pipe work can be easily fixed. Then radiators are fixed.
2.8.0 Conservator : Conservator should be assembled with its pipe work, etc. making sure that all gasketed joints are oil-tight and the pipe work is clean and free from moisture. While topping up oil in the reactor, it should be ensured that oil is filled to a level indicated by the oil gauge on the conservator in commensurate with the filling oil temperature.
2.9.0 Buchholtz Relay: The Buchholtz is checked for correct functioning of the reed switches. The angle of inclination is also to be checked. The gas release pipe is to be connected to the top petcock. In service, the top petcock should be open and gas release pipe should be full of oil. When the gas is to be collected through the gas release pipe, initially the oil will flow out and then the gas can be collected.
2.10.0 Dehydrating Breathers : The breather pipe work shall be properly cleaned. The oil level in the oil seal at the bottom should be filled to the correct level with reactor oil. It is to be ensured that the breathing hole at the bottom of the seal is not blocked by dirt, etc. The silicagel to be filled into the breather shall be blue colour.
2.11.0 Temperature Indicators
a. Before installing, the accuracy of the instrument shall be checked by hot oil or water bath. b. The thermometer pocket should be filled with reactor oil.
c. The connection of the winding temperature indicator CT is made to the thermometer pocket . 2.12.0 Current Transformers : Current transformer should be kept flat at all times. All CT secondary
terminals should be short circuited or loaded before energising the reactor. .
2.13.0 Final topping up is now done up to a level in conservator commensurate with filling oil temperature with clean dry oil and any other work such as wiring of various alarm / trip contacts, earthing of neutral and tank is completed. The interposing valves between the radiators and the tank are opened.
3.0.0 TESTING AND COMMISSIONING
a) Checking of ratio, polarity and phase relationship b) Resistance Measurement of Windings..
c) Insulation Resistance : IR values between windings and between windings to earth shall be checked, while checking these values no external lines, lighting arrestors, etc. should be in circuit. Motor operated megger should be used for measuring IR values.
d) Check the bushings for conformity of connection to the line etc.
e) Check for adequate protection of electric circuit supplying the accessories.
f) Buchholtz Relay Test :. Buchholtz relay operation for alarm and trip are checked by injecting air through the test petcock.
g) Magnetic Oil Level Gauge : The low oil level alarm of the oil gauge shall be checked.
h) Temperature Indicators :The contacts of WTI and OTI for alarm and trip are checked and set at required temperatures depending upon ambient temperatures and loading conditions. i) Control Cabinet / Marshalling Box: The wiring from various accessories to marshalling box
j) Oil samples from top and bottom of tanks selector switch and diverter switch tanks of tap changer and radiator banks, etc. are tested as per IS : 335. DGA tests are to be done after start of commercial operation to obtain bench work results.
k) All remote annunciations/controls shall be checked and ensured upto the purchaser’s DAS. l) 2 kV /Minute test between bushing CT terminal and earth.
m) Check for cleanliness of the reactor and the surrounding.
n) DGA of oil sample just before commissioning and after 24 hours of commissioning. o) Capacitance and tan delta measurement of winding & bushing.
p) Frequency Response Analysis (FRA) General Checks
• All oil valves are in correct positions, closed or opened as required. • All air pockets are cleared.
• Thermometer pockets are filled with oil.
• Oil is at correct level in the bushings, conservator, diverter switch tank, etc. • Earthing connections are done
• The colour of silicagel (blue) and oil in the breather cup. • Arcing horn gaps on bushings are properly adjusted
• Heaters in cubicles, conservator, etc. where provided should be checked. • Any other alarm / trip contacts of flow meters differential pressure gauges, etc. 4.0.0 ENERGISING:
If all the above tests / checks are found satisfactory, allow a setting time of at least 24 hours for oil and release air from all points. The reactor shall be energised after setting the protective relays to the minimum extent possible. Wherever possible, the voltage should be built up in steps. Any abnormality during commissioning such as vibration of radiator parts, hum etc. should be observed. After a few hours of energisation at no load, the reactor shall be switched off. The Buchholtz relay should be checked for collection of air / gas. Abnormalities noticed should be corrected. All protective relays should be reset to normal values. Reactor can now be re-energised and loaded gradually.
SECTION-3 : TECHNICAL SCHEDULES
SECTION-3 : TECHNICAL SCHEDULES TABLE OF CONTENTS
SECTION – 3.1 : TECHNICAL SCHEDULE-SHUNT REACTOR... 3 SCHEDULE 3.2 PERFORMANCE GUARANTEES ... 9 SCHEDULE – 3.3 - DEVIATION SCHEDULE TO TECHNICAL SPECIFICATION ... 10 SCHEDULE – 3.4 - DEVIATION SCHEDULE TO COMMERCIAL SPECIFICATION ... 11 SCHEDULE – 3.5 - SCHEDULE OF SUB-VENDORS LIST... 12 SCHEDULE – 3.6 - QUALITY ASSURANCE PLAN ... 13 SCHEDULE – 3.7 - DETAILS OF SIMILAR SUPPLIES MADE DURING PAST FIVE YEARS ... 14 SCHEDULE – 3.8 - CONCURRENT COMMITMENTS OF THE BIDDER ... 15 SCHEDULE – 3.9 - OVERALL TIME SCHEDULE... 16 SCHEDULE – 3.10 - REQUIREMENTS OF THE CONTRACTOR AT SITE... 17 SCHEDULE – 3.11 - CONTRACTOR’S RESOURCE DEPLOYMENT SCHEDULE... 18 SCHEDULE - 3.12 - SCHEDULE OF TEST AND INSPECTION ... 19 SCHEDULE - 3.13 - SCHEDULE OF TYPE TESTS ... 20
SECTION – 3.1 : TECHNICAL SCHEDULE- SHUNT REACTOR ( To be submitted alongwith the Bid)
SL NO DESCRIPTION
SPECIFIED DATA
50 MVAR 63 MVAR
1. Name & Place of Manufacturer
2. Service Out door
3. Application/Designation
4. Reference Standards IS: 2026
5. Rating MVAR
6. Rated voltage 420 KV
7. Rated frequency 50 Hz
8. Number of phases 3
9. Reference ambient temperatures
a. Maximum ambient air
temperature 50 Deg C
b. Maximum daily average
ambient air temperature 40 Deg C
c. Maximum yearly weighted
average ambient temperature 32 Deg C
10. Type of Reactor Neutral earthing
Resistance earthed
11. Type of Cooling ONAN
12.
Temperature rise over 50 deg C
ambient .
a. Top oil by Thermometer
method 50 Deg C
b. Windings by Resistance
method 55 Deg C
13.
Hot spot temperature at weighted
reference ambient temperature 98 Deg C
14.
Impedance voltage at rated
current
15.
Reactance at rated current &
rated frequency at Normal tap %
16.
Separate source power frequency
withstand voltage Insulation level kV rms
17.
Full wave lightning Impulse
withstand voltage 1300 kVp
18.
Short circuit withstand current & Duration
40 kA For 2 Sec 19. HV Terminal arrangement
SL NO DESCRIPTION SPECIFIED DATA 50 MVAR 63 MVAR b. Type OIP Condensor c. Bushing class 420 kV
d. Minimum Creepage distance 31.5 mm / kV
e. Rated Current Amps
f. Lightening impulse voltage 1425 KVP g. Power frequency withstand
voltage 1050 KVrms
h. Phase to Phase Air clearance mm i. Phase to Earth Air clearance mm
20. Neutral Bushing a. Make b. Type Solid porcelain c. Bushing class 145 kV
d. Minimum Creepage distance 31.5 mm/kV e. Rated Current
f. Lightening impulse voltage 650 kVp g. Power frequency withstand
voltage 275 kV rms
h. Phase to Phase Air clearance i. Phase to Earth Air clearance 21. Neutral grounding reactor
a. Rated voltage from insulation
strength considerations 145kV
b. Rated frequency 50HZ
c. No.of phases one
d. Type Outdoor
e. Insulation Graded
f. Maximum continuous current 10A(rms) g. Rated short time current
(10sces) 60A (rms)
h. Rated impedance at rated short time current
600 to 2500ohm (This is an indicative value, actual value will be confirmed during detail
SL NO DESCRIPTION SPECIFIED DATA 50 MVAR 63 MVAR engineering.) 22. Weight a) Core stampings Kg b) Copper Kg c) Tank Kg
d) Fitting & accessories Kg
e) Oil Kg
f) Total Weight Kg
23. Oil quantity required for first filling Lts. 24. Overall dimensions a. Length mm b. Breath mm c. Height mm 25. Dispatch details - a. Mode of transport
b. Weight of heaviest package Kg c. Dimensions of largest package
(i) Length mm (ii) Breadth mm (iii) Height mm 26. Untanking height mm 27. Type of windings 28.
Resistance per phase at 75 deg
C winding temperature of ohms 29. Winding Current density Amps/ sqmm
30.
Vacuum withstand capability of tank only As per CBIP Manual 31. Thickness of tank a. side plates mm b. bottom plate mm c. Top plate mm 32. Core
a. Material of core laminations CRGO b. Thickness of core laminations mm c. Type and thickness of
insulation of core laminations d. material of core bolts
