Gts For Kumarswamy Iron Ore Project

NMDC LIMITED
HYDERABAD
KUMARASWAMY IRON ORE PROJECT BELLARY DIST - KARNATAKA
TENDER DOCUMENT FOR
PACKAGE - II DOWNHILL CONVEYOR SYSTEM
VOLUME IV OF V
MECON LIMITED BANGALORE
MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD REV. 0
JANUARY 2010
NMDC LIMITED
MECON LIMITED
KUMARASWAMY IRON ORE PROJECT PACKAGE NO II VOLUME I of V Chapter No 1. 2. 3. 4. 5. 6. Description Check list Notice Inviting Tender (NIT) Instructions to Tenderers (ITT) General Conditions of Contract (GCC) Special Conditions of Contract (SCC) Erection Conditions Of Contract (ECC) DOWN HILL CONVEYOR SYSTEM CONTENTS
VOLUME II of V 1. Preamble, Summary of Prices, Price for exemptions / variations and Price Format
VOLUME III of V Chapter No A B C D E F G H I J K L M Description Brief on the Project and Intent Of Tender General technical conditions General site information Scope of work and battery limit Performance guarantee and warranty Surface preparation and painting Quality assurance, inspection and testing Construction, erection, testing and commissioning Engineering services Project management services Site services List of Tender Drawings Part/1 - Documents/ drawings to be submitted along with the tender Part/2 Questionnaire and design data sheets to be filled and submitted along with the tender
NMDC LIMITED
MECON LIMITED
KUMARASWAMY IRON ORE PROJECT PACKAGE NO II N O P Q1 Q2 DOWN HILL CONVEYOR SYSTEM
Documents /drawings to be submitted by successful Tenderer Spares, Special tools & Tackles List of Preferred makes of equipment Technical specification Mechanical Technical specification Environmental
Enclosures: 1. 2. 3. 4. Tender drawings as per the list under chapter-L Specimen QAP format for Structural & Mechanical equipment Specimen QAP format for Electrical equipment Specimen Inspection call format.
VOLUME IV of V Chapter No Q3 Q4 Q5 Description Technical specification Electrical Technical specification Automation and Control Technical specification Plant Communication System
VOLUME V of V Chapter No Q6 Q7 Q8 Q9 Description Technical specification Civil Technical specification Structural Technical specification Hydro Engineering
Technical specification Fire Detection and Suppression System for Down Hill Conveyor Q10 Technical specification General Layout, Roads and Fire Fighting Enclosures:- One Compact disc containing soft copy of the following: 1. 2.
3.
Soft copy of Questionnaire and design data sheet Chapter-M (Part-2 of 2) Soil investigation report (for reference only) Waste Dump Locations - Sketch dated 14.09.07
NMDC LIMITED
MECON LIMITED
KUMARASWAMY IRON ORE PROJECT

PACKAGE NO - II CHAPTER NO. Q3 VOLUME - IV of V PAGE No. 1 of 272
CHAPTER-Q3 ELECTRICAL
INDEX
Sl. No. 1.0 2.0 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 2.10 2.11 2.12 2.13 2.14 2.15 3.0 4.0 5.0 Description SCOPE OF WORK EQUIPMENT SPECIFICATION 11kV & 6.6kV HT SWITCHGEAR & 11kV CICO OUTDOOR PANEL 11kV & 6.6kV HT CAPACITOR WITH SERIES REACTORS BATTERY, BATTERY CHARGER & D.C. DISTRIBUTION BOARD TRANSFORMERS VARIABLE VOLTAGE VARIABLE FREQUENCY DRIVES LT MOTORS LT SWITCHGEAR PANEL /LT PMCC /MCC CABLES (HT, LT & CONTROL) POWER DISTRIBUTION BOARDS / MAIN LIGHTING DISTRIBUTION BOARD AND SUB DISTRIBUTION BOARDS ILLUMINATION EQUIPMENT SPECIFICATION MISCELLANEOUS ELECTRICAL ITEMS EARTHING AND LIGHTNING PROTECTION OVERHEAD LINES (11kV ) EQUIPMENT SIZING & SELECTION APPLICABLE STANDARDS AND CODES ERECTION, TESTING & COMMISSIONING DRAWINGS AND DOCUMENTATION MAJOR EQUIPMENT LIST (INDICATIVE)
MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD 2010, MECON Limited. All rights reserved.
Rev. 0
NMDC LIMITED
MECON LIMITED

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

to the CICO panel shall be provided by client form existing substation. From the DP structure-1, 11 KV OH line will start which is 3 kilometer length. Double pole structures with all accessories shall be provided at both ends of the Overhead line. From the DP structure-2 (at TH3) power shall be fed to the tenderers 11kV switchgear through cable. The 11kV switchgear shall cater power to all motors, lighting loads, belt feeder, reversible conveyor, various facilities at Transfer House TH-3, and all downstream equipment covered under this package. The following substations shall be foreseen by the tenderer: i. At tail end of the DHC, tenderer shall plan a substation to accommodate 6.6kV HT switchgear, Distribution transformer, lighting transformers, VFDs, and other electrical equipment. At head end of the DHC two numbers of substation buildings (ie. One near TH5 and another near TH3) shall be provided. At substation near TH5,, 11kV HT switchgear, Distribution transformer, lighting transformers, VFD drive for reversible conveyor, etc shall be located. At substation near TH3, VFD panel for belt feeder (725) shall be provided in a separate AC room with other electrical equipment as per requirement.
ii.
1.2
The major equipment / services covered in this tender shall include but not limited to the following: Equipment at Downhill conveyor system tail end:
1.2.1
One number single incomer 6.6 kV Switchboard to cater to the 6.6 kV loads, 690V loads, 415V LT & Lighting loads (230V phase to phase) of the Down hill conveyor system tail end comprising of required feeders and spare feeders of minimum of one number for each type as per enclosed typical drawing. For protections of each feeders refer tender drawing no. MEC/01/Q6DH/KIOP/II/214/TS
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 1.2.2 VOLUME - IV of V PAGE No. 4 of 272
HT capacitor banks with current limiting reactor, RVT, to ensure a power factor of not less than 0.95 at the tenderers 6.6kV incomer. SICAP construction (In a closed container) shall be considered. 110 VDC, 200AH (Minimum),, Plante' type Lead Acid battery bank, dual redundant Float Cum Boost Charger, DCDB for control supply to HT switchboard Transformers: 6.6/0.433 kV, required Distribution Transformer kVAR, 3 phase, ONAN,
1.2.3
1.2.4
6.6/0.72 kV, required kVAR, 3 phase, ONAN, converter duty transformer for Down hill regenerative conveyor. 6.6/0.230 kV, required transformer for lighting kVAR, 3 phase ONAN
Dry type Booster transformers to cater to welding power receptacles and lighting loads as required. 1.2.5 690V VVVF Drive (with Active Front end) for the downhill conveyor (723), & 415V VVVF Drive for the Belt feeder (720) 415 V, TPN, PMCC with bus sectionaliser to feed repair loads one side and all process related loads on other side, with required feeders including capacitor bank feeder. Rotor resistance boxes / control panel for Slip ring motors as required. HT, LT (energy efficient-eff2) motors & 690V Inverter duty motors Electrics for Belt feeders, EOT cranes, Hoists, magnetic separators and other equipment covered under this package. Local Control stations for drives and equipment for local control with indications, Junction boxes of different sizes (For Power, control, instrument, Lighting). Rev. 0
1.2.6
1.2.7 1.2.8 1.2.9
1.2.10
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MECON LIMITED

In-line Magnet separator, Metal detector and control panel etc as required. Equipment at Head end side of Downhill conveyor:
1.2.12 1.2.13
One Number 11kV Outdoor CICO VCB panel (at Donimalai 11kV switchyard) One number 11 kV Switchboard (with single incomer) to cater to loads of the Down hill conveyor system head end, comprising of required feeders and spare feeders of minimum of one number for each type as per enclosed typical drawing. For protections refer tender MEC/01/Q6DH/KIOP/II/214/TS. drawing no.
1.2.14
HT capacitor banks with current limiting reactor, RVT, to ensure a power factor of not less than 0.95 at tenderers 11kV incomer. SICAP construction (In a closed container) shall be considered. 110 VDC, 200AH (Minimum), Plante' type Lead Acid battery bank, dual redundant Float Cum Boost Charger, DCDB for control supply to 11kV HT switchboard . Transformers: 11/0.433 kV, required Distribution Transformer kVAR, 3 phase, ONAN,
1.2.15
1.2.16
11/0.72 kV, required kVAR, 3 phase, ONAN, converter duty transformer for downhill regenerative conveyor. 11/0.230 kV, required transformer for lighting kVAR, 3 phase ONAN
Dry type Booster transformers to cater to welding power receptacles and lighting loads as required.
1.2.17
690V reversible regenerative VVVF Drive for the reversible conveyor (727) system & 415V VVVF Drive for the Belt feeder (725) Rev. 0
NMDC LIMITED
MECON LIMITED

1.2.18
11 kV over-head line with Squirrel ASCR conductors from Donimalai 11kV switchyard Double pole structure to Downhill conveyor head end near TH3. (Line length is 3.0 Kilometers). OH line shall include one number DP structure at both ends and minimum 2nos. cut off points shall be provided. DP structure-1 & 2 shall have horizontal GOS switch with earth-switch, Dropout fuses, Lightning arrestors, stay sets, earthing, earth pits, fencing etc as per specification. Secondhand rail poles (9 Meter long, 90lb/yard) shall be used for 11 kV OH lines. Minimum 13Mtrs long rail poles shall be used for DP structures & OH line road crossings. Earth conductor shall be run along with OH line. Earth conductor shall be provided on the top of the phase conductors (ie. Y type conductor spacing shall be planned for phase conductors) . Rail poles and bracings for OH line and DP structures shall be de-rusted and painted with two coats of red oxide followed by two coats of epoxy silver paint 415 V, TPN, PMCC with bus sectionaliser to feed repair loads one side and all process related loads on other side, with required feeders including capacitor bank feeder. Rotor resistance boxes / control panel for Slip ring motors as required. LT (energy efficient-eff2) motors and 690V Inverter duty Motors. Electrics for Belt feeders, EOT cranes, Hoists and other equipment covered under this package. Local Control stations for drives and equipment for local control with indications, Junction boxes of different
1.2.19
1.2.20 1.2.21 1.2.22 1.2.23
Other Items: Modifications to the existing tripper conveyor equipment 122 developing and hooking up all hardware /software at owners existing system / power & control cabling from/to owners existing system and at the system being provided under this package for smooth operation, effective control and monitoring of both systems in an integrated manner. MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD Rev. 0 2010, MECON Limited. All rights reserved. 1.2.24
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MECON LIMITED

MCCB in shop floor for cranes / hoists and power supply arrangement (Shrouded Bus Bar Power supply system) to cranes / hoists. Complete mounted Electrics for cranes, hoists, etc. Main lighting distribution boards, Lighting distribution boards, Sub-distribution boards, etc. with suitable provision for switching ON/OFF from PLC in control room including necessary control wiring, push button station, indicating lamps etc. Lighting for 200 meters of every approach road to buildings and to conveyor Gallery coming under this package. Light fixtures, lamps, switches, sockets, ceiling fan, and sirens etc. Industrial type (for plant buildings) & Decorative type (Control room, VVVF drives rooms, non-plant buildings etc.). Portable, rechargeable emergency lights with converter/inverter to be considered for control rooms, transfer houses etc., Light fixtures as required for equipment lighting, focus/flood lighting for chutes, external lighting around the buildings, approach roads. Neon type Aviation obstruction lamps with photocell control for buildings more than 30m height, to cover the profile of the building. Monorail with manual hoist for panel lifting (If required) The following additional information may be noted and taken care about lighting. i. Lighting shall be carried out using High Pressure Sodium Vapor (HPSV) lamps, Metal Halide (MH) lamps, fluorescent tube light and compact fluorescent lamps depending on the mounting height / aesthetics Integral type control gearbox shall be considered for well glass fittings, High bay, Medium bay, Streetlight etc. Rev. 0
1.2.26
1.2.27 1.2.28
1.2.29
1.2.30
1.2.31
1.2.32 1.2.33
ii.
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MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 iii. VOLUME - IV of V PAGE No. 8 of 272
Timer and contactor control for streetlights, outdoor lights, and other area lights with suitable provision for switching ON/OFF from PLC in control room / PLC room along with provision to switch ON/OFF locally. 20% spare feeders / starters with at least one of each type and rating shall also be provided in PMCC / MCC / PDB / MLDB / LDB / SLDB / DCDB / other distribution boards Galvanized Flood light poles / street light poles including foundations and earthwork for buried pipes, cable trenches, earth pits etc. Surface wiring in GI conduits in Transfer Houses, Conveyor galleries, etc., and concealed PVC conduit wiring for office buildings, Electrical switchgear, control room etc. (civil buildings).
iv.
v.
vi.
1.2.34 1.2.35
63A TPNE, 32A TPN & 20A 1 phase power socket outlets as required. All required sizes of cable trays with cable tray supports, HT termination kits, cable accessories, cable duct, structural supports, road crossing pipes1000mm below road, lugs, glands, clamps, tags, route marker etc. Cable trays shall be laid horizontally only. Conveyor structural supports should not be used as cable tray supports. All interface hardware, software, power monitors / multifunction meters, control, communication & signaling cables etc., required for connecting I/Os from relevant incoming, power feeders, motor feeders of HT, MT & LT, LT switchgear/ MCCs, PDBs, LDBs field devices (whether explicitly specified in detail or not) required for: i. ii. Control and operation of plant including illumination in a safe manner in automated and other modes. Monitoring the status and parameters (ON, OFF, trip, voltage, current, frequency, MD, power, power factor etc), from the PLC in the central control room.
1.2.36
Addressable type Pull cord switches, Addressable type Belt sway switches, zero speed switches with contacts for MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD Rev. 0 2010, MECON Limited. All rights reserved.
1.2.37
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MECON LIMITED

connections to PLC and for interlocking with drive with status display of each switch for conveyors at local and remote in PLC monitors. Pull cord switches shall be hardwired to switchgear also. 1.2.38 Limit switches, proximity switches, level switches / transmitters, pressure switches / transmitters, DP switches, speed sensors, encoders, Hooters / Bells etc. as required for the various equipment operation and safety. All Cables (HT, LT, power, control, Optical fiber cable, illumination, and other special cables, wires for illumination) supply laying and termination including accessories and consumables accessories (Viz HT Cable termination kits, Terminal / Junction boxes, double compression brass cable glands, crimping type lugs etc. as required for laying and termination of cable. Complete Earthing & Lightning protection system for the plant, buildings, equipment and electrical works carried out under the scope of this tender including. Air-lock room with airtight door arrangement shall be provided for control room & Air-condition rooms. Minimum 2 entry / exits should be provided for all Electrical / Switchgear rooms & control rooms. Ventilation systems for HT & LT switchgear rooms, Battery room, MCC room, Electrical rooms & cable cellars etc. with Pressurized ventilation system with Multiple TA Fans without duct. Exhaust fans ventilation for Battery room shall be provided. Air conditioning system for Control rooms and rooms where PLC, VVVF drive rooms & Shift in-charge room are installed. Wall mounted / pedestal fan shall also be provided for PLC control rooms / office rooms. Detailed specification for A/C and ventilation system are covered in chapter Q2 of this tender document Battery room shall be provided with acid resistant flooring, wall tiles and acid proof lighting fixtures/exhaust fans. Wash facility shall also be provided in battery room Rev. 0
1.2.39
1.2.40
1.2.41
1.2.42
1.2.43
1.2.44 1.2.45
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MECON LIMITED

GI cable trays (ladder and perforated type) with coupler plates and electro-galvanised hardware etc. with painted supporting brackets and cable structures nylon cable ties, saddles, aluminium clamps, punched aluminium cable tags, route markers, cable tray separators, ferrules insulating tapes, sealing compound, etc., Mainly overhead cable laying shall be considered. GI pipes of different sizes as per site requirement for cable protection, for cable laying in ground / floor / through concrete etc. and cable entering / leaving buildings / rooms/ walls / floors, cable duct / structural supports / pipes 1000mm below road for road crossing. Fabricated steel structures, checkered plates, MS plates and Anchor fasteners for supporting/ mounting of electrical equipment viz. Cable trays, Panels / boards, light fixtures, local control stations etc. All structures shall be de-rusted and two coats of epoxy-based paint over one coat of primer shall be applied. Chequered plates of 6mm thick with stiffeners and collapsible handles shall be provided for closing floor cutouts after fixing the panels. Checkered plates shall be provided with one coat of primer and one coat of epoxy based paint of black colour. All accessories like branch/pull/junction boxes, cross arms brackets for supporting light fixtures, distribution board etc., saddle / clamps, single core cable and other miscellaneous items required for the completeness and efficient working of the system whether explicitly specified or not in this specification. RCC cable trenches / ducts with removable RCC cover wherever approved by the owner/consultant. Excavations of earth trenches and back filling (with bricks / concrete slabs over sand above and below cables, soil over bricks / concrete slabs etc.) only in special locations, as approved during detail engineering. Fire barriers / fire partition & pressure seals wherever cables enter /exit pressurized areas. Rev. 0
1.2.47
1.2.48
1.2.49
1.2.50
1.2.51
1.2.52
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MECON LIMITED

Safety items for electrical systems such as fire extinguishers, safety charts, first aid box, hand gloves, fire buckets with stand, danger boards, rubber mats, Key boxes, Digital clock etc. Switchgear rooms & Control room furniture. Tools and Tackles. First fill of grease, lubricant, insulating oil, electrolyte etc. and other consumables necessary for commissioning and operation of the equipment. Any other requirement, whether specifically mentioned herein or not but required for completion of works and satisfactory performance of the plant is included in the scope The scope mentioned for instrumentation and automation and Plant communication system under different Chapters shall also be complementary to the scope mentioned herein Commissioning spares. 2 years operational spares as specified. Successful Tenderer shall have to arrange his own arrangement for construction power supply. SERVICES
1.2.54 1.2.55 1.2.56
1.2.57
1.2.58
1.2.59 1.2.60 1.2.61
1.2.62 1.2.63
Soil resistivity test shall be conducted by the successful tenderer. Co-ordination with all agencies for inspection of work / installation, pre-commissioning (no load / load) tests, integrated (no load /load) testing & commissioning, handing over, conducting PAT / FAT and liquidating defects etc. till handing over of the installations and performance guarantee. Documentation (preparation and submission in requisite copies of all drawings, test certificates, O & M manuals and any other drawings/documents required for the erection of the plant and installation). Rev. 0
1.2.64
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Liaison with statutory bodies on behalf of the Owner and obtaining all necessary clearances / approvals including modifications to be carried out, if any, as per their specific requirement without commercial/contractual implications to the owner. Submission of all necessary documents and drawings, paying the required inspection fees (fees to be reimbursed by owner on production of receipts) and liaisoning with the statutory bodies for inspection of installation as and when required and make all arrangements for the same. Obtaining of approvals for drawings, prior permission to energize, all HT and other electrical installations from DGMS. STANDARDS, CODES AND REGULATIONS Design supply and installation of electrical system & equipment under this package shall conform to the requirements of latest revisions of IEC, Indian Standards, DGMS standards IE Rules, local rules and regulations. IE rules. IE Rule No.45, clause 1. No electrical installation work including additions, alterations, repairs and adjustments to existing installations, except such replacement of lamps, fans, fuses, switches, low voltage domestic appliances and fittings as in no way alters its capacity or character, shall be carried out upon the premises of or on behalf of any consumer/owner/ or occupier for the purpose of supply to such consumer, owner, except by an electrical contractor licensed in this behalf by the state government and under the direct supervision of a person holding a certificate of competency and by a person holding a permit | issued or recognized by the state government. IE Rule No.45, clause 2.No electrical installation work which has been carried out in contravention of clause (1.3.2) shall either be energized or connected to the works of any supplier. IE Rule No.63, clause 1.Before making an application to the inspector for permission to commence or re-commence supply after an installation has been disconnected for one Rev. 0
1.2.66
1.3 1.3.1
1.3.2
1.3.3
1.3.4
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MECON LIMITED

year and above at high or extra high voltage to any person, the supplier shall ensure that the high or extra high voltage electric supply lines or apparatus belonging to him are placed in position properly joined and duly completed and examined. The supply of energy shall not be commenced by the suppliers unless and until the inspector is satisfied that the provisions of rules 65 and 69 (both inclusive) have been complied with and approval in writing of the inspector has been obtained by him. 1.3.5 All linemen, wiremen, electricians, supervisors and engineers engaged by the contractor or his sub-contractor shall posses valid license & the same shall be submitted for verification if called for. In view of the above, along with bid, the Tenderer shall furnish, the list of sub-contractors having valid electrical contractors license of appropriate category in Karnataka whom he proposes to engage for electrical erection / testing & commissioning and for obtaining statutory approval. VOLTAGE LEVELS 1 2 3 4 5 6 7 1.4.1 VVVF Drives : controlled motors Motors (DOL start : up to and including 160 kW) Control voltage : Control voltage (for : HT switchboard) Lighting fixtures : Small Power sockets : Welding switch : socket outlets 415 /690 Volts, 3 Ph (as per requirement) 415V +/- 10%, 50Hz +/5%, 3Ph, 4 wire AC 110V AC obtained through control transformers & protection device. 110V DC obtained by providing suitable batteries and battery charger 230V AC (phase to phase) 230V AC TPNE, 415V AC, 50 Hz
1.3.6
1.4
DC control, if required during detailed engineering, due to longer control cable lengths provided in place of AC controls. In this case provision of suitable control gear and rectifier units with protections / annunciations etc. in Switchgear / PMCC / MCC panel is also included in the Rev. 0
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MECON LIMITED

scope. This aspect shall be kept in view while submitting the offer. 1.5 SUPPLY VOLTAGE VARIATIONS AND FAULT LEVEL a) POWER SUPPLY VARIATIONS Voltage level Voltage Variation Frequency Variation 5% 5% 5% 5% 10 %
230 V 10 % 415 V 10 % 6.6 kV 10 % 11kV 10 % Combined voltage and frequency variation b) FAULT LEVELS Voltage level 230 V 415 V 6.6 kV 11 kV System earthing 1.6
In KA 25 40 25 25 Resistance earthing on 6.6kV side Solid earthing on 11kV & 415V
CLIMATE CONDITIONS The climate of area is mild and pleasant during summer months and moderately cold during winter. Max. Ambient Temperature Min. Ambient temperature Rain fall Relative humidity Height above Mean sea level : 450C : 150C to 80C : 600mm to 800mm per annum during monsoon : 100% not occurring Simultaneously with maximum temperature : More than 1000M above MSL
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 1.7 1.7.1 NOISE POLLUTION CONTROL Noise control measures shall be adopted to restrict noise levels in and around the plant. Maximum noise level tolerable in rooms & offices, work areas and within the plant boundary, have been specified herein. The equipment and the services shall be designed such that these levels are not exceeded. The maximum noise level guaranteed for each equipment and system with detailed description of noise control measures adopted. The maximum noise levels for rooms and offices must permit a good understanding of speech. Limiting exposure values of sound pressure levels for different areas are given below: Office/conference rooms Control rooms, Computer rooms Factory and shop area - General Where telephone conversation is Required - Plant boundary 1.7.4 : : : : : 65 dB (A) 55 dB (A) 85 dB (A) 65 dB (A) 65 dB (A) VOLUME - IV of V PAGE No. 15 of 272
1.7.2
1.7.3
The plant and machinery shall be designed such that the continuous exposure noise level of 85 dB (A) is not exceeded. Adequate numbers of suitable earplugs shall be supplied for operating people to approach the areas with higher noise levels. MAKE AND INTERCHANGEABILITY The makes of equipment shall be limited to preferred makes indicated in technical specification and such of those equipment for which preferred makes are not indicated, makes of such equipment shall be subject to prior approval by Owner / Consultant. Similar equipment and components shall be of same make. Equipment of same type and rating shall be interchangeable. Rev. 0
1.8 1.8.1
1.8.2
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MECON LIMITED

All materials used and all equipment supplied shall be new and the best of their respective kinds and shall be of the class most suitable for the purpose for which they are intended. The quality of material and installations shall be to the highest standard of Indian and international practices. The decision of owner/consultant with in this regard is final and binding. When quality of work is not satisfactory in the opinion of consultant/owner, and when so directed the work shall be redone including supply of required equipment and material at no extra cost to the owner and without affecting the agreed milestones. MODE OF CONTROL FOR ILLUMINATION Conveyor gallery illumination (especially of long conveyors) is designed to provide graded levels of illumination so that either one in every three luminaries OR two in every three luminaries can be switched ON based on requirement. If required all the lights in the conveyor gallery can be made ON. For achieving this 2 Nos. four core power cables shall be laid from junction houses where corresponding LDBs are located and terminated / looped in junction boxes. For conveyor gallery lighting / Outdoor area and street lighting the LDB's, DBs and Feeder pillars shall have contactors for each of the incoming /outgoing circuits. Number of contactors shall be decided as per requirement of owner / consultant and shall also include internal wiring. However any other specific requirements will be finalized during detailed engineering / approval of drawings and the same shall be provided without any cost implications. The control from PLC shall also be done apart from local (panel / DB). Contactors on the incoming side of each LDB's / Feeder pillars shall be provided for switching ON / OFF the whole board and also for few feeders on outgoing side of the LDB's / SDIs, as desired by owner/consultant, to control the lighting of limited areas. Contactor coil shall be rated for 230V, tapped from the main busbars of LDB for switching ON from remote. ON /OFF controls from PLC shall also be done apart from local DB. Exact requirement shall be indicated at the time of approval of the drawings. ON Rev. 0
1.8.4
1.9 1.9.1
1.9.2
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MECON LIMITED

/OFF switches or pushbutton stations shall be located in the plant control rooms (if required). 1.9.3 Outdoor lighting (i.e. Street lighting, area lighting, peripheral lighting etc.) shall have provision for control of fitting in auto and manual modes. In auto mode the lights shall be switched ON by sensing natural light by adjustable photo cells with relay unit (Timers with relay are not acceptable) and the manual mode of operation shall be from near the board or from PLC monitor. INSCRIPTION All equipment shall be provided with indelible / permanent type inscription plates identifying the equipment as per approved drawing. All components, terminal blocks, relays, indicating lamps, control switches shall be provided with permanent inscription plates with inscriptions as per approved drawings. Identification plates of the equipment shall have letters of 15-mm size. 5 mm characters shall be used for panelmounted components. PAINTING Metal parts of all equipment shall be protected against corrosion. The sheet steel parts shall be cleaned by sand blasting (wherever required) and shall undergo rust removal by seven-tank process consisting of alkaline, degreasing, de-scaling, pickling and phosphating. Two final coats of epoxy spray painting shall be applied over two coats of primer. The colour of finished painting shall be as per the approval of owner/ consultant TYPES OF STARTER/ CONTROLS FOR DRIVES
1.10 1.10.1
1.10.2
1.11 1.11.1
1.11.2
1.12 1.12.1
The braking system and controls of the downhill conveyor shall be latest state of art technology so that the braking system takes care of all safety requirements and ensures no undue tension, lifting & slackening in the belt under varying conditions (normal / emergency) of loading pattern on the belt. This shall also ensure material stability on the belt (i.e. if the braking or starting is too rapid the material MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD Rev. 0 2010, MECON Limited. All rights reserved.
NMDC LIMITED
MECON LIMITED

doesnt avalanche Down the hill). The requirements specified in detail in mechanical equipment specification shall be considered. 1.12.2 1.12.3 Mechanical brakes shall also be provided for conveyors /crane / hoists, as required. DOL / RDOL starters shall be adopted for all other motors in the project as per the requirement. The motors envisaged are mainly squirrel cage motors. Energy efficient motors shall be used preferably for continuous running applications. Dust suppression system pump and the solenoids shall also be fed from the MCC. The solenoids shall be suitable for 240V DC. Pump shall be continuously working when the plant is in operation but when plant is not operating for some time the pump shall continue to run and re-circulate in tank automatically. If plant is stopped for long time then the system can be switched off. Atomized water spray shall work till the material presence is sensed by switch to be provided below the conveyor for that purpose or equipment is in operation. EQUIPMENT SPECIFICATION 11kV & 6.6kV HT switchgear & 11kV CICO Outdoor Panel DESIGN CRITERIA 11 & 6.6kV HT 11kV CICO switchgears (Outdoor) (Indoor) Fully compartmentalized metal clad horizontal draw out sheet steel enclosed conforming to IP4X (for indoor panel) & IP 55 with canopy (for Outdoor panel). Fully type tested as per IEC 62271.Inter compartmental partitions as per IP 2X or as per manufacturers standard practice Rev. 0
1.12.4
2.0 2.1 2.1.1 I) Cubicle
1. Type
NMDC LIMITED
MECON LIMITED

2. Thickness of sheet steel
(Minimum thickness) : 2.5 mm hot rolled sheet steel or as per manufacturers standard practice 2 mm cold rolled sheet steel as per manufacturers standard practice 6.6kV & 11kV, 11kV, 3 phase, 3 3 phase, 50 Hz, wire, 50Hz 3 Wire As per Requirement
a) Sides/bottom/partition between panels

b) Front & rear hinged door &
covers
3. Rated voltage 4. Continuous rated current at 450C 5. Short circuit withstand capability of switchboard including busbars a) Short time rating b) Dynamic rating 6. Insulation level a) Impulse withstand value b) 1 min. PF withstand value 7. Busbars a) Material of busbars b) Temperature rise of busbars at rated current over 450Cambient c) Inter panel busbar chamber partition d) Busbar joints e) Insulation f) Phase identification g) Support insulators 8. Auxiliary connections 9. Safety shutters : :
: : : :
25 KA (RMS), 1 sec 63 KA peak 60 KVP for 6.6kV & 75 kVP for 11kV 20 KV (RMS) for 6.6kV & 28 kVP for 11kV Aluminium Alloy As per IEC Not applicable Zinc passivated bolts Encapsulation of Main & feeder Busbars joints to full insulation Colour tapes Non-hygroscopic, non-tracking, resin cast insulator. Silver-plated, 16A plug and socket with necessary interlocks. Automatically operated shutters with facility to lock the busbar and cable side shutters independently. Rev. 0 75 kVP 28 kV (RMS)
: : : : : : : : :
NMDC LIMITED
MECON LIMITED

10. Locking facility
Special door locking with Integral locking facility carriage position lock
key for
11. Accessories with each cubicle

a) Panel illumination lamp with switch b) Space heater c) 3 pin power socket with switch d) Base channel e) Termination accessories : : : : : CFL To be provided in metering compartment 240V, AC, 50 Hz heater with thermostat & control switch To be provided Base channels as required shall be supplied as part of cubicle HT cable sealing kit, compression type brass cable glands and tinned copper lugs for HT power, LT power and control cables to be terminated in the panels. As Specified
f) Name plates, inscription plates for components, switches, feeder identification. g) Flexible copper connections between hinged doors and cubicle for earthing h) Breaker accessories visible and accessible from outside, with the cubicle door closed.
: :
To be provided Breaker position TEST/ SERVICE Breaker ON/OFF, spring charged Mechanical trip push button accessible from outside with panel door closed Mechanical close push button accessible only after opening the door To be provided as per manufacturers standard practice To be provided on front and rear To be provided
i) Removable welded wire mesh behind the panel j) Danger notice boards and instruction plates k) Breaker operation counter
: : :
Rev. 0
NMDC LIMITED
MECON LIMITED

l) Components to be mounted on the front door of cubicle
Push buttons, control & selector switches (operating height shall not exceed 1800 mm), lamps, meters, relays Bottom LT power, control, CT, D.C, A.C terminals shall be segregated and identified. CT terminal shall be CATD-m4 type Earthing trucks for bus earthing and cable earthing for each panel type with safety interlocks and audiovisual indication. IP4X Front ON/OFF/TRIP/Trip circuit Healthy, breaker test position, breaker service condition & Spring charged .All lamps to be LED type. Annunciation windows shall be considered for all feeders VAJHM23
m) Outgoing Entry for power and control cable n) Terminals
: :
o) Earthing trucks
p) Enclosure q) Indicating lamps
: :
r) Annunciator
s) Master trip relay : 12. Operational clearances a) In front for withdrawal of : To be indicated by Tenderer truck b) At the back of the panel : To be indicated by Tenderer 13. Minimum safety clearances in : air a) Between phases in mm : as per IEC as per IEC b) Between phase & earth in : as per IEC as per IEC mm 14. Control Schemes : As per approved drawings II) Breaker for I/C, Transformers & capacitor feeders/Vacuum contactor with fuse for 6.6kV motor feeders (if required) 1. System : 6.6 kV & 11kV 50 Hz, 3 phase 3 wire 2. Highest system voltage : 7.2 KV for 6.6kV & 12kV for 11kV
3. Design ambient : 450C MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD 2010, MECON Limited. All rights reserved.
Rev. 0
NMDC LIMITED
MECON LIMITED

4. Ratings a) Rated current in IP4X enclosure at 450C ambient b) Symmetrical breaking capacity c) Making capacity & dynamic stability rating d) Short time current rating
: : : : : : : : : : : : : : : : :
As per Requirement 25 KA (RMS) for VCBs 63 KA peak for VCBs 25 KA (RMS), 1 sec for VCBs 20 KV (RMS) 28kV (RMS) for 6.6kV & 28 kVP for 11kV 60 KVP for 75 kVP 6.6kV & 75 kVP for 11kV Auto re-closure duty not required Less than 5 cycles Shall be re-strike free Vacuum 1.3 Spring charged stored energymanual independent closing Manual and motor drive 110 V DC 80-110% of rated voltage 110 V DC 80-110% of rated voltage Both AC and DC to be provided DC trip coil AC trip coil 110 V DC 240 V AC 70-110% of rated voltage One One 8 No + 8 NC (Silver plated contacts) 10A at 240 V AC 4A at 110 / 220 V DC Rev. 0
5. Insulation level
a) One min. P.F withstand value KV RMS b) 1.2/50 microsecond impulse withstand value KV (peak) 6. Operating duty 7. Total break time 8. Critical current 9. Arc extinction medium 10. First pole to clear factor 11. Operating mechanism a) Type of closing b) Method of closing c) Spring charging motor 1) Rated voltage 2) Operating voltage range d) Closing Coil 1) Rated voltage 2) Operating voltage range e) Shunt trip coil 1) Rated voltage 2) Operating voltage range 12. No. of poles/ phase 13. No. of breaks / pole 14. Auxiliary contacts 15. Rating of auxiliary contacts
: : : : : :
NMDC LIMITED
MECON LIMITED

16. Wiring of auxiliary contacts
All auxiliary contacts shall be wired contacts to terminal block, external to draw out truck Without opening the door Silver plated copper moving contacts, contacts with selfaligning feature having sufficient contact pressure. IEC- 62271 To be provided for Motor feeders, capacitor feeders & dry type transformer feeders to suit the insulation level of connected equipment. Resin cast, bar primary As per requirement (sizing calculations shall be submitted for approval) Same as for switchboard Same as for switchboard Same as for switchboard Same as for switchboard IS 2705, 1992 Resin cast, natural air cooled, enclosed in cubicle 6.6KV/11kV/0.110 KV / 0.110KV 3 3 3 1 phase, star/ star/ star 50VA each Class 1.0 core for metering and class 3P for protection
17. Test, service position of breaker 18. Material of fixed & moving contacts
: :
19. Breaker fully type tested as per. 20. Surge diverters in case of VCBs / Vacuum Contactors
: :
III) Current transformer 1. Type 2. Ratio, burden, accuracy class cores 3. a) Short time rating b) Dynamic stability current 4. Insulation level a) Impulse withstand voltage b) PF withstand voltage 5. Applicable standard IV) Potential transformers 1. Type 2. Ratio 3. Connection 4. Rated burden
: : : : : : : : : : :
Rev. 0
NMDC LIMITED
MECON LIMITED

5. Voltage factor
1.1 Continuous & 1.9 for 8 hours for noneffectively earthed system
1.2 Continuous & 1.5 for 30 seconds for effectively earthed system
6. Neutrals 7. Insulation level a) Impulse withstand voltage & peak b) PF withstand voltage KV (RMS) 8. Protection a) HV side b) LV side 9. Mounting of BUS PT Line PT 10. Applicable standard V) Metering System A) Indicating Meters 1. Type of meters 2. Type of movement 3. Size 4. Dial finish 5. 6. 7. 8. 9. Mounting Accuracy class Voltage / current Range Applicable standard
Neutrals to be brought out for earthing on HV & LV side Same as switchboard Same as switchboard
: :
: : :
HRC fuse for each phase MCB with auxiliary contact N.A. part of incomer N.A. Separate draw cubicle side out
IS: 3156 1992
: : : : : : : : :
Ammeters, voltmeters, PF meter, frequency meter, watt meter with MDI Taut band 144 sq for I/C, 144 sq. mm 96 sq for O/G feeders White painted dial with pointer type needle Flush mounting 1.0 110 V PT, 1A CT sec. current As specified IS: 1248-2003 Rev. 0
NMDC LIMITED
MECON LIMITED

B) Integrating meters 1. Type
2. Features
3. Accuracy class 4. Coil rating a) Current b) Voltage 5. Mounting VI) Auxiliary equipment 1. Protection relays 2. Control switches
: : : :
Microprocessor based metering system to read phase & line voltages, line currents, 3 phase MW, MVAR, MVA, MWH, MVARH, MVAH, Max. demand in MW, MVA & MVAR with adjustable integrating period Metering system shall also have Max. demand controller, a serial port (RS 485) for connecting the metering to PLC system. The system shall be supplied with interconnecting cable, terminal accessories, software for data logging & management. 0.5 1A CT sec 110 V AC, PT sec. Flush mounting
: :
Numerical protection relays with adequate binary I/Os. 16A, 440 V AC 10A, 110 V DC Quick make, quick break, flush mounted, stay-put/ spring return, IS: 13947 2A, 110 V DC 10A, 440 V AC 1 No +1 NC Flush mounted, IS: 13947 LED type suitable for flush mounting. Assembly for bulb is from the front. By MCBs
3. Push buttons
4. Indicating lamps
5. Control circuit protection
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 2.1.2 2.1.2.1 VOLUME - IV of V PAGE No. 26 TECHNICAL SPECIFICATION for both 11kV, 6.6kV boards & Outdoor CICO panel GENERAL The switchgear shall comply with list of applicable codes and standards and enclosed specification and drawings. The switchgear shall be factory assembled and fully type tested as per IEC . 2.1.2.2 2.1.2.2.1 TYPE OF GEAR The switchgear shall be metal clad, dead front, air insulated, natural air cooled, fully compartmentalized, fully draw-out, self standing indoor cubicle conforming to IP4X for 6.6kV & 11kV panels and IP 55 with canopy for 11kV CICO panel. Each cubicle shall be constructed on unit principle. Each switchboard shall comprise of number of cubicles forming a single continuous board. It shall be possible to perform all switching operations with door closed. Interlocks required for safe switching, operation and maintenance shall be provided. Wherever possible, mechanical interlocks shall be provided in addition to electrical interlocks. CUBICLE Each cubicle shall be fully compartmentalized with metallic partitions having separate chambers for main busbars, CTs and cable terminations, switching device, LV chamber for metering, protection and control equipment. The metallic partitions shall be earthed and compartments thus formed shall be dust and vermin proof. This state of the compartments shall be maintained while switching device is in service position. Pressure relief flaps, which cannot be opened from outside shall be provided to vent upwards in case of arcing faults inside the cubicle. To ensure personnel safety, the following conditions shall be met for internal arcing faults: i. ii. Correctly secured doors, covers etc., must not open. Parts, which may cause hazard to personnel, must not fly-off. Rev. 0 of 272
2.1.2.2.2
2.1.2.3 2.1.2.3.1
2.1.2.3.2
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 iii. 2.1.2.3.3 VOLUME - IV of V PAGE No. 27 Earthing connections must remain effective. of 272
LV compartment, switching device & termination compartments shall be segregated from those of adjacent cubicles. Busbars chamber shall be provided preferably with seal-off bushings to segregate busbar chambers of adjacent panels. Lockable lift-off type front door shall be provided for switching device compartment. LV compartment shall have independent hinged door with locking facility. Rear side of cubicle shall be provided with hinged doors with locking provision. Inspection window of clear glass / polycarbonate shall be provided in cable termination chamber for viewing the cable termination. All mechanical indications of breaker truck / carriage positions, Breaker ON/OFF/ Trip conditions, spring charged/ discharged indications shall be freely visible from outside. Emergency trip push button shall be accessible from outside. The mechanical close pushbuttons for incomers and bus-coupler panels shall be rendered ineffective. All control switches, indication lamps, meters, protection and auxiliary relays shall be flush mounted on the swing panel of respective LV compartment. Height of operating handles of control switches, push buttons, reset rods of relays shall be less than 1800 mm from floor level of switchgear room. BUSBARS Busbars shall be made electrolytic grade Aluminium alloy. Maximum temperature of busbars including joints at rated current shall not exceed the limits specified in IEC 60694. Provision shall be made for taking up changes in length of busbars due to change in temperature. Short time thermal withstand capability and dynamic stability of busbars shall as applicable to the switchboard.
2.1.2.3.4
2.1.2.3.5
2.1.2.3.6
2.1.2.3.7
2.1.2.4 2.1.2.4.1
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 2.1.2.4.2 VOLUME - IV of V PAGE No. 28 of 272
Bus bar cross-section shall be selected based on the temperature rise indicated. Main busbars shall have same cross sectional area throughout its length and feeder busbars shall be rated corresponding to breaker rating. Main & feeder busbars shall be fully insulated and busbar joints shall be provided with removable insulation shrouds. Entire bus work, CTs shall be supported on resin cast insulators of adequate creepage distance. CIRCUIT BREAKER/ CONTACTOR WITH FUSES The circuit breaker shall be three pole vacuum break, horizontal draw-out type with stored energy, spring charged operating mechanism. The circuit breaker design shall ensure re-strike free operation and have very low value of chopping current under all switching duties. Switching surge voltages while switching ON or OFF of low inductive currents, locked motor currents, capacitor currents etc. shall not exceed 2.5 PU (Max.). In case switching voltage is more than 2.5 PU, the value shall be indicated in the offer. In case of possibility of high transient voltage, more than 2.5 PU, metal oxide, gapless surge arrestors shall be provided. The breaker with its operating mechanism and surge arrestors shall be suitable for high frequency of operation (switching On and OFF) and shall be able to operate reliably with a long period of interval between maintenance. Further the surge arrestors shall be provided with pressure relief vents preferably. Provision of mechanical indication for the arrestors failure is preferred. The air clearance between phases and between phase to earth shall be adequate to meet the dielectric strength requirements/BIL specified.. Breakers of same rating shall be identical and interchangeable at site. Parts of the breaker required for maintenance, inspection or replacement shall be easily accessible. Surge arrestor should be provided for capacitor feeders & Dry transformer feeders. Rev. 0
2.1.2.4.3
2.1.2.5 2.1.2.5.1
2.1.2.5.2
2.1.2.5.3
2.1.2.5.4
2.1.2.5.5
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 2.1.2.5.6 2.1.2.6 2.1.2.6.1 VOLUME - IV of V PAGE No. 29 AC & DC trip circuit supervision relay shall be considered Operating mechanism All circuit breakers shall be provided with motor operated stored energy, manual independent closing and shunt trip mechanism with built in anti-pumping feature and trip free operating mechanism conforming to IEC. The shunt trip and closing coil and spring charging motor shall be suitable for AC or DC control supply indicated in design criteria. In case of circuit breakers serving as motor feeders or substation incoming and bus coupler feeders, both AC & DC shunt trip coils shall be provided. In case of circuit breakers with more than one operating spring, they shall be so interlocked that the springs are charged to the same extent and the breaker can be closed only if all the springs are charged to the required values. In the event of manual charging of springs, means shall be provided through a limit switch in the operating mechanism to cut off the electrical circuit of spring charging motor on insertion of the operating lever. In order to ensure the reliability and long operating life for the mechanism, the mechanism shall be light, with a high mechanical strength and abrasion resistance to avoid high rate of wear and tear and with few components. The number of components in the breaker and operating mechanism shall be kept to a minimum and they shall be designed to be free of undue stresses during normal or short circuit operations. Further they shall ensure a high frequency of operations indicated in technical particulars. All the moving parts of the mechanism requiring inspection, maintenance and lubrication shall be easily accessible. The life of the operating mechanism shall not be less than 30, 000 operations in case of vacuum breakers. Trip coil shall operate satisfactorily between 70% and 110% of rated voltage while closing coil and spring charging motor shall operate satisfactorily between 80% and 110% of rated voltage. Rev. 0 of 272
2.1.2.6.2
2.1.2.6.3
2.1.2.6.4
2.1.2.6.5
2.1.2.6.6 2.1.2.6.7
NMDC LIMITED
MECON LIMITED

The closing and tripping circuits shall be self-opening on completion of their respective functions, irrespective of position of the breaker ON/OFF switch. Mechanical breaker ON/OFF and spring charged indication shall be provided positively coupled to the operating mechanism and visible from the front with cubicle door closed. Each breaker shall be provided with mechanical trip push button, accessible with door closed. Auxiliary contacts Each circuit breaker shall have required number of auxiliary contacts to control circuit changes for indication, protection, interlocking, supervision, metering and others. All auxiliary contacts shall be positively operated by the main apparatus and all contacts shall be adequate to make, carry and interrupt the currents in their circuits. Minimum of 4 NO + 4NC auxiliary contacts shall be available for owners exclusive use at site. Multiplication of breaker auxiliary contacts shall be avoided. However in case of necessity, electrically reset latched relays shall be used. Further these contacts shall be available in both test and service positions. i. ii. iii. iv. v. vi. Breaker auxiliary contacts available in test and service position and those available in service position only shall be clearly indicated. Normally open and normally closed contacts shall be interchangeable at site. All the contacts for customers use shall be wired up to the terminal block. Advance and retard contacts as required by the control circuits shall be provided. Contact sequence diagram shall be provided. Interlock with door limit switch shall be provided to ensure that the breaker cannot be closed in Service. Additional Breaker aux. contacts as scheme requirement shall be multiplied by using mechanically latched electrically reset type relay only. Rev. 0
2.1.2.6.9
2.1.2.6.10 2.1.2.7 2.1.2.7.1
2.1.2.7.2
2.1.2.7.3
NMDC LIMITED
MECON LIMITED

2.1.2.7.4
A readily identifiable mechanical emergency trip device as well as provision for manual charging of springs through the cubicle door shall be provided for each breaker. Breaker truck/ carriage The circuit breaker with its control units, operating mechanism, isolating and interlocking gears, auxiliary switches, isolating contacts and wiring shall be carried on a horizontally with-drawable, sheet steel, dead front truck / carriage on wheels / guide channels. The truck / carriage shall be provided with handles for maneuvering the breaker into position. All Circuit breaker trucks / carriages of same rating shall be identical in all respects and shall be interchangeable at site. The circuit breaker truck / carriage shall have three clear position viz. the service position where the control and power terminals of the circuit breaker are engaged; the test position, where the power terminals of the circuit breaker are isolated, while the control terminals remain engaged; maintenance position where both power and control terminals of the circuit breaker are isolated. The service and test position of the circuit breaker shall be within the cubicle and it should be possible to keep the door closed, with the breaker truck. Carriage in either test or service position. However the maintenance position can be with door open. The truck movement inside the cubicle shall be within guide ways, on metal / nylon roller and the movement of the truck shall be smooth and reasonably effortless. At the end of the travel i.e. in service position or in test position it shall be ensured that the breaker terminals engage positively. Further, mechanical indications shall be provided to be visible from the front of cubicle door for the position of the truck / carriage. The truck / carriage shall be provided with locking arrangement for locking them in either test or service position, to prevent movement due to short circuit forces. Rev. 0
2.1.2.8 2.1.2.8.1
2.1.2.8.2
2.1.2.8.3
2.1.2.8.4
2.1.2.8.5
NMDC LIMITED
MECON LIMITED

Spring loaded, sliding earth terminals shall be provided on both sides of the truck/ carriage, making positive connection with the earth strip provided with cubicle to ensure that all non conducting metal parts are securely earthed before moving the breaker truck / carriage to test and service positions. The location of the earth terminal shall be such that, it should be first to make and last to break to ensure personal safety. All the non-conducting metals parts shall be bonded together and connected to the earth terminal by means of a separate connection. Bolted connections of the framework of the truck / carriage shall not be used as earth continuity conductors. Interlocks Mechanical interlocks shall be provided on each truck/ carriage to prevent mal-operation and in particular to ensure that: i. ii. The truck cannot be moved in or out of its cubicle with the circuit breaker closed. The circuit breaker can only be closed when the truck is in one of the positions i.e. the service position, a definitely located test position or fully out of the cubicle in the maintenance position. The necessary contacts for the same shall be provided on the truck / carriage at these locations. The truck cannot be pushed to service position, if either set of safety shutters is not free and not in its normal closed position. The truck cannot be pushed to service position without making the connections of control isolating contacts. In case of plug and socket connections for isolating contacts, it shall be ensured that the correct sequence of connections is maintained.
2.1.2.9 2.1.2.9.1
iii. iv. v.
2.1.2.10 2.1.2.10.1
Isolating contacts and shutters Power isolating contact assembly shall have self-aligning silver faced contacts with replaceable fingers or equivalent construction. The moving contact shall engage with the fixed contacts through opening in the bus bar and current transformer chambers. Each opening shall be covered by Rev. 0
NMDC LIMITED
MECON LIMITED

vermin proof spring-loaded automatic safety shutters. With the safety shutter closed, it shall not be possible to introduce even small tools such as screwdrivers and complete protection shall be offered against accidental contact with live terminal, in line with protection class of enclosure specified in the design criteria. 2.1.2.10.2 Independently operable, bus bar and cable end shutters shall be provided, operated by the movement of the truck/ carriage, so that when the breaker truck is moved out of service position, the shutters shall enclose the live terminals to prevent inadvertent access to these terminals. The shutters shall be provided with independent locking arrangement. The shutters shall preferably be of transparent polycarbonate material to enable visual inspection of bus bar terminals and finger contacts with the shutters closed. Shutters shall be positively operated by the travel of the truck/ carriage, each shutter independently of the other. Bus bar shutters shall be labeled to distinguish them from feeder shutters and both shutters shall be independently lockable in the closed position. Auxiliary control connections The wiring on each truck/ carriage shall be connected to the wiring on its cubicle by means of plug and socket connections or by means of spring loaded sliding finger contacts. In case of plug and socket arrangement interlock shall be provided so that plug is removed before the breaker is withdrawn to maintenance position and breaker cannot be moved into service position without inserting the plug into the socket. Further there shall be an interlock to prevent improper connections. In case of finger contact arrangement, perfect alignment of male and female contacts shall be ensured and the contacts shall be of high conductivity, electrical grade copper with silver facing. Clear distinction shall be made between the Rev. 0
2.1.2.10.3
2.1.2.10.4 2.1.2.10.5
2.1.2.11 2.1.2.11.1
2.1.2.11.2
2.1.2.11.3
NMDC LIMITED
MECON LIMITED

contacts, those available in test and service position and those available in service position only. 2.1.2.12 2.1.2.12.1 Cable Termination The cubicle shall be suitable for terminating cables or bus trunkings as specified. Sufficient space and support arrangements shall be provided for terminating specified number of power cables with bottom entry as specified. If the required number of cable terminations cannot be accommodated in the respective cubicle, additional dummy panel with necessary bus-work shall be provided. Required no. of compression type cable glands and tinned copper lugs shall be provided. Where cable terminations are specified, HT cable sealing kits shall form part of cubicle. Where core balance types CTs are specified, the same shall also be enclosed inside the cubicle. Blank G.I plates, gasketed and bolted to the cubicle, for glanding and terminating low voltage control and power cables shall be provided. Compression type brass cable glands shall be supplied for LT cables and control cables of specified type and size. Heavy duty tinned copper lugs of crimping type shall be provided. INSTRUMENT TRANSFORMERS Current transformers The instrument and protection transformers shall be supplied as specified and shall have the ratings, outputs and accuracies as specified or required. The current transformers ratio specified are provisional and are subject to alteration and confirmation later. Where outputs and accuracies are not specified, these shall be such as may be required by the metering or protective circuit in which they are used. Separate cores shall be used for metering & protection.
2.1.2.12.2
2.1.2.12.3
2.1.3 2.1.3.1 2.1.3.1.1
2.1.3.1.2 2.1.3.1.3
All current transformers shall be designed to have over current factors to withstand the fault currents of the associated system as applicable to the switchboard. MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD Rev. 0 2010, MECON Limited. All rights reserved.
NMDC LIMITED
MECON LIMITED

Current transformers used for protection shall have an accuracy limit factor not less than 10. Those used for metering shall have a saturation factor 5. All current transformers shall have 1Amp. secondaries and shall be of the air insulated, plain ring type, encapsulated in thermal setting resin and with bar primary. All CTs shall be mounted in a separate chamber on the fixed portion of the cubicle, on the outgoing side of the circuit breakers, so that circuit breaker trucks of same rating and of different circuits having different C.T ratios are interchangeable. Polarity of primary and secondaries of all the CTs shall be clearly marked. Short time thermal rating & dynamic fault current withstand rating of CTs shall match with the switchboard rating. Voltage transformer (PT) Voltage transformers shall be built-up of CRGO electrical steel. The voltage transformers shall be resin cast dry type, mounted on draw-out trucks. The PTs shall be single phase or three-phase type as specified. When 3 phase PTs are offered they shall be star/ star/star or star/star/open delta type as specified, fully insulated with neutral points brought out for earthing on both sides. Basic features of draw-out truck/ carriage specified for breaker shall also applicable for draw-out truck of PT including safety shutters. HT side of PTs shall be protected by HRC fuses, mounted on draw-out truck. LT terminals shall be terminated on separate power terminal block located in the same panel. When PTs form part of non effectively earthed system, it shall have a voltage factor of 1.9 for 8 hours. Primary side neutral point shall be earthed through a removable link and one phase shall be earthed on the secondary side, through a removable link.
2.1.3.1.5
2.1.3.1.6 2.1.3.1.7 2.1.3.2 2.1.3.2.1
2.1.3.2.2
2.1.3.2.3
2.1.3.2.4 2.1.3.2.5
Rev. 0
NMDC LIMITED
MECON LIMITED

Where line PTs are specified, they shall be offered in independent cubicle in a draw-out truck unless agreed otherwise. ACCESSORIES Relays All relays specified shall be flush mounted in dust proof cases and shall match the appearance of the instruments mounted on the same panel. Each relay shall be identified with relay number indicated in the approved control schemes both on its case and on drawout part. Protective relays shall be of the easy with-drawable type. Trip circuits shall be automatically broken and current transformer secondary circuits shorted, when a relay is withdrawn from its case. A marking strip shall be provided in front of each terminal block and a diagram plate at the back of each case to identify connections. Relay contacts shall withstand repeated operation and shall make or break the maximum currents in their circuit without deterioration. All spare contacts shall also be wired upto external terminal blocks in the cubicle. Relay coils shall carry their normal currents, indefinitely and such currents as can occur under fault conditions. Relay mechanism shall not be affected by vibration or external magnetic fields, which may occur in normal operation. All relays in tripping circuits shall have mechanically operated flag indicators. Indicators, mechanical or electrical, shall also be provided on other relays to identify the type of fault that may have occurred. Indicators shall be capable of being reset without opening the relay case. It shall not be possible to operate the relay by hand or to alter is settling, without opening the case. All relays shall operate satisfactorily from 50 to 120% of rated voltage.
2.1.4 2.1.4.1 2.1.4.1.1
2.1.4.1.2
2.1.4.1.3
2.1.4.1.4
2.1.4.1.5
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 2.1.4.2 2.1.4.2.1 Numerical Relays: General requirements Protection relays shall be fully type tested, of approved types and shall comply with the relevant IEC255 standards. Relays of numerical technology including monitoring and control shall be preferred. They shall be designed for flush mounting in relay panels or in the doors of the low voltage compartments of the switchgear units. The cases shall be dust and moisture proof to IP 51 according to IEC 529. The connection terminals shall be allocated at the case rear side and shall allow alternatively screw or crimp-snap-in connection. 2.1.4.2.2 The relays shall satisfy the following requirements: i. EMC: the relay shall be type-tested w.r.t. interference suppression, 1 MHz Burst disturbance, immunity to Electrostatic discharge, immunity to radiated electromagnetic energy, electrical fast transient or burst, current/voltage surge immunity, immunity to conducted disturbances induced by radio frequency fields, power frequency magnetic field immunity. The relay shall withstand one-minute power frequency voltage of 2 kV RMS and impulse voltage (1.2/50 micro second) of 6 kV. The relays shall be suitable for operation in a tropical climate and for the ambient temperature and humidity levels specified. Relays, whether mounted in panels or not, shall be provided with clearly inscribed labels describing their application and rating in addition to the general purpose labels. The protection measuring relays shall be numerical type. The analogue to digital converted measuring qualities shall be processed in microprocessor-based hardware units according to proven protection algorithms. VOLUME - IV of V PAGE No. 37 of 272
ii.
iii.
iv.
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 v. VOLUME - IV of V PAGE No. 38 of 272
The sampling frequency shall not be less than 12 times rated power system frequency. Reliable shielding against electromagnetic interference shall be assisted by the following measures: a. b. c. d. e. Metal relay case Shielded input-transformers Opto-Coupled/ galvanically inputs DC/DC converter supply Relay outputs
isolated
binary
2.1.4.2.3 2.1.4.2.4
The complete relay shall be according to IEC255-22-1to 4. The relays shall have an integrated setting keypad and an alphanumeric display the setting shall be menu-guided and setting values shall be entered as numbers. The setting ranges shall be limited and checked for plausibility. Setting shall be possible on-line without restart of the microprocessor system. The setting values shall only be valid after a final code word cheek. The display shall normally indicate selectable load values, such as currents or voltages, and shall automatically change over to fault indications, such as faulted phase, tripping time, etc., when system faults occurs. The function assignment of binary inputs, relay outputs and indications shall be freely programmable. The functions shall be selectable from a library in the relay manual. It shall also be possible to build group alarms or group indications. It shall further be possible to store up to four setting groups in impedance and 11 over current relays. The required setting -group can be enabled by digital inputs. A lockable control switch must be provided for each circuit breaker allowing the auto re-closure to be switched on or off. Displays on the Relays The following important information must be displayed without operator action: i. Protection information disturbances. arising from network Rev. 0
2.1.4.2.5
2.1.4.2.6
2.1.4.2.7
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 ii. iii. 2.1.4.2.8 Information about internal possibly group indications. Status indications VOLUME - IV of V PAGE No. 39 faults and of 272
monitors,
These indications may be by LED or displays or a combination of both. Display shall be in English language and shall be textual. Protection information about network disturbances, internal faults and monitors shall be indicated with red LEDs. Ready for operation shall be indicated with green LEDS. Fresh optional shall be indicated with red LEDS. For graded protection (e.g. d.m.t. and i.d.m.t), run-time indication must be available. Range 0-approx. 6s with 10 ms resolution. Run-time indication must be started by the general pick-up signal and stopped by dropout. Protective relays must be designed as to show the last eight event. Information must be retained for 24 hours if the power supply fails and displayed when power is restored. Further, it shall be possible to display further information on request (e.g. fault impedance, fault current at instant of TRIP command, line values as primary values). The software version must be displayed on request. Contacts Potential free, freely assignable output contacts shall be provided. In addition, one dedicated output contact indicating relay healthiness shall be provided.
2.1.4.2.9
2.1.4.2.10
2.1.4.2.11
2.1.4.2.12
2.1.4.2.13
2.1.4.2.14
Remote interrogation via serial ports Provision must be available, which will allow information to be interrogated from serial ports (for off-line PC's and online central units). Scope of data dependent on protection type and application, e.g.: i. ii. System fault reporting Fault records (currents and voltages, time resolution 1 to 2 ms). Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 iii. iv. v. vi. 2.1.4.2.15 Status indications Relay monitor Line parameters. Setting values. VOLUME - IV of V PAGE No. 40 of 272
The protection relay shall also used for detection and storage of protection information and for fault record. In such a case the requirements are: i. Fault reporting data shall be stored for at least the last three events (three general start signals). The memory shall be arranged in a first-in, first-out manner. The memory capacity shall cover sequences up to 3 sec. in transmission systems and approx. 1.5 sec in sub transmission and distribution systems. Fault record must be started by the general pick-up signal and the preceding 100msec must also be recorded. When the memory is full, always the earliest record shall be erased. The relationship between protection information and analogue disturbance values must be definitive. For the use of numerical relays without a central unit, models must be available which correlate date and time to the protection functions. Time recording accuracy of 1 minute in 1 month is adequate. Date and time settings must be possible both via the serial port and keyboard on the relay. Power failure reserve of at least 24 hours is required.
ii.
iii.
iv. v.
2.1.4.3
External signal inputs The relays shall have required binary inputs to receive individual signals from other relays (e.g. a buchholz signal to a numeric relay) or from devices located in the field.
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 2.1.4.3.1 Fault reporting Numerical relays shall be interrogated both from an integral keypad and from a serial port. 2.1.4.3.2 2.1.4.3.3 Operation from keypad Resetting indicators Resetting must be possible at the relay but must only affect the indications and not the memory content. The same applies for remote reset. For relays in individual housings, reset must be possible without opening the case. A reset button must be provided on the front of relays built into cabinets 2.1.4.3.4 Erasure of stored information in memory It must be possible to erase data stored in memory (e.g. after testing), but the method must be such that accidental erasure is prevented. 2.1.4.3.5 Selection of indications Selection of indications in the display must be possible, on the relay, and from remote. 2.1.4.3.6 Setting and interrogation i. For setting and interrogation of the set values, relays must have integral operating elements. These functions must be possible without reference to the handbook - menu guided or sufficient instructions on the relay. Inputs, which are outside the design range, must be rejected. Design must prevent accidental or careless alteration of set values. e.g. a password. Input of parameters must be in secondary values. VOLUME - IV of V PAGE No. 41 of 272
ii.
2.1.4.3.7
Serial Communication Interfaces i. It shall be possible via a serial port (RS 432), to set and interrogate relays, using an external device. Operation and setting of the various makes and Rev. 0
NMDC LIMITED
MECON LIMITED

types of relays must be possible with common PC hardware. Communication shall be based on approved standard. This serial port shall be located in relay front. ii. For integration into a numerical, co-ordinated protection and control system or a substation automation system, relays must be provided with an additional serial interface located at the back of the relay. Unless agreed otherwise, this port shall be RS 485 port; where specifically indicated a fibre optic interface shall be provided. Communication wise this port shall use approved protocol to suit the substation automation system envisaged.
2.1.4.3.8
Self-monitoring and failure annunciation. i. The protection systems must provide the best possible level of self-monitoring. Failure of the selfmonitoring function must be indicated and signaled. The occurrence of a failure (in hardware or software) shall not lead to nuisance trip of the relay. A separate, potential-free contact shall be provided for DC supply monitoring. The contact must be reset and the relay automatically made ready for service when the supply returns.
ii.
2.1.4.3.9
Auxiliary Power supply and battery i. Relays, which rely, for there operation, on an external DC supply shall be catered to from the station battery at 110V DC. The relay shall be suitable for a ripple content of 12% in the auxiliary source. DC/DC converters shall provide galvanic isolation between the internal static circuits and the external station battery. The relay shall be provided with an internal battery back up to ensure back up to the internal clock, switching statistics, fault/status record, values of parameters such as voltage/current/time at fault. The battery condition shall be monitored and a message shall be generated in case of weak battery. Rev. 0
ii.
NMDC LIMITED
MECON LIMITED

An integral DC voltage buffer shall ensure uninterrupted performance of the relay in case of DC voltage interruptions <50 m. sec.
2.1.4.4 2.1.4.4.1 2.1.4.4.2
Indicating instruments All indicating instruments shall conform to IS 1248. Indicating instruments shall be of size 144 x 144 mm for incomers, Motor feeders and capacitor outgoing feeders, 96 x 96 mm for other outgoing feeders and conform to 1.0 accuracy class unless specified otherwise. Meters shall be suitable for PT secondary of 110V (line) and CT secondary of 1A. Scales shall be suitably provided depending on the ratio of instruments transformer. All indicating instruments shall have non-reflecting bezels, clearly divided and indelibly marked scales and sharply outlined pointers. They shall be provided with zero adjusting devices for external operation. Indicating instruments shall be taut band type with circular scale. Frequency meter where specified shall be digital type indicating up to 2 decimals. Power factor meter shall be 3-phase type and shall have range of 0.3 lag to 0.3 lead. Integrating meters shall conform to class 2.0 accuracy. These meters shall be 3-element type suitable for 3 phases, 3-wire system. All integrating meters shall have cyclometer register. Maximum demand indicators shall be for 30 min. or 15 Min. integration periods as specified. Control switches Circuit breaker operating switches shall be of the pistol grip type, spring return to neutral and lockable in that position. They shall be arranged to close the breaker by being turned clockwise. The trip, neutral and close positions shall be clearly indicated. The movement shall be such that the switch cannot be operated inadvertently and that it is mechanically interlocked to trip before close. Control switches shall be suitable for use in DC circuits upto 220 V and AC circuits up to 440 V. the switch shall have break rating of 2A at 220V DC & 5A at 440 V AC. Where specified, the switch shall have lost motion device. Rev. 0
2.1.4.4.3
2.1.5 2.1.5.1
2.1.5.2
NMDC LIMITED
MECON LIMITED

Switches for any purpose other than circuit breaker operation shall be of a different design. Local remote control switches shall be stay put type, lockable in any position. The switch shall be quick make, quick break type. 2.1.6 2.1.6.1 WIRING & FERRULES All wiring shall be carried out with 1100 volts grade single core wires having stranded copper conductor of 2.5 sq. mm for CT circuits and 1.5sq. mm for potential circuits. The wire shall be insulated with fire resistant material HR-PVC-1050C or equivalent approved by engineer. All control wiring shall be terminated using eye type tinned copper lugs on to the stud type terminals. More than two wires shall not be terminated onto a single terminal. All holes or tubes for wiring runs shall be bushed and shall have room for reasonable future additions. Control cables when laid in HT busbar chamber, cable shall be taken through PVC conduits. No joints or tees shall be made in wires between terminals. The wire shall be identified by numbered ferrules at each end, all in accordance with the connection diagram, equi-potential terminals shall have the same ferrule numbers. All ferrules shall be made of non-deteriorating materials. They shall be white except in case of warning ferrules, which shall be red. Ring type ferrules shall have the character engraved on it. The ferrules shall be firmly located in each wire so that they cannot move freely on the wire. Wiring across hinges shall be by flexible wires. The colour code for control wiring shall be as enumerated below: i. ii. iii. Spring charging motor and metering circuits Black Closing tripping, protection relays and main power supply circuits Red Annunciation and indication circuits White
2.1.6.2
2.1.6.3 2.1.6.4
2.1.6.5
2.1.6.6
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 2.1.7 2.1.7.1 CONTROL CIRCUIT PROTECTION In each panel, control power circuits shall be fed through MCBs. Closing circuit, tripping and control circuit, lamp circuit shall be segregated and protected by independent MCBs. Potential circuits of meters shall be provided with MCBs. MCBs shall also be provided for auxiliary supplies to meters. Incoming DC supply and 240V AC supply for auxiliaries shall be provided at Incomer panel of the switchboard. For this purpose adequately rated DC and AC I/C MCBs shall be provided. INSCRIPTIONS Each unit and each component shall be clearly labeled to indicate its purpose. Owner's nameplates at front and back of each cubicle shall be engraved on white back ground with black lettering of 10mm size. Each component label shall include the component symbol shown on the connection or schematic diagram. All components mounted inside the cubicle provided with screwed inscription plates. shall be VOLUME - IV of V PAGE No. 45 of 272
2.1.7.2 2.1.7.3
2.1.8 2.1.8.1 2.1.8.2
2.1.8.3 2.1.8.4 2.1.8.5 2.1.9 2.1.9.1
The characters to be engraved on the cubicle labels shall be furnished at a later stage. EARTHING Two earth terminals shall be provided on each switch cubicle, at the back near the floor. An earth bus of adequate cross section shall be fixed to these terminals. The earth bus bar shall be electrically continuous and shall run the full extent of each board. The earth bus shall be of same material as the busbars and shall have a minimum cross section of 500 sq. mm aluminium. Each unit shall be constructed to ensure satisfactory electrical continuity between all metal parts not intended to be alive and the earth terminals of the unit. Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 2.1.10 2.1.10.1 PAINTING The switch unit cubicle shall be finished with approved colour shade conforming to IS 5-2004, to be indicated during drawing approval. Breaker truck shall have same colour as cubicle. The sheet metal parts shall be subjected to following pre-treatment before final painting: i. ii. iii. 2.1.10.2 2.1.11 2.1.11.1 2.1.11.2 Degreasing Pickling for complete rust removal Phosphating VOLUME - IV of V PAGE No. 46 of 272
Corrosion resistant primer painting. Two final coats of epoxy painting shall be given. SPECIAL TOOLS The switchboard shall be supplied with a set of special tools required for its normal operation and maintenance. Minimum 3 Nos of removable levers for charging the spring by hand in case of emergency (power failure) and 6 nos. breaker rack-in rack-out handles shall be supplied per each HT switchboard. TESTS Current transformers At works i. ii. iii. iv. v. vi. vii. Ratio test Verification of terminal making & polarity Accuracy class test Power frequency high voltage test for 1 minute Measurements of knee point voltage and secondary winding resistance Insulation resistance test Physical inspection as per the approved drawings Rev. 0
2.1.12 2.1.12.1
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 At site i. ii. iii. iv. v. vi. 2.1.12.2 Ratio test Measurement of terminal marking and polarity Measurements of knee point voltage and secondary winding resistance Power frequency withstand test for 1-minute along with switchboard. Insulation resistance test if required Physical inspection as per the approved drawings VOLUME - IV of V PAGE No. 47 of 272
Potential transformers At works i. ii. iii. iv. Ratio test Verification of terminal making & polarity Power frequency HV test for 1 minute Insulation resistance test
At Site i. ii. iii. iv. 2.1.12.3 Ratio test Verification of terminal making & polarity Power frequency HV test for 1 minute Insulation resistance test
Switchboard At works i. Type test reports Type test reports for type test carried on similar units manufactured in India shall be furnished along with the tender. Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 ii. VOLUME - IV of V PAGE No. 48 of 272
The switchboard shall be subjected to the Tenderers standard tests and to the routine tests as per applicable standards. These tests shall include.
2.1.12.4
Cubicle At works i. ii. iii. Insulation resistance tests Power frequency high voltage withstand test for minute. Milli-volts drop across incoming and outgoing jumpers connection with C.B closed and in service position. Temperature rise test on switchboard with circuit breaker. (Optional) Physical inspection as per the approved drawings and checking of clearance Operational tests as per relevant standards Tests to prove inter-changeability of similar parts Tests to prove correct operation of control gear at 80% and 120% of control voltage and master trip relay at 70% and 110% rated voltage. Tests to prove correct wiring of switchboard.
iv. v. vi. vii. viii.
ix. At site i. ii. iii. iv. v.
Insulation resistance tests Power frequency high voltage withstand test for 1 minute. Tests to prove correct wiring / operation of: Isolating contacts, plug and sockets etc., Protective relays including indication and alarms Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 vi. vii. viii. ix. Instruments Milli-volts drop across incoming and outgoing jumper connection with C.B closed and in service position Tests to prove inter-changeability of similar parts Tests to prove correct operation of control gear at 80% and 110% of control voltage and master trip relay at 70% and 110% rated voltage. All the protective individually. relays shall be calibrated VOLUME - IV of V PAGE No. 49 of 272
x. 2.1.12.5
Circuit Breaker At works i. ii. iii. iv. v. vi. Insulation resistance tests Power frequency high voltage withstand test for minute. Milli-volt drop across circuit breaker terminals Operation tests at rated auxiliary voltage pressure (30 make & 30 break operations) and
Measurement of resistance of closing and tripping coils Test to prove satisfactory operation of closing and tripping mechanisms at 80% rated voltage and 70% rated voltage respectively. Measurement of opening and closing time of breaker, both at minimum control voltage and normal control voltage. Power consumption operations. Functional tests Physical inspection as per the approved drawings. Rev. 0 for closing and opening
vii.
viii. ix. x.
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 xi. xii. At site i. ii. iii. iv. Insulation resistance tests Power frequency high voltage test for one minute for all CB except EHV CB. Multi-volt drop across circuit breaker terminals Test to prove satisfactory operation of closing and tripping mechanisms at 80% rated voltage and 70% rated voltage respectively. Operational and Functional tests Tests to prove inter-changeability of similar parts. VOLUME - IV of V PAGE No. 50 Tests to prove inter-changeability of similar parts. Measurement of closing speed, opening speed and contact travel. of 272
v. vi. 2.2 2.2.1
11kV & 6.6kV HT CAPACITOR WITH SERIES REACTORS Design Criteria for Capacitor Bank: Sl. ITEM NO. CAPACITOR BANK a. Nominal System Voltage b. Bank rating c. d. e. f. g UNIT a. b. c. Rated voltage of bank Rated current of bank Type of connection Tolerance on capacitance Type CAPACITOR Rating Rated voltage Rated current 6.6kV HT 11kV HT CAPACITORS CAPACITORS 6.6kV 11kV Required kVAR based on approved calculations 7.7 kV 13.32kV As required Single Star connected with RVT No ve tolerance, + ve tolerance as per IS 13925 Indoor (SICAP construction (In a closed container) shall be considered) As Required 7.7 KV As required
13.32kV
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 d. e. f. g. h. i. Capacitance Tolerance VOLUME - IV of V PAGE No. 51 of 272
No -ve tolerance, +ve tolerance as per IS 13925
j. k. 2.2.2 2.2.2.1 2.2.2.1.1
Protection of Capacitor Internal fuse units Power loss (tan delta) Not to exceed 0.20 Watt per KVAR including loss in the fuse subject to tolerance as per applicable standards. Permissible overloads Max. permissible overloads as per IS 13925. Type of grounding Ungrounded. Effectively Earthed Type of discharge device Internally through resistor provided within the capacitor unit to limit discharge time to 50V in 300 secs. Capacity to receive in rush Not less than 100 times rated current current. Temperature category Maximum ambient temperature of 50 0C. TECHNICAL SPECIFICATION GENERAL The power factor correction equipment is proposed to be installed as a packaged unit and shall be suitable for the total Down hill conveyor plant operating conditions. The capacitors covered under conform to the requirements of: this specification shall
2.2.2.1.2
IS: 13925 (1998) Parts 1 & Part 2-2002 IS: 12672 (1989) 2.2.2.2 2.2.2.2.1 Constructional requirements The capacitors shall be supplied as a packaged unit (SICAP construction (In a closed container) shall be considered) suitable for indoor installation. The three phases of the banks shall be installed in tiers and the dimensions of the packaged unit shall be brought out in the offer. The capacitor banks shall consist of internally fused capacitor units in series / parallel to achieve the required Rev. 0
2.2.2.2.2
NMDC LIMITED
MECON LIMITED

rating. The units shall be single star connected and RVT shall be considered for residual over voltage. 2.2.2.2.3 Individual capacitors shall be in stainless steel containers and shall be of 100 % polypropylene dielectric and high purity Aluminium foil. The winding of element shall be carried out in controlled atmosphere free from dust and air borne contaminants. Subsequently, the units shall be sent for impregnation. The capacitors shall be vacuum dried in controlled temperature. The impregnating oil, which shall be non-pollution PCB type, shall be filtered and processed to improve its electrical properties and to render it free from impurities. The impregnating oil shall be then filled in vacuum. After impregnation, the units shall be sealed. It shall be ensured while sealing that air is not trapped. The number of series groups in each rack shall be one or more. The insulation level of bushing used for capacitor units shall be suitable for the number of series groups in each rack. The post insulator for the rack shall be selected considering the number of series groups in a rack. The assembly as such shall be mounted on pedestal insulator to insulate it from ground. Individual capacitor units shall be provided with internal fuses, which shall be of current limiting design. However, care shall be taken in selection to ensure that the energy released into a faulty unit is not capable of rupturing the container. The fuses shall not deteriorate due to inrush currents. Also fuses in healthy units shall not melt when carrying discharge current from faulted units. In the unlikely event of cascaded failure of elements in a row, the last fuse shall be capable of disconnection with a voltage of not less than 150 % of rated voltage across the unit. The capacitor bank supporting structure shall be fabricated from galvanized steel utilizing standard available sections. All hardware shall be zinc passivated.
2.2.2.2.4
2.2.2.2.5
2.2.2.2.6
2.2.2.2.7
2.2.2.2.8
Rev. 0
NMDC LIMITED
MECON LIMITED

Individual units shall be provided with internal discharge device to bring down crest voltage to less than 50V in 5 minutes or less. Operational requirements The capacitor units shall be so designed that temperature rise at any point on the container does not exceed 250C. The units shall be designed to give 100 % reactive capacity at rated voltage and frequency and not more than 110% at 230C. The capacitor shall be capable of withstanding 10 % over voltage continuously as well as inrush currents, which are likely to occur. The capacitor unit shall be capable of continuous operation of 130 % rated current. It shall also be suitable for 3 % line current unbalance. Test requirements The capacitor offered shall be of type-tested design as per IS: 13925 (1998). Further, they shall be subject to all routine tests as laid down in the IS. Internal fuses shall be subject to the test requirements as indicated in IS: 12672 (1989). SERIES REACTOR Design Criteria for Series reactor ITEM System Voltage (kV) Type Rating of series reactor Winding material Class of insulation Temperature rise Impulse withstand voltage (kVP) SPECIFICATION 6.6 & 11 Dry, Air core, resin cast 6% Copper Class F wound Class B 65
2.2.2.3 2.2.2.3.1 2.2.2.3.2
2.2.2.3.3
2.2.2.3.4
2.2.2.4
2.2.2.4.1
2.2.2.4.2
2.2.3 2.2.3.1 S.NO. a b c d e f g
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 h i 2.2.3.2 2.2.3.2.1 Power Frequency withstand 26 voltage (kV rms) Continuous rating in Amps As per IS Including harmonics TECHNICAL SPECIFICATION Each set single star connected capacitor banks shall be provided with series reactor and RVT shall be provided. The design and performance of reactor shall comply with the requirements of IS: 5553 (1990). The reactor shall be dry, air cored, air-cooled, resin impregnated / cast resin type suitable for indoor installation and weather conditions specified elsewhere. The insulation of the reactor shall be class F with temperature rise limited to class B. 5 taps shall be provided in the reactor for a total variation of +/- 5% of the reactance in steps of +/- 2.5 %. The reactor shall be designed for a through fault rating of 3 seconds duration. The reactor shall be provided in a closed container along with capacitor and RVT. The minimum magnetic clearances required between reactor and other equipment shall be specified and maintained. The reactor shall be free from hums and vibrations. The noise level at rated voltage and frequency shall be as per NEMA standard. The design of reactor shall be such as not to cause undesirable interference with radio / communication circuits. The reactors shall be located on the line side. They shall be of shielded type and rated current shall not be less than 130 % of rated capacitor bank current/ as per IS requirement. The reactor shall be of type-tested design. All routine tests as per IS: 5553 shall be carried out on the offered reactors. Insulators Insulators shall be made of high strength porcelain and shall be suitable for the service voltage and BIL specified. Rev. 0 VOLUME - IV of V PAGE No. 54 of 272
2.2.3.2.2
2.2.3.2.3
2.2.3.2.4
2.2.3.2.5
2.2.3.2.6 2.2.3.3 2.2.3.3.1
NMDC LIMITED
MECON LIMITED

Further the insulators shall be high creepage type with minimum creepage distance of 31 mm / kV. 2.2.3.3.2 Porcelain used for the manufacture of insulators shall be homogenous and free from flaws or imperfections that might affect the mechanical and dielectric quality. They shall be thoroughly vitrified, tough and impervious to moisture. Glazing of porcelain shall be uniformly brown colour, free from blisters, burrs and other similar defects. Insulators of the same rating and type shall be interchangeable. The porcelain and metal parts shall be assembled in such a manner that any thermal expansion differential between the metal and porcelain parts throughout the range of temperature variation shall not loosen the parts or create undue internal stresses which may affect the electrical or mechanical strength and rigidity. Each cap and base shall be of high-grade cast steel or malleable steel casting and they shall be machine faced smoothly and galvanized. Insulators shall be stack type. BATTERY, BATTERY CHARGER & D.C. DISTRIBUTION BOARD D.C. SYSTEM General Reliable and uninterrupted D.C. control supply shall be provided for 6.6kV & 11kV switchgears. Further quality of control supply shall be maintained within specified limits under all operating conditions. For CICO panel DC power supply shall be provided by Client. 2.3.1.2 Location The equipment required for D.C. control supply system shall be located in side the Switchgear room.
2.2.3.3.3
2.3 2.3.1 2.3.1.1
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 2.3.1.3 Equipment The system comprises one DC Battery bank and two identical automatic float cum boost chargers with associated protection, control and annunciation equipment and D.C. board. 2.3.1.4 Type of load on the D.C supply system Auxiliary Control switchgear. 2.3.1.5 2.3.1.5.1 Mode of operation Both the chargers and DC battery can be connected either to float or boost bus. An intermediate cell of the battery shall be permanently connected through a blocking diode to provide uninterrupted power supply in case of failure of DC supply from chargers. Normally one of the chargers shall operate in float mode supplying trickle-charging current of the battery and total DC load of the plant. The other charger will be in stand by mode & shall supply the float load automatically if first charger fails. When battery is under boost charging, one of the chargers will operate on boost charge mode and other charger operating in float mode shall supply the DC load. In case of AC power failure to float charger, DC supply will be automatically available from the battery, which is being charged through the blocking diode and the second charger shall go into float mode. In case of failure of AC supply of both chargers or failure of both chargers, DC battery, which is in parallel with float charger, shall automatically supply the load. DESIGN CRITERIA BATTERY Rated voltage No. of cells Tap cell for blocking diode 110V DC : 55 : 42nd cell Rev. 0 supply power requirement of HT VOLUME - IV of V PAGE No. 56 of 272
2.3.1.5.2
2.3.1.5.3
2.3.1.5.4
2.3.2 2.3.2.1
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 AH capacity Type of cell Type of container & cover Nominal voltage per cell Voltage at the end of 10 hour discharge Quick/boost charging voltage Trickle charging voltage Boost charging rate for fully charging the battery from 1.85 V PC Voltage at the end of 10 hour discharge Mounting arrangement Applicable standard 2.3.2.2 BATTERY CHARGER Supply voltage Charger rating a) Float mode b) Boost mode Operation a) Float b) Boost Permissible variation in output voltage for specified variation in supply voltage, load and both % ripple in the output voltage at any voltage and load without battery. a) Float mode b) Boost mode Indicating instruments Protection relays Annunciation 3 Phase, 415V +10% as required as required Automatic Automatic (2 rate charging) + 1% VOLUME - IV of V PAGE No. 57 of 272
: Minimum 200 AH at 10-hour discharge rate at 27C to final voltage of 1.85V per cell. : Stationary Plante type lead acid cell : SAN : 2.0 V : 1.85 V per cell. : 2.6 V per cell : 2.25 V per cell : : 1.85 V per cell. : Double row, Single tier : IS 1652 1991
0.5% 3% As specified As specified As specified
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 Type of panel VOLUME - IV of V PAGE No. 58 of 272
Sheet steel enclosed floor mounted in IP: 42 enclosures fully compartmentalised.
2.3.2.3
D.C. DISTRIBUTION BOARD Rated voltage 110V DC Max. Voltage 170V DC Rated current of 100A busbars Material of busbars Copper electrical grade No. of busbars 2 Insulation of busbars Fully PVC sleeved and supported on non-hygroscopic insulating material. No. of feeders. 1 I/C and 8 O/G Type of panel Sheet steel enclosed floor mounted in IP: 52 enclosures, fully compartmentalized.
2.3.3 2.3.3.1 2.3.3.1.1
TECHNICAL SPECIFICATION BATTERY Rating i. On failure of the mains supply, the battery previously having been on float charge should be able to maintain the total control supply for 10 hours. The minimum Ah rating of the battery shall not be less than the value specified in design criteria. Based on the requirements of equipment offered, the Tenderer shall select the battery size considering the above min. requirements. The battery shall be suitable for frequent charging and discharging without affecting the life of cells, materially. The battery shall be suitable for two rate automatic charging. Under emergency requirements, it shall be possible to charge the battery at higher charging currents.
ii.
iii.
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 iv. VOLUME - IV of V PAGE No. 59 of 272
The battery shall be suitable for continuous floating trickle charging i.e. battery is floating on the DC bus with other loads connected in parallel. Isolation between battery charger & battery shall be considered.
v. 2.3.3.1.2 Type
The battery shall comprise station class, Plante type lead acid cells in SAN container conforming to IS: 1652-1991. Ah capacity shall correspond to 10-hour discharge rate to final voltage of 1.85 VPC at 27C. 2.3.3.1.3 Charging The battery shall be suitable for two-rate automatic charging with constant current controller and constant potential controller. It shall also be suitable for manual charging. 2.3.3.1.4 Construction Construction of positive and negative plates shall ensure trouble free service. The cells shall have top lids to exclude dust. Vent plugs shall be provided on top lids. The battery shall be mounted on anti-acid painted teak wood stands in two rows, in double tier arrangement. The polarity of terminals shall be clearly marked. 2.3.3.1.5 Accessories All accessories required for installation, operation and maintenance of the battery shall be supplied with the battery as specified in design criteria. First filling of acid with 10% excess quantity shall be supplied in nonreturnable containers. Accessories for battery bank Accessories required for installation, maintenance of battery shall be provided. i. operation and
Teakwood Battery stand suitable for double row, double tier arrangement for 110V system. Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 ii. iii. iv. v. vi. Cell and stand insulators. Plastic cell number plates with fixing accessories. Copper cell connectors with adequate lead coating. Syringe type hydrometer. Thermometer with specific gravity correction scale. VOLUME - IV of V PAGE No. 60 of 272
vii. 3-0-3V, cell testing voltmeter, class 1.0 viii. Acid resisting funnel, rubber siphon, pair of rubber gloves, rubber apron, acid resisting jug of 2 liters, wall type teak wood holders. ix. x. 2.3.3.2 2.3.3.2.1 Wooden Spanner and special tools (if any). First filling of acid plus 10% spare in non-returnable plastic containers.
CHARGER GENERAL i. ii. Charger shall be rated to supply total DC load / Boost charging current of the battery bank. The same charger shall be suitably rated to fully charge the battery to full capacity, from fully discharged condition with final voltage of 1.85V PC, within 8 hours. The min, rating of charger in float and boost mode shall be as specified in design criteria.
iii. 2.3.3.2.2
Supply system Charger shall be suitable for operation on 415V + 10%, 50Hz + 5%, 3 phase 4 wire, neutral solidly earthed system with max. 3 phase fault level of 40 kA (RMS). Separate power supplies shall be considered for two chargers
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 2.3.3.2.3 Construction i. The charger cubicle shall contain transformer, thyristors, control protection, metering, signaling equipment etc. The charger cubicle shall be sheet steel enclosed, dust and vermin proof, self-standing, floor mounting type with bottom cable entry through removable gland plates. All the equipment shall be so mounted that adequate space is provided for accessibility to each component. All the components shall be accessible on opening front or backside door. Min. thickness of cold rolled sheet steel shall be 2.0 mm. All meters, control switches, indicating lamps. ON/OFF switches, protection relays shall be mounted on the hinged front door. VOLUME - IV of V PAGE No. 61 of 272
ii.
2.3.3.2.4
Charger transformer Each charger transformer shall be adequately rated to function as float charger or boost charger transformer. The transformer shall be 3 phase, double wound, class B insulated, natural air-cooled type suitable for panel mounting. The transformer shall be designed for 45 deg. C ambient with temperature rise of winding limited to 50 deg. C.
2.3.3.2.5
Rating i. Two identical natural air-cooled chargers, each suitable for operation in automatic float/manual float mode and automatic constant current control/manual current control mode shall be supplied. Each charger shall be fully independent of the other and all components of each charger shall be mounted in the respective charger. The constant potential controller shall maintain output voltage within +1% of set voltage for variation of + or 10% in input AC voltage and 0 100% load variation, and for both occurring simultaneously. The output voltage shall be adjustable continuously.
ii.
Rev. 0
NMDC LIMITED
MECON LIMITED

The charger shall have constant current controller suitable for two rate charging. Provision shall be made to set the charging current. The ripple content in the output waveform without battery shall not exceed 0.5% in float mode and 3% in boost mode measured at any voltage and under any load conditions without connecting battery. The ripple factor shall be verified at the factory, during factory testing at no extra cost. Constant current and voltage settings shall be drift free under all operating conditions. The charger shall incorporate fully controlled 3-phase rectifier. The thyristors shall be provided with necessary surge and over current protections. It shall have built-in current limiting protection. Each thyristor shall be provided with semi-conducting HRC fuses, selected based on its protection requirement. HRC fuses shall have trip indicator and micro switch contacts of trip indicator shall be wired for annunciation. The charger shall have automatic boost charge terminating device to terminate the charging as soon as battery is fully charged and the same shall be indicated through alarm.
iv.
v.
vi.
vii.
viii.
2.3.3.3 2.3.3.3.1
DC DISTRIBUTION BOARD DC board shall be sheet steel enclosed, dust and vermin proof, self-standing, floor mounting type, suitable for top cable entry with removable gland plate. The panel shall be compartmentalized with fully insulated, main DC copper busbars and copper bus connection to individual outgoing feeders. The min. thickness of cold rolled sheet steel shall be 2.0 mm. All meters, switches, push buttons indicating lamps, relays etc., shall be flush mounted on the front door.
2.3.3.3.2
Rev. 0
NMDC LIMITED
MECON LIMITED

Incoming feeder shall be provided with MCCB and outgoing feeders with double pole MCBs and feeder ON indication lamp. MCCB/MCB shall have auxiliary contact, closing in the off position and same shall be wired for alarm annunciation. The number of feeders shall be as indicated in the schedule of quantities. DCDB & Chargers shall be provided as separate units. INSTRUMENTS, INDICATIONS AND RELAYS The following shall be provided in each battery charger panel: Indicating instruments i. ii. iii. iv. AC input voltage and current suitable for reading individual line values DC output voltage and current Battery charging/drain current Trickle charging current
2.3.3.3.4 2.3.4 2.3.4.1 2.3.4.1.1
2.3.4.1.2
Signal lamps i. ii. iii. iv. AC supply on lamps - 3 Nos. (R, Y, B LED type) DC supply on lamp Float mode on lamp Boost mode on lamp
2.3.4.1.3
Relays i. ii. iii. iv. v. AC input supply failure DC bus under voltage relay DC bus over voltage relay Boost bus over voltage relay Boost bus over current relay
2.3.4.2 2.3.4.2.1
The following shall be provided in the DC board Indicating instruments i. ii. DC supply current from charger DC bus voltmeter to read voltage between + ve bus & earth, - ve bus & earth and voltage between +ve bus & ve bus through voltmeter selector switch. Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 2.3.4.2.2 2.3.4.2.3 2.3.4.3 VOLUME - IV of V PAGE No. 64 of 272
Signal lamps: Supply ON lamps for each outgoing feeder Relays: Battery earth fault relay The following shall be provided with audio annunciation with Microprocessor based annunciation system. i. ii. iii. iv. v. vi. vii. viii. ix. x. xi. xii. xiii. xiv. xv. AC supply failure for each charger AC supply DC bus under voltage at < 99V DC bus over voltage at > 121 Failure of blocking diode Battery earth fault Battery supply breaker open DCDB incoming supply breaker open Outgoing feeder open for each O/G feeder Failure of charger-1 Failure of charge-2 Over voltage in boost bus Over current in boost bus Failure of DC supply (to be announced through AC hooter) Further one set of individual contacts for each of the above type of faults shall be made available at DCDB Three reserve channels
2.3.4.4 2.3.4.4.1
Indicating instruments All indicating instruments shall be of 96 x 96 mm size, flush mounted type suitable for vertical mounting, conforming to accuracy class of 1.5 as per IS 1248. Ac meters shall be of taut band type. DC meters shall be moving coil type. Where applicable, DC meters shall be center zero type. All meters shall have nonreflecting bezels, sharply outlined pointers and zero adjusting device. Terminations All power and control cables shall be terminated using tinned copper lugs of adequate mechanical strength. Compression type brass cable glands shall be supplied for all power and control cable terminations. Gland plate shall be removable type. Rev. 0
2.3.4.4.2
2.3.4.5 2.3.4.5.1
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 2.3.4.6 2.3.4.6.1 Fuses All fuses used for protection of power circuit, voltage circuits shall be link type HRC fuses in insulating base and holder, power fuses shall have trip indicator with micro switch contacts for annunciation. Diode thyristor protection fuse shall be semiconductor type with matching protection characteristics. Necessary discrimination shall be considered while selecting fuse ratings. DC circuits shall be provided with fuse on both lines. Indicating lamps All indicating lamps shall be LED type. All the lamps shall be flush mounting type. Cubicle wiring All busbars, all connections within the charger and DC boards, shall be carried out with copper busbars/insulated copper conductors. Min. cross-section for power wiring shall be 6 sq. mm. copper and 2.5 sq. mm copper for control. All terminations shall be ferruled and numbered in accordance with the schematic diagram. Aluminum conductor shall not be used for power and control wiring of DC supply. Busbars shall be fully insulated with PVC sleeves and supported on non-hygroscopic insulating material. Terminal boards AC and DC terminals shall be segregated. All power and control terminals shall be stud type. Each terminal shall be numbered as per approved control diagrams. Inscriptions: All feeders, lamps, control switches, meters shall be provided with inscription plates as applicable to switchgear. All components shall be provided with inscription plates as per approved drawings. VOLUME - IV of V PAGE No. 65 of 272
2.3.4.7 2.3.4.7.1 2.3.4.8 2.3.4.8.1
2.3.4.9 2.3.4.9.1
2.3.4.9.2
2.3.4.9.3
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 2.3.5 2.3.5.1 2.3.5.2 TESTS The equipments shall be tested as per approved Quality Assurance Plan in MECONs format. At site i. ii. 2.4 2.4.1 Visual inspection test. Checking of layout as per approved drawings. VOLUME - IV of V PAGE No. 66 of 272
TRANSFORMERS Distribution Transformers (6.6/0.433kV & 11/0.433kV), converter duty transformers (6.6/0.72 kV &11/0.72kV) , Lighting transformers (6.6/0.230 kV & 11/0.230kV) Design parameters Power supply system in which transformer is to be used 12kV / 7.2kV Solidly grounded (11kV), Resistive earthing (6.6kV) Solid grounded (415V) 25 KA 25 kA (For Lighting Trafo.) Uni-directional, Bi-directional in case of converter duty transformer. Distribution/Converter duty/Lighting Distribution transformer are as per IS 2026, Drive transformerIEEE C57.18.10-1998, IEC 61378-1:1997 Outdoor Mineral oil filled Core type
2.4.1.1 1
a) Primary side (HV) maximum Voltage b) System earthing Primary side (HV) 2 3 4 Secondary side (LV) Max. 3 phase fault levels Primary side (HV) Secondary side (LV) Direction of power flow Transformer application Applicable standards
Transformer type Indoor/ outdoor Dry type/ liquid filled Core type/ shell type
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 6 7 8 9 Auto wound / two winding/ three winding Number of phases Rated frequency Rated no load voltage HV winding VOLUME - IV of V PAGE No. 67 of 272
Two winding, Three winding incase of converter duty transformer. Three 50 Hz., 5% 11kV/ 6.6kV 0.433kV for distribution trafo. 0.720kV for converter duty transformer 0.230kV (Ph to Ph) for lighting trafo. ONAN Mineral oil As per requirement
LV winding 10 11 Cooling Method of cooling Cooling medium Rated MVA at rated voltage & principle tap (ONAN rating) for distribution and lighting transformers Additional details for converter duty transformers a) Fundamental kVA: KVA is calculated with rated voltage and the fundamental component of the load current. b) RMS kVA: KVA is calculated with rated voltage and total RMS load current. c) Equivalent kVA: KVA is calculated with rated voltage and defined equivalent sinusoidal current, which will give the same losses in the transformer than the actual load current, when all its harmonic components are considered in relation they cause losses in the transformer. Overloading as per IS 6600
12
As per requirement
As per requirement As per requirement
13
Required
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 14 Max. Temp. rise at rated MVA & principal tap Top oil by thermometer method over design ambient temp. Any winding (HV&LV) by resistance method over design ambient temp. of 450C Hot spot temp. based on the design ambient of 450C Percentage impedance voltage at rated current, frequency, principle tap and 750C Between HV-LV Tappings Off-circuit/ ON load Manual /automatic No. of steps Percentage variation /step Winding in which tappings are required External terminal Short circuit withstand capability of transformer on any tapping for 3 phase and line to ground faults across LV winding Insulation 18 PF withstand kV (RMS) HV winding 20KV/28kV (RMS) LV Winding 2.5KV (RMS) Winding insulation category a) HV-uniform /non-uniform b) LV-uniform/ non-uniform Impulse withstand KVP 60KVP /75kVP Switching Impulse withstand NA VOLUME - IV of V PAGE No. 68 of 272
400C over 450C
450C over 450C 1050C
15
4.0 % up to 1000kVA and 5.0% above 1000kVA Off Circuit Manual 5 2.5 (Equal) -5% to +5% HV Not less than 2 sec.
16
17
Full Insulation Full Insulation
19
Rev. 0
NMDC LIMITED
MECON LIMITED

20
Winding data No. of windings Winding material Winding connection (HV \ LV1 winding) Vector groups HV-LV
Two/Three Copper Delta / star Dyn11 For general distribution & lighting transformers As required For converter duty transformer CRGO SILICON STEEL As indicated in write-up
21
Core laminations Type Material Noise level in DB scale when measured 4 ft. from the transformer edge at a height of 5 ft. above the floor at rated voltage and load
22
23
Bushing current transformers (For Power, Distribution & converter transformers only) a) Location No. of cores on the CT Type Ratio Protection class Knee point voltage CT sec. resistance at 750C Short time rating for 2 sec Magnetising current at Vk/2 Accessibility Tank cover HV neutral : : : : NA : Tank cover LV neutral As Required 5P15-required VA Class PS, shall be as per calculation Less than 5 ohms Shall be as per selected Vk Shall be accessible without removing tank cover/active parts
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 Bushings Type Line bushings HV LV Porcelain Porcelain VOLUME - IV of V PAGE No. 70 of 272
24
25
26 27 i) ii)
Voltage class 12/7.2kV Current rating in Amps. Minimum Creepage Not less than 31 mm per kV of rated voltage of distance the bushing Short time As per transformer rating & insulation level Terminal arrangement Primary (HV side) Cable box with Air insulated Disconnect chamber Secondary ( LV side) To suit cable connection/ Busduct Radiators Detachable Transformer mounted on: Rollers/ flanged wheels If rollers: Fixed or removable Distance between rollers Axis parallel to HV-LV Axis perpendicular to HV-LV Flanged wheels (removable) Rail gauge (in both axis) Bi-directional rollers Removable Tenderer to indicate Tenderer to indicate Not applicable Not applicable
Neutral bushings HV LV Not Porcelain 2 nos. applicable 1.1 kV 1.1 kV As reqd.
iii)
If distribution transformer rating is 1000kVA and above busduct shall be considered 2.4.1.2 Fittings & accessories i. 150mm dial type OTI and WTI with max. reading pointer and with 2 sets of independently adjustable potential free N.O contacts for alarm and tripping.
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 ii. iii. iv. v. vi. VOLUME - IV of V PAGE No. 71 of 272
Double float buchholz relays with potential free alarm and trip contacts and isolating valves on both sides. Double diaphragm explosion vent. Dehydrating breather with silica gel and oil seal. Radiators with top & bottom stop valves & drain and air release plugs. Conservator with sump and drain valve with cover plate and oil filling hole with cover plate, oil level indicator and MOG with alarm contact. Marshalling box. Air release plug on tank cover. Valves with cover plates a). b). c). d). Top & bottom sampling valves Top & bottom filter valves Drain valve Residual drain plug
vii. viii. ix.
x. xi.
Jacking pads and towing lugs Lifting lugs a). b). c). For tank cover For core and winding For complete transformer with oil
xii. xiii. xiv. xv.
Grounding pads Rating & diagram plates, identification plate Rollers or flanged wheels as specified Inspection opening with cover Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 Paint shade Paint shade RAL 7032 Paint shade 692 as per IS 5 (For lighting transformer) Type tests to be conducted or certificates to be submitted in line of conducting test. 2.4.2 TECHNICAL SPECIFICATION FOR DISTRIBUTION (6.6/0.433kV & 11/0.433kV)/ CONVERTER DUTY TRANSFORMER (6.6/0.72kV & 11/0.72kV)/ LIGHTING TRANSFORMER (6.6kV / 230 V &11kV / 230 V) General This specification covers design, manufacture, inspection and testing at manufacturer's/their sub- suppliers works, packing and forwarding, delivery at site storage, erection, testing and commissioning of distribution transformers conforming to this specification and enclosed design criteria. Tenderer shall furnish data of the equipment offered along with the tender as required under questionnaire. Tenderer shall also indicate deviation if any from this specification, in the offer. Transformer rating and over loading Transformers shall be capable of delivering the rated current at a voltage equal to 105 percent of the rated voltage without exceeding the temperature limits specified for oil, winding and hot spot. Transformers shall operate satisfactorily without injurious heating at rated KVA, at any voltage with in 10% of the rated voltage of the particular tap. Transformer shall be designed for 50 Hz 5% unless otherwise specified. Transformers for two or more limits of voltage or frequency or both shall operate satisfactorily at its rated KVA with out injurious heating under all the rated conditions of voltage or frequency or both provided an Rev. 0 VOLUME - IV of V PAGE No. 72 of 272
2.4.2.1 2.4.2.1.1
2.4.2.1.2 2.4.2.1.3 2.4.2.2 2.4.3.1.1
2.4.3.1.2
2.4.3.1.3
NMDC LIMITED
MECON LIMITED

increase in voltage is not accompanied by decrease in frequency. 2.4.3.1.4 Transformers shall be suitable for over loading as per IS: 6600. Unless specified 0otherwise On-load tap changer/off circuit taps switch, terminal bushings, other auxiliary components/equipments shall be designed for maximum permissible overloading. Short time over loading to the extent of 50% shall be considered for this purpose, for all transformers, unless specified otherwise. Transformers rating shall be selected considering 20 % extra over the actual capacity for future shall be considered. Since downhill conveyor is ~4900 m long, adequate number of booster transformers shall be considered to cater to large number of welding receptacles & lighting in the conveyor gallery, through PDBs/LDB. Transformer rooms shall be sized to provide 1.25 M clearance on all sides of the transformer. Further, grill type-rolling shutters to be provided for transformers Hot spot temp specified in the data sheet shall be based on design ambient temp. Short circuit with stand capability Transformers shall be capable of withstanding thermal and mechanical stresses during 3 phase, line to line, double line to earth and line to ground dead short circuits at the transformer terminals, for a period specified, without any injury. Temp. of the windings prior to the short circuit shall be considered as max permissible value in the normal operation. For this purpose, infinite supply system and solidly earthed systems shall be considered.
2.4.3.1.5
2.4.3.1.6
2.4.3.1.7
2.4.3.1.8 2.4.2.3 2.4.2.3.1
2.4.2.3.2
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 2.4.2.4 2.4.2.4.1 Vibration and noise level Design and manufacture of transformer shall be such as to reduce noise and vibration level. The noise level shall not be more than 5 dB above NEMA standard publication TR-1 or as specified. Harmonics The transformer shall be designed with particular attention to the suppression of harmonics, especially the third and fifth. Flux density The max. flux density in any part of the core and yokes, at normal voltage and frequency, shall be such that the flux density under over voltage condition as per applicable clause of specification. This shall not exceed the max permissible values for the type of laminations used and core construction adopted. Transformer shall be designed to withstand the following over fluxing conditions. 110% of max. flux density continuous (corresponding to rated voltage.) 140% for 5 seconds and 125% for 1 minute. Magnetic circuit The cores shall be constructed from high grade, low loss, high permeability cold rolled non-ageing grain oriented silicon steel laminations. Thickness of laminations shall be 0.3 mm or less. Surface insulation of laminations shall be rust resistant and have high inter laminar resistance. Insulation shall withstand annealing temperature as high as 850 degrees centigrade. The insulation shall be resistant to the action of hot oil. The insulation structure for the core to bolts and core to clamp plates shall be such as to withstand a voltage of 2000V AC for one minute. Rev. 0 VOLUME - IV of V PAGE No. 74 of 272
2.4.2.5 2.4.2.5.1
2.4.2.6 2.4.2.6.1
2.4.2.6.2 2.4.2.6.3
2.4.2.7 2.4.2.7.1
2.4.2.7.2
2.4.2.7.3
NMDC LIMITED
MECON LIMITED

Whenever the CRGO sheets are punched or sheared into laminations, laminations shall be annealed in a non-oxidizing atmosphere to relieve stresses and restore the original magnetic properties of CRGO sheets. The laminations shall be free of all burrs and sharp projections. The design of magnetic circuit shall be such as to avoid static discharges, development of short circuit paths with in itself or to the earthed clamping structure and production of flux components at right angles to the plane of the laminations, which may cause local heating. Oil ducts shall be provided where necessary to ensure adequate cooling. The winding structure and major insulation shall not obstruct the free flow of oil in such ducts. All steel sections used for supporting the core shall be shot or sand blasted after fabrication. The finally assembled core and coil assembly shall be rigidly fixed to the tank to avoid shifting during transport, handling and short circuits. Adequate provision shall be made for lifting the complete core and coil assembly. The supporting framework of the cores shall be so designed as to avoid the presence of pockets, which would prevent complete emptying of the tank through the drain valve, or cause trapping of air during filling. Windings Transformers shall be suitable for isolated/non- effectively earthed neutral system as specified. The coil clamping arrangement and the finished dimensions of any oil ducts shall be such as not impede the free circulation of oil through the ducts. The windings and connections of all transformers shall be braced to withstand shocks, which may occur during transport or due to short circuits, repeated peak loads and other transient conditions during service.
2.4.2.7.5
2.4.2.7.6
2.4.2.7.7 2.4.2.7.8
2.4.2.7.9
2.4.2.8 2.4.2.8.1 2.4.2.8.2
2.4.2.8.3
Rev. 0
NMDC LIMITED
MECON LIMITED

Windings shall be subjected to a shrinkage treatment before final assembly, so that no further shrinkage occurs during service. Adjustable device shall be provided for taking up any possible shrinkage of coils in service. The conductors shall be transposed at sufficient intervals in order to minimise eddy currents and equalise the distribution of currents and temperature along the windings. Coil clamping rings shall be of steel or of suitable insulating material. Axially laminated material other than bakelised paper shall not be used. Completed core and winding assembly shall be dried in full vacuum to eliminate presence of moisture. After drying process, the full assembly shall be impregnated with oil immediately. No strip conductor wound on edge shall have a width exceeding six times its thickness. The winding material shall be copper. Windings shall not have sharp bends, which might damage insulation and/or produce dielectric stresses. Coil shall be supported using dried and high-pressure compressed wedge type insulation spacers at frequent intervals. All insulating materials used shall be compatible with transformer oil, under all service conditions. All threaded connections shall be locked. Leads from the winding to the terminal board and bushings shall be rigidly supported to prevent injury during short circuits/vibration. Permanent current carrying joints in the windings and leads shall be welded or brazed. Clamping bolts for current carrying parts inside the transformer shall be compatible with oil under all service conditions specified, to be lifted by cranes or jacks, transported by road, rail or water without over straining any joints and without causing subsequent leakage of oil Rev. 0
2.4.2.8.5
2.4.2.8.6
2.4.2.8.7
2.4.2.8.8 2.4.2.8.9 2.4.2.8.10 2.4.2.8.11
2.4.2.8.12 2.4.2.8.13
2.4.2.8.14 2.4.2.8.15
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 2.4.2.9 2.4.2.9.1 Tap switch Tappings as specified shall be provided on the higher voltage winding of each transformer and shall be arranged so as to maintain as far as possible the electromagnetic balance of the windings. Transformer with off circuit tap changer shall be provided conforming to the specification. Oil All transformers and all associated oil filled equipment shall normally be supplied along with first filling of oil and 10% excess quantity of oil shall also be supplied in non-returnable drums. The oil shall conform to IS-335. Transformer cooling Radiators: Transformers shall have detachable type directly mounted radiators unless specified otherwise. Bolted, gasketed, and flanged connection shall be used for connecting the radiators to the tank. All radiators shall be detachable type and shall be provided with machined or ground flanged inlet and outlet branches. Separately mounted radiator banks if specified shall be connected to the tank by flanged pipe connections. It shall be possible to withdraw the transformer from service position without disturbing radiators. Shut off valves blanking plate, drain plug, air release vents, shall be provided in each interconnecting pipe. Accessories The following accessories shall be provided for each Radiator / Radiator bank Top and bottom shut off valve and blanking plate: i. ii. iii. 19 mm dia bottom drain plug and 19mm dia top filling cum air release plug. Lifting lugs Thermometer pockets in the inlet and out let pipes with thermometers fitted, (In case of separately Rev. 0 VOLUME - IV of V PAGE No. 77 of 272
2.4.2.9.2 2.4.2.10 2.4.2.10.1
2.4.2.11 2.4.2.11.1 2.4.2.11.2
2.4.2.11.3
2.4.2.12 2.4.2.12.1
NMDC LIMITED
MECON LIMITED

iv. 2.4.2.13 2.4.2.13.1 Tank
mounted radiator banks) Top and bottom filter valves for each separately mounted radiator bank.
Tank shall be made from high quality low carbon steel and shall be oil tight welded construction. Conventional type tank construction should be used upto 31.5 MVA rating. The tanks of all transformers shall be complete with all accessories and shall be designed so as to allow the complete transformer filled with oil, where specified, to be lifted by cranes or jacks, transported by road, rail or water without over straining any joints and without causing subsequent leakage of oil. Fully assembled transformer together with its radiators, conservator and other fittings shall withstand for one hour, a pressure corresponding to twice the normal head of oil or to the normal pressure plus 35 kn/m2 (5 lb/in sq) which ever is higher, measured at the base of the tank. The permanent deflection after the excess pressure has been released, shall not exceed the following. Horizontal length of flat plate ( mm ) up to and including 750 751 to 1250 1251 to 1750 1751 to 2000 2001 to 2250 2251 to 2500 2501 to 3000 above 3000 permanent deflection in mm 5.0 6.5 8.0 9.5 11.0 12.5 16.0 19.0
2.4.2.13.2
2.4.2.13.3
: : : : : : : :
Rev. 0
NMDC LIMITED
MECON LIMITED

The main tank body excluding tap-changing compartment, coolers shall be capable of withstanding following vacuums. Voltage rating Vacuum pressure /sqm Up to Up to 1.6 34.7 72 kV Above 1.6 68.0 up to 20 Above 20 100.64 MVA gauge MM of Hg kn. 250 500 760
2.4.2.13.5
The base of each tank shall be so designed that it shall be possible to move the complete transformer unit by skidding in any direction without injury when using plates or rails. Tank cover shall be of adequate strength and shall not distort when lifted. Inspection openings shall be provided as necessary to give easy access to bushings, testing earthing connection without removing tank cover. At least two openings of adequate size shall be provided at each end of the tank. Inspection covers shall have lifting arrangement and weight shall not exceed 25 kg. Tank covers shall have pockets for bulbs of oil and winding temperature indicators. Wherever specified, thermometer pockets shall have captive screwed top to prevent ingress of water. The pockets shall be located in the position of maximum oil temperature and it shall be possible to remove the instrument bulbs without lowering the oil in the tank. Lifting and haulage facilities Lifting lugs shall be suitable for lifting the transformer with oil. Minimum of 4 jacking lugs, in accessible positions shall be provided to raise or lower the complete transformer with oil using hydraulic or screw jacks. Minimum height of the lugs above base shall be 300 mm excluding under base dimensions if detachable, for transformers up to 10t weight and 500 mm for transformers above 10 t. Transformer shall be provided with detachable, bi-directional flanged wheels or rollers as specified. Means shall be provided for locking the 90 degrees swivel movements in positions parallel to and at right angles to the longitudinal axis of the tank. Wherever specified, flanged wheels shall be provided suitable for use on gauge track as specified. Rev. 0
2.4.2.13.6
2.4.2.13.7
2.4.2.14 2.4.2.14.1
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 2.4.2.15 2.4.2.15.1 Terminations Terminations as indicated in the specification shall be provided. i. ii. 2.4.2.15.2 HV side /LV side Cable box VOLUME - IV of V PAGE No. 80 of 272
Cable Box Where cable boxes are specified, the cable box shall be airinsulated type suitable for the type and number of cables specified. The size of cable box shall meet the minimum dimensional requirement of cable termination. Double compression type brass cable glands and tinned copper lugs shall be supplied. Cable boxes shall be air-insulated type with clearances as specified. Further, air insulated disconnecting chamber shall be provided with inspection opening. Transformer may thus be withdrawn from its pen without disturbing cable connection. The gland plate shall be bolted type and shall be sufficiently big to remove the trifurcated cable from the cable box, without damaging the terminations.
2.4.2.15.3
Cable sealing kits of specified type along with associated accessories like stress relieving cones, insulating tapes, trifurcating boot, HT insulating paste etc. shall be supplied along with transformer. Bushings Electrical characteristics of bushings shall be in accordance with IS-3347 and IS-2099. Minimum rated current of the line end bushing shall be 1.5 times the rated current of the corresponding winding. Where repeated peak loads are specified, bushing rating shall be selected accordingly. Oil communicating type bushings shall be used for voltage ratings upto 36KV. Oil used in bushings shall conform to IS-335. Oil gauge shall be provided when oil in bushings is not in communication with that in the transformer. Rev. 0
2.4.2.16 2.4.2.16.1
2.4.2.16.2
2.4.2.16.3
NMDC LIMITED
MECON LIMITED

Clamps and fittings made of steel or malleable iron shall be hot dip galvanized. Bushings rated more than 400A shall have non-magnetic clamps and fittings only. When bushing CTs are specified, the bushing shall be so arranged that it can be removed without disturbing the current transformers, secondary terminals and connections or pipe work. Clearances in air between live conductive parts and live conductive part to earthed structure shall be as follows: Nominal system Impulse test Clearances voltage voltage kVP Phase to Phase to phase mm earth mm 11kV (E) 75 240 140 6.6 kV (UE) 0.433kV 40 2.5 90 25.4 25.4 90 19 19
2.4.2.16.5
2.4.2.16.6
0.230 kV 2.5 (Lighting transformer) 2.4.2.16.7 2.4.2.16.8
For altitude exceeding 1000m above sea level, the clearance should be increased by 3% for every additional 300m. Bushings shall be suitable for atmosphere present in the place of installation. Total creepage distance shall not be less than 31 mm/kV of highest system voltage and 50% of this shall be protected creepage distance. Higher creeepage distances shall be provided for polluted atmosphere, as specified in data sheet. Bushing current transformer Where bushing CT's are specified, the same shall conform to the specification indicated in the data sheet. Hot spot temp. of CT's shall be as specified for transformers. It shall be possible to remove the CT's at site, without opening the transformer tank cover/active part.
2.4.2.17 2.4.2.17.1
2.4.2.17.2
Rev. 0
NMDC LIMITED
MECON LIMITED

All secondary leads, including tappings shall be brought to a weatherproof terminal box. Rating and terminal marking plate of the CT shall be screwed to the terminal box. CT's shall be wired from the terminal box to the marshalling box. Conservator Conservator shall be located in such a position as not to obstruct the electrical connections to the transformer. The conservator volume shall be sufficient to maintain the oil seal from ambient temp. of 5 degrees centigrade to oil temp. of 90 degrees centigrade, with oil level varying within min. and max. levels the extension shall be for at least 25 mm. 150 mm dial type magnetic level gauge with alarm and trip connection shall be provided. In addition, prismatic type oil level gauge with min. and max. levels marked shall also be provided. Taps or valves shall not be fitted to the oil gauge.
2.4.2.18 2.4.2.18.1
2.4.2.18.2
2.4.2.18.3
Drain valve shall drain completely. one end of conservator shall be bolted into position so that it can be removed for cleaning purposes. If the sump is formed by extending the feed pipe into the conservator vessel shall be provided.
A silica gel breather with inspection window and oil seal shall be mounted at 1.4 meter above transformer base and connected to the conservator. Buchholz relay All transformers shall be provided with double float buchholz relay fitted in the pipe connecting the tank and the conservator. Pipe shall be 25 mm dia. for transformers up to and including 1000 KVA, 50 mm for ratings from 1001 to 10,000 KVA. 80 mm for ratings above 10 MVA. Pipe shall be arranged at a rising angle of 3 to 9 degrees to the horizontal, upto the buchholz relay. Valves shall be provided on either side of relay after providing necessary length of straight pipes. The relay shall have petcocks at the top and bottom, drain plug, inspection windows, calibrated scale to indicate gas present, built in test facility and terminal box with oil tight brass gland. The relay shall have electrically separate; potential free self reset contacts for alarm and trip. Contacts shall be rated to make, carry & break 0.5 Amp. at 220 V DC. Rev. 0
2.4.2.18.4
2.4.2.19 2.4.2.19.1
NMDC LIMITED
MECON LIMITED

The contacts shall be wired to marshalling box. The relay shall conform to EE make type OBGM unless specified otherwise. 2.4.2.20 2.4.2.20.1 Valves and connections All valves shall be of gun metal/cast steel, full way type with internal screw and shall be opened by turning counter clockwise when facing the hand wheel. All valves opening to atmosphere shall be fitted with blank flanges. Means shall be provided for padlocking the bottom valves in open and closed position. All valves shall be provided with an indicator to show clearly the position of the valve. Oil sampling valves shall be provided at top and bottom of the main tank and these shall not be fitted on the filter valves. All transformers shall have bottom drain valve, top and bottom filter valves suitable for connecting to oil filtration unit. Joints and gaskets All gaskets used for making oil tight joints shall be of proven material such as granulated cork-bonded synthetic rubber or synthetic rubber gaskets compatible with oil. Explosion vent/pressure relief device Pressure relief device provided shall be of sufficient volume for rapid release of any pressure that maybe generated within the tank and which might result in damage to the equipment. The device shall operate at a static pressure of less than the hydraulic test pressure for transformer tank. Means shall be provided to prevent ingress of rainwater. The relief device shall be mounted on the main tank and if on the cover shall be fitted with skirt projecting 25mm inside the tank and of such a design to prevent gas accumulation. If diaphragm is used, it shall be of suitable material and situated above max oil level. The equaliser pipe connecting the pressure relief device and conservator shall be provided for relieving or equalising the pressure in the pressure relief device.
2.4.2.21 2.4.2.21.1
2.4.2.22 2.4.2.22.1
2.4.2.22.2
2.4.2.22.3 2.4.2.22.4
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 2.4.2.23 2.4.2.23.1 Thermometers 150 mm dial type top oil, thermometer and winding temperature indicator for the LV windings shall be provided for all transformers. Further an additional winding temperature indicator for Automatic Control of Blowers shall be provided. Each thermometer shall have potential free N.O alarm contact and trip contact. No multiplying contactor / relay shall be used. Temperature setting of each contact shall be independently adjustable at site. A manual reset type max. temp indicator shall be provided for each thermometer. Each winding temp indicator shall have temp. sensing element, image coil and bushing mounted current transformer. Each thermometer shall be provided with remote temp. indicator along with associated accessories. The remote temp. indicators shall be mounted on RTCC panel. All contacts shall be rated to make 0.5A(min) and break 0.2 A (min) at 220 DC. All contacts shall be wired to marshalling box. In addition to the above winding temperature indicators /controllers shall be provided, for control of forced cooling system of the transformer. 150 mm dial type top oil, thermometer shall be provided (For lighting transformer only) Local Control Boxes Sheet steel of 3 mm thick/cast aluminium enclosed, transformer mounted, outdoor weather proof marshalling box conforming to IP-55 enclosure shall be provided for auxiliary equipment of the transformer. This may be provided with double door arrangement for outdoor applications. Marshalling box shall accommodate control and protection equipment of transformer, temp. indicators, bushing CT secondary terminals, terminal blocks, etc. Rev. 0 VOLUME - IV of V PAGE No. 84 of 272
2.4.2.23.2
2.4.2.23.3
2.4.2.23.4
2.4.2.23.5
2.4.2.23.6
2.4.2.23.7 2.4.2.24 2.4.2.24.1
2.4.2.24.2
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 2.4.2.24.3 2.4.2.24.4 VOLUME - IV of V PAGE No. 85 of 272
Space heaters with temp. controller, illuminating lamp and toughened glass windows shall be provided. Mechanical indications, temperature indicators, brass glands for terminating cables etc. shall be provided in each box. All auxiliary equipment, protection and signalling contacts shall be wired to these transformer-mounted cabinets. Internal Earthing arrangements All metal parts of the transformer with the exception of individual core laminations, core bolts and associated individual clamping plates shall be maintained at some fixed potential by earthing. Core clamping structure earthing The top main core clamping structure shall be connected to the tank body by a copper strip of adequate cross section. The bottom clamp structure shall also be connected to the tank by one or more of the following methods. i. ii. iii. By connection through vertical tie rods of the top structure. By direct metal-to-metal contact with tank base maintained by the weight of the core and windings. By connection to the top structure on the same side of the core as the main earth connection to the tank.
2.4.2.25 2.4.2.25.1
2.4.2.25.2 2.4.2.25.3
2.4.2.25.4 2.4.2.25.5
Earthing of coil clamping rings. Where coil-clamping rings are metal at earth potential, each ring shall be connected to the adjacent core clamping structure on the same side of the transformer as main earth connections. Earthing of magnetic circuit: Magnetic circuit shall be earthed at one point only. This shall be brought out of the tank cover through a suitably rated bushing and earthed through a removable link. This bushing shall be clearly identified with inscription plate. When the magnetic circuit is divided into pockets by cooling ducts parallel to the planes of laminations or by insulating material above 0.25 mm thick, tinned copper strip bridging pieces shall be inserted to maintain electrical continuity between pockets. Rev. 0
2.4.2.25.6
NMDC LIMITED
MECON LIMITED

Earthing of bushing CT's: Where Bushing CT's are provided, secondary winding shall not be earthed inside. Both ends of winding shall be fully insulated and terminated out side in weatherproof terminal box. one end of CT secondary shall be earthed in the terminal box. Magnetic core of CT's shall be earthed. Size of Earth connection: All earth connections, except those from the individual coil clamping rings shall be done by copper conductor with min cross-section of 80 sq. mm copper. Connections inserted between laminations of different sections of core shall not be less than 20 sq. mm. Fittings and Accessories Transformer shall be provided with fittings and accessories as specified in the data sheet. SPECIAL REQUIREMENTS TRANSFORMER FOR CONVERTER DUTY
2.4.2.25.8
2.4.2.26 2.4.2.26.1 2.4.2.27
The transformers intended for connecting to DC drives shall conform to the minimum requisites stipulated here, in addition to the general requirement: 2.4.2.27.1 The coils and supports must be rigid enough to withstand the short circuit force generated during overloads. The windings and insulation system shall be so designed to withstand the different nature of voltage distribution. Since the transformers are intended to be connected directly to converters, the inductance shall be chosen to limit the high di/dt to provide protection of semiconductor devices. The windings and connection shall be braced to withstand shocks, which may occur due to switching, short circuits and other transient conditions. The value of flux density shall be selected to avoid any saturation during operating conditions. The leakage flux produced by harmonics shall not be so high as to cause high value of stray losses. Rev. 0
2.4.2.27.2
2.4.2.27.3
2.4.2.27.4 2.4.2.27.5
NMDC LIMITED
MECON LIMITED

For converter duty transformers both secondary windings shall have the similar ratings of primary winding (ie. If primary is 2500kVA then each secondary shall have the rating of 2500kVA) Core and windings: i. An electrostatic shield shall be placed between primary and secondary windings to minimize the mutual capacitance effect between the windings. A magnetic shield shall be provided between primary and secondary windings to suppress the harmonics generated in the converter circuit and for equipment protection purposes. Windings may be either copper, aluminium or mixed. LV windings preferably Foil windings (mechanically strong), which is mandatory in transformers for VSD duty.
2.4.2.27.7
ii.
iii.
2.4.2.27.8 2.4.2.27.9
Transformer shall suit for Class-E loading cycles as per IS: 4540. PROTECTION AND MONITORING For conservator transformers: i. ii. iii. iv. v. Thermometer with alarm and trip contacts Oil level indicator Pressure relief device Buchholz relay Silica gel breather
2.4.2.28 2.4.2.28.1
Tests The transformers shall be tested as per approved Quality Assurance Plan in MECONs format.
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 2.4.3 2.4.3.1 2.4.3.1.1 VOLUME - IV of V PAGE No. 88 of 272
Dry type Booster Transformers (for Lighting loads & welding power receptacles load) TECHNICAL SPECIFICATION The lighting Transformer shall be copper wound dry type natural air-cooled suitable for indoor and continues duty as per IS: 11171-1985 with type of enclosure conforming to IP 23. Insulation: Class F with temperature rise limited to class B.
2.4.3.1.2
The tolerance on losses, impedance, temperature rise etc. shall be as specified in IS: 2026 and the same shall be indicated and submitted along with the offer. The connection shall be delta primary and star secondary, star point solidly earthed. The transformer shall be capable of satisfactory operation and its rated output on all taps and at any voltage, which does not vary from its rated primary voltage by more than 5%, and at a declared frequency. 3 phase, 50Hz dry type transformer adequate rating (not less than 40 kVA) shall be provided for feeding the lighting loads of conveyor gallery, outside area, transfer house and near by areas. Transformers rating shall be selected considering 20 % extra over the actual capacity for future use. 3 phase, 50 Hz dry type transformer adequate rating (not less than 40 kVA) shall be provided for feeding the Welding receptacles of conveyor gallery, outside area, transfer house and near by areas. Transformers rating shall be selected considering 20 % extra over the actual capacity for future use. Transformer rooms shall be sized to provide1.25 M clearance on all sides of the transformer. These transformers shall be placed at frequent intervals of downhill conveyor in a separate room
2.4.3.1.3 2.4.3.1.4
2.4.3.1.5
2.4.3.1.6
2.4.3.1.7
It shall be designed to withstand thermal and mechanical stress of short circuit without any injury. MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD Rev. 0 2010, MECON Limited. All rights reserved.
2.4.3.1.8
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 2.4.3.1.9 2.4.3.1.10 2.4.3.1.11 VOLUME - IV of V PAGE No. 89 of 272
Particular attention shall be given to the suppression of harmonics. Core of each transformer shall be made of cold rolled grain oriented (CRGO) high permeability sheet steel. Insulation of windings and connection shall not deteriorate when the transformer is operated continuously at its specified rating. The inter-turn and inter-coil insulation shall be so designed that the dielectric stress is uniformly distributed throughout the winding under all conditions. All test in accordance with relevant IS: 2026 shall be carried out at works and certificate to that effect in duplicate shall be submitted to Owner/ Consultant. Insulation resistance between Phases, Phase to Earth and between primary & secondary shall not be less than 5 MOhms (five Mega-Ohms). It shall be the responsibility of the Tenderer to guarantee this value. The transformers shall be provided with cable boxes at primary and secondary The transformer to be provided with the following: Set of earthing terminals Set of lifting lugs Rating plate and connection diagram engraved on a brass plate Double compression type brass cable gland.
2.4.3.1.12
2.4.3.1.13
2.4.3.1.14
2.4.3.1.15 2.4.3.1.16
2.4.3.1.17
Nameplate shall have manufacturers name, serial number, rating etc., and shall be fixed permanently to each transformer in a convenient position. Order number of owner with data should been engraved on the plate permanently fixed to each transformer. The transformer enclosure shall conform to IP 23. Hot spot temperature rise shall be within allowable limit of the class of insulation used. Rev. 0
2.4.3.1.18 2.4.3.1.19
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 2.4.3.1.20 2.4.3.2 2.4.3.2.1 2.5 2.5.1 Input voltage Incoming feeder VOLUME - IV of V PAGE No. 90 of 272
Lifting lug shall be provided to facilitate transport and erection. Tests The transformers shall be tested as per approved Quality Assurance Plan in MECONs format. VARIABLE VOLTAGE VARIABLE FREQUENCY DRIVES Design Criteria : 690V, 3 phase for DHC (723) & reversible conveyors (727) 415V, 3 phase for belt feeders : 690V ACB shall be considered for both DHC & reversible conveyor drives 415V MCCB for belt feeder +10%, -15% : 50 Hz 5% : 45 deg C : 0 to Input voltage, 3 phase : 0.01 Hz : 150% for 1 minute/10 minute (constant torque) 110% for 1 min/10 min (squared torque) : Adjustable to 15 kHz : Adjustable : Adjustable : One no for speed reference : Two nos. for speed and current : As required : As required : Required : Required, regenerative energy feed back to mains for regenerative conveyors.
Voltage Variation Input frequency Ambient temperature Output voltage Resolution Short time overload Capacity Switching frequency Acceleration time Deceleration time Analog inputs Analog outputs Digital outputs Digital inputs Torque boost at start Energy saving mode
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 Converter Inverter Equipment VOLUME - IV of V PAGE No. 91 IGBT(Active front End) bridge converter for AC/DC. DC link circuit with reactor/capacitor IGBT bridge for Inverter for DC/AC. Harmonic transformer. Main PLC to take care of interlocking and sequencing etc. of 272
Sizing Of The Drives
Class of Protection Cable/ Busduct entry
Total Harmonic Distortion 2.5.1.1 2.5.1.2
Sized to the next higher rating of the derived current value considering heavy duty application and all margin aspects. IP 42 For incoming top entry shall be considered for busduct and bottom entry for cables. All outgoings shall be bottom entry. As per IEEE 519
VVVF drives shall be located in AC room. However the drives shall be rated for continuous duty at 45 0C DOL By-pass arrangement with contactors over load relay for VFD panels shall be provided (for all drives other than Down Hill conveyor drives so that drive can start and run even without VFD. All VFDs shall be provided with serial communication interface (for all parameters) with plant PLC. Communication link shall be RS 485 Modbus / Profibus protocol. PLC shall work as a master, while VFDs shall take I/P signal from PLC and shall wok as slaves. Load sharing of drives(in case of multi- drives) shall be controlled by both PLC & VFDs. PLC shall provide all torque reference to the VFDs
2.5.1.3
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 2.5.2 2.5.2.1 VOLUME - IV of V PAGE No. 92 of 272
Specific Requirements of DHC (723) & Reversible Belt Conveyor (727): For the Downhill conveyor system (723), a multidrive configuration (Active Front End Technology) with following distinct sections shall be considered: i. Supply unit 2 Nos 100% redundant (of rating equal to sum total of all working drive unit in case of multiple drive units )The unit/s shall be IGBT with a main switch, filter & converter of rating commensurate with sum total rating of working units. Common DC Bus section Drive unit(Inverter): Individual drive units (regenerative 4-qudrant for down hill conveyor motor), preferably with built in PLC & smoothing capacitors connected to common DC bus. Braking & control unit including chopper resistor as required. Also refer clause 1.12.1. spare inverter: 100% redundant spare inverter truck (in a dummy panel without any AC/DC busbar & wiring) They shall be provided as a continuous lineup of panels with incoming ACB. Power supply to the line-up shall be provided from the MCC in Tenderers scope of supply Down Hill Conveyors shall have Load sharing feature between the drives at Tail end. Necessary software, Hardware & communication cables in this regard shall be included.
ii. iii.
iv. v.
vi.
2.5.2.2
For the Reversible conveyor (727), a configuration (Active Front End Technology) with following distinct sections shall be considered: i. Supply unit: 2 Nos 100% redundant IGBT supply unit shall be considered. The unit/s shall be IGBT with a main switch, filter & converter.
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 ii. iii. Common DC Bus section Drive unit(Inverter): 2 Nos drive units (regenerative 4-qudrant), preferably with built in PLC & smoothing capacitors connected to common DC bus. Braking & control unit including chopper resistor as required. Also refer clause 1.12.1. VOLUME - IV of V PAGE No. 93 of 272
iv.
Typical block diagram representing the arrangement of VVVF drives for DHC (723) & reversible conveyor (727) shall be as shown in the tender drawing No, MEC/01/Q6DH/KIOP/II/219/TS. 2.5.2.3 Interface Between VFD and Braking System (For DHC (723)& For Reversible Belt Conveyor (727) The interface between the VFD and braking system may be realized through the plant PLC. Necessary signals exchange between plant PLC and the Braking system PLC shall be achieved as per the design requirement and suitable reference signals shall be generated to VFD PLC from Plant PLC 2.5.3 2.5.3.1 2.5.3.1.1 VFD PANEL DESIGN CONSTRUCTIONAL FEATURES The frequency converter panels shall be sheet steel enclosed, suitable for floor mounting, self standing, single front, non-compartmentalized, accessible & maintainable from front. The minimum thickness of sheet steel shall be 1.6 mm for non-load bearing members and 2.0 mm with stiffeners, if required, for load bearing members. The enclosure class of protection shall be IP-42. The final paint shade shall be RAL 7032. Painting shall be epoxybased. Doors and covers shall be provided with synthetic/ neoprene rubber gaskets. Door shall be of hinged construction with concealed hinges. Rev. 0
2.5.3.1.2
2.5.3.1.3 2.5.3.1.4
NMDC LIMITED
MECON LIMITED

Kick guard / base plate of ISMC 75, painted black, shall be provided at the bottom of all cubicles. Lifting and earthing lugs shall be provided. Three phase busbars shall be provided. Bus bars shall be of Aluminium E91E grade. The allowable temperature rise of busbars shall be 40 deg C over ambient of 45 deg C. Continuous earth bus shall run through out the length of the board. Panels shall be suitable for bottom cable entry. It shall be possible to extend the panels at both ends. COMPONENTS FREQUENCY CONVERTERS i. Frequency converter unit shall mainly consist of a three-phase rectifier bridge, D.C. Link with capacitors/ reactor, inverter bridge, microprocessor based control system & capacitor pre-charging circuit. DC chopper and resistors connected at DC link for emergency electrical braking. Frequency converters shall be suitable for constant torque/squared torque applications as required. The frequency converter shall be 6-pulse vector control type using IGBT's for the inverter bridge operating on pulse width modulation (PWM) principle. 12-pulse vector control PWM VFD with power loss ride through & encoder loss ride through facilities shall be used for regenerative downhill conveyors. Each frequency converter shall be provided with a digital local control station to be mounted on the cubicle door and an analog control station to be mounted near the motor. Specifications for these control stations are included elsewhere in this document. Rev. 0
2.5.3.1.8 2.5.3.1.9 2.5.3.2 2.5.3.2.1
ii. iii. iv.
v.
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 vi. VOLUME - IV of V PAGE No. 95 of 272
Each frequency converter shall be equipped with thermistor relay. Frequency converters shall be provided with in addition, output contactors, braking resistors etc if required. Frequency converters shall be provided with RS-485 serial bus interface profibus for control and monitoring by PLC. Frequency converter protective features: a. Converter b. Motor Thermal overload over temperature using thermistor relay stall loss of phase/phase guard Current imbalance Critical frequency lock out. shall have the following Self-diagnostic for microprocessor faults Over current instantaneous trip Short circuit protection for inverter Adjustable current limit Earth fault protection Over temperature at heat sink d.c. bus under voltage d.c. bus over voltage shall have the following
vii.
viii.
ix.
Frequency converter operational features: a. b. c. d. e. f.
Adjustable acceleration/deceleration time Auto restart Parameter lock Constant speed option Power loss ride through Torque boost at start (adjustable) Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 g. h. i. j. k. l. VOLUME - IV of V PAGE No. 96 Adjustable switching frequency Programmable U/F curve Programmable digital inputs/outputs Programmable inputs/outputs analog (4-20 mA) of 272
Indications on cubicle for "converter ready", "converter running", "converter fault". Mushroom headed press to lock twist to release Emergency Stop push button for each drive on cubicle door. Analog inputs/outputs of the frequency converter shall be galvanically isolated type. Digital outputs shall be potential free type. Components for the same function and rating shall be of identical design and of modular construction to reduce the inventory. Each cubicle shall be provided with panel illumination lamp, panel space heaters and 15A, 3 pin socket with switch. 230V AC supply for this shall be obtained through separate control transformer with fuses on the primary and MCB at the secondary side. Auxiliary contactors for contact multiplication, indication, interlock, control etc., shall be mounted in the cubicle and shall be suitable for 110V AC. Control supply shall be obtained through a separate control transformer with fuses on the primary and MCB at the secondary side. Control transformers shall have one leg of secondary earthed and shall be provided with + / - 2.5 % and + / - 5 % primary tapings.
m. n. o.
p.
q.
r.
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 s. VOLUME - IV of V PAGE No. 97 of 272
Relays shall be provided for interfacing with plant PLC. These shall be provided with surge arresting devices across the coil. Incoming ACB feeder shall be provided with R, Y, B phase indication lamps, voltmeter with selector switch and ammeter with selector switch. Starters for auxiliary unit indicating motor space heater supply for motors rated 75 kW and above at 240 V AC shall be provided in the panel.
t.
u.
2.5.3.2.2
DIGITAL CONTROL STATIONS i. Digital control stations shall be totally sealed type with membrane switches and LED/LCD display unit. It shall normally be plugged into the cubicle board with possibility of detachment. The digital control station shall be provided with the following: a. b. c. d. e. f. START switch STOP switch Speed raise switch Speed lower switch Function/control/reset switches LED/LCD seven segment display unit
ii.
2.5.3.2.3
CONTROL PHILOSOPHY FOR VFDS Control of the frequency converter shall be possible from any one of the following three locations i. From PLC: This shall be through analog / digital signals. Following minimum digital / analog signals shall be input from PLC. a. b. c. PLC Start. Local enables. 4-20 mA speed reference. Rev. 0
NMDC LIMITED
MECON LIMITED

Following minimum digital / analog signals shall be input to PLC. a. b. c. d. e. Drive ready. Rrive run Drive trip Thermistor trip 4-20 mA signals for SPEED & CURRENT
Further PLC & VFD interface shall be through serial link as specified in Clause.2.5.1.3 ii. From drive cubicle through digital control station Digital control stations shall be totally sealed type with membrane switches and LED/LCD display unit. It shall normally be plugged into the cubicle board with provision of detachment. The digital control station shall be with the following minimum provision: a. b. c. d. e. f. iii. START switch STOP switch Speed raise switch Speed lower switch Function/control/reset switches ED/LCD seven segment display unit
From Local control station mounted near motor Following minimum signals shall be input from this control station to the VFD a. b. c. d. e. f. g. START STOP EMERGENCY STOP SPEED INCREASE SPEED DECREASE LOCAL/REMOTE SELECTOR Brake selector switch and individual brake ON/OFF PBs for local testing of brake for regenerative downhill conveyors only or as applicable. Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 h. VOLUME - IV of V PAGE No. 99 of 272
Indicating Lamps for ready to Start/ Run/ trip status.
Following signals shall be output from control station: a. b. c. 2.5.3.3 2.5.3.3.1 2.5.3.3.2 TESTS The VVVF Drives shall be tested as per approved Quality Assurance Plan in MECONs format. Site tests: i. ii. iii. iv. v. 2.6 2.6.1 Insulation Light load test Rated current test Checking of auxiliary devices Control system test LOCAL ENABLED for indication READY TO START for indication 4-20 mA signals for SPEED and CURRENT for meter indication.
LT MOTORS Design Criteria for Low Voltage Three Phase Squirrel Cage Induction Motors
DRIVEN EQUIPMENT DETAILS i) ii) Application Coupling type : To be indicated by Tenderer : Direct flexible / Rigid / Beltpulley : To be indicated by Tenderer : To be furnished by Tenderer : To be indicated by Tenderer
iii) Moment of inertia iv) Speed-torque characteristics enclosed v) Absorbed kW
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 MOTOR DETAILS To be indicated by Tenderer 415V +/-10% for motors upto 160 kW 690V +/-10% For VFD driven inverter duty motors for DHC (723) & reversible belt conveyor (727) Nominal Frequency 50 Hz 5% (Variable for Conveyor Motors through VFD) i) Design Ambient Temperature : 45 0 C ii) Enclosure a)Class of protection : For Indoor :IP 54 or better For outdoor:IP 55 or better with bolted canopy b)Hazardous Area Classification : As applicable iii) Class of insulation : Class F iv) Temperature rise above : Limited to class B design ambient v) Type of cooling : IC 411 (TEFC) vi) Duty type and designation : As per application vii) Starting requirements For continuous duty motors as specified below: a)Equally spread / hour : 6 starts b)Successive cold : 3 starts c)Successive hot : 2 starts viii) Method of starting : DOL / VFD, as per application ix) Mounting requirements : a)Shaft Orientation : Horizontal b)Mounting : Foot / Flange x) Speed As per application a) No. of poles : As per application b)Speed range (for VFD : As per application operation) xi) Terminal box a)Location of main TB (when : Separate for stator, RTD/ viewed from DE) thyristor, space heater: Preferably at top b)Rating of TB : 40 KA (0.25 secs) at 415V Application Nominal Voltage VOLUME - IV of V PAGE No. 100 of 272
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 Xii) Anti-condensation heaters xiii) Temperature elements a)Thermistors VOLUME - IV of V PAGE No. 101 of 272
: Required for motors rated 30 kW and higher. Additional TB to be provided. sensing :
: For DOL start, 6 nos. to be provided in series for ratings 30 kW and above to 75 kW (excluding 75kw) For VFD start 6 nos. to be provided in series for ratings 2.2 to 22 kW (both inclusive) b)Winding RTD : 6 nos. Pt-100 Simplex, 3 wire @ 2 / phase for DOL start for ratings 75 kW and above : 6 nos. Pt-100 Simplex, 3 wire @ 2 / phase for VFD start for ratings above 22 kW c)Bearing RTD's : 1 no Pt-100, Duplex 3 wire at each bearing for motors rated 75 kW and above Note: Additional TB to be provided for RTD/BTD xiv) Bearing type : Re-greasable ball / roller anti friction xv) Bearing insulation : On NDE side for motors rated 75 kW and above fed by VFD's xvi) Vibration Severity : Limited to Normal class as per IS: 12075(1987) xvii) Noise level : Limited to "Reduced sound Power as per IS: 12065 (1987) xviii) Final paint shade : As per approved GA drawings Note: Painting shall be epoxy resin based. xix) Torque a) Ratio of starting torque to : 1.6 minimum rated torque b) Ratio of pull out torque to : 2.5 rated torque c) Ratio of locked rotor : 6.0 current to rated current
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 xx) Over speed VOLUME - IV of V PAGE No. 102 of 272
xxi) Direction of rotation 2.6.2 2.6.2.1
: 1.2 times rated speed for 2 minutes. For crane duty motors 2000 rpm for 2 minutes. 1.3 times rated speed for 2 minutes. For 723 & 727 conveyor motors : Bi-directional
TECHNICAL SPECIFICATION LT MOTORS
2.6.2.1.1 Construction Features i. The stator frame and end shields shall be fabricated from cast iron of high quality conforming to IS: 210(1993), They shall be ribbed externally to maximise heat dissipation. The feet shall be integrally cast with the stator frame Bolted feet construction is not acceptable. The stator and rotor cores shall be of low loss, high permeability steel stampings duly varnished to reduce eddy current losses. The stampings shall be hydraulically pressed, keyed and clamped to ensure rigidity. The motor shaft shall be of cylindrical design made of high carbon steel. The cross section shall be chosen to provide high torsional strength and minimize deflection. The shaft shall be finely machined to ensure fit and eccentricity shall be minimized. Unless specified otherwise, the motor shall be with single shaft extension with slotted keyway. Motor shall be provided with half key. The motor shall be cooled by means of an external fan mounted on the rotor shaft. The fan shall be protected by a cowl, which shall be bolted to the stator frame. The fan shall be of cast iron preferably. The body of the fan shall be provided with 2 numbers, diametrically opposite drilled holes to enable removal of fan without breakage. The fan shall be designed to ensure low Rev. 0
ii.
iii.
iv.
NMDC LIMITED
MECON LIMITED

noise and adequate ventilation. The fan should be suitable for bi-directional rotation. v. The motor shall be provided with ball/roller bearings with grease lubrication. Greasing nipples and arrangement for drainage of excess/old grease shall be provided as a standard feature. Seals shall be provided to ensure that excess grease does not reach the windings. The L10 life of bearings shall not be less than 40000 hours under rated conditions. Bearings shall be suitable for bi-directional rotation. For vertical motors, NDE bearings shall be angular contact type and DE bearings shall be deep-grooved ball bearings type.
vi.
vii.
Anti-friction bearing housing shall be equipped with bearing lubrication fittings and grease plugs. Both, when not accessible, shall have stainless steel extension pipe fittings to allow regreasing of the bearings while the motors are in operation. All vertical motor bearings shall be capable of withstanding weight of the driven equipment rotating assembly, down thrust during the operation and up thrust during starting. These loads will be supplied by the driven equipment manufacturers
All terminal boxes shall be IP 55 or better The terminal box for motor shall be of cast-iron and shall be mounted on R.H.S when viewed from DE side. The terminal box shall be suitable for rotation in steps of 90.The design of terminal box shall be spacious to suit termination of armoured aluminium conductor cable. Six ends of windings shall be brought to the terminal box and shorting links shall be provided. The terminal box shall be provided with gland plate. If required, cable spreader box/trifurcation box shall be provided additionally to facilitate termination of larger size/multiple cables. Double compression brass cable glands shall be provided along with the motor. Rev. 0
viii.
ix. x.
xi.
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 xii. xiii. xiv. VOLUME - IV of V PAGE No. 104 of 272
All terminal boxes shall have threaded opening(s) and gasketed terminal box cover.
conduit
One no. internal earthing terminal shall also be provided in the terminal box as a standard feature. The terminal box shall also feature a cover plate. The cover plate shall be bolted to the terminal box with Allen key bolts. Where space heaters / thermistors / RTD's are specified, separate TB's shall be provided for these accessories. Terminal marking shall conform to IS: 4728 (1975) Phase terminals shall be stud type of FRP material. Terminals for space heaters shall be stud type; terminals for thermistor / RTDs may be clip-on type suitable for 2.5 sq. mm conductor.
xv.
xvi. xvii.
xviii. The rotor shall be dynamically balanced with half key. Other shaft mounted components viz. fan, coupling half etc., shall be balanced separately. Balancing shall be carried out at rated rpm of the motor. The balancing weights shall be firmly secured to the rotor. The balance quality grade shall conform to class G2.5 as per IS: 11723, Part I (1992). xix. xx. xxi. The motor shall be provided with lifting lugs/eye bolts to facilitate erection/ maintenance requirements. All nuts, bolts, studs shall be based on metric units. The motor shall be provided with a rating plate stainless steel (316L)with punched markings. Markings shall be provided as per IS: 325 (1996).The following details shall be furnished on the rating plate a.
b. c.
Each motor having special starting capabilities shall have a separate rating plate listing the special capabilities, including elevation rating. Anti friction bearing numbers equipment tag number
Rev. 0
NMDC LIMITED
MECON LIMITED

d. e. f. g. h.
xxii.
A separate nameplate shall display the motor tag number. Nominal efficiency Power factor Full load slip RPM Torque values for speed range and amps for that torue value
The painting of motor shall be epoxy-powder coated type. Final paint shade shall be as indicated in Ordering Data Sheet.
2.6.2.1.2
Electrical Design i. ii. Motor shall be suitable for DOL/VFD as required Motor insulation shall be class F with temperature rise restricted to class B. The motor winding shall be given special tropical and fungicidal treatment to ensure protection against tropical weather, Fungus, oil, abrasive /conductive dust. The motor insulation shall be given any of the following treatments to brace the coils: a). b). c). iv. v. Powerhouse treatment At least 3 cycles of dip and bake shall be allowed. Trickle impregnation. Vacuum pressure impregnation (VPI)
iii.
VPI method shall be preferred. The overhang of the stator windings shall be given an additional coat of epoxy gel to minimise the effect of end turn forces at switch-on. The vendor shall furnish the details of bracing method employed in the tender and data sheets to be approved. Stator slot wedges shall be of non-magnetic material. Rotor shall be of rigid cage design. Rotor bars shall be of high conductivity ETP copper and shall be firmly wedged in the rotor slots. The portion of rotor bars in Rev. 0
vi. vii.
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MECON LIMITED

the rotor slot shall be un-insulated. The rotor bars shall be brazed to the end short circuiting rings, which shall be of annealed high conductivity copper. If retaining rings are provided in vendors design, same shall be forged non-magnetic material.
viii.
ix.
All Motor windings shall be of copper only. Aluminum windings shall not be acceptable.
Corona effects on the materials shall not reduce the electrical or mechanical integrity of the insulation system.
Motor rated 30 KW and above shall be provided with single phase anti-condensation heaters as a standard feature. The heaters shall be placed in the lower part of the motor and shall be accessible for easy replacement/maintenance. Motors rated 75 kW and above shall be provided with embedded RTDs. At least two RTDs shall be provided per phase at the hot spot. These RTDs shall be Pt-100, 3 wire, and Simplex type. The RTDs shall be subject to following tests:
x.
xi.
a). b).
xii.
IR test: Minimum 10 Meg-ohm, valve between RTD and ground at 250 VDC HV test: RTD shall withstand 1.5KV for one minute.
For motor-rated 75 kW and above, in addition to winding RTDs, one no. 3 wire Duplex type Pt-100 RTD shall be provided at each bearing. For motor rated 30 kW and above upto 75kw (excluding 75 kW), the motors shall be compulsorily provided with thermistors of PTC type. The main terminal box of the motor shall be rated for 40 KA/ 0.25 sec at 415V. The motor frame shall be provided with two diagonally opposite tapped holes for earthing along with required hardware viz. bolts/screws, plain and Rev. 0
xiii.
xiv. xv.
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 spring washers. galvanized type. xvi. The VOLUME - IV of V PAGE No. 107 hardware shall of 272
electro-
For all motors speed Vs power factor curve, speed Vs toque curve, speed Vs current curve shall be furnished for consultant/purchaser approval
2.6.3 2.6.3.1 2.6.3.2
SPECIAL REQUIREMENTS FOR MOTORS FED FROM VARIABLE SPEED DRIVES (VFD) Motors to be used with Variable Frequency Drives and/or inverter shall be of Inverter Duty type. This rating shall be also appear on the nameplate. For motors fed from VFD's the insulation system shall be strengthened as follows: i. Motors for variable frequency drive applications shall be rated to match the specified load, converter and site installation. Motor design shall incorporate measures for withstanding:
a). b). c).

d).
Increased winding losses due to supply distortion. Increased voltage stress due to converter operation loads. Increased voltage stress due to converter generated voltage waveform dV/dt. Increased bearing stress due to circulating current through motor bearings and higher rotor operating temperatures
ii.
Stator end turns shall be suitably braced by providing coat of epoxy gel. Additional mechanical bracing if any, considered by the vendor shall be brought out. Stator winding insulation system shall be of VPI type. Stator magnet wires shall be provided with an additional coat of polyamide/polyester over and above the enamel paint to increase their PDIV rating, Triple build magnet wires shall be provided for stator wires. Phase insulation shall be provided for all the ratings. Rev. 0
iii. iv.
v.
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 vi. VOLUME - IV of V PAGE No. 108 of 272
Motors in the range of 2.2 kW to 22 kW shall be provided with thermistors. Motors above 22 kW shall be provided with windings RTDs @ 2 per phase. The critical speed of motor shall lie well above the required speed range of operation where supersynchronous operation is envisaged. Motors rated 75kW and above shall be provided with insulated bearings on NDE side. DHC & reversible conveyor motor shall be of form wound construction, with one side (NDE) bearing insulated and winding shall be suitably braced to withstand the switching surges (average 3kHz) associated with VFD operation; the motor shall be dynamically balanced for the envisaged speed range of operation. The insulation system shall be VPI type. The successful tenderer shall be solely responsible for proper selection of the motor for the given load application and the output characteristics of the drive.
vii.
viii. ix.
x.
2.6.4 2.6.4.1
PERFORMANCE REQUIREMENT Motor shall be able to start and accelerate under rated load at 80% of rated voltage, without exceeding the specified temperature. If while running, the voltage drops to 70% the motor shall be capable of delivering rated torque and continue to run without stalling for 5 minutes. The motor shall be capable of withstanding 150% of rated voltage and current for 2 minutes without damage. The motor shall be designed to provide the required starting torque where speed-torque characteristics of load are included in the specification. Where the specification does not contain the load characteristics, motor shall be designed to provide minimum 160% starting torque. The pullout torque of the motor shall not be less than 250% at rated voltage and frequency. Rev. 0
2.6.4.2
2.6.4.3 2.6.4.4
2.6.4.5
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 2.6.4.6 VOLUME - IV of V PAGE No. 109 of 272
Continuous duty motor shall be suitable for following starting requirements i. ii. iii. 6 equally spread starts/hour 3 Successive cold starts 2 Successive hot starts
2.6.4.7 2.6.4.8 2.6.4.9
The locked rotor current shall not exceed 600% of rated current including tolerance as per IS. For defining the safe stall time, the rotor temperature shall be limited to 3750C. The motor vibration in all three axes shall conform to the requirement of Normal class as per IS: 12075(1986). Vibration severity shall be preferably measured as vibration velocity. The mean sound power level for motor when tested and measured in conformance to IS: 12065 (1987) shall be limited to class Reduced Sound Power as defined in the standard and the motor noise level shall not exceed 85 dBA
2.6.4.10
sound pressure level at 1 m from the motor when operated on sine wave power whichever is more stringent.
2.6.4.11 The value of full load speed, full load current and efficiency shall be as specified above or as set out in IS: 8789 (1996) with tolerances as per Table I of IS: 325 (1996) whichever is better. 690 V Motors Bearing RTD shall be Duplex type TEST REQUIREMENT The motors shall be tested as per approved Quality Assurance Plan in MECONs format. LT SWITCHGEAR PANEL / LT PMCC / MCC LT switchgears shall receive power from 6.6/.433 kV & 11/0.433kV distribution transformers to cater power to all LT loads i.e motors, VFD fed Motors & PDBs, etc. MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD 2010, MECON Limited. All rights reserved. Rev. 0
2.6.4.12 2.6.5 2.6.5.1 2.7
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 2.7.1 A) Design criteria VOLUME - IV of V PAGE No. 110 of 272
POWER SUPPLY CONDITIONS : : : : : : : : 415 V, TPN + / - 10 % 50 Hz +/-5% Solidly grounded 40 KA 110V, 1 Ph 240V, 1 Ph
Nominal voltage Variation in voltage Nominal Frequency Variation in Frequency System Earthing Fault level (1sec) Control supply for O/G feeders Auxiliary supply for space heaters etc B) CONSTRUCTIONAL FEATURES Construction
Enclosure class protection Sheet steel thickness Tier formation
: Single front, multi-tiered, fully-draw out, floor mounted, compartmentalized for PMCC / MCC. Single front, multi-tiered, fully-draw out, floor mounted, compartmentalized, twotiered for LT switchboards. of : IP 52 or better : 1.6mm (min.) CRCA, for non-load bearing members and 2.0 mm (min.), CRCA for load bearing members : Two tier for ACB feeders in LT switchgear and multi tier modules for PMCC/MCC. : Bottom cable entry for PMCC/ MCC etc. : Bottom for all switchboards
Incoming termination Outgoing cable entry Minimum clearances in air a) Between phases b) Between live parts and ground 1 minute PF withstand for main circuits Paint shade Pollution grade Module design
: 25.4 mm : 19mm for solidly earthed system 25.4 mm for non-effectively earthed system. : 2.5 kV r.m.s : As per approved drawing : 3 : Modules with components and wiring shall be standardized to few for ease of replacement as per requirement.
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 C) BUSBARS : E91E Aluminium : As per requirement : As per rated currents of circuit breakers : 850 C VOLUME - IV of V PAGE No. 111 of 272
Material for phase and neutral busbars a) Main busbars b) Bus connections to circuit breakers Final temperature at rated continuous current of busbars in busbar chambers PVC sleeves/ shrouds Materials busbar D) of
: Busbars to be sleeved and shrouded at all joints earth : Aluminium, 50 x 6 mm (min.)
BREAKERS : Fully draw out, air break : 3 : To be indicated by Tenderer : 450 C
Type of breaker No. of poles Rated current at 45 deg C Specified design ambient temperature In panel breaker rating Rated ultimate short circuit breaking capacity Rated short-circuit making capacity Rated service shortcircuit breaking capacity Utilization category Rated short time withstand current (1 sec) Type of release Protection functions to be provided in adjustable release - Over current - Short circuit
: As per busbar rating : 50 KA : 105 KA (peak) 50 KA : B : 50 KA : Micro processor based
: Yes, inverse-time type : Yes, with options for both inverse time and definite time Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 - Earth fault Under voltage release with independently adjustable voltage range and time setting range Operating mechanism Requirement of electrical/ manual operation Auxiliary voltages for a) Closing coil b) Trip coil c) Spring changing motor E) MCCB : Air break : 3 : A : O/L, S/C, E/F (Earth leakage) & shunt trip coil with pad locking facility ultimate short : 50 kA breaking Type No. of poles Utilization category Protection : - do : Preferable VOLUME - IV of V PAGE No. 112 of 272
: Trip free, stored energy : Both operations required.
: 240 V, AC, Range: 80 110 % : 240 V, AC, Range: 50 110 % : 240 V, AC, Range: 80 110 %
Rated circuit capacity Rated service short : 105kA circuit breaking capacity F) SWITCHES : : : : : : : :
Type No. of poles Utilization category Rated current Features required Door interlock Padlocking Operating Handle Visual indication
Double Air break TP/TPN AC23B As per drive requirement with 32A min Yes In ON & OFF Yes For ON & OFF positions
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 G) FUSES VOLUME - IV of V PAGE No. 113 of 272
Type : H.R.C Rupturing capacity : 80 kA r.m.s Visual "Fuse Blown" : Required indication H) CONTACTORS : : : : Electromechanical, double air break 3 AC-3 150 % of motor rated current with 16A min at AC3 duty
Type No. of poles Utilization category Rated current Coil voltages Pick-up Drop-off I) Type No. of poles Reset Other features Mechanical trip position indicator Test button Auxiliary contacts Protective cover Single phasing preventer J)
: 80 100% of rated : 40 - 60% of rated
OVERLOAD RELAYS ambient : Thermal, compensated : 3 : Hand/Auto site selectable : Required : : : : Required 1 NO + 1 NC Required Inbuilt temperature
CURRENT TRANSFORMERS : Dry Resin cast : 5A : 1.0, ISF < 5 : 5P 15 p.f. : 2.5 kV r.m.s
Type CT secondary Accuracy Metering Protection One-minute Withstand voltage
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 K) INDICATING INSTRUMENTS AMMETER : Taut band, square dial : 1.5 : : : : 144 x 144 mm 96 x 96 mm Required For continuous running drives rated above 11 kW & for feeders rated 100A & above. VOLUME - IV of V PAGE No. 114 of 272
Type Accuracy class Size For I/C & B/C For other feeders Zero adjust CT operation L) L.T. CAPACITORS
No. of banks per bussection 3 Phase delta connected capacitor bank rating Unit capacitor rated voltage Unit capacitor preferred rating (single phase) Unit capacitor type Dielectric Ambient temperature Unit capacitor tolerance (capacitance) Capacitor tolerance (capacitance) Permissible dielectric loss Discharge device
: To provide 0.95 lag P.F. : 440 V, Ratings to be indicated by Tenderer : 440 V : : : : : Required kVAR, Tenderer to indicate Dry, self healing type MPP 45 0 C -5% to + 10%
: 0% to + 10% : < 0.25 W / kVAR
: Resistor and reactor to reduce inrush current Discharge time to 50V : Less than 60 secs Unit capacitor degree of : IP2X protection Safety device : For over pressure Control philosophy : Manual by PB's on panel / auto (PLC). Over voltage withstand : 1.1 time rated voltage, continuous. Over voltage protection required
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 2.7.2 2.7.2.1 2.7.2.1.1 TECHNICAL SPECIFICATION GENERAL LT switchboard / PMCC shall have one incomer, 2 bus sections with Bus sectionalizer to cater power to all LT loads i.e motors, VFD fed Motors, PDBs etc. Bus sectionalizer shall be given in such a way that during maintenance the entire motor/process loads shall be isolated from other maintenance loads LT switchboard shall comprise equipment for power supply and control and protection of equipment. All its components mounted in the cubicle shall carry continuously specified rated current without exceeding the final temperature applicable to various equipment corresponding to the design ambient temperature. Final temperature shall be as per relevant IS adjusted to design ambient specified. Where final temperature is specified, the same shall be applicable. LT switchboard with breakers, CTs, busbars shall have breaking dynamic withstand and short time rating corresponding to those specified for the LT breaker. Breakers shall be capable of operating satisfactorily under symmetrical and all asymmetrical faults corresponding to breaking capacity specified. Each cubicle shall have provision to terminate required number of cables considering multi-tier arrangement. Twotier arrangement shall be preferable. Design of breaker cubicles shall be such as to provide inter changeability of breaker carriages of same rating at site. Where electronic tripping units are used, they shall be tested for proper functioning using manufacturers recommended test kits. CONSTRUCTIONAL FEATURES The LT switchgear/ PMCC / MCC units shall be indoor, self supported, floor mounting, dead front, fully compartmentalised to conform to Form 4 requirement of IS Rev. 0 VOLUME - IV of V PAGE No. 115 of 272
2.7.2.1.2
2.7.2.1.3
2.7.2.1.4
2.7.2.1.5
2.7.2.1.6
2.7.2.1.7
2.7.2.2 2.7.2.2.1
NMDC LIMITED
MECON LIMITED

8623, multi- tiered, air insulated, natural air cooled, metal clad factory assembled, fully wired, type tested assemblies. The switchgear shall allow extension at either end. 2.7.2.2.2 The switchgear / PMCC / MCC when erected shall form a continuous single line-up of panels. Each shipping section shall comprise not more than three verticals and shall be provided with lifting arrangement. ACB panels shall be restricted to two-tier formation. The maximum and minimum working height for switchboard shall be not more than 1800 mm and not less than 350mm respectively. PMCC / MCC shall be in multi- tiered formation with max. and min. operating heights shall be not more than 1800 mm and not less than 350mm respectively. The switchgear shall be single front/double front, drawout/fixed type as specified in the Design Criteria. The enclosure class of protection shall be IP- 52 or as indicated in Design Criteria. The enclosure shall be fabricated from CRCA sheet steel whose thickness shall be minimum 2mm for load bearing members and min. 1.6 mm for non-load bearing members. All doors and covers shall be provided with synthetic rubber gaskets. All hinges shall be concealed type. Feeder module doors and cable alley doors shall open in opposite directions. For single front type switchgear, the vertical panels shall be provided with rear lift-off doors in two sections. Each lift off section shall be provided with handles. The switchgear shall be suitable for bottom incoming cable entry and bottom outgoing cable entry as specified in Design Criteria. 20% spare feeders subject to a minimum of one feeder of each type and rating shall be provided. Each vertical shall be provided with anti-condensation heater and lamp. Rev. 0
2.7.2.2.3
2.7.2.2.4
2.7.2.2.5
2.7.2.2.6
2.7.2.2.7 2.7.2.2.8
2.7.2.2.9
2.7.2.2.10 2.7.2.2.11
NMDC LIMITED
MECON LIMITED

2 Nos breaker-handling trucks for ACB's shall be included in scope supply along with the panels as part of supply. Requirements for draw-out construction With-draw-able modules shall be provided with 3 distinct positions: i. ii. Service - Both power and control circuit connections to be made. Test Power circuit shall be off while control circuit shall remain connected and can be tested by means of "Test Push Buttons" Isolated Both power and control circuit shall be disconnected.
iii. 2.7.2.2.15 2.7.2.2.16
Means shall be provided to identify each position. Draw out units shall be provided with its own door. Earth continuity to the compartment doors shall be ensured by suitable jumpers to the main structure. Draw out unit shall be mounted on guide rails and shall be provided with rollers. The units shall be self-aligning. Power contacts shall be spring loaded, stab-in type. Control contacts shall be spring loaded, self-aligning type. Each withdrawal unit shall be provided with double scraping type earth connections, which shall be first to make and last to break type. Safety shutters shall be provided to ensure that no live parts are accessible once the module is withdrawn. Identical draw out modules shall be interchangeable Make up of Modules Incoming feeder: Shall be ACB / MCCB unit of adequate rating in draw-out module. Where rating is 630 Amp or above the same shall be air circuit breaker in draw out execution. MCCB / ACB Rev. 0
2.7.2.2.17 2.7.2.2.18
2.7.2.2.19 2.7.2.2.20 2.7.2.3 2.7.2.3.0 2.7.2.3.1
NMDC LIMITED
MECON LIMITED

shall be with microprocessor based direct acting self powered adjustable O/C, E/F, and S/C release. ACB shall be provided with separate LED indication for each fault and a fault reset button. Self-diagnostic feature shall be provided in the release as a standard feature. 2.7.2.3.2 Provided with voltmeter and ammeter with selector switches. Meters shall be with accuracy class 1.0 and size 144 x 144 mm. Provided with microprocessor based multi function (power monitor) metering system with RS 485 communication port and pulse energy output with connection to PLC. Provided with R, Y, ON/OFF/TRIP lamps B phase indication lamps and
2.7.2.3.3
2.7.2.3.4 2.7.2.3.5
MCCB shall have 1 NO + 1 NC contacts rated for 6A, AC 11 duty. ACB shall have minimum 4 NO & 4 NC auxiliary contacts rated for 6A, AC 11 duty. ACB shall be provided with mechanical and electrical operation with anti pumping arrangement and trip circuit supervision through lamp and test push button Control supply feeder Each LT switchgear / PMCC / MCC shall Provided with dry type control transformer (at least 3 KVA rating 2 nos. with changeover switch) of 415/110V with + 2.5, + 5% primary taps, Fuse and Neutral Link at primary side and DPMCB on secondary side for each transformer. In case of two bus sections each bus section shall be provided with a control transformer rated to cater to the control supply requirement of the entire switchboard. The secondary shall be centre tapped. One secondary leg of the transformer shall be connected to earth bus through link. Control transformer shall be dry type, double wound, having insulation class B. Each control transformer module shall be provided with voltmeter of accuracy class 0.5 and Control supply ON" indicating lamp.
2.7.2.3.6
2.7.2.4 2.7.2.4.1
2.7.2.4.2
Separate transformers shall be provided in each bus-section for space heater, panel lighting load etc. MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD Rev. 0 2010, MECON Limited. All rights reserved.
2.7.2.4.3
NMDC LIMITED
MECON LIMITED

If DC control voltage is envisaged by Tenderer suitable isolators, fuses, protections, rectifiers etc. required for this shall be provided without any extra price. MCCB feeders With self powered release for O/C, S/C and E/F. With 1 NO + 1 NC auxiliary contacts rated for 6A at AC11 duty. Provided with ON, OFF and Trip lamps for all ratings. Additionally ammeter shall also be provided for all feeders rated 100 A and above Motor feeders Provided with MPCB / MCCB with 2 NO + 2 NC auxiliary contacts rated for 6A at AC 11 duty. MCCB / MPCB shall be interlocked with control circuit Main contactor shall be suitable for AC 3A duty with minimum rating of 16A. Selection shall be as per component selection chart. The contactor shall have minimum 2 NO + 2 NC auxiliary contacts rated for 6A at AC 11 duty. Interposing relays for remote PLC control shall be provided in individual feeder module. Coil voltage for these relays shall be 110/230 V AC. Overload relays to be provided for motors rated up to less than 55 kW. Overload relay shall be Manual reset, 3element bimetallic type. Drives of 11 kW and above shall be provided with CT operated O/L relays with protection Class 5P10. Drives rated 55 kW and above shall be provided with motor protection relay with thermistor protection (With 6 thermistors), negative sequence, thermal O/L, S/C Protection, Earth leakage protection with CBCT, Repeated start protection, Locked rotor protection (similar to MM30 or MULTILIN 239) as specified in the component selection table.
2.7.2.5 2.7.2.5.1 2.7.2.5.2 2.7.2.5.3
2.7.2.6 2.7.2.6.1 2.7.2.6.2 2.7.2.6.3
2.7.2.6.4
2.7.2.6.5
Rev. 0
NMDC LIMITED
MECON LIMITED

Drives upto 11 kW shall be provided with direct reading ammeters on Y phase. Drives above 11 kW shall be provided with CT operated ammeters. CTs shall have 5A secondary and accuracy class 1.0. Ammeter shall have accuracy class 0.5 and shall be of size 72 X 72 mm. They shall be suitable to read starting current and shall be changeable scale type. Reversible drives shall be provided with mechanically and electrically interlocked contactors. SP MCB (10 kA) shall be provided for control supply to module. ON/FORWARD/REVERSE/OPEN/CLOSE, OFF, TRIP indication lamps (LED clustered) shall be provided. 240V AC provision shall be kept in the module for motor space heaters for motors above 30 kW. Selection of components shall be so as to provide Type 2 co-ordination / discrimination as per IS-13947 Main Busbars and connections Busbars shall be made of E91E grade Aluminium alloy. Cross section of busbars selected shall ensure temperature of busbars and joints is limited to 850C at rated currents. In addition, it shall withstand mechanical forces for specified peak short circuit current and have 1 sec. short circuit thermal rating at specified short circuit current. Horizontal busbars shall be housed in totally enclosed compartments with removable bolted covers. High tensile cadmium plated bolts with suitable spring washers shall be used for busbar joints. Prior to joining, oxide-inhibiting grease shall be applied after cleaning the surfaces. Busbars shall be fully insulated for working voltage with specified phase and ground clearances. Heat shrunk PVC sleeves for busbars and shrouds for joints shall be Rev. 0
2.7.2.6.8
2.7.2.6.9 2.7.2.6.10 2.7.2.6.11 2.7.2.6.12 2.7.2.6.13 2.7.2.7 2.7.2.7.1
2.7.2.7.2
2.7.2.7.3
NMDC LIMITED
MECON LIMITED

provided. Further busbars shall be colour coded for phase identification. 2.7.2.7.4 Busbars shall be supported on non-hygroscopic antitracking, flame retardant insulating supports. Busbar chamber of each panel shall be segregated from the busbar chamber of adjacent panels. All busbars and main current carrying connections shall have the same cross sectional area throughout their lengths. The busbar supports and their terminal connections shall be designed to permit expansion and contraction of the buses with variations in temperature, which may occur in actual service. Busbars shall have minimum cross section corresponding to current density of 0.8A / sq. mm at rated current for Aluminium Bus Bars. Actual current density shall be as per requirements of permissible maximum temperature at rated loading. The connecting busbars for the incoming line circuit breaker shall have continuous current capacity same as specified for main busbars but not less than incomer breaker rating. For the outgoing feeders, the connecting busbars shall have the continuous current capacity not less than the rated current of the circuit breaker, irrespective of the release settings. The size of the neutral busbars shall be 50% of the size of the main busbars. Earth bus shall be provided running continuously at the bottom of the switchgear with a bolted link to the neutral busbar. Horizontal busbars shall be extensible on both sides. Auxiliary busbars Auxiliary busbars shall be provided for control supply, space heater supply. These busbars shall be segregated from the main busbars and adequately sized to meet the specific requirement. Material of these busbars shall be electrolytic tough pitch copper. The busbars shall be adequately supported and due clearances shall be observed. Rev. 0
2.7.2.7.5
2.7.2.7.6
2.7.2.7.7
2.7.2.7.8 2.7.2.7.9
2.7.2.8 2.7.2.8.1
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 2.7.2.9 2.7.2.9.1 L.T. Circuit breaker The circuit breakers shall be triple pole, trip free, air break, fully drawout, shunt trip, selective type for achieving discrimination. All current carrying contacts of the breaker shall be silver-plated. The main contacts shall have ample area and contact pressure for carrying the rated current of the circuit breaker, to avoid excessive temperature and the resultant pitting. The tips of the arcing contact shall be made out of suitable arc resisting material. Arc chute shall be provided on each pole and so fitted that it can be easily removed for inspection of the main contacts. The contacts shall meet against spring pressure with a self-cleaning action. Inter-phase barriers of proper design shall also be incorporated. The connections of main power and auxiliary control circuits shall be fitted with self-aligning contacts. The fixed portions of the sliding contacts shall be easily accessible for maintenance and checking. If plug and socket are used for auxiliary control circuit connection, mechanical interlock shall be provided to ensure the following: i. ii. Remove the plug before the breaker is withdrawn from the test position and Movement of breaker from test to service position shall be possible only after connecting plug and socket. shall have the following three distinct VOLUME - IV of V PAGE No. 122 of 272
2.7.2.9.2
2.7.2.9.3
The breaker positions: i. ii.
Service position: Normal service position with main and auxiliary control circuits remaining connected. Test position: In this position, main power contacts of the breaker are fully disconnected while the auxiliary control circuits remain connected. Isolated / maintenance position: In this position the breaker shall be fully out of the cubicle and both the main power and auxiliary control circuits are disconnected. Rev. 0
iii.
NMDC LIMITED
MECON LIMITED

These three positions shall be possible with door closed. An automatic mechanical indicator shall be provided to indicate these positions, visible from outside. It shall be possible to lock the breaker in test and isolated position. The circuit breaker, together with its operating mechanism isolating and interlocking gears, contacts and wiring, shall be fixed on a withdrawable carriage. Each carriage shall have a dead front panel. Mechanical interlocking shall be provided on each carriage to prevent mal-operation and in particular to ensure that i. ii. The carriage cannot be moved in or out of its cubicle with the circuit breaker closed. The circuit breaker can only be closed when the carriage is in one of the three positions viz. the service position or fully out of the cubicle in the maintenance position. Inadvertent withdrawal of a circuit breaker carriage too far beyond its supports shall be prevented by suitable mechanical stopper. Interlocked rigid clamping and anti lifting arrangements shall be provided for circuit breaker trucks in the service and test positions.
2.7.2.9.4
iii.
iv.
2.7.2.9.5
The circuit breaker shall be capable of carrying continuously and interrupting satisfactorily the currents specified without un-due heating or wear of the contacts, under the specified site conditions. Automatically operated shutters shall be provided to screen the fixed portion of the contacts assembly when the breaker is fully withdrawn from the cubicle. Circuit breakers of identical rating shall be physically and electrically interchangeable. Operating Mechanism Circuit breaker shall be provided with either a power operated mechanism or a manual operating mechanism as specified in Design Criteria. Rev. 0
2.7.2.9.6
2.7.2.9.7 2.7.2.10 2.7.2.10.1
NMDC LIMITED
MECON LIMITED

Manually operated mechanism shall be of independent spring charging, stored energy type. Power operated mechanism shall be of motor wound, spring charging, stored energy type. The operating mechanism shall be trip free and designed to reduce mechanical shocks to a minimum during operation. The operating mechanism shall operate normally even when circuit breaker is closed on fault. The mechanism shall be provided with mechanical indicators to indicate spring condition i.e., CHARGED, DISCHARGED. The operating mechanism shall be provided with following features: i. ii. It shall not be possible to close the breaker unless spring is fully charged. Closing of the breaker shall immediately and automatically initiate spring charging to ready for the next closing stroke. Failure of the spring shall not initiate closing or prevent intentional tripping. Means shall be provided for manual charging with motor supply being cut-off automatically when charging handle is inserted. Spring charging motor shall be suitable for AC or DC supply as per Design Criteria with variation from 85% to 110% of rated voltage. Provided with a shrouded mechanical trip button accessible from outside. Electrical and mechanical anti-pumping protection One open-close-open operation of the circuit breaker shall be possible after power supply failure to motor.
2.7.2.10.3
2.7.2.10.4
2.7.2.10.5
iii. iv.
v.
vi. vii. viii.
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 2.7.2.11 2.7.2.11.1 Protection Releases: The circuit breakers shall be provided with microprocessor based direct acting protection releases for overload, short circuit and earth fault protections. The release shall be ambient temperature compensated for ambient 0 temperature up to 60 C and shall be self-powered type requiring no auxiliary supply. The performance of the release shall not be affected by the magnitude of the fault current. The release shall be provided in a separate case and shall be tested in accordance with IS /IEC for mechanical stresses (shocks and vibrations), dielectric strength etc. The overload function shall be inverse-time type whereas for short circuit and earth fault it shall be possible to choose between inverse time and definite time characteristics. For all the three protections it shall be possible to set the fault current and time separately. Individual indications shall be provided for each type of fault. The release shall also be provided with the following features: Self-monitoring for microprocessor mal function. An indication shall be available for the healthiness or otherwise. Manual reset pushbutton for trip resetting An external contact for signaling the trip/microprocessor malfunction. Individual contact for each type of fault shall be preferred Function blocking for the three protections separately. VOLUME - IV of V PAGE No. 125 of 272
2.7.2.11.2
2.7.2.11.3
2.7.2.11.4 2.7.2.11.5 2.7.2.11.6 2.7.2.11.7 2.7.2.11.8
2.7.2.11.9
2.7.2.11.10 Zone selectivity so that in the case of two or more breakers connected in series, the breaker nearest to the fault clears the fault first while informing the upstream breaker of the occurrence of the fault. This selectivity shall be available on short circuit and ground fault protections when definite time characteristic has been selected for these protections MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD 2010, MECON Limited. All rights reserved. Rev. 0
NMDC LIMITED
MECON LIMITED

2.7.2.11.11 Self-test facility for the release when breaker is isolated. Auxiliary supply/power pack required to be included in scope. 2.7.2.11.12 Communication facility on RS 485 serial link interface. 2.7.2.11.13 Circuit breaker for incomers, bus couplers and motor feeders shall be provided with adjustable under voltage release. It shall be possible to adjust both voltage and time settings. 2.7.2.12 Auxiliary contacts
2.7.2.12.1 All contacts shall have adequate capacity to make, carry and interrupt the current in their circuits. Minimum rating shall be 5A at 415 V AC 2A at 220 V DC. Each circuit breaker shall be provided with 6 NO + 6 NC auxiliary contacts. Out of these, 3 NO + 3 NC shall be spare auxiliary contacts for owners exclusive use at site. The design of the contacts shall be such that they can be easily converted from normally open to normally closed type and vice versa. All the auxiliary contacts shall be wired internally up to the terminal blocks in the fixed portion of the breaker cubicle. In case multiplication of contacts are required, the same shall be done using electrically reset latched type relays. 2.7.2.13 2.7.2.13.1 Interlocks The switchgear shall be provided with all necessary interlocks designed to prevent incorrect operation and to ensure safety of operating personnel and also the equipment. Each breaker shall have door interlocking mechanism and interlock defeat facility. Castle-key interlock shall be provided for incomers and bus sectionaliser to prevent parallel operation where specified. Moulded Case Circuit Breakers Protection Circuit Breaker(MPCB) (MCCB's)/Motor
2.7.2.14 2.7.2.14.1
MCCBs/MPCBs shall be of triple pole construction suitable for panel mounting, Operating mechanism shall be trip free, quick make, quick break type.
Rev. 0
NMDC LIMITED
MECON LIMITED

Provided with front operating handles and mechanical ON/OFF indicators. In case of trip, the handles shall rest in an intermediate position. MCCB's/MPCBs shall be provided with thermal overload release and magnetic short circuit release. The releases shall be adjustable type. MCCB's of 160A and above shall be microprocessor based, self powered releases for O/C, S/C and E/F.and earth leakage relay with CBCT Where MCCB's are used in the motor starter modules, in conjunction with contactor and thermal overload relay, type 2 co-ordinations shall be provided. Provided with ON, OFF and Trip lamps. Additionally ammeter shall also be provided for all feeders rated 100A and above. All MCCBs of rating 160 A and above shall be with microprocessor based releases MCCBs / MPCBs shall have following accessories and features: i. ii. iii. iv. v. Shunt trip release(for MCCB) Auxiliary contact set of 1 NO + 1 NC contacts Fault signaling contact set of 1 NO + 1 NC contacts Insulation shields to isolate the connections between each pole Finger protection plate to prevent accidental contact
2.7.2.14.3
2.7.2.14.4
2.7.2.14.5
2.7.2.14.6 2.7.2.14.7
2.7.2.14.8 2.7.2.14.9
The compartment door shall be interlocked with the handle of the MCCB All outgoing feeders up to 630 A ratings shall be MCCB feeders.
2.7.2.14.10 Ratings selected shall be at least 125% of the full load current of the motor.
Rev. 0
NMDC LIMITED
MECON LIMITED

2.7.2.14.11 Motor protection circuit breaker shall be used for small rating drives up to rating 18.5kW such as valves, space heaters. 2.7.2.14.12 Space heater supply shall also be taken from circuit breakers 2.7.2.15 2.7.2.15.1 Contactors The contactors shall be electro-mechanical triple pole, airbreak type with the coil operating voltage as specified in the control scheme. The coil shall be suitable for operation in the range of 85% to 110% of the rated coil voltage. The utilization category of the contactors shall match with the load requirements. The contactor rating shall be chosen to provide type 2 discrimination. However, the minimum rating of contactors shall be 16A. The contactor shall be provided with adequate no. of NO and NC auxiliary contacts. The auxiliary contacts shall be such that NO contacts close after the main poles have closed and NC contacts open before the main poles have closed. Further, it shall be possible to change NO contacts to NC and NC contacts to NO at site. Contactors of reversible motors shall be electrically and mechanically interlocked. The closed state of the contactor shall be identifiable by means of a mechanical indicator. Overload relays Overload relays shall be thermal, triple pole, manually reset, ambient temperature compensated and positive acting type with in-built single phasing preventer. The range selection shall be such that the setting ranges overlap. Relays may be direct acting or CT operated depending on current rating. In the latter case, CTs shall be in Tenderer's scope. The relays shall have following features: Rev. 0 visually
2.7.2.15.2
2.7.2.15.3
2.7.2.15.4 2.7.2.15.5 2.7.2.16 2.7.2.16.1
2.7.2.16.2
2.7.2.16.3
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 i. ii. VOLUME - IV of V PAGE No. 129 of 272
It shall be possible to change from manual reset to auto-reset at site. Resetting the relay shall be possible from the front with the compartment door closed Mechanical trip position indicator shall be provided. Test button shall be provided. Protective cover shall be provided to avoid intentional tampering of settings, auto/manual reset and test button provided with 1 NO + NC auxiliary contacts. The trip class of the thermal overload relays shall be chosen based on the type of load and shall be subject to approval. In general for applications such as pumps etc. where starting time is less than 10 seconds, the trip class shall be 10. For high inertia loads, the trip class shall suit the starting time.
iii.
2.7.2.17 2.7.2.17.1
Relays All protection relays shall be draw out flush mounted in dust proof cases control circuits shall be automatically broken and current transformer secondary circuits shorted when a protection relay is withdrawn from its case. A marking strip shall be provided in front of each terminal block and a diagram plate at the back of each case to identify connections. All spare contacts shall also be wired upon the externals. Relay coils shall carry their normal currents indefinitely and such currents than can occur under fault conditions. Relay mechanism shall not be affected by normal vibrations or external magnetic fields. All indicating and protection relays shall have mechanically operated hand reset flag indicators. Indicators shall be capable of being reset without opening the relay case. It shall not be possible to operate any relay by hand or to alter its setting, without opening the case. Means shall be provided for testing relays from the front of the panel, preferably by test plugs for insertion between the finger contacts of draw out relays. Rev. 0
2.7.2.17.2
2.7.2.17.3
2.7.2.17.4
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 2.7.2.18 2.7.2.18.1 Current transformer Protection and measuring current transformer shall be of cast resin, bar/ wound primary type with 5A or 1A secondary as per scheme requirement. . Measuring current transformers shall conform to accuracy class 1 and burden of CTs shall be as required by the associated measuring instruments and connecting leads. The CTs shall have saturation factor of 5. Protection current transformers shall have their accuracy as minimum 5P and burden as required by the protection circuit in which they are used and shall have minimum saturation factor not less than 10. CTs for restricted earth fault protection shall conform to Class 'PS', Part IV of IS 2705. All CTs shall withstand without injury dynamic stability and thermal stability currents specified for the switchboard. The current transformer ratios specified are provisional and are subject to alteration and confirmation later at the time of approval of manufacturer's drawings. Current transformers shall have a short time withstand rating equal to the short time withstand rating of the associated switchgear for one second for breaker feeders; for fuse backed feeders, the CTs shall have a withstand capacity not less than that of the let through on isolating link. The CT pointing shall be marked indelibly on the CT as well as the leads wiring it to the terminal block. Voltage Transformers Voltage transformers shall be dry, cast resin type with accuracy class 1.0 for measuring VT's and class 3.0 for protection VT's. The high voltage side of VT's shall be protected with current limiting fuses. The secondary side of VTs shall be protected by means of fuses sized to prevent overload. Fuses shall be so located that it shall be possible to replace the same with the switchgear in energized condition. Rev. 0 VOLUME - IV of V PAGE No. 130 of 272
2.7.2.18.2
2.7.2.18.3
2.7.2.18.4
2.7.2.18.5
2.7.2.18.6 2.7.2.19 2.7.2.19.1
NMDC LIMITED
MECON LIMITED

VTs shall have a continuous over voltage factor of 1.2 with short time over-voltage factors as below i. ii. 1.5 for 30 seconds in case of effectively earthed systems 1.9 for 8 hours in case of non-effectively earthed systems
2.7.2.19.3 2.7.2.19.4 2.7.2.20 2.7.2.20.1
VT polarity shall be marked indelibly on the VT as well as the lead terminals at the terminal block. In case the secondary windings of the VT are required to be earthed, the same shall be done with an isolating link. Control Transformers: PMCCs shall have adequately rated control transformers 415/110V with + 2.5% + 5% taps on primary (minimum 3 KVA) dry type double wound, having insulation class B. Control supply ON" lamp and voltmeter of accuracy class 1.5 shall also be provided. Control transformer shall be dry type. The primary side of the control transformer shall be protected by fuse/neutral link and by MCB. Secondary side of the transformer shall be protected by MCB Control and selector switches Control and selector switches shall be rotary type with enclosed contacts. The various positions shall be identified through escutcheon plates. Control switches shall be spring return type and selector switches shall be stay put type. Control switches shall be provided with pistol grip handle whereas handles for selector switches shall be oval/wing knob type. The rated operational current of the switches shall be not less than 4A (AC-11) at 240 V AC and 1A (DC-11) at 220 V DC. Breaker control switch shall have 3 positions: trip, neutral and close. To close the breaker the switch shall be turned Rev. 0
2.7.2.20.2
2.7.2.21 2.7.2.21.1
2.7.2.21.2
2.7.2.21.3
2.7.2.21.4
NMDC LIMITED
MECON LIMITED

clock-wise, to trip the breaker the switch shall be turned anti-clockwise. To close the breaker switch shall be tripped before closing. Lost motion contacts shall be provided. 2.7.2.21.5 Voltmeter selector switches shall be seven position type capable of reading both phase and line voltages and with OFF position. Ammeter selector switches shall be fourposition type with OFF position and shall have make before break contacts. Pushbuttons Pushbuttons shall be oil tight type and provided with escutcheon plates marking the function. All pushbuttons shall be provided with 2 NO + 2 NC contacts; each contact shall have rated operational current of not less than 4A (AC 11) at 240V AC and 1A (DC 11) at 220V DC Pushbuttons for 'START', OPEN, 'CLOSE', 'LEFT', 'RIGHT', 'FORWARD', 'REVERSE' etc. shall be flush type with spring aided self reset contacts and shall be coloured green. Pushbuttons for 'STOP' shall be flush type with spring aided self reset contacts and shall be of red colour. Pushbuttons for 'EMERGENCY STOP" shall be mushroom headed type with stayout contacts and shall be of red colour. Further the operation of the button shall be press to lock and twist to release. Indicating lamps Indicating lamps shall be of low wattage cluster LED type. It shall be possible to replace the lamp without opening the compartment door. Red, Yellow and Blue colour lenses shall be provided for the lamps of the incomer.
2.7.2.22 2.7.2.22.1
2.7.2.22.2
2.7.2.22.3
2.7.2.23 2.7.2.23.1
Breaker modules shall be provided with ON, OFF and AUTOTRIP indications. Incomer modules shall be provided with R, Y, B phase indication lamps. DOL starter modules shall be provided with ON, OFF and TRIP lamps. RDOL starters shall be provided with OPEN/CLOSE, FORWARD/REVERSE, LEFT/RIGHT, UP/DOWN indication lamps as applicable in addition to OFF and TRIP indications. MCCB power modules shall be provided with ON and OFF indications. Transformer modules shall have ON indications MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD Rev. 0 2010, MECON Limited. All rights reserved.
2.7.2.23.2
NMDC LIMITED
MECON LIMITED

The colours of indication lamps for various applications shall be as follows: i. ii. iii. ON, OPEN/CLOSE, FORWARD/REVERSE etc.: Red OFF TRIP : Green : Amber
2.7.2.23.4 2.7.2.24 2.7.2.24.1
Each indication lamp shall be provided with an escutcheon plate indicating its function. Indicating instruments All indicating instruments (voltmeters/ammeters) shall be of taut band, square dial, flush mounting type, suitable for vertical mounting and back connection and conform to IS 1248. The accuracy class of instruments shall be class 1.5 Ammeters shall be graduated to read min. 1% of full-scale reading. Instruments for all feeders shall have sizes as per Design Criteria. All indicating instruments offered shall be of the best make and shall have non-reflecting bezels, clearly divided and indelibly marked scales and sharply outlined pointer. All instruments shall be provided with a zero adjusting device for external operation. Ammeters shall be suitable for operation on CT and scaled to read actual currents flowing in the circuit. Internal wiring and ferrules Wiring inside the cubicles shall be carried out using 650 /1100 V grade, PVC insulated, stranded, single core conductor wires. For power circuits, the minimum size shall be 4-sq.mm copper. For control circuits the minimum size shall be 1.5 sq. mm copper; for CT circuits the minimum size shall be 2.5 sq. mm copper wires. Spare auxiliary contacts shall be wired up to the terminal block. Not more than two connections shall be made at any terminal. one
2.7.2.25 2.7.2.25.1
2.7.2.25.2 2.7.2.25.3
Rev. 0
NMDC LIMITED
MECON LIMITED

Wires for inter-panel wiring shall be taken through the bottom-most tier of the switchgear, which shall be kept vacant for this purpose. All metal cut outs provided for facilitating wiring shall be pushed. Each wire shall be identified at both sides by ferrules. Ferrules shall be of interlocking type of yellow colour with black engraved lettering. Equi-potential ferrules shall carry the same identification number. Terminal Blocks Terminal blocks shall be 650V grade, of non-hygroscopic, non-tracking moulded plastic type. Terminal blocks shall be segregated based on the circuit voltage. Individual terminals shall be numbered with engraved black-on-white labels. Where it is necessary to duplicate terminals, same shall be done with solid links. Power terminals shall be stud type with phase separation barriers control terminals shall be rated for 10A min. and they shall be suitable for 2.5 sq. mm conductor. At least 20% spare control terminals shall be provided in each block. Terminals for CT secondary leads shall be provided with shorting and disconnecting / earthing facilities and shall be similar to CATD M4 design of Elmex. Power and control terminals shall be shrouded. It shall be possible to carry out work on any module separately without coming into accidental contact with the immediately located modules. Labeling and Nameplate Labels shall be provided for each component of each module of the switchgear. These shall be white engraved on block, PVC type. Paper labels are not acceptable. Labeling shall be done as per approved scheme drawings. Nameplates shall be provided for each feeder each vertical and for the switchgear as a whole. These shall be of Rev. 0
2.7.2.25.5 2.7.2.25.6
2.7.2.26 2.7.2.26.1
2.7.2.26.2
2.7.2.26.3
2.7.2.26.4
2.7.2.27 2.7.2.27.1
2.7.2.27.2
NMDC LIMITED
MECON LIMITED

anodised aluminium with engraved lettering on a black background. 2.7.2.27.3 In addition, danger plates shall be provided for each switchboard. In case of single front switchgear, the rear side of each panel shall be marked with the panel number. Cable termination accessories Un-drilled G.I gland plates of minimum 3 mm thickness and double compression type brass glands shall be provided for termination of cables. The gland plates shall have gaskets. Required number of tinned, crimping type copper lugs shall be provided. Provision for terminating core on to earth bus and neutral bus shall be made. Earthing Two earth terminals shall be provided on each cubicle, at back. An earth bar of specified cross section shall be fixed to the terminals. The earth bar shall be electrically continuous and shall run the full extent of each board. Terminals shall be provided for external earth connections. All relay and meter bodies shall be earthed by one separate green earth conductor. Special tools Each switchboard shall be supplied with 2 nos. height adjustable circuit breaker / Module handling trolley for removal and replacement of the with draw-able circuit breaker carriage and five numbers fuse pullers. A set of special tools as required for the normal operation and maintenance shall also be supplied with each switchboard Painting Metal parts of all equipment shall be painted adopting approved painting procedure. Two coats of finished paint of specified colour shade shall be supplied. L.T. Capacitors LT capacitor banks shall be provided for improvement of power factor and shall be a part of the PMCC. Capacitor Rev. 0
2.7.2.28 2.7.2.28.1
2.7.2.29 2.7.2.29.1
2.7.2.30 2.7.2.30.1
2.7.2.31 2.7.2.31.1
2.7.2.32 2.7.2.32.1
NMDC LIMITED
MECON LIMITED

bank cubicles shall be in non-drawout type modules. Power and control components of the capacitor bank shall be housed in draw-out type modules where drawout feature has been specified for PMCC. 2.7.2.32.2 Capacitor banks shall be delta connected using phase units rated for 440V. Where capacitor banks of different voltage ratings are specified, the same shall be built-up from a single standard capacitor unit of appropriate rating. Each capacitor bank shall be controlled independently and shall be provided with individual switch fuse unit. Power contactor; line CT's with taut band ammeter, ammeter selector switch, auto/manual selector switch etc. All switching equipment shall have capacitor switching rating not less than 150% of rated current of capacitor bank. Contactors shall be selected based on AC-3B utilisation category rating. Control scheme for capacitor bank shall be designed for manual and automatic modes. In manual mode, the capacitor bank shall be switched manually through ON/OFF pushbuttons. To facilitate automatic mode, each bus section shall be provided with multistage power factor relay for group control of capacitor banks connected to the bus. Individual capacitor units shall be dry, self-healing type. The dielectric material shall be polypropylene, duly metalised by vapour-deposition process. Each unit shall be provided with external discharge device and internal fuses. The external discharge device shall be such that the crest voltage is brought down to 50V in one minute or less. Each unit shall also be provided with a pressure sensitive protective device. Impregnating material used shall be of non polluting PCB type The individual capacitors shall be capable of withstanding 10% over voltage on a continuous basis as well as inrush currents up to 300 times the rated current. The protection class of enclosure of capacitor shall be IP 20 and shall be suitable for ambient temperature of 450 C
2.7.2.32.3
2.7.2.32.4
2.7.2.32.5
2.7.2.32.6
2.7.2.32.7
Rev. 0
NMDC LIMITED
MECON LIMITED

The capacitor shall comply with the requirements of IS13340/13341, IEC 60831-1 Power factor control relay to facilitate group switching shall have the following features i. ii. iii. iv. v. vi. vii. viii. ix. Limitation of defective capacitor steps and their indication Automatic self-adjustment to any capacitor step value Programmable target power between two switching. Manual switching option Indication of active capacitor steps Automatic selection to prevent repetitive switching of same capacitor steps Automatic switch off capacitor banks in case of power failure Potential free contact Digital indication of p.f. setting parameters. factor, time delay
2.7.2.33 SL no 1 2 3 4 5 6 7 8 9 Motor kW 0.10.75 1.1-1.5 2.2 3.7 5.5 7.5 9.3 11 15
COMPONENT SELECTION CHART FOR PMCC/MCC MPCB/ MCCB (A) MPCB MPCB MPCB MPCB MPCB MPCB MPCB MPCB MPCB Contactor (Minimum Thermal) (A) 16 16 16 16 16 32 32 32 63 CT Ratio (A) 25/5 30/5 Ammeter Range (A) 0-5/30 0-7.5/45 0-10/60 0-15/90 0-20/120 0-20/120 0-25/150 0-30/180 Cable size Cable type YRY YRY YRY YRY YRY YRY YRY YRY YRY
4 x 2.5 4 x 2.5 4 x 2.5 4 x 2.5 4x4 4X4 4x6 4 x 10 4 x 10 Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 10 11 12 13 14 15 18.5 22 30 37 45 55 MPCB 100A MCCB 100A MCCB 200A MCCB 250A MCCB 250A MCCB 250A MCCB 400A MCCB 63 63 105 105 170 170 40/5 50/5 60/5 75/5 100/5 125/5 VOLUME - IV of V PAGE No. 138 0-40/240 0-50/300 0-60/360 0-75/450 0-100/600 0-125/750 of 272 AYFY AYFY AYFY AYFY AYFY AYFY
4 x 25 3.5 x 35 3.5 x 50 3.5 x 70 3.5 x 70 3.5 x 120
16
75
250
150/5
0-150/900
3.5 x 185
AYFY
17
90
400
200/5
0-200/1200
2(3.5x 95)
AYFY
Notes: i. Components shall be selected to provide Type 2 discrimination as per IS 13947. However, the minimum ratings of switches and contactors shall comply with the above table. Motor feeders up to 18.5 kW shall be provided with O/L relays and earth leakage relays and the MPCB's shall have only S/C element. For motors rated above 18.5 kW and up to 37 kW the feeder shall be equipped with MCCB's with S/C element, thermal O/L relays and earth leakage relays. For motors 55 kW and above, the feeder shall be equipped with MCCBs with microprocessor based adjustable releases for O/C, S/C, Earth leakage protection relay with CBCT and comprehensive motor protection relays of L & T (MM30)/ Multili 239/Schneider (SEPAM20) make.
ii.
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 2.7.2.34 2.7.2.34.1 Fuses All fuses shall be HRC link type (knife edge). They shall be current limiting, non-deteriorating type having a minimum breaking capacity of 80 KA rms. All fuses shall be provided with visible indications for "Fuse Operated" condition. TEST REQUIREMENTS The switchboards/ capacitor units shall be tested as per approved Quality Assurance Plan in MECONs format. CABLES (HT, LT & CONTROL) Selection of cables: HT Power cable: On the basis of system fault level, S/C current carrying capacity, Thermal heating effect, grouping factor, ambient temperature Etc. No straight through joints shall be acceptable for lengths of cables less than drum lengths. LT Power cable: On the basis of Voltage drop (15% during starting & 3% during running), Thermal heating effect, grouping factor, ambient temperature Etc. Minimum size of the cables for various sizes of motors shall not be less than those indicated in the Component selection chart in section 2.7.2.33 LT PMCC/MCC. No straight through joints shall be acceptable for lengths of cables less than drum lengths. Control cable: Minimum size shall be 1.5mm2 copper and reserve cores minimum 2 for upto 7 core cable, 3 for 10 core cable & 5 for upto 24 core cable shall be considered. Standardized number of cores shall be 3,5,7,10,14,19,24. Separate control cables shall be used for different control voltages and a single multi-core control cable shall in no case be used for different control voltage applications. Sequential length marking shall be provided in outer sheath of all HT, power and control cables & Multi core control cable shall be serially numbered at every meter interval. VOLUME - IV of V PAGE No. 139 of 272
2.7.2.35 2.7.2.35.1 2.8 2.8.1 2.8.1.1
2.8.1.2
2.8.1.3
2.8.1.4
2.8.1.5
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 2.8.2 2.8.2.1 1 2 3 4 HT CABLE (6.6 kV & 11kV) DESIGN CRITERIA System voltage Highest system voltage System neutral Fault level a) Symmetrical RMS b) Peak Installation Ambient temperature Insulation Conductor material Armour Sheath material : : : 6.6kV (UE) & 11kV (E) 3 phase, 3 wire 7.2kV /12kV High Resistance earthed 6.6kV) / Solid grounded (11kV) 25 kA 62.5 kA Laid direct in ground/ on cable trays / in conduits and in cable stockade/cable channels 45 deg. C XLPE Aluminium Galvanised Steel Strip Armoured Armour conductance 50% as that of largest main conductor Extruded PVC inner and outer sheath conforming to type ST-2 (as per IS: 5831) with FRLS compound additive + 10% + 5% As specified Three core VOLUME - IV of V PAGE No. 140 of 272
5 6 7 8 9 10
: : : : : : : :
11
12 13 2.8.2.2
Additional information a) Voltage variation b) Frequency variation Cable size Number of cores
: : : :
TECHNICAL SPECIFICATION Type of Cables 6.6 kV HT (UE) & 11kV (E) cables shall be circular, compacted, stranded, multi-core, Aluminium Conductor, XLPE insulated, screened, extruded PVC ST2 inner sheathed, Galvanised Steel strip (Single Layer) armoured, extruded PVC ST2 outer sheathed, conforming to IS 7098 Part 2 (1985).
2.8.2.2.1
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 2.8.2.2.2 Conductor Stranded aluminium conductor (grade H4, class 2 as per IS: 8130, 1984) shall be used as current carrying conductors for cables. 2.8.2.2.3 Screening (Conductor and insulation) The conductor and insulation shall be screened by extruded semi conducting compound. The cores/ conductor shall be screened by extruded semi-conducting compound in combination with non-magnetic metallic tape of copper. 2.8.2.2.4 Insulation Phase conductor shall be insulated with cross-linked polyethylene (XLPE) insulation material conforming to Table 1 of IS 7098 (Part-2), 1985. Dry/Inert gas/Radiant curing shall be adopted for curing/cross linking of polyethylene. Wet/steam curing is not acceptable. Colour identification of cores shall be provided. 2.8.2.2.5 Inner sheath Cable shall be provided with extruded PVC inner sheath conforming to type ST-2 (as per IS: 5831) covering the core of cable and shall be compatible with insulation provided for the cables. 2.8.2.2.6 Armour The armouring for cables shall comprise a single/ double layer of GI strip or single layer of GI strip with interspersed copper strands as per IS 3975. The conductance of the armour shall be not be less than 50% of that of the phase conductor. 2.8.2.2.7 Outer sheath The outer sheath shall be of an extruded layer of black PVC material (type ST-2 as per IS: 5831) with FRLS compound compatible with the specified ambient and operating temp of cables. The sheath shall be resistant to water, ultra violet radiation, fungus, termite and rodent attack. The FRLS shall have the following parameters: MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD 2010, MECON Limited. All rights reserved. Rev. 0 VOLUME - IV of V PAGE No. 141 of 272
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 Critical Oxygen index Temperature index Smoke density rating Acid gas, Gas generation 2.8.2.2.8 Core Identification Core identification by colour strips applied on the cores, by different coloring of XLPE insulation, or by using colored strips, red, yellow, blue colours respectively shall be used to identify phase conductor. 2.8.2.2.9 Cables Drums i. Cable shall be supplied in non-returnable wooden drums. The wood used for construction of the drum shall be properly seasoned and free from defects and wood preservative shall be applied to the entire drum. All ferrous parts shall be treated with a suitable rust preventive coating to avoid rusting during transit or storage. Cable drums shall conform to IS: 10418, 1982 (Specification for drums for electrical cables). The cables shall be supplied in the convenient drum length to be indicated by the supplier. The standard packing length in cable drum for the above HT cables shall be 500 m for cable size (3x240 sq mm) and 750 m for cable size (3x70 sq. mm). The minimum length supplied shall be within the tolerance limit of 0% on total ordered quantity. The maximum length supplied shall be within the tolerance limit of +5% on total ordered quantity of each size of cable. However, before winding the cables on drums, Tenderer shall obtain Purchasers approval for the drum lengths. Cable ends shall be sealed by non-hygroscopic sealing caps. Incremental cable length in metres shall be embossed on the outer sheath at every one-meter interval. Cable drums will be stored in the open yard at site where it will be subjected to rains and other climatic Rev. 0 VOLUME - IV of V PAGE No. 142 More than 29% More than 250 deg.C More than 80% Less than 20% of 272
ii. iii.
iv.
v.
NMDC LIMITED
MECON LIMITED

variations. The wooden drums shall not deteriorate and collapse during storage for at least 2 years. 2.8.2.2.10 Cable Identification for HT cables The outer sheath of the cable shall be embossed/ stamped with the following details at regular intervals: i. ii. iii. iv. Name of manufacturer / trade mark Voltage grade Year of manufacture Number of cores and nominal cross-sectional area of conductor
2.8.2.2.11 TESTS (HT cables): i. ii. The Cables shall be tested as per approved Quality Assurance Plan in MECONs format. At Site a) High Voltage Test b) Insulation Resistance Test c) Continuity Test. 2.8.3 2.8.3.1 LT Power and Control cable LT power and control cables shall be 1100 V grade, heavy duty, stranded Aluminium/copper conductor, multi core, PVC type A insulated, extruded PVC type ST-1 inner sheathed, GI strip/round wire armoured, PVC type ST-1 outer sheath with FRLS compound complying with IS 1554, Part 2. All LT cables shall be 3.5 core. The cable sizes shall be calculated considering maximum 3% voltage drop during running and maximum 15% voltage drop during starting. Other de-rating factors like temperature, method of laying, duty-rating etc. shall also be considered for sizing cables. However the minimum size of cables for various motors Rev. 0
2.8.3.2
NMDC LIMITED
MECON LIMITED

shall be not less than those indicated under Component selection chart for PMCC/MCC. Cable type YRY is copper conductor cable (round wire armoured) and Cable type AYFY is Aluminium conductor cable (Flat wire armoured) as per the selection chart. Max LT power cable size to be limited to 240 sq mm 2.8.3.3 2.8.3.3.1 Outer Sheath The outer sheath shall be of an extruded PVC type ST-1 as per IS- 5831.with FRLS compound The sheath shall be resistant to water, ultra violet radiation, fungus, termite and rodent attacks. The colour of the outer sheath with FRLS compound shall be black. The FRLS compound should have the following parameters: Critical Oxygen index Temperature index Smoke density rating Acid gas, Gas generation 2.8.3.4 Inner sheath The inner sheath shall be of extruded PVC type ST-1 as per IS- 5831. 2.8.3.5 Armour The armouring for cables shall comprise a single/ double layer of GI strip or single layer of GI strip with interspersed copper strands as per IS 3975. The conductance of the armour shall be not be less than 50% of that of the phase conductor. 2.8.3.6 Insulation Conductors shall be insulated with extruded PVC type A as per IS 5831. MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD 2010, MECON Limited. All rights reserved. Rev. 0 More than 29% More than 250 deg.C More than 80% Less than 20%
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 2.8.3.7 Conductor i. Aluminium conductor shall be stranded, grade H4, class 2 as per IS 8130 for LT power cables 6 mm2 and above. Copper conductor shall be annealed, stranded copper conductor class 2 as per IS 8130 for control cables below 4.0 mm2 and shall have 7 strands for the conductors. Conductor for instrumentation/signal cables shall be of high conductivity annealed, tinned, stranded, copper class 2 as per IS 8130. VOLUME - IV of V PAGE No. 145 of 272
ii.
iii.
2.8.3.8
Identification of cores i. Colour coding shall be acceptable for all cables up to 5 cores. Cable with more than 5 cores shall have Hindu Arabic numerals printed on each core. The printing shall be reversible. Where colour coding is used for cables with up to 5 cores, the choice of colours shall be red, yellow, blue, black and gray.
ii.
2.8.3.9 2.8.3.9.1
Cable drums Cable shall be supplied in non-returnable wooden drum. The wood used for construction of the drum shall be properly seasoned and free from defects. Wood preservative shall be applied on the entire drum. All ferrous parts shall be treated with a suitable rust preventive coating to prevent rusting during transit or storage. Cable drums shall conform to IS 10418, 1982. Cable ends shall be sealed with non - hygroscopic cap. Minimum drum length shall be indicated by the Tenderer in his offer. The actual length supplied on each drum shall be within the tolerance limit of 5% with an overall tolerance of 5% on total ordered quantity for each size of cable. However the maximum drum length for the largest power & control cable shall not be less than 1000 m in order to avoid joints. Rev. 0
2.8.3.9.2
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 2.8.3.9.3 2.8.3.10 2.8.3.10.1 VOLUME - IV of V PAGE No. 146 of 272
Incremental cable lengths in meters shall be embossed on the outer sheath at every 1m interval. Cable Identification for LT and control cables The outer sheath of the cable shall be embossed/ stamped with the following details at regular intervals: i. ii. iii. iv. Name of manufacturer / trade mark Voltage grade Year of manufacture Number of cores and nominal cross-sectional area of conductor
2.8.3.11
Tests (LT & Control) The cables shall be tested as per Assurance Plan in MECONs format. approved Quality
2.8.3.12
Festoon / Flexible cable LT power and control cables shall be 1100 V grade, flexible copper conductor (Festooned cables on cable trolley), multi stranded type IE1 compound insulated, un-armoured, type SE2 compound outer sheathed cables complying with IS 9968 parts I & II.
2.9
POWER DISTRIBUTION BOARDS / MAIN LIGHTING DISTRIBUTION BOARD AND SUB DISTRIBUTION BOARDS Power Distribution Boards shall receive power from PMCC to cater power to Crane, Hoists, welding Power receptacles, magnetic separators etc., MLDBs shall receive power from 6.6/.230 kV distribution transformers to cater power to all lighting loads.
2.9.1 2.9.1.1
General The distribution boards shall be continuously without overheating, designed to carry the rated current Rev. 0
NMDC LIMITED
MECON LIMITED

specified in the schedule of quantities. The boards shall be suitable for 415/ 230 Volts. +/- 10%, 50 Hz. +/- 5%, 3 Phase, 4 / 3 wire as per application requirements for lighting (mainly 230V, 3ph, 3 wire, solidly earth system) and motor feeders. 2.9.1.2 The busbars shall be rated to limit the temperature rise within 40 deg.c over the specified ambient temperature of 45 deg.c (total temperature: 85 deg.c) The power distribution boards shall comply with IS 8623 Part I&II, IEC 439 and other relevant Indian/International Standards. The ratings of incomer and feeders shall be as per requirement. Number and rating /details of feeders are to be decided based on the requirement and 20% spare with at least one of each type and rating (Min 2 feeders). Construction Sheet steel enclosure, cubicle type Floor mounted, selfstanding / supporting type. Totally enclosed, dust, damp and vermin proof Single front, dead front and preferably without rear access. With IP 52 (for indoor installation) and IP- 55 (along with canopy for outdoor and dusty areas installations) enclosure. Suitable neoprene gaskets shall be adequately provided on all doors and covers for making the boards dust proof. Factory assembled, fully compartmentalized, fixed type, in tier formation with Aluminium busbars in separate compartment. The number of accepted tier formation shall be subject to the condition that the operating handles shall be above 400 mm from floor level and shall not exceed 1800 mm from floor level for convenience of the operating personnel. There shall not be more than 6 compartments in a vertical section. Easily extensible on both sides at site.
2.9.1.3
2.9.1.4
2.9.2 2.9.2.1 2.9.2.2 2.9.2.3 2.9.2.4
2.9.2.5
2.9.2.6
Rev. 0
NMDC LIMITED
MECON LIMITED

Continuous boards suitable for cable entry from bottom. The boards shall be provided with lifting eyebolts for each shipping section. The cubicles shall be manufactured using high quality CRCA sheet steel of at least 2 mm thick for load bearing members and 1.6 mm for none load bearing members. All operating handles shall be accessible from the front side of the cubicle. The operating handles shall be suitably interlocked mechanically with the door such that the door can be opened or closed only with the switch in OFF position. Provision for defeating the door interlock also shall be provided. Each unit compartment shall have full metal barrier on all sides except front, which shall be a hinged door. All hinges shall be concealed. Each vertical section shall have a busbar alley on one side for tap off to feeders and cable alley on the other side and shall be provided with door / removable covers at the front. A base channel/frame of minimum 50 mm height and 2.5 mm thickness shall be provided. All inscriptions shall be on traffolite / anodised aluminium sheets with white letters on black background. Standard danger board of suitable size shall be provided. Busbars, busbar supports, connections Distribution board shall have horizontal busbar chamber and protective shrouds at the top running throughout the length of the board. The busbar chamber shall have removable covers for easy maintenance. Outgoing feeders shall be connected to the main busbars through vertical busbars provided in the busbar alley. Vertical bus bars shall be easily accessible for maintenance. Vertical bus bars for TP&N shall be arranged to run full height of the vertical section irrespective of whether the bottom most section is used or left as empty feeder. Busbars (triple pole and neutral) shall be Rev. 0
2.9.2.8
2.9.2.9
2.9.2.10
2.9.2.11
2.9.2.12 2.9.2.13
2.9.3 2.9.3.1
2.9.3.2
2.9.3.3
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 i. ii. iii. iv. 2.9.3.4 Aluminium conductor Uniform in cross section through out the length of the bus and identified by colour code throughout. Selected giving due consideration to proximity effect. Size of the neutral bus shall not be less than half of the size of main busbar. VOLUME - IV of V PAGE No. 149 of 272
All the busbars shall have dynamic stability for the peak current and thermal stability for the specified symmetrical short circuit current for 1 second without any deformation, deterioration or damage. Busbars shall be provided with heat-shrunk PVC sleeves. An earth bar of adequate cross section for terminating fourth core of outgoing cable shall be provided running throughout the length of the distribution board at the bottom with provision to connect to shop earth grid at either end of the board. Size of earth bar shall however be not less than neutral bus size. Removable bus link shall be provided between neutral and earth bus bars. Bus bar support shall i. Have high dielectric strength and high impact strength capable of withstanding dynamic stability currents. Be of non-hygroscopic type Be with anti tracking barriers Be self-extinguishing and fire retardant insulators with ribbed construction to prevent tracking due to dust accumulation and to have larger creepage distance.
2.9.3.5 2.9.3.6
2.9.3.7
ii. iii. iv.
2.9.3.8
The busbars shall be rated to limit the temperature rise within 40 deg.C over the specified ambient temperature as indicated in the design criteria.
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 2.9.3.9 2.9.3.10 VOLUME - IV of V PAGE No. 150 of 272
Allowance shall be made for reduction in section by boltholes. Busbar, connecting fishplates, zinc bi-chromate bolts, nuts and washers shall be provided at each end of a shipping section to facilitate connection at site. The clearance between bare phase power busbars and between phase and earth in air shall not be less than 25 mm and 19 mm respectively. All busbar joints shall be of bolted type. Belleville/ spring washers shall be used for joints to prevent loosening. Busbars shall be phase identified by colour code. Cable alley Each vertical section shall have a cable alley along side with removable tank cover. Cable alley shall have adequate space for terminating copper power cables. Barriers running complete height of the board shall effectively isolate the cable alley from horizontal and vertical busbars. Bottom cable chamber shall be left free completely for accommodating power cables and shall be completely isolated from vertical busbars. Removable, un-drilled gland plates shall be provided for each cubicle/vertical. There shall be no horizontal cross bracings within 250 mm of gland plates where the cables enter. All power-outgoing terminals shall be brought out to a separate terminal block/strip through solid links with bellows and located in the cable alley.
2.9.3.11
2.9.3.12 2.9.3.13 2.9.4 2.9.4.1 2.9.4.2 2.9.4.3
2.9.4.4
2.9.4.5 2.9.4.6 2.9.4.7
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 2.9.5 2.9.5.1 Interchange-ability All identical equipment and corresponding parts, accessories shall be fully interchangeable without any modification. Components and equipment that are not fully interchangeable are liable for rejection and the supplier shall replace all such items by fully interchangeable ones free of cost. Make up of Modules Incoming feeder: Shall be ACB / MCCB unit of adequate rating in drawout module. Where rating is 630 Amp or above the same shall be air circuit breaker in draw out execution. ACB shall be with microprocessor based direct acting self powered adjustable O/C, E/F, and S/C release. ACB release shall be provided with separate LED indication for each fault and a fault reset button. Self-diagnostic feature shall be provided in the release as a standard feature. Provided with voltmeter and ammeter with selector switches. Meters to have accuracy class 1.0 and size 144 x 144 sq. mm. Provided with R, Y, ON/OFF/TRIP lamps B phase indication lamps and VOLUME - IV of V PAGE No. 151 of 272
2.9.5.2
2.9.6 2.9.6.1 2.9.6.1.1
2.9.6.1.2
2.9.6.1.3 2.9.6.1.4
ACB shall have minimum 4 NO + 4 NC auxiliary contacts rated for 6A, AC 11 duty.ACB shall be provided with mechanical and electrical operation with anti pumping arrangement and trip circuit supervision through lamp and test push button. Moulded Case Circuit Breakers (MCCB's): MCCBs shall be of triple pole construction suitable for panel mounting, Operating mechanism shall be trip free, quick make, quick break type.
2.9.6.2 2.9.6.2.1
Rev. 0
NMDC LIMITED
MECON LIMITED

The MCCBs shall be provided with front operating handles and mechanical ON/OFF indicators. In case of trip, the handles shall rest in an intermediate position. MCCBs of rating 160A and above shall be provided with microprocessor-based release for O/C, S/C, E/F, which shall be fully adjustable. Where MCCBs are used in the motor starter modules in conjunction with contactor and thermal overload relay, type 2 co-ordination shall be provided. MCCBs shall have following accessories and features: i. ii. iii. iv. v. Shunt trip release 1 NO + 1 NC contacts rated for 6A, AC 11 duty. Fault signalling contact set of 1 NO + 1 NC contacts Insulation shields to isolate the connections between each pole Finger protection plate to prevent accidental contact
2.9.6.2.3
2.9.6.2.4
2.9.6.2.5
2.9.6.2.6 2.9.6.3 2.9.6.3.1 2.9.6.3.2
The compartment door shall be interlocked with the handle of the MCCB Indicating instruments and current transformers All indicating instruments (voltmeters and ammeters) shall conform to IS 1248. All indicating instruments shall be of taut band flush mounting type size 96 mm x 96 mm and shall conform to 1.5 accuracy class. All instruments shall be provided with zero adjusting device for external operation. Ammeters shall be suitable for operation on CT and scaled to read actual currents flowing in the circuits. All measuring current transformers shall conform to IS 2705. The current transformers shall be of cast resin type, Rev. 0
2.9.6.3.3 2.9.6.3.4 2.9.6.3.5
NMDC LIMITED
MECON LIMITED

with bar primary, 5A secondary current and class 1 accuracy. The burden of CTs shall be as required by the associated measuring instruments and connecting leads. 2.9.6.4 2.9.6.4.1 2.9.6.4.2 2.9.6.4.3 MCCB Feeders: With microprocessor based adjustable, self powered release for O/C, S/C and E/F. With 1 NO + 1 NC auxiliary contacts rated for 6A at AC11 duty. Provided with ON, OFF and Trip lamps for all ratings. Additionally ammeter shall also be provided for all feeders rated 100 A and above. Indicating lamps All indicating lamps shall be of low wattage cluster LED type. Red, Yellow and Blue colour lenses shall be provided for the lamps of the incomer. Wiring and terminations i. ii. The DB shall be completely factory assembled and wired. Power connections shall be done by 1100 V grade single core PVC insulated copper conductor or by aluminium strips of sizes adequate for the respective ratings. Control / Aux. wiring shall be by 650 V/1100V grade PVC single core copper conductor of min. cross-section 2.5sq.mm. Each wire shall be identified by ferrules at each end in accordance with schematics. Wiring to the door shall be done by flexible cable and the cables shall be bunched, sleeved and cleared so that no mechanical damage can occur to the cables during door movements. All terminations shall be of adequate current rating and size to suit individual feeder rating.
2.9.6.5 2.9.6.5.1
2.9.6.5.2
iii. iv.
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 v. VOLUME - IV of V PAGE No. 154 of 272
Outgoing power terminals shall be designed for connecting PVC copper cables of sizes indicated in schedule of items Not more than 2 wires shall be connected at one control terminal. Required number of heavy-duty double compression type brass cable glands suitable for the outgoing cables, projected nipple type complete with two lock nuts and earthing washer (provided with earth studs) shall be supplied. Edge of cable glands shall have threaded projection to enable the lock nut to fit from inside of the equipment. Terminals, crimping type cable lugs and glands shall be suitable for the cable sizes to be indicated by the Owner/ Consultant during the execution of order.
vi. vii.
viii.
ix.
2.9.6.6 2.9.6.6.1 2.9.6.6.2 2.9.6.6.3
MINIATURE CIRCUIT BREAKERS (MCBs) The MCB shall conform to IS 8828 or International Standards. The MCBs shall have a breaking capacity of not less than 9 kA rms. The MCBs offered shall be L series or G series having an instantaneous tripping current of 5 or 7 times the rated current respectively. Painting Final outer surface colour shall be Owner/ Consultants preferred shade as per IS 5 For detailed specification on painting, refer chapter. the relevant
2.9.6.7 2.9.6.7.1 2.9.6.7.2 2.9.6.7.3
The designation of the board shall be painted using stencils and white coloured 50 mm high letters. The designations shall be as indicated in schedule of quantities Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 2.9.6.8 2.9.6.8.1 2.10 2.10.1 Sl. No. 1. 2. 3. 4. 5. 6. TESTS The PDBs/MLDBs shall be tested as per approved Quality Assurance Plan in MECONs format. ILLUMINATION EQUIPMENT SPECIFICATION Recommended type of light fittings and level of Illumination: Area Control Room Electrical Room/Switchgear Room Conveyor galleries Transfer Houses/ parking sheds Stairs/walk way Open areas etc. Street lighting, outside light fittings on building, Approach road to units from main plant route roads. Office rooms Battery room Discharge Chutes Type of fittings Mirror optic type FTL / CFL Mirror optic type FTL / CFL MH/HPSV Well glass MH/HPSV Well glass fittings MH/HPSV Well glass Metal Halide Flood lights on poles MH/HPSV street/ flood light fittings Mirror optic type FTL / CFL Mirror optic type FTL / CFL Focussed lights Level of Illumination (Lux) 400 250 50 100 100 30 VOLUME - IV of V PAGE No. 155 of 272
7.
20
8. 9. 10
300 150 100
2.10.1.1
Maintenance factor for indoor lighting: i. ii. Control room & Electrical room: 0.8 All other areas: 0.6 0.7. Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 2.10.1.2 2.10.1.3 2.10.1.4 VOLUME - IV of V PAGE No. 156 of 272
Reflection factor for civil building shall be based on the final finish. GLS lamps shall not be used anywhere in the project. THE LEVEL OF ILLUMINATION INDICATED ABOVE FOR VARIOUS AREAS SHALL BE THE GUARANTED PARAMETER FOR ACCEPTANCE OF ILLUMINATION SYSTEM FOR DIFFERENT BUILDINGS / AREAS. LIGHTING DISTRIBUTION AND SUB DISTRIBUTION BOARDS. DESIGN CRITERIA The lighting distribution and sub distribution boards shall be sheet steel enclosed, wall / recess mounting type conforming to IP: 55 for outdoor / dusty areas and 52 for indoor and suitable for use on 230V, 50 Hz., 3 phase AC system. The board shall have TP/DP MCCB/MCB as incoming and TP/ DP MCB as outgoing feeders. These boards are meant for use in plant area buildings. These shall be factory built standardized boards or fabricated based on specification and approved drawing. CONSTRUCTIONAL DETAILS The lighting distribution and sub distribution boards shall be wall / recess mounted type made of minimum 1.6 mm thick sheet steel totally enclosed, dust and vermin proof construction having separate chambers for incoming and outgoing feeders. The board shall be fabricated using high quality CRCA sheet steel. Suitable neoprene gaskets shall be provided for all doors and covers for making the board dust proof. The incomer chamber shall have TP / DP MCCB /MCB of adequate rating. Outgoing shall be 4 /8 / 12 way DP MCB's of 10A/16A, 10kA rating etc., suitably mounted on DIN Rail / channel. Earth leakage protection with 100 mA sensitivity shall be provided for all outgoing feeders in LDBs, SDBs etc. Rev. 0
2.10.2 2.10.2.1 2.10.2.1.1
2.10.2.2 2.10.2.2.1
2.10.2.2.2 2.10.2.2.3 2.10.2.2.4
NMDC LIMITED
MECON LIMITED

The ratings of incomer and feeders shall be as per requirement. Number and rating /details of feeders are to be decided based on the requirement and 20% spare with at least one of each type and rating (Min 2 feeders). The operating handle of the incoming MCCB shall be accessible from the front side. The operating handle shall be suitably interlocked mechanically with the door of the incomer chamber so that the door can be opened or closed only when the switch is in OFF position. A manual interlock defeat shall also be provided. The outgoing MCBs shall be housed in a separate chamber. The chamber shall have provision for mounting Photoelectric cell and Contactor wherever necessary. The operating knobs of the MCBs shall be accessible only after opening the front door. The outgoing's chamber shall be covered completely with Hylum / FRP sheet. The 3mm thick Hylum / FRP sheet provided shall effectively shroud all the live parts against accidental contact and only the operating knobs of the outgoing MCBs shall project out. The door shall have pad looking facility. Bus bars shall be of Tinned copper. Bus bars shall be shrouded and phase, earth and Busbars shall have the same cross sections upto 100 A rating. The incoming compartment door shall have 3 Nos. (RYB).
2.10.2.2.6
2.10.2.2.7
2.10.2.2.8
2.10.2.2.9
2.10.2.2.10 In case of boards where MCB's fed from different phases are mounted side by side FRP / Hylum barriers / separators shall be placed between each MCB or required spacing shall be provided. 2.10.2.2.11 The board shall have knockout holes / un-drilled gland plates at top and bottom for cable entries. 2.10.2.2.12 All the incoming and outgoing feeders shall have specially designed termination arrangements to accommodate multiple cables or higher size cables required as per schedule of items / approved drawings. 2.10.2.2.13 Safety clearances as per IE rules shall be provided for various components in the board. MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD 2010, MECON Limited. All rights reserved. Rev. 0
NMDC LIMITED
MECON LIMITED

2.10.2.2.14 Board shall have continuous earth bus of adequate size 2.10.2.2.15 For details of MCCBs, MCB's refer to specification given elsewhere. 2.10.2.2.16 Necessary Mounting Bracket. 2.10.2.2.17 For conveyor gallery lighting / Outdoor area and street lighting the LDB's /EDBs and DBs Feeder pillars shall have contactors for each of the incoming /outgoing circuits. Number of contactors shall be decided as per requirement of owner / consultant and shall also include internal wiring. However other details will be furnished during detailed engineering/ approval of drawings. 2.10.2.2.18 180/260V Booster transformers shall be considered to cater power supply to lighting loads on conveyor galleries and the quantity shall be as per requirement 2.10.2.2.19 Contactors on the incoming side of each LDBs / Feeder pillars shall be provided for switching ON / OFF the whole board and also for few feeders on outgoing side of the LDB's as desired by owner/consultant, to control the lighting of limited areas from PLC located in the plant control room. 2.10.2.2.20 Min. size of switch and contactors shall be 32 Amp. 2.10.2.3 2.10.2.3.1 2.10.2.4 2.10.2.4.1 PAINTING For details, refer the relevant chapter. TESTING All the boards viz., MLDB's, LDB's, and sub distribution shall be tested as per approved Quality Assurance Plan in MECONs format. LIGHT FIXTURES, LAMPS AND ACCESSORIES GENERAL All the luminaries shall be suitably designed for dusty and Highly moisture area manufactured and tested in Rev. 0
2.10.3 2.10.3.1 2.10.3.1.1
NMDC LIMITED
MECON LIMITED

accordance with relevant IS specifications so far as they are applicable. 2.10.3.1.2 All the luminaries shall be commercial / industrial / decorative type as per specific requirement. All the lighting fixtures shall be complete with all parts, including earthing arrangement and accessories for efficient performance whether specifically asked in the specification or not. Individual light fittings shall be provided with suitable arrangements for GI threaded conduit entry of 19 mm dia unless otherwise specified. Terminals of all fittings shall be suitable for taking 2.5 sq. mm flexible, copper conductor PVC insulated, PVC sheathed armoured cable with armour conductivity shall be 50% of phase conductor. The earthing terminal provided shall effectively earth the entire luminaries. The clearance between the live parts and the enclosures earthing and other safety factors shall be governed by the latest revisions of the IS specification and IE rules. The luminaries shall be suitably designed to provide economically the required level of illumination on the working plane when mounted at normal standard height in accordance with the type of fixtures. The luminaries shall be suitable for operating at normal supply voltage of 230 V(Phase to phase), 50 Hz with voltage variation of +/- 10% or at voltages as specified. Ballasts of copper conductor shall be used for all fittings. P.F correction capacitor to improve P.F up to 0.95, electronic igniter, necessary connectors etc., shall also be provided where required. The lamp holders of the fittings shall be suitable to take the lamp supplied. Mounting accessories like chain, for fittings mounted in false ceilings anchor bolt and all erection accessories required for complete installation is in the scope of the Tenderer.
2.10.3.1.3
2.10.3.1.4
2.10.3.1.5
2.10.3.1.6
2.10.3.1.7 2.10.3.1.8
Rev. 0
NMDC LIMITED
MECON LIMITED

Down rods / chains for mounting light fittings and fans and GI / MS conduits, brackets, flats, hooks, channels, etc., also to be supplied and installed as required.
2.10.3.1.10 All luminaries are to be supplied with required lamps as indicated in the approved drawings / specifications. 2.10.3.1.11 All fixtures supplied shall be as per type / specification as specified in the drawing including necessary control gears mounting brackets/accessories hardware consumables required for wall ceiling suspension/recess including down rod/chain/Anchor bolts. 2.10.3.1.12 All discharge lamp fittings shall be supplied with suitable ballast, power factor improvement capacitor, igniter, etc. The ballast terminals shall be made for various tappings for use on a wide range of mains voltage making it versatile in application. 2.10.3.1.13 All control gear for high bay HPSV & Metal Halide luminaries shall be supplied separately wherever required for installation at ground floor levels and the igniter / control gear shall be suitable for a distance upto 30 metres from lamp /fittings without affecting the performance / output in any way. Tenderer to categorically confirm. 2.10.3.2 2.10.3.2.1 FLUORESCENT/ PL TYPE LUMINAIRE Fluorescent light fitting shall be made of CRCA sheet steel housing white epoxy stove enameled incorporating all electrical accessories such as electronic ballast spring loaded rotor lamp holders, reflectors/louvers, etc., BULK HEAD LUMINAIRE
2.10.3.3 2.10.3.3.1
The body of the fitting shall be made of epoxy Grey powder coated die cast Aluminium fitted with heat resistant glass cover, anodised Aluminium reflector and galvanised wire guard made of suitable dia to ensure protection to glass. Proper sealing of inside against outside influences like water vapour etc., is to be achieved with the help of a neoprene gasket glued to the housing and positioned between ring and housing. The fitting shall be provided with control gear and ceramic BC/ES lamp holder suitable for MH lamps pre wired up to the terminal block. The housing shall have MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD Rev. 0 2010, MECON Limited. All rights reserved.
NMDC LIMITED
MECON LIMITED

suitable conduit threaded entry and fixing lugs shall be provided for mounting on wall / ceiling. All MS hardware parts shall be cadmium plated and passivated to withstand corrosion. The fitting shall be weatherproof. 2.10.3.4 2.10.3.4.1 WELL GLASS FITTING The body of the fitting shall be made of epoxy Grey powder coated die cast aluminium fitted with heat resistant well glass cover, galvanised wire guard and anodised aluminium reflector. Proper sealing of inside against outside influences like water vapour etc., is to be achieved with the help of a neoprene gasket glued to the housing and positioned between ring and housing. The fitting shall be provided with built in control gear and ceramic BC/ES lamp holder suitable for MH lamps pre wired up to the terminal block. The housing shall have suitable conduit threaded entry and eye bolt on top for suspension. All MS hardware parts shall be cadmium plated and passivated to withstand corrosion. The fitting shall be weather proof. METAL HALIDE LUMINAIRE The body of the fitting shall be made of epoxy Grey powder coated die cast aluminium housing for control gear, with anodised aluminium reflector. The fitting shall be provided with adjustable GES lamp holder pre wired up to the terminal block. One no. earth terminal shall be provided near the terminal block. The fitting shall be provided with epoxy Grey powder coated MS suspension bracket with an eyebolt. STREET LIGHT LUMINAIRE Integral type street light fitting shall be of single piece die cast aluminium construction. The housing shall be finished with paint of stove-enameled gray out sides and white inside the lamp compartment. The lamp compartment shall have suitable reflectors, porcelain lamp holders with E40 brass holder having very good mechanical strength. The fitting shall be supplied with necessary ballast, p.f improvement capacitor, necessary connector block, GI pipe bracket to support the bracket for mounting the light fitting. The fitting shall be completely wired up with wires Rev. 0
2.10.3.5 2.10.3.5.1
2.10.3.6 2.10.3.6.1
NMDC LIMITED
MECON LIMITED

suitable to withstand the higher temperature; the fitting shall be gasketed to make it rain waterproof. One No. earthing terminal shall also be provided. The fitting shall be supplied with the necessary lamp. 2.10.3.7 2.10.3.7.1 FLOOD LIGHT LUMINAIRE The flood light fittings shall be of integral / non integral type as specified in the schedule. The Luminaire comprising of die cast aluminium housing with heat resist toughened glass, Highly polished stainless steel reflectors, complete with ballast, power factor improvement capacitor, etc., suitable for mounting on pole/wall/column including necessary brackets. AVIATION OBSTRUCTION FOR NEON LAMP) LUMINAIRE (SUITABLE
2.10.3.8 2.10.3.8.1
Aviation obstruction lights shall consist of yellow painted cast Aluminium body housing, with built-in 75VA step up transformer and heat resistant, clear, toughened, thick glass dome mounted on hinged die cast aluminium ring secured to the body. The Luminaire shall be provided with Neon spiral plugged into spring loaded high-tension nylon socket and wired up to the terminal block. The Luminaire shall be suitable for mounting on a pipe bracket. PHOTO ELECTRIC SWITCH / NATURE SWITCHES Photoelectric switch shall be suitable for pole mounted enclosing of a light sensitive control system, power contactor for load switching, MCB and terminal blocks. The enclosure comes with complete with mounting brackets, double compression weatherproof glands, openable door with lock and key. The enclosure should be weather proof, electric shock proof, termite proof, outdoor mountable UV stabilised electrically insulating body with flame retardant characteristics. Override options for maintenance and based switching OFF selection option shall be provided. Operating voltage range shall be suitable for 230V Phase to phase, minimum 5000 cycles switching endurances, operating state indication shall be provide with LED indication. Operating illuminance levels shall be < 60 Lux Rev. 0
2.10.3.9 2.10.3.9.1
2.10.3.9.2
NMDC LIMITED
MECON LIMITED

for > 30 seconds for switching ON and > 10 Lux for > 30 seconds for switching OFF the circuits. 2.10.3.10 STREET LIGHT (G.I) POLE/ FLOOD LIGHT (G.I)POLE
2.10.3.10.1 Galvanized Steel tubular street light pole shall be swaged and welded construction as indicated in the schedule. Each pole shall be comprising of a looping/terminal box clamped with top level 550mm above ground level along with a suitable earth terminal. A base plate 300 x 300 x 10mm welded to the bottom of the pole. The looping box shall be provided with a suitable busbar arrangement to loop 3 to 4 cables (type and size shall be as per schedule of items/drawings). 5A fuse cutout and an earthing terminal shall be provided. 2.10.3.10.2 The pole shall be provided with a cap having 3 nos. fixing bolts at 120 degrees apart, pipe arm with suitable stiffeners shall be provided to mount the street high fitting. The dia of the pipe shall be suitable to carry the weight of fitting etc and suitable for mounting the fitting. 2.10.3.10.3 The pole shall be provided with necessary cross arms for mounting one or more numbers of flood light fittings where required. Both underground cable and earth cable shall be terminated at the terminal/looping box. Further wiring to the light fixture shall be done by three-core flexible copper wire (2 core for power supply and third core for earthing). The earth terminal at the terminal box shall be further connected to the earth terminal on the pole by aluminium cable. 2.10.3.10.4 Steel tubular pole cap, terminal box and all other MS material shall be epoxy painted hot dip galvanized to 80 micron thickness. All hardware like nuts, bolts, etc shall be of stainless steel or zinc passivated. 2.10.3.10.5 The steel tubular pole shall be suitable for mounting on concrete foundation. The civil work for street light pole foundation forms a part of erection. 2.10.3.10.6 The depth of concrete foundation made of cement concrete 1:3:6 (1 part cement: 3 part sand: 6 parts stone aggregate) laid on top of a mud mat of 100 mm thickness MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD 2010, MECON Limited. All rights reserved. Rev. 0
NMDC LIMITED
MECON LIMITED

shall be 2000 mm below the ground level for poles having 8m to 11m length and 2200mm below the ground level for poles having 12m to 14.5 m length. The concrete foundation below the ground level shall be 450 mm x 450 mm square for poles having length 8m to 11m and 600 mm x 600mm for poles having length 12m to 14.5m. Concrete coping of dia 350 mm and 450 mm respectively shall be provided for the above poles for a height of 600 mm above the ground level. For any poles having length other than that indicated above the foundation shall be suitably designed by the Tenderer and got approved by consultant. 2.10.3.10.7 The terminal box shall be embedded in the coping (part of foundation above ground above ground level) so that the front of the box is accessible and slightly below the top level of foundation. GI pipes to be given as inserts to guide the cables from cable trench to terminal box 2.10.3.10.8 Earthing of street light pole shall be provided with earthing provision as per IS. 2.10.3.10.9 Steel tubular poles shall conform to IS 2713 Part II 1980 with designation to be got approved before procurement 2.10.4 2.10.4.1 2.10.4.1.1 LAMPS FLUORESCENT LAMP Fluorescent lamps shall be cool daylight and shall be suitable for switch start. Fluorescent lamps wherever specifically indicated shall be of TLF type (built-in reflector type). The lamp shall have high luminous efficiency, high lumen output. Trulite (CRI-86) similar to Philips make shall be supplied for offices, control rooms, switch gear rooms etc. as required. SODIUM VAPOUR LAMP The lamps shall be suitable for universal burning position and shall be colour corrected and shall have caps E-40 with ES/GES threads. All the lamps shall be suitable for external igniter. Lamps shall be ovoid or tubular type as specified.
2.10.4.2 2.10.4.2.1
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 2.10.4.3 2.10.4.3.1 COMPACT FLUORESCENT LAMPS The lamp shall be designed for low energy consumption, cool day light appearance, excellent colour rendering with longer life. The lamp shall be suitable for use with wall or ceiling mounting fittings suitable for compact fluorescent lamp. MERCURY VAPOUR LAMPS The lamps shall be suitable for universal burning positions and shall have E-40 with ES/GES threads lamps shall be ovoid shaped. METAL HALIDE LAMPS Metal halide lamps supplied shall be suitable for the burning position envisaged. The lamps shall have high colour stability throughout its life and ensure good colour uniformity over the light. SOCKET, SWITCHES, FANS INSTALLATION ACCESSORIES SOCKET OUTLETS SOCKET OUTLETS AND OTHER VOLUME - IV of V PAGE No. 165 of 272
2.10.4.4 2.10.4.4.1
2.10.4.5 2.10.4.5.1
2.10.5 2.10.5.1
2.10.5.1.1 FLUSH/SURFACE MOUNTING (DECORATIVE TYPE)
6A / 16A, 6A, 240V, single phase, 3 pin socket outlet shall be flush / surface mounting type along with decorative type switch. The socket shall be 6A / 16A combined (universal type) having 6 pin, or 16A, 3 pin with suitable piano type switch, Fuse & indicating lamp. 2.10.5.1.2 INDUSTRIAL TYPE PLUG SOCKET OUTLET 10A/20A, 240V, single phase, 3 pin industrial type socket outlet with interlocked switch and MCB. The outer casing shall be made of non-corroding die cast aluminium alloy, moulded of superior grade phenolic /polyester compound.
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 2.10.5.1.3 JUNCTION AND OUTLET BOXES i. Junction and outlet boxes fabricated with sheet steel shall have a minimum thickness of 1.6 mm unless otherwise specified in schedule of items. All these items shall be painted whether indicated specifically or not. The JB shall have earthing terminals & terminal block, required no. of knockouts for cable entry etc., The exact size and number of knockouts & cable glands shall be decided by the Tenderer as per actual requirement. VOLUME - IV of V PAGE No. 166 of 272
ii.
2.10.5.1.4 CONTROL SWITCHES (DECORATIVE TYPE) i. Single pole decorative type, 6A or 16A switches shall be used for light point wiring in control rooms, office premises/non plant buildings All branch switches shall be placed in line conductor of the circuit.
ii.
2.10.5.1.5 SWITCH BOARDS (FOR DECORATIVE SWITCHES AND SOCKETS) The switch board shall be made of 1.6 mm thick sheet steel and painted including supports for switches, sockets, fan regulator etc., but excluding front cover in case of decorative switches & sockets which will be of FRP sheet of approved quality, design and colour. Clear depth of the box shall not be less than 60 mm, but adequate for easy mounting of fan regulators. All fittings shall be in flush pattern in case of concealed wiring. The FRP cover sheet thickness shall not be less than 4 mm. In case of more numbers of sockets / switches / regulators are to mounted in one location, these can be mounted in a bigger size switch board with necessary clearance etc., between switches instead of individual switch board for each switch. Sheet steel enclosure shall be painted with two coats of epoxy paint above two coats of epoxy based primer.
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 2.10.5.1.6 SELECTOR SWITCH BOARD Controlling the illumination in various premises will be from these S/SW boards, which will be located in control rooms. Each S/SW board shall be made of 1.6 mm thick sheet in IP 52 class of enclosure suitable for wall/ column mounting with openable-hinged front door on which 10 Nos. of selector switches/ push buttons are mounted. Each selector switch shall have 2 positions (ON/OFF) with contacts rated for 10 Amps. All terminals shall be wired to a terminal with 2.5 flexible copper cable properly ferruled. Each S/SW boards shall have removable gland plates at top and bottom, suitable for multiple cable terminations. Each board shall have a main nameplate at top and inscription for each selector to indicate zone of control apart from ON/OFF inscriptions. Main and selector switch inscriptions will be furnished during approval of drawings. 2.10.5.1.7 BOLTS & NUTS / BRACKETS / DOWNRODS / CHAIN All screws, bolts nuts and washers used for Illumination work shall be of brass or cadmium passivated MS to resist corrosions. All brackets, down rods, chains used for suspension of tube light, well-glass fittings shall be made of MS Conduits / channels / angles / strips as approved by site engineer. Two coats of epoxy spray painting shall be applied over two coat of epoxy-based primer for all accessories. 2.10.5.1.8 CEILING FAN FANS AND REGULATORS i. All ceiling fans supplied shall be conforming to relevant IS and with capacitor starting, class 1 type suitable for voltage range of not less than 230 V AC (phase to phase) supply. Fans shall be supplied complete with fan motor, fan blade, insulated hangers canopy and regulator alongwith a down rod of suitable length as required. The speed regulators shall be of electronic type for step less variation from zero to 100%. All ceiling fans supplied shall have double ball bearings. VOLUME - IV of V PAGE No. 167 of 272
ii.
Rev. 0
NMDC LIMITED
MECON LIMITED

All ceiling fans shall be wired to a junction box and suspended from a hook in shackle and insulated from the same. All joints in the suspended rod shall be screwed and all joints or bolts in connection there with shall in addition be secured by means of split pin. The canopy at the top of the suspension rod shall effectively hide the suspension. The lead-in wires shall not be smaller than 0.75 Sq. mm (24/0.2 mm) PVC insulated flexible copper conductor cable and shall be protected from abrasion. Unless otherwise stated, all ceiling fans shall be hung at 150mm above the light fitting level or as directed by the Engineer in-charge. The length of the down rod supplied shall be suitable for this purpose. Generally the ceiling fans shall be mounted 2500/3000, above FFL. The down rod length shall be considered based on roof profile (slope or flat)
iv. v.
vi.
vii.
2.10.5.1.9 EXHAUST FAN i. Exhaust fan shall have totally enclosed with highly efficient heavy duty motor mounted on ball bearing, precisely and dynamically balanced blades/impeller to ensure smooth and trouble free operation, rigid frame with rubber pads for silent operation finished with epoxy based painting for better chemical, mechanical and corrosion resistant. The exhaust fan shall be supplied with wire guard/bird mesh screen as required. The exhaust fan shall be provided with earthing terminal.
ii. 2.10.6 2.10.6.1 2.10.6.1.1
CABLES & WIRES GENERAL The cables & wires shall be suitable for voltage up to and including 1100 V with heavy duty aluminium/copper conductor, multi core, PVC insulated, extruded PVC sheathed or unsheathed as specified, armoured or un Rev. 0
NMDC LIMITED
MECON LIMITED

armoured as specified, conforming to IS: 1554 & 694 for cables & wires. 2.10.6.2 LT Power and Control cable For details refer elsewhere in the tender document 2.10.6.3 WIRES (FRLS) i. Conductor shall be composed of plain annealed high conductivity copper or aluminium conductor as specified. Wires up to 1.5 Sq. mm shall be either solid or stranded in case of copper conductor and solid in case of aluminium conductor. Wires above 1.5 Sq. mm shall have stranded conductors. Aluminium conductor upto 10 sq. mm shall be solid for cables and stranded for higher size. Conductors having cross sectional area up to 25 Sq. mm shall be circular For flexible cords the conductor formation shall be according to IS: 8130.
ii.
iii. iv. v. 2.10.6.4
Insulation i. The insulation shall consist of an extruded layer of suitably compounded FRLS & high quality PVC. ii. The insulation shall be so applied that it fits closely on the conductor and it shall be easily removable without damage to the conductor.
2.10.6.5 2.10.6.5.1
Core Identification The individual cores of single core and multi-core cables shall be identified by different colour of PVC insulation as indicated below:
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 VOLUME - IV of V PAGE No. 170 Cables for fixed wiring & Flexible cords i. ii. iii. iv. 2.10.6.6 2.10.6.6.1 2.10.7 2.10.7.1 Single Core: grey Red, Black, Yellow, blue, white or of 272
Cores: Red & Black Cores: Red, Yellow & Blue & Red, Black & Yellow / Green Cores: Red, Yellow, Blue & Black (or) Red, Yellow, Blue, & Yellow / Green
TESTS The equipments shall be tested as per approved Quality Assurance Plan in MECONs format. CONDUITS: GI Conduit Electrical conduit shall conform to relevant IS. Rigid metal conduits shall be threadable with heavy protection. The internal bore of all conduits must be suitable for cable drawing and the ends free from burrs.
2.10.7.2
PVC Conduit Rigid heavy duty PVC conduit as per IS: suitable for electrical wiring may also be used wherever indicated in the approved drawings or specifically approved by Engineer. It shall be of approved make.
2.10.7.3
PVC Casing, Capping & Accessories PVC casing, capping & accessories like Tees, elbows, JBs shall be of heavy duty fire retardant self extinguishing, Acid & Alkali resistant, PVC toughness that will not dent, snap-fit covering, desired colour.
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 2.10.8 2.10.8.1 G.I. PIPES All the pipes supplied shall be suitable for cable drawing, without any internal burrs, smooth internal surface and threaded at both ends with coupling at one end. Class B type GI pipes as per IS shall be used for the following cable routes: i. ii. iii. Cables running on floor shall be laid in buried pipes. All cables laid upto a level +200mm from floor level shall be in GI pipes. Cables crossing road, entering building from outside through wall/foundations etc. shall be laid in GI pipes. All GI pipes shall have a suitable fish wire for drawing cable. VOLUME - IV of V PAGE No. 171 of 272
2.10.8.2
iv. 2.10.9
EARTHING Earthing shall confirm to IS 3043 1987.For detailed specification refer elsewhere in the tender document
2.10.9.1 2.10.9.1.1
Earthing of lighting distribution boards: The lighting board shall be provided with two separate earth terminals. An earth busbar of appropriate cross section shall be provided inside the lighting board and connected to the earth terminals provided on either side of the board. Adequate number of holes / terminals shall be provided on earth bus with suitable provision for terminating the earth wire. GI strip / GI wire insulated single core cable of suitable size shall be used for earthing the lighting board, by connecting the two earth terminals separately to the earthing main in the shop / earth pit.
2.10.9.1.2
2.10.9.1.3
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 2.10.9.2 2.10.9.2.1 VOLUME - IV of V PAGE No. 172 Earthing of light fixtures and socket outlets: The single core PVC insulated copper wire and the third core of the flexible wiring cable shall be used for earthing the light fixtures and single phase socket outlets etc Earthing of metal boxes and brackets: Not less than 14 SWG GI wire or suitable size PVC insulated copper wire shall be used for earthing all metal boxes and brackets. Earthing of street light poles / Flood lighting poles: At every 5th pole including first and end poles a separate earth station shall be provided. The poles will be earthed by connecting its earth terminal to the junction box through 8 SWG GI wires. Apart from the above, continuous earthing connection from pole to pole shall be carried out using 8 SWG GI wire. The earth terminal at the junction box shall be connected to the main earthing ring through 8 SWG GI wire. MISCELLANEOUS ELECTRICAL ITEMS LOCAL CONTROL STATIONS / PUSH BUTTON STATION Cast aluminium (LM6) construction, dust and vermin proof, wall / structure mounting. Enclosure conforming to IP-65 (for indoor) with Canopy for out door installation. Internal wiring shall be carried out with HR PVC extra flexible wires of 2.5 mm sq. copper. Terminals to be suitable for copper conductor of 2.5 sq. mm with 20% spare terminals. Suitable knockouts with glands on the bottom for cable entry. Control switches, push buttons, meters, annunciations and indication lamps (All indicating lamps shall be LED clustered Rev. 0 of 272
2.10.9.3 2.10.9.3.1
2.10.9.4 2.10.9.4.1
2.11 2.11.1 2.11.1.1 2.11.1.2 2.11.1.3 2.11.1.4 2.11.1.5 2.11.1.6
NMDC LIMITED
MECON LIMITED

type) mounted on front with Inscription in English on corrosion resistant metal strips 2.11.1.7 Emergency Stop push button to be stay put type with mushroom head press to lock and Twist to unlock type. Emergency stop push button hard wired to MCC / HT switchgear. All pushbuttons shall have 2 NO + 2 NC contacts rated for 5 A at 220VAC/ 1A at 110 VDC. Switches shall have spare contacts. Motors starters shall be provided with suitable dual (4-20mA) output transducers connected to the secondary of the current transformer in respective panels / modules for local ammeters. LCS Shall devices: be provided with minimum following
2.11.1.8 2.11.1.8.1
For DOL drives: Local / Remote selector switch, STOP, EMERGENCY STOP and START pushbuttons, LED lamps (local permissive, status etc.), Digital Ammeter (for above 30KW or VFD controlled LT motors) For VFD controlled motors additional devices (i.e. lamps, push buttons switches, meters etc.) as indicated under TS for VFD shall also be provided. For RDOL drives: FORWARD/REVERSE, STOP and EMERGENCY STOP pushbuttons, LED lamps (local permissive, status etc.), Digital Ammeter (for above 30KW or VFD controlled LT motors) For VFD controlled motors additional devices (i.e. lamps, push buttons switches, meters etc.) as indicated under TS for VFD shall also be provided. For HT drives: spring return to neutral type pistol grip TN-C switch, EMERGENCY STOP pushbutton, Digital Ammeter, LED lamps (local permissive, status etc.), breaker close prohibit switch and other additional PB's/switch as required. For Inline Magnetic separator LCS: Motor ON/OFF, Magent ON/OFF Push button, Selector switch for excitation mode selection, ZSS reset PB, Meter for current & Voltage. Various lamps for ON/OFF /Trip/ metal detected indication.
2.11.1.8.2
2.11.1.8.3
2.11.1.8.4
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 2.11.1.8.5 2.11.2 2.11.2.1 VOLUME - IV of V PAGE No. 174 For VFD drives as indicated in VFD specification. GI cable trays Cable trays shall be of 3000mm standard length and shall be fabricated from minimum 2.5 mm thick CRCA sheet steel. The tray shall be ladder type with folded rungs and side rails. The side rails shall have an inner lip formed by folding the sheet. The trays shall be hot dip galvanised to a minimum thickness of 80 microns. Supply of GI tray coupler plates and electro-galvanised hardware shall be part of supply of trays. The tray shall be suitable of withstanding a load of 70 kg at the centre and UDL of 70 kg with a support span of 3000 mm without exceeding the deflection limit. The cable trays shall be in standard widths of 600/450/150 mm. Cable trays shall be laid horizontally along the conveyor gallery. WELDING RECEPTACLES & POWER SOCKETS General The plug and socket units shall be suitable for operation at 415 volts, 50 Hz, 3 phase, 4 wire system with earthed neutral having symmetrical fault capacity as specified in the design criteria. The plug and socket units shall be designed for the satisfactory operation for the climatic and site conditions specified in the design criteria. The plug and socket units shall comply with the relevant Indian Standards. Welding sockets shall be available at every 60 Meter intervals in conveyer galleries, maximum three welding sockets can be looped. Construction The contacts of plug shall be adequately shrouded and contacts in sockets shall be sufficiently deep recessed to Rev. 0 of 272
2.11.2.2 2.11.3 2.11.3.1 2.11.3.1.1
2.11.3.1.2
2.11.3.1.3 2.11.3.1.4
2.11.3.2 2.11.3.2.1
NMDC LIMITED
MECON LIMITED

ensure safety for operating personnel against risk of accidental contact to live parts. 2.11.3.2.2 2.11.3.2.3 2.11.3.2.4 2.11.3.2.5 2.11.3.2.6 2.11.3.2.7 The socket and plug assembly shall be non-reversible. The earthing pin shall be long enough to ensure that earth connection is made first and broken last. The units shall be complete with compression type cable glands. The units shall be painted brilliant green as per IS-5 shade 221. Each unit shall be provided with inscription plates made of traffolite sheets with white letters on black background. The plug and socket assembly shall be provided with integral interlocked rotary switch. It should ensure that the plug could be inserted or removed only with the switch in the OFF position. The unit shall be provided with HRC fuses for short circuit protection. The components shall be enclosed in dust proof enclosure conforming to IP 55 degree of protection. The switch shall be AC 23B rated/heavy duty type. The unit shall be suitable for wall/column mounting The units shall have the following standard ratings. i. ii. iii. 2.11.3.3 2.11.3.3.1 Tests All routine tests as per relevant Indian Standards shall be conducted at manufacturer's works in the presence of owner/consultant and test certificates shall be furnished. Copies of type test certificates shall also be furnished. 415volts 63 Amps and 32 Amps. with 3 pole, neutral and earth. 240 volts. 20 A 3 Pin. 24V,AC 2pin with built in transformer/240V AC 2 pin.
2.11.3.2.8 2.11.3.2.9
Rev. 0
NMDC LIMITED
MECON LIMITED

ROTOR RESISTANCE AND ASSOCIATED CONTACTOR CONTROL PANEL FOR SLIP RING INDUCTION MOTORS, (Wherever applicable shall be provided.) The control panel with resistors shall be suitable for mounting near the motor, away from the dusty area. The secondary controllers shall be designed to operate in conjunction with stator controllers operated through PLC in auto mode of operation. FeCrAl resistor (10 Min. rating) units with temperature rise limited to 275 deg C shall be used for rotor control. The rotor resistance elements shall be designed for achieving required starting torque without exceeding peak torque values to more than two times the motor rated torque during switching over of the rotor contactors. The resistance elements shall be designed for starting duty of slip ring motor. RESISTORS Air cooled, robust, heavy duty type Rated for minimum 10 minutes duty and to match the required current. Maximum temperature limited to 275 degree centigrade. FeCrAl grid type Resistance box to be mounted to withstand vibration and also to have proper ventilation and easy removability of individual resistance box, suitable for Aluminium conductor cable termination. Enclosure class shall be IP 33. PULL CORD SWITCHES These shall be of Di-Cast Aluminium material, heavy-duty type with minimum 2 N.O. + 2 N.C contacts rated for 5 amps. at 240V A.C. These shall be of dust & vermin proof design conforming to IP-65 class of enclosure. Pull cord switches shall be provided at spacing as specified under relevant chapter. Rev. 0
2.11.4.1
2.11.4.2 2.11.4.2.1 2.11.4.2.2 2.11.4.2.3 2.11.4.2.4 2.11.4.2.5
2.11.4.2.6 2.11.5 2.11.5.1
2.11.5.2
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 2.11.5.3 2.11.5.4 VOLUME - IV of V PAGE No. 177 of 272
All the N.O. + N.C contacts shall be wired and brought to Local Control boxes at the drive end of the conveyor. Pull cord switches shall have ON/ operated indication lamps on it. One contact of these switches shall be hard wired to MCC and the other wired to PLC.The Status of each pull cord switch shall be available on PLC at any time. There are two possible ways of wiring the pull-rope switch to the safety circuit of the system one of the following as below, i. ii. To a category 4 safety relay. To a serial bus communication system connected to safe remote digital inputs
2.11.5.5
2.11.5.6
Each pull-rope switch and drift switch shall have a second contact with its own address, so that exact position can be indicated in the PLC, a remote station or portable service PC. The large number of pull-rope and drift switches shall be connected in groups from both sides of a remote I/O box, which shall be placed at approximately 1000m intervals. Pull cord switches shall be hard wired to MCC also. BELT ALIGNMENT SWITCHES These shall be of heavy-duty type with dust & vermin proof enclosure conforming to IP-65. Minimum 2 N.O + 2 N.C contacts (for each position) rated at 5A & 240V shall be provided. Belt alignment switches shall be provided at spacing as specified under the relevant chapter. Each switch shall have ON/ operated indication lamps on it. The Status of each belt alignment switches shall be available on PLC at any time. SPEED SWITCHES Electronic speed sensors shall be provided for each conveyor to detect under speed/ belt slippage. They shall be suitable for operation at 240V single phase AC. These Rev. 0
2.11.5.7
2.11.5.8 2.11.6 2.11.6.1
2.11.6.2
2.11.7 2.11.7.1
NMDC LIMITED
MECON LIMITED

shall be suitable for operation in dusty atmosphere with minimum maintenance. In case of belt slippages, the contact shall give signal wired to PLC so as to stop the conveyor. Enclosure class shall be IP 65. 2.11.8 2.11.8.1 LIMIT SWITCHES Limit switches as required shall be supplied along with technological / mechanical equipment for interlocking, monitoring & control of equipment. The quantities of limit switches shall be as per process / technological requirement and to be indicated in equipment data sheet by Tenderer. For over travel positions mechanical lever operated limit switches and normal operation zone end position limit switches shall be proximity type electronic switch. Limit switches for electromechanical sensor shall be suitable for heavy duty, high impact operation with robust construction and capable of withstanding repetitive operations. The contacts making and breaking arrangements shall be reliable and having high mechanical endurance. Number of making and breaking contacts shall be as per requirement with minimum 2NO + 2NC contacts adequately rated for handling the inductive currents in the circuit. The limit switches shall be housed in cast metal-clad (Cast aluminium body) of robust construction having dust and oil tight enclosure conforming to IP 65. The roller shall be made of high grade, wear resistant material with provision for roller lever to be mounted in steps of 90 deg. Precision limit switches, where adopted, shall be designed for reliable accurate operation having exceptionally long life. The normal travel end / intermediate position limit switches shall be 2-wire proximity type. PROXIMITY SWITCHS The Proximity switches shall be suitable for detecting the metals without contact and indicate their presence by providing a switched signal. They shall be suitable for operating in any mounting position. Nominal sensing range 35mm (min), operating distance 0 to 28.3 mm (value based on standard measurement with mild steel a shorter sensing range for other metals). The same shall be suitable Rev. 0
2.11.8.2
2.11.8.3 2.11.9 2.11.9.1
NMDC LIMITED
MECON LIMITED

for operating under high mechanical and ambient stress (i.e. high temperature, dust etc.) conditions. The proximity switches shall be universal type, with 2 sensors in one housing, 2 wire system suitable for use with 20V to 250V AC/dc control supply. The switch shall be provided with LED indications for indication of operating status. The switches shall be provided with enclosure class of IP-67. 2.11.10 2.11.10.1 DIGITAL TECHOGENERATORS It will be of robust construction and designed to give guaranteed accuracy of speed sensing. It shall generate consistent output pulses (minimum 1500 ppr) of positive or negative polarity as applicable by accepting shaft rotation.The output pulses shall be suitable for feeding into high impedance electronic circuit / instrument for digital measurement and control or PLC. The enclosure class shall be IP 67. It will be provided with ambient temperature compensating device. It shall be also provide 4-20 mA output for required for interlocking, operation and monitoring. This specification will also be applicable for Belt weigh scale encoder. Arrangement of mounting of techo generators and its coupling with motor or equipment shall be decided considering ease of maintenance, accuracy of measurement and safety of equipment. BRAKES Brakes for down hill conveyor no. 723 and reversible conveyor no. 727 shall be of disc spring apply / hydraulic release type. For other conveyors, electro-hydraulic thruster operated brakes shall be provided. The starters for these brakes motor shall be DOL starters with MPCB, contactor, overload relay etc. located in respective drive control panel or module.
2.11.10.2
2.11.11 2.11.11.1
2.11.11.2 2.11.11.3
The brake mechanism shall be provided with suitable means for adjustment of gap, brake torque, shoe positioning and shoe adjustment etc. The shoe linings shall be made from tough heat resistant material with fixing MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD Rev. 0 2010, MECON Limited. All rights reserved.
2.11.11.4
NMDC LIMITED
MECON LIMITED

rivets adequately counter-sunk to prevent rubbing against the brake wheel. Alternatively, shoe linings shall be glued with epoxy based fixing compound having adequate adhesive strength 2.11.12 2.11.12.1 SUB-STATION SAFETY EQUIPMENT RUBBER MAT Front and rear of all HT and LT switchboards panel shall be provided with 19 mm thick rubber red color mat of 6.6 kV/ 11kV grade. 2.11.12.2 CO2 FIRE EXTINGUISHER Switchgear room shall be provided with minimum 2 numbers of CO2 fire extinguishers for each substation/ electrical building. 2.11.12.3 FIRE SAND BUCKETS Each substation will additionally be provided with 4 nos. fine river sand filled buckets with stand. 2.11.12.4 SHOCK TREATMENT CHART Each substation & switch room shall be provided with Minimum two numbers of nicely framed shock treatment charts at easily viewable and readable place. 2.11.12.5 CAUTION BOARDS & DANGER PLATES The substation panels, transformer yards and switchboard panels shall be provided with caution boards & danger plate to avoid unauthorized entries. 2.11.12.6 HAND GLOVES 2 sets of Hand gloves for 6.6kv & 11kV 4770 2.11.13 SINGLE LINE DIAGRAM All the substation shall be provided with nicely framed as built Single Line Diagram indicating system voltage, current MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD 2010, MECON Limited. All rights reserved. Rev. 0 grade as per IS
NMDC LIMITED
MECON LIMITED

rating, fault level, feeder number and capacity, fuse rating, connected equipment tag no. etc. 2.12 2.12.1 2.12.1.1 2.12.1.1.1 EARTHING AND LIGHTNING PROTECTION Earthing General requirements Entire system shall be earthed in accordance with the provisions of the relevant IEC recommendations / IS: 3043 - 1987 (Code of practice for earthing) and Indian Electricity Rules, so that the values of the step and contact potentials in case of fault are kept within safe permissible limits. Earthing and lightning requirements details mentioned under clause no. 3.7 and those mentioned under illumination and Instrumentation and automation parts of this specification are complementary to this clause and shall be followed in total without extra cost. Parts of all electrical equipment and machinery not intended to be alive shall have two separate and distinct earth connections. Plant Building and electrical room housing Tenderers MCC shall be provided with a ring main earthing system each. Individual ring main earthing systems shall again be interconnected to each other and to existing plant earth grid as a network. The ring earthing system around building shall be laid at a distance of approximately 1.5m from the building and at a depth of approximately 0.8m. The ring shall be bonded at intervals to the building steel structures and also to pipes, wherever they are crossing. The earthing shall further be connected at intervals to deep earthing electrodes to achieve a combined earth resistance should be less than or equal to one ohm. For the purpose of dimensioning the main earthing lines/conductors, the duration of the earth fault current shall be taken as 1 second.
2.12.1.1.2
2.12.1.1.3
2.12.1.1.4
2.12.1.1.5
For different floors in a building, localized ground mats shall be formed and connected to the ground-earthing ring MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD Rev. 0 2010, MECON Limited. All rights reserved.
2.12.1.1.6
NMDC LIMITED
MECON LIMITED

through vertical risers. The earthing mat shall be common to both power and lighting installations. 2.12.1.1.7 The plant grid resistance shall be maximum 1 ohm should be maintained. For individual earth pits Maximum 3 ohms. Each and every equipment, machinery, structures etc. shall be properly earthed at least at two points. Each floor of electrical buildings, Transfer houses etc. shall be form an earth grid with 50 x 6mm GI flat and also a continuous earth strip shall be run along with cable trays. Earthing Stations The earthing station shall comprise of earth electrode, layers of salt and charcoal, clamps, clips, bolts/nuts, washers, civil masonry work (600x600x450 mm internal dimension) of the pits including supply of cast iron frame and cover, cast iron pit marker etc as per IS 3043.The earthing electrode shall be of G.I. pipe (class B) of 100 mm dia & 3.0 mtr. Length GI funnel and wire mesh including supply of necessary materials (metal /gravel, cement) and excavation of earth for providing earth pit shall be Included. Earthing system for computers and microprocessor-based equipment/PCs shall be distinct and separate from the power and lighting equipment-earthing system. For earthing of individual equipments and interconnection between earth pits GI flats shall be used. The sizes of earthing cables, if any, shall be as specified in TS shall be used / followed. The sizes of earth conductors for various equipment shall be as follows: 75 X 10 mm GI flat 50 X 6 mm GI flat 50 X 6 mm GI flat 25x6 mm GI flat 6 sq. mm stranded GI wire 16 sq. mm stranded GI wire 25 X 3 mm GI flat Rev. 0
2.12.1.1.8
2.12.1.2 2.12.1.2.1
2.12.1.2.2
2.12.1.2.3
Main earthing ring : MV/HT motors and : switchgear LT PMCC / MCC : LDB/EDB/Feeder Pillar etc. : LT motors up to 2.2 kW : LT motors 3.7 kW to 15 : Kw LT motors 15 kW to 45 kW : MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD 2010, MECON Limited. All rights reserved.
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 LT motors above 45 kW Local control stations, safety Switches etc lighting fixtures, sockets, metal boxes etc. 2.12.1.3 2.12.1.3.1 Joints/terminations All joints of earth conductor shall be through approved termination method so as to form rigid earth ring. All such joints shall be given necessary coating of cold galvanized paint as per relevant standards and a coat of suitable bitumen compound to prevent corrosion. Joints shall form part of laying of earth conductors and they shall not be considered as terminations for payment purposes. No extra costs shall be applicable for joints of all the earth conductors. In the case joints are made by using suitable connectors the entire joint shall be fully sealed by suitable compound so that no metallic part is exposed. The Tenderer shall make his own arrangements for the necessary crimping tools, soldering equipment, drilling machines and other tools and tackles, which are necessary for completing the installation. The size of earth conductor indicative, higher sizes wherever required shall be provided as per standards and statutory requirement without any extra costs to owner. The Tenderer shall provide adequate number of earth electrodes and equipment earthing conductor as per site requirements. Any modifications (additional earth electrode / conductors or changing type and size of electrodes / conductors and their layout) suggested by CEI of Government of Karnataka or DGMS on the grounding / earthing work done by the Tenderer shall be carried out at no extra cost. Lightning protection Lightning protection shall be provided as per relevant IS: 2309 and Complete lightning protections shall be included in scope of work. This shall consist of air terminations, Rev. 0 : : : VOLUME - IV of V PAGE No. 183 of 272
50 X 6 mm GI flat 6 sq mm stranded GI wire Same size as conductor (copper) phase
2.12.1.3.2
2.12.1.3.3
2.12.1.3.4
2.12.1.3.5
2.12.2 2.12.2.1
NMDC LIMITED
MECON LIMITED

horizontal roof conductors, down comers of size 25 x 3 GI flats, test links, earth stations etc. All roof conductors and down comers shall be cleated at every 2 meters intervals in horizontal laying and at every 1 meter interval on roof and vertical run, columns etc. Down conductors shall follow the most direct path possible between air termination and earth termination avoiding sharp bends. Down conductor shall have a testing point adjacent to the earth electrode. The earth strips grid and the spikes above the main surface of the roof of the structures / buildings shall be bonded to and form part of the air termination network. Vertical air termination points (spikes) shall project at least 30 cm above the structures / buildings / objects on which it is fixed. Each conductor shall have an independent earth termination. All earth termination shall be interconnected. The lightning protection system pits shall not be further interconnected to the plant earthing system. All items and parts shall of galvanized steel. 2.13 2.13.1 2.13.1.1 2.13.1.1.1
OVERHEAD LINES (11 kV)

RAIL POLES GENERAL The rail poles for the transmission lines shall be of good quality and shall be truly vertical. For 11 kV OH lines 9 Mtrs long second hand rail pole shall be used and at road crossings, bends & vital points 13 Mtrs long rail poles with minimum weight of 90 lb/yard shall be used. All rail pole shall be provided with 250x250x8 mm base plate welded all round. Planting depth of 11 kV pole shall be 1800 mm. Brackets for rail pole shall be provide with suitable packing for proper fixing. Cradle guard shall be provided at road crossing & as directed by the Owner/Consultant site engineer. The chemical composition and physical property of the steel sections shall conform to IS 2062 (1984) and its subsequent amendment. The poles shall be fixed at an interval of approximately 5060Mtrs (maximum). However the location and distance shall vary as per site conditions (not more than 60Mtrs). Rev. 0
2.13.1.1.2
2.13.1.1.3
NMDC LIMITED
MECON LIMITED

A through hole 14 mm dia shall be provided in each pole at a height of 300 mm above the Concrete pedestal. 1.5 M length of pole shall be buried within the PCC foundation. PCC work shall be minimum up-to 400 mm above ground level. Poles shall be painted with primer red oxide and finished with Aluminium paint in the portion above ground level. The portion buried under ground, additional two coats of bitumen paints shall be applied. The system design includes extensive survey of the HT overhead line routes to establish the feasibility of installation the network and for incorporating required diversions because of the difficult site conditions / to maintain required clearances/ for safety needs etc. The installation shall be complete in all respects for smooth and trouble free operation and requiring absolutely minimum care and maintenance. The complete associated civil works including site preparation required for the HT overhead line installation is included in the tenderers scope.
2.13.1.1.6
2.13.1.1.7
2.13.1.1.8
2.13.1.1.9
2.13.1.1.10 Although every required item of work may not be explicitly described in the specification I BOQ, the tenderer shall furnish all items necessary for the work without any exception and shall confirm the completeness of scope in the offer. No deviation on this will be acceptable. 2.13.1.1.11 Overhead line is to be supplied and erected which in brief comprises of supply of poles, insulators, conductors (SQUIRREL) etc. and erection of poles including civil works, stringing, testing and commissioning of each circuit I line. The length of this line is 2.0 kM to 3.0 kM 2.13.1.1.12 It will be the responsibility of the tenderer to obtain necessary approval of all concerned statutory authorities such as CEI / DGMS before charging the equipment 2.13.1.1.13 Scope includes OH lines route survey & fixing the exact route. Scope also includes plant & bush cutting (if required) MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD 2010, MECON Limited. All rights reserved. Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 2.13.1.2 2.13.1.2.1 2.13.1.2.2 DESIGN & INSTALLATION The entire overhead line installation shall be designed & installed in accordance with IS 5613-1995 for 11 kV. In view of the hilly terrain and high wind speeds at Bellary, the HT lines shall be laid on rail pole structures (for 11 kV) all along. The general features / requirements for each HT line is as follows: 11kV HT Line shall be provided with i. ii. iii. iv. v. 2 nos.-11kV GOS/ AB switch, with locking arrangement & lock, one at either end of the HT line. 2 sets of lightning Arrestors, one at either end of the HT line. Dropout fuses at either end Surge counters on both ends of DP structures. Double pole structures at suitable intervals and stringing with ACSR conductors along-with sets of Pin/ String / strain (Tension) insulators as required. ACSR conductors on Pin/ Suspension insulators & earth wire as required. Stay sets / arrangement wherever required. Earth pits All necessary hardware and concerning materials. VOLUME - IV of V PAGE No. 186 of 272
vi. vii. viii. ix. 2.13.1.2.3 2.13.1.2.4
The specifications of various equipments are given else ware in this specification. The successful Tenderer is required to undertake extensive detailed survey of the site to design & prepare line alignment (route) drawing for each HT line separately showing the location of cut-points/ break-points (with co-ordinates) where the proposed line is taking a turn in horizontal or/and vertical plane. Tenderer is required to calculate the various forces Rev. 0
NMDC LIMITED
MECON LIMITED

exerted by the dead weight of the ACSR conductor as well as during high wind speeds along the route of the HT line. 2.13.1.2.5 The amount of forces thus calculated shall be well within the permissible limits specified for the ACSR conductors selected for the line. Design of Double pole structure and the stay arrangement also shall be with adequate factor of safety. All the design calculations as specified above along-with assumptions if any and the HT line alignment drawings shall be furnished for approval by the purchaser/ engineer. The approval by the purchaser is for the purpose of general layout clearance with respect to other existing and / or proposed facilities / equipments / buildings etc. and this approval does not relieve the tenderer of his obligations for the feasibility, stability and adequacy of the proposal. Span for 11 kV OH lines shall be considered as 40-50 meters (Maximum). 11kV DISCONNECTING SWITCH DESIGN CRITERIA : : : : : : : : : : : : : : : : 11 kV (RMS) 11 kV (RMS) at 1500m altitude 50 Hz Resistance grounded + 10% + 5% 45 deg. C Outdoor Horizontal, single break 630A 25 kA for 3 secs. 62.5 kA peak Local, manual
2.13.1.2.6
2.13.1.2.7 2.13.2 2.13.2.1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Nominal system voltage Rated voltage of isolator Rated frequency System earthing Voltage variation Frequency variation Design ambient air temp. Service Type Rated continuous current Rated short time current Rated peak through fault current Operating mechanism Earthing switch requirement Dry and wet one minute power frequency withstand voltage for the isolator and earthing switch a) Between phase and between phase and earth
28 kV RMS at 1500mm altitude Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 b) Across isolating distance 16 : VOLUME - IV of V PAGE No. 188 of 272
32 kV RMS at 1500mm altitude
Impulse withstand volt (1.2x50 micro sec.) positive and negative polarity for the isolator & earthing switch a) Across the isolator distance : b) To earth and between poles (full : insulation) Magnetizing current breaking : capacity at 6.6 kV RMS Material of main contact :
85 kV peak at 1500mm altitude 75 kV peak at 1500mm altitude
17 18
19 20
Material of blade Creepage distance of insulator a) Total b) Protected Centre phases line distance
: : : :
Silver-plated copper contacts pressure relieving double break type. Copper / Aluminium alloy 31mm/ kV Min. half of creepage distance 280mm 3 NO + 3 NC 3 NO + 3 NC Shall be provided
total
21 22 23
between : : : : : : : : :
24
No. of auxiliary contacts on main isolator for customer's use No. of auxiliary contacts on earthing switch and earthing blade a) Interlock between disconnect switch and earthing blade b) Interlock between CB and disconnect switch a) Temperature rise of the main contacts above ambient of 450 C while carrying the rated current b) Temperature rise of metal parts acting as springs Applicable standards Local / Remote selector switch
Not more than 300 C Shall not reach a value where elasticity of material is impaired. IS: 9921 Part I to IV N.A.
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 2.13.2.2 TECHNICAL SPECIFICATION VOLUME - IV of V PAGE No. 189 of 272
2.13.2.2.1 Type
i.
The disconnecting switch shall be Manual operated air break, triple pole, gang operated, single break suitable for horizontal, upright mounting on galvanized steel structures. Isolators having contacts moving in horizontal plane are preferred.
The disconnect switch shall be capable of interrupting small inductive and capacitive currents such as those while disconnecting lines at no load or transformer no load currents. The isolator blades shall be able to carry the rated current continuously without exceeding temperature limits mentioned in design criteria.
ii.
2.13.2.2.2 Earth switch The isolator shall be provided with Manual operated earth switch, when specified, forming integral part. The rating of earth switch shall be same as that of isolator with respect to rated peak short circuit current and making current. The earth switch shall be operated by a separate operating mechanism but shall be mechanically (castle key interlock) interlocked with the isolator so that the grounding blade can be closed only, when the isolator is open and the isolator can be closed only when the earth switch is open. 2.13.2.2.3 Additional interlocks Not Applicable 2.13.2.2.4 Operating mechanism i. ii. The operating mechanism for disconnect switches shall be suitable for local manual operation. The manual operation should be easy but not easily accessible. There should be proper locking arrangement for manual operation. The operating mechanism shall have positive control of blade movements at all times and under most Rev. 0
iii.
NMDC LIMITED
MECON LIMITED

hazardous conditions. Linkages shall be fitted free from slack and lost motion. iv. v. All bearings shall be heavy-duty type, lubricated for life and sealed against dust and moisture. The manual-operating handle shall be mounted on the base supporting structure. Guide bearings shall be provided at a height of 750mm above ground level. All brackets, angles, guides, guide bearings and other members necessary for attaching the operating mechanism and operating handles to supporting structure shall be supplied as an integral part of disconnect switch. Flexible jumper connection shall be provided for earthing of operating handle.
2.13.2.2.5 Constructional features i. The switchblade of main and earth switch shall be copper. It shall be of one solid piece construction and shall be assembled that no part of the blade can move relative to the other. The thickness and section of the blade shall be such that it retains its form and straightness under all conditions of operation including the flow of system fault current for the period specified. It shall also be capable of withstanding all torsional and bending stresses due to the operation of switches. The isolators shall have high pressure self aligning adjustable contacts. The contacts shall be well protected all round by a metal cover which provides not only electrostatic screening but also prevents coarse dust from entering between the contacts. The contacts shall be designed such that the contact pressure is released before any movement of blades in the opening direction takes place and is applied after the closing travel is completed. There shall be sufficient wiping action of the contacts to make them self cleaning. The contacts shall be made of high grade high conductivity heat resistant material and shall be silver plated.
ii.
Rev. 0
NMDC LIMITED
MECON LIMITED

The earthing switch of disconnect switch shall be complete with all parts that are necessary or essential for the efficient operation. Such parts shall be deemed to be within the scope. Disconnect switch and earth switch including their operating mechanism shall be such that they cannot be dislodged from their open or closed position by gravity, wind pressure, vibrations shocks etc. The disconnect switch/earthing switch contacts shall be of silver faced copper. All live parts shall be of non-rusting and non-corroding metal. Current carrying parts shall be of non-ferrous material such as copper or Aluminium. Bolts, screws shall be provided with lock washers, keys or equivalent locking facilities and if provided on current carrying parts shall be made of non-rusting and non-corroding metal such as copper/silicon alloy. Base channels and other structural members such as operating pipes, phase coupling rods etc., operating mechanism boxes, bolts, pins etc., shall be hot dip galvanised. The thickness of galvanising shall not be less than 100 microns. All similar parts shall be interchangeable. The disconnect switch shall be such that no lubrication of any part is required except at very infrequent intervals. During the course of normal operation it is likely that the disconnect switch/earth switch may be left in the open/closed position for long periods. Disconnect switch shall be such that it is free from visible corona discharge in both closed and opened positions.
iv.
v. vi.
vii.
viii. ix.
x.
xi.
The clearance between live parts and grounded structures shall not be less than those specified in relevant standards. Inter phase clearance and mounting height shall be more than l.5m. The length MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD Rev. 0 2010, MECON Limited. All rights reserved.
xii.
NMDC LIMITED
MECON LIMITED

of break in open position shall be such that there is absolutely no possibility of arc over from the live parts to the de-energised parts on which any maintenance work may have to be done. 2.13.2.2.6 Auxiliary contacts N.A. 2.13.2.2.7 Insulators i. Insulators shall be made of high strength porcelain and shall be suitable for the service voltage and BIL specified. Porcelain used for the manufacture of insulators shall be homogeneous and free from flaws or imperfections that might affect the mechanical and dielectric quality. They shall be thoroughly vitrified, tough and impervious to moisture. Glazing of porcelain shall be uniformly brown colour, free from blisters, burs and other similar defects. Insulators of the same rating and type shall be interchangeable. The porcelain and metal parts shall be assembled in such a manner that any thermal expansion differential between the metal and porcelain parts through the range of temperature variation shall not loosen the parts or create undue internal stresses which may affect the electrical or mechanical strength and rigidity. Each cap and base shall be of high grade cast steel or malleable steel casting and they shall be machine faced smoothly and galvanised. Insulators shall be stack type.
ii.
iii.
2.13.2.2.8 Accessories Name Plate: Stainless steel name plate shall be provided on disconnect switches, earthing switches and operating devices. The name plate shall contain the information set out in IS-9920 & 9921 Suitable locking arrangement with lock (Godrej Navtal - 5 levers) shall be provide for each isolator operating MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD 2010, MECON Limited. All rights reserved. Rev. 0
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mechanism so that it can be locked in either fully open OR fully closed positions.
Grounding pads
Each pole of the disconnect switches shall be provided with two grounding pads at opposite ends, brazed to the base channel. Flexible copper ground connectors shall be provided for connecting operating handles of disconnect switches and earthing switches to the grounding system. Tools and auxiliary equipment All the special tools and auxiliary equipment necessary for the proper operation and maintenance of the disconnect switches shall be supplied. A list detailing the tools and auxiliary equipment shall be included. 2.13.2.2.9 Testing All isolators shall be mounted at works and tested as per IS: 9920 & 9921. 2.13.3 11 kV LIGHTNING ARRESTORS The lightning arresters shall be self-supporting type in single pole Assembly suitable for outdoor installation. 2.13.3.1 Design criteria Service Nominal system voltage Highest system voltage System frequency System earthing : : : : : : Ambient temp. maximum Rated arrestor voltage : Max. 100% 1.2x50 micro sec. : Spark over voltage Nominal discharge current of : 8x20 micro sec. Wave Max. front of wave impulse : spark over voltage Outdoor 11 kV 12 kV 50 Hz Solid grounded 450 C 11 kV RMS Not more than 13 kVP 10 kA (heavy duty) Not more than 15 kVP
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 VOLUME - IV of V PAGE No. 194 Front steepness for front of : 250 kV / Micro sec. wave impulse spark over voltage Pressure relief class : Class A Impulse current withstand a) High current low duration : 100 kA peak test value (4x10) micro sec. Wave b) Low current, long : Not less than 150 A peak duration test value c) Virtual duration of : 2000 Micro sec. rectangular wave One minute power frequency withstand voltage of arrestor insulation a) Dry b) Wet Insulation level of system Creepage distance of arrestor housing Accessories required a) Discharge counter with Ammeter b) Grading rings c) Mounting insulators d) Clamps & connectors on arrestor terminals No. of units on which acceptance tests are to be carried out Thickness of galvanizing of metal parts Applicable standards a) For lightning arrestor b) For arrestor housing MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD 2010, MECON Limited. All rights reserved. : IS : 3070 Part I : IS: 5621 - 1980 Rev. 0 : 28 kV RMS : 28 kV RMS : 28 kV RMS 31mm/kV of 272
: Yes : No : Yes : Yes : 3 or as per IS: 3070 Part I : Not less than that indicated in IS: 3070 Part I.
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 Surge counters VOLUME - IV of V PAGE No. 195 of 272
: Shall be considered for Dt structures.
2.13.3.2
TECHNICAL SPECIFICATION
2.13.3.2.1 Constructional features i. ii. The arresters shall be suitable for mounting on outdoor structures. The arrestor shall adequate thermal discharge capacity for switching surges, long duration surges and multiple strokes. The arrestor shall be capable of withstanding internal pressures developed due to the above discharges without operation of pressure relief vents. The arrestor shall be provided with pressure relief devices, which will prevent shattering of porcelain in case of excessive gas pressure build up. The insulator housing of the arrestor shall be of porcelain with high mechanical strength and rigidity suitable for operation under site conditions listed in design criteria. All metal shall be non-rusting and non-corroding metal. Bolts, screws etc., shall be provided with lock washers. Arrestors shall be capable of spark over on frequent switching surges.
iii.
iv.
v.
vi.
2.13.3.2.2 Accessories A) Terminals i. Line and earth terminal connectors and clamps shall be supplied with the lightning arresters.
B) Name plate ii. Each lightning arrestor shall be provided with a stainless steel nameplate in accordance with IS: 3070 part I. Rev. 0
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MECON LIMITED

2.13.4
2.13.4.1 2.13.4.1.1
DOUBLE POLE STRUCTURES (11 kV)

GENERAL Double pole structures with bracings and cross arms for supporting / installing the pin and / or strain insulators shall be designed as per the following specification. Each pole is a heave duty second hand rail (IRSHSB) of length 13-meter minimum, having a unit weight of 90-lb./ yard. Wherever necessary as per ground clearance required extra length of the rail pole shall be welded (full strength butt weld) to make the DP structure longer / higher. The general recommended profile of the DP structure with cross arm(s), bracings, placement of ACSR conductors and earth wire shall be as per IS. The end of line Double Pole structures shall be designed suitable for mounting one lightning arrestor, Dropout fuse per phase and Air break switch. Further this DP structure shall be provided with extra cross arm(s) arrangement to erect / install HT XLPE Aluminium cables with outdoor termination. It shall facilitate termination of each core of the HT cable directly without any further links. The arrangement of all the components on this DPS shall be furnished alongwith the offer separate double channel (ISMC-100) cross arms shall be provided for installing a set of lighting arrestors, DO fuse and one Air break switch on either side. Earth shall be excavated to make pits size 1Mx1Mx2.5M (depth) for each pole of the DP structure. The rail pole shall be placed over a small (50100 mm thick) padding of concrete in perfectly vertical position and then the entire pit shall be concreted & compacted using a concrete mix of 1 cement: 3 coarse sand: 6 graded stone aggregate including curing thereafter. Compacting the soil around, using boulders / earth shall be carried out if required at no extra cost. The average distance between the DP structures of any HT line shall not be greater than 40 meters in case of hilly terrain and 50 meters incase of flat ground terrain. There shall be cut points with strain insulators as well as pin Rev. 0
2.13.4.1.2
2.13.4.1.3
2.13.4.1.4
2.13.4.1.5
2.13.4.1.6
NMDC LIMITED
MECON LIMITED

insulator (for supporting jumpers) at intervals not exceeding 4 spans. 2.13.4.1.7 Each DP structure shall be complete with bracings (ISA 50 x 50 x 6), channels ISMC-100 as cross arms for pin insulators and additionally double channel (ISMC-100) cross arms for strain insulators wherever applicable. Each pole of the Double pole structures shall be provided with anti-climbing devices. Danger boards (Normal) indicating the voltage and in three languages (English, Hindi & local) shall be provided for each DP structure. Each DP structure shall be earthed as per the rules of IE/DGMS (E). Stays Stays shall be provided for the DP structure at all cut points wherever strain (tension) insulators are envisaged and at other places as necessitated by the various forces acting on the line. For 11 kV OH line stays shall be provided for every Crossings (line diverting locations) bends, curvatures and at both ends. No. of stays shall be designed as per the layout, site conditions and static & dynamic forces that arise due to severe stormy / cyclonic conditions. Where required 6 nos. of stays per DP structure shall be supplied / provided. Each stay set shall be galvanized complete with 25 mm dia x 1.85 mtr long stay rod, anchor plate of size 300x300x10 mm thimble, stay clamps, bow tightner, 7 x 4.0 mm dia GI wire, strain insulators etc. If required, size of gay wire & accessories shall be increased. The stay wire shall usually make an angle of 30 deg to 45 deg with the vertical depending up to the alignment of the line. Pits of size 1M x 1Mx 2.5M (depth) shall be excavated for placement of anchor plate of stay set and the pit shall be concreted & compacted using a concrete mix of 1 cement 3 Rev. 0
2.13.4.1.8
2.13.4.1.9 2.13.4.2 2.13.4.2.1
2.13.4.2.2
2.13.4.2.3
2.13.4.2.4
2.13.4.2.5
2.13.4.2.6
NMDC LIMITED
MECON LIMITED

coarse and 6 graded stone aggregate, including curing thereafter. Compacting the soil around using boulders / earth shall be carried out if required at no extra cost. 2.13.4.2.7 2.13.5 2.13.5.1 GI stranded wires shall comply with the specific requirements of IS 21411979, IS 48261979 & IS 6594 1974. ACSR Conductor & Earth wire: ASCR CONDUCTORS
2.13.5.1.1 DESIGN CRITERIA 1 2 Reference standard Stranding and wire dia a) Aluminium b) Galvanized steel Nominal copper area, sq. mm/ Al. area, sq. mm Rated current at 350C @ 1Mph DC Resistance at 200C ohm/km Squirrel IS 398 1996 6/2.11 1/2.11 13/21 >115A 835
3 4 5 6 2.13.5.2 2.13.5.2.1 2.13.5.2.2
Rated strength of conductor kgf
TECHNICAL SPECIFICATION Squirrel ACSR conductors shall be used for 11kV system. ACSR conductors shall conform to IS: 398 (1996). Central core shall be made of galvanized steel wires, with zinc of uniform thickness complying with Table 1 of IS 4826 (1979) for ACSR conductors. Accessories for compression, twisting joints, repair sleeve shall form part of ACSR conductor. Clamps and connector for connecting of ACSR conductor shall be made of alloy casting. Bi-metallic connectors shall be used for connecting equipment terminals made of copper or brass, bolts, nuts and washers for connector shall be made of mild steel and shall be electro-galvanised and passivated to make them corrosion resistant conforming to requirements of BS 1706.
2.13.5.2.3
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 2.13.6 VOLUME - IV of V PAGE No. 199 Post type insulators for 11kV (If used) Post type insulators shall be built up of interchangeable units and shall be of uniform composition and sufficiently strong to withstand all forces during short circuit conditions. The minimum total creepage distance for each phase shall be 31mm / kV based on highest system voltage. Electrical and mechanical insulators shall be follows: characteristics of post type of 272
Basic impulse insulation level peak Power frequency withstand voltage
Creepage distance
75 kV 28 kV RMS 31 mm / kV of highest system voltage
2.13.7
Suspension or tension insulators for 11kV Suspension or tension insulators for OH Line & switchyard shall consist of required number of insulators of 146 x 254 mm. Individual units of both suspension and tension insulator sets shall be identical and interchangeable. The electromechanical characteristics of suspension and tension insulator shall be as follows:
Basic impulse insulation level

Power frequency withstand voltage
Creepage distance
2.13.8 2.13.8.1 2.13.8.2 Pin Insulator for 11kV
75 kV peak 28 kV RMS 31 mm / kV of highest system voltage
The pin insulators shall comply with the India Standard specification IS: 731 1971, as amended from time to time. The insulators conforming to any other internationally accepted standard, which ensures equal or better quality than the standard mentioned above would also, be acceptable. Where the material is offered according to the International Standard, an English version of the specifications shall be attached with the tender. Rev. 0
2.13.8.3
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 VOLUME - IV of V PAGE No. 200 Following electrical characteristics shall apply: Sl. No. A B C D E F G 2.13.9 Description Nominal system voltage Highest system voltage Visible discharge voltage Wet one minute power frequency withstand, voltage (kV, rms) Impulse withstand voltage 1.2/50 micro second wave, Minimum creepage distance (mm) Power frequency puncture 11 kV Pin Insulator KV (rms) 11 12 9 35 75 230 1.3 times the actual dry flash over voltage 11kV 12 31mm / kV 28 75 ---------Class C as per IS Brown glazed porcelain Forged/Heat Treated Malleable cast iron as per IS 10136 and hot dip galvanized IS-731/IS-2486 of 272
Insulators (11 kV) Normal voltage Highest system voltage KV (RMS) Creepage distance Dry/wet flash over voltage KV (RMS)
Impulse withstand/flash over KV (peak)

Visible Discharge Voltage, kV Strength Class KN Type of insulator Metal parts
Fixing arrangements, Applicable standards

Tests at works Tests at sites
: As per IS : Physical inspection
2.13.10
2.13.10.1
INSULATOR FITTINGS
GENERAL
2.13.10.1.1 All insulator fittings and accessories, which are necessary for complete and satisfactory installation, shall be provided. Such fittings shall be deemed to be within the scope of this MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD 2010, MECON Limited. All rights reserved. Rev. 0
NMDC LIMITED
MECON LIMITED

specification, whether mentioned or not. The fittings shall be manufactured as per relevant standards. Hardware shall be made of hot dip galvanized steel as per IS 2633. 2.13.10.1.2 Each strain insulator assembly shall be supplied along with hot dip galvanized hardware suitable for terminating ACSR conductor of appropriate size and to fix to supporting structures. The hardware shall include forged steel shackle with bolt and nuts, horn, holder ball link, tower side adjustable arcing horn, line side arcing horn, socket eye, dead and clamps jumper terminal. All bolts and nuts, flat washers, spring washers etc., shall be supplied along with string insulator assembly. 2.13.10.1.3 Each tension string insulator assembly shall be supplied along with hot dip galvanized hardware suitable for terminating ACSR conductor and to fix to supporting structures. The hardware shall include ball hook, adjustable arcing horn, fixed arcing horn, and socket eye, clamps suitable for the terminations indicated. 2.13.11 2.13.11.1 2.13.11.2 Insulator pins The pins shall comply with IS 2486. The pins shall be of single piece preferably made by the process of forging. They shall not be jointing, welding, shrink fitting or any other process from more than one piece of material. The pins shall be of good finish, free from flaws and other defects. The finish of collar shall be such that a sharp angle between collar and shank is avoided. All ferrous parts nuts and washers except those made of stainless steel shall galvanized. Threads of nuts and tapped holes shall be cut after galvanizing and shall be well oiled or greased. Arcing horns and rings Arcing horns or rings shall be attached to bushing and post type insulators and to the conductor clamps and fittings, including those of suspension and tension insulator sets them-selves. Tension insulators sets shall have arcing ring at their outgoing end. The design of the arcing horns or rings shall be such as to reduce, as far as possible, cascading and damage to the conductors, clamps, insulator fittings, Rev. 0
2.13.12 2.13.12.1
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 insulators and conditions. 2.13.12.2 2.13.13 to other fittings, VOLUME - IV of V PAGE No. 202 under all flash of 272 over
The arcing horns or rings shall be of substantial design in order to minimize flash over. Shield wire Shield wire shall be 7/8 SWG stranded GI wire.
2.13.13.1 2.13.14 2.13.14.1
Any mid-span acceptable.
jointing
of
ACSR
conductor
is
not
Insulators & Fittings 11 kV porcelain insulators (Pin and strain insulators) shall conform to IS: 731-1971 and IS 3188-1980, as amended from time to time. The porcelain shall be sound, free from defects, thoroughly vitrified and smoothly glazed. The glaze shall be brown in colour and cover all the porcelain parts of the insulators. The design of the insulators shall be such that stress due to expansion and contraction in any part of the insulator shall not lead to deterioration. The porcelain shall not engage directly with hard metal. The insulators shall be manufactured in automatic temperature controlled kilns to obtain uniform baking and better electrical and mechanical properties. The insulators shall be suitable for a minimum failing load of (a) 45 KN applied in traverse direction for pin insulators and (b) 45 KN applied axially for strain insulators. The minimum creepage distance shall be (a) 320 mm for pin insulators and (b) 400 mm for strain insulators. All insulator fittings shall comply with the requirements of IS 2486 (latest revision) parts 1 to 4 and tests specified therein.
2.13.14.2
2.13.14.3
2.13.14.4
2.13.14.5
2.13.14.6 2.13.14.7
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 2.13.15 Wire mesh (Cradle guard) A suitable GI wire mesh (guard) shall be provided under the HT line wherever it is crossing the roads, P&T lines, other power lines and at places to be specified by the Owner/ Engineer while approving the line alignment drawings. The minimum clearance under maximum sag conditions of ACSR conductor shall be 1.25 mtrs between the conductor and the mesh. 2.13.16 Earthing VOLUME - IV of V PAGE No. 203 of 272
2.13.16.1
Earthing shall be provided in accordance with the Code of practice for Earthing IS 3043 and Indian Electricity Rules 1956 as amended from time to time and the relevant regulations of KSEB, central electricity authority and shall meet the approval of DGMS (E).
A continuous earth wire of size 7 x 8 SWG galvanized iron shall be laid all along the HT line preferably located above the power conductors, and connected to earth pits provided for the purpose. Minimum current carrying capacity shall be as per IS governing mines. Conventional Earth pits with charcoal and salt shall be provided at either end of each line as well as at each cut point and at each 5rd pole along the HT line and connected to both the poles of DPS & earth wire running at the top separately. Separate earth pits shall be provided for lightning arrestors and connected to the same directly. Each stay wire shall be permanently and efficiently earthed and a stay insulator has been fixed at a height not less than 3 Mtrs from the ground. Each earth pit shall comprise of pipe electrode of size 100 mm dia, 3 mtrs length GI pipe with all accessories required such as charcoal, salt, clamps / clips bolts / nuts / washers, funnel and also the masonry work of the pits including supply of bricks cement and excavations of earth for pit.
2.13.16.2
2.13.16.3
2.13.16.4 2.13.16.5
2.13.16.6
Rev. 0
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MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 2.13.17 General Brief specifications for various installation accessories to be supplied by the Tenderer are given in this part. However, the bidder shall quote for reputed make of such equipment and shall furnish all relevant data about the equipment he has quoted enabling the owner/engineer to properly assess the bid. All equipment supplied shall conform to relevant Indian Standard specifications. Tenderer shall furnish G.A. drawings for all the equipment under his scope of supply. Tenderer shall furnish all the technical data and drawings required. All equipment shall be routine tested as per relevant IS and test certificates shall be submitted in ten copies for approval. The materials offered should be complete with all components and accessories, which are necessary or usual for their satisfactory performance and efficient maintenance. Such parts shall be deemed to be within the scope of this contract whether specially included or not. The accessories shall include but not limited to the following as required. i. Accessories for jointing successive length of conductors such as compression/twisting joints, repair sleeves etc. Accessories for fastening the conductors to the supporting structures through the insulators such as dead-end clamps, binding wires and binding tape. Connectors such as parallel grove connectors, spacer clamps, 4 way Terminal connectors etc. clamps tie connectors, VOLUME - IV of V PAGE No. 204 of 272
ii.
iii.
iv.
Protective accessories such as armour Rods / tapes, vibration dampers, wire dampers, shield wires.
The accessories shall conform to the requirements of IS 2121-1991.
Rev. 0
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MECON LIMITED

All casting shall be free from blowholes, cracks and other casting defects. All current conveying parts shall be designed and manufactured to have minimum contact resistance. The surface of the equipment shall be smooth and free from sharp edges, burrs and other projection. The tenderer shall include all required connectors, clamps, fittings etc required for the erection of the overhead lines and insulators. The Tenderer shall verify that the buses, which are used in tension and overhead ground wire, shall be free from joints or splices. The equipment used for stringing the conductors and overhead ground wires shall be such that the conductors are not damaged or injured. All sections of conductors damaged by the application of gripping attachment shall be replaced before the conductors are pegged in place. All data such as stringing tables given tension with temperature variations shall be supplied by the conductor for approval. The Tenderer shall be responsible for supplying and installing the various conductors required for connection of various equipment. The price should be inclusive of bolts, nuts and washers required for installation. All connections etc., shall be so made that stress between connecting terminals will be reduced to minimum. The physical layout of the system shall be such that the system extension can be carried out with minimum changes. 2.13.18 2.13.18.1 Tests & Inspection Routine tests shall be carried out on all equipment at manufactures works as per appropriate IS regulations. The Tenderer shall arrange all necessary facilities, free of cost for inspection and testing of the equipment by the purchaser no equipment shall be dispatched to site without a provisional certificate of acceptance issued by the Purchaser /consultant. Inspection and test shall be carried out at the place of manufacture as well as on receipt of the equipment at site. Inspection and tests do not relieve the Tenderer of his contractual obligation regarding performance of equipment at site / in actual use. Type test certificates of all equipments, under Tenderer's scope shall be submitted. Rev. 0
2.13.18.2
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 2.14 2.14.1 2.14.1.1 EQUIPMENT SIZING & SELECTION TRANSFORMERS The transformers shall be selected from one of the ratings given below: 63 kVA, 100 kVA, 160 kVA for Lighting transformer 630 KVA, 1000 KVA, 1250kVA, 1600 KVA, 2000 KVA for distribution transformer/converter transformer. A load factor of 0.9 for continuously running loads and 0.4 for intermittently running loads. Transformer regulation for the peak load considerations. A margin of 20% after considering all the factors enumerated above. 2.14.2 2.14.2.1 DC SYSTEM The battery shall requirements. i) ii) be sized to meet the following VOLUME - IV of V PAGE No. 206 of 272
Momentary loads (up to 1 min) Continuous load (up to 10 hours)
- Simultaneous Tripping load of all HT breakers + (ii) - all continuously energized relays/Meters/lamps/aux contactors + critical DC lighting load.
2.14.2.2
The end of discharge cell voltage shall be as per IS: 1652. The battery capacity at C10 rate of discharge shall be worked out for durations of 1 min & 10 hours and the highest capacity shall be considered. The final battery rating arrived at shall consider temperature correction factor as per IS and aging factor of 20%. The float cum booster charger shall be rated to cater to the trickle changing current of batteries as well as the boost charging (2 rate) of a fully discharged battery and continuous load on DC bus including 20% margin. The boost charger shall be rated to charge the battery from fully discharged condition to charged condition within 8 hours.
2.14.2.3
Rev. 0
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MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 2.14.3 2.14.3.1 CABLES Power cables shall be sized/ selected based on the following requirements: i. Continuous current carrying capacity arrived at after applying derating factors for grouping, ambient air temperature/soil temperature/ soil thermal resistivity, duty factor etc. Cable derating factor shall be considered as 0.65 for all HT & LT power cables. Voltage drop: the voltage drop at motor and during starting shall be limited to 15%. Voltage drop under running conditions i.e. at rated current shall be limited to 2% from HT switchgear to MV/HT motor terminals; for LT motors, the voltage drop, totally, from PMCC/MCC to the motor terminals shall not exceed 3 % during full load (rated current of motor) operation. The total voltage drop from MLDB to the farthest luminaire shall not exceed 3%. Short circuit capacity: The cables shall be capable of withstanding following fault clearing times for the fault magnitude at the applicable point VOLUME - IV of V PAGE No. 207 of 272
ii. iii.
iv. v.
2.14.3.2
CB controlled motors/transformer feeders connected to HT switchgear and protected by instantaneous. O/C protection: 0.2 secs. I/C to HT switchboard/Any other distribution feeder: 1 sec. For circuits, which are protected by fuses, cables need not be sized to withstand the S/C current. However they need to be rated for the let through currents of the fuses/full load current of the feeder whichever is higher. Control cable shall be provided with spare cores as follows: For up to 7 core cables: 2 cores spare For greater than 7 core to 24 core cables: 3 cores spare
2.14.3.3
2.14.3.4
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 2.14.4 SWITCHBOARDS The breakers selected for I/C & O/G feeders shall be rated 1.25 times the continuous current it is required to carry. 2.14.5 2.14.5.1 FEATURES OF ELECTRICAL PREMISES. The following electrical premises shall be provided : At tail end of the DHC, tenderer shall plan a substation to accommodate 6.6kV HT switchgear, Distribution transformer, lighting transformers, VFDs, and other electrical equipment. At head end side of the DHC two numbers of substation buildings (ie. One near to TH5 and another near to TH3) shall be provided. At substation near TH5, , 11kV HT switchgear, Distribution transformer, lighting transformers, VFD drive for reversible conveyor(727) etc shall be located. At substation near TH3, VFD panel for belt feeder (725) shall be provided in a separate AC room with other electrical equipment as per requirement. 2.14.5.2 The buildings shall be of civil construction with RCC framework and shall be provided with at least two access staircases. Electrical buildings provided near TH5 and at the tail end of DHC shall be two storied structures. The substation at TH3 shall be single storied structure. Toilets shall be considered on each floor. While sizing the switchgear room provision for extension on either side by minimum 2 panels space shall be considered. Clearances shall be considered as follows while planning equipment layout in the substation: i. ii. iii. Two HT switchboards facing each other. HT switchboard facing LT Switchboard. Clearance from wall, column etc to rear of switchboards : 2500 mm : 2000 mm :1000mm Rev. 0 VOLUME - IV of V PAGE No. 208 of 272
2.14.5.3 2.14.5.4 2.14.5.5
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MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 iv. v. Two LT switchboards facing each other. Clearance between two adjacent switchgears or wall Top of switchgear VOLUME - IV of V PAGE No. 209 : 2000 mm : 800 mm + 2 panel spaces for future switchgear. : 500 mm : 800 mm facing each other. of 272
vi.
vii. Between two battery banks
Electrical buildings near TH5 and at Tail end of DHC 2.14.5.6 The HT Switchgear, LT PMCC/MCC, DCDB, battery charger, Batteries, MLDB Etc. shall be located in switchgear room in the ground floor. The switchgear room shall be provided with concrete cable channels to facilitate laying of cables. The switchgear room shall be provided with pressurized ventilation system. The transformers shall be kept in ground floor in transformer rooms enclosed from all directions and at the front rolling shutter of link type to facilitate natural ventilation shall be provided. The parition wall between adjacent transformer enclosure as well as between any transformer enclosure and switch gear room shall be at least 345 mm thick brick wall / 225 mm thick PCC. Transformer rooms shall be provided with oil soak pit as per IS. An oil separator chamber sized for the cumulative oil content of all transformers shall also be provided, away from the substation. The clearances around the transformer shall be 1.25 Mtrs. VFDs, automation panels, UPS, UPS batteries etc shall be located in the first floor of the respective building in airconditioned room. The first floor shall also house Shift incharge room, office room for 6 engineers, room to house the HMI/operator station . Air conditioning shall be provided for the above rooms in first floor except office room and the A/C plant shall be located in the first floor in a separate room.
2.14.5.7
2.14.5.8
Suitable lifting and handling arrangement shall be considered for lifting the panels provided in 1st floor. MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD Rev. 0 2010, MECON Limited. All rights reserved.
2.14.5.9
NMDC LIMITED
MECON LIMITED

HT capacitor banks shall be placed in a separate room in the ground floor. Electrical building near TH3
2.14.5.11
VFD panel (Belt feeder 725), automation panels, UPS, UPS batteries etc shall be housed in the ground floor of the building in air-conditioned room. The room shall be provided with concrete cable channels to facilitate cable laying.
2.15 APPLICABLE STANDARDS AND CODES: 1. IS 6665-1972 2. IS 3043-1987 Reaffirmed-1991 3. IS 732-1989 - Third Revision 4. IS 5216-1982 Part I-First Rev. Reaffirmed 1990 5. IS 4160-1967 Reaffirmed-1990 6 IS 1293-1988 Second Revision Amendments (2) Reaffirmed 1990 7. IS 2667-1988 8. IS 9537 Part 1 1980 Part 2 1981 Part 3 1983 Part 4 1983 Reaffirmed 1990 9. IS 6946-1973 (Withdrawn) Reaffirmed-1990 Superseded by IS: 9537 Part 5 10. IS 3419-1989 11. IS 3837-1976 Reaffirmed-1990 12. IS 1913 Part I 1978 - Second Revision Reaffirmed 1992 : Industrial lighting code of practice. : Earthing-Code of Practice : Electrical wiring and installations : Guide for safety procedures and practice in electrical work : Industrial type Interlocking switch socket : Plug & socket outlets
: Fittings for rigid steel conduits for electrical wiring : Conduits for Electrical installation General requirements Rigid steel conduits Rigid conduits of insulating material Pliable self recovering Conduits : Flexible non metallic conduits for electrical Installation : Fittings for rigid non-metallic conduits. : Rigid steel conduits for electrical wiring and accessories. : General and safety requirement of lighting fittings Tubular Fluorescent lamps. Rev. 0
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MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 13. IS 374 1979 Third Revision Amendment (3) Reaffirmed 1990 15. IS 4237-1982 First Rev. Reaffirmed 1991 Superseded by IS: 13947 Part I 16. IS 2516 (Part I & II Section I) 1985 Second Rev. Reaffirmed 1991 Part I 1980 Sec.2, First Rev. Part V Sec.2 1980 Superseded by IS: 13947: Part II and 13118 17. IS 10118-1982 Part 1 to 4 Reaffirmed 1991 VOLUME - IV of V PAGE No. 211 of 272
: Fans and regulators, ceiling type
: General requirements for switchgear and control gear for voltages not exceeding 1000 V. A.C. : Requirements and tests, voltages not exceeding 1000VAC or 1200V DC General and definitions for voltage above 1000V AC : Informations to be given with enquiries, tenders and orders and : rules for transport, Erection and maintenance, for voltage above 1000V AC. : Code of practice for selection, installation And maintenance switch gear and control gear. : Degrees of protection provided by enclosure for low voltage switchgear and control gear.
18. IS 2147-1962 (withdrawn) Reaffirmed 1990 Superseded by : IS 13947-part 1 : HRC cartridge fuse links. 19. IS 9224-1979/ 1980 Part- I Reaffirmed 1991 Superseded by IS: 13703 Part 1 Part II-1979 Reaffirmed 1991 Superseded by IS: 13703 Part 2 Sec 1 and 2208 Part IV-1980 Reaffirmed 1991 Superseded by IS: 13703 Part 4 20. IS 1554 Part I : PVC insulated (heavy duty) electric Third Rev. cables for working voltage up to and Part II 1988 including1100V. Second Rev. Reaffirmed-1988 21 IS 694 1990(Third Revision). : PVC insulated cables for working voltages up to and including 1100V MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD 2010, MECON Limited. All rights reserved. Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 22 IS 9968 Part I-1988 (First Revision) Reaffirmed 2005, Amendments (2) Superseding IS: 434 Part 2 Part II-2002 (First Revision) Reaffirmed 2005, Amendments (1) 23 IS 7098 Part I-1988 (Second Revision) Reaffirmed 2005, Amendments (1) Part II-1985 (First Revision) Reaffirmed 2005, Amendments (1) 24 IS 2026 Part I-1977 (First Revision) Reaffirmed 2001, Amendments (3) Part II-1977 (First Revision) Reaffirmed 2006, Amendments (2) Part III-1981 (Second Revision) Reaffirmed 2006, Amendments (1) Part IV-1977 (First Revision) Reaffirmed 2006, Amendments (2) Part V-1994 Reaffirmed 1999 25 IS 11171-1985 Reaffirmed 2006 26 IEC 61378-1:1997 27. IS 9511-1980 Reaffirmed 1990 28. IS 5578-1985 First Rev. Reaffirmed 1991 29. IS 5728-1970 (Withdrawn) Superseded by IS: 13234 VOLUME - IV of V PAGE No. 212 Elastomeric insulated cables Elastomer insulated cables: For working voltages upto and including 1100 V Specification for Elastomer-insulated Cables For Working Voltages from 3.3 kV up to and Including 3 3kV XLPE cables Crosslinked polyethylene insulated PVC sheathed cables: For working voltage upto and including 1 100 V Crosslinked polyethylene insulated PVC sheathed cables: For working voltages from 3.3 kV upto and including 33 kV Transformers General Temperature-rise Insulation level and dielectric tests Terminal marking, Tappings and connections Transformer/Reactor bushings minimum external clearance in airspecification Specification for Dry-Type Power Transformers Converter duty transformers : Earthing knobs for neutral conductors. : Guide for marking of insulated conductors. : Guide for short circuit calculations. Rev. 0 of 272
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 30 IS 2551-1982 First Rev. Reaffirmed 1990 31 IS 9676-1980 Reaffirmed 1987 32 IS 8923-1978 Reaffirmed 1990 33 IS 5-1978 Third Rev. Reaffirmed 1991 34 IS 8289-1976 Amendment (1) Reaffirmed 1991 35 IS 2713 Part-I to III 1980 Second Rev. Reaffirmed 1991 36 IS 3854-1988 Reaffirmed-1990, Superseding IS: 2120 and 4949 37. IS 3480-1966 Reaffirmed-1990 38. IS 5133-1969 Part-I Part-II Reaffirmed-1990 Superseded by IS: 14772 39. IS 371-1979 Reaffirmed-1990 40 IS 3722-1983 Part-1 First Rev. Reaffirmed 1991 41. IS 7752-Part I 1975 Reaffirmed 1991 42. IS 12943-1990 43. IS 4615-1968 44 IS 5082-1981 Reaffirmed 1991 45 IS 8828-1993 VOLUME - IV of V PAGE No. 213 : Danger boards : Reference ambient temperature for electrical equipment. : Warning symbols for dangerous voltages. : Colours for paints. : Electrical Equipment with type of protection 'n' : Street light pole : Switches to domestic and similar purposes. : Flexible steel conduits for electrical wiring. : Boxes for enclosure of elect. accessories : Steel & cost iron boxes. Boxes made of insulating materials : Ceiling roses. : Letter symbols and signs used in electrical technology. : Guide for improvement of power factor in consumers installation. : Brass Glands for PVC cables. : Switch socket outlets. : Wrought Aluminium & Aluminium Alloy Bars, Rods, Tubes & Sections for Electrical Purposes. : Circuit Breakers for Over current protection for household & similar installation. : Flexible steel conduits for Electrical wiring. Rev. 0 of 272
46 IS 3480-1966
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 47. IS 1777 1978 First Rev. Amendment (1) Reaffirmed 1990 48. IS 2309 49. IS 3646 Part I 1992 Part II 1966 Part III 1968 50 VOLUME - IV of V PAGE No. 214 of 272
: Industrial Lighting Fittings with metal reflector. : Lightning protection. : Code of practice Interior Illumination General requirement and recommendation for working interiors : Schedule of illumination and glare index : Calculation of coefficients of utilization by the BZ method : Capacitors for electric discharge lamps (fluorescent and mercury lamps)
IS 1569 1976 First Rev Amendment (1) Reaffirmed (1990) 51 IS 10322 : Luminaries for streetlight fittings Part I 1982 Reaffirmed 1989 : General Requirements Part II 1982 : Constructional requirement Reaffirmed 1989 Part III 1984 : Screw and screw less terminations Part IV 1984 : Methods of test Reaffirmed 1990 52 IS: 9283 (1995) : Motors for submersible pump sets 53 IS 1258 1979 : Buyonet lamp holders 54 IS 1534 (Part I) 1977 Ballast for fluorescent lamps for switch start circuits. Reaffirmed - 1988 55 IS 3323 1980 : Bi-pin lamp holder for TL lamps Reaffirmed 1992 56 IS 2215 1984 : Starter for TL lamps Reaffirmed 1992 57 IS 3324 1982 : Holders for starters for TL lamps Reaffirmed 1988 58 IS 2418 1977 TL lamps for general lighting service Reaffirmed 1992 Part - I Requirements ad tests Part II Standard lamp data sheets Part III Dimensions of Bi-pin cap Part IV Ganges of Bi-pin cap 59 IS 5077 1969 Decorative light fittings Reaffirmed 1990 60 IS 9974 1981 High pressure sodium vapor lamps Part I General Requirements and tests MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD Rev. 0 2010, MECON Limited. All rights reserved.
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 Part II IS 10276 1982 IS 1569 1981 IS 2268 1988 IS 5081 1990 IS: 8623 (1993) Part 1 Part 3 66 67 68 69 70 IS: 11353 (1985) IS: 7118 (1973) IS: 9409 (1980) IS: 12063 (1987) IS: 12083 (1986) Part 1 Part 2 : : : : : : : VOLUME - IV of V PAGE No. 215 of 272
61 62 63 64 65
71
IS: 13947 (1993)

Part 1 Part 2 Part 3 Part 4 Part 5
: : : : Low voltage switchgear and control
Standard lamp data sheets Edison Screw lamp holders Cast acrylic sheets for use in luminaries Electric call bells and buzzers for indoor use Glass tubes for fluorescent lamps for general lighting service. Specification for low-voltage switchgear and control gear assemblies Requirements for type tested and partially type tested assemblies Particular requirement for equipment where unskilled persons have access for their use Guide for uniform system of marking and identification of conductors and apparatus terminals Recommendations for direction of movement for control devices operating electrical apparatus Classification of electrical and electronic equipment with regard to protection against electrical shock. Classification of degrees of protection provided by enclosures of electrical equipment. Electrical relays Contact performance Insulation tests
gear
: General Rules : Circuit breakers : Switches, disconnectors, switch disconnectors and fuse combination units : Contactors and motor-starters : Control circuit devices and switching elements
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 72 73 74 SP 39 (1987) IS: 13947 (1993) IS: 13703 (1993) Part 1 Part 2 / sec 1 Part 2 / sec 2 75 IS: 2705 (1992) Part 1 Part 2 Part 3 Part 4 IS: 3156 (1992) Part 1 Part 2 Part 3 IS: 4146 (1983) IS: 4201 (1983) IS: 722 (1977) Withdrawn IS: 8530 (1977) IS: 1248 IS: 6875 Withdrawn VOLUME - IV of V PAGE No. 216 of 272
76
77 78 79 80 81 82
Part I (1973) Superseded by IS: 13947 Part 5 : Sec 1 Part II (1973) Superseded by IS: IS 13947 Part 3: Sec 1
: Indian standard guide for insulation coordination within low voltage systems : Degrees of protection provided by enclosures for low voltage switchgear and control gear. : Low voltage fuses for voltage not exceeding 1000V A C or 1500 V DC : General requirements : Fuses for use by authorised persons supplementary requirements : Fuses for use by authorised persons examples of standardized fuses : Current transformers : General requirements : Measuring current transformers : Protective current transformers : Protective current transformers special purpose applications : Voltage transformers : General requirements : Measuring voltage transformers : Protective voltage transformers : Application guide for voltage transformers : Application guide for current transformers : AC electricity meters : Maximum demand indicators : Direct acting indicating analogue electrical measuring instruments and their accessories. : Specification for control switches (Switching devices for control and auxiliary circuits including contactor relays) for voltages up to and including 1000V AC and 1200 V DC : General requirements and tests : Push buttons and related control switches Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 Part III (1980) Superseded by IS: IS 13947 Part 5: Sec 1 IS: 325 (1996) IS: 4722 (1992) IS: 12075 (1986 VOLUME - IV of V PAGE No. 217 : Rotary control switches : Three Phase Induction Motor Specification : - Rotating electrical machines. : Mechanical vibration of rotating electrical machines with shaft height 56 mm and higher measurement, evaluation and limits of vibration intensity. : Permissible limits of noise level for rotating electrical machines : Degrees of protection provided by enclosures for rotating electrical machinery : Terminal marking and direction of rotation for rotating electrical machinery : Designation of methods of cooling for rotating electrical machines : - Guide for testing three - phase induction motors : - Temperature - rise measurement of rotating electrical machines : Method of determination of efficiency of rotating electrical machines : Type of duty and classes of rating assigned. Steel Tubes, Tubulars and Other Wrought Steel Fittings - Specification Part 1: Steel Tubes General Requirements for Enclosures for Accessories for Household and Similar Fixed Electrical Installations Specification : - Dimensions and output series for rotating electrical machines : Dimensions of flange mounted A.C. induction motors. : Dimensions of three-phase foot mounted induction motors. Rev. 0 of 272
83 84 85
86 87 88 89 90 91 92 93 94 95
IS: 12065 (1987) IS: 4691 (1985) IS: 4728 (1975 IS: 6362 (1995) IS: 4029 (1967) IS: 12802 (1989) IS: 4889(1968 IS: 12824 (1989) IS 1239: 2004 Part-1 Sixth Revision, Amendment (1) IS 14772-2000, Superseding IS 5133: Part 2 - IEC 72 IS: 2223 IS: 1231 (1983) (1974)
96 97 98
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 99 S: 8789 (1996) (1976) (1980) (1966) VOLUME - IV of V PAGE No. 218 of 272
100 IS: 8223 101 IS: 9628 102 IS: 3682
103 IS: 12615 (1989) 104 IS 13925: Part 1: 1998
105 IS 13925: Part 2: 2002/IEC 60871-2: 1999 106 IS 13925: Part 3: 2002/IEC 60871-3: 1996
107 IS 13340: 1993, IEC-831
: I - Values of performance characteristics for three-phase induction motors. : Dimensions and output ratings for foot mounted rotating electrical machines with frame number 355 to 1000. : Three phase induction motors with type of protection n. : Flameproof ac motors for use in mines. : Energy efficient three-phase squirrel cage induction motors. : Shunt capacitors for ac power systems having a rated voltage above 1000 V Part 1:General performance, testing and rating safety requirements Guide for installation and operation (superseding IS 2834: 1986) : Shunt Capacitors for A.C. Power Systems Having a Rated Voltage Above 1000 v - Part 2: Endurance Testing : Shunt Capacitors for A.C. Power Systems Having a Rated Voltage Above 1 000 v - Part 3 : Protection of Shunt Capacitors and Shunt Capacitor Banks : Power Capacitors of Self-healing Type for AC Power Systems having Rated Voltage up to 650 V Specification A.C. Metal Enclosed Switchgear and Controlgear for Rated Voltages Above 1 kV and Up to and Including 52 Kv : Requirements for ageing test, selfhealing test and destruction test on shunt capacitors of the self-healing type for ac power systems having a rated voltage upto and including 650 V
108 IS 3427-1997, Amendment (1) Reaffirmed-2002 First Revision 109 IS 13341: 1992 IEC
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 110 IS 13010: 2002 (First Revision) Superseding IS: 722 (Part 3): 1977 and (Part 8): 1972 111 IS 13779: 2002 (First Revision) Reaffirmed 2004, Amendment (4) Superseding IS: 722 (Part 3): 1977 and (Part 8):1972 112 IS 14415: 1997 Reaffirmed 2002 superseding IS:722 (Part 5):1980 113 IS 14390: 1996 Reaffirmed 2001 superseding IS:722 (Part 7):1987 114 IS 14372: 1996 Reaffirmed 2000 superseding IS:722 (Part 7):1987 115 IS 10418-1982 Reaffirmed-2006 116 IS 3925-1980 (First Revision) Reaffirmed-2000 Amendment (1) 117 IS 8130-1984 (First Revision) Reaffirmed-2006 Superseding IS: 1753 and12982 118 IS 5831-1984 (First Revision) Reaffirmed-2000 Amendment (1) 119 IS 3975-1999 (Third Revision) Reaffirmed-2004 Amendment (1) 120 IS 5424-1969 Reaffirmed-1999 Amendment (5) 121 IS 4770-1991 (First Revision) Reaffirmed-2006 Amendment (1) VOLUME - IV of V PAGE No. 219 of 272
AC Watt hour Meters, Class 0.5, 1 and 2 - Specification AC Static Watt-hour Meters, Class 1 and 2 - Specification
Volt-Amphere hour meters for restricted power factor range specification Var-hour meters, Class 3.0
Volt-ampere hour meters for full power factor range
Drums for electric cables Specification for Eugenol Conductors for insulated electric cables and flexible cords PVC insulation and sheath of electric cables Mild steel wires, formed wires and tapes for armouring of cables Specification for rubber mats for electrical purpose Rubber Gloves - Electrical Purposes Specification
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 122 IS 1652-1991 (Third Revision) Reaffirmed-2002 Amendment (2) 123 IS 2309-1989(Second Revision) Reaffirmed-2005 Amendment (1) 124 IS 10028 VOLUME - IV of V PAGE No. 220 of 272
Stationary cells and batteries, leadacid type with plante positive plates Code of practice for the protection of buildings and allied structures against lightning Code of Practice for Selection, Installation and Maintenance of Transformers - Part 1 : Selection Selection Installation Maintenance Methods of High Voltage Testing - Part II : Test Procedures Methods of high voltage testing: Part 3 Measuring devices
Part-1 1985 Reaffirmed 2006 Part-2 1981 Reaffirmed 2006 Part-3 1981 Amendment (1) Reaffirmed 1998 125 IS 2071-1974 Part-2 First Revision, Amendment (1) Reaffirmed-2006 IS 2071-1976 Part-3 First Revision Reaffirmed-2001 Superseding IS 2070 126 IS 2120-1963 Superseded by IS 3854 127 IS 2208-1962 Superseded by IS 3854 128 IS 13234-1992 Reaffirmed 2002 Superseding by IS IS 5728 129 IS 4949-1968 Reaffirmed 1999 Amendment (5) Superseded by IS 5728
15-ampere tumbler switches HRC cartridge fuse links for voltage above 650 volts Guide for Short-circuit Current Calculation in Three-phase A.C. Systems 2 Amp switches for domestic and similar purposes
3.0 3.1 3.1.1
ERECTION, TESTING & COMMISSIONING SCOPE OF WORK The scope of work includes erection, testing and commissioning of complete electric's for the Plant being supplied under this package viz. HT/LT switchboards, HT capacitors, Batteries, Power, Distribution, Converter Duty & Rev. 0
NMDC LIMITED
MECON LIMITED

Lighting transformers, motors, Air conditioning system, VFDs, plant safety switches, EOT cranes, Hoists, illumination, cables, Welding sockets, cable trays, earthing and lightning protection system etc. And all other items included in the scope of supply. 3.1.2 Scope of work also includes i. ii. iii. iv. v. Liasioning with Contractors, statutory bodies and other
Preparation of site sketches/drawings to enable cable laying and inter-connections, Preparation of as built drawings Loading/unloading and transportation Owner supplied equipment to site of
Civil works associated with the erection of electrical equipment like grouting of insert plates, Leveling, chipping, grouting, making/closing openings Supply and erection of erection accessories like Cable trays supporting structural supports, anchor / grip bolts, GI pipes, fasteners, cable clamps and ties, cable markers etc.
vi.
3.2 3.2.1
INSTALLATION OF TRANSFORMER In case of transformer, the accessories shipped loose, by the manufacturer shall be assembled by the Contractor at site. Contractor shall place the transformer on the rails / Foundation at the location indicated in the layout drawing of sub station then arrangement shall be made to prevent movement of transformer in any direction. All the accessories shall then be properly mounted and both mechanical and electrical connections should be made as per the manufacturers drawings. Two samples of oil from the transformer, one from the conservator and the other from the tank through drain Rev. 0
3.2.2
3.2.3
3.2.4
NMDC LIMITED
MECON LIMITED

valve, shall be tested as per of IS 10028: Part 2 & 3 for dielectric strength and if it is observed that the values are low, the oil has to be filtered and if required drying of transformer shall be carried out to get required dielectric strength as per relevant Indian Standards. Dielectric strength shall be checked again before energizing. 3.2.5 The joint between the flange of the transformer and the transformer termination box shall be checked for air tightness. Wherever the power / control cables project above ground, for termination to cable box / marshalling box, the same shall be run in GI conduits of suitable cross section and the same shall be supported properly and pipe ends shall be sealed with bitumen compound. The Contractor shall follow the following sequence of erection of transformers: Unpacking of closed/ packed cases and compare with the packing list. Physical check and inspection, pay particular attention to damages such as tank sides or cooling tubes dented Protruding fitting damaged. Oil sight glass broken Bushings cracked or broken Bolts lose due to vibration in transit. Transportation to erection site Erection on foundation / rails Assembly of transformer Radiator bank Cooling fans Buchholz relay MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD 2010, MECON Limited. All rights reserved. Rev. 0
3.2.6
3.2.7
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 Conservator tank Explosion vent Marshalling box Air breather silica gel Tap changer Bushings Thermometer etc. Checking of oil level filtration/ drying of oil. Alignment Anchoring and tack welding Mechanical check Wiring and sealing of wiring of assembled parts Laying, meggering, termination, dressing and clamping of cables Tagging and marking of cables Testing of cables. Earthing - Earthing station, earthing of transformers, earthing strip, earth resistance to comply with IER (latest version) Testing of assembled part Testing and calibration of meters, relays, CTs, PTs, thermometers etc Connections of busbars/ cables to primary and secondary of transformers Series of tests on transformers as per suppliers/ engineers instruction, IS 10028: Part 2, & 3 and manufacturers recommendations. MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD 2010, MECON Limited. All rights reserved. Rev. 0 VOLUME - IV of V PAGE No. 223 of 272
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 VOLUME - IV of V PAGE No. 224 Submission of completion report in the format Charging of transformer Loading of transformer Painting work Handing over to engineer /owner NOTE: All high voltage tests shall comply with IS 2071 Part II and III. All works in connections with the transformer shall comply with IS 10028: Part 2 & 3 and IER (latest revision) 3.3 3.3.1 Installation of HT & LT switchboards / VFD panels The board number shall be verified with equipment number and single line schematic drawing for the correctness of the panels. Minimum clearances in air between phases, phase and ground shall be checked. In case, if clearances do not meet the specified requirements, live parts shall be insulated to rated voltage after obtaining necessary approval from Owner/Consultant. Each panel and total switchboards shall be aligned and leveled along both axes. Free movement of breaker truck in each cubicle and inter-changeability of breaker trucks shall be checked before final fixing of cubicles. The frames for the switchgear shall be secured to the foundations by means of anchor bolts or welding to embedded plates. The grouting and patching of anchor bolts. Any minor civil works like chipping foundations; leveling and finishing shall form part be a part of electrical installation. Before fixing up switchboard, the bus ducts if, any, shall be connected and checked for alignment. Any adjustment for proper alignment shall be carried out. Nameplate details shall be checked as per approved drawings. After the base frames are properly secured in foundation, all the panels of the switchboard shall be installed as per general arrangement drawing and ensure that all the panels are in the required sequence. Tightness Rev. 0 of 272
3.3.2
3.3.3
3.3.4
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MECON LIMITED

of bolts, clamps and connecting terminals shall be checked. The connecting links between the transportable sections of the main switchboard shall be connected properly. While joining shipping sections, bus ducts, fishplates and bus bars shall be cleaned and contact grease shall be applied wherever required. 3.3.5 Outgoing cables shall be connected at the switchgear panels as explained under "installation of cables". The drilling of gland plates at site shall be done after checking the suitability for termination, laying of cables at site. The continuity of all the bus bars and earth continuity conductor provided in the switchgear shall be checked after installation is complete. All bus bars points shall be tightened using torque wrench as per manufacturer's specification. Before final commissioning of units, the switchboard shall be painted neatly at the points where there are scratches and peeling off of paint. Suppliers/engineer's instructions shall be followed for installation, testing etc. Earthing for the equipment shall be carried out with two suitable earthing conductors. 2 Nos. earthing conductors from the equipment shall be connected to the earth grid. The following sequence of erection of switchgear's shall be followed i. Transportation to the place of installation from stores including from owners stores in case of free issue items Unpacking the cases and physical inspection of switchgear for breakages, missing parts or damages as compared with the packing list. Erection of base channel and alignment. Erection on foundation, assembly, Alignment, Welding and anchoring. Connection of bus bars. Installation and wiring of relays, meters etc. Laying, meggering, termination, dressing clamping of power and control cables. and Rev. 0
3.3.6
3.3.7
3.3.8
3.3.9
ii. iii. iv. v.
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 vi. vii. Tagging and marking of cables. Earthing station, earthing strips, earthing equipment and measurement of earth resistance as per IER 1956/IS 3043 with the latest revision. Connection of power and control cables. Checking and testing of all relays, meters, other protective accessories and control and power circuit wiring, phase sequence connection, checking of all circuit breakers for proper alignment of handles with doors. Ensure movement of handle, check for opening, closing and draw out operations. Using a vacuum particles etc. cleaner, remove dust, small VOLUME - IV of V PAGE No. 226 of 272
viii. ix.
x. xi. xii. xiii. xiv. xv. xvi.
Clean all insulating surfaces with dry cloth or as indicated by the manufacturer. Drying of panels with anti-condensation heaters. HT and other tests on power and control cables. Tests on switch gear as per supplier / engineer's instructions and as indicated in the specification. Submission of preliminary completion report. Connection of DC control supply to switch gear and checking of manual and electrical operation of breakers, control circuits and interlocks, operation of protection relays. Charging of switchgear
xvii.
xviii. Functional tests xix. xx. xxi. Painting of all accessories, structures etc Submission of completion report in format Handing over to engineers/owners Rev. 0
NMDC LIMITED
MECON LIMITED

For VFDs, installation shall be as per manufacturers standard and shall follow the above erection instructions (as applicable). Capacitor reforming shall be done as per manufacturers standard before it shall be connected to the process application. All works connected with switchgear shall comply with IS 3427-1997 and as per engineer/owner's instructions and IS 13947- Part1 INSTALLATION OF PDB, WALL MOUNTED DBS Scope under equipment erection of items specified above shall include: i. ii. iii. iv. v. vi. vii. Physical inspection Installation on the foundations/supports. Assembly and interconnection of shipping sections if any as per manufacturer's instructions. Mounting and connection of wiring of loose supplied items like relays, meters etc., if any. Checking of components wiring and interlocks. Applying touch paints. Making the equipment ready for charging after completing all associated works.
NOTE:
3.4 3.4.1
3.4.2
Floor mounted equipment shall be welded to the plate inserts provided in the floor, after leveling. Wall mounted equipment shall be fixed to the wall at appropriate height, so that height of operating handles does not exceed 1800mm. After installations of equipment, all interconnected wiring shall be checked with approved wiring and single line drawings. All relays, meters shall be tested and calibrated. All mechanical and electrical interlocks, protection and control schemes shall be checked. Rev. 0
3.4.3
3.4.4
NMDC LIMITED
MECON LIMITED

Where protection CTs are mounted, tests as applicable to CTs including magnetization characteristics shall be checked. All power cable connections, bus bar joints shall be checked. All labeling and feeder inscriptions shall be checked with approved drawings. Shall comply with IS 1886 and IER (latest revision). INSTALLATION OF PREFABRICATED CABLE TRAYS The Contractor shall install cable trays/troughs complete with all associated accessories like coupler plates, dropout trays, horizontal elbows vertical elbows, tees, reducers, hangers, tray supports as per approved layout drawings. Cable trays shall be supported at every 1.5-m length for horizontal and 1.0m for vertical run. Wherever cable tray route requires to be changed/altered, Contractor shall carry out such alterations after obtaining the permission of engineer. Modifications in the cable tray routings at site shall be in the scope of the Tenderer and the Tenderer shall not be entitled for any extra charges on this account. Constructional details and supporting arrangement for the cable trays shall be as shown in the drawings to be furnished during installation, or as per contractors drawing approved by owner/consultant. Cable trays shall not be used as walkways. Cable trays shall be earthed as specified. INSTALLATION OF CABLES General Scope under cabling shall include i. ii. Cable and cable drum inspection and handling Laying, meggering, clamping of cables. termination, dressing and
3.4.6
3.5 3.5.1
3.5.2
3.5.3
3.5.4 3.5.5 3.6 3.6.1
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 iii. iv. v. vi. vii. 3.6.2 Tagging and marking of cables HT/LT tests on cable Identification of phases Connection of equipment Marking of cables tray ready for charging after completing all associated work. VOLUME - IV of V PAGE No. 229 of 272
Important note i. For cable installation/laying, if cutting of foundations or structures is required, prior permission shall be obtained from the owner/engineer. Cabling shall not be carried out in areas of excessive temperatures. Wherever a cable crosses a temperature expansion joint in structure, sufficient sag shall be provided. Cables of different voltage levels and noise classification if any shall be taken on in the trays/racks (or other means specified) in different trays as per standards and drawings. In no case instrument cables are to be run along with power cables. Cable trays/racks shall not be used as a walkway, either, during installation or while cable pulling or at any other time of installation.
ii.
iii.
iv.
3.6.3
Cable inspection and handling i. On receipt of cable drums, the Contractor shall inspect each cable drum and check for size, length, and type with respect to supplier's seal and making /documents. Loading and unloading of cable drums shall be done by crane and drums shall be carefully lifted and deposited on ground. If crane is not available then the drum shall be carefully rolled down on a suitable ramp of rails. The drum shall be rolled as per the direction indicated by the arrow on the drum in order to prevent Rev. 0
ii.
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MECON LIMITED

the turns of the cable from loosening on the drum. Under no circumstances shall a drum be dropped to the ground as the shock may cause serious damages to the inner layer of cables. iii. iv. v. No cable drum shall be slung except by a bar or spindle through the centre of the drum. In no case the drum be stored with the flanges horizontal. Only cable jacks shall be employed for removing the cable from the drum. For removing the cables from the drum, the drum should be properly mounted on jacks on a cable wheel, making sure that the spindle is strong enough to carry the weight without bending and that it is laying horizontally in the bearings so as to prevent the drum creeping to the one side or the other while it is rotating. The drums should be mounted such that when the drum is turned against the direction of arrow, the cable is paved out from the top of the drum to avoid any danger of bending and breaking the cable if unreeled from the bottom.
3.6.4
Cable pulling and laying i. Cable rollers shall be used for pulling and laying of cables. Cables shall be properly handled while laying to avoid any damage to the cables. Cables may be pulled by hand or by the use of pulling eye securely clamped to the conductors. Jacket, armour or outer jacket shall be secured to the clamp to prevent relative movement. If mechanical means are used to pull on the conductors, force must not exceed values recommended by the manufacturer. The pulling eye shall be securely fastened to the ends of all the conductors so that the load is evenly distributed. The ends of all cables to which pulling eyes are attached shall be cut off before terminations are made. Bending radius for permanent bends shall not be less than those specified by manufacturer. Rev. 0
ii.
iii.
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 iv. VOLUME - IV of V PAGE No. 231 of 272
When pulling cables, the bending radius, pulling tensions and wall pressure at bends shall be strictly in accordance with manufacturer's recommendations.
3.6.5
Cable cutting/splicing i. Cables cut from the drums and distributed route lengths shall be carefully planned mind that splices shall not be allowed specified approval for larger lengths (cable not permitted normally). for various bearing in except on splices are
ii.
All cables shall be cut to required lengths only after assessment of correct lengths required, by actual measurement at site. Contractor shall take extra care while cutting and terminating the cables to ensure that wastage of cables as short lengths is minimised, by resorting to most economical cable cutting schedule as approved (so as to keep the cutting wastage of cable to minimum possible extent). The cables shall be arranged on trays/racks/arms etc., as per approved cable layout and cable rack layout drawings.
3.6.6
Cabling on trays / racks i. All the cabling shall be carried on ladder type cable trays having a rung spacing of 250mm except: a) b) When installed in rigid steel conduits, In case of individual equipment feeder on drops to device when properly supported on channels or run in perforated type GI trays, When installed in duct banks or embedded conduits or buried underground.
c) ii.
Cable tray/rack system to be provided for cabling installation has been explained elsewhere in this specification. A clearance equal to one diameter of the bigger cable shall be maintained between two adjacent higher rated power cables on the trays/racks/risers and clamped by separate clamps, which shall follow the profile of the Rev. 0
iii.
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MECON LIMITED

cable. Common clamping/strapping shall be done for a bunch of control cables and small power cables. iv. Cables shall be clamped at every 3.0 meters on the horizontal trays/racks and at 750/1000mm at bends, take off points and on vertical trays/racks. Cable leading to cable box of equipment shall be supported at a distance of 0.450 meters from cable gland/cable box and cable gland shall be suitably earthed. Cable shall be clamped only after the cables are neatly arranged, dressed, tailored and kept in position. Type of cable clamps/straps, fixing bolts/nuts/washers and materials of cable clamps shall be as specified elsewhere in the specification. Cable drops to equipment shall be as per standards.
v.
vi. vii.
viii. 3.6.7
Cabling in conduits/pipes i. Cables through floor slabs/walls are to be passed through rigid, galvanised steel pipe sleeves in accordance with the standards. Wherever sleeves have not been cast in slabs the latter is to be core drilled for a suitable sleeve. Except where otherwise shown on the drawings, sleeves to extend 150mm above and 100mm below slab to provide mechanical protection for cables. Cables entering or leaving the conduits shall be sealed with non-hardening silicon compounds. It is also Contractor's responsibility to satisfy him-self regarding the conditions of the embedded conduits. Prior to pulling cables each duct shall be rodded by suitable means. After rodding an 8 gauge pulling wire is to be left in each duct. Embedded conduits will be identified in accordance with the drawing. The ends of the conduits shall be plugged when work is halted for any period of time.
ii.
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 3.6.8 Cable laying direct in ground i. For cable laying direct in ground if approved. Suitable trenches shall be excavated in the ground to the required sizes (Minimum depth of 1000MM) and at locations shown in approved drawings. Cable shall be laid directly in the excavated trench on the sand bed. This sand shall be leveled and cables laid over it. The cables shall be covered with sand. The layer of sand over the cables shall be covered with dove tailed PCC slabs and then good earth shall be back filled, rammed and leveled over the PCC slabs. Suitable separation shall be provided in the trench if more than one run of cables are taken in the same trench and between cables of different voltage grades. More than one layer of cable laying is not allowed. Maximum width shall be 1200mm. There shall not be any crossover of cables when laid in the ground. Necessary cable marker plates as per Indian Standards made out of cast iron shall be fixed at every 30 meters interval and at all bends along the route of buried cable trench on central line of the trench. Voltage rating of the cables shall be engraved on the marker plates. The cost of marker plates shall be included in the cost of cable laying/trench work. VOLUME - IV of V PAGE No. 233 of 272
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3.6.9
Cable entry at buildings i. Pressure seals and fire barriers shall be provided at the places where cables enter pressurised electrical rooms as per standards. Cable transits and tray installation at buildings entry shall be in accordance with approved drawings. All wall openings shall be effectively sealed after installation of cables to avoid water leakage
ii.
Wherever buried cables enter the building the same shall be taken through medium duty GI pipes embedded at the entry portion. After taking cables through the above pipes, the same shall be sealed by MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD Rev. 0 2010, MECON Limited. All rights reserved.
iii.
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MECON LIMITED

using suitable compound so as to avoid ingress of water. 3.6.10 Cable jointing i. Joining of two cables is allowed only when the route length of a cable is more than the standard available drum length. However while procuring the cables Contractor should consider and advise the cable supplier to supply even higher drum lengths as per larger route length of a cable. During the preliminary stage of laying the cable, consideration should be given to proper location of the joint position so that when the cable is actually laid, the joints if any, are made in the most suitable places. Joints shall not be made at passageways and at road crossings. On cable trays/racks or in any other route where there are two or more cables laid together, the joints if any, shall be arranged to be staggered by two or more meters so as to reduce the possibility of one joint failure effecting the other. Before jointing is commenced, using suitable megger shall check the insulation resistance of both sections of the cable to be jointed. In jointing of armoured PVC cables, hot pouring compound shall not be used. Only cold sealing compound shall be used. Individual conductors in cables shall always be jointed number-to-number or colour-to-colour of the insulation over the conductors. Suitable marking with identification .to be provided wherever cable joint is buried in ground.
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All materials required for cable jointing such as jointing kit, compounds, insulation tape, cable lugs, glands, fittings etc., and other consumable materials shall be arranged by the Contractor wherever necessary. MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD Rev. 0 2010, MECON Limited. All rights reserved.
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 ix. 3.6.11 VOLUME - IV of V PAGE No. 235 Loop lengths of Approximately provided on both sides of a joint. 4 Mtrs shall of 272 be
Cable termination i. Cable shall enter switchgear panels from the bottom. Cables to individual cubicle shall be neatly laid out and may be supported on channel type trays. Conductors of control cables where applicable shall be carefully and neatly arranged in compact group. The entire group shall be placed and tied with nylon straps to the points of pass out for connection of individual conductors to terminal blocks. Spare conductors shall be terminated with sufficient length to permit future connection to the terminal block associated with the control cable. Cores of control cables where applicable shall be carefully and neatly arranged in a compact group at point of termination. The entire group shall be laced and tied with nylon strips to the point of fan out for connection of individual coress to terminal blocks. Spare conres shall be terminated with sufficient length to permit future connection to the terminal block associated with the control cable.
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3.6.12
Conduit and cable identification i. All conduit, and all cable runs shall be identified at all terminations, including junction boxes, exposed points etc., in accordance with approved conduit and cable schedules. Each conductor termination shall have an identification number in accordance with standards. Where cables are laid in trays identification tags shall also be provided at every 30 meters apart.
ii. iii. 3.6.13 3.6.13.1
Fire Proof sealing system (FPS) Fire proof sealing system shall consist of i. Fire-stops/fire-seals for sealing of cable/cable tray and conduit/pipe penetrations, both horizontal and vertical, Rev. 0
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MECON LIMITED

through brick or RCC walls/floors, to prevent the spread of fire from one area, which is separated from others by fire-resistant barriers. ii. Fire-breaks' provided on long runs of cable racks/trays to prevent the propagation of fire along the cable rack, within a single fire-area or fire- zone.
3.6.13.2
The FPS system shall also include all the necessary accessories and equipment required for supporting, holding in position, fixing and installation of the fire-stop/fire-break. The FPS system shall comply in all respects with the requirements of the codes and standards listed below IEEE-634 ASTM-E-814 ANSI-IEEE-383 IEC-331 IEC-332
3.6.13.3
3.6.13.4
Fire Stop/Seal The FPS system adopted for cables or cable trays penetrating through walls and floor openings, or cables passing through embedded conduits/pipes/ pipe-sleeves, constitutes a `fire stop/seal', which is meant to prevent spreading of fire between areas separated by fire-resistant barriers.
3.6.13.5
Fire Break The fire proofing system, other than fire-stops, adopted to retard flame propagation along long runs of horizontal or vertical cable trays in the same fire zone or area, in an event of a fire, shall constitute a `fire-break' and shall be provided by applying a suitable fire-resistant coating on cables and cable trays for the required length, with or without a fire resistant panel, at the point of the fire break to obtain the fire-rating specified.
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 3.6.13.6 3.6.13.6.1 Performance Requirements Requirement of fire stops i. The material, design and construction of the fire stops shall be such as to provide the fire-rating of 120 minutes for a fire on any side and meet all requirements listed in this specification and the relevant codes and standards. The materials used in the fire stops shall be nonhygroscopic, compatible with the type of cables. The fire stops shall be suitable for retrofitting of cables through the penetration seal without disturbing the sealing of the cables already existing. VOLUME - IV of V PAGE No. 237 of 272
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3.6.13.6.2
Requirements of fire breaks Each firebreak shall have a fire-rating of 30 minutes and shall be capable of withstanding for the duration specified, a fire on any side of the fire break.
3.6.13.7 3.6.13.7.1
Application of fire proof sealing system Fire stops Fire stops shall be provided for cable penetration openings listed below i. ii. The passage of cables/cable trays pipe sleeves/embedded conduits through walls / floors. Vertical raceways, which carry cables between successive floors, through openings provided in the RCC floor slab, shall be sealed by fire stops at each floor level. Cable entry through openings in floor slabs below HT/LT switchgear, MCCs, various control and relay panels and other bottom entry panels, shall be effectively sealed by fire stops.
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Rev. 0
NMDC LIMITED
MECON LIMITED

3.6.13.7.2
Location of firebreaks i. ii. Firebreaks shall be provided on both cable rack and trenches at all cable tray intersections and tee-offs. On linear runs of cable trays between fire stops or fire breaks, fire breaks shall be provided at intervals of 15 metres on horizontal cable runs and 5 m on vertical cable runs. Fire breaks in linear runs of cable trenches between intersections and tee-offs shall be provided at intervals of 30 metres.
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3.6.13.8
Contractor shall furnish the type test certificates for the fire stops and fire breaks after award of contract for Owner / Owners Representative review. If the certificates are not satisfactory all the tests shall be conducted free of cost. The offered system i.e. fire stops and fire breaks shall be identical (or better) with the system which is successfully type tested for the specified rating i.e. the composition density of the material, thickness of coating in case of fire breaks and any other properties of the material / system offered shall be identical or better than the tested system and shall be subject to Owner / Owners Representative approval. Performance Tests: Tests on Fire Stops The fire stops shall be subjected to the following type tests: i. ii. Fire Rating Test Hose Stream Test
3.6.13.9 3.6.13.9.1
3.6.13.9.2
Type tests shall be conducted on different fire stop test specimens described above as per IEEE-634. The sizes of the fire stop test specimens shall be similar to the largest of the sizes being used in the plant. Preconditioning of fire stop test specimens
3.6.13.9.3
Rev. 0
NMDC LIMITED
MECON LIMITED

Before conducting the fire rating and hose stream tests, each test specimen shall be preconditioned for thermal ageing, water immersion and vibration. 3.6.13.9.4 Test on Fire Stops During the fire rating test, the transmission of heat through the cable penetration fire stop shall not raise the temperature on its unexposed surface above the self ignition temperature of the outer cable covering, the cable penetration fire stop material, or material in contact with the cable penetration fire stop, with a maximum temperature limit on the unexposed surface of 200oC. 3.6.13.9.5 Tests on firebreaks Firebreaks shall undergo the following tests as per ANSIIEEE-383: i. ii. 3.7 3.7.1 Ampacity test Flame test OF EARTHING /LIGHTNING
INSTALLATION PROTECTION General i.
The principal requirements of the grounding are: a) b) Low resistance and adequate current carrying capacity. Uniform and near uniform ground potential on all structural metal work on all metal enclosures and/or supports of equipment and apparatus.
ii.
The earthing network shall be as per actual site conditions. Earthing network of all LT substations and Existing plant shall be interconnected.
Rev. 0
NMDC LIMITED
MECON LIMITED

The earthing system to be installed shall conform to IS 3043, Indian Electricity Rules and Regulations of CEI of Karnataka Government and DGMS standards. The scope also includes all the civil work associated with complete earthing network. All earth connection shall ensure a permanent low resistance contact. Earth connections required to be removed for the purpose of testing of equipment/earthing network shall have bolted connection and joints fastened. All earthing connections shall be visible for inspection. All electrical equipment (indoor and outdoor) shall have 2 separate and distinct earth connections. Air termination rods of lightning protection systems shall be connected to earthing network as per IS 3043 & IS: 2309. The grounding connection to the lightning arresters, air termination points of lightning protection system shall be as short as possible. Sharp turns in these conductors shall be avoided. It has to be ensured that main earth bus in the installation as well as earth buses in individual sections/areas shall form complete ring and they shall be interconnected. The earth conductors shall be neatly taken along with the power cable route, which may be on the cable trays / racks / risers or buried cable run way. Wherever earth conductors are taken on racks/trays/risers, they shall be neatly clamped at every 3 meters interval on the horizontal racks and at every 750mm interval on the vertical racks / risers / bends/ take off points etc. and connected to trays and supports also. Wherever burying of earth conductors are specified, they shall be buried as per approved drawings. Rev. 0
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NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 xiii. xiv. VOLUME - IV of V PAGE No. 241 of 272
Wherever earth conductor crosses the road, it shall be taken through GI pipes at least 600mm below. At all terminations of earth conductors or equipment, sufficient length shall be left for easy movement of the equipment from its position for alignment purposes. Wherever not detailed, the route of the conductor and location of the earth pit shall be arranged, so as to avoid obstructions, crossing etc., according to convenience at site and shall be got approved by the owner's representative in-charge of the work.
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3.7.2
Earth pits i. The arrangement of earth electrode/pit shall be as shown in IS: 3043. Termination arrangement of interconnecting earth conductor is included in the scope of earth pit Interconnecting earth conductor shall be jointed by approved termination arrangement on the electrode. The distance between two pits shall not be less than 6 meters. The earthing station shall comprise of earth electrode, of G.I. pipe (class B) of 100 mm dia & 3.0 mtr. Length GI funnel and wire mesh including supply of necessary materials excavation of the pits in all soils Homogenous mixture of salt & charcoal/coke breeze, clamps, clips, bolts/nuts, washers, civil masonry work (600x600x450 mm internal dimension) (metal /gravel, cement) including supply of cast iron frame and cover, cast iron pit marker etc as per IS 3043. The electrodes shall be well packed with Homogenous mixture of salt & charcoal/coke breeze, up to the level of connections.
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Masonry work of the earth pit shall be carried out only after well ramming of riddled soil and complete settling of loose soil. As such electrodes shall be fixed in the ground before commencing of any other MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD Rev. 0 2010, MECON Limited. All rights reserved.
v.
NMDC LIMITED
MECON LIMITED

work of the installation and masonry work shall be taken only at the end after completion of all other works in the installation. 3.7.3 Joints/terminations i. All joints of earth conductor shall be through approved termination method so as to form rigid earth ring. All such joints shall be given necessary coating of cold galvanised paint as per relevant standards and a coat of suitable bitumen compound to prevent corrosion. Joints shall form part of laying of earth conductors and they shall not be considered as terminations for payment purposes. No extra costs shall be applicable for joints of all the earth conductors. In the case joints are made by using suitable connectors the entire joint shall be fully sealed by suitable compound so that no metallic part is exposed. The Contractor shall make his own arrangements for the necessary crimping tools, soldering equipment, drilling machines and other tools and tackles, which are necessary for completing the installation. The number of earth electrodes and size of earth conductor indicated is tentative. The Contractor shall provide adequate number of earth electrodes and equipment earthing conductor as per site requirement. Any modifications (additional earth electrode / conductors or changing type and size of electrodes / conductors and their layout) suggested by CEI of Government of Karnataka or DGMS on the grounding / earthing work done by the Contractor shall be carried out at no extra cost. Lightning Protection system
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3.7.4
The lightning protection system is included in the scope of work of the contractor and the same shall comply with IS 2309. This shall consist of air terminations, horizontal roof conductors and down-comers of 25 x 3mm GI flats, test links, earthing stations etc. All roof conductors and downcomers shall be cleated at every 2 Meters intervals and 1-M MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD Rev. 0 2010, MECON Limited. All rights reserved.
NMDC LIMITED
MECON LIMITED

intervals on roof slab and columns respectively. All connectors, cleats, clamps, anchors etc shall be of galvanised steel. Normally joints and sharp projections shall be avoided in down-comers. Each down-comers shall be terminated in an earth station through a test link. The earth station shall be interconnected to the plant-earthing grid. 3.8 3.8.1 Battery, Battery Charger and DCDB The board number shall be verified with equipment number and single line / schematic drawing for the correctness of the panels. Battery racks, inter cell and inter-tier connectors and number of cells shall be verified. Minimum clearances in air between phases, phase and ground shall be checked. In case, if clearances do not meet the specified requirements, live parts shall be insulated to rated voltage after obtaining necessary approval from engineer/owner. The switchboard shall be aligned and leveled along both axes. The frames for the switchgear shall be secured to the foundations by means of anchor bolts or welding to embedded plates. The grouting and patching of anchor bolts shall be done by the electrical installation Contractor. Any minor civil works like chipping foundations; leveling and finishing shall be a part of electrical installation contract. Check the nameplate details as per approved drawings. After the base frames are properly secured in foundation, the switchboard shall be installed as per general arrangement drawing. Tightness of all bolts, clamps and connecting terminals shall be checked. The connecting links between the transportable sections of the main switchboard shall be connected properly. While joining shipping sections, bus ducts, Aluminium fishplates and bus bars shall be cleaned and contact grease shall be applied wherever required, by the Contractor. Outgoing cables shall be connected at the switchgear panels as explained under "installation of cables". The drilling of gland plates at site shall be done by the Rev. 0
3.8.2
3.8.3 3.8.4
3.8.5
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MECON LIMITED

Contractor after checking the suitability for termination, laying of cables at site. 3.8.6 The continuity of all the bus bars and earth continuity conductor provided in the switchgear shall be checked after installation is complete. All bus bars points shall be tightened using torque wrench as per manufacturer's specification. Before final commissioning of units, the switchboard shall be painted neatly at the points where there are scratches and peeling off of paint during transit. Suppliers/engineer's instructions shall be followed for installation, testing etc. Earthing for the equipment shall be carried out with two suitable earthing conductors. 2 Nos. earthing conductors from the equipment shall be connected to the earth grid. The Contractor shall follow the following sequence of erection of DC switchboard and battery bank i. ii. Transportation to the place of Contractor's stores/owner's stores. installation from
3.8.7
3.8.8
3.8.9
Unpacking the cases and physical inspection of equipment for breakages, missing parts or damages as compared with the packing list. Erection of switchboard, battery rack on floor inserts Welding and anchoring. Installation of batteries on racks Laying, meggering, termination, clamping of power and control cables. Tagging and marking of cables. Earthing of switchboard Connection of power and control cables. dressing and
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Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 x. VOLUME - IV of V PAGE No. 245 of 272
Checking and testing of all relays, meters, other protective accessories and control and power circuit wiring. Using a vacuum cleaner, remove dust, small particles etc. Clean all insulating surfaces with dry cloth or as indicated by the manufacturer. Heating of panels by anti-condensation heaters. HT and other tests on power and control cables. Tests on switchboard as per supplier / engineer's instructions and as indicated in the specification. Installation of inter cell and inter tier connectors. Filling up of electrolyte to required level. Submission of preliminary completion report.
xi. xii. xiii. xiv. xv. xvi. xvii.
xviii. Connection of charger to battery bank xix. xx. xxi. 3.9 3.9.1 Initial charging of battery bank from DC switchgear. Functional tests. Submission of completion report in format.
ILLUMINATION EQUIPMENTS GENERAL The scope includes receiving and storage of equipment at site, transportation, handling, installation, testing and commissioning of all units/items under the scope of supply of the Contractor, his scope also includes installation and termination of cables to / between owners electrical equipment and sealing of cable conduits, floor / slab openings, minor civil works required for erection etc.,
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 3.9.2 VOLUME - IV of V PAGE No. 246 PROCEDURES FOR INSTALLATION OF ITEMS The Contractor shall follow general procedure for installation of the equipment / items implicitly covered in this section read with special instruction to Contractors. Equipment/cabling / earthing and other electrical system installation shall be carried out in accordance with the latest editions of relevant Indian Standards and codes of practice and the installation shall fully comply with the requirement of the Indian Electricity Rules and statutory regulations, DGMS standards that are in force at the place of installation. 3.9.3 3.9.3.1 LIGHTING BOARDS MAIN LIGHTING BOARD The main lighting distribution board shall be floor-mounting type. Suitable base channel shall be supplied and the floor inserts, if necessary, incorporated in the civil works. G.A drawings shall indicate foundation details and insert requirement also along with arrangement of panel boards. Installation of equipment includes supply and installation of necessary hooks/arms for cable support and all other connected works. 3.9.3.2 LIGHTING DISTRIBUTION BOARDS The lighting distribution boards/sub-distribution boards will be generally mounted on a wall or structural column. The distribution board shall be mounted in such a way that the operating handle of the incomer and outgoing switchgears shall not exceed 1800 mm from the finished floor level for easy operation. The panel will be fixed on the wall/column securely by means of suitable bracket and fixing clamps/bolts etc. The Contractor shall also design and incorporate in the civil works necessary pipe inserts etc., for cabling to the board. 3.9.3.3 LIGHT FIXTURES, FANS ETC. of 272
All light fittings such as bulk head, well glass, fluorescent tube light fittings, street light fixtures, flood light fixtures etc., are to be installed as per given/ approved layout MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD Rev. 0 2010, MECON Limited. All rights reserved.
NMDC LIMITED
MECON LIMITED

drawings, and direction of site engineer conforming to Standard installation norms and practices. Apart from the technical requirements, aesthetic requirement also to be satisfied while designing supporting arrangements and fitting layout. Brackets / down rods / chains for suspension of light fixtures and fans irrespective of length are to be included in the scope of work for supply & installation of respective fixtures / fans. 3.9.3.4 CONTROL SWITCHES, SWITCHBOARDS SOCKET OUTLETS AND
All the control switches sockets and switchboards are to be installed as per given drawing. When no drawings are given, they will be installed as per specification, standard norms and direction of site engineer. The switch controlling the socket shall be connected to live side of the socket. 3.9.3.5 JUNCTION BOX, OUTLET BOX, ANCHOR BOX ETC. All junction boxes including terminal blocks wherever required outlet boxes are firmly fixed to walls/ceiling/structures using MS bracket and bolt and nuts. The front cover of these boxes shall be flush with the wall/roof finish in case of concealed mounted type. The location of these boxes shall be selected in such a way that easy accessibility is available for maintenance. All these boxes shall be of minimum 1.6mm thick duly painted as per specification given else where in this document. 3.9.4 LAYING OF CABLES Cables shall be laid direct in ground in all kinds of soil or in the prepared RCC ducts. If required, GI pipe shall be provided wherever these cables cross the roads/water lines, sewerage lines etc. GI pipe shall also be provided wherever the cables enter the building. For details of cable laying refer elsewhere in the tender documents. MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD Rev. 0 2010, MECON Limited. All rights reserved.
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 3.9.5 3.9.5.1 3.9.5.1.1 ELECTRICAL WIRING Definitions for wiring: The definition of terms shall be in accordance with Indian standard code of practice for electrical wiring installation IS 732-1989 except for the definition of Point. The following shall be deemed to the included in the point wiring, starting from D.B. to fitting via switch / push button. i. ii. iii. Switch & socket of required type and rating. Metal Junction box, shrouded brass batten holder, ceiling rose or connector as required. Fan hooks and in case of concealed wiring suitable sheet steel box for neatly housing the connector and covering the fan hook in case of fan point. Metal box, bushed conduit or porcelain tubing where cables pass through walls / floors etc., Heavy/Medium class GI/PVC conduit / PVC casing N capping as required including intermediate metal junction / looping boxes / pull boxes, & accessories like tees, elbows, bends collars charges etc., All metal boards and boxes sunk or surface type for mounting control switches, sockets etc., including those required for mounting fan regulator but excluding those under the main and sub distribution switchgears. The faceplate of control switchboard should be decorative plastic type / Hylum type as per IS. All fixing accessories, such as nuts, bolts, check-nuts, bushes, clips, nails, screws, fill plug, rawl plug, etc., as required. Connections to ceiling rose, connector, socket outlet, lamps holder, switch, fan regulator etc., VOLUME - IV of V PAGE No. 248 of 272
3.9.5.1.2
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NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 ix. x. xi. xii. xiii. xiv. xv. VOLUME - IV of V PAGE No. 249 of 272
Earth wire from light / fan points to the common earth including connections. Looping, interconnections and end-terminations with socket / ferrules etc., wherever required. Earth wire from three pin socket outlet point / fan regulator to the common earth including connections. Fish wire in case of concealed wiring. Painting / varnishing as required. Required length of wiring including reasonable spare length of cables at termination points. Where ever light fitting is not indicated in the drawing and point wiring shall be terminated in the lamp holder, necessary lamp, as indicated in the drawing, shall be provided as part of point wiring.
3.9.5.2 3.9.5.2.1
Wiring other than point wiring: The cost of electrics shall also include the cost of material and installation charges including cost of wire for complete wiring length as detailed below: i. ii. iii. Cables as specified All fixing accessories such as clips, nails, screws, saddles, plug etc., Interconnections with switch/switch boards or any electrical item including all accessories required for terminations.
3.9.5.3 3.9.5.3.1
System of wiring Distribution i. The wiring shall be carried out on each system as may be specified in the tender schedules. Power point wiring shall be kept separate and distinct from "Lighting"/"Fan wiring. All conductors shall be run as far as possible along the walls and ceiling, so as to Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 be accessible inspected. ii. and capable VOLUME - IV of V PAGE No. 250 of being of 272
thoroughly
Light and fans may be wired on a common circuit. However, such circuit shall not have more than 10 points of light/fan, 5A socket outlets in a singlephase circuit or 900 Watts whichever is less. The balancing of circuits in the poly-phase installations shall be ensured in each lighting boards. In large rooms, light and socket outlet points shall be distributed over more than one circuit.
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3.9.5.3.2
Joints and looping back Unless otherwise specified the wiring shall be done in the "Looping" system. Both the phase and the neutral conductors shall be looped at the switch box/junction box nearest to the point of entry. Jointing of cables at junction boxes located on ceiling is not allowed. No bare or twisted joints are allowed at any point. Looping of neutrals between different circuits for point wiring is not allowed. No joints in conductors shall be made at intermediate points in the through run of cables unless the length of a final sub-circuit, sub-main or main is more than the length of the standard coil.
3.9.5.3.3
Positions of wiring runs and points: All runs of wiring and the exact positions of all points and switch boxes shall be first marked on the building and approved by the engineer before actual commencement of the work.
3.9.5.3.4
Wiring terminations: Wiring shall be terminated in junction box/ceiling rose/brass batten holder as directed by owner/engineer where no fitting is mentioned. In case of house wiring, wiring shall be terminated in brass batten holder for all tube light, decorative light, (single pendent fitting) and at locations where no fittings are specified.
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 3.9.5.3.5 Provision for maximum load: All conductors, switches and accessories etc., shall be suitably rated so as to be capable of carrying, without their respective ratings being exceeded, the maximum current, which will normally flow through them. 3.9.5.3.6 Fixing to walls and ceiling: Rawl plugs on ordinary walls or ceiling for conduit, hooks etc., may be used. The plugs shall be fixed into the walls/ceiling with necessary special tools. The holes drilled and the screws used shall be of the correct size as specified by the manufacturer of Rawl plugs. Where the equipment to be fixed is heavy suitable insert shall be embedded in the civil works and the equipment suitably fixed to these inserts. Wooden plugs shall not be used for fixing the equipments/ junction boxes / fittings. 3.9.5.3.7 Damage to wall/floor: Conduits/switch boards/junction boxes shall be placed in position before finishing the wall/flooring and before concreting the roof. However in unavoidable cases, the wall/floor etc. shall be cut to accommodate switchboards, conduit etc., and made good at no extra cost. 3.9.5.4 3.9.5.4.1 Conduit wiring: General: i. The installation shall generally be carried out in conformity with IE rules and IS 732, 1989 as amended up to date and also the relevant regulations of the Electric supply authority concerned. Normally concealed conducting is envisaged for the civil buildings and surface wiring in conduit for structural buildings. The conduit wiring shall be done in accordance with the specification laid down in the following paragraphs. At all the switch and socket positions or where the conduit terminates at ceiling or wall points, a metal box shall be provided. Rev. 0 VOLUME - IV of V PAGE No. 251 of 272
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Provisions must be made to enable cables to be withdrawn and new ones drawn without interfering with the conduit system throughout the life of the installation. Therefore, all inspection box and draw-in boxes must be installed in positions where they will remain accessible. Cable shall be drawn into the conduit only when the site engineer has given his consent and has satisfied himself that the conduit work has been properly carried out. Suitable means shall be taken to prevent entry of insects inside conduit. A draw wire shall be used for drawing cables in conduit. When drawing-in a number of cables, they must be fed-in very carefully at the delivery end. Cable reels should be used for this purpose. In hot weather when the insulation on the cable is liable to become soft, the drawing-in can be assisted by rubbing French chalk on the cables. As much slack cable as possible shall be left in all draw-in and inspection boxes, switch boxes, and distribution boards to facilitate alterations or repairs when necessary. The rate quoted for conduit shall be deemed to be inclusive of supporting saddles/brackets, supporting structures etc., (excluding cable trays), supply & installation of accessories like collars, tees, elbows, bends, junction box/pull box / ceiling rose, consumables etc.,
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Surface conduit system (using conduits / casing N capping) i. The conduit casing N capping must be arranged in a fashion to avoid crossing at points where they take different directions.
All conduit accessories shall be of threaded type and under no circumstances pin grip type or clamp grip type accessories shall be used. MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD Rev. 0 2010, MECON Limited. All rights reserved.
ii.
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MECON LIMITED

Inspection elbows and inspection tees may not be used if there is insufficient room for drawing in cables and if it presents a shoddy appearance. A standard round box or rectangular box will be used in this case. For conduits upto 25 mm diameter, the small circular boxes may be used for conduits larger than 25 mm, rectangular boxes of suitable size shall be used. The conduits should be run, as straight as possible and in drops they should be vertical.
iv. 3.9.5.4.3
Concealed conduit system i. The conduits will be installed during building construction and must be buried in floors, walls and ceiling in such a manner that the cables can be drawn in at any time after the completion of the building. When the conduit is run to switch and other positions in wall, it will be run in a chase out into the wall. The chases must be deep enough to allow atleast 10 mm of cement and plaster covering. At ceiling point, the conduit boxes will be flush with the finish of concrete ceiling. Extension rings may be used to suit the thickness of plaster. At the position of ceiling points, metal box shall be provided. Suitable junction box/ceiling rose shall be fixed to the box for connecting light/fan fitting etc., Suitable outlets will be provided in the fittings for concealed wiring. For other technical particulars specification for surface conduit system shall be referred to. To facilitate drawing of wires in the conduit, a suitable GI fish wire shall be laid and kept inside the conduit.
ii.
iii.
iv.
3.9.6 3.9.6.1
EARTHING Checking procedures to be followed
The pit of proper dimensions and various materials for the earthing shall be kept ready for checking by the engineer. MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD Rev. 0 2010, MECON Limited. All rights reserved.
NMDC LIMITED
MECON LIMITED

All measuring/testing instruments shall also be arranged for testing. In case the pipe is buried without the above check being carried out, the same shall be liable to opened out and re-dome after proper check at no extra cost. The earth pit is to be excavated in all kinds of soil including rocky soil. 3.9.6.2 Installation of Earthing Circuit All exposed metal parts such as LT Switchgear, Power distribution board/Lighting boards/feeder pillar enclosure, metal clad switches enclosure, lamps brackets, lamp holder, plug sockets enclosure, lighting poles, junction box, etc., shall be properly earthed by connecting these to the earth electrode by means of bare GI wire/flat or single core cable of approved size to pass the fault current safely to earth in case of leakage at the apparatus or in the system. The minimum size of earthing wire unless specified otherwise is indicated below: i. Loop earthing ring for LDB/ sub distribution board earthing - minimum size of 25 x 6 mm GI strip buried in floor/wall/trench etc., in side the shop. Light point earthing - same size as point wiring single core PVC insulated copper wire / bare copper wire in case of GI conduit wiring of same size or equivalent.
ii.
3.9.6.3
Earthing of MLDB/EDB/LDB etc., The Distribution board shall be provided with two separate earth terminals. An earth busbar of appropriate cross section shall be provided inside the distribution board and connected to the earth terminals provided on either side of the board. Adequate number of holes/terminals shall be provided on earth bus with suitable provision for terminating the earth wire. GI strip / Armoured copper conductor single core cable of same size of phase / neutral up to 6 sq. mm shall be used for earthing of equipment by connecting the two earth terminals separately to the earthing main in the shop.
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 3.9.6.4 VOLUME - IV of V PAGE No. 255 Earthing of light fixtures and socket outlets The single core PVC insulated copper wire of same size as the phase conductor and the third core of the flexible wiring cable shall be used for earthing the light fixtures and singlephase socket outlets etc. as per drg/specific approval of owner / consultant Earthing of metal boxes and brackets Not less than 14 SWG GI wire shall be used for earthing all metal boxes and brackets. 3.9.6.5 Earthing of street light poles / Flood lighting poles: i. At every 5th pole including first and end poles a separate earth station shall be provided. The poles will be earthed by connecting its earth terminal to the junction box through 8 SWG GI wire. Apart from the above, continuous earthing connection from pole to pole shall be carried out using 25x6mm GI strip or alternatively the 4th core/ half core of the cable shall also be used for earthing of street lighting poles. The earth terminal at the junction box shall be connected to the main earthing ring through 8 SWG GI wires. of 272
ii.
3.9.6.6
Earthing of Feeder Pillar i. The feeder pillar shall be provided with two separate earth terminals. An earth busbar of appropriate cross section shall be provided inside the feeder pillar and connected to the earth terminals provided on either side of the feeder pillar. Adequate number of holes / terminals shall be provided on earth bus with suitable provision for terminating the earth wire. A separate earth station shall be provided for each feeder pillar GI strip (25x6 mm)/ Insulated single core cable of suitable size shall be used for earthing the feeder pillar, Rev. 0
ii.
iii. iv.
NMDC LIMITED
MECON LIMITED

by connecting the two earth terminals separately to the earthing station. 3.10 3.10.1 3.10.1.1 TESTING AND COMMISSIONING GENERAL The contractor, based on the broad outline procedure indicated in this specification, shall finalise with owner/engineer, the detailed procedure for testing and commissioning along with time schedules for both. The Contractor shall adhere to the general guidelines given for testing and commissioning of the equipments /items implicitly covered under heading special instructions to Contractor general condition of contract and technical specification. The intention of specifying below, the procedure for testing and commissioning and different tests to be conducted, are only to give guideline to the Contractor. The Contractor shall not restrict himself in carrying out only the tests specified here, but all tests as per relevant Indian Standards shall satisfactorily be conducted on each equipment. On successful completion of erection of each item/equipment, a final inspection will be carried out at site by owner/engineer, for correctness and completeness of erection. MECHANICAL INSPECTION AND CHECK UP OF THE EQUIPMENT After installation, but before any power supply is connected, the Contractor shall make a complete mechanical check and clean all installed electrical equipment and systems. This shall include, but not restricted, to the following: i. Visually inspect all equipment/item for defects if any, and check equipment numbers against drawings to ensure that equipment has been correctly located and proper installation is done.
3.10.1.2
3.10.1.3
3.10.1.4
3.10.2
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 ii. VOLUME - IV of V PAGE No. 257 of 272
Check name plates of individual feeders and others, distribution boards, distribution fuse boards etc., for conformity with the data given on the supplier's drawings/ standards and specification sheets. Check connections tightness. to all equipment's for
iii. iv. v. vi.
Check correctness of cabling and its terminations. Check phasing, polarity. Check all electrical and mechanical interlocks and other equipments for safety and to ascertain that those are functioning as per intention and accomplishes their purposes. Check all plug in contacts for alignment and grip. Check all contactors for free manual operation Remove all blocking devise installed for shipment.
vii. viii. ix. x. xi. xii.
Check all the coils for their continuity and proper voltage. Check that the fuses are correctly rated and installed are clean undamaged and fit for operation. Check that all disconnect switches are clean, undamaged and operate properly. Ensure that all contacts are tight and the joints, linkages and contacts properly lubricated (where applicable). Check interlocks and auxiliary devices and also the operation of the circuit breakers with the protection relay circuit connected. Vacuum clean equipment before energizing. LT switchgear power distribution boards, distribution fuse boards, plug and sockets, switch fuse and like equipments All interconnected wiring shall be checked thoroughly for correct connections with the wiring and schematic Rev. 0
xiii. xiv.
xv.
NMDC LIMITED
MECON LIMITED

drawings of the manufacturer and the drawings supplied by the owner before energising. xvi. All cable/bus bar connections shall also be thoroughly inspected and checked for corrections, foreign materials, tightness etc., before energising the equipment. All labeling shall be checked against drawings. All components within the main equipments shall be tested for proper performance and correct operation before commissioning the equipment.
xvii.
xviii. Continuity and insulation tests shall be conducted. xix. xx. xxi. Switchgear rated 415 volts shall be tested with a 1000 volts megger. Auxiliary wiring rated less than 415 volts shall be tested with 500 volts megger. Equipment giving insulation resistance readings of less than 10 meg Ohms shall not be energized. Necessary steps shall be taken for improving the I.R value. All protective relays shall be tested at sufficient points to establish their proper functioning in accordance with the manufacturer's specification.
xxii.
3.10.3 3.10.3.1
PRE-COMMISSIONING TESTS All pre-commissioning tests at site on all the equipments/items shall be carried out as per relevant standards and as directed by the owner/ engineer. High voltage tests and primary and secondary injection tests on all components/ equipment shall form part of precommissioning tests. All cables, heating cable units, immersion type heaters, connection type unit heaters and metallic conduits shall be tested to ensure electrical continuity.
3.10.3.2
Rev. 0
NMDC LIMITED
MECON LIMITED

Circuit breakers, contactors, relays, remote devices and other electrical operation equipment shall be functionally tested. Relays, thermisters, photocells and other equipment requiring operational setting shall be set and checked. OPERATIONAL TESTING Upon completion of the electrical installation and at such time as the owner/ engineer may direct, the Contractor shall conduct apparatus and system operating tests for approval and acceptance purposes. All apparatus control schemes, interlocking safety and protective devices etc., shall be demonstrated to operate and function in accordance with the requirements of this specification. All malfunctions and improper operations disclosed through these tests shall be corrected to the satisfaction of the owner/ engineer. All necessary corrections to the Contractor supplied equipment shall be at the Contractor's expense. The Contractor shall employ skilled persons and laborers required during the course of this operational testing. INSULATION RESISTANCE INSTALLATION TEST FOR LIGHTING
3.10.3.4 3.10.4 3.10.4.1
3.10.4.2
3.10.4.3
3.10.4.4 3.10.5 3.10.5.1
The insulation resistance shall be measured by applying 500 V DC between earth and the whole system of conductor or any section thereof (with all fuses in place, all switches closed and all lamps in position) by a megger of suitable range. The insulation resistance of the installation shall be not less than 50.0 meg ohms divided by the number of outlets on the circuit except that it need not exceed 1 meg ohm for the whole installation. The insulation resistance shall also be measured between all conductors connected to one phase conductor of the supply and all the conductors connected to the neutrals or Rev. 0
3.10.5.2
3.10.5.3
NMDC LIMITED
MECON LIMITED

other phase conductors of the supply with all lamps in position and switch off and its value shall be not less than that specified above. 3.10.6 3.10.6.1 TESTING OF POLARITY OF NON-LINKED SINGLE POLE SWITCHES In a two wire installation, test shall be made at each point to verify that cutouts and all non-linked single pole switches have been fitted in the same conductor throughout and such conductor shall be labeled or marked for connection to the phase conductor only and not on the neutral or earthed conductor. In a three wire or a four wire installation a test shall be made to verify that every non-linked single pole switch or cutout is fitted in a conductor which is labeled or marked for connection to the phase conductors of the supply. Acceptance of the electrical Contractor's work described herein is contingent upon the successful testing of all electrical apparatus, systems and associated wiring, (testing methods shall be in accordance with procedures readily recognizable. All tests shall be performed in the presence of the owner/ engineer. For all types of visual inspections, checking, pre-commissioning, commissioning tests and acceptance tests, relevant IS for the tests given therein shall be followed in addition to the instructions of engineer/owner for such tests. TESTING SYSTEM AND COMMISSIONING OF EARTHING
3.10.6.2
3.10.6.3
3.10.7 3.10.7.1
The contactor shall inspect and test all earthing works carried out by him, including all interconnections between group loops, earthing of electrical rooms and grounding of equipment and ensure that the connections are permanent and that the earthing circuit is continuous. The Contractor shall test the buried earth grids supplied by him and others within the zone assigned to him. The Contractor shall measure and record earth resistance at various earth connection points. Rev. 0
3.10.7.2 3.10.7.3
NMDC LIMITED
MECON LIMITED

Equipment earthing internal to each equipment such as fourth core earthing in the motor terminal boxes shall be shown to the owner/engineer. Only after checking of such connection by the owner/engineer, the terminal boxes shall be closed. Earthing system and connections shall be tested as follows: i. ii. Resistance of individual earth electrode shall be measured after disconnecting it from the grid. Earthing resistance of the grid shall be measured after connecting all the electrodes to the grid and generally the test value shall conform to IS code of practice unless otherwise specified. The earth resistance shall be less than 1 Ohm for the grids constructed by the Contractor.
3.10.7.5
3.10.7.6
The resistance to earth shall be measured at the following: i. ii. At each electrical electrode independently. Combined earthing system used to earth electrical equipment enclosures, metal structures etc.,
3.10.8 3.10.8.1 3.10.8.2
TESTING AND COMMISSIONING OF CABLING SYSTEM The Contractor shall inspect and test all cabling works carried out by him. All cables shall be tested before and after jointing/termination as per relevant Indian Standards. Jointing/ termination shall be redone, if found unsatisfactory without any extra cost to the owner. For testing, all cables shall be megger tested before jointing. After completion of jointing, all LV cables shall be megger tested. The cable cores should be tested for continuity absence of cross phasing, insulation resistance to earth and insulation resistance between conductors.
3.10.8.3
3.10.8.4
Rev. 0
NMDC LIMITED
MECON LIMITED

Before energizing, the insulation resistance of every circuit, circuit cable shall be measured from phase to phase and from phase to ground. Where splices or terminations are required in circuits measure insulation resistance of each length of cable before splicing and/or terminating. Repeat measurements after splices and/or terminations are complete. Measure the insulation resistance of directly buried cable circuits before trenches are back filled. Repeat measurement after back filling. DC high voltage test shall be made after installation of the following: i. ii. All 1100 volts grade cables in which straight through joints have been made. All cables above 1100 V grade.
3.10.8.6
3.10.8.7
3.10.8.8
3.10.8.9 3.10.8.10
For record purposes test data shall include the measured values of leakage current. The DC high voltage test shall be performed as detailed below: i. Cable shall be installed in final position with the entire straight through joints complete. Termination shall be kept unfinished so that motors switchgear, transformer etc., are not subjected to test voltage. The test voltage and duration shall be as per relevant codes and practice of Indian Standard Institution. The result of all the tests conducted at site shall be furnished in a tabulated form given below, to the owner for their approval. All tests shall be performed with genuine instruments. The contractor shall, therefore, submit a list of all such instruments proposed to be used for testing the installation.
ii. iii.
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 3.10.9 Training Contractor shall train the work force of owner / consultant with his technical and supervisory personnel for safe, and efficient operation and maintenance of the equipment and system installed by the Contractor. The Number of personnel to be trained and the duration and structure of the training shall be mutually discussed and finalized. 4.0 4.1 4.1.1 DRAWINGS AND DOCUMENTATION DRAWING AND DOCUMENTS TO BE SUBMITTED The scope of Contractor includes supply of all drawings, documents, operation and maintenance manuals, catalogues, as built drawings of the plant, equipment supplied and work done, for comments/ approval / information/ reference of owner / consultant at no extra cost. All drawings, specifications, furnished by the owner/consultant shall be treated as strictly confidential property of the owner/consultant. All drawings and informations furnished by the Contractor shall become property of the owner/consultant. Drawings, specifications and schedule of quantities shall be treated as supplementary to each other and should anything appear in one that is not described in the other, the Contractor for any such omission shall take no advantage. For such discrepancy / inconsistency, the Contractor shall seek the instructions from the owner/consultant before proceeding with the work and the clarifications/ decisions given by the owner/consultant shall be treated as final and binding on the Contractor. LIST OF DRAWINGS VOLUME - IV of V PAGE No. 263 of 272
4.1.2
4.1.3
4.2 4.2.1
The Contractor shall submit requisite copies of a list of all drawings and documents he proposes to submit for the contract. The drawings shall be categorized into (a) For owner / consultants approval (b) For owner / consultants information (c) As built drawings (d) Operation and maintenance manuals and catalogue (e) Manufacturing drawings. MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD Rev. 0 2010, MECON Limited. All rights reserved.
NMDC LIMITED
MECON LIMITED

The list shall be approved by the owner/consultant and may be revised or extended if necessary for proper execution of work / documentation. Each drawing and document in the list shall be identified as follows: i. ii. iii. Serial number and drawing number Descriptive title Proposed date of submission.
4.2.3
4.2.4 4.3 4.3.1
Broad category of drawings and documents to be submitted are listed in else where in the specification. APPROVAL OF DRAWINGS/ DOCUMENTS/ MANUALS The Contractor shall furnish drawings as indicated in technical specification for each item for approval of the owner / consultant according to agreed time schedule. Contractor shall furnish, if requested, additional drawings, calculations, information to the consultant/ owner to enable him to examine / study the drawings for approval. If incomplete drawings/ documents not meeting the owner/consultants requirements are sent the responsibility for any delay in approval shall be that of Contractor. Where drawings are returned to the Contractor with marking not approved. The Contractor shall resubmit the revised drawings for approval. Where the drawings are returned to the Contractor with marking Approved as Noted, Contractor shall make the necessary modifications/ changes and resubmit revised drawings for final approval. If any subsequent alterations are found necessary on the drawing approved by the consultant/ owner, all drawings and data that are affected by such alterations shall be duly revised and re-submitted for the approval of the engineer as said above. Owner/ consultant will scrutinize drawings/ data furnished by Contractor and comments, if any, will be communicated to the contractor within 2 weeks from the date of receipt. Rev. 0
4.3.2
4.3.3
4.3.4
4.3.5
4.3.6
4.3.7
NMDC LIMITED
MECON LIMITED

In order to expedite the approval of drawings related to procurement / manufacture, Contractor shall present the drawings to the owner / consultant and incorporate the necessary changes after discussions and obtain the approval. Contractor shall be responsible for correctly incorporating all the points conveyed to him and resubmit the drawings to the owner/consultant for final approval. If the Contractor is unable to incorporate some of the comments, such non-compliance shall be clearly stated in a forwarding letter with reasons without delay. However it shall be owners / Consultants discretion to accept or reject the non-compliance Work shall be carried out exactly as indicated on the approved drawings and data and no alterations shall be made without the written approval of the Owner/consultant. Approval of drawings by owner / consultant shall not relieve the supplier of his contractual obligations and responsibility for engineering, design, workmanship, materials and performance of the equipment. AS BUILT DRAWINGS All the drawings/ documents supplied by the Contractor for owner/consultants comments/ approval, if required, shall be revised / modified, after owner/ consultants approval, to incorporate all the modifications / changes necessitated at various stages of execution of contract viz., During inspection & testing at works and site During erection, commissioning of individual equipment During integrated commissioning of total system Due to changes in associated connecting equipment not supplied by the Contractor (based on the information furnished by the owner/ consultant). Contractor shall furnish as-built drawings required for normal operations, maintenance, testing of all equipments Rev. 0
4.3.9
4.3.10
4.3.11
4.3.12
4.4 4.4.1
4.4.2 4.4.3 4.4.4 4.4.5
4.4.6
NMDC LIMITED
MECON LIMITED

in specified number of copies. All the approved drawings, manufacturers drawings, installation drawings are included in as-built drawing. 4.5 4.5.1 DOCUMENTS AND TEST REPORTS Contractor shall furnish any relevant calculations asked for. It shall also contain manufacturers catalogues, operation and maintenance manuals for all types of relays / Equipments used. Contractor shall furnish bound volumes of copies of factory routine and type test certificates for all equipment. After completion of site testing of all the equipment, Contractor shall furnish the site test results of all equipment. This shall also indicate clearly rectifications carried out during testing, in case site test results vary very widely with factory test results, commissioning engineer's observations shall be clearly indicated against corresponding equipment, identified by manufacturer's serial number. Site test results and certificates for all equipments shall also be furnished in bound volume. Contractor shall furnish bound volume indicating list of spares supplied for each equipment. The volume shall contain, manufacturers catalogue number of components with description. It shall also indicate precautions to be taken for storing. OPERATION, INSTRUCTION MANUALS / CATALOGUES. AND MAINTENANCE
4.5.2 4.5.3
4.5.4
4.6 4.6.1
Instruction manual shall give step-by-step procedure for i. ii. iii. iv. Erection, testing and commissioning Operation Maintenance Repair
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 4.6.2 Instruction manual shall also contain i. ii. iii. iv. v. List of spare parts with ordering specifications and manufacturers catalogues List of consumables with specifications, brand names and annual consumption figures. Drawings relevant for erection, operation, maintenance and repair of the equipment. Procedure for ordering spares. Contractor shall submit the following data / documents in specified number of copies and reproducible prior to handing over the installation to the owner/consultant. Copies of approved drawings along with reproducible shall be submitted. All drawings approved by consultant / owner. Equipment manufacturing drawings submitted for information of consultant / owner. Equipment drawings maintenance. required for operation and VOLUME - IV of V PAGE No. 267 of 272
vi. vii. viii. ix. x. xi. xii. xiii.
Inspection reports, factory and site test certificates in bounded volume As built drawings incorporating all site modifications Instruction manuals and catalogues List of spares
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 5.0 SL. NO 1 1a MAJOR EQUIPMENT LIST (INDICATIVE) VOLUME - IV of V PAGE No. 268 of 272
ITEM DESCRIPTION HT SWICTHGEAR 6.6 kV, 630A, 25 kA (1 Sec), 20 kV RMS / 60 kVP, Indoor, Metal clad, compartmentalized factory built and fully wired HT switchboard in IP4X enclosure with horizontal numerical draw-out protection based VCB for incomer auxiliary feeder, relays, and transformer feeders, capacitor feeders with CTs, PTs, relays, multi Microprocessor function meters
QTY.
Lot
indications. Surge arrestors for capacitor feeders shall be provided. Panel shall be suitable for bottom cable entry with protections as shown in single line diagram No. MEC/01/Q6DH/KIOP/II/214/TS and as per enclosed specification comprising following minimum feeders. Incomer feeder 1No. (VCB) Line PT feeder 1 No. Transformer feeders- As required + 1 Spare Capacitor feeders 1 No. Note: 1 no of each (Bus & Cable) earthing trucks for 6.6kV switchgear to be included in scope of supply. 1b 11 kV, 630A, 25 kA (1 Sec), 28 kV RMS / 75 kVP, Indoor, Metal clad, compartmentalized factory built and fully wired HT switchboard in IP4X enclosure with horizontal draw-out VCB for incomer feeder, transformer feeders, capacitor feeders with CTs, PTs, numerical protection relays, auxiliary relays, Microprocessor based multi function meters and indications. Surge arrestors for capacitor feeders shall be provided. Panel shall be suitable for bottom cable entry with protections as shown in single line diagram No. MEC/01/Q6DH/KIOP/II/214/TS and as per enclosed specification comprising following minimum feeders. Incomer feeder 1No. (VCB) Lot
Rev. 0
NMDC LIMITED
MECON LIMITED

Line PT feeder 1 No. Transformer feeders- As required + 1 Spare Capacitor feeders 1 No. Note: 1 no of each (Bus & Cable) earthing trucks for 11kV switchgear to be included in scope of supply. 2 11 kV, 630A, 25 kA (1 Sec), 28 kV RMS / 75 kVP, Outdoor, Metal clad, compartmentalized factory built and fully wired 11kV CICO panel with horizontal drawout VCB, with CTs, PTs (PT shall be in a separate cubicle), numerical protection relays, auxiliary relays, Microprocessor based multi function meters and indications. Panel shall be suitable for bottom cable entry with protections as shown in single line diagram No. MEC/01/Q6DH/KIOP/II/214/TS and as per enclosed specification. 3 7.7 kV & 13.32kV, required KVAR, capacitor banks in single star configuration along with cast resin 6% series reactors, RVT, cables/ conductors and mounted on a composite galvanized steel frame suitable for indoor installation as per specification. 4 6.6 kV (UE) & 11kV (E), required size, XLPE insulated, armoured, extruded PVC sheathed and FRLS outer sheathed, aluminium conductor HT cable as per the specification 5 6.6 kV (UE) & 11kV (E) End termination kits suitable for required sizes of XLPE, armoured cable with all required accessories including terminations for indoor/outdoor application 6 110VDC, 55 cells, Plante type lead acid battery in SAN container with battery stand, inter row and inter cell connectors, stand insulators and other accessories as per specification 7 Dual redundant Auto / manual float cum boost Battery chargers (FCBC) rated in floor mounting sheet steel IP 42 enclosure suitable for incoming 415 V, TPN supply with constant current and constant potential charging controllers, protection, metering, relays etc as per specification and suitable for bottom cable entry.
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Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 8 VOLUME - IV of V PAGE No. 270 of 272 Lot
100 A, 110V DC Distribution Board in IP 52 sheet steel enclosure suitable for floor mounting, with bottom entry, with one no 100 A incoming MCCB and required nos. 25 A outgoing double pole 16A MCBs feeders including 20% spares with metering / indications etc as per specification 9 415V, 50Hz, TPN, 40kA (1sec) indoor, single front, fully draw out, type tested, compartmentalised, PMCC with incoming ACB feeder and required outgoing ACB/MCCB/DOL/RDOL feeders including automatic power factor correction equipment/capacitors. Control/ metering/ indication equipment as per approved control schemes with bottom incoming & outgoing cable entry, complete with brass double compression cable glands and tinned crimping type copper lugs as per Specification. 2 Nos. adjustable height breaker handling trucks for PMCC to be included in scope of supply 10 415V, 50Hz, TPN PDB suitable for all required power loads as per specification. 11 MLDB, SLDBS, LDBs, DBS & etc. with necessary arrangements for centralized controls as per specification 12 Transformers i) 6.6/0.433 kV & 11/0.433kV ONAN, required KVA, 3 phase, 2 winding, Outdoor Transformers. HV & LV cable box with air insulated disconnect chamber, additional neutral bushing, accessories and spares as per detailed specification ii) 6.6/0.230kV & 11/0.23kV ONAN, required KVA, Outdoor type, 3 phase Lighting transformers with, star point solidly earthed as per detailed specification iii) Booster transformers with required KVA, dry type, , star point solidly earthed as per detailed specification 13 6.6/0.72kV & 11/0.72kV ONAN, required KVA, 3-phase converter duty transformer as per specification
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Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 14 VOLUME - IV of V PAGE No. 271 of 272
15
16
17 18 19 20 21 22 23 24
25
11 kV OH line (including route survey) with Squirrel conductor laid on 9Mtr long second hand rail poles (90Lb/yard) and 13Mtr long rail poles at road crossings with all accessories (i.e. poles, cross arms, insulators, earth wire, clamps, bolts and nuts, erection accessories etc.) with stay arrangement (7 x 4 mm dia stranded GI wire, Anchor plate, bow thimble Etc). Stay sets at every 3rd pole, crossings, bends and at both ends Including painting & civil foundations as per the specification. Double pole structure with 2 rail poles, (13M long90lb/yard) including cross bracings of ISMC and GOS with earth switch, LAs, DO fuses stay sets, earthing, fencing etc. as per the specification including civil works. Motors ( MV, LV) Design, Engineering, manufacture, Supply, erection, Testing and commissioning of 415V, 690 Volts 3 Ph, 50 Hz, induction motors as per specification. 690V Multiple drive Variable Frequency Drive (VFD) units (Regenerative 4 Quadrant) for down Hill conveyor & Reversible Belt conveyors, 415V VFDs for Belt feeders Industrial type 63A, 415V, 5 pin, Interlocked type, IP 65 Welding receptacles with plug top in ABS plastic/cast aluminium alloy enclosure as per specification. Indoor lighting fixtures, decorative / industrial sockets (5A, 5A / 15A, 10/20A) ceiling Fans, Exhaust fans Etc. as per specification Outdoor lighting fixtures, Steel tubular poles for street lights/ flood lights as per specification Plant safety equipment Pull cord switches, Belt sway switches, Proximity switches Controls and associated equipment under this package. 1100V grade, heavy duty, stranded aluminium/ copper conductor, PVC insulated, extruded PVC inner and FRLS outer sheathed, GI wire/strip armoured (with armour conductivity not less than 50% that of Phase conductors) power, illumination, control cables Including terminations using double compression glands, lugs, consumables Flexible Festoon cables of different sizes Including terminations using glands, lugs, consumables
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Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q3 26 VOLUME - IV of V PAGE No. 272 of 272
27
28
29
30 31 NOTE: 1.
PVC insulated copper wires of different sizes, GI/ PVC conduits as per specification for wiring to various lighting fixtures including required flexible wire and conduits as required Earthing stations with 3.5M Long, 100 mm. Dia, class B, G.I pipe electrode with G.I funnel and wire mesh including civil works, salt, charcoal, cast iron cover, earth pit marker etc as per IS-3043 and DGMS standards. GI Earth flat/Ropes /Wires for earthing and lightning protection systems as per specification. (Different sizes of flexible earthing cables) 3M long GI cable trays ladder type of 600/450/150 mm width complete with tray coupler plates, Electro galvanized hardware as per specification. Fabricated steel structures duly de-rusted with 2 coats of primer and final coat of epoxy paint for cable tray supports etc Class - B Medium Grade GI pipes as per IS 1239 including bending as per requirement and fixing to wall/column from 65 mm to 150 mm dia as per requirement Local control stations for all motors as per specification Erection accessories including switches, JBs, pull boxes, mounting accessories/ brackets, support structures etc.
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EQUIPMENT LIST indicated above is for purpose of guidance only. All items required for the satisfactory operation of the plant shall be under the scope of the Tenderer whether explicitly mentioned herein or not.
Rev. 0
NMDC LIMITED
MECON LIMITED

CHAPTER Q4 TECHNICAL SPECIFICATION AUTOMATION AND CONTROL
CONTENTS Sl. No. 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 Introduction Scope of Work & Services Standards & Voltage Levels Design Criteria for Control & Instrumentation Technical Requirements, Control, Safety and Sequential Interlocks Technical Design Specification Erection, Testing and Commissioning List of Major Equipments Description
Rev. 0
NMDC LIMITED
MECON LIMITED

1.0
INTRODUCTION
This specification is intended to provide the technical guidelines for Control & Instrumentation system with auxiliaries and accessories for the Down Hill Conveying System (Package-II) of Kumaraswamy Iron Ore Project (KIOP) for NMDC Ltd. The C&I system called for in the specification shall be designed for safe, reliable, efficient and smooth operation of the plant and its associated auxiliaries with minimum intervention of the operating personnel during normal working of the plant, load fluctuation / safe shut down of the unit. The C&I system shall be based on PLC with the latest state of the art technology. The PLC based Automation including SCADA and Field Instruments / equipments envisaged to cater to the centralized control and monitoring requirements of the Down Hill Conveying package which comprises mainly of the following sections & Utilities: i. ii. iii. iv. v. Down hill conveyor no. 723 with controlled braking system Reversible conveyor no. 727 with controlled braking system Transfer Houses and RCC Silo Belt Conveyors, Belt weigh scale, Belt feeders and Inline over band magnetic separator Other auxiliaries
The proposed Automation System configuration shall be based on the drawing Drg. No. MEC/01/Q6DH/KIOP/II/215/TS. The main objective of implementing the proposed system is to improve reliability of operation, facilitate optimal utilisation of electrical equipment & other utilities monitoring and control of various plant units by providing user-friendly systems. The specification shall be read in conjunction with the attachments giving the technical details. All these documents shall form as a whole the complete specification. It is not the intent to completely specify all details of design and construction features herein. Nevertheless, the instruments / system / equipment and their installation shall conform to high standards of engineering design and workmanship in all respects. In the event of any conflict between this specification, related standards, etc., the vendor shall refer the matter to MECON and obtain clarifications and then proceed with the manufacture of the items in question.
MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD 2010, MECON Limited. All rights reserved. Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q4 1.1 OBJECTIVES The main objective of implementing the proposed system is for reliable operation of plant (including controlled starting and stopping and controlled braking of the down hill conveyor), management of electrical energy & other utilities, centralised control and monitoring of various plant units, Operational parameters etc. The offered System must cater to the following major objectives: i. Control of basic sequential start/stop operation of all Equipment in respective process sections from a central location like Crushing plant control room. Field instruments / equipments like weighing sensor / transmitter, limit switches, level switches/ transmitters, interfacing with the VFDs of down hill conveyor system etc., interfacing / connecting to third party PLC based control systems for monitoring and control of complete operation activities. Monitoring of the status of various equipment including safety and Operational interlocks. Preparation of operator-friendly Graphic Interface systems. Alarm monitoring and Logging. Measurement and centralized logging of process parameter and throughput information. Integration of VFD, Soft-starters for automatic process regulation and control. Measurement and monitoring of important electrical equipment parameters and comprehensive logging of the same. Preparation (also co-ordination with vendors of other automation systems) for preparation of detailed MIS and Log/report format for each process section, switchgear, energy consumption and break down analysis etc. Integration of various Process sections from operational and interlocking aspects.
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VOLUME - IV of V PAGE No. 3 of 75
ii.
iii. iv. v. vi. vii.
viii.
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NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q4 x. xi. xii. VOLUME - IV of V PAGE No. 4 of 75 Development of comprehensive Process-related parameter to be used for on-line central MIS system for different locations Controlled Starting, Stopping and braking under various loading conditions. Interfacing, Controlled starting, Stopping and braking under various loading conditions of existing conveyors to be taken care in the PLC for sequence operation.
Rev. 0
NMDC LIMITED
MECON LIMITED

2.0
SCOPE OF WORK & SERVICES

This specification together with the attachments like, drawings, documents annexed herewith covers the basic requirement of design, manufacture, supply, erection, testing, commissioning of control and instrumentation system.
2.1
SCOPE OF SUPPLY, WORK & SERVICES The scope of supply and works shall completely cover the entire C&I, Automation equipment, functions, activities and documentation specified under the accompanying Technical Specification. It shall also include but not limited to the following: i. Design, engineering, manufacture, procurement, programming, inspection, delivery to site, storage, erection, termination, testing, loop checking, commissioning and handing over of complete automation system consisting of control and instrumentation, field instruments, Programmable Logic Controller (PLC) and its sub-systems, UPS as specified in the Technical Specification on turnkey basis for Down Hill Conveying System (DHC) Package-II of KIOP for NMDC. The plant shall be automated through the PLC. Enclosed drawing MEC/01/Q6DH/KIOP/II/215/TS, broadly defines the automation concept envisaged. The PLC shall have redundancy in processor, power supply, communication modules, communication networks. Remote Input-Outputs (RIO) concept has been envisaged. RIOs shall be located at different geographical locations and shall communicate to the DHC PLC located in the control room, through dual redundant fiber optic cable links. Refer clause 6.3. Tentative number of RIO units is shown in the automation configuration drawing, which may increase during detailing for which no commercial implication shall be applicable. Down Hill Conveying (DHC)-PLC located in the Control Room at the tail end of down hill conveyor shall take care of the total control and monitoring of the conveyor system and other equipments / accessories envisaged in the Package II. This also includes the Reversible Conveyor No.727 and other conveyors like the 718, 719, etc.
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ii.
iii. iv.
v.
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q4 vi. VOLUME - IV of V PAGE No. 6 of 75 DHC PLC shall be networked with the Crushing Plant PLC of Package-I vendor on dual redundant communication link on fiber optic cable. For the implementation - cable (supply & laying), HDPE pipes, necessary hardware & software and engineering required for the same shall be provided by the vendor. Refer clause 5.7. Extension of the data network using redundant link on SMF fibre optic cable upto crusher control room and installation of one operator workstation at the crusher control room. For the implementation cables (supply and laying), necessary hardware required for the same shall be provided and erected by the vendor. Console desk required shall be furnished by the Package-I vendor. Refer clause 5.7. Interfacing of Numerical Relays in HT switch board, Energy meters / power meters / multifunction meters (MFM) with PLC on communication link. Refer clause 5.6. Interfacing of VFDs with PLC on communication link. Refer clause 5.5. Hardwiring of protection, interlock, feedback signals between the Crusher PLC and DHC PLC; Existing Tripper Conveyor Control System and DHC PLC. For the implementation cables (supply and laying), necessary hardware required shall be provided and erected by the vendor. Conveyor safety switches like belt slip, belt rip, belt alignment, pull chord, speed sensor-transmitter, limit switches, digital belt weigh scale, etc. shall be provided and wired to the PLC. Necessary C&I for belt conveyors, belt feeders, tripper conveyors, belt weigh scale, inline magnetic separators, metal detectors, dust suppression system, etc. shall be provided and wired to PLC. The Downhill Conveyor Brake control system and Reversible Conveyor Brake control system shall be PLC based. Necessary C&I for the brake control system shall be provided by the tenderer. Control system shall have communication link and IOs hardwired to the DHC-PLC. Required hardware, software and cabling for implementation, is in the tenderers scope. Refer clause 5.10.
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vii.
viii.
ix. x.
xi.
xii.
xiii.
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q4 xiv. VOLUME - IV of V PAGE No. 7 of 75 The measurements and controls indicated is the minimum requirement for the system. Vendor shall engineer the system and shall include additional measurements, controls and protections required to make the system complete in all respects for safe, efficient, reliable & ease of operation. Tender shall facilitate plant lighting, conveyor gallery lighting, open area lighting etc., to be switched ON-OFF through PLC system as well as local LDB with Local remote selection switches. All switches, interconnecting relays, push buttons etc., are in Tenderers scope. Supply and laying of instrumentation cables signal, control, power, earthing, communication cables, fiber optic cable. Supply and erection of junction boxes, local panels, cable trays, conduits, GI pipe, HDPE pipe, glands, impulse tubing, pneumatic tubing.
xv.
xvi. xvii.
xviii. Surge protection devices for the signal and power line. xix. xx. Supply of erection hardware and accessories required for installation. Supply, laying, terminating of cables from field instrument, MCC/VFD to marshalling cabinet of PLC. Vendor shall terminate all the field inputs / outputs to local junction box / panel by segregating analog and digital signal and from the local junction box / panel to the marshalling cabinet of PLC, using multi-core / multi-pair cables. Digital output signals shall be connected to field devices through interposing relays. Supply of one programming. laptop with software and license for
xxi. xxii.
Supply, erection, commissioning of HMI stations (Operator Stations, Engineering Stations) with required engineering software, runtime software and licensing.
xxiii. Tenderer shall provide all required hardware and software support for interfacing the PLC system with that of Crusher Plant (Package-1) and for development of the HMI graphics related to downhill conveying system in the PLC & HMI
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q4 VOLUME - IV of V PAGE No. 8 of 75 station of Package-1, located in the Crusher Control Room, for centralized operation. Refer clause 5.7. xxiv. Supply, erection, testing and commissioning of Parallelredundant UPS system of sufficient capacity with Power Distribution Board (PDB). Refer clause 6.13. Vendor shall distribute the electrical power from UPS-PDB to the field instrument, PLC, RIO, consoles. xxv. Supply and erection of Earth pits required for instrumentation and automation.
xxvi. Supply, erection of cabinets, desk / furniture like console desk, printer desk, chairs, etc.
xxvii.
Vendor shall design and develop software and logic required for safe and trouble-free operation of the plant.
xxviii. The Vendor shall provide necessary support and assistance during interfacing and integration of free issue equipments provided by NMDC and during interfacing of the DHC-PLC with Crusher PLC. xxix. Submission of documents as mentioned in the Drawing and Documents clause. xxx. Finalising inspection procedure with the client / consultant and arranging for inspection at the manufacturers premises.
xxxi. The vendor shall arrange all tools and tackles, special testing equipments and consumables required for erection, calibration and commissioning activities. xxxii. The Vendor shall provide skilled technical personnel for the erection, testing and commissioning of field instruments, UPS, PLC under the supervision of respective equipment suppliers. xxxiii. Supply of commissioning spares. Tenderer to furnish the list. xxxiv. Supply of two years maintenance spares for trouble free operation and Special Tools & Tackles. Refer Volume III, Chapter O Spares, Special Tools & Tackles.
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NMDC LIMITED
MECON LIMITED

xxxv. Providing Training to NMDC engineering and operating personnel. xxxvi. The scope also includes civil works like floor cutout, chipping, digging, grouting, concreting including filling material etc, required for the erection of instrumentation equipments like cabinets, junction boxes, cabling etc. wherever required. xxxvii. Any additional item / equipment which are not specifically mentioned in technical specification but are required to make the system complete in all respects for safe, efficient, reliable operation and guaranteed performance shall be considered and listed by the tenderer. 2.2 VENDORS RESPONSIBILITY i. Any exception / deviation from the technical specification shall be indicated and description of exception / deviation and reason shall be provided. Proper sizing of PLC, considering the spares in I/O channels, CPU. Proper sizing of UPS, to provide sufficient power to PLC, its accessories and field instruments and with spare capacity. Proper sizing and selection of instruments for the process conditions. The components shall be assembled at the vendors premises and the materials shall be shipped in assembled condition. Before despatch to site, surfaces of all equipment / components / accessories which are intended to be painted shall be thoroughly cleaned and be painted with undercoat and finishing paints. Damage suffered during transit / erection / subsequent handling shall be made good by the vendor without implications before the final acceptance. Vendor will be responsible for all damage due to improper preparation of the goods for shipment and storage.
Rev. 0
ii. iii. iv. v. vi.
vii.
viii.
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q4 ix. VOLUME - IV of V PAGE No. 10 of 75 The instrument / equipment supplied shall meet the guaranteed performance specified in the specification when operated at the rated / specified conditions. The acceptance of the equipment shall be subject to satisfying these parameters during shop test at vendors works and / or at site installation in complete assembled condition. Design criteria & technical details of C&I equipments shall be as indicated / mentioned in this specification.
x.
2.3
TRAINING The vendor shall train NMDC Engineers / Operators / Technicians on PLC system for acquaintance, installation, testing, commissioning, operation and maintenance at manufacturers works & site. The Tenders detailed proposal for training shall be based on the following broad guidelines: i. Two batches of Four engineers from client / consultant, each shall be trained at Tenderers Factory on Hardware maintenance and Diagnostic features. Two batches of two engineers shall be trained at Tenderer's premises on Programming Techniques, both Basic & Advanced. One Training session at Project site for 4 days (Two days per group of 12 supervisors per group) focused on specific hardware related maintenance and Diagnostics. One familiarization session at Project site for Project executives and Sr. Officers (25 participants) for two days on functional aspects of the Automation System. Participation of two NMDC engineers at Tenderers premises during engineering & Application Software development for a total period of two months per engineer. All facilities such as workspace, PCs, Training setup, guesthouse accommodation & local transportation etc. for the NMDC engineers shall be provided by the Tenderer during this deputation period.
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Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q4 2.4 POST-COMMISSIONING SERVICES The Tenderer shall make available at project site one engineer, thoroughly familiar with the hardware and software aspects of the system, for a period of twelve months from the date of successful commissioning. The charter of this engineer shall be to assist & guide the system Operations and maintenance / troubleshooting. The engineer shall be available on round-the-clock basis at site. These engineers shall be equipped with basic tools such as notebook PCS, calibrators, comprehensive documentation etc. It is very important to note that these engineers are accountable for updating the system documentation with changes/fieldmodifications carried out during this stabilisation period. VOLUME - IV of V PAGE No. 11 of 75
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NMDC LIMITED
MECON LIMITED

3.0
3.1
STANDARDS AND VOLTAGE LEVELS

STANDARDS All the equipments and their accessories covered in this specification shall be designed, manufactured and tested in compliance with the latest relevant standards and codes of practices published by the Bureau of Indian Standards and Foreign Standards such as ANSI, ISA, OSHA, NEC, IEC, IEEE, NEMA, ASTM, BS, DIN, etc., wherever applicable, in order that specific aspects under Indian conditions are taken care of. The equipments shall also conform to the latest Indian Electricity Rules as regards, safety, earthing and other essential provision specified therein for installation and operation of electrical / electronic equipments. Besides this, the equipment and works shall conform to the relevant Acts, Rules, Directions of the Statutory Institutions, State and Central Government of India.
3.2
PROTECTION Degree of protection of the Instrumentation equipment shall be the following classes of International Protection as per IEC 947.1, 1988; IEC 529, 1992 and IS 13947 (Part-1), 1993. Devices / instruments in field Panels, Boxes in field Cabinets, Panels in electrical room IP-65 IP-65 IP-42
3.3
VOLTAGE AND SIGNAL LEVELS i. UPS Voltages a) Input Voltage b) Output Voltage Instrument Power 415 V AC, 50 Hz, 3 Phase 110 V AC, 50 Hz, 1 Phase
(with V, F variation as specified in Chapter Q3)
ii.
110 V AC, 50 Hz (UPS Power)
for Flow meter, Weighing system, etc.
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q4 iii. iv. Transmitters PLC Signal Levels a) b) c) d) Analog Input Analog Output Digital Input Digital Output 4-20 mA DC, isolated loop powered 24V DC by PLC 4-20 mA DC, loop powered 24V DC by PLC Potential free at Instruments & MCC. PLC interrogation at 110V AC 110V AC for Solenoids and lamps Potential free for MCC VOLUME - IV of V PAGE No. 13 of 75 4 - 20 mA DC isolated output, loop powered 24V DC
110V AC required for input interrogation, relay, lamps etc. shall be generated using redundant power packs. Indication Lamps in field panel / control panel shall be LED type.
Rev. 0
NMDC LIMITED
MECON LIMITED

4.0
DESIGN CRITERIA FOR CONTROL & INSTRUMENTATION

The Control & Instrumentation shall permit centralized automatic control, monitoring and operation of the plant from the crusher control room through the DHC-PLC. The PLC system will be located in the automation room which takes care for operation, monitoring, controlling of Downhill Conveyor, Reversible Conveyor, belt conveyors, magnetic separators, metal detectors, etc. and interfacing with Crusher PLC for interlocks. The system shall be capable of monitoring remotely from crusher control room. The C&I system shall be designed based on the latest state of the art technology. The controls shall be designed to provide automatic sequencing of start up, running and shutdown of the system along with protection and interlocks as required The offered C&I system shall be designed to have a fully automated control using Group level Sequence control concept. The C&I equipment system called for in this specification shall consist of a PLC based system for carrying out the functions of measurement system, control system, protection and interlock system, Human Machine Interface functions and communication system. No independent relay-based controls are envisaged. The specification of the C&I equipments are specified under the clause Technical Specification. Sequence control facilities shall be provided to start up and shut down functional sub group of the plant. The design of the control system shall be hierarchical. The system shall generally consist of following levels: i. Drive controls: The first level covers all the binary control functions associated with all remotely controlled plant drives including analog processing if any. Sub-group controls: The second level co-ordinates the control of some first level drives. It incorporates binary control for a particular functional sub group. Functional group controls: A functional group consists of different units, which individually represent and control a part of the complete plant and can be divided into two or more sub groups. Every sub group is controlled by an independent
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ii.
iii.
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q4 VOLUME - IV of V PAGE No. 15 of 75 sub group control, which controls the operation of various drives. Once a start signal is issued by a functional group, the sub group control brings the sub group from one state into another operating condition by issuing command signals in a programmed sequence. It brings the sub group from a shut down state into a working condition and vice-versa. The functional group instrumentation and control system co ordinates the entire sub group controls belonging to one functional group. iv. Group Level Controls: shall automatically Line up all the required sub groups and start the Downhill Conveying System automatically.
All the required Hardware and software to implement the above hierarchical structure shall be included in the scope. The PLC logic implemented shall provide for fully automated sequence operation. 4.1 PROTECTION, INTERLOCK AND SEQUENCE CONTROL This system shall enable the operator for safe start up and shutdown and carryout normal operation both from control room and local areas. Hardwired Emergency Stop push button also shall be provided in the control room at convenient locations. Protection and Interlock shall be provided for all the equipment and system to safeguard the equipment against abnormal conditions. Controls shall be provided to start/shutdown various systems and/or any equipment with associated auxiliaries and to operate the system on line with less number of operations and higher safety. Sequence control shall be provided to start and stop the "functional systems" or "sub-systems" and associated equipment & auxiliaries. The sequence control shall have the following features: i. Once the start up or shutdown of equipment is initiated either manually or automatically from the system, the control of associated auxiliaries shall be automatic with facility for manual operation at each stage (step). Criteria check up for each stage of operation with monitoring and displaying, of unfulfilled criteria. Bypass facility for each criteria when only the feedback signal/display is incorrect but the actual condition is fulfilled. This activity shall be logged with annunciation in PLC.
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ii. iii.
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q4 iv. VOLUME - IV of V PAGE No. 16 of 75 Adequate time delay between the steps as dictated by the process to establish an operating parameter or healthiness of equipment. Normally, the auxiliaries of the standby equipment shall be running (as applicable) so that the standby equipment is started without loss of time.
v.
The following minimum interlock functions shall be met for various equipment/system as applicable: i. Permissive conditions for equipment start shall be provided. The permissive conditions within the equipment are bearing temperature normal, winding temperature normal, adequate suction pressure, bearing vibrations normal, bearing lubrication oil pressure normal (as applicable),etc., The permissive conditions from a system / relative equipment for establishment of free path for the flowing medium under all startup, emergency and shutdown conditions. Selection of standby equipment and starting the equipment automatically on the tripping of running equipment Isolation of the tripped equipment from the main process. Any other conditions for safe starting of the equipment and shutting down the equipment.
ii.
iii. iv. v.
4.2
PROCESS CONTROL SYSTEM OVERVIEW The C&I system called for shall be designed for safe, reliable, efficient and smooth operation of the plant and its associated auxiliaries with minimum intervention of the operating personnel during normal working of the plant. The C&I system shall be based on PLC with the latest state of the art technology. This specification and PLC automation configuration drawing enclosed (MEC/01/Q6DH/KIOP/II/215/TS) defines the minimum technical requirements of plant automation system comprising of PLC and its peripherals. The plant automation system shall be capable of controlling and monitoring the entire functional unit by executing all functional requirements.
Rev. 0
NMDC LIMITED
MECON LIMITED

The Downhill Conveying system and its auxiliaries shall be controlled, monitored and operated through the PLC. The PLC shall be located in the automation room of electrical building. The PLC shall receive all the field signals and perform the interlocks, protection, sequence and control operations. The filed IOs shall be interface to the PLC control system through Remote IO (RIO) unit geographically distributed. The Remote IO unit shall communicate with the controllers on redundant links of RIO bus, using single mode fibre optic cable. The tentative RIO locations are indicated in the automation configuration drawing. However quantity and location of RIOs are subject to change during detail engineering. The Brake Control System PLC of downhill conveyor and reversible conveyor shall be interfaced to the DHC-PLC through redundant communication link, preferably on Profibus in addition to hardwired IOs. Crusher Plant PLC provided by NMDC shall be interfaced with the DHC-PLC on redundant communication link using single mode fibre optic cable. Operators interface to the plant and process is through PC based HMI workstation with SCADA software. HMI stations will comprise of 1-Operator Workstation and 1-Engineering Workstation. The Engineering station shall also be used as an Operator Workstation. The Engineering station shall be located in a DHC automation room. The Operator station shall be located in the crusher control room. Operator workstation installed in the crusher control room shall be linked to the data bus of DHC-PLC using redundant FO cable. Thus the workstation shall act as extended node of DHC-PLC. Extension of the PLC data bus to the central control room shall be using SMF fibre link. For this purpose the required switches with fibre and UTP ports shall be considered. The SMF cable shall be with minimum 4 cores so that 2 cores each shall be used for data bus and 2 cores shall be spare. The visual display of the workstation provides various colour graphics of the plant process, which are dynamic and real time to plant operating conditions. The keyboard & mouse of the workstation enables the operator to provide the set-points and commands to control the process.
NMDC LIMITED
MECON LIMITED

The power supply to the PLC, Remote IOs, Workstations, Field Instruments shall be through UPS. The UPS shall be redundant, load sharing mode, with 25% spare capacity for future use. The philosophy shall be that the plant shall be operated and controlled from PLC with all closed-loop set in auto-mode. Sequencing, interlocking and logic functions shall be implemented in the PLC. Redundancy in PLC is adopted to increase the availability of the control system. PLC shall have the data acquisition and control of the process parameters of the various plant units, which can also be subsequently used to generate various reports for Management Information System. 4.3 SOFTWARE The complete licensed software shall include both system and application software to carryout the engineering, monitoring and operation, maintenance function and provision for communication links and proven Serial Links to the Controllers of Electro-hydraulic Power packs of Conveyors Brake systems of Conveyor 723 & 727, Local PLCs etc. The requirements of HMI are detailed under the clause technical specification.
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NMDC LIMITED
MECON LIMITED

5.0
TECHNICAL REQUIREMENTS, SEQUENTIAL INTERLOCKS
CONTROL,
SAFETY
AND
The control system shall enable safe control and monitoring of the entire conveying system and its auxiliaries to achieve optimum performance reliability, safety and availability. The safety interlock system shall include complete protection of operating personnel and equipment without causing unnecessary trips or imposing undue delay during start-up from a standstill condition or following a trip. 5.1 DESIGN CONSIDERATIONS The design of the safety interlocking system shall be based on the following basic principles and is intended to shut down the conveying system and / or disconnect the associated handling equipment from the electric power supply under certain abnormal operating conditions: i. To trip the minimum equipment in the sequence during abnormal operating conditions leaving all the other equipment running which may safely be permitted to continue operation. To annunciate and indicate initiating cause for equipment which has tripped. To prevent restarting of equipment until safe conditions are restored, hooters are annunciated and equipment shall be restarted by the operator. To prevent mal-operation of equipment on interruptions and restoration of control voltage. To eliminate the necessity for any manual bypassing of an interlock to permit starting and stopping of equipment. If incorrect operation is done, annunciation indicates the incorrect path selection.
ii. iii.
iv. v. vi.
5.2
OPERATIONAL REQUIREMENTS Pressing of Sequence Start Key from HMI shall give a warning signal for a Preset time (may be one minute but adjustable to any desired time interval) by way of siren alarm throughout the system in the selected path for alerting the personnel at site to clear away
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NMDC LIMITED
MECON LIMITED

from the respective ore handling equipment. After one minute, the siren alarm shall stop and another two minutes shall be allowed for the movement of personnel and subsequently starting the equipment in the selected path, sequentially. If the system fails to start, after issuance of sequence start signal, hooter shall repeat till the fault is cleared / acknowledged. The logic shall take care that the incorrect path operation is prohibited. Pressing of Emergency Stop key shall cut-off the starting and running control supplies and supplies shall not be restored until Emergency Stop key is reset by pressing Emergency Stop key. Also it shall stop all the running equipment. The following are the common minimum permissive conditions to start any conveyor: i. ii. iii. iv. v. vi. vii. Pull cord switch Belt Slip Belt Rip Belt Alignment Motor overload relay Hydraulic drive Zero speed switch : : : : : : : Neutral Reset Reset Reset Reset Ready Permissive
In addition to the above, zero speed switch permissive shall be taken as permissive condition for running of any conveyor. The tripping of any equipment shall automatically and successively trip all downstream side equipment, including magnetic separators. Tripping of any equipment down stream of crushers shall not trip crushers for pre-determined time to enable clearing of Crusher cage. For stopping the sequence the Sequence Stop command shall be given from HMI or from push button. This shall stop the feed end equipment first and then after leaving about 20 minutes the last equipment in the sequence shall stop so that all the other preceding equipment shall stop sequentially. However, the timer provided shall be adjustable between 10 to 30 minutes. Each equipment in conveying system shall have status and alarm indicated in HMI. Operating stop and trip conditions of each equipment shall be indicated as per the approved colour code. Similarly energised, de-energised and trip conditions of magnetic separators shall be indicated on the HMI. The trip indication shall be flashing under trip conditions until accept button is pressed.
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q4 5.3 ANNUNCIATION REQUIREMENTS Individual point Annunciation shall be provided for each of the following in HMI. The annunciation system given below are minimum required but shall not be limited to the same. i. ii. iii. Annunciation for trip of individual belt conveyors. Annunciation for fault in individual conveyor drives / crusher motor / screen motor trip on O/L / fault of HT motors. Annunciation shall be provided for all belt conveyors and belt feeders to annunciate the tripping due to each of the following conditions separately: a. b. c. d. e. f. g. h. iv. v. vi. Pull cord switch operated. Belt sway switch actuated. Belt slip switch actuated. Belt rip switch actuated. Zero speed switch actuated. Emergency Switch operated. Brake Fault. Any other causes VOLUME - IV of V PAGE No. 21 of 75
Annunciation for motor trip due to high bearing temperature and winding temperature. Annunciation for trip of conveyor due to metal detection by metal detector. Individual annunciation for each Conveyor for the tripping due to following: a. b. c. d. e. f. Belt sway switch actuated on conveyors Belt slip switch actuated on conveyors Belt rip switch actuated on conveyors Pull chord switch operated on conveyors Zero speed switch actuated on conveyor Emergency switch operated in conveyors
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NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q4 vii. VOLUME - IV of V PAGE No. 22 of 75 Individual annunciation for the following conditions of the electrical power system: a. b. c. d. e. f. viii. Main DC supply feeder failure. Switchgear Incomer and Bus coupler auto trip. 415V switchgear / MCC trouble. Transformer Alarm and Trip. Motors bearing, winding temperature high alarm. UPS and Battery system trouble.
Any other annunciation points required shall be included. However the final annunciation list is subject to Purchasers approval.
5.4
HMI SCREEN The HMI Screen shall accomplish the following: i. On selection of sequential path the red lamps associated with the equipments in the selected path shall give a slow steady flicker. On successful operation of each equipment the red lamp shall become steady. Should any equipment fail to operate the red lamp shall give a fast flicker. Green lamp shall give steady glow when any equipment is stationary / not switched on. On giving OFF / STOP command along with validity, should any equipment fail to stop the green lamp associated with that particular equipment shall give a flicker. For local operation blue lamp associated with each equipment intended to be started from local, in the de- interlocked mode shall glow steadily. If the local manual starting of any equipment is omitted the blue lamp associated with the particular equipment shall flicker.
ii.
iii.
Auto / Manual selection shall be available in HMI.
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NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q4 5.5 VFD & PLC INTERFACE VFD shall be interfaced with the PLC through hardwired IOs. Control and feedback signals shall be hardwired to the PLC-RIO though marshalling. Also the VFD shall be interfaced with PLC through redundant communication link. The communication link shall be preferably on Profibus. 5.6 MULTIFUNCTION METER, RELAYS & PLC INTERFACE Numerical relays and MFMs in HT panel shall be interfaced with the PLC on redundant serial communication links like RS485-Modbus. MFM in MCC shall be interfaced with PLC on redundant Profibus communication links. Data signals from the relays - Voltage, Current, Power, Power Factor shall be transmitter to PLC as minimum. 5.7 CENTRAL CONTROL ROOM CRUSHER CONTROL ROOM PLC shall be networked with the Crushing Plant PLC provided by Package-I Vendor on dual redundant communication link on fiber optic cable. For the implementation - communication cable (supply & laying of fiber optic from the PLCs), HDPE pipes, necessary hardware & software and engineering required for the same shall be provided by the vendor. The plant is envisaged to be operated from the centralised location - crusher control room. The crusher control room is provided with 3 HMI workstations by the crusher package vendor. During normal operation, the DHC system will be operated and controlled from the centralised location- crusher control room. The operator workstation in the crusher control room, provided by Crusher package vendor, shall display the DHC graphics and shall facilitate the operation of the DHC from the crusher control room. Tender shall also provide the graphic pages details for development of HMI graphics in this operator workstation to enable the operator for easy operation and control of DHC. The redundant communication link between the DHC PLC and Crusher PLC shall be using SMF fibre link. For this purpose the required switches with fibre and UTP ports shall be considered. The SMF cable shall be with minimum 12 cores and after using the cores
NMDC LIMITED
MECON LIMITED

for data other cores shall be spare. Tenderer shall provide necessary support, assistance during interfacing of the same. Additionally, the operator station provided by the tenderer shall also be installed in the crusher control room for operation, monitoring and control of the DHC system. Operator workstation installed in the central control room shall be linked to the DHC PLC using redundant FO cable and redundant Ethernet switches. Thus the workstation shall act as extended node of DHC PLC. Extension of the PLC data bus to the central control room shall be using SMF fibre link. For this purpose the required switches with fibre and UTP ports shall be considered. Console desk furniture required for this operator station shall be provide by Package-I vendor. 5.8 DOWNHILL CONVEYOR 723 Downhill Conveyor is operated by 2 motors which are VFD driven. The PLC shall work as master and VFD as salve, shall receive command from the PLC. The load sharing of the motors shall be internally done by the PLC and VFD. PLC shall provide the required torque reference to the VFD and ensure sharing of the load between the motors from continuous feedback it gets from the system. Following types of controlled stopping modes, as minimum shall be provided for the Downhill Conveyor: Mode Mode Mode Mode Mode 5.9 1: 2: 3: 4: 5: Normal Stopping Power Fail Stopping Power Fail, PLC or Multi Drive Fail Stopping Power Fail, PLC & Brake Controller Fail Stopping Emergency Stop
REVERSIBLE CONVEYOR 727 Reversible Conveyor is operated by VFD driven motors. High resolution encoder/tachometer shall be provided to sense the speed and direction of motion of the conveyor. The conveyor shall be controlled by the DHC-PLC.
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PACKAGE NO - II CHAPTER NO. Q4 5.10 CONVEYOR BRAKE SYSTEM The braking system of Downhill Conveyors 723 and Reversible Conveyor 727 shall have individual, dedicated PLC based control system each, called DC-BS-PLC and RC-BS-PLC. The sequence of operation, control, protection and interlocking etc., of the braking system shall be achieved through the dedicated PLC. The control system shall facilitate monitoring and control of braking time, speed, hydraulic system pressure, brake pad temperature, constant deceleration, controlled start-up ramp, controlled release of brake, etc. PLC shall consist of processor module, power supply module, communication module, input-output module and keypad with display unit mounted on the panel for operation of the system at local. Redundancy shall be provided in processor, power supply and communication module. PLC shall be powered from the UPS. DC-BS-PLC and RC-BS-PLC shall be programmed for various operating modes: i. ii. iii. LOCAL // AUTO-MANUAL LOCAL // MAINTENANCE REMOTE : for operations from local : for maintenance purpose : for operation from DHC-PLC. VOLUME - IV of V PAGE No. 25 of 75
LOCAL/REMOTE selection shall be from the DHC-PLC. In event of power failure and controller failure, the brake system shall move to fail-safe conditions. Brake system PLCs shall be interfaced with the DHC-PLC through hardwired IOs. Critical / interlock signals and feedback signals shall be hardwired to the DHC-PLC. Also, break system PLCs shall be interfaced with DHC-PLC through redundant communication link. The communication link shall be preferably on Profibus. The minimum control & instrumentation required for each Brake System, is indicated below. However, the vendor shall provide all required measurements, controls, alarms & interlocks required for safe, efficient & satisfactory operation of the system. Instrumentation Requirements: i. Caliper Release Switch: Brake caliper apply/release indicator micro switch shall be provided.
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PACKAGE NO - II CHAPTER NO. Q4 ii. VOLUME - IV of V PAGE No. 26 of 75 Pad Wear Indicators: Brake pads shall be equipped with pad wear indicators connected to the PLC. The PLC shall inhibit conveyor restart if the pad wear indicators signal excessive war (time to change pads). Caliper Air Gap Adjustments: Caliper shall be equipped with self-adjusting air gap mechanism, or shall be equipped with sensors to measure the air gap and provide a signal to the PLC so that a warning of required air gap adjustment can be issued, or to inhibit conveyor restart if the air gap is excessive. Pressure Transducer: Pressure transducer shall be provided for monitoring of the caliper pressure. Pressure Gauges: Pressure gauges shall be provided for visual indication of the accumulator pressure and caliper pressure. Hydraulic Assembly Pressure Switches: Pressure switches shall be provided on each hydraulic assembly. - A Pressure switch shall be provided for pump control, through PLC and shall be located on the accumulator line. It shall be set to open on decreasing pressure at 1600 PSI (Adjustable) with a maximum hysteresis of 250 PSI. A Pressure switch shall be provided to detect full brake release and shall be located on the caliper line. It shall be set to close on increasing pressure at 1450 PSI (adjustable) with a maximum hysteresis of 250 PSI. All pressure switches shall be open under low pressure. The switch accuracy shall be repeatable to 2 percent of the set point.
iii.
iv. v.
vi.
vii.
Filter Differential Pressure Switches: The on-line filters shall be equipped with a differential pressure switch to indicate blocked or dirty conditions. The switch shall be closed under low pressure. Oil Temperature Switches: The reservoir assembly shall be equipped with temperature switches to monitor the hydraulic fluid temperature.
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PACKAGE NO - II CHAPTER NO. Q4 VOLUME - IV of V PAGE No. 27 of 75 A Temperature switch shall be provided for low temperature detection (alarm) and heating system control, if required. It shall be set to close on decreasing temperature. A Temperature switch shall be provided for high temperature detection (alarm) and cooling system control if required. It shall be set to close on increasing temperature. A Temperature switch shall be provided for high-high temperature detection (trip). It shall be set to open on increasing temperature.
Temperature switches shall have a minimum hysteresis of 5 degrees C and a maximum hysteresis of 10 degrees C. The switch accuracy shall be repeatable to 2 percent of the set point. ix. Oil Level Switches: The reservoir assembly shall be equipped with level switches to monitor the hydraulic fluid level. A Level switch shall be provided for low level detection (alarm). Level switch shall be provided for low-low level detection (trip). Both switches shall be set to open on decreasing.
Control Requirements: i. Hydraulic Pump Control: The hydraulic pump will be controlled by the PLC to maintain sufficient accumulator pressure for full brake release. No local hardwired interlocks are required. Brake Control: Drive assemblies shall have low speed shaft caliper/disk brake systems, controlled from a common hydraulic control source. The counter-pressure (braking force) on several of the brake calipers may be adjustable by a modulating pressure control valve (proportional control valve). The control valve shall be compatible with the overall control response time. The pressure control valve shall respond to a 4-20 mA signal. Emergency Circuit: The hydraulic circuit shall be equipped with a solenoid vent valve between the digital calipers and
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PACKAGE NO - II CHAPTER NO. Q4 VOLUME - IV of V PAGE No. 28 of 75 the tank. This valve shall fail open upon loss of power. As this valve will be normally-open, fluid from the digital calipers will dump to the tank in case of PLC failure or UPS failure. The PLC may also activate the emergency circuit upon detecting excessive or prolonged over speed, or upon sensing malfunction of other components, (such as normally-closed valves ordinarily used to deploy these calipers or the proportional brake control). The digital calipers shall begin to apply pressure to their rotors within 125ms after the valve opens. The digital calipers shall have attained zero pressure (full torque) within 125ms of initial engagement. The hydraulics shall also be equipped with an emergency circuit connected to any proportional calipers through a solenoid vent valve. This valve shall fail open upon loss of power. As the valve will be normally-open, the circuit will come online in case of PLC failure or UPS failure. The PLC may also activate the emergency circuit upon detecting malfunction of the proportional brake control, or upon detecting excessive or prolonged over speed. The emergency circuit shall be capable of reducing the hydraulic pressure to the proportional calipers so as to regulate their torque according to a preset curve described below. As such, the circuit shall be equipped with all necessary components including but not limited to check valves, pressure relief valves, fixed and adjustable orifices, pressure gauge, and an emergency accumulator. The proportional calipers shall begin to apply pressure to their rotors after the valve opens. The proportional calipers shall have attained 20%2% of their torque of initial engagement. The circuit shall gradually bleed fluid from the proportional calipers over the next ten (10) seconds so as to achieve zero pressure. Over the interval between one (1) second and eleven (11) seconds after initial engagement, the torque applied by the proportional calipers shall increase gradually from 20%2% to 100% or full torque. During this bleed time, the rate of torque increase shall be as constant as circuitry permits, vendor to report the characteristics of bleed and initial application.
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PACKAGE NO - II CHAPTER NO. Q4 iv. VOLUME - IV of V PAGE No. 29 of 75 Overspeed Valve: The hydraulic circuit shall be equipped with a solenoid vent valve to dump the caliper hydraulic fluid directly to the tank. This valve shall fail closed on loss of power. This valve will be a normally closed valve activated by the PLC on detection of an overspeed of more than 20%. The caliper shall begin to apply pressure to the rotor after the signal to open the overspeed valve has been given. The caliper pressure shall have attained zero pressure (full torque) within 1 second of initial engagement. Any measurement / control not listed but essential for completing the process in total shall also be covered under the scope of the vendor. 5.11 DUST SUPPRESSION SYSTEM The tenderer shall provide necessary C&I for the dust suppression system. The system shall be operated and controlled from the DHCPLC. The system shall have Auto or Manual mode.
6.0
6.1
TECHNICAL DESIGN SPECIFICATION

PROGRAMMABLE LOGIC CONTROLLER
6.1.1 General The conveying system shall be operated, monitored and controlled through dedicated PLC, located in the Downhill Conveying System automation room. Redundancy in the PLC shall be provided towards processor, power supply, communication modules, communication network. PLC shall be featured to provide communication ports RS-485 Modbus and Ethernet as indicated in the architecture drawing. PLC shall be able to operate satisfactorily from 15 Deg.C to 55 Deg.C and 20% to 95% humidity. The system shall be programmed in general as per logic diagram or ladder diagram. Online modification of program (ladder logic), input / output assignment, loop creation, logic / sequence table creation,
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graphic creation shall be possible from the engineering station without affecting the plant operation. FORCE ON and FORCE OFF of any input or output internal coils / contacts of the ladder logic or logic diagram shall be done during online and test run (in engineering mode). The system shall have extensive set of self-diagnostic hardware and software for easy and fast maintenance. Diagnostics shall be provided at PLC, Communication, HMI levels. Online replacement of any modules shall be possible so that removal / addition of any module shall not interrupt the system. Operation of PLC shall not be affected by a momentary power loss. Single hardware failure shall affect few numbers of control loops and shall not affect the process. Failure of engineering station shall not affect the process and dynamic data shall be available in operating station and also operation shall be possible from Operator stations and local control stations, if any. Critical system alarms are to be configured for display in the operators screens. Alarms like processor failure, power supply failure, communication link failure, communication module failure, IO link failure are to be configured for display in the operators screens. The design of system electronics shall be in compliance with the Electro magnetic compatibility requirements as per IEC:801 [Electro magnetic compatibility for industrial Process measurement and control Equipment]. 6.1.2 Processor The PLC shall be microprocessor-based system with 32-bit processor. Processor shall be of modular in construction and expandable in future by extending additional modules. The processor shall be redundant and work on hot redundant mode. On failure of one processor, the control shall get transferred to the other processor. Switching over from main processor to standby processor shall be automatic and bump-less. In case of failure of
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complete processor system i.e., both processors failing, the system output shall go to fail-safe condition automatically. Failure of processor should be annunciated in the Operator station and Engineering station and remote monitored station. The offered processor type shall have a minimum reference capacity to handle 1000 real time inputs/outputs. The loading of the processor shall be upto 60% to achieve optimum performance. The size of the primary memory shall be sufficient for the storage of the program instructions required by the logic schemes. Loading of memory shall be 60% and shall have 40% free space for future use. Memory shall be expandable. Generally memory shall be non-volatile. In case volatile memory is provided, battery back up shall be provided for minimum of twelve months to keep the storage intact. A battery drain indication shall be provided to indicate battery drain at least one week before the battery gets drained and the same shall also be annunciated in the Operator station. The processor shall have capability to implement all the control functions required to execute the logic schemes. The minimum functional requirements of the processor are as follows: i. ii. iii. iv. v. vi. vii. viii. ix. x. xi. Multi loop controls. PID, Cascade, feedback control Timer ON delay, OFF delay. Self-tuning capacity for closed loop. Algorithms, Arithmetic function, comparison, limiter, selector, and logic function etc., Automatic start up sequence and automatic shutdown sequence. Emergency and safety shutdown. Communication with various levels Diagnostics of the entire system as well as its connected equipment. Capable of interfacing special modules like positioning, weighing, etc., Ladder logic or Structured-Text programming shall be accessible by any windows-based operating system.
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PACKAGE NO - II CHAPTER NO. Q4 6.1.3 Input-Output System General This subsystem basically comprises input / output (I/O) units along with other accessories. It provides the main interface between process/ instrumentation system and the control room automation system Each input / output channel shall be electrically isolated from external control circuit by suitable means. The minimum isolation level between input / output logic circuit shall be 1000V DC. The input / output channel shall be protected against the reversal of power supply polarity. Surges withstand capacity for IO modules shall be as per IEEE standards. All the cards shall be modular & plug-in type. On-line replacement of modules shall be possible and shall not affect the processing / other cards in the rack. The field cables shall not be brought directly to the I/O cards. The same shall be routed through the field termination / marshalling racks. Interrogation voltage for binary inputs shall be through fused terminals. For different type of inputs /outputs, different coloured wires and terminal blocks shall be provided. All internal wires shall be neatly dressed, bundled together and routed in PVC channels / cable alleys with removable covers. The terminals for connection of external cables shall be located in marshalling rack/panels. Terminal blocks shall be Cage Clamp type. The size of marshalling rack/panels shall be decided during detail engineering considering number of field cables to be terminated. The maximum number of inputs / outputs per module shall be limited as follows: i. ii. iii. iv. Digital Input Module Digital Output Module Analog Input Module Analog Output Module : : : : 32 32 16 16 Channel Channel Channel Channel
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PACKAGE NO - II CHAPTER NO. Q4 Analog Inputs Module i. ii. iii. iv. v. vi. vii. Analogue input cards shall be differential type. Galvanic isolation shall be provided for individual channels of Analog input modules. Channel shall be capable to accept SMART transmitter Channel shall loop power the transmitters with 24VDC. Measurement DC signals shall be in the range 4-20 mA. Load driving capability of minimum 600 ohms at 24 VDC Module shall have provision of filtering the measuring signals and input-open circuit detection. Healthy status indication on the module shall be provided. VOLUME - IV of V PAGE No. 33 of 75
Analog Output Module i. ii. iii. iv. Galvanic isolation shall be provided for individual channels of Analog output modules. Analog DC output signals shall be generally in the range 4-20 mA. Load driving capability of minimum 600 ohms at 24 VDC. Healthy status indication on the module shall be provided.
Digital Input Module i. ii. Digital input channels shall be optically isolated. Contacts to be sensed are potential free from the field switches or from MCC. The signal shall be interrogated at 110V AC. The channel state of binary input module shall be visible from the indicators on the front panel of the card.
iii.
Digital Output Module i. ii. Digital output channels shall be optically isolated. The voltage used for the binary output module for field instruments shall be 110V AC and towards MCC, potential free contacts are to be provided. The channel state of binary output module shall be visible from the indicators on the front panel of the card.
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PACKAGE NO - II CHAPTER NO. Q4 iv. VOLUME - IV of V PAGE No. 34 of 75 Digital outputs used for commands or going directly to field shall be taken through fused terminals having fuse-blown indication. For switching of external devices through binary output from PLC, interposing relays working on 110V AC shall be used. All interposing relays shall be preferably located separately in the panel.
v.
6.1.4 Power Supply Module Power supply module shall be redundant and suitable to operate on 110V AC, 50Hz, single phase from UPS. Failure of one power supply module shall not affect the process control. The module shall provide power supply to the processor, IO rack. Switchover due to power supply failure shall be bumpless and automatic. The bulk power supply modules shall work on hot redundant mode and shall have a common output to feed to the processors, IOsystem in such a way that in case of failure of one module, the other shall takeover without interruption of processor operation. Switchover between the bulk power supply modules shall be bumpless and automatic. The power supply module shall have LED for showing healthiness of the module. All modules shall have over-current and over-voltage protection. Suitable cooling arrangement shall be provided for each module to ensure their continuous operation. 6.1.5 Communication Module The communication module and network shall be redundant and offer continuous uninterrupted communication for all the connected equipment. Switching over between the networks shall be automatic and bumpless. Redundant communication network links shall be connected to redundant network modules. Indication for failure of communication module / network shall be available in module and workstation level. Communication between IO sub-system / RIO and processor shall be redundant. Communication between processor and operator / engineering station shall be redundant. Redundant communication link shall be provided between the Numerical Relays, MFM and PLC.
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Communication between processor and operator / engineering station shall be on industrial Ethernet with TCP/IP with 100 Mbps speed. The communication bus shall have provision for 25% expandability for connecting additional nodes. RS-485 Modbus communication port shall also be provided as a feature, to communication with third party systems. 6.1.6 Scan Time & Update Time The parameters indicated below are under worst loaded conditions and shall be better during normal operating conditions: i. ii. iii. 6.2 Scan time for analog signals Scan time for digital signals Scan time for pulse signals : : : 250 m-sec 100 m-sec 100 m-sec
SPARE PHILOSOPHY The following spare philosophy shall be followed in each PLC & RIO panel: i. ii. iii. iv. v. vi. 20% spare free slots shall be provided for expansion by inserting additional modules. 20% spare input / output channels of each module type shall be provided and shall be wired upto the terminal blocks. 20% spare free terminal blocks shall be provided in PLC panel and marshalling panel for future use. 20% spare relays shall be provided and all contacts wired upto terminal blocks for future use. 20% spare free space shall be provided in cabinets to install relays for future. 20% spare ports of each type shall be provided in the Ethernet switch.
6.3
REMOTE IO (RIO) Remote IO concept has input/outputs located at RIO generally consists communication interface been envisaged for interfacing the field various remote locations to the PLC. The of the field input-output cards, PLC module, power supply unit arranged in a
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cabinet. Redundancy shall be provided at communication module, communication network and power supply. The communication between RIO and PLC shall be dual redundant. The redundant communication links shall be on fiber optic cable with two physical cables (with spare fibers) routed in two different physical paths. System failures shall be annunciated in the PLC. All necessary hardware and software required for fiber optic transmission shall be considered by the tenderer. The fiber optic cable shall be run in HDPE conduit of required size from Remote I/O modules to control processors. The I/O modules in RIO shall be designed for harsh environmental conditions of temperature, dust, etc. However the remote I/O system shall be so designed that it functions well even when there is no air conditioning. Remote IOs shall be located in the following areas: i. ii. iii. Near electrical room at tail end of down hill conveyor Near TH5 Along Downhill conveyor 723 (4nos)
However the quantity and location of RIOs shall be decided during detail engineering. Since the IOs to be connected to the RIO units are distributed along the length of approx.5km, throughout the route of DHC, the number of RIO panels may increase. Based on the system offered, the tenderer is required to assess the number of RIO panels and consider an increase in the number of panels. Minimum 6 numbers of RIO panels shall be offered and any increase in RIO panels during detail engineering shall be without any cost implications. Power supply to remote IO system shall be from the UPS. Failure of input to RIO shall be annunciated at the HMI of the Crusher Control Room. At Control room (tail end of down hill conveyor) and electrical room near TH-5, the Remote IO with associated marshalling cabinets shall be located in the RIO room which shall be dust free. The RIO room shall be air-conditioned.
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Along the downhill conveyor, the RIOs shall be housed in a double door cabinet with IP65 protection. RIO and marshalling shall be accommodated in the same panel. 6.4 OPERATOR STATIONS, ENGINEERING STATION AND PRINTERS The conveying system shall be provided with Workstations one Operator Stations and one Engineering Station. The Workstation shall be on Windows XP platform. Softwares offered for programming, controlling and monitoring shall be fully compatible with Windows 2000/XP platform. Dedicated individual licenses shall be provided for use of the software in these workstations. The Operating Station shall present the necessary plant information in a manner, which can be easily understood and absorbed by the Operator. The Engineering Station shall also provide the facilities to engineer and program so as to control the plant process and shall be loaded with engineering software. It shall also be possible to use the Engineering Station as Operator Station. These displays shall be in the form of plant overviews, area overviews, group and sub group overviews, drive level displays, alarm list, sequences of event list with time stamping, mimic diagrams, hardware status displays, logs, bar charts, trends curves, etc. All workstations shall have the following minimum design features and shall be identical and interchangeable: i. ii. iii. iv. v. vi. vii. viii. ix. x. Processor of latest configuration (preferred 2.5GHz & above). Minimum 2 GB RAM and shall be expandable. Minimum 320 GB Hard Disc. Drive controllers IDE, SATA. High resolution 22-inch TFT colour monitor with pixel resolution of 1280x1024, 32-bit color support as minimum. Serial, Parallel, USB Ports, dual network interface modules for connecting the data highway, printers etc., Latest DVD-RW for data back-up and installation. Optical scroll mouse and QWERTY keyboard. Dynamic graphic capability with control through dynamic graphics. Console Furniture for mounting the monitors, key-board, mouse and the electronic unit of the workstation along with strain relieving type of chair for each station.
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One high resolution A3 size colour laser printer shall also be provided for data logging, report generation and alarm printing. Necessary consumables for printing shall be provided with the printer. Sufficient quantity of consumables shall be supplied for operating the system upto guarantee period and hand over the excess after commissioning. Separate Laptop shall be provided for programming, testing, troubleshooting of the PLC. Laptop shall have the following minimum design features: i. ii. iii. iv. v. vi. vii. viii. 6.5 Processor of latest configuration (preferred 2.2GHz & above). Minimum 2 GB RAM and shall be expandable. Minimum 250 GB Hard Disc. High resolution 15-inch XGA screen colour monitor with pixel resolution of 1280x1024, 32-bit color support as minimum. Ports: Ethernet, Wireless LAN, VGA Out, Serial, USB, PS2, Wireless Infrared Sensor Latest DVD-RW for data back-up and installation. Optical scroll mouse and QWERTY keyboard. Accessories: Power Adapter, Spike Protector, Carry Case
HUMAN MACHINE INTERFACE (HMI) Generally, the operation of plant will be carried out from the PLC with HMI Software in Operator stations and Engineering stations in the following modes: Local Mode Enables the drive to be operated from the local start/stop station for maintenance purposes. This method prevents the sequence group control and ignores interlocks and permissives, but does not override the protection for that drive. Enables the drive to be fully controlled from the control room, with interlocks and permissives active. The local start button is disabled, however the local stop button always remains functional. There are two ways to control drives in this mode:
Remote Mode
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PACKAGE NO - II CHAPTER NO. Q4 * Manual VOLUME - IV of V PAGE No. 39 of 75 Individual drives can be Started / Stopped (at operator console) independently of the sequence group control logic. Drives are Started / Stopped by the sequence group control logic, and cannot be manually started/stopped individually. Both the local and remote stop functions are operational, but any stop command will trigger all interlocked plant to also trip.
Auto
Typically, the drive symbols on the graphic display shall be a multicolour variable, indicating by colour code their current status. Typically this will display the following states: Ready (stopped) Running Isolated MCC fault (eg, overload trip) Field fault (eg, emergency stop) These will be finalised during detailed engineering. Local / remote status should be indicated by the appearance of text LOC adjacent to the drive symbol when in local, text blanked when in remote, or some equivalent display format. Typically each motor drive control has a detail pop-up window control faceplate, which shows the following information: MCC module isolated (includes loss of control supply) Overload / fault status Emergency Stop status Motor Run status Motor Current (or power for VFDs) Low sump level start permissive on pumps Any other specific functions, e.g. underspeed, pull-wire trip VFD healthy (as applicable) Control functions Local / remote selector switch Stop and start buttons These will be finalised during detailed engineering.
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The general philosophy is that any function, which trips or prevents a drive from starting, must be displayed, so that the operator can rapidly determine the cause of any problem preventing the plant from running. In general and as minimum trending is required for all drive motor currents, density meters, flow meters, bin levels as applicable. Drives may be subject to three categories of control, as defined below: * Protection Any function, either hardware or software, that protects the operator or machine from injury/damage, and creates avoidable risk if by-passed. * Interlock Any status (excluding protection) which is necessary to enable a drive to run. Loss of that status trips the drive when running, or prevents it from starting.
* Permissive Any condition which must be fulfilled to enable the drive to start, but is not required to be maintained once the drive is running. HMI software shall be accessible using any Windows based operating system. Visual display call up time shall not exceed one (1) second. HMI software shall have the following as minimum: i. ii. iii. iv. v. vi. vii. viii. ix. x. xi. xii. Plant overview graphics. Plant detail graphics. Group displays. Analog / Digital indication and controls. Sequence control. Real time trend. Historical trend. Loop detail displays. Diagnostics displays. Window displays and Popup screens Reports. Alarm and event handling.
HMI Workstations shall have a page configured System Configuration, to display all the nodes & buses in the network and indicate healthiness / status of each.
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PACKAGE NO - II CHAPTER NO. Q4 i. Plant Overview Graphics These graphics will be designed and developed to provide unit / area status and control. Process flow will generally be indicated with the status of plant sections and main process variables displayed. The operator shall be able to select a plant detail graphics from the plant overview graphics. The overview display will have freely assignable blocks. Other displays shall be accessible by function key available in MIMIC screen. ii. Plant Detail Graphics Custom built graphics shall be used for showing a detail of sections of the plant. The status of all relevant rotating equipment and all process and utility variables shall be displayed. The operator will control the plant rotating equipment and on-off devices utilizing control functions available on the plant detail graphics i.e. as a minimum: a. b. c. d. e. f. g. Perform "local/remote" selection. Perform "duty/standby" selection. Action "stop/start", "open/close". Interface with sequences, which will indicate reached in both normal and failed condition. Interlocks and permissive. Validate maintenance equipment. Accept alarms. mode operation of rotating step VOLUME - IV of V PAGE No. 41 of 75
The system shall have the capability of having and developing graphic symbols generally used such plants. A symbol library shall also be provided as standard. It shall be possible to monitor any variable/parameter/alarm status in the controllers and change set point value, manipulated variable, controller mode etc., from the graphic display. Also compressors/ pumps/ blowers status and valve status shall be displayed on the graphic display with different colour.
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PACKAGE NO - II CHAPTER NO. Q4 iii. Group Displays All the relevant process data shall be grouped together to enable the operator to perform a control management of individual small sections of the plant. Loop details shall be displayed in a bar graph format, numeric displays, colour changes and descriptions and shall include the following details: a. Analog Indicator: Bar graph, numerical value, engineering limits, alarm set points, loop tag, loop description. Analog Controller: Bar graphs of process variable and controller output, numeric values of process variable, controller output and control setpoint, alarm setpoint and control setpoint indication, controller status such as auto/ manual, local/remote, loop tag, loop description, engineering units. Totalizers: Numeric values of totalized units and actual value, totalizer status, engineering units, loop tag, loop description. Status of sequence Sequences: terminology, loop tag, loop description. in process VOLUME - IV of V PAGE No. 42 of 75
b.
c.
d. e.
Binary Indication: Status of all selections, status of loop tag, loop descriptions.
The operator will perform all the analogue control functions from these displays. As a minimum the operator shall be able to perform the following actions: a. b. c. d. Analog Controllers: Control set point adjustment, manual/auto selection, and manual output adjustment. Totalizers: Reset functions, target adjustment. Sequences: Manual/auto selection, step control in manual. Binary Control: Stop/start rotating and vibrating equipment, open/close process devices, selection of various modes.
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PACKAGE NO - II CHAPTER NO. Q4 iv. Trend Displays Trend displays of both "real-time process variables and historical process variables shall be available and shall be designed to allow for variable time frames as well as range adjustment "zooming". Multi-colour assignment of tag references shall be possible. At least 4 separate measurement signals shall fit simultaneously onto one screen display with different colors. Each measurement signal shall show identification data, scale and unit, and the instantaneous value of measurement. The time scale of the trend display shall be selectable at, e.g., 5 mins, 20 mins, 1 hour, 3 hours and 12 hours. It shall be possible to scroll back the trend display over the previous 24 hours minimum to 10 days depending on scan interval. Storage of historical trend will be on non-volatile memory such as hard disk or CDs. It shall be possible to sample and store data at the intervals mentioned below: a. b. c. d. At intervals of 1 second or 10 second for the real time trend. At 1 min., 2 min., 5 min., 10 min. historical trend. Alarm and Event Listing Whenever a condition occurs that falls outside of the normal operating envelope an alarm will be generated. of interval for VOLUME - IV of V PAGE No. 43 of 75
The alarm list generated shall carry relevant information as to the alarm nature, the loop tag and time of occurrence. Normal operational events such as motors starting or stopping, valves opening or closing shall be considered events and a list of selected events shall be provided. The event list and alarm list will be considered one chronological list, where events and alarms are distinguished by priority levels. The alarm / event list shall extend at least up to the 300 latest entries. A priority code shall determine the manner in which alarms and events are handled. The object will be to avoid the situation where a large number of
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PACKAGE NO - II CHAPTER NO. Q4 VOLUME - IV of V PAGE No. 44 of 75 alarms are routinely acknowledged by the operator without investigating the cause thereof. v. Loop Detail Displays a. Loop detail displays will mainly be used by system control engineers. These displays will be interactive allowing adjustments of all control and indication parameters. Access to the adjustments will be by a password. The PID parameter adjustments are as specified elsewhere in this specification. Loop display shall provide separate detailed display for each of the process inputs. The graphic representation will be similar to that of group display. The following additional information shall be displayed in alpha numeric form: c. Controller tuning constant (on demand) Control mode Process variable zero and span values Alarm set point Limits on set point, output (on demand) Computational constants like ratio, bias (on demand) Integrated value Output to final control element (manipulated variables) Engineering units.
b.
It shall be possible to change the following through the key-board of operator station / engineering station: Changing tuning constants Changing process variable for testing Changing limits on set points, outputs etc. Specifying alarm by-pass function Changing alarm set points Changing control mode Changing output to final control element For digital points, it shall be possible to issue start/stop or open /close command. Changing time span of trend
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PACKAGE NO - II CHAPTER NO. Q4 d. VOLUME - IV of V PAGE No. 45 of 75 The loop display shall also contain a trend displaying process variable for six minutes for tuning purpose. Output limits shall be settable and displayed.
e. vi.
Delay Accounting Graphics These graphics shall be interactive. The PLC shall report down-time of equipment and the system derived reason for the down-time. The operator/ engineer shall be able to edit section of the graphics and insert comments relating to reason why the down-time resulted.
vii.
Report Graphics All latest reports generated by the PLC shall be available as a graphic display to the operator.
viii.
PLC Diagnostic Alarm / Indication / Graphics Detail PLC diagnostic alarm / indication/ graphics shall be available on operator station.
ix.
Window Operation Function Multi-window: The multi-window functions shall be provided to display without erasing the currently displayed panel, by opening up multiple rectangle windows on the screen. The number and function of windows shall be as follows: a. b. c. d. e. f. Trend window Process window Alarm window Graphic window Dialogue window Menu window
Minimum of two windows shall be displayed simultaneously. Quarter size window: The following standard operation displays shall be displayed as quarter size windows: a. b. c. Group display Loop display Trend display
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q4 d. e. Graphic display Alarm summary display VOLUME - IV of V PAGE No. 46 of 75
Popup screen : Popup screen shall be provided for all motors, valves, fans etc., The following function shall be possible from Popup screen: a. b. c. x. Showing interlocks and permissive. Feed back / demand of control valve, VFD etc., Switching ON / OFF of all motors, valves, fans etc.,
Reports Report formats shall be freely selected by the customer. The following reports shall be included as a minimum: a. b. c. d. Shift reports, every 8 hours. Daily report, every 24 hours. Monthly report. Rotating equipment running hours report. standard printouts shall be initiated
The following automatically: a. b. c. d.
Alarms for process and system diagnostics. Events Operator actions such as acknowledgements of alarms, set point changes, motor stop/ start commands, selections, etc. Scheduled reports, logs and scratch pad.
The following printouts shall also be available to be printed out on request: a. b. c. d. Historical and real-time trends. Latest reports VDU Screen dump. System configuration and all software programs, complete with suitable comments for clarifications purposes.
xi.
Alarm and Event Handling All alarms and selected events shall be time tagged. The PLC shall provide a priority level distinction of alarms and events.
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q4 VOLUME - IV of V PAGE No. 47 of 75 Process Alarms: New alarms shall be brought to the attention of the operators by means of audible devices and blinking fields on the graphics displays, depending on the alarm priority. Acknowledge facility shall be provided to silence the audible device. Alarms may be acknowledged but not reset until the cause of the alarm has returned to normal. An engineering facility shall be provided to override alarms. The operator shall be alerted to failures System Alarms: and be provided with detailed information as to the type of fault and its location. Events: An event is defined as a change of the state of a binary variable not defined as an alarm. Events shall be displayed as colour changes or message lines and no operator action shall be required to confirm these changes in process conditions. xii. Alarm Monitoring & Display Alarm Management a. It shall be possible to display process alarms as well as system alarms on the operator stations for operator's attention and action. Alarms shall appear immediately on the operator stations as and when they occur on priority basis. Alarm shall be identified without changing display by using of multi-window technique. It shall be possible to set process alarm limits from the operator keyboard i.e. alarm limits on absolute value of measured variable, rate of change of measured variable high and low deviations set points and, high extra-high and low, extra-low points on process variable and output. Top of the screen shall be reserved for showing the latest alarms irrespective of type of display. It shall be possible to access to any type of display, which contains the latest alarm with a maximum of two keystrokes.
b.
c.
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q4 d. VOLUME - IV of V PAGE No. 48 of 75 All alarms shall be displayed as they occurred or generated with change in the color of display in the following sequence, activating on audio signal. e. Continuous flashing - Unacknowledged alarm Steady display - Acknowledged alarm
The system shall not put off the visual flashing even after the condition returns to normal unless it is acknowledged by the operator for important alarms. The important alarms shall have a capability to regenerate alarms when its alarm won't return to normal within a certain period. Minimum of 4 alarm priority levels shall be definable with distinct audio signals for each. In addition to the system fixed alarm type, more than 10 user definable alarms (specifying display color and priority) shall be available.
f. g.
Alarm Summary Display a. It shall be possible to display summary of all alarms in the sequence of their occurrence and shall disappear from display only when they are acknowledged and cleared. The alarm display shall list the following for each alarm as a minimum: b. c. The date and time of occurrence Point identification (i.e. tag number) Point description Type of alarm (absolute value or deviation)
The system shall be able to display on alarm summary a minimum of 200 alarms. For the latest 20 tags displayed on alarm summary panel, it shall be possible to go directly to group display or any display by a mouse click. Alarms can be selectively displayed, limited important alarms or limited to a certain area. to
d.
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q4 Alarm History The history of alarm shall be maintained in the hard disk and can be reported by specifying the following search items and search conditions. a. Search items b. Process alarm messages System alarm messages Status change messages Operation record messages Annunciator messages Sequence messages VOLUME - IV of V PAGE No. 49 of 75
Search conditions Control station number Tag number (ex. starting with F******) Start time and stop time
6.6
SOFTWARE REQUIREMENT (LADDER LOGIC OR STRUCTURED-TEXT PROGRAMMING) The minimum software requirements of the processor are listed below. Feedback control Feedback control function such as regulatory controllers, indicators integrating / differentiating and computing units shall be provided as complete software function blocks. Feedback controllers shall have self-tuning capacity and also tuning from operator station (manual) Sequence logic control functions: Sequence logic control functions shall be used with feedback control functions to perform a pre-defined sequence of steps. Sequences can automatically change the mode of controllers, perform interlock functions and sequence status units allow sequence progress to be monitored and controlled from an operator station.
Rev. 0
NMDC LIMITED
MECON LIMITED

Sequence logic control functions shall be executed in any way as below. i. ii. Sequence Table (Table decision method) Sequence Logic Diagram (Interlock block diagram method)
Open Loop Control Open loop control is to be used to operate individual equipment as fans, blowers, process drives / motors, motorised valves, on-off valves and solenoid valves. Open loop control shall be implemented using software functional blocks, with the aid of which it shall be possible to program the controls easily, quickly and clearly. General requirements for the functional blocks are: i. The open loop control software package shall perform the combining of incoming commands into logical groups and also perform the forming of a priority system. In the cases of a supply voltage failure and a voltage return or change, the open loop control software package must not give unintended control commands. The control software package shall have inputs for the manual and automated control switch-over, locking (release) signals, protection (tripping) signals, state and range limit signals, state of safety switches and error signals. The control software package shall not allow pumping of devices being controlled. Control of the device is prevented after tripping of the protection switch until tripping has been acknowledged in the control room and a new command has been issued.
ii.
iii.
iv.
Group Control Loops The software package shall contain functional blocks for the implementation of group controls and other sequence control functions. Sequence control functions shall also include a provision for step-by-step control. Manual operation of sequences via operator station is required.
NMDC LIMITED
MECON LIMITED

Start up and shut down procedures shall be controlled by the group control software package (in the same manner as individual control software package). In circuits with back-up provision, the changeover to back-up circuit in cases of a malfunction shall be automatic. Closed Loop Control Closed Loop Control is based on Proportional-Integral-Derivative (PID) control, cascade control, ratio control and feed forward control blocks with manual/auto selection, absolute alarming and for special cases set point deviation alarming. The control output limiting shall be included. The closed loop control and measurement functions shall be programmed using a method based on the combining together of functional blocks. The PID loop shall receive process variable from field instruments (e.g. transmitter) through the input channel and perform the required PID algorithm. The controlled variable shall be sent to final control element (e.g. control valve) through the output channel. Each individual closed loop control circuit shall be switchable from manual state to automatic state and vice-versa. The switching shall be possible both via the program software as an automatic control, or manually from the control room. When changed to manual mode, the controllers output or actuator shall remain in the state that it was before change over from automatic control, unless it receives a separate command either manually or automatically. Change over of control state from manual to automatic and viceversa shall take place in a bumpless fashion. The upper and lower regulators of cascade circuits shall be connected together bumpless, and there shall be possibility to select manual/auto mode case by case. In case of a malfunction of the measurement circuit, the controller circuit will automatically switch to manual, and this event will be announced in the control room. Any program malfunction shall prevent the switching of the circuit to automatic. After a power failure, the controller circuit will output one of the following states:
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q4 i. ii. iii. Remains constant Settles at the selected value Settles at the interlocked value VOLUME - IV of V PAGE No. 52 of 75
The adjusting parameters of the regulator circuit (PID measurement filtering constant) shall be selectable from the control room operations terminal by pressing a single key or selecting a single code. Password protection of selected function is required. It shall be possible to control adjusting parameters with outside signals on a continuous basis. It shall also be possible to change parameter according to external criteria. Self-calibration and manual calibration of PID loops shall be possible. Selector blocks and computations Alarm blocks for low-low, low, high and high-high switch points are required. High-low signal selector is needed for control purposes. It shall be made possible to do hours-of-operation and start-upquantity computations from the binary outputs. It shall be possible to do quantity computations from the analog signals. Supervision Function The PLC shall continuously supervise all its components and the equipment connected to it. In case of a disturbance, the operator cum engineering stations / workstations shall get alarms, indications, and graphics notice on the monitor and critical alarms shall be printed out in the printer located in the control room with time stamping. Such critical alarms shall be specified in the application software and shall also be user programmable. The operator shall be able to supervise and carry on trouble shooting by means of the system trouble shooting displays. 6.7 CABINETS / PANELS / CONSOLES The panels shall be upright, floor mounted and dead front type and shall have ventilation with steel mesh. The outside colour of the panels shall be powder coated with colour RAL 7032 or equivalent international code. The inside colour of all these panels shall be brilliant white. Panels shall be provided with anti-vibration mounting pads.
NMDC LIMITED
MECON LIMITED

The panel shall be made from CRCA steel sheet with a minimum thickness of 2 mm. The gland plate shall be of thickness 3mm. The width of panel shall be as per approved panel G.A. drawings. Panels shall have lifting hooks or eyebolts on the top at the four corners, for ease of transportation. Cabinets shall be equipped with front and rear access doors. Doors shall be equipped with locking arrangement with a master / common key for all cabinets. All the cabinets shall be free standing, enclosed type and shall be designed for bottom entry of cables. The panel surface shall be thoroughly degreased, smoothed, filled and painted with rust resistant two coats of primer and three coats of paint to present a smooth and flat finish. Front of panels shall be primed and filled as required giving at least two coats of primer and minimum three coats of final colour above the primer coating to present a smooth and mat finish. Legend plates shall be provided on the panel face, desk face and for instruments behind panel/desk to identify equipment. Overall dimensions of nameplates shall be decided by the text of legend, maintaining overall consistency and clarity and avoiding size variations. Equipment inside the panel shall be so located that their terminals and adjustments are readily accessible for inspection and maintenance. Panel power supply shall be through circuit breaker. Instrument power supply shall be through fused terminals blocks with LED indication. Miniature circuit breakers shall be provided on the outgoing side. The inside of panel shall be illuminated, preferably using CFL lamp. The illumination lamp shall be switched on/off using a door switch, through isolating switch. Fans shall be used for effective cooling of PLC and subsystem panel. Electrical accessories e.g. circuit breakers, control switches, push buttons, panel lighting fixtures, light switches etc. required for the panel shall be of acceptable reputed make and these shall be supplied with the panels/desks. These should be suitable for the application and environmental conditions.
Rev. 0
NMDC LIMITED
MECON LIMITED

The lower 700 mm of panel section shall be free from equipments / module except terminal blocks and glands plate. Terminal blocks shall be suitable for 2.5sq.mm of cable and shall be Cage Clamp type. Terminal connecting screws shall also be suitable to connect 1.0 / 1.5 sq.mm. cables. Panel / cabinets shall be provided with the following items: i. ii. iii. Utility Power socket (of 240V AC, 15W rating). Power earthing bolts on either side of the panel at the bottom. Copper bus-bar (of size 25x3mm) mounted on an insulated base inside the panel with holes and nut-bolts - for instrument signal earthing. Visual indication shall be provided for failure of power supply on the local panels.
iv.
Consoles shall have specification similar to as defined above, in construction and electrical features. 6.8 INSTRUMENTATION CABLES All cables shall have PVC insulated primary insulation of PVC as per IS-5831 Type-A and inner and outer jacket shall be PVC as per IS5831 Type ST-1. Oxygen index of PVC shall be over 30% and temperature index shall be over 250C. The insulation grade shall be 600 V / 1100 V as a minimum and shall meet insulation resistance, voltage and spark tests requirements as per BS:5308 Part-II. All cables shall be armoured. Armour over inner jacket shall be galvanised steel wire / flat strip as per IS:1554 Part-I. Maximum DC resistance of the conductor of the completed cable shall not exceed the following: i. ii. iii. 12.3 ohms / km at 20C for cables with 1.50 mm2 conductor. 19.5 ohms / km at 20C for cables with 1.00 mm2 conductor. 26.0 ohms / km at 20C for cables with 0.75 mm2 conductor.
Rev. 0
NMDC LIMITED
MECON LIMITED

The mutual capacitance of the pair or adjacent cores shall not exceed 250nF/m at a frequency of 1 kHz. The capacitance between any core and screen shall not exceed 400nF/m at a frequency of 1 kHz. L/ R ratio of adjacent cores shall not exceed 40H/ohm for cables with 1.5 mm2 conductor and 25H/ohm for cables with 1.0 mm2 and below conductor. The drain wire 30 ohms / km. resistance including shield shall not exceed
Vendor shall ensure minimum of 20% of quantity of each type of cables supplied as spare including any special cable. And in each multi pair/core cables 20% pairs / cores shall be kept as spare. Running length of cable shall be printed at least at every 5 meter interval. Signal Cables Single pair shielded signal cables shall be used between field instruments and junction boxes / local control panels. Multipair individually and overall shielded signal cables shall be used between junction boxes / local control panels and control room in general. Signal cable shall be as per BS:5308, Part-II. The single pair shall be 1.0 mm2 conductor size, of annealed tinned electrolytic copper conductor of 7 strands with each strand of 0.43 mm diameter. Multi-pair cables with 0.75 mm2 conductor size of annealed tinned electrolytic copper conductor of 7 strands with each strand of 0.37 mm diameter. Shield shall be aluminium backed mylar tape bonded together with the metallic side down helically applied with either side having 25% overlap and 100% coverage. The minimum shield thickness shall be 0.05 mm in case of single pair and 0.075 mm in case of multipair cable. Drain wire shall be provided for individual pair and overall shield which shall be 0.5 mm2 multi stranded bare tinned annealed copper conductor. The drain wire shall be in continuous contact with aluminum side of the shield.
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q4 Control Cables Three core control cables shall be used between field mounted solenoid valves and junction boxes/local control panels. Multi core control cables shall be used between junction boxes / local control panel and control room mounted devices in general. Control cables shall be as per IS:1554 Part-I. These control cables shall have 1.5 mm2 conductor size with 7 stranded conductors of annealed tinned electrolytic copper, with each strand of 0.53 mm diameter. Cable shall be 1100V grade. Core number marking shall be provided for each core at every 500 mm interval for easy identification. Power Cables Three core power cable shall be used to power the instruments. Power supply cables shall be as per IS:1554 Part-I. The conductor size shall be 7 stranded 2.5 mm2 copper conductor with PVC insulation, armoured. Outer sheath colour shall be Black. Cable shall be 1100V grade. Fiber Optic Cable Fiber optic cable shall be used to interconnect the PLC with the central DDCMIS. The fiber optic cables shall be as per International Standards ITU-T-G651 & G652 and IEC793-1. Armoured loose tube construction, double polythene sheathing, anti-rodent, anti-termite single mode (9/125-micron) fiber optic cable shall be used for laying directly underground, buried in trenches, along walls / structures in GI pipes / conduits, on trays & racks. The technical parameters of the Fiber Optic Cables are as below. General Construction: i. ii. iii. iv. Armour (for armoured cables) Stainless steel tape Moisture barrier Water blocking powder Sheathing Black HDPE with anti termite adhesives Strength member 2 steel/ FRP rods VOLUME - IV of V PAGE No. 56 of 75
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q4 Fiber Optic Cable (SMF): For Single Mode (9m/125m) Cable: i. ii. iii. iv. v. No. of cores - 12 No. of cores in each tube - 2 Attenuation: 0.22dB/km @1310nm 0.37dB/km, @ 1550nm VOLUME - IV of V PAGE No. 57 of 75
Cable Specifications- Physical Cable drum length: 5000m 5% Cable Specifications- Mechanical Tensile Strength (IEC 794-1-E7): During Installation-2000N @0.25% Fiber Strain. During Service: 1000N. Torsion Resistance (IEC-794-1-E7): 10cycles (180) with load of 400N. Crush Resistance (IEC-794-1-E3): 2000N (100mmx100mm). Impact Resistance (IEC-794-1-E4): 10 Impacts @ 25N-m. Kink Resistance (IEC-794-1-E10): 24D; D-Cable Diameter. Cable Specifications- Environmental Operation: -20C to +70C Storage: -20C to +70C Installation: -10C to +50C
vi.
6.9
CABLE TRAYS Cable trays shall be perforated type. Cable trays with supporting structure shall be of hot dip galvanised steel sheet material of thickness 2mm. The trays shall have vertical edge of height not less than 50 mm on both the sides.
6.10
JUNCTION BOXES Junction boxes shall be of Die Cast Aluminium 3mm thickness or better and shall conform to weather-proof IP65. Terminal blocks shall be suitable to connect 1.0 / 1.5 / 2.5 sq.mm. cables. Terminals blocks shall be Cage Clamp type. Junction boxes shall be sized to accommodate the terminations with 20% spare terminals in each box. All wires in junction boxes shall be neatly dressed and
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q4 ferruled. Junction boxes shall be provided with double compression type cable glands and these shall be firmly grounded. Each junction box shall have spare entries, minimum of 10% or 3 nos. whichever is higher. Spare entries shall be provided with plugs. Voltage levels within the junction box shall be isolated from lower voltages and shall be labeled. 6.11 SYSTEM GROUNDING Generally the earthing for the system shall confirm to IS: 3043 Protective Earthing PE (Frame Earthing): All enclosures of the PLC equipment shall be connected to separate earth conductor, which shall be connected with plant critical earthing system. Technical Earthing TE (Signal Earthing): Technical earthing (with one or more separate earth pits) shall be provided, having minimum earth resistance as specified by PLC manufacturer. Common signal ground points of PLC, Instruments and screens of signal cables shall be earthed to this technical earthing system. Control rooms shall be provided with TE bars and shall be different from PE system connected to the electronic earthing system. Shields of 24 VDC signal cables shall be connected to TE system only at one end. i.e. at control rooms. 6.12 FIELD INSTRUMENTS Each instrument shall be tagged using a SS nameplate attached firmly to it at a visible place furnishing the following information as applicable: i. Manufacturers name/trade mark ii. Model No. Serial No. iii. Tag No. iv. Operating range v. Supply Voltage vi. Body material vii. Wetted part material.
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q4 All inscription shall be in English. Instruments shall be designed for continuous operation in dusty, wet atmosphere containing grit and micron size dust particles. Enclosure shall be weather proof IP-65. 6.12.1 Pressure Measurement All pressure measuring instruments shall have protection IP65. Pressure gauge dial shall be 150mm size, white, non-rusting aluminium, with black figures. The dial face shall be marked with pressure element material. Pointers shall have micrometer adjustment. The gauge shall have accuracy of 1% of FSD as minimum, with over range protection of 130% of FSD. Window shall be of shatterproof glass. Pressure gauges shall be provided with snubbers, gauge savers wherever applicable and 3-way gauge cocks of SS316. All pressure instruments shall be provided with block and bleed, bypass, drain/vent valves etc. as per installation requirement. For water / air applications, the bourdon tube type of pressure gauge shall be used. The sensing material and movement material shall be SS304. The process connection shall be NPT(M), bottom entry. Pressure transmitters shall be of SMART, 2-wire type, 4-20mA output, integral LCD display with NPT(F) process connection. Wetted parts shall be made of material, which is corrosion resistant to process fluid. Accuracy shall be 0.25% or better; with over pressure withstand capacity of at least 130% of range or maximum working pressure whichever is higher. Span and zero adjustments shall be easily accessible. DP type transmitters shall normally have 3 valve manifold of SS316 and drain arrangement. Pressure transmitters with 2 valve manifold of SS316. Pressure switches shall be either diaphragm type or bellow type and installed with 3-way gauge cock of SS316. Electrical connection shall be NPT(F). Process connection shall be NPT(M) or otherwise indicated. Repeatability shall be 0.5% of URV as a minimum. For low-pressure application, where long elements are used, well-supported protecting tube shall be installed to prevent mechanical damage and erosion of the elements.
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q4 6.12.2 Level Measurement Radar type level sensing system consists of the sensor and the transmitter. The system shall be capable of continuously measuring and displaying the level of Iron ore in RCC silo. The sensor shall have a sonic frequency of 10GHz with minimum blocking distance. The process connection shall be ANSI 1 flanged, with beam angle of 10 and shall resist material build up. Antenna shall be of SS material and parabolic type or better. Air purge facility shall be provided to maintain the sensor face clean. Transmitters shall be of the SMART type with HART Protocol. The output of the transmitter shall be 4-20mA DC, isolated. Transmitter shall have LCD display. The accuracy of the system shall be 0.25% of FSD or better. System accuracy shall not be affected by changes in process medium concentration, density, or particle size distribution. Resolution of the system shall be 1mm. The system shall be suited for outdoor installation and shall have IP65 or better enclosure. The power supply to the system shall be 110V AC. The system shall provide at least, but not be limited to, the following features: i. ii. iii. iv. v. Frequency optimization to suit the application. Adjustable blanking zone. Battery free, non-volatile memory. Output linearization to create output signal proportioned to level. Temperature compensation. VOLUME - IV of V PAGE No. 60 of 75
Level switch shall have die cast aluminum case. Wetted parts shall be of SS316. Accuracy shall be 2%. Switch shall have 2SPDT contacts with electrical connection NPT(F). 6.12.3 Temperature Measurement Local temperature gauge shall be hermetically sealed type with dial of 150mm size, white, non-rusting aluminium, with black figures. The dial face shall be marked with temperature element material. Pointers shall have micrometer adjustment. The gauge shall have accuracy of 1% of FSD as minimum. Window shall be of shatterproof glass.
NMDC LIMITED
MECON LIMITED

Temperature switch shall have die cast aluminum case. Wetted parts shall be of SS316. Accuracy shall be 2% with over range protection of 125%. Switch shall have 2SPDT contacts with electrical connection NPT(F). The temperature transmitters shall be SMART, 2-wire type and output of the transmitter shall be 4-20mA DC, isolated with LCD display. Transmitter shall be capable of accepting the three wire inputs from RTD. Transmitter shall be configurable type, having built-in cold junction compensation for thermocouples and linearisation function. Accuracy shall be 0.25% or better. 6.12.4 Impulse lines Seamless SS tubes of size (12 mm) OD (1.5 mm thick) shall be used for impulse pipes. As far as possible impulse lines shall be welded. Double compression type joints shall be provided. For proper drainage, impulse lines from primary point to transmitter shall be laid with gradient of 1:10 atleast. All erection fittings shall be rust proof. 6.12.5 Automatic Valves The Control and On-Off valves shall be supplied complete with actuator and accessories (such as electro-pneumatic positioner, position transmitter, solenoid valve, position switches, air filter regulator with pressure gauges, air lock relay, air isolation valve, handwheel, etc. as applicable) in assembled condition. Accessories shall be securely mounted and easily removable for maintenance works. Control valve sizing shall be based on ISA S75.01. Actuator sizing shall be such that it must be capable to generate power to stroke the valve through its full travel at 125% of maximum pressure drop condition with specified stroke time. The Control valve / On-Off valve on failure will move to safe end position as per process requirement / as indicated in the data sheets. The flow direction shall be clearly marked on the valve body. Pneumatic signal lines shall be SS tubing 6mm dia with 0.8mm wall thick. Pneumatic tubing shall be as per ANSI B21 standard. All the fittings shall be of SS and double compression type. Connections shall be NPT.
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q4 6.12.6 Proximity Sensors In general the proximity type travel / position limit switches shall be used wherever the application allows. In areas prone for explosion, NAMUR type proximity sensors shall be used. Switch shall have 2NO+2NC potential free contacts. Electrical connection at the terminal box shall be suitable for 1.5sq.mm connection and cable entry for external cables shall be of NPT (F). Switch shall be rated for IP:65. 6.13 UNINTERRUPTED POWER SUPPLY (UPS) Automation UPS in control room at tail end of down hill conveyor and electrical room near TH5 are envisaged. UPS for the automation shall be online and parallel redundant with load sharing. UPS shall be of provided with SMF (Sealed Maintenance Free) battery with backup time of 4 hrs. The UPS shall be as per IEC standards. The UPS shall include power input device, rectifier unit, battery unit, inverter unit, automatic by-pass unit with SCVS. Facility shall be provided for manual transfer of load from inverter to bypass. The output voltage of the UPS shall be 110V AC, 50Hz, single phase. The UPS shall provide potential free contacts. The operating temperature range shall be 0-50 deg.C with 95% RH Non-condensing. The maximum noise shall be 60db @ 1mtr distance. The UPS shall have finish RAL-7035 or equivalent international code. The battery shall be installed in floor mounted racks. UPS offered for each area shall be of sufficient capacity; required for smooth, efficient and trouble free operation of the unit/area. The UPS shall be capable to provide power to PLC, HMI network and field instrument. Each UPS shall be designed to have 25% of spare capacity of rated power. UPS shall have on-line monitoring and diagnostic system with LCD screen on the control panel which shall have comprehensive information on the equipment status and assist in fault diagnosis. The UPS shall have the following salient features: i. Bumpless switchover of load on either UPS, on failure of the other UPS.
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q4 ii. iii. VOLUME - IV of V PAGE No. 63 of 75 Bumpless switchover of load on battery, on failure of incoming mains Bumpless switchover of load on SCVS, on failure of both UPS, battery.
Power from the UPS shall be distributed through Power Distribution Board (PDB). Spare feeders of 20% shall be provided for future expansion in the PDB. Instrument power supply shall be through circuit breaker and isolating transformers. Electric motor actuators shall have independent circuit breakers.
Rating Type Input voltage Inverter type Inverter Efficiency Output voltage Output frequency Output voltage regulation Output voltage waveform Total harmonic distortion Transient response Dip Peak Recovery to normal Over load capacity Audible noise LCD / LED indication : : : : : : : : shall be calculated according to the requirement Online and on 100% parallel redundant mode. 415V +10% - 15%, 3 phase @ 50 Hz 5% High frequency switching sinusoidal with pulse width modulation. 90% 110VAC, single phase for automation. PF 0.8 Free running 50 Hz, 0.1% tracking bypass 2% ( 1 to 4 %) selectable. Better than 1% for simultaneous variation from no load to full load & input voltage to any extreme Sinusoidal Less than 3 % for linear load, less than 5 % for Non linear load for 100% step load Typical 5 %, Max 8 % Typical 5 %, Max 8 % Upto 60 m secs i.e., 3 cycles 125% for 10 min Less than 60 dB at 1 meter distance Mains OK, Inverter OK, Overload, On battery, Low battery, Inverter trip, By pass ON, Load on inverter, Load on Bypass, Bypass frequency out of range. shall be provided Rev. 0
: : : : : : : : :
Auto bidirection static switch
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q4
Environment Relative humidity Switch gear Remote indication Bi-directional static switch with SCVS Batteries Battery backup Capacity Enclosure Isolation transformer Configuration Remote Indication Communication Port Dimensions Weight Make : : : : : : : : : : : : : : : : 0-50 deg. C 95% RH non condensing Input MCCB, Bypass MCCB, Battery isolator, inverter ON/OFF switch, manual bypass switch Provision for all the available LCD / LED for remote shall be provided Sealed maintenance free batteries 4 hours Min 120 % of the actual load requirement for the system to be calculated by vendor IP 42 shall be provided with class H insulation at incomer diagram to be submitted UPS healthy, Battery On hardwired to PLC Shall be provided and wired to PLC. As per manufacture As per manufacture As per approved vendor list
6.14
SURGE PROTECTION DEVICES (SPD) The lighting and surge protection devices shall comply with IEC 62305, BS EN 62305, DIN EN 61643-11, IEC60364-5-53. The SPD shall be tested as per recommendations of IEC 61643-1. Documentary proof to declare conformity to compliance with the international standards shall be submitted. Protection for UPS: The power supply to the UPS shall be protected by suitable SPD for lighting surge of 7KA of 10/350 microseconds for each phase to neutral and 25KA of 10/350 microseconds for neutral to earth. Additionally, phase to neutral shall be capable of handling surge of 30KA of 8/20 microseconds.
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q4 Protection for Input-Output Modules: Input-output modules shall be protected by suitable SPD for lighting surge of 6KA of 10/350 microseconds and switching surge of 10KA of 8/20 microseconds. Protection for PLC: The power supply to the PLC shall be protected by suitable SPD for lighting surge of 7KA of 10/350 microseconds for each phase to neutral and 25KA of 10/350 microseconds for neutral to earth. Additionally, phase to neutral shall be capable of handling switching surge of 30KA of 8/20 microseconds. VOLUME - IV of V PAGE No. 65 of 75
7.0
ERECTION, TESTING, COMMISSIONING

On the basis of guidelines specified in this specification, vendor shall submit their own testing, installation, commissioning and acceptance procedure. For hardware, the procedure shall include purpose of test, test definition of input, procedure, results expected and acceptance criteria. It shall include details of the method, list of tests, sequence of execution, results expected and acceptance criteria. The testing and acceptance of the system shall be carried out on the mutually agreed procedures and criteria based on these guidelines and vendor standard procedures.
7.1
FACTORY ACCEPTANCE TEST (FAT) Vendor shall demonstrate functional integrity of the PLC system hardware and software. No material or equipment shall be transported until all required tests have been successfully completed and the material / equipment have been certified 'Ready for shipment' by purchaser / consultant. It shall be vendor's responsibility to modify and / or replace any hardware or software if the specified functions are not completely achieved satisfactorily during a FAT. Testing and FAT shall be carried out in 2 phases. Under the first phase, vendor shall perform tests at his works to ensure that all components function in accordance with the specification for each type of test. A test report shall be submitted for purchaser /
Rev. 0
NMDC LIMITED
MECON LIMITED

consultant review. Following tests shall be performed by the vendor and reports shall be forwarded to purchaser. i. ii. iii. Quality Control Test, which shall be carried out to assure quality of components and modules. System Pretest, which shall be physical check of all modules, racks, cabinets etc. System Power-Up Test, which shall test functionally all hardware and software.
The second phase of the testing shall systematically, fully and functionally test all hardware and software in the presence of purchaser / consultant. All systems shall be interconnected to simulate, as close as possible, the total integrated system. Vendor shall submit the procedure for Factory Acceptance Test for approval by purchaser / consultant. 7.2 INSTALLATION, TESTING AND COMMISSIONING Vendor shall offer the services of an installation team which would install the equipment in the control room, lay the interconnecting cables inside control room, check out, test and commission the system. During erection, necessary erection hardware, equipments and accessories shall be provided by the vendor. Vendor's responsibility at site shall include all activities necessary to be performed to complete the job including: i. ii. iii. iv. v. Receipt of hardware / software and checking completeness of supplies. Installation of the system including free supply equipment if any. Field cabling & termination and inter cabinet cabling and termination. Check out equipment installation Checking of interconnections, hardware configuration, overall system functioning etc. and software
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q4 vi. vii. viii. Loop checking. Commissioning and online debugging of the system. Involvement during plant commissioning and performance of final acceptance test. VOLUME - IV of V PAGE No. 67 of 75
7.2.1 Field Inspection: All equipments shall be inspected thoroughly by vendor after its receipt at site for completeness and proper functioning. Vendor must initiate the remedial action, in case unsatisfactory operation of any item is observed, with an intimation to Purchasers Engineer-incharge. Vendor must document all observations including details of any malfunction observed, items / equipments requiring total replacement and must document the reasons for the same. 7.2.2 Loop Checking: Loop checking shall be carried out by vendor including checking the interconnections, configuration and overall system functioning. Vendor's scope of work in loop checking shall include termination of field cables in the control room, checking of interconnection between instrument / equipment, ferruling / tagging of interconnecting cables in control room, ferruling of field cables in control room and performing overall loop performance check. Vendor shall coordinate with the erection sub-contractor for smooth and proper loop checking. Any discrepancy found during checking shall be brought to the notice of the Purchasers Engineer-incharge. Complete loop checking shall be performed in his / her or his / her authorised representative's presence. The input signals shall be simulated by disconnecting / connecting the field wires for all field switches connected to PLC. Wherever receiver cards are used, the set point shall be generated by giving the input signal to receiver card. All outputs shall be checked in field, either for actual operation of solenoid valve or actual pick-up of electrical contactor for rotary equipments. After loop checking is completed, vendor shall connect back any terminals and connections removed for loop checking.
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q4 7.2.3 Functional Test: All the system functions shall be checked thoroughly for proper functioning. The tests shall include: i. ii. iii. iv. v. vi. vii. viii. ix. Visual and mechanical. Complete system configuration loading. Demonstration of all system function. Checking of all system displays. Checking of correct functioning of all keyboards. Demonstration of all system diagnostics. Checking of proper functioning of all printers and printing of all reports. Checking of all disc drives. Complete checking of logic system: loading of user's program and check out of results and checking the protections & interlocks. VOLUME - IV of V PAGE No. 68 of 75
7.3
SYSTEM ACCEPTANCE TEST The purchaser shall provisionally take over the system from vendor after system acceptance test. System acceptance test shall be started only after the satisfactory performance of loop checking and verification of records. Vendor shall provide the procedures for the same.
7.4
FINAL ACCEPTANCE TEST The owner will take over the system from the vendor after the final acceptance test which involves successful uninterrupted operation of the total integrated system. Vendor shall provide the procedures for the same. The warranty period commences from the day owner takes over the system.
7.5
ERECTION Instruments installed in open shall be provided with suitable canopy/protection boxes, which are to be fabricated at site.
Rev. 0
NMDC LIMITED
MECON LIMITED

All the equipment fed from electrical system and installation shall meet the statutory requirements of Indian Electricity Rules. Equipment shall not be mounted below 750mm from the floor level. Junction boxes shall be installed at man-height. Transmitters shall be positioned as close as possible to the measuring point and yoke mounted on instrument stands approximately 1.5m above floor level. Pneumatic signal lines shall be 6mm dia with 0.8mm wall thick SS tubing. In corrosive atmosphere, tubing shall be PVC sheathed. All the level and flow sensors installation shall be as per manufacturers recommendation and relevant standards / practices only. All alarm and trip switches shall be calibrated over the entire range and finally set and checked for alarm / trip points and reset points as per the alarm / trip set point schedule. After setting, these shall be sealed. Pressure / differential pressure measurements For pressures above 1.6 Kg/sq. mm seamless tubes of sizes 12mm(d) x 1.5mm(t) or more shall be used for impulse lines. Ermeto type of joints shall be provided for impulse lines. For proper drainage impulse lines from primary point to transmitter shall be laid with a gradient of 1:10 atleast. All impulse lines shall be supported at regular intervals. Pipe fittings shall be of suitable material and covered by rust inhibitor. Local indicators shall be mounted so that the scales are clearly visible from point of manual control/ observation. All pressure/ differential pressure instruments shall be provided with block and bleed / bypass, drain / vent etc., as per the installation standards and shall have accessibility. Pneumatic Valves Control valves shall have isolation valves on both sides and by-pass valves. Instruments shall be provided with isolating valves, equalizing valves, drain valves at suitable places and shut off valves at tapping points wherever applicable.
NMDC LIMITED
MECON LIMITED

Pneumatic tubing to the final actuator shall be of the same size as the connector provided on the actuator. Smaller tubing with reducer fittings shall not be used. Instrument air lines shall be pneumatically tested for leaks. Isolation valves on instrument airlines shall be of full-bore ball valves. Panels / Cabinets PLC panels, Marshalling panels shall be erected with anti-vibration pads. These pads shall attenuate shop vibration / shock effects to tolerable levels of PLC control equipment. Field side termination shall be carried out first and then panel side termination will be done. During termination no cards will be placed in the respective slots. Before charging of PLC panels all short circuit test and earthing shall be completed. All the gland plate shall be installed after termination of all cables in PLC panels, Marshalling panels and shall be sealed properly. Cable inside the PLC panels and Marshalling panels shall be properly dressed and incoming / outgoing cables shall have sleeves indicating cable tag number and origin / termination of the cable. 7.6 CALIBRATION Calibration and functional checking of all type of primary and secondary instruments shall be done strictly as per manufacturers instructions and as per the general procedural guideline, prior to installation All control valves shall be checked for free movement of the stem. Alignment of valve positioners shall be checked. The rated pressure of the flanges shall be checked. Limit switches shall be adjusted to the specified values. Proper connection and the action of the actuator shall be checked. The control valve along with positioner shall then be calibrated for the rated stroke and checked for linearity as per manufacturers
NMDC LIMITED
MECON LIMITED

specification. After operating the valve from the control room, the position indication of the valve shall be balanced. 7.7 CABLE TERMINATION Termination of copper conductor cables shall be by means of compression type tinned copper lugs. Each control cable core entering control panel, etc. shall be neatly dressed and served with nylon cord. Glanding at the field side and at control room side shall be done using double compression cable glands. Ferrules shall be used for all terminations. Polymer sleeve with full ferrule number printed shall be used instead of individual alphanumeric ferrule. Cross-ferruling philosophy shall be adopted, as finalised during engineering. 7.8 CABLE LAYING All instrumentation cables shall be carried in perforated cable trays except when installed in rigid steel conduits or in duct banks or embedded conduits or buried underground. Instrument cables and power cable shall not be installed on the same cable tray. A minimum clearance of 300mm shall be kept between instrument and power cable. Cables shall be fixed to rack/trays as required for proper support, accessibility and neatness of installation. Hanging of cable racks over panels shall not be permitted. Sharp bends in cables should be avoided. The cables shall be handled as per the manufacturers recommendation and installed as per standard industrial practice. All cables shall be tested for proper insulation prior to laying. Cables shall be clamped rigidly at intervals of not more than 1 meter. Cable racks for cable trays shall be fixed at a maximum interval of 1.5 m. A galvanised steel stranded conductor or galvanised MS flat of minimum cross-sectional area 520 sq.mm (65 mm x 8 mm) shall be carried in each isolated tray or in one tray of a bank of tray. This shall be used for earthing each tray at every 15m. The Vendor shall ensure that cable trays, drops etc. are not installed in such a way as to make difficult the maintenance and/or removal of mechanical or electrical equipment.
NMDC LIMITED
MECON LIMITED

Cable cut from the drums and distributed for various route lengths shall be carefully planned bearing in mind that splices will not be allowed in PVC cables. All wall openings shall be effectively sealed after installation of cables to avoid leakage of water. For cable laying, if cutting of foundations or structures is necessary, prior permission shall be obtained from the Purchaser. Wherever a cable crosses a temperature expansion point in structure, sufficient sag shall be provided. Cables which are not laid in cable trays shall be laid through protected GI conduits. Wherever cables are laid in ground, the trench bottom shall be filled with a layer of sand. This sand shall be leveled and cables laid over it. The cable shall be covered with sand. A protective layer of bricks shall be provided on top of which the earth will be backfilled, rammed and leveled. Suitable separation shall be provided if more than one run of cable is taken in the same trench. All cables shall be provided with identification tags indicating cable numbers in accordance with the cable schedule. Tags shall be fixed at both ends of cable, at joints and at 30m spacing for straight runs. For cable run shorter than 30m, one cable tag shall be provided in the middle. These tags shall be in addition to the end tags. The tags shall be of durable fiber or aluminium sheet with the numbers punched on them and securely attached to the cables with non-corrosive wire. The cable tags shall be marked with cable number, size and voltage grade. Individual cores of control cables shall have for identification plastic interlocked type ferrules with engraved numbers at both ends of the circuit. All spare cores shall also have ferrules at both ends for identification and use. Adequate length of cables shall be pulled inside the switchboards, control panels, terminal boxes etc. so as to permit neat termination of each core/conductor.
Rev. 0
NMDC LIMITED
MECON LIMITED

All power cable terminations shall be by means of crimping type cable lugs. Control cables shall be terminated by crimping or directly clamped in the terminal blocks by screws. No joint shall normally be made at any intermediate point in through-runs of cables unless the length of the run is more than the length of standard cable drum. In cases where jointing is unavoidable, the same shall be made by means of standard cable jointing boxes/kits. All openings for cable entry in the equipment shall be sealed and made proof against entry of creeping reptiles. Unused openings, if any, shall be effectively closed. The control cables shall be clamped by means straps both for horizontal and vertical runs, at turning from horizontal to vertical direction and clamps shall be placed at an interval of 1.5 meter and 1 meter in vertical run. of suitable PVC each bend and vice versa. The in horizontal run
Supporting brackets for trays shall be provided at intervals not exceeding 1.5 meter. The supporting brackets shall be galvanised after fabrication. For future installation of cables, provision shall be made to keep 20 percent space as spare on each rack/tray.
Rev. 0
NMDC LIMITED
MECON LIMITED

8.0
SL 1
LIST OF MAJOR EQUIPMENTS

DESCRIPTION PLC System: * Processor * Power Supply Module * Communication Module to Workstation * RIO Communication Module * Input-Output Cards -- Digital Input, Digital Output, Analog Input, Analog Output * RS-485 Communication Module * Interface Communication Module * Ethernet Network Switches * Ethernet Network Cables (Cat-6 or better) * Communication Cables * Bulk Power Supply units * Other required components QUANTITY 1 set
2 3 4 5 6 7 8 9 10 11 12 13
Cabinets System, RIO, Marshalling, Power Operator Workstation -- Processor, Memory, Storage devices, 22 TFT Monitor, Mouse, Keyboard Engineering Workstation -- Processor, Memory, Storage devices, 22 TFT Monitor, Mouse, Keyboard A3 Colour Laser Printer Console desk furniture for workstation, printers Engineering, Runtime, Application Software for HMI stations with licensing UPS (Parallel Redundant) with Power Distribution Board for Automation system Laptop with software and license for programming & testing Earthing system with earth pit Radar Level Transmitter -- RCC Silo Control & Instruments required for Conveyor Brake System Field Instruments required for safe operation of the conveying system
Lot 1 no. 1 no. 1 no. Lot Lot 2 nos. 1 no. 1 Lot 1 no. Lot Lot
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q4
14 Cables: * Signal Cable * Control Cable * Power Cable * Fiber Optic Cable * Earthing cable 15 16 17 Surge Protection Devices Hooters located at tail end of down hill conveyor and at TH-3 Erection Hardware: * Junction Boxes * Canopy of JB and other field instruments * Cable Trays with supports * GI Conduits, Flexible Conduits, HDPE pipes * Impulse tubing / piping * Isolation valves * Structural Steel * Other required hardware 18 19 20 21 22 23 24 NOTES Integration with the Crushing Plant PLC of Package-I vendor with required hardware and software. Integration of lighting system with PLC with required hardware and software. Engineering software, runtime software and licensing Engineering and Software development Erection, Testing, Calibration, Commissioning, Guarantee/Acceptance Test Training with documentation Commissioning spares 1 The list indicates the major equipments for PLC and instruments. 2 Any other hardware as required for successful completion of the system shall be considered and provided by the vendor. 3 Detailed BOM shall be submitted by the vendor, meeting the complete technical requirements. Lot Lot Lot Lot Lot Lot Lot Lot Lot Lot Lot Lot 2 nos. Lot
Rev. 0
NMDC LIMITED
MECON LIMITED

CHAPTER - Q5
TECHNICAL SPECIFICATION PLANT COMMUNICATION SYSTEM
1.0 GENERAL A two-channel Distributed Amplifier type system shall be provided to facilitate loud speaking communication/ announcement facilities between various locations along the downhill conveyor, transfer houses, control rooms and operating personnel in other working units. 2.0 SCOPE OF WORK Scope of work shall include Design, Engineering, Supply, Erection, Testing and Commissioning of the system complete with its sub-units and cables, pipes, erection and mounting accessories etc. The system shall be supplied and commissioned along with the other technological equipment. 3.0 SYSTEM FEATURES The system shall have the following features: The system shall be of two-channel, distributed amplifier type having facilities for simultaneous communication on two modes namely Page and Private without any interference. In the Paging mode, conversation shall be heard over the loud speakers for all to hear and this shall be normally used to locate people and also to convey messages of general nature. In the Private mode, conversation shall not be heard over the loudspeaker but it shall be carried over the telephone handsets. This mode shall be used for actual conversation, exchange of information and issue of specific instructions. For use of this mode, the caller first makes an announcement requesting the called person to come to a nearby field station. Once the called person reaches the field unit, further communication can proceed in private mode using the handset of the field station.
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q5 4.0 SYSTEM OPERATION The system shall essentially comprise of a number of communication handset stations each of which will be provided with a telephone handset, no. of micro switches (spring return to normal) for specific functions, amplifier, hook switch, loudspeaker muting switch, volume control, other associated equipment and the loud speaker. The paging call shall be made by lifting the handset off the hook and pressing the press to page switch. This shall, initiate, a call attention ding-dong sound to be transmitted to all the speakers to call attention of nearby people before the announcement is made. The paging message shall then be transmitted over the Loudspeaker when the paging person shall speak in the microphone of the handset. While paging under this channel, the loud speaker near the paging handset shall automatically get muted to eliminate the acoustic feedback. The page switch shall then be released to allow the paged/ called person to come to the nearest handset station. When paged person comes to the nearest handset station and lifts the handset off the hook of the handset station, it shall be possible for the two persons, to carry on the conversation on the private mode. It shall be possible to leave the paging channel free for further independent use, while the private channel is being used. During the conversation on the private mode, to mute the loud speakers of the nearest engaged hand station, loudspeaker mute switch is be pressed on the respective handset station. 5.0 SYSTEM DESCRIPTION The system shall mainly comprise of different types of Field Stations or Handset stations and shall employ a distributed architecture i. e. each handset station / loudspeaker shall have its own preamplifiers, line amplifiers suitable for long line signal transmission and power amplifier to suit loudspeaker capacity. The description of various system units shall be as below: VOLUME - IV of V PAGE No. 2 of 9
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q5 5.1 HANDSET STATIONS: The following types of handset stations shall be offered: Desk mounted indoor type Wall/ Column mounted indoor type Wall/ Column mounted outdoor type Functioning of these handsets stations are identical except for the type of mounting. Choice of different handset stations shall be based on the locations of their mounting as given below Desk mounted indoor type Office rooms, Control rooms with conditioned environment etc. VOLUME - IV of V PAGE No. 3 of 9
Wall/Column mounted indoor type - Rooms and Covered places in shop floor areas with less ambient dust. Wall/Column mounted outdoor type- Outdoors locations and places with harsh ambient and high ambient dust. Each handset shall be provided with sensitive dynamic noise canceling type microphone, retractable-coiled cord of min. 1.2 meters. The handset mouthpiece shall be protected from dirt and other foreign particles by means of filters. All the switches including the hook switch shall be dust proof micro switches, suitably protected from the prevalent atmosphere, and shall have, an extremely long life. Handset shall be made of high impact polystyrene to prevent it from breaking due to fall or rough handling etc. Two way noisecanceling device shall be provided in the handset mouth piece to minimize the picking up of the ambient noise. The amplifier units in the handset station shall be of plug in type so that maintenance of the faulty unit shall be done without much down time. These amplifiers shall be of special design suitable for industrial use such that while providing high line drive audio signal, it shall also provide a special anti-side-tone circuit. MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD 2010, MECON Limited. All rights reserved. Rev. 0
NMDC LIMITED
MECON LIMITED

It shall be possible to control the volume of the transmitted and received messages and these controls shall be provided on the amplifier. The desk-mounted handset stations shall be elegant and be made of mild steel/ FRP/ high impact polystyrene. The wall-mounted handset stations shall be weatherproof and dust proof made up of LM6 Al. alloy construction & shall be provided with gaskets of neoprene/ suitable material. For intelligibility of the human speech, the microphones of the handsets shall be noise canceling along with directional feature and provide necessary acoustic filters/ circuits to screen out the effect of external noise. The handset station shall be mounted on or within a control box complete with matching transformer, hook, page switch, loud speaker mute switch power indication lamp, terminal strips. The handset station shall also contain amplifying system of the station as per the details given elsewhere. 5.2 LOUDSPEAKERS: The loudspeakers shall be of weatherproof type, sturdy design, suitable for operation under rough conditions. The loudspeakers shall be of two types: i) Re entrant Horn type Loudspeakers: They shall be of power rating 20 W complete with driver units, impedance matching transformers, weather canopies, mounting brackets suitable for wall /column mounting and other accessories. They shall be designed to have uniform sensitivity, high efficiency and shall provide crisp clear speech reproduction. The mounting bracket shall be with adjustable base, suitable for vertical and horizontal mounting. Firm fixing arrangement with spring/ washers shall be provided. Cone type Loudspeakers: a) Permanent magnet, cone type speaker with 6 watts power, line matching transformer shall be housed in sturdy metal cabinet suitable for wall/column or ceiling mounting. Rev. 0
ii)
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q5 b) c) VOLUME - IV of V PAGE No. 5 of 9
The speaker shall be provided with volume level adjustment with a selector switch. The cabinet shall have grilled metal faceplate to diffuse high frequencies and prevent damage to the speaker. Housing shall be treated with acoustic under-coats to prevent resonance.
All the loudspeakers shall be housed in weatherproof, dustproof and vermin proof enclosure. 6.0 DESIGN REQUIREMENTS The following design requirements shall be complied: i. ii. Ambient Operating temperature - 45C Input Power supply shall be 230 V, +/- 10%, 1 Ph., AC, 50 Hz +/- 5%, Single phase from a reliable UPS Source of Power Supply located in the Transfer House Buildings at the Head and Tail Ends distributing the loads on either side of the Down Hill Conveyor. The tenderer shall make arrangements if necessary to boost the voltage to the requisite level for proper functioning of the PA stations. However, the supplier may suggest any alternate power supply arrangement considering long conveyor lengths keeping in view the voltage drop. iii. iv. Complete system Frequency response Amplifying System a) b) v. Frequency Response Control provisions 200Hz 5000Hz +/- 3dB Volume, Bass, Treble control 200Hz 5000Hz min.
Microphone a) Frequency Response b) Type 300Hz 4000Hz Noise canceling Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q5 vi. Speakers a) Re-entrant Horn Speaker (For outdoor use) Bell Diameter - 260mm (typical) Effective Frequency range - 200Hz 10000Hz Power handling capacity - Normal-20W RMS, Peak25W b) Cone Speaker Effective Frequency range - 200Hz 10000Hz Power handling capacity - Normal 6 W RMS, Peak 8 W vii. Material / Degree of protection Handset Handset station: Indoor desk mounted Indoor wall mounted Outdoor wall mounted Loud speaker, Re-entrant type Junction boxes Type of Page and Party system viii. AMPLIFIER SPECIFICATIONS Sl No 1 Parameters Input sensitivity Power Amplifier 1 V RMS at 1 kHz across 8 Ohm 11 V RMS 8 Ohm Line Amplifier 1mA RMS at 1 kHz across 600 Ohm 4 V RMS across 600 Ohm 600 Ohm Rev. 0 -Mild steel/ FRP/ high impact polystyrene, IP 42 - Die cast Al/ IP55 - Die cast Al/ IP65 - Die cast Al/ IP 65 - Die cast Al/ IP-.65 - Distributed amplifier type. - High impact polystyrene VOLUME - IV of V PAGE No. 6 of 9
2 3
Output Voltage Load Impedance
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q5 4 5 6 7 8 9 10 11 7.0 Max Output Power Signal to Noise ratio Frequency Response Total Harmonic Distortion Operating Voltage No Signal Current drawn Max Current drawn Protection VOLUME - IV of V PAGE No. 7 of 9
20 W 1W 60 dB 60 dB 200 Hz 10 kHz + 3 200 Hz 10 kHz + 3 dB dB < 1% < 1% 48 V DC (typical) < 25mA 600 mA Short Circuit 16 V DC (typical) < 10mA 200 mA Short Circuit
LOCATION OF SUBSCRIBER STATIONS Downhill conveyor no.723 18 nos. (1 no. @ 300 m. along the (including Tail/drive house) conveyor, approximately), Outdoor column mounted type Conveyor 718 Conveyor 719 Transfer House TH 1 Structural shed over Silo Transfer House TH 2 Transfer House TH 2A Transfer House TH 3 Transfer House TH 4 Transfer House TH 5 Transfer House TH 6 Conveyor 721 Conveyor 727 Conveyor 727-1 Conveyor 727-2 Transfer House (Existing at the Tail End of Tripper Conveyor No.122) Control rooms 1 no., Outdoor column 1 no., Outdoor column 1 no., Outdoor column 1 no., Outdoor column 2 nos. in different column mounted type 1 no., Outdoor column 1 no., Outdoor column 1 no., Outdoor column 1 no., Outdoor column 1 no., Outdoor column 1 no., Outdoor column 1 no., Outdoor column 1 no., Outdoor column 1 no., Outdoor column 1 no., Outdoor column mounted type mounted type mounted type mounted type floors, Outdoor mounted mounted mounted mounted mounted mounted mounted mounted mounted mounted type type type type type type type type type type
2 no., Indoor desk mounted type (1 in each control room) 1 no. for elect/ mech. Maint. Incharge room 1 no. in Crushing plant control room (Exact location of the units shall be decided during detail engineering.) MEC/01/Q6DH/NMDC-KIOP/PKG-II/TD 2010, MECON Limited. All rights reserved. Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q5 8.0 CABLES AND ACCESSORIES The cable network shall comprise of signal, power, loudspeaker cables, wires, junction and termination boxes and accessories etc. All external/ outdoor cabling shall be with armoured cables to laid in trays (cables of different voltage grades to be laid in different trays) or supported on walls and structures. Internal cables may be armoured or unarmoured as per requirement. Unarmoured cables shall be laid in conduits. Conduits shall be of medium duty (class B) rigid steel, hot dipped galvanized, conforming to IS, size min. 25 mm. 9.0 EARTHING Earthing of all steel metallic parts of enclosures of all equipment covered in this specification, which are non current, carrying, shall be bonded to an earth bus provided in the equipment. Proper earthing terminals are provided in amplifiers and all other equipment in this specification. Earthing shall be done by Copper wire of cross-section not less than 6 mm2. The supply and installation of all earthing wires, earthing plates and other materials for earthing the entire system shall be covered in the scope. 10.0 QUALITY ASSURANCE, INSPECTION & TESTING All materials, components and equipment covered under the Technical specification for this Project shall be procured, manufactured, tested, erected and commissioned as per a comprehensive Quality Assurance Programme. It shall be the primary responsibility of the contractor to draw up and implement such a programme that shall be duly approved by the Purchaser/Consultant/their authorised Inspection Agency. The detailed Quality Assurance Plan (QAP) for manufacturing and testing of equipment shall be prepared by the contractor and submitted for approval by the Purchaser/their authorised Inspection Agency. VOLUME - IV of V PAGE No. 8 of 9
Rev. 0
NMDC LIMITED
MECON LIMITED

PACKAGE NO - II CHAPTER NO. Q5 11.0 GUARANTEE & WARRANTY All the equipment supplied and jobs carried out by the Tenderer shall be guaranteed for satisfactory performance for a period of 12 months from the date of commissioning of the system. Date of issue of commissioning certificate by the client shall be considered as the date of commissioning. 12.0 SPARES The Tenderer shall furnish a list of spares required for operation and maintenance of the system for two years. 13.0 BILL OF QUANTITIES SL. NO. DESCRIPTION UNIT QTY. VOLUME - IV of V PAGE No. 9 of 9
STANDARD TWO CHANNEL, DISTRIBUTED AMPLIFIER TYPE, LOUD SPEAKER INTERA) COMMUNICATION SYSTEM CONSISTING OF OUTDOOR WALL/ COLUMN MOUNTING TYPE 1 SUBSCRIBER STATION INDOOR DESK MOUNTING TYPE SUBSCRIBER 2 STATION SIGNALLING CABLE - ARMOURED/ 3 UNARMOURED 4 LOUD SPEAKER CABLE - UNARMOURED 5 6 7 8 B) C) D) POWER CABLE - ARMOURED/ UNARMOURED JUNCTION BOXES FOR SUBSCRIBER UNITS, LOUD SPEAKERS, POWER SUPPLY UNITS ETC. FOR INDOOR AND OUTDOOR USE ERECTION AND MOUNTING ACCESSORIES GI PIPES, CLASS B TYPE TRAINING DRAWINGS AND DOCMENTATION 2 YEAR OPERATION SPARES
SET SET LOT LOT LOT LOT LOT LOT LOT LOT LOT
34 4 1 1 1 1 1 1 1 1 1
Rev. 0

Gts For Kumarswamy Iron Ore Project

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NMDC LIMITED

KUMARASWAMY IRON ORE PROJECT BELLARY DIST - KARNATAKA

TENDER DOCUMENT FOR

PACKAGE - II DOWNHILL CONVEYOR SYSTEM

MECON LIMITED BANGALORE

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

KUMARASWAMY IRON ORE PROJECT

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

KUMARASWAMY IRON ORE PROJECT

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

KUMARASWAMY IRON ORE PROJECT

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

KUMARASWAMY IRON ORE PROJECT

1.2.7 1.2.8 1.2.9

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

KUMARASWAMY IRON ORE PROJECT

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

KUMARASWAMY IRON ORE PROJECT

1.2.20 1.2.21 1.2.22 1.2.23

KUMARASWAMY IRON ORE PROJECT

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

KUMARASWAMY IRON ORE PROJECT

KUMARASWAMY IRON ORE PROJECT

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

KUMARASWAMY IRON ORE PROJECT

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

KUMARASWAMY IRON ORE PROJECT

1.2.54 1.2.55 1.2.56

1.2.59 1.2.60 1.2.61

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

KUMARASWAMY IRON ORE PROJECT

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

KUMARASWAMY IRON ORE PROJECT

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

KUMARASWAMY IRON ORE PROJECT

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

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

KUMARASWAMY IRON ORE PROJECT

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

KUMARASWAMY IRON ORE PROJECT

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

KUMARASWAMY IRON ORE PROJECT

KUMARASWAMY IRON ORE PROJECT

2.0 2.1 2.1.1 I) Cubicle

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

KUMARASWAMY IRON ORE PROJECT

2. Thickness of sheet steel

a) Sides/bottom/partition between panels

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

KUMARASWAMY IRON ORE PROJECT

10. Locking facility

11. Accessories with each cubicle

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

KUMARASWAMY IRON ORE PROJECT

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

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

p) Enclosure q) Indicating lamps

KUMARASWAMY IRON ORE PROJECT

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

KUMARASWAMY IRON ORE PROJECT

16. Wiring of auxiliary contacts

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