Design basis report.pdf

M/s. SHREE CEMENTS LIMITED 1X23.5 MW CEMENT PLANT WHR POWER PLANT AT RAS, RAJASTHAN. DESIGN BASIS REPORT (ELECTRICAL) DOC NO: DALIANEAST-CCE-20006-DBR-XXX-800

JULY 2013

EPC CONTRACTOR

M/s. DALIAN EAST NEW ENERGY DEVELOPMENT CO., LTD. DALIAN, CHINA.

ENGINEERING CONSULTANT

CETHAR CONSULTING ENGINEERS LIMITED.

(100% Owned by TRACTEBEL Engineering Pvt. Ltd) No.672/476, Ground FLOOR, TEMPLE TOWER NANDANAM, CHENNAI- 600 035, INDIA.

M/s DALIAN EAST NEW ENERGY DEVELOPMENTCO.LTD 1X23.5 MW WASTE HEAT RECOVERY POWER PLANT FOR SHREE CEMENTS LIMITED, RAS, RAJASTHAN

DOCUMENT CONTROL SHEET

DESIGN BASIS REPORT (Electrical)

DALIANEAST-CCE20006-DBR-XXX-800 / REV 00

26.07.13

00

C.Sudarmathi

P.Manivannan

S.Manivel

Document No.

Issue Date

Rev No.

Prepared By

Reviewed By

Approved By

DALIANEAST-CCE-20006DBR-XXX-800 / REV 00

DESIGN BASIS REPORT (ELECTRICAL )

Page 2 of 27

M/s DALIAN EAST NEW ENERGY DEVELOPMENTCO.LTD 1X23.5 MW WASTE HEAT RECOVERY POWER PLANT FOR SHREE CEMENTS LIMITED, RAS, RAJASTHAN

1.00.00.

INTRODUCTION

This Design basis report covers the features of Electrical system/ equipment and design philosophy to be adopted for 1 x 23.5MW WHRB Power Plant at Shree Cement Limited, Ras, and Pali District- Rajasthan State. Detail engineering works would be carried out in accordance with the concepts developed in this report. This report covers the major features and design philosophy proposed to be adopted for the following
Power Generation System and Evacuation (Via Tie feeder)
Generator
AVR Panel
LAVT Panel
NGR Panel
Generator relay and control panel
Synchronizing Panel
segregated phase bus duct
11kV Switchgear
Auxiliary distribution transformers
Non- segregated phase bus duct
LT PCC / MCC / APFC/DBs
DC System
Cabling system
Plant lighting system
Plant earthing and Lightning protection system

2.00.00.

PROJECT SITE DATA:

Location

:

BangurCity, RAS Pali District,Rajasthan

Altitude

:

378.0 m above MSL

Ambient air temperature

:

(Dry)

-

Minimum: 9°C

-

Maximum: 48°C

Design temperature for

:

50°C electrical equipment

Design relative humidity

:

40%

Basic wind velocity

:

4.7 m/s

DALIANEAST-CCE-20006DBR-XXX-800 / REV 00

DESIGN BASIS REPORT (ELECTRICAL )

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M/s DALIAN EAST NEW ENERGY DEVELOPMENTCO.LTD 1X23.5 MW WASTE HEAT RECOVERY POWER PLANT FOR SHREE CEMENTS LIMITED, RAS, RAJASTHAN

3.00.00.

Average annual rain fall

:

368.34 mm

Seismic zone

:

Zone III

CODES & STANDARDS

All the electrical equipment and materials shall generally conform to Indian Standards and CBIP recommendations for power station design. Statutory

guidelines

of

the

following

will

also

be

observed

in

implementation of Power plant.

3.01.00.




Indian Factories act




Indian Electricity Act




Indian Electricity rules




TAC (Fire protection) Regulations for electrical equipment




Indian Standard Code.




CBIP Recommendations.




IEC.




IEEE.

Standards in below to be followed for the Respective equipment as per contract.




Transformer

: IS 2026




Circuit Breaker

: IEC - 56 / IS 13118




LT Switchgear

: IS 4237 / IS 4047




LT Cables

: IS 1554 / IS 7098 Part I




Current Transformer

: IS 2705




Potential Transformer

: IS 3156




Earthing

: IS 3043




Lightning Protection

: IS 2309




Motors

: IS 325 / IS 4029




Insulation Rubber mates

: IS15652-2006

DALIANEAST-CCE-20006DBR-XXX-800 / REV 00

DESIGN BASIS REPORT (ELECTRICAL )

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M/s DALIAN EAST NEW ENERGY DEVELOPMENTCO.LTD 1X23.5 MW WASTE HEAT RECOVERY POWER PLANT FOR SHREE CEMENTS LIMITED, RAS, RAJASTHAN

4.00.00.

DESIGN CONSIDERATIONS

The Electrical system will be designed based on the requirements for the safe, reliable performance, easy operation and maintenance of all equipments covered in this report and the associated electrical system.

4.01.00.

Basic Design Basis Data:




Proposed Capacity

:

23.5 MW




Configuration & rating

:

1 x 23.5 MW




System Frequency

:

50 Hz ± 5%




Generation voltage

:

11kV




CPP Auxiliary Voltage

:

11000V & 415V (± 10% )




DC System Voltage

:

110V




Control Supply Voltage

:

110 V ± 10% for AC, 110 V, - 15% for DC




Design Max. ambient temp :

50 deg C




Design life

At least 30 years




Periodic maintenance interval:

Greater than 4 years




Environment

Tropical,dusty,chemical,laden,

:

:

atmosphere


VFD selection

:

VFD power selection shall be considered

after

derating

at

max. ambient temp

4.01.01.

Following fault levels will be considered for design of all electrical equipment at various voltage levels. Fault levels shall be restricted to the same.

System

Fault Level

Duration

11 KV System

40KA

1 seconds

415 V System

50KA

1 seconds

110 V DC System

10 KA

1 seconds

DALIANEAST-CCE-20006DBR-XXX-800 / REV 00

DESIGN BASIS REPORT (ELECTRICAL )

Page 5 of 27

M/s DALIAN EAST NEW ENERGY DEVELOPMENTCO.LTD 1X23.5 MW WASTE HEAT RECOVERY POWER PLANT FOR SHREE CEMENTS LIMITED, RAS, RAJASTHAN

4.01.02.

The system details at various utilization equipment voltages will be as given below

System Neutral

S.No.

Service

Voltage

Phase

01.

Generation

11 KV

AC, 3Ph

11 KV

AC, 3Ph

02.

HV Distribution

Earthing Low Resistance Non Effectively Earthed Solidly earth at

04.

LV Panels

415V

AC, 3Ph

transformer star point

05.

LV Motors

415V

AC, 3Ph

Earthed

230V

AC,1Ph&N

Earthed

AC, 1Ph&N

Earthed

Lighting / Space

06.

heater Circuits

4.01.03.

The

07.

UPS

230V

08.

DC System

110V DC

system

details

at

DC (2 Wires) Unearthed

various

utilization

equipment

Auxiliary/Control voltages will be as given below

Sl.

Service

No. 01.

02.

03.

Voltage

Control Voltage (HT Panel) Aux. Voltage

110V DC

Remarks Protection, Breaker control and indication

230 V UPS

Metering

Control Voltage

110V DC /

Protection, Breaker control

(PCC)

AC

and indication

(HT Panel)

DALIANEAST-CCE-20006DBR-XXX-800 / REV 00

DESIGN BASIS REPORT (ELECTRICAL )

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M/s DALIAN EAST NEW ENERGY DEVELOPMENTCO.LTD 1X23.5 MW WASTE HEAT RECOVERY POWER PLANT FOR SHREE CEMENTS LIMITED, RAS, RAJASTHAN

04.

05.

06.

07.

Aux. Voltage (PCC) Control Voltage (MCC)

110 V AC

230V AC

Metering Breaker control and its indication

Aux. Voltage

110V AC (2

Feeder Control and its

(MCC)

Wire)

indication

Aux.Voltage

240 V

Space heater/cubicle lamp,

(MCC)

AC (2 Wire)

etc.

5.00.00.

System Configuration

5.01.00.

Power Generation & Evacuation

One no rated 25 MW, 11kV at 0.8 pf and synchronous generator with brush less excitation system will generate power for the plant with excitation transformer. One number Evacuation feeder in HT panel will be used for evacuation of power. The Plant auxiliary supply will be taken through 2 nos of 2.5 MVA 11/0.433 kV auxiliary distribution transformers.

5.02.00.

Plant start up power & Normal Running

The plant start up power is fed through customer 11 KV Cement plant panel in Evacuation feeder. The plant auxiliaries are started through by closing evacuation feeder breaker which is connected to customer 11kV cement plant panel.

Once the STG is started, the incomer breaker of the generator feeder connecting to the 11 kV switchgear at CPP can be closed i.e. the generator will be synchronized with the start-up supply source. When the STG is in service it will feed its own auxiliary loads and excess power will be evacuated through evacuation breaker.

DALIANEAST-CCE-20006DBR-XXX-800 / REV 00

DESIGN BASIS REPORT (ELECTRICAL )

Page 7 of 27

M/s DALIAN EAST NEW ENERGY DEVELOPMENTCO.LTD 1X23.5 MW WASTE HEAT RECOVERY POWER PLANT FOR SHREE CEMENTS LIMITED, RAS, RAJASTHAN

6.00.00.

Equipment Design

6.01.00.

Generator:

The generator will be 2 poles, 50Hz, star connected, 3 phase type and it is designed for continuous operation at its rated output of 25 MW at 0.8pf. The cooling system will be closed air circuit water cooled (CACW) type.

The generator will be capable of continuous operation at rated MVA & power factor at any voltage from 90% to 110% of rated voltage and within a frequency range of 45 to 55 Hz.

The generator will be of cylindrical rotor design, degree of protection conforming to IP 54 for alternator & IP 54 for exciter. The generator will be provided with brushless digital excitation system. The generator is resin rich type with class F insulation and class B temp rise.

6.02.00.

AVR panel:

The excitation system shall be with Microprocessor based Digital AVR with 2 nos auto channel and 2 nos manual channel. The digital Auto excitation regulator will be fed through excitation transformer.

6.03.00.

LASCPT PANEL

11 KV HT LASCPT panel shall include Surge Capacitor, Lightning arrestor Excitation transformers, and Potential transformers. Degree of protection for LASCPT Panel shall be IP55.




Surge Capacitor

: 12kV, 0.25µF




Lightening arrestor

: 12kV, 10kA




Excitation Transformer : 11KV / 220V, YD11




Potential transformers : 11 kV/√3 /110V/√3/110V/√3/110V/√3

DALIANEAST-CCE-20006DBR-XXX-800 / REV 00

DESIGN BASIS REPORT (ELECTRICAL )

Page 8 of 27

M/s DALIAN EAST NEW ENERGY DEVELOPMENTCO.LTD 1X23.5 MW WASTE HEAT RECOVERY POWER PLANT FOR SHREE CEMENTS LIMITED, RAS, RAJASTHAN

The following table illustrates the Potential Transformers considered in LASCPT Panel.

Sl.No

PTs

CORE 1

CORE 2

CORE 3

CL – 3P, 100VA

CL – 3P , 100VA

(For GPR -2)

(For GPR-2)

(For Generator

CL – 3P , 100VA

CL – 3P , 100VA

Metering cum Syn

(For GPR -1)

(For GPR-1)

CL – 0.2, 100VA 1

PT – 1

(For AVR Panel metering) CL – 0.2, 100VA

2

PT – 2

Panel) 3

6.04.00.

PT – 3

CL – 0.2, 100VA

CL – 3P , 100VA

CL – 3P , 100VA

(Spare PT)

(Spare)

(Spare)

(Spare)

NGR Panel :

11 KV HT NGR panel having Current transformers for phase and standby E/F,63.51 Ohm Resistance , 100 Amps , for 30 sec, max limit up to temperature rise 375 deg C and Motorized neutral isolator with vacuum contactor. Degree of protection for NGR Panel shall be IP55 for enclosure and IP42 for resistance.




Resistance

: 11kV, 63.51 Ohm, 100A for 30 sec




Vacuum contactor

: 12kV, 400A

DALIANEAST-CCE-20006DBR-XXX-800 / REV 00

DESIGN BASIS REPORT (ELECTRICAL )

Page 9 of 27

M/s DALIAN EAST NEW ENERGY DEVELOPMENTCO.LTD 1X23.5 MW WASTE HEAT RECOVERY POWER PLANT FOR SHREE CEMENTS LIMITED, RAS, RAJASTHAN

The following table illustrates the Current Transformers considered in NGR Panel.

CTs

RATIO

CORE 1

CORE 2

CORE 3

CL : 0. 2, 10VA CT-1

100 / 1A

(Generator

CL:5P20,10VA

CL:5P20,10VA

Metering Cum

(GPR-1)

( For GPR-2)

Syn Panel) CL : 0. 2, 30VA , CL : PS , KPV ≥ CT - 2

2500 / 1A

Imag ≤ 15 (For

250 ( For GPR-

AVR Metering)

2)

CL : 0. 2, 30VA , CT - 3

2500 / 1A

Imag ≤ 15 (Spare)

CL : PS , KPV ≥ 250 (For GPR-1)

-

-

CL : PS , KPV ≥ CL : 0. 2, 30VA , 250 (For CT - 4

2500 / 1A

Imag ≤ 15

Generator

(Spare)

Metering cum

-

Syn Panel)

6.05.00.

Generator Relay panel.

Protection of the generator shall be achieved through microprocessor based, 2 Nos Numerical relay (P-343), one as primary and the other as back up. This panel shall be of free standing, floor mounting, sheet steel enclosed type. Degree of protection shall be of IP55. The panel mainly consists of:




Metering for Generator.




Generator protection relay.




Auxiliary relays for protection.

DALIANEAST-CCE-20006DBR-XXX-800 / REV 00

DESIGN BASIS REPORT (ELECTRICAL )

Page 10 of 27

M/s DALIAN EAST NEW ENERGY DEVELOPMENTCO.LTD 1X23.5 MW WASTE HEAT RECOVERY POWER PLANT FOR SHREE CEMENTS LIMITED, RAS, RAJASTHAN

6.05.01.

The following protections are envisaged in protection relay of generator-




Generator Differential Relay (87G)




Over Fluxing (24)




Negative Phase Sequence (46)




Non – directional phase over current ( 50)




Inadvertent Energisation (Dead machine) (50/27)




Neutral voltage displacement / Residual over voltage (59N)




Voltage restrained over current (51V)




Non – directional earth fault (51)




Loss of Excitation (40)




Generator VT fuse failure protection (60)




Reverse power Relay (32 )




Low Forward Power protection (37)




Under & over Frequency Relay (81U / 81O)




Thermal over load relay ( 49)




Rotor earth fault Relay (I & II stage) (64R)




Stator earth fault Relay(51N)




Circuit breaker failure protection Relay (CBFP)




AC control Supply Failure Relay




DC control supply Failure Relay




100% stator earth fault relay (27TN)




Under Voltage Relay(27)




Over voltage relay (59)




Earth fault relay (64F)




Master trip relay (86-T A&B, 86-G A&B, 86C)




Trip circuit supervision relays (95)




Check synchronizing relay(25C)




Guard relay (25G)




No volt relay (27 I)




Auto synchronizer (25A)




PT protection & supervision relay (60)




CT protection & supervision relay




MRU -4 relay far sensing HT Bus PT for df/dt

DALIANEAST-CCE-20006DBR-XXX-800 / REV 00

DESIGN BASIS REPORT (ELECTRICAL )

Page 11 of 27

M/s DALIAN EAST NEW ENERGY DEVELOPMENTCO.LTD 1X23.5 MW WASTE HEAT RECOVERY POWER PLANT FOR SHREE CEMENTS LIMITED, RAS, RAJASTHAN

6.06.00.

Generator Control , Metering cum Synchronizing Panel

Considering various operating conditions of power plant Synchronizing facility will be provided as under:

Auto, Manual synchronizing facility shall be provided for Generator breaker, evacuation feeder breaker, Spare Power Evacuation Feeder breaker

and

Auto/Manual

Generator selector

incomer switch

breaker

in

will be

Generator

provided

Control,

through

metering

&

synchronizing panel (GCMSP). Degree of protection shall be of IP55.

To facilitate auto synchronizing one number Auto synchronizer shall be provided.

To facilitate manual synchronizing of breakers, double voltmeter, double frequency meter, Synchroscope with cutoff switch, Synchro check relay, Live/ Dead bus synchronizing switch and necessary lamps will be provided.

2 Nos 24 window annunciator shall be considered foe alarm and indication purpose. Emergency push button for Generator and turbine trip shall be provided. All the meters shall be digital with 0.5 accuracy class.

Transducers for 3P-4Wire MW (4 output), MVAr (2 Output), 3 Nos Voltage (Two

output), Frequency (Two Output), 3 Nos Current (2 Output) shall

be provided. It shall be programmable type with accuracy class ± 0.5%, 4-20 milli Amps output & auxiliary supply shall be 230V AC.

6.07.00.

GENERATOR BUS DUCT ( SPBD)

11 KV, 3 Phase 3200 Amps, Segregated Phase Bus dud (SPBD) shall be provided for generator Phase terminal to LASCPT Panel and Generator Neutral terminal lo NGR panel. Maximum allowable temperature rise on bus duct shall be 40 deg C and enclosure shall be 25 deg C. The degree of protection for enclosure shall be IP55.

DALIANEAST-CCE-20006DBR-XXX-800 / REV 00

DESIGN BASIS REPORT (ELECTRICAL )

Page 12 of 27

M/s DALIAN EAST NEW ENERGY DEVELOPMENTCO.LTD 1X23.5 MW WASTE HEAT RECOVERY POWER PLANT FOR SHREE CEMENTS LIMITED, RAS, RAJASTHAN

6.08.00.

High Voltage Switchgear:

The following High Voltage switchgear is envisaged. The design basis of High Voltage switchgear will be as follows.

6.08.01.

6.08.02.




Type

:

Metal clad, draw out




Service

:

Indoor




Rated voltage

:

11kV




rated current

:

3200A




Bus Bar Material

:

Copper




Degree of protection

:

IP4X for enclosure




Type of circuit breaker

:

VCB




Duty cycle of breaker

:

O-0.3sec-CO-3min-CO




Closing mechanism at CB

:

Spring charged stored energy




Short Circuit Rating

:

40kA for 1 sec

FEEDER DETAILS




Generator Feeder with PT 1 No. + 1 SPARE




Transformer feeder (2.5 MVA) 2 Nos + 1 SPARE




Power Evacuation feeder with PT 1 No. + 1 SPARE




Bus PT 1 NO

Protection & Metering Envisaged:

The protections envisaged for different feeders are listed below. Main protective relays will be Numerical fixed type. However auxiliary relays will be electromechanical type only.

A) 11 KV Incomer feeders:




Instantaneous and definite time over current protection. (50/51)




Directional over current and earth fault protection. (67/67N)




Under voltage protection with timer (27+2)




Trip circuit supervision relay(74)

DALIANEAST-CCE-20006DBR-XXX-800 / REV 00

DESIGN BASIS REPORT (ELECTRICAL )

Page 13 of 27

M/s DALIAN EAST NEW ENERGY DEVELOPMENTCO.LTD 1X23.5 MW WASTE HEAT RECOVERY POWER PLANT FOR SHREE CEMENTS LIMITED, RAS, RAJASTHAN




Master trip relay(86)




Anti pumping relay(94)




DC Fail relay(27D)

B) 11 KV Power evacuation feeder:




Instantaneous and IDMT over current protection.(50/51)




Directional over current and earth fault protection. ((67/67N)




Cable differential protection (87C)




Under voltage protection with timer (27+2)




Trip circuit supervision relay(74)




Master trip relay(86)




Anti pumping relay(94)




Neutral voltage displacement (59N)




DC Fail relay(27 D)

C) Auxiliary transformer feeder:




Instantaneous and definite time over current protection.




Instantaneous and definite time earth fault protection.




Winding temperature protection (49 WT)




Oil temperature protection (49 OT)




Bucholz relay (63).




Trip circuit supervision relay(74)




Master trip relay(86)




Anti pumping relay(94)




DC Fail relay(27 D)

D) Bus PT feeder




Under voltage relay with timer (27+2)




DC Fail relay(27 D)




Voltage balance relay 60)

DALIANEAST-CCE-20006DBR-XXX-800 / REV 00

DESIGN BASIS REPORT (ELECTRICAL )

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M/s DALIAN EAST NEW ENERGY DEVELOPMENTCO.LTD 1X23.5 MW WASTE HEAT RECOVERY POWER PLANT FOR SHREE CEMENTS LIMITED, RAS, RAJASTHAN

6.08.03.

Metering:

Incoming feeder shall be provided with energy meters of class 0.5 accuracy, Digital Ammeter & Digital voltmeter. Auxiliary transformer feeder shall be provided with Energy meter and Ammeter. However evacuation feeder shall be provided with 0.2 accuracy class Trivector meter & Digital ammeter.

6.09.00.

LV Transformers:

6.09.01.

LV Auxiliary Transformers

Auxiliary Transformers are Oil impressed type, 2.5 MVA rated ,2 x 100% capacity, 11/ 0.433kV, ONAN cooled, Dyn11 vector group, 8.25 % impedance, 99.5% efficiency at 50% load, 99.0% efficiency at 100% load, outdoor type. This transformer will be provided with off load tap switch having +5 to -5 % taps in steps of 2.5% on HV side. The LV side neutral of this transformer will be solidly grounded.

The following assumptions as per normal power plant practice had been made in sizing the transformer

Load factor

= 0.8 for continuous load, 0.2 for intermittent load

Coincidence factor = 0.05 for motorized valves, 0.5 for AC & heater unit, 1 for continuous load General:

The flux density considered is 1.67 T for the core and yoke at the rated MVA, voltage & frequency. The transformer & all its accessories including CTs shall be designed to withstand without any injury the thermal & mechanical effects caused due to short circuit fault. Transformers shall withstand, without injurious heating, the combined voltage & frequency fluctuations.

DALIANEAST-CCE-20006DBR-XXX-800 / REV 00

DESIGN BASIS REPORT (ELECTRICAL )

Page 15 of 27

M/s DALIAN EAST NEW ENERGY DEVELOPMENTCO.LTD 1X23.5 MW WASTE HEAT RECOVERY POWER PLANT FOR SHREE CEMENTS LIMITED, RAS, RAJASTHAN

The transformer will be provided with following accessories and fittings:




Double float type buchholz relay having alarm and trip contacts




Dial type (150 mm) oil temperature indicator with alarm and trip contacts.




Dial type (150 mm) winding temperature indicator (WTI) with alarm and trip contacts.




Magnetic oil level gauge, with low level alarm contact.




Tap position indicator (Local )




Jacking pads.




Bi-directional flange wheels with suitable locking arrangement.




LV neutral CT for LV REF protection and standby earth fault protection.

6.09.02.




Rating & Diagram Plate




Earthing Terminals




Lifting Lugs




Radiators




Silica Gel Breather




Explosion Vent with Diaphragm




Bottom drain cum Filter Valve




Top Filter Valve




Pressure relief valve.

Lighting Transformers:

Two no 2X100% dry type lighting transformer

of 100 KVA, 415/415,

Dyn11, AN, 8.25 % impedance, greater than 99.5% efficiency at 50% load, 99.0% efficiency at 100% load, ±10% variations on secondary side in 2.5% steps shall be provided. Lighting transformer shall be of class H insulation with temperature rise limited to class F.

6.10.00.

NSPBD:

415 V, 3 Phase + Neutral 4000 Amps TPN Sand witch type Non Segregated Phase Bus duct (NSPBD) shall be considered for connecting DALIANEAST-CCE-20006DBR-XXX-800 / REV 00

DESIGN BASIS REPORT (ELECTRICAL )

Page 16 of 27

M/s DALIAN EAST NEW ENERGY DEVELOPMENTCO.LTD 1X23.5 MW WASTE HEAT RECOVERY POWER PLANT FOR SHREE CEMENTS LIMITED, RAS, RAJASTHAN

between auxiliary distribution transformer and 415V PCC. Maximum allowable temperature rise on bus duct is 40 deg C and enclosure is 25 deg C. The degree of protection for enclosure shall be IP54.Bus conductor & Bus enclosure shall be Electrolytic grade Aluminum & MS respectively. Bus bar material shall be of Aluminum flats grade 83401 WP, IS 5082

6.11.00.

Low Voltage Switchgear - 415V

6.11.01.

LTPCC:




Type

:

Fixed type




Service

:

Indoor




Current Rating

:

4000 A




Short circuit Rating

:

50kA for 1 Sec.




Protection

:

IP4X




Busbar material

:

Aluminium




Maximum current density

:

0.8A/mm2




Incomers

:

Two with 4000 A ACB breaker




Closing/tripping of ACB

:

110 V DC / AC

The protections envisaged for different feeders were listed below.

a) LTPCC Incomers:




Instantaneous and IDMT over current protection (50/51)




Instantaneous and IDMT earth fault protection (50/51N)




Restricted earth fault relay (64R)




Standby earth fault Relay (51N)




Under voltage protection with timer(27+2)




DC failure relay (27 D)

b) LTPCC outgoing feeders




Thermal & magnetic releases for overcurrent & short circuit protection shall be provided.

DALIANEAST-CCE-20006DBR-XXX-800 / REV 00

DESIGN BASIS REPORT (ELECTRICAL )

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M/s DALIAN EAST NEW ENERGY DEVELOPMENTCO.LTD 1X23.5 MW WASTE HEAT RECOVERY POWER PLANT FOR SHREE CEMENTS LIMITED, RAS, RAJASTHAN

c) LTPCC Bus PT feeders




Under voltage relay (27)

Metering:

Energy meter shall be provided in the all incoming and outgoing feeders of PCC. Analog type ammeter and voltmeter with selector switch shall be provided on the incoming feeders. For Bus PT feeders voltmeter with selector switch will be provided

6.11.02.

MCC

MCC shall be double front as per the contract. MCC shall have uniform height placed side by side.




Type

:

Free standing fixed type




Service

:

Indoor




Short circuit Rating

:

50kA for 1 Sec.




Current Rating

:

as per requirement




Enclosure

:

IP 52




Rated voltage

:

415V




Maximum current density

:

0.8A/mm2




Bus bar Material

:

Aluminum




Incomers

:

Two

The CPP shall have following MCCs:


TG MCC




Boiler MCC (1 No for each PH + 1 No for each AQC)




A/C, P&V MCC




ACC & CWS MCC




WTP MCC




ACDB, MLDB, DCDB




APFC MCC




Emergency MCC

DALIANEAST-CCE-20006DBR-XXX-800 / REV 00

DESIGN BASIS REPORT (ELECTRICAL )

Page 18 of 27

M/s DALIAN EAST NEW ENERGY DEVELOPMENTCO.LTD 1X23.5 MW WASTE HEAT RECOVERY POWER PLANT FOR SHREE CEMENTS LIMITED, RAS, RAJASTHAN

6.12.00.

415V Motors

Motors are of TEFC IP55 enclosure with Class `F’ insulation with a temperature rise limited to Class `B’. LT motors shall have premium efficiency (IE-3 type). Protection class shall be IP65. All the S1 Duty Cycle (continuous running) motors shall be compatible with VFD (Inverter grade for VFD application).

Local Push Button Station (LPBS) shall be provided for all the motors and MOV's (for VFD LPBS shall have RPM meter and raise lower push buttons). For motors 3.7 kW and above ,LPBS shall be equipped with Ammeter.

All motors below 75 kW: 415V rated, 3 phase/SFU+110 V (from MCC) AC control contactor + O/L relay with single phase preventer

From 75 kW and above: 415 V rated, 3 phase contactor/ circuit controlled from MCC through Digital motor protection relay with bearing temp.

For above 22kW motors ammeters shall be provided. For above 30kW motors Space heaters shall be provided. For 75kW and above motors bearing & winding temperature monitoring shall be provided.

7.00.00.

DC system

One no 800AH 1X100% (2V X 55), 110 Volts , 2 wire ungrounded system , four (4) hours back up Vented type Plante Lead acid Battery of adequate capacity with their Float cum Boost charger shall be considered for DC loads with associated FRP battery racks etc..

110 V DC power supply is the most reliable source of power supply for control, protection, interlock and annunciation requirements of the power station.

DALIANEAST-CCE-20006DBR-XXX-800 / REV 00

DESIGN BASIS REPORT (ELECTRICAL )

Page 19 of 27

M/s DALIAN EAST NEW ENERGY DEVELOPMENTCO.LTD 1X23.5 MW WASTE HEAT RECOVERY POWER PLANT FOR SHREE CEMENTS LIMITED, RAS, RAJASTHAN

The rating of charger will be calculated as below:

Float charger: Continuous DC load + trickle charging current of battery +15 % margin.

Boost charger Boost charging current of battery+ continuous DC load.

Float cum Boost charger: Boost charging current of battery.

Battery Charger

7.00.01.




Type - One float and float cum Boost charger




Voltage regulation - 110V ± 1%




Service - Indoor




Enclosure - Sheet steel




Degree of protection - IP – 42




AC input - 415V, 3ph, 3W, 50Hz, 50kA




Busbar Material – Aluminum

DC Distribution Board

DC Distribution Board constructional features will be given below




Type - Fixed type NON-Compartmentalized




Service - Indoor




Enclosure - Sheet steel




Degree of protection - IP – 42




Short circuit rating - 10kA for 1 sec (Tentative)




Bus bar Material – Aluminium

DALIANEAST-CCE-20006DBR-XXX-800 / REV 00

DESIGN BASIS REPORT (ELECTRICAL )

Page 20 of 27

M/s DALIAN EAST NEW ENERGY DEVELOPMENTCO.LTD 1X23.5 MW WASTE HEAT RECOVERY POWER PLANT FOR SHREE CEMENTS LIMITED, RAS, RAJASTHAN

8.00.00.

Auto Power Factor Correction Panel

2 Nos x 500 WAR , 113 STEPS (50 KVAR OF -10 Nos ) capacitor units shall be hermetically sealed type, with two bushings and shall be designed to carry a minimum of 1 .5 times the rated current at 110% of rated voltage and 1.35 times rated reactive power, continuously. The capacitors should be of non PCB type, suitable for operation in tropical areas

9.00.00.

Cabling System:

9.01.00.

Cables:

9.01.01.

HT Power cable

HT power cable used for 11 kV systems will be 12.7/22kV (E) grade. The cable will be heavy-duty, stranded Aluminum conductor with FRLS, conductor screened with semiconductor, extruded XLPE insulation and insulation screen (semiconductor +copper tape), extruded PVC inner sheath, G.S flat (for multi-core)/aluminium wire (for single core) armoured and extruded PVC (ST-2) outer sheathed conforming to IS7098 part-II. Maximum

operating

temperature

under

normal

condition

for

XLPE

insulation cables will be 90°C. Trefoil Clamps for HT Cable shall be provided.

The following rating of HT cable XLPE (UE) insulated shall be envisaged for the Plant




LASCPT panel to HT switch gear panel - 4RX 1C X 630 Sq.mm/ph




GPP-4 HT panel to Existing HT Panel for power evacuation - 4R X 1C X 630 Sq.mm/ph




GPP-4 HT Panel to Auxiliary transformer 1 & 2 - 1R X 3C X 300 Sq.mm

DALIANEAST-CCE-20006DBR-XXX-800 / REV 00

DESIGN BASIS REPORT (ELECTRICAL )

Page 21 of 27

M/s DALIAN EAST NEW ENERGY DEVELOPMENTCO.LTD 1X23.5 MW WASTE HEAT RECOVERY POWER PLANT FOR SHREE CEMENTS LIMITED, RAS, RAJASTHAN

9.01.02.

LT Power cable

LT power cable used for 415V AC, 230VAC, 110V AC & 110 V DC system will be 1.1kV (E) grade, stranded aluminum conductor with FRLS, XLPE insulated, not extruded PVC inner sheath, G.S. Flat/round wire with armoured, extruded PVC (ST-2) outer sheath conforming to IS 7098 partI. Maximum operating temperature under normal condition for XLPE insulation cables will be 90°C. Cables less than 10 sq.mm shall be of copper conductor. DC Power cables for EOP will be UNINYVIN CABLE & Cable for UPS will be Copper armour cable. Separate earthing cable shall be laid from each VFD to respective Motor.

9.01.03.

Control cable

Control cables will be 1100V (E) grade, multi-core with stranded 1.5 mm² and copper conductor with FRLS, PVC insulated, extruded PVC inner sheath, G.S. flat / round wire armoured and extruded sheath of PVC (ST1) with numbering of all cores, conforming to IS 1554 part-I/IS 5831.

9.02.00.

Cable Tagging

Cable tagging shall be at both end & at every 20 meter considered for all cable. Anodised type tagging plate will be provided.

9.03.00.

Cable Trays

Cables laid in overhead racks shall be GI ladder/perforated type trays for electrical/instruments with proper prefabricated bends respectively in outdoor areas and supports shall be MS (painted). The top cable tray shall be covered with GI sheet canopy/GI sheet covering in outdoor cable racks. All outdoor cable racks shall be vertically oriented. Galvanized cable trays for Boiler, Turbine, ACC and BOP area shall be supplied. For WTP area all cable tray shall be FRP type only.

DALIANEAST-CCE-20006DBR-XXX-800 / REV 00

DESIGN BASIS REPORT (ELECTRICAL )

Page 22 of 27

M/s DALIAN EAST NEW ENERGY DEVELOPMENTCO.LTD 1X23.5 MW WASTE HEAT RECOVERY POWER PLANT FOR SHREE CEMENTS LIMITED, RAS, RAJASTHAN

Separate cable tray for HT Power, LT Power, Control Cable, Instt. Analog Input/output cable each, Instt. Digital Input/output cables each & Compensating Cable shall be considered.

No. Of Cable layers per Cable tray shall be as follows:




HT Power Cable & LT Power(up to 120 mm2) Cable - One Layer




LT Power Cable (below 120mm2) - Two Layer




Control Cable - Three Layer




Instt. Cables - Three Layer

10.00.00.

llumination System:

10.01.00.

Basic Concept

The system provides lighting and service power at 240V, single phase 50 Hz to receptacles and single phase feeders in plant areas. The plant illumination system

includes normal cum Emergency lighting and critical

DC lighting.

10.02.00.

100 % Normal cum Emergency A.C lighting

Normal cum Emergency A.C. lighting will be provided by lighting fixtures distributed throughout the plant. Separate circuits with timers will be provided where round the clock lighting is not required. Lighting fixtures will be fed from respective area lighting panels, which in turn receive supply from lighting distribution board. MLDB shall be provided with Dual incomer. LDBs shall be equipped with 30 mA ELCB. In Normal condition the Main lighting distribution board will be fed from 415V PCC & Emergency MCC through 2 x 100%, lighting transformer. In blackout condition then the supply for MLDB shall be fed from Emergency MCC (which is connected to Customer DG set) through lighting transformer.

DALIANEAST-CCE-20006DBR-XXX-800 / REV 00

DESIGN BASIS REPORT (ELECTRICAL )

Page 23 of 27

M/s DALIAN EAST NEW ENERGY DEVELOPMENTCO.LTD 1X23.5 MW WASTE HEAT RECOVERY POWER PLANT FOR SHREE CEMENTS LIMITED, RAS, RAJASTHAN

10.03.00.

Emergency DC Lighting

Critical DC lighting will be provided with bulk head lamps at Cable Cellar MCC room, CCR, TG house, stair cases, steam drums on all boilers & Start up vents. This DC lighting will remain OFF normally and will be switched ON automatically when main AC supply fails. The power supply for lighting will be fed from 110V DCDB. FL DC lamp with integral battery shall be provided for Boiler area MCC room.

10.04.00.

Power Receptacles / Welding Sockets

1 Phase & 3 Phase power receptacles will be provided for alternative floors of Boiler area, each floor ACC areas and at least 3 Nos in TG building, MCC room, cable cellar area. 3 Phase Welding Sockets will be provided at each stage of boiler, TG Floor & as required in ACC area etc. 24 Volt AC power receptacles with transformers and proper distribution at all location of boilers, ACC floors will be provided.

10.05.00.

The type of fixtures & type of luminaries for different areas is listed below:

Area Description Cable gallery, Transformer Area Compressor room, Battery charger room, P&V room & Storeroom MCC Switchgear room Battery rooms Control Rooms & Office rooms

Type of Fixture

Type of Luminaries

Industrial Trough Type

2x28 W Fluorescent Lamp

Industrial Trough type with Reflector Arrangement

2x36 W Fluorescent Lamp

Corrosion Proof

TG Building Operating floor

Industrial Trough type with mirror optics Integral Well glass Industrial type Industrial type high bay

TG Building Staircases

Industrial Trough Type

Turbine houses

DALIANEAST-CCE-20006DBR-XXX-800 / REV 00

DESIGN BASIS REPORT (ELECTRICAL )

2x36 W Fluorescent Lamp 2x28 W Fluorescent Lamp 1 X 80W HPMV 1x400 W MH Lamp 2x36 W Fluorescent Lamp Page 24 of 27

M/s DALIAN EAST NEW ENERGY DEVELOPMENTCO.LTD 1X23.5 MW WASTE HEAT RECOVERY POWER PLANT FOR SHREE CEMENTS LIMITED, RAS, RAJASTHAN

Boiler area, Boiler platforms ACC, & WTP Toilet areas Street Lights & Outdoor lights DC lights in TG Building DC lights in Boiler area MCC room

Integral Well glass Industrial type Integral Well glass Industrial type Integral Well glass Industrial type with timer arrangement Bulk head type FL with integral battery type

11.00.00.

Earthing & Lightning Protection System

11.01.00.

Plant Earthing:

1x70 W MH Lamp 1 X 36 W Fluorescent Lamp 1 x 150 W MH Lamp 1X 100W GLS 2x28 W Fluorescent Lamp

System earthing will be adopted to facilitate earth fault relaying and to reduce the magnitude of transient over-voltage. The system earthing involves earthing of the neutrals of generator. Low impedance earthing is used for 11 KV system to limit the earth fault current to about 100 A by grounding generator neutral by means of Neutral Grounding Resistor (NGR). A ground grid of 32mm MS Rod will be provided encircling the plant through a system of grounding electrodes and pits to keep ground resistance less than one ohm. Earth mat shall be laid below 500mm below absolute ground level and earth pits shall be 1.5 meter away from nearby building walls. Every electrical system will have dual earthing. Treated earth pits will be considered for generator NGR, Aux. Transformer Neutral, lightning arrestor & equipments. All Earthing electrodes shall be of Gel type maintenance free (homogeneous readymade mixture). All instrument earth pits shall be maintenance free and configuring delta spaced by 6 meter with redundant copper cable connection. The underground grid shall be connected with lightning protection earth electrodes below ground at average depth of 500 mm.

DALIANEAST-CCE-20006DBR-XXX-800 / REV 00

DESIGN BASIS REPORT (ELECTRICAL )

Page 25 of 27

M/s DALIAN EAST NEW ENERGY DEVELOPMENTCO.LTD 1X23.5 MW WASTE HEAT RECOVERY POWER PLANT FOR SHREE CEMENTS LIMITED, RAS, RAJASTHAN

11.01.01.

Equipment Earthing:

Electrical equipment shall be provided with two separate and distinct grounding pads, each complete with tapped hole, galvanized bolt and spring washer for connection to station ground conductors.

The neutral of generator and transformer shall be earthed through two dedicated earth pits.

Flat from the main earthing grid to local network and electrical equipment will be GI flats of suitable size, except for smaller items, which will be connected using steel wire. However, for portable equipment, if one of the conductors of the connecting cable/plug socket is earthed, no other earth connection is required.

An earthing conductor will be installed along the entire length of top most power cable trays. The tray earth will be connected at various locations to the station earth grid. The offsite areas will be connected through the earth flats running along the cable trays. Earth continuity will be provided for all cable trays & conduits. The following aspects will be addressed during design, of the equipment earthing system to be adopted.




Availability of sufficient earth current for effective relaying.




Stabilization of circuit potential with respect to earth.

The size of earth conductor used for individual equipment earthing




Main Ground Conductor: 32 mm MS rod




Earth Electrodes : MS Rod 32 mm dia, 3 m long pipe




Generator and Transformer Body: 75 mm x 10 mm GI Flat.




Transformer and Generator Neutral: 75 mm x 10 mm GI Flat.




HT switchgear Panels: 50 mm x 6 mm GI Flat.




415V PMCC, MCC, DCDB, MLDB Structures, Bus duct, Control Panel, Cable




Trays: 50 mm x 6 mm GI Flat.

DALIANEAST-CCE-20006DBR-XXX-800 / REV 00

DESIGN BASIS REPORT (ELECTRICAL )

Page 26 of 27

M/s DALIAN EAST NEW ENERGY DEVELOPMENTCO.LTD 1X23.5 MW WASTE HEAT RECOVERY POWER PLANT FOR SHREE CEMENTS LIMITED, RAS, RAJASTHAN




LT AC Motors from 110kW up to 132 KW: 50 mm x 6 mm GI Flat.




LT AC Motors above 30kW up to 90 KW: 25 mm x 6 mm GI Flat.




LT AC Motors from 5.5kW up to 30 KW: 25 mm x 3 mm GI Flat.




LT AC Motors below 5.5 KW : 8 SWG GI wire




Local Panels, LPBS, Switch sockets, LDBs, JB,Receptacles: 8 SWG GI wire

11.02.00.

Lightning Protection:

The main purpose of the lightning protection system is to provide protection to structures from lightning strokes and provide a low resistance-conducting path for lightning discharge to earth. For metal structures, which are continuous down to the ground level, no lightning protection

is

required

except

adequate

grounding

connections.

Air

termination network with down conductor and earthing electrodes will be provided on the basis of IS-2309 recommendations.

The zone of protection will depend on each structure height, overall shape, and physical location in relation to other structures.

DALIANEAST-CCE-20006DBR-XXX-800 / REV 00

DESIGN BASIS REPORT (ELECTRICAL )

Page 27 of 27