Project: : Raw water System for New Plate Mill Section-2

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ELECTRICAL SPECIFICATIONS

1.0 SCOPE :

The scope will include design, engineering, manufacture, assembly, shop fabrication,
testing at works, transportation to site, unloading and storing at site, erection, testing,
commissioning, trial operation including supply of erection consumables, hardware,
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labour, tools & tackles etc. The scope of work also includes all civil, structural and
architectural works associated with installation of the electrical system and equipment at
site.

2.0 POWER SUPPLY ARRANGEMENT:

Power supply to the propsed “Water System Area” shall be arranged by the purchaser as
per folllowing

• One of 6.6kV supply from Purchaser’s 6.6kV switchboard.shall be tapped to cater the
HT loads of Scale Pit area (At a distane of about 200M from the scale pit pump house as per
NIT)
• One no. of 415V supply tapped from the Purchaser’s 415V switchboard to cater LT
loads for the scale pit area. (At a distane of about 200M from the scale pit pump house as per
NIT)
• Three nos. of 6.6kV supply from Purchaser’s 6.6kV switchboard.tapped to supply
power to HT loads located in Settling Tank pump house. (At a distane of about 500M from the
water system area as per NIT)
• One of 6.6kV supply from Purchaser’s 6.6kV switchboard.shall be tapped to cater the
HT & LT loads of Water system area (At a distane of about 500M from the scale pit pump
house as per NIT)

For all the above, termination and cabling from the outgoing terminals of Purchaser’s
6.6 & 0.415kV switchboard is considered.

2.1 Electrical Control Rooms (ECR)

Four numbers of Electrical Control Room (ECR) is proposed for the water system area ie
ECR-1 adjacent to Recirculating Pump house, ECR-2 adjacent to Laminer Plate cooling
Pump house, ECR-3 adjacent to Settling Tank Pump House ECR-4 adjacent to Scale Pit
Pump house.
Main Control room for the water system area shall be located in the ECR-1 .ECR-1 shall
receive 6.6kV power supply from purchaser’s switchboard which will feed LT power to
ECR-2 & ECR-3 through LT transformers.

2.2 ECR- 1
Electrical control room - 1 will be located adjacent to Recirculating pump House, and
envisaged as Main Electrical Control Room.

Power supply to 6.6kV & LT distribution transformer of the water system area shall be fed
from HT MCC located in ECR-1 consisting of the following :

a) Vacuum Circuit Breaker for Incomer – 1 No.

b) Vacuum circuit Breaker feeder for Distribution Transformer feeders - 2 Nos
c) Vacuum contactor panels for motor feeders – 10 Nos.
d) Vacuum circuit Breaker spare – 1 No.
e) Vacuum contactor panels for motor feeders – 1 No.

Distribution transformers will be installed in this Electrical Control room to feed power to
LT loads of ECR2 & 3
.
2.3 ECR- 2

Electrical control room - 2 will be located adjacent to Laminer Plate cooling Pump house
and shall receive power from ECR-1 to cater the LT loads in Laminer cooling pump
house & Settling tank pump house. HT motors in Laminer cooling pump house shall be
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fed from the HT MCC located in ECR-2. HT motors in Settling tank pump house shall be
directly fed from the purchaser’s 6.6kV switchboard.

2.4 ECR-3
Electrical control room - 2 will be located adjacent to Laminer Plate cooling Pump house
and shall receive power from ECR-1 to cater the LT loads in Laminer cooling pump
house & Settling tank pump house. HT motors in Laminer cooling pump house shall be
fed from the HT MCC located in ECR-2. HT motors in Settling tank pump house shall be
directly fed from the purchaser’s 6.6kV switchboard.

3.0 UTILIZATION VOLTAGE:

4.1 Motors 200 kW & above : 6.6 kV. 3Ph, AC

4.2 Motors rated below 200KW : 415 V, 3 Ph, 50Hz
4.3 Anti-condensation heaters : 240V, 1 Ph. AC
4.4 Normal/Emergency Lighting : 240V, Ph. AC

4.0 6.6 KV SWITCHBOARD:

Intelligent type 6.6kV switchboards shall be provided with provision for PROFIBUS
communication. The Switchboard assembly will comprise a continuous, dead-front line-
up of free standing, vertical cubicles. Each cubicle will have a front hinged door with
latches and a removable back cover. Minimum thickness of MS sheet steel used will be 2
mm. Switchboard will be such as to allow extension at either end. The working zone will
be restricted within 700 mm to 1600 mm from floor level. Dummy panel will be provided
in the Switchboard line up, if required. Switchboard will be designed for cable entry from
bottom.

Switchboard cubicle will be so sized as to permit closing of the front access door when
the breaker is pulled out to TEST position.

Circuit breakers, instrument transformers, bus-bars, cable compartment etc., will be

housed in separate compartments within the cubicle.

All relays, meters, breaker control switches, selector switches and indicating lamps will
be flush mounted on the respective cubicle door or on control cabinet built on the front of
the cubicle. The relay will be Electro-magnetic type

The main buses and connections will be of high conductivity Hard Drawn Copper, sized
for specified current ratings. Bus bars will be of same size for the entire length of the
Switchboard. Continuous current rating of bus connections / dropper will be same as that
of continuous in panel current rating of associated breaker

Circuit breakers will be of horizontal isolation and horizontal draw out type, having
SERVICE, TEST and DISCONNECTED positions with positive indication for each
position.

For motor wound mechanism, spring charging will take place automatically after each
breaker closing operation. One open-close-open operation of the circuit breaker will be
possible after failure of power supply to the motor.

Relays will be of draw out design with built-in testing facilities and flush mounted at the
front of panel. Small auxiliary relays may be in non-draw out execution and mounted
within the cubicle. 6.6 KV Switch board will consist two Incomers & one Bus-coupler with
required number of outgoings.
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5.0 TRANSFORMERS:

The Distribution transformer is sized to cater power supply to entire Loads of

Recirculating Pump House, Laminer cooling Pump House & Settling Tank Pump House.
Transformer will be loaded 80% to cater the entire loads, with the standby transformer.

7.1 6.6 /0.433 KV DISTRIBUTION TRANSFORMER:

6.6 /0.433 KV, 50HZ, Dy11, AN - 2 No., Indoor, and Air cooled transformers located at
Main ECR near Recirculating Pump House to cater entire Loads of Recirculating Pump
House, Laminer cooling Pump House & Settling Tank Pump House.

The H.V. Side of the transformer is fed from 6.6 KV (UE) aluminium conductor, XLPE
Cable. The LV side of the transformer will feed power to the respective PMCC through
Metal Enclosed Bus duct.

Temperature scanner is provided for the monitoring the temperature.

7.2 LIGHTING TRANSFORMER:

Lighting Transformer will be 415/230V, 50Hz suitable for Indoor, Cast resin dry type to
cater power supply to Lighting loads within the Battery limits of Entire water system area
through Main Lighting Distribution Boards. Lighting transformer will be provided with off
circuit tap changer (OCTC) +5% to -5% voltage variation in steps of 2.5%.

Lighting Transformers of required rating is considered at following locations,

• 1 No. of 415/230V, 50Hz, at Main ECR near Recirculating Pump House.

6.0 POWER & MOTOR CONTROL CENTER (PMCC):

Power & Motor Control Center will be draw out type, single front, floor mounted type.
MCC’s will be fully compartmentalized with metal/ insulating partitions between
compartments. Horizontal and vertical busbars and bus connections will be of high
conductivity aluminium.

PMCC’s will be fabricated out of 2/1.6 mm thick CRCA sheet steel. The degree of
protection will be IP- 52. Motor feeder above 30kW having Ammeter at PMCC. All motor
feeders are DOL starter. This PMCC will comprise of 2 nos. of Air Circuit Breakers as
incoming, 1 no. sectionalizer and required numbers of MCCB unit along with contactor &
protective Relays as per requirement as outgoing feeders.10 % spare feeders with
minimum 1 number for each type and rating will be provided.

Following 3 Nos. PMCC’s are envisaged to cater the loads at various locations.
• PMCC-I: located in ECR Near Recirculating pump House.
• PMCC-II: located in ECR Near Leminer cooling pump House
• PMCC-III: located in ECR Near Scale Pit area.
All PMCC’s shall be of intelligent type with provision for PROFIBUS communication for all
incoming & outgoing feeders

7.0 CABLES:

• H.V. POWER CABLE:

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The HV Power cables 6600 volt power cable will be 3 core aluminium conductor cable,
cross linked polyethylene, individual screen with extruded semiconducting compound,
galvanized flat strip armoured, inner sheathed of PVC tape & overall PVC sheathed
FRLS type of required sizes, suitable for restricted earthed neutral system.

• LV POWER / CONTROL CABLE:

The LV Power cables will be 1.1KV grade, Multi-stranded, XLPE insulated, PVC
sheathed FRLS, single wire armoured, fire retarding type Copper / Aluminium conductor
cable. Minimum size of copper cable will be 2.5 sq.mm. above 2.5 sq.mm size,
aluminium cable will be used.

The Control cables will be 650 V grade, Multi-stranded, PVC insulated, PVC sheathed
FRLS, single wire armoured, fire retarding type Copper conductor cable having a
minimum size of 1.5 sq.mm.

For motors rated above 75kW, power shall be taken to the motor through power junction
boxes. From the junction box power shall be fed to the motor through Copper flexiable
cable(EPR insulated).

• POWER JUNCTION BOXES

For motors of rating 75 kW and above a suitable junction box near to the motor shall be
provided. The aluminium conductor cables from the drives/motor control for the same
shall be terminated in the junction box

8.0 CABLE TRAYS:

Cable trays will be ladder type made of sheet steel Galvanized Pre fabricated. Cable
trays will be made of Galvanised Iron. Prefabricated type perforated type cable trays
shall be provided for control cables. The cables will be laid along fabricated trays and be
properly grouped as power cables, control cables etc., spaced from each other and
clamped. 6600 volt and 415 power cables will be grouped separately. The top tier of the
cable rack will be covered with cable tray cover.

9.0 CABLE GLANDS:

Cable glands will be double compression type. The glands will be of robust construction
capable of clamping cable and cable armour (for armoured cables) firmly without injury to
insulation. The glands will be heavy duty brass, machine finished and nickel chrome
plated of minimum 10 micron thickness. All washers and hardware will be made of brass
with nickel chrome plating. Rubber components will be of neoprene and of tested quality.

Cable glands for use in hazardous area will be flame proof type.

10.0 CABLE LUGS:

Cable lugs will be heavy duty tinned copper/aluminium crimping type for power cables
and control cable will be tinned copper crimping type.

11.0 MOTORS:
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Energty Efficient Motors will be considered as per Tender document Specification
General Technical Specification No. RSP-ERM/GTS-E-04 for Auxiliary Ac Motors And
Controls,.

12.0 LOCAL CONTROL STATION:

The Local Control Stations (LCS) will be metal enclosed, suitable for outdoor/indoor
mounting on wall or steel structures. The enclosure will be made of cold rolled sheet
steel of at least 1.6 mm thickness. LCS will be painted to shade no. 632 of IS:5 in
accordance with relevant code. The LCS will be dust and vermin proof. The LCS will be
provided with removable undrilled gland plates.
LCS shall have Start/stop pushbuttons & ammeter (For feeders rated 37kW & above).
For LCS located near the cooling tower area, LCS shall be provided with
FRP/thermoplastic enclosure.

13.0 EARTHING & LIGHTNING PROTECTION:

Proper earthing arrangement for the plant will be provided as per I.E Rules. Additional
earthing grid will be developed around the periphery of all Electrical Control room
( ECR ), Pump Houses & Cooling Towers. Each motor, transformer, switch panel and
other electrical equipment will be earthed by two separate earthing strips. In addition all
the motors will be earthed through the armoring of the connecting cable. Earthing Strip
Size is considered as required but not less than what is mentioned in the tender
document RSP-ERM / GTS- E-06 CLAUSE 13.0, Page 48 of 77.

Lightning protection is not considered for the water system area. Only Over Head tank
shall be provided with lightning protection with air terminals & down conductors..

14.0 220V DC BATTERY & BATTERY CHARGERS:

D.C. system will provide reliable DC source for control, indication, protection and
annunciation of, 6.6 kV switchboards & PMCC’s located in various ECR. Separate DC
source shall be envisaged by the purchaser for HT switchgear protection & tripping.
DCDB’s shall be considered in all ECR’s for distributing DC supply to various loads.

DCDB will be fabricated out of 2mm Thick CRCA Sheet steel, floor mounted, free
standing type with IP-42 Protection with required no. of outgoings.

15.0 UPS SYSTEM WITH CABINET:

230 VAC, 50 Hz UPS of required capacity will be provided with lead Acid Planet batteries
for 30 minutes back up arrangement. The UPS system will be parallel redundant, without
SCVS. The UPS system will be ‘ON LINE’ which will ensure that there is no break in the
power supply to the PLC based control system. In the event of loss of power supply, it
will be able to maintain the status record of various equipment of plant control system on
uninterruptible power supply having capacity to feed the load of PLC system for duration
of ½ hour during which the power supply is restored.

16.0 LIGHTING SYSTEM:

• LIGHTING DISTRIBUTION PHILOSOPHY:

NORMAL:
We have considered a MLDB with two incomers, powered through two nos. of 415/230
KV Lighting Transformers located in ECR-1 to cater lighting loads within battery limits.
Normal supply to MLDB shall be fed from the Lighting trafo fed from PMCC & incase of
failure MLDB shall be fed by the emergency supply availed from the purchaser’s
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emergency bus(at a distance of 500m from the water system area) through Lighting
transformer.

• NORMAL LIGHTING:
The design will be such as to provide minimum lighting levels as mentioned in tender
document for different areas. Standard Lamp Lumen method will be adopted for interior
& exterior lighting in order to determine the number of lighting fixtures for obtaining the
desired average level of illumination. Lighting software is used for calculation.

• EMERGENCY LIGHTING:
The emergency lights will be complete with fitting. The unit will be complete with battery
of suitable AH capacity to run for three hours continuously and fitted with automatic
battery charging/inverter device. The emergency lights shall be suitable type to meet the
site conditions.

• AREA LIGHTING:

Area lighting for the entire water system area is

a) Periphery lighting for ECR’s are considered with lighting fixtures mounted on
proposed building wall/ Columns.
b) We have considered periphery lighting for all pump houses, cooling towers,
stairway lighting for the over head tank.
c) Street lighting within the battery limits is considered.

17.0 WELDING SOCKETS:

415V, 3 Ph 5 pins industrial type interlocked power plug & socket with switch will be
provided. Welding receptacles will be connected with each other in loop-in loop-out
connection (to the extent of 5 nos. max.) located at strategic locations.

18.0 COMMUNICATION SYSTEM:

Not envisaged

19.0 SAFETY ITEMS:

We have considered following as Safety items in our scope of supply:

a) Rubber mats in front of HT and LT Panels

b) CO2 Fire Extinguisher in each Substation and process areas.
c) Fire Bucket filled with dry sand in each Substation and process areas.
d) Shock Treatment Chart.
e) Danger Board – As required
f) Rubber hand Gloves
g) First Aid Box.

20.0 TESTING EQUIPMENTS:

Electrical testing equipments considered as per Tender document.