ELECTRICAL POWER DISTRIBUTION AND AUTOMATION

01

Design Basis

01.01 Standards All electrical equipment shall be designed, manufactured, and tested in accordance with the latest Standards issued by the Bureau of Indian Standards, IPSS, and International Electro technical Commission (IEC). In case of conflict between above standards and this technical specifications shall prevail. The equipment/systems offered shall conform to the latest Indian Electricity Rules (IER), and NEC as regards safety, earthing and other essential provisions specified therein for installation and operation of electrical equipment. Statutory requirements of the State Government and Government as well as other statutory authorities shall also be complied with. 01.02 Ambient Conditions Electrical Rooms. LT Sub-Station switchgear room ( Pressurized Ventilation ) MCC Rooms ( housing Intelligent MCCs, VFD panels, TR controllers, R I/Os, etc. ) Cable Basement / tunnels. Control Rooms. Control rooms Air Conditioned. Relative Humidity of equipment General 01.03 Power Supply Conditions: System Voltage 11 KV, 50 Hz, 3-phase, 3-wire, resistance earthed 40kA for 3 sec. 415 V, 50 Hz, 3-phase, 4-wire, solidly earthed 50kA for 1 sec. 6.6 KV: + 6% & - 9% 415V: 10% + 3% & - 6%. Control circuit for MCC / PMCC / PDB AC 240 V 10%, 50 Hz+3% - 6%, 1 Ph, 2Wire. AC 240 V 10%, 50 Hz +3% - 6%, 1 Ph, 2Wire.

+ 45 Deg. C + 35 Deg. C + 50 Deg. C + 24 Deg. C 95% RH

Voltage variations

Frequency variation Control Voltage: Panel Space Heater supply & Auxilliary loads Indication & Control of HT equipment and relay / control panels

DC 110 V

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Instrumentation, Telecom (of Purchaser), PLC and other critical systems Cluster LED for indication

Through UPS AC 110 or 240 V 1 %. : 24V DC for PLC driven, otherwise 240VAC / 110 VDC : 24V DC : 24V DC : 24 VDC : 24 VDC : 4 - 20 mA. : 0-5 v dc

Double/ Single solenoid valves PLC I/O voltage PLC Digital Input PLC Digital Output Analog Input / Output Analog input Other supply conditions will be as per GTS 01.04 Make of Equipment

Selection of the manufacturer of electrical equipment, instruments and control or any other specialised items will be from reputed sources and generally will be from the accepted makes of Purchaser. For other reputed makes not included now in the present Customers Approved Vendors List, but considered by the Tenderer, the same will be selected based on prior approval of Purchaser. 01.05 Power distribution 11 KV HT Power will be received from the existing substation source (clients scope) and it will be further step down to 6.6 KV for HT Motors and 0.433 KV for LT Power Loads to the respective LSS (Local Sub Station) as specified. 01.06 SOME SPECIFIC FEATURES OF POWER DISTRIBUTION SYSTEM 1. We have included LTSS, MCCs, ACDBs, MLDB, and ELDB Etc. We have provided VCB for Drive motors 110 KW to 160 KW. 2. Above 160 KW motor will be 6.6 KV rated. 3. MCCs, MLDB, ACDBs shall be fed from LT substations. 01.07 TECHNICAL SPECIFICATION OF PLC SYSTEM OFFERED 1. 2. The system will be generally compatible to Automation (Level-1) system of the New CHP as per NIT. Monitoring, Control, Interlocking and Sequential functions for the entire New CHP including interfacing with its associated various machines and auxiliary system will be achieved through PLC based Level-1 automation system. All the automation equipment are supplied as per List of Preferred Makes, furnished. Automation system includes independent PLC systems with redundancy in :- processors, power supply modules, communication modules, network interface modules. All required licensed software i.e. System software, HMI software, Application programme etc. For PLC, Workstations, communication interface amongst various automation systems etc. will be provided. All types of system cables, communication cables, LT power cables,

3. 4.

5.

6.

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special cables, etc., will be included. for Control room furniture will be supplied. 01.08 Specific features of Automation system 1. For monitoring, control, interlocking and sequential operation of material transportation system including Yard machines, PLC based automation systems has been provided. Considering information exchange & operational requirement all the systems is be suitably interfaced with each other. All the printers is be provided with network connectivity. Each Operator Workstations has 21" Flat Dual TFT Monitor. The automation system is be powered from UPS. All the ACB MCC is also have communication ability to Automation system. All the communication cables will be laid in GI pipes. Separate pipes with separate routes (to the extent possible) are provided.

2. 3. 4. 5.

GENERAL CONTROL The PLC system is designed to handle all operations from the central control room except for the following: 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. Operation of Stacker-Reclaimer will be controlled only from the Operators cabin mounted on the machine implemented with a stand alone PLC which can interface with the Main CHP PLC. ON/OFF operations of wagon tipplers. Control operations of traveling tipplers. ON/OFF operations from paddle feeders Sump pumps (if any). The Sampling equipment will be controlled from its local panel mounted near the machine with provision for remote operation from CHP control room. Belt weigher DE System. DS System. Side arm charger. Ventilation system.

The system will consist of the following configuration i. The IOs large consist of the following signals: a. Inputs/ outputs for motors, HT/ LT switchyard and transformers, bunker levels, chute jam detectors and other conveyor safety instrumentation. b. Energy meter inputs for voltage current and power. c. Temperature measurements are taken through scanners at the location of motors and transformers. These are connected to the PLC on MODBUS RS 485. Motor vibrations are taken as analog inputs and connected to the AI cards at the respective remote IO locations. These are shown in the attached drawings. There will be one remote IO panel and respective marshalling cabinet in TP-5 area in line with location of the HT panel/ MCC rooms. The main control room will have the hot-standby CPUs with local IOs for Switch yard, motors, pumps and related equipment.

ii. iii.

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iv. v. vi. vii. viii. ix. x.

The remote IOs will be networked with the CPU with Ethernet on dual redundant fiber optic. The related accessories and hardware will be installed in the respective MCC rooms. Local control panels will be connected and status indications and Start and Stop operations will be provided from control room. There will be two Operator Stations (OS) and one Engineering-cum Operator Station (ES/OS). One laptop loaded with required software for engineering of main CHP PLC from Remotely located IOs. The operating stations will be connected to the CPU by a ring network on Ethernet platform. Two numbers of color laser will be provided on the network. Other data relating to the CHP status will be transmitted to the main plant DCS through redundant FO network from the main CPU to the DCS.

INSTRUMENT LIST: The following is the list of instrument and measuring devices required and considered in the system:

Sr. No 1 2 3 4 5 6

Description Bunker level ultrasonic transmitters Chute jam detectors Zero Speed switches Pull chord switches Belt sway switches Temp. scanners 8 ch.

Qty 20 nos. 1 Lot 33 Nos. 1 Lot 1 Lot 12 nos.

TYPICAL IO COUNT FOR MOTORS: S.no Equipment Signal label Start Stop Auto/manual Local/remote ES Trip FBK ZSS RFB Start Stop Auto/manual Local/remote ES Trip FBK WT BT Vibrations DI DO 1 1 I/O AI 0- AI 4-20 5V ma

RTD

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

Motor(LT)

1 1 1 1 2 1 1 1 1 1 1 1 6 2 6

Motor(HT)

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18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62

Flap gate

BW-1

MD-1

ILMS-1

RG RPG

ZSS RFB Start Forward Start Reverse Auto/manual Local/remote Trip Torque switch Flap gate position Trip FBK RFB Start Stop Auto/manual Local/remote ES Trip FBK ZSS RFB Weigh Signal Start ON FB Stop Auto/manual Local/remote Trip FBK Start Stop Auto/manual Local/remote RFB Trip FBK Open Close Start Forward Start Reverse Auto/manual Local/remote Trip Torque switch Flap gate position Trip FBK RFB Start Stop Per Unit

2 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 10

Scoop tube position Bunkers LT

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Energy meters and relays will be connected on MODBUS to the local IO panel. The IO count in each location is shown in the drawing. IO CARDS CAPACITY: The following are the card capacities for the configuration: Sr. no 1 2 3 4 Description Digital input Digital output Analog input 4- 20 ma / 0-5 v Analog input RTD No. of channels 32 32 8 8

CONTROL DESK: The control desk functions as an interface between the operators and the CHP. It consists of the following components: 1. 2. 3. 4. 5. 2 OS with SCADA ES/OS for both as SCADA and engineering station. Push buttons to operate the equipment on manual mode from control desk. Emergency push buttons that act as over-riding function for taking emergency actions. The process alarms and system alarms will be displayed in SCADA in a suitable manner.

CONTROL PHILOSOPHY: The control philosophy is largely with the specifications given. The following describes in brief the philosophy that was considered in design: 1. The modes of control are as follows: Auto is sequential run from SCADA as per the paths defined in the tender document. Manual running individual equipment from SCADA Local running of equipment from local PBs or from MCC Remote running of equipment form control desk PBs. The combination of above models can be programmed based on operational requirements. 2. The modes can be selected trough selector switches located on control desk or MCC. 3. If the selector switch is on AUTO, the soft buttons in SCADA AUTO/ MANUAL can be used to run each equipment from SCADA. But unless all the equipment are on AUTO the sequences cannot be run. 4. Either on AUTO/ MANUAL or REMOTE/ LOCAL the following protections will always be available: Motor overload trip

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5. 6. 7. 8. 9.

10. 11.

Motor winding temperature Motor bearing temperature Motor vibrations. Zero Speed, belt sway, pull- chord protections. All switchyard operations can be controlled from SCADA. The electrical parameters like power and current will be displayed in SCADA. Alarms for all operating parameters will be available on SCADA. Trends for operating data like temperature, vibration, current, voltage, power, etc. can be made available as per operating requirements. The local control panels will be operated locally and signals for monitoring and command will be given to PLC for centralized operations. The centralized operations will be possible only if the local control panel is in REMOTE mode. Until a motor has READY conditions, the system will not commence operation, irrespective of AUTO/MANUAL. The operating sequence and the control philosophy will be as per the tender document.

SEQUENCES AND INTERLOCKS: Operational Sequence: i. To start up the plant in sequence it will be ensured that local / remote selector switch of individual drives are placed in remote position and all equipment are in normal condition. The first step will be to define the selected path of convenience and by properly positioning the related flap gates and rack and pinion gates. After flap gates and rack and pinion gates are bought to positions properly, plant start-up command will be issued to use an audible warning through hooters, along the path to warn the personnel working on the equipment. The number and location of hooters to be decided to suit requirement. The warning will last generally for two minutes, but adjustable, indicated by a lamp on MMI console. After warning hooters are silenced, a definite time will be allowed for movement of personnel etc. after which all the equipment in the selected path will be read sequence starting and the system will be started within a preset time. This condition will be indicated in the MMI. Readiness of the equipment in the selected path will be indicated by slow flickering of the lamps in the selected path. All other equipment that are not falling in the selected path will not receive any permissive to start. Next step is to issue start command starting from the discharge end equipment. When this equipment starts and has come up to a speed very close to its full speed and a preset time has elapsed long enough to clear the chutes, then only the next equipment at its feeding side will get the permissive to start. This process will continue till loading end equipment is reached. The system will be started within a preset time, which can be adjusted from minimum time required to start the plant equipment plus 15 minutes. The lamp indicating Ready for Sequential Starting condition will remain lit only during this period. If, however, the sequence is not started within the preset period after the hooters are stopped a fresh warning will be issued for starting the equipment, which could not be started during the above preset time. Also, if any equipment fails to reach its designed speed within a preset time, the equipment will automatically get isolated from the supply and no subsequent equipment can be started unless the cause is investigated and the fault is rectified and restarted. Under running condition of the plant, if any equipment stops, due to safety interlock or any reason whatsoever, all the equipment behind it towards feeding end will

ii.

iii.

iv.

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stop instantaneously to avoid jamming or overloading of the equipment, except crushers, which may be allowed to run. v. Further by positioning local/remote selector switch to local, it will be possible to start individual drive from local push button station, through PLC, bypassing process interlock while inherent safety interlock of equipment will remain functional. Local / Remote selector switch will be located in HT Switchgear / respective PMCC for the drives which are being controlled from HT Switchgear / PMCC. Local /Remote selector switch will be located in respective local starter /control panel for the equipment / drive which are being controlled locally. Normal stopping of the plant will be effected through PLC based MMI station that will stop the feeding equipment instantaneously and allow a time gap for stopping the plant as a whole. The emergency stop PB will stop the entire plant under sequence instantaneously. Apart from this, individual equipment will be stopped through PLC based MMI station as well as respective local control panel / local push button station. Single push button start with sequential operation will be available with PLC program for all the conveyors.

vi.

vii.

Annunciations: Annunciation system will be PLC based for following fault conditions and will be provided in the operator station: a) b) c) d) e) f) g) h) i) j) k) l) m) n) o) p) q) r) s) t) u) v) w) x) y) z) Zero Speed Switch operated for Conveyor (Group). Zero Speed Switch operated for Crusher (Group). Belt Sway Switch operated (Group). Pull Cord Switch operated (Group). Motor overload Trip (Group) Motor Protection Relay operated (Group). 6.6 KV Motor winding temperature high/very high (Group). 6.6 KV Motor bearing temperature high/very high (Group). Crusher bearing temperature high (Individual). Crusher Vibration High (Individual). D. C. Supply failure (individual). Supply failure of PLCMain CPU fails Standby CPU in service(Individual). Bunker Level High (Group). Bunker Level Low (Group). Metal Detected. (Group). Suspended Magnet fault (Group ). Sump level high and pump not running Location-wise. DS System fault (Area-wise). DE System fault (Area-wise). Stacker/ Reclaimer Trip (Group). Paddle Feeder Trip (Group). Travelling Tripper Trip (Group). 6.6 KV motor Trip circuit unhealthy (Group). 415 V motor Trip circuit unhealthy (Group) - Substation wise Wagon Tippler Trip (Individual) Coal Sampling Unit Trip (Group)

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Interlock Scheme

The scheme will include broadly the following interlocks: a) Each conveyor will be interlocked with belt sway, zero speed and pull cord switches etc. Further, in the event of any conveyor reaches 80% of its rated speed, then only the preceding equipment will get permissive to start. The starting sequence of the conveyors will follow a direction opposite to that of flow of material. Before starting any equipment the flap gates will be positioned properly, without which the equipment cannot be started. Any equipment will not start unless the succeeding equipment is already in operation. Stop/Tripping of any equipment will trip the preceding equipment. Local start push buttons mounted on local control station located near each drive will be interlocked with respective local/remote selector switch. The interlock scheme will be such that simultaneous operation of all parallel conveyors and equipment are possible without hampering safety requirements. The interlock scheme will be such that the overloading of conveyors due to multiple feeding from other conveyors and feeders are avoided. The gates which are not coming directly in line of desired operation will not be kept in interlock for that line without sacrificing safety interlock so as to allow maintenance of such gates. Brake will be applied immediately after the motor is stopped. Brake will be released first and then only the motor will get the power. Positive interlocking between brake limit switch and motor control circuit will be provided.

b)

c)

d) e) f)

g)

h)

i)

j)

01.09 Type of cables and Cable laying 1. All HT Power Cable related to 11 KV and 6.6 KV System voltage will be XLPE Insulated Aluminum (UE) grade armored in the range of 3C x 185 Sq.mm to 3C x 400 Sq.mm. No. of run is be decided based on the voltage drop calculation. All LT power cables is be XLPE insulated Al armored of suitable size for fixed wirings. Trailing cable is be EPR insulated copper class- v duty. Control Cable is be PVC insulated multicore armored copper 2.5sqmm for fixed wiring. All special cable is be based on the application. HT and LT cables will be laid through over head structure/ conveyor gallery and cable trench etc. to suit the requirement.

2. 3. 4. 5.

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01.10

Design basis for Illumination system a. General Technical Specifications will be referred for designing of Illumination System. In addition to this, following points is be considered. b. Illumination levels of all units is be as per GTS. c. The maintenance factor for design of illumination level is be considered as 0.6 0.8 as per the requirement. d. For arriving at utilization factor, manufacturer's recommendation is be followed. e. All rooms with false ceilings is be provided with recessed type decorative mirror optics fittings. f. All decorative type fittings is be mirror optics type. g. All buildings is be provided with peripheral lighting. h. The power factor of lighting system is be improved to 0.9 by providing in built capacitors with individual light fittings. i. Area, outdoor and peripheral lighting is be fed from separate LDB/SLDBs having two modes of control - AUTO and Manual. Under AUTO mode lights is be automatically switched ON/OFF through timers where as in Manual mode, lights is be switched ON/OFF through local control station located in Dispatcher/Control room. Selector switch for mode of control is be located on local control station. j. Area lighting, wherever applicable, is be provided through 400W, HPSV flood light fittings mounted on lighting towers. k. Handy portable rechargeable lights to be provided. l. All the offices is be provided with ceiling fans. m. For indoor lighting, outgoing feeders in MCB DBs is be 20A SPN MCBs. Each feeder is not be loaded more than 2 kW. Incomer to MCB DB is be suitably rated heavy duty switch and ELCB for detection of leakage current. n. For area and road lighting, 3 phase & neutral feeders may be used and accordingly suitably rated 4 core cables may be provided. o. HPSV lamp fittings is be provided with external electronic igniters and a built in sensor to sense failure of lamp and switch off igniters. p. Single phase/three phase circuits are connected to RYB phase such that total connected load to each phase equal and phase balancing is achieved. q. Stroboscopic effect is be corrected by providing power factor improvement capacitor and power phase distribution. r. Point wiring is be done through PVC insulated PVC sheathed aluminum cable. Minimum 6 sq.mm aluminium cable for 15A socket outlet and min. 4 sq.mm cable for lighting circuit is be considered. s. Single phase 3 pin 230V ,15A and 5A, switch-socket outlets is be provided with interlocked switches (male and female units) at the following locations: t. At each floor of building at every 30 m intervals or minimum one for each row/side. u. Two numbers each in switch gear room, cable basement, control room and MCC room. v. Group control and sectorial control is be envisaged through MCBs provided in the respective LDBS. Separate control switches is be envisaged for light points and fan points. w. Near every chute in Junction houses and other technological buildings 24V, 5A

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sockets is be provided for maintenance lighting by hand lamp. 01.11 Lightning Protection and Earthing i). The lightning protection of the plant unit will be determined after calculating as per the local weather condition and detailed plant construction dimension and height. Generally, lightning protection will be considered for all buildings and plant structure as per IS:2309. The lightning protection system will meet the relevant Indian code of practice and Standard and generally meet the requirements of General Specification. ii). The earthing and system grounding will be as per relevant Standard and will generally meet the requirements of General Specification. 01.12 Requirement of HT feeder from Purchaser HTSS The following HT feeder are is required from Purchaser HTSS a. Two numbers of 11 KV feeder will be provided from the purchaser end as per the requisite capacity for the CHP Substation (10 MVA). The requisite load list for HT and LT loads for the LSS-1 and LSS-2 has been enclosed for reference.

b.

01.13 415 V LT feeder for emergency board The purchaser has to provide the necessary emergency DG back up for the emergency load of the CHP Plant. The approximate load is 500 KVA with retendancy.

01.14 Location and Room Sizes for CHP-LSS 1, TP3 LSS 2 and TP13 - LSS 3. TABLE A S. No. Building Room Sizes DETAILS 11 KV Switchgear Panel, 6.6 KV Switchgear panel, 8 MVA Transformers, LT MCCs, PDB, MLDBs, APFC Panels, UPS Panels, Battery Charger Panel etc. 11 KV Switchgear Panel, 415 LT Switchgear panel, 2 MVA Transformers, LT MCCs, PDB, MLDBs, APFC Panels, UPS Panels, Battery Charger Panel etc.

1.

CHP LSS - 01

25 Mt x 16 Mt

2.

TP5 LSS - 02

25 Mt x 16 Mt

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