APSIPL-05- EPC- 3-B11 ELECTRICAL SYSTEMS - DC SYSTEM
Page 1 of 14 11.0 DC System
The DC System and its accessories shall conform to the latest editions of national and international standards indicated in Data sheet given below also, the DC system and its accessories shall comply with the requirements indicated in Data Sheet given below and specific requirements indicated below.
11.1 DC power supply with Ni-Cd battery cells forming bank shall be the source of the power supply for control, protection, interlock, annunciation of the complete plant including I&C system during the running of the plant as well as for a safe shutdown at the time of the total power supply failure. For feeding the DC supply for the above, the following shall be provided.
11.1.1 1 x 100% battery bank with associated float-cum-boost-charger and one spare float-cumboost charger, 1 No. DC switchboard shall be provided for each gas turbine generator (GTG) unit. The GTG unit DC system shall be sized to cater complete unit loads.
11.1.2 1 X 100% battery banks with associated float-cum-boost-charger and one spare float-cum-boost charger, 1 No. DC switchboard shall be provided for 220 kV switchyard. The switchyard DC system be sized to cater complete 220 kV switchyard loads
11.1.3 2 x 100% battery banks with associated float cum boost-chargers and 1 No. DC switchboard shall be provided for station DC system. The station DC system shall be sized to cater the following loads :
(a) One steam turbine generator (STG) system.
Plus
(b) One gas turbine generator (GTG) system.
Plus
(c) Common station system
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APSIPL-05- EPC- 3-B11 ELECTRICAL SYSTEMS - DC SYSTEM
Page 2 of 14 Plus
(d) 220 kV switchyard system.
11.2 Tie feeders shall be provided between station DCDB, GTG DCDB, STG DCDB and switchyard DCDB
11.3 Two (2) nos. 100% +/- 24V/+24V batteries and associated float cum boost chargers and one DCDB shall be provided for each of GTG and STG set for feeding the 48V/+24V load requirements. Provision in the +/- 24V DCDB for earthing the middle point through cable shall be provided with links.
11.4 Scheme for earth fault detection shall be provided for each DC bus and feeders.
11.5 Battery shall be sized to cater for the following loads with minimum duration as indicated. The voltage at the end of duty cycle shall be 1.1V/cell for Ni-Cd type battery.
(b) Starting current of all automatically started DC drives.
(c) Solenoid valves.
(d) In rush current of excitation system.
11.5.2 Emergency Load (For 2 hours duration)
(a) Running currents of essential DC motors.
(b) Emergency lighting
11.5.3 Continuous Load (For 10 hours duration)
(a) Indicating lamps on switchgears and control panels
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APSIPL-05- EPC- 3-B11 ELECTRICAL SYSTEMS - DC SYSTEM
Page 3 of 14 (b) Control room emergency lighting
(c) Auxiliary relays
11.5.4 I & C system loads
11.6 Further, for arriving at the battery capacity, the following shall be considered.
11.6.1 The temperature correction factor as given in IS. For this purpose, electrolyte temperature shall be considered as 5 deg. C above the ambient temperature.
11.6.2 25% margin for ageing as per IEEE guidelines.
11.6.3 A design margin of 20%.
11.7 Battery Chargers
11.7.1 Float charger will be rated to cater the following : (a) Trickle charging current of the battery (b) 10 hours load indicated above. (c) Standing load due to all units running, starting or tripping whichever is higher. (d) 20 % spare capacity over above loads (e) The float voltage output of the float charger shall be automatically adjusted depending upon the ambient temperature such that the batteries remain floating throught the range of variation of temperature as specified in Project information.
11.7.2 The boost charger unit shall be rated such that the battery can be fully charged from fully discharged condition within 8 hours.
11.8 Specific Requirements
11.8.1 220V Batteries
(a) The battery offered shall be Ni-Cd type confirming to IS:10918 suitable for indoor application.
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APSIPL-05- EPC- 3-B11 ELECTRICAL SYSTEMS - DC SYSTEM
Page 4 of 14 (b) The battery shall be of closed top or sealed in type. Open type cells are not acceptable.
(c) The battery shall be complete with accessories and devices, including but not limited to the following :
(i) Battery racks (ii) Porcelain insulators, rubber pads etc. (iii) Set of lead coated intercell, inter-tier and inter bank connectors as required for the complete installation. (iv) Electrolyte for first filling +10% extra.
(d) One set of variable resistor load suitable for carrying out discharge tests at 5 hour discharge rate & suitable shunt for measuring current on all batteries shall be supplied. Alternatively, electronic controls for carrying out discharge test of the batteries at selectable rate can also be provided.
11.8.2 220V Battery charger
(a) The float cum boost charger offered shall be static type composed of silicon controlled rectifiers and diodes (complete with resistor/capacitor network for surge protection) connected in three phase wave bridge circuit. It shall be provided with an adequately rated isolation transformer and filters on input to minimise harmonics on the output to keep ripple factor within acceptable limits.
(b) Charger shall have provision for manual control if the automode fails. Load limiting features shall be provided. The same shall be designed for adequate short time over load to take care of the starting of the largest DC motor/testing of lamps, etc. with other DC loads connected to bus. The rectifier shall utilise power semiconductors and heat sinks rated to carry 200% of the load current continuously. The heat sink temperature shall not be permitted to exceed 85 deg C irrespectivce of the panel temperature.
(c) The chargers shall be provided with automatic voltage regulation in float mode and automatic constant current regulation in boost mode.
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APSIPL-05- EPC- 3-B11 ELECTRICAL SYSTEMS - DC SYSTEM
Page 5 of 14
(d) The charger shall essentially comprise the following items but not limited to :
(i) One (1) moving coil DC voltmeter of size 96mm x 96 mm of suitable range.
(ii) One (1) moving coil ammeter, with shunts, size 96 mm x 96 mm to read output current of float- cum-Boost charger.
(iii) One (1) moving coil centre zero ammeter, with shunt, size 96 x 96 mm to read discharge/charge current of the battery, with suitable range.
(iv) One (1) cubicle space heater suitable for 240V AC, 50Hz, single phase supply.
(v) One (1) 240V AC lamp for cubicle internal lighting.
(vi) Two (2) - On/Off switches with fuses for space heater and internal lighting.
(vii) One (1) pilot lamp with series resistor on DC load side to indicate DC "On" condition.
(viii) One (1) set of pilot lamps with series resistors on AC main input to indicate mains AC "ON" condition.
(e) Fault indicating lamps shall be provided on the charger cubicle and initiating contacts shall be provided for remote alarm for each of the following faults :
(i) Mains AC failure (ii) Float charger AC input fuse blown (iii) Charger DC output fuse blown (iv) Charger U/V and current limit protection (v) Charger over voltage protection (vi) Charger overcurrent protection (vii) Charger filter condenser fuse blown (viii) Charger rectifier fuse blown
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APSIPL-05- EPC- 3-B11 ELECTRICAL SYSTEMS - DC SYSTEM
Page 6 of 14
(f) Type of cooling for the charger panel shall be such that no external fans are required to dissipate the heat developed within the panel.
(g) Two sets safety gears, hydrometers, voltmeters, spanners, min-max temperature indicator etc. shall be provided with each battery bank.
11.9 D.C. switchboards
11.9.1 For feeding the 220V DC loads 220V DC Switchboard as per clause 11.1.1 to 11.1.3 shall be provided.
11.9.2 The switchboards shall be provided with suitable quantity and type of outgoing feeders for the auxiliaries, control supplies to various panels/systems. For each load and auxiliary, one separate feeder shall be provided. In addition, the following feeders shall be provided in switchboard.
(a) Spare feeders - 20% of each type and rating with a minimum of two nos. feeders. This is the minimum quantity at the time of handing over the plant.
(c) Alarm module for common alarm of out-going feeder fault - 1 No.
11.9.3 Current ratings The short circuit current rating of the switchboard shall be arrived considering the contribution from charger & battery with 5% margin, with a minimum of 15 kA. The continuous current rating of the bus bars, incomers, ties for 220V DC switchboards shall be the maximum D.C. load (excluding the momentary load) on the bus plus 20% margin rounded off to the next higher standard rating.
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APSIPL-05- EPC- 3-B11 ELECTRICAL SYSTEMS - DC SYSTEM
Page 7 of 14 11.9.4 Specific requirements
(a) DC switchboards shall comply with all the requirements of this specification and technical requirements table.
(b) Positive and negative bus bars in the DC switchgear shall be completely segregated from each other by sheet steel partitions.
(c) Module details
(i) Incomer
The incomer modules shall be switch-fuse unit controlled. Each incomer shall be provided with
Ammeter & voltmeter Earth fault relay with potential free contact for remote annunciation. Ammeter to read Earth fault current under voltage relay with timer Indicating lamps for ON, OFF, earth fault, under voltage conditions One current and one voltage transducer for remote indication Necessary hardware & circuitry for fault alarm and for lamp test & reset.
(ii) Outgoing switch fuse feeders & tie feeders/Bus coupler
These feeders shall have DC switch, fuses (2 nos.) "ON" & "Fault" indicating lamps, supply supervision relays, lamp test, accept & reset push button through common alarm module.
The feeders rated 200 Amps & above shall be provided with a shunt & ammeter.
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APSIPL-05- EPC- 3-B11 ELECTRICAL SYSTEMS - DC SYSTEM
Page 8 of 14 (iii) Motor modules
For motors, starters shall be preferably housed within the DC switchgear module. However the resistors can be separately located in boxes/panels within the DC switchgear room. The starting current of the motor shall be limited to 200% of full load current.
The motor modules shall be provided with
Switch, fuses, air break contactors Thermal overload relays Starting resistors with associated timers ON, OFF, Fault indicating lamps Necessary auxiliary contactors for fault alarm circuit 240V space heating circuit ON, OFF- PBs for testing purposes One shunt & ammeter Appropriate circuitry for receiving the ON, OFF commands from remote panels/systems, interlocks, 'OFF' command from local push buttons, etc. MCB for space heating circuit
(iv) Space heating module
240V 1 ph, space heating module shall be provided with incoming side switch fuse, suitably rated 415/240V cast resin type transformer (expected heating loads of the switchgear and the connected motors + 30% margin) secondary fuse, and supply indicating lamp and connection to space heating buses. The 415V power supply for these modules shall be obtained from the 415V main switchboard. (v) Alarm module
Alarm module for outgoing feeder faults shall be provided with switch fuse, alarm accept, reset PBs,
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APSIPL-05- EPC- 3-B11 ELECTRICAL SYSTEMS - DC SYSTEM
Page 9 of 14 supply 'ON' lamp, `fault detected' lamp, hooter, necessary auxiliary contactors, control circuit for detecting, annunciating, accepting, resetting the fault in any module of the particular bus section. Contacts from this module for common feeder fault and its own module supply failure shall be provided and used for annunciation in CRT.
Alarm module for incomer faults shall be similar to the above except that it shall work on 240V AC supply.
11.10 Tests for Batteries
All tests shall be conducted as per the relevant standards. Tests shall comprise:
14.10.1 Type Tests : Performed at Manufacturer's works or type test report on identical rating and type of cell issued by an authorised test house shall be furnished
11.10.2 Acceptance Tests : Acceptance tests as per relevant standards shall be performed at vendors works. Also acceptance tests shall be performed at site after installation and commissioning of the battery including capacity test and test for voltage during discharge.
11.10.3 A locking resistor bank which can be automatically controlled using time and current signals along with the charger shall be supplied to facilitate discharging of voltages as a part of routine maintenance tests.
11.11 Tests for battery chargers
The following routine tests shall be conducted at works
11.11.1 Visual checks for dimensions and general arrangement.
11.11.2 Wiring checks
11.11.3 Functional checks
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Page 10 of 14
11.11.4 Voltage regulation for rated input supply for loads from 0-100%.
11.11.5 Load test to show the charger can deliver the rated duty without the current limiter device operating.
11.11.6 Ripple measurement by oscilloscope at different loads.
11.11.7 Demonstration of guaranteed efficiency and power factor.
11.11.8 Insulation test (with 500V megger)
11.11.9 High voltage test, excluding electronic controller, at 2kV AC for one minute.
11.11.10 Heat run test shall be conducted at full load for 24 hours at the vendor works on charger.
11.12 Tests for DC distribution board
11.12.1 All routine tests as per applicable standards shall be conducted on the board.
11.12.2 Type test reports on a identical switchgear issued by an authorised test house shall be furnished
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APSIPL-05- EPC-3- B14 DC SYSTEM DATA SHEET SL. NO. DESCRIPTION UNITS VALUES / REQUIREMENTS
Page 11 of 14
1.0
DC SYSTEM
1.1 Type of charger Combined float-cum-boost
1.2 DC system voltage (Nominal) 220 V , 24V / +24V
1.3 DC system earthing Unearthed for 220 V DC
1.4 Ambient design temperature 0 C 50
2.0 BATTERY DETAILS
2.1 Maximum time for boost charging of battery Hrs 8
2.2 Battery type Ni - Cd
2.3 Minimum end cell voltage Min. of 1.1 V per cell for Ni-Cd
2.4 Battery capacity By Bidder
3.0 BATTERY CHARGER DETAILS
3.1 DC voltage setting adjustment of AVR for float charging + 10% of nominal voltage
3.2
Voltage stabilisation for constant voltage regulator (i) +1% of set DC voltage for + 10% voltage and +5% frequency variation in power supply
(ii) + 5% during transients
3.3 DC current adjustment for boost charging 30% to 100% of maximum boost charging current
3.4 Current stabilisation for constant current regulator for boost charger + 2%
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APSIPL-05- EPC-3- B14 DC SYSTEM DATA SHEET SL. NO. DESCRIPTION UNITS VALUES / REQUIREMENTS
Page 12 of 14
3.5 Permissible ripple content at rated continuous load 3% maximum
3.6 Degree of protection IP 42
4.0 DC BOARD
4.1 Reference ambient air temperature 50 0 C
4.2 Degree of protection for enclosure IP 54
4.3
Type of construction
Fully draw-out, compartmentalised
5.0 APPLICABLE STANDARDS
5.1 Basic climatic and mechanical durability tests for components for electronic and electrical equipment IS 9000
5.2 Environmental tests for electronic and electrical equipment IS 9000
5.3 Metal clad base material for printed circuits for use in electronic and telecommunication equipment IS 5921
5.4 Transformers and inductors (power, audio, pulse and switching) for electronic equipment IS 6297
5.5 Printed wiring boards IS 7405
5.6 Environmental requirements for semi-conductor devices and integrated circuits IS 6553
5.7
Terminals for electronic equipment
IS 4007
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APSIPL-05- EPC-3- B14 DC SYSTEM DATA SHEET SL. NO. DESCRIPTION UNITS VALUES / REQUIREMENTS
Page 13 of 14
5.8
Factory build assemblies of switchgear and control gear for voltages upto and including 1100V AC and 1200V DC IS 8623
5.9 Air break switches IS 4064
5.10 Miniature circuit breakers IS 8828
5.11 HRC cartridge fuses IS 9224
5.12 Contactors IS 2959
5.13 Control switches / push buttons IS 6875
5.14 Indicating instruments IS 1248
5.15 Degree of protection IS 2147
5.16 Code of practice for phosphating iron and steel IS 6005
5.17 Semi-conductor converters IEC 146-1-1/2/3
5.18 Semi-conductor rectifier equipment safety code IS 6619
5.19 Stationary cells & batteries
5.20 Ni-Cd battery IS 10918
5.21 Water for storage battery IS : 1069
5.22
Sulphuric acid
IS - 266
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APSIPL-05- EPC-3- B14 DC SYSTEM DATA SHEET SL. NO. DESCRIPTION UNITS VALUES / REQUIREMENTS