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3 - 12 Specification For Monitoring Control and Protection of SHP Stations
3 - 12 Specification For Monitoring Control and Protection of SHP Stations
3 - 12 Specification For Monitoring Control and Protection of SHP Stations
GUIDELINES FOR
MONITORING CONTROL AND PROTECTION OF SHP
STATIONS
LEAD ORGANISATION:
ALTERNATE HYDRO ENERGY CENTRE
INDIAN INSTITUTE OF TECHNOLOGY, ROORKEE
1
CONTENTS
1.0 INTRODUCTION 1
1.1 OBJECTIVE 1
1.2 GENERAL 1
1.3 REFERENCES AND CODES 2
SECTION – I GENERAL TECHNICAL CONSIDERATIONS FOR 3
PREPARING SPECIFICATIONS
1.0 MONITORING OF SHP 3
1.1 SYSTEMS FOR MONITORING 3
1.2 REQUIREMENTS OF MONITORING SYSTEM 5
1.3 LEVELS OF MONITORING 6
1.4 CONTROL OF UNITS OF SMALL HYDROPOWER 6
PLANT
1.5 PROTECTION OF SHP GENERATING UNITS 17
1.6 GENERATOR CONNECTED IN PARALLEL TO 31
GRID
1.7 GENERATORS CONNECTED IN PARALLEL ON 31
A COMMON BUS
1.8 PROTECTION GROUPS 32
1.9 PROTECTION OF POWER TRANSFORMERS 33
1.10 FIRE PROTECTION SYSTEM 33
SECTION – II TECHNICAL SPECIFICATIONS FOR CONTROL, 36
PROTECTION & METERING ( MICRO HYDEL UPTO
100 KW)
2.1 SCOPE 36
2.2 APPLICABLE STANDARDS 36
2.3 DESIGN CRITERIA 36
2.4 PROTECTION AND METERING 37
2.5 TESTS 39
SECTION - III TECHNICAL SPECIFICATIONS 40
CONTROL, PROTECTION AND METERING
(FOR SHP ABOVE 100KW TO 1000KW)
3.1 SCOPE 40
3.2 CONTROL EQUIPMENT 40
3.3 SYNCHRONIZATION 40
3.4 ALARM AND ANNUNCIATION 41
3.5 METERING 41
ITEMS PAGE NO.
1.0 INTRODUCTION
1.1 OBJECTIVES
1.2 GENERAL
The generating units of a small hydropower plant may have its shaft vertical,
horizontal or inclined with the type of turbine selected to suit the site’s physical conditions.
Small hydro turbines may be selected as per site conditions, head and discharge available.
Small hydro-generator are of the alternating current type and may be either synchronous or
induction type. Usually small hydro units up to 5 MW are expected to require minimum
amount of field assembly and installation work. While machine having capacity from 5 MW
to 25 MW may have slow speed, large diameter and with split generator stator that require
final winding assembly in the field.
Mini & micro power stations are generally provided system suiting to these being run
unattended or with few attendants while bigger machines up to 5 MW capacity have more
elaborate arrangement of control monitoring and protection. Machine having capacity up to
25 MW and provision of parallel operation with other systems will have more comprehensive
control, monitoring & protection system.
This guide will serve as a reference document along with available national &
international codes standards, guide & books. For the purpose of convenience Section-I of
this guide has been subdivided as follows
• Monitoring
• Control
• Protection
1
1.3 REFERENCES AND CODES
IEEE Std 1020 - IEEE guide for control of small hydro electric power
plants
IEEE Std 1010 - IEEE guide for control of hydro electric power plants
IEEE Std 60545:1976 - Guide for commissioning operation and maintenance of
Hydraulic Turbines
IEC 61116:1992 - Electro mechanical guide for small hydroelectric
installations
IEEE std 1046 - IEEE application guide for distributed digital control
and monitoring for power plants
IEEE std. 1249 - IEEE guide for computer–based control for power
plant automation
IEEE std. C 37101 - IEEE guide for generator ground protection
IEEE std. C 5012 - IEEE standard for salient pole 50 Hz and 60 Hz
synchronous generator and generator / motors for
hydraulic turbine application rated 5 MVA and above
IEEE std 4214 - IEEE guide for preparation of excitation system
specification
ANSI/ IEEE std 242:1996 - IEEE recommended practice for protection and
coordination of industrial and commercial power
systems
ANSI/ IEEE std C 372-1987 - IEEE standard electrical power systems device function
numbers
ANSI/ IEEE std C 37.95 : 1974 - (R1980) IEEE guide for protective relaying of utility
ANSI/ IEEE std C 37.102:1987 - IEEE guide for generator protection
MASON, CR - Art & science of protective relaying 1956
AHEC/PFC/FINAL REPORT 2002
2
SECTION – I
Monitoring of operating parameters of the generating unit and their auxiliaries is very
important for the life and optimum utilization of available discharge for generation. The
efficient running of unit require regular monitoring. The primary input data and generation
output data are monitored periodically. The details of data required for monitoring
performance of a generating station is as following.
3
1.1.3 Electro-mechanical Operating Parameters
4
1.2 REQUIREMENTS OF MONITORING SYSTEM
1.2.1 Instrument Transformers & Sensors
Current and voltage transformers of rated voltage and appropriate ratio, class of
accuracy is selected as per the requirement of the system.
Sensors
The sensors for temperatures, pressures, levels speed are installed at the proper
location.
Analogue type of meters, separate for each parameter with selector switches etc were
being used earlier installed on control panels. Now a days digital meters are being used for
such parameters. Digital multifunction meters are now in use, only one meter provides
several parameters an selection, as well as provides routine display. Few analogue meters like
power meters (kW), voltmeters, ameters with selector switches are provided for operational
facilities.
Indicating lamps of suitable colours as per code and practices should be provided on
control panels for indication status of machine and various auxiliaries, pumps, electrical
equipment like breaker, isolator, AC/DC supply system etc. Lists of such indication and
relays are enclosed as Annexure-I&II.
The protection system relays and auxiliary relays also provided signals to alarm and
annunciation system. A set of annunciation windows are provided on control panels for each
fault clearing relay with accept test and reset facility through push buttons. Alarm and trip
annunciation indicate the fault and advise operating personnel of the changed operating
conditions.
Recently control of machine and auxiliaries is done through PLC based control
system automatically in addition to manual systems with local and remote facilities. The data
5
are acquired through sensors and operation of machine is achieved on present values through
PC Monitors etc.
The PLC will acquire data from generating units, transformers, switchgears auxiliaries
through transducers / sensors/ CTs/ VTs wherever signals are week, noise level is high
shielded cables should be used for carrying data / signals. For sending output signal PLC will
use relays for operating breakers etc and comparators for giving ON/OFF signal.
• Alarm
• Tripping
In case of manned power plant ‘alarm’ comes first so as to make the operator alert if
no corrective action is possible then tripping command with indication / hooter and
annunciation will be there.
But in case of unattended power plant direct tripping command will be initiated and
shut off the facility to avert possibility of any damage to the plant.
For small hydro installation simplicity of control system is advised, however, the
sophistication of control should be based on the complexity and size of the installation,
without compromising unit dependability and personal safety. Simplicity of control is
desirable to keep total cost of installed equipment as well as cost of maintenance, repair and
tests at economical level. Moreover a simpler system is more reliable as compared to
complex one.
Transducers or signal transmitters are provided either at the control panel or at the
equipment.
6
1.4.2.2 Induction Generator
For conventional method of connecting induction generator to the grid, the generator
is started and accelerated to synchronous speed. In fact, the rotor speed of generator shall be
(1% slip) more than grid frequency. This is done to avoid monitoring action of generator.
Once the generator frequency matches with grid frequency the generator breaker is closed.
Now the generator is connected with the grid and running at no load.
At this stage grid power factor is to be checked and capacitor banks are switched on
as per requirement to provide necessary reactive power and further loading of unit is done
upto full load.
All these functions can be performed manually as well as automatically through PLC,
computer, microprocessor based control system.
For smaller machines which are unattended provision of integrated digital control &
SCADA system is preferred.
The control logic system for small hydro start stop sequencing can be provided by
hardwired relay logic, programmable controllers microprocessor based systems or a
combination of these.
7
• Event recording
• Synchronizing and connecting the unit to grid
• Control of real & reactive power
The unit control system must be able to provide startup and shutdown sequencing
under both normal and abnormal conditions. Under normal conditions, the unit is started and
stopped in manner that produces minimal disturbance to the system. For instance of normal
stop sequence entails a controlled unloading of machine and when completely unloaded, the
generator breakers or contactor is tripped. On the other hand protective relay operation will
initiate immediate tripping of the unit and complete shutdown as quickly as possible.
For certain mechanical troubles the unit is unloaded as quickly as possible before
tripping, in order that the potential damage from over speed is avoided.
The unit control system, in order to control and monitor various control sequences,
must interface with number of plant systems, including the following:
Typical startup and shutdown sequence are shown in fig. 1-3 for a Francis turbine
unit, which, for the sake of illustration, are shown as including synchronous generator and
governing system.
8
Fig. 1: Typical Start Sequence of Synchronous Generator
9
Fig. 2: Typical Normal Shut Down and Mechanical Trouble Stop Sequence of
Synchronous Generator
10
Fig. 3: Typical Electrical Trouble Stop Sequence for Synchronous Generator
There are many functions to be controlled in a small hydropower system. For example
turbine governor controls the speed of turbine, plant automation covers operations as auto
start, auto synchronization, remote control startup or water level control and data acquisition
and retrieval covers such operation as relaying plant operating status, instantaneous system
efficiency or monthly plant factor.
This is the speed / load control of turbine in which governor adjusts the flow of water
through turbine to balance the input power with load.
11
In case small plants in the category of micro hydel (100 kW unit size), load
controllers are used, where excess load is diverted to dummy load to maintain constant speed.
With an isolated system, the governor controls the frequency of the system.
In interconnected system, the governor may be used to regulate unit load and may
contribute to the system frequency control. Figure 4 shows the different types of control
applicable to turbines.
Plant control deals with the operation of plant. It includes sequential operation like
startup, excitation control, synchronization, loading unit under specified conditions, normal
shutdown, emergency shutdown etc. The mode of control may be manual or automatic and
12
may be controlled locally or from remote location. Plant control usually include monitoring
and display of plant conditions. Different plant controls are given in fig 6.
For hydroelectric power plants the components of the control system can be shown in
vertical array as shown in fig 7.
13
• At lowest level (process level) process which includes, generator exciter, turbines,
switchgears, motors, pumps, valve etc is being controlled.
• At middle level there is control interface equipment which sends signals to the
apparatus from controlling equipment and for apparatus to transmit data back to
controlling equipment. Auxiliary contacts of motor starter, relays instrument
transformer signal conditioner, transducers or other interface devices.
• At top level there is controlling system which initiates control signals and receives the
data transmitted from apparatus control interface equipment. At this level itself
human-machine interface is included.
The control system can further be defined by identifying following three categories of
control:
• Location:
a. Local - control is local at the controlled equipment within the sight of
the equipment
b. Centralised - control is at other place, but within the plant
c. Off site - control is at remote place which may be quite far from the
plant (Remote)
• Control mode:
a. Manual - Each operation requires a separate and distinct initiation.
However it may be applicable for any of the three locations
b. Automatic - With single initiation several operations in appropriate
(PLC/ computer/ sequence are done. This system can also be applicable to any
Microprocessor of the above three locations
Controlled)
• Operation (supervision)
a. Attended - Operators are all the time available at the plant to perform
control action either locally or centralized control
b. Unattended - Operating staff is not available at the plant. There may be
occasional visits by operation & maintenance people to ensure
security of plant.
Following four types of signals are provided between control board and particular
equipment
• Analog inputs for variable signals from CTs, VTs, RTDs, pressure, flow, level,
vibration etc.
• Digital inputs provides digitalized values of variable quantities from the equipment
• Digital outputs – command signals from control boards to equipment
• Analog outputs – transmit variable signals from control to equipment e.g. governor,
voltage regulator etc.
14
1.4.5.4 Communication Links
Following methods are available for implementing control from a remote location:
• Hardwired communication circuits (telephone type line, optical cables etc.)
• Leased telephone lines
• Power line carries communication system
• Point to point radio
• Microwave radio
• Satellite
Power line carrier including insulated ground wire system can be used for
communications purposes. This method couples a high frequency signal on the power line or
insulated ground wire and is decoupled at an offsite point.
Space radio can be used, utilizing power frequencies and micro wave radio can be
practical if hydro plant owner has an existing microwave system.
The communication link between control board and equipment should be reliable.
15
• Fire protection
• AC Power supply
• DC Power supply
• Service water
• Service air
• Water level monitoring
• Turbine flow monitoring
Control of a hydro plant generating unit was typically performed from central control
board located in centralize control room. The control board contained.
a. IEEE guide for control of small hydro electric plants, “ANSI/IEEE standard 1011,
1990’.
b. IEEE guide for control of hydroelectric power plants “ANSI/IEEE standard 1010,
1991.
Architecture and communication are two potential problem area for computerized
control system.
In 1990, the International Organisation for standardistion developed a model for open
architecture and protocol, know as SI (open system interconnection) – ISO mode.
Programmable Logic Controllers (PLC) type plant controllers combine with PC based
SCADA systems are used as Governors and for plant control & data acquisition. This makes
the system less costly and reliable and therefore, can be used for small hydropower
generation control.
16
Personal computer based dedicated digital control system can perform all functions of
governing, unit control, protection and also data acquisition & storage and are more
economical and reliable. These dedicated systems with back up manual control facility of
turbine control in emergency by dedicated semi automatic digital controllers can be a low
cost option for small hydropower station.
The abnormal operating conditions that may arise should be detected automatically
and corrective action taken in a timely fashion to minimize the impact. Relays (utilizing
electrical quantities), temperature sensors, pressure or liquid level sensors, and mechanical
contacts operated by centrifugal force, etc., may be utilized in the detection of abnormal
conditions. These devices in turn operate other electrical and mechanical devices to isolate
the equipment from the system.
Where programmable controllers are provided for unit control, they can also perform
some of the desired protective functions.
Loss of individual items of auxiliary equipment may or may not be critical to the
overall operation of the small plant, depending upon the extent of redundancy provided in the
auxiliary systems. Many auxiliary equipment problems may necessitate loss of generation
until the abnormal conditions has been determined and corrected by operating or maintenance
staff.
The type and extent of the protection provided will depend upon many considerations,
some of which are: (1) the capacity, number, and type of units in the plant; (2) the type of
power system; (3) interconnecting utility requirements; (4) the owner’s dependence on the
plant for power; (5) manufacturer’s recommendations; (6) equipment capabilities; and (7)
control location and extent of monitoring. Overall, though, the design of the protective
systems and equipment is intended to detect abnormal conditions quickly and isolate the
affected equipment as rapidly as possible, so as to minimize the extent of damage and yet
retain the maximum amount of equipment in service.
Small hydroelectric power plants generally contain less complex systems than large
stations, and therefore tend to require less protective equipment. On the other hand, the very
small stations should be typically unattended and under automatic control, and frequently
have little control and data monitoring at an off-site location. This greater isolation tends to
increase the protection demands of the smaller plants.
17
An inherent part of the power plant protection is the design of the automatic controls
to recognize and act on abnormal conditions or control failures during startup. Close
coordination of the unit controls and other protection is essential.
18
1.5.2.2.3 Generator Switchgear and Bus
Utility line faults and other abnormal utility system conditions should be detected and
the plant be disconnected from the utility system. Abnormal utility system conditions include
the following situations:
There are numerous ways of providing the functional protective requirements of the
plant. While standard devices are generally available that can provide the protective functions
required, however each station should have specific design suitable for protection
requirements of the power plant equipment as well as the interconnection.
The following section describes components of a typical protection system that might
be applied to a small hydro plant. Discussions and diagrams are included to illustrate location
and arrangement of relays.
19
Resistance temperature devices operating relays can also be used to detect generator stator
overheating.
Pressure and level switches installed in the turbine air and oil systems, to alarm, block
startup, or trip, as necessary.
Direct-connected or electrically driven speed switches for alarm, control, and tripping.
1.5.3.1.4 Vibration
Vibration detectors monitoring turbine or generator shaft sections, with alarm and trip
contacts.
1.5.3.1.6 Fire
Sensors located in areas where fire can occur and connected to a central fire monitor
for alarm. Small generators usually do not have fire sensors or suppression equipment, since
they are not usually enclosed.
Sensing devices are integral to the protected systems, such as automatic greasing
system, wicket gate shear pins, transformer, cooling and station sump drainage system.
The protective relays stand watch and in the event of failures short circuits or
abnormal operating conditions help de-energize the unhealthy section of power system and
restrain interference with rest of it and limit damage to equipment and ensure safety of
personals. The protective relays should possess following features:
• Reliability – To ensure correct action even after long period of inactivity and also to
offer repeated operation under sever condition.
• Selectivity – To ensure that only the unhealthy part of system is disconnected
• Sensitivity – Detection of short circuit or abnormal operating condition.
• Speed – To prevent and minimize damage and risk to instability of rotating plant.
20
• Stability – The ability to operate only under those conditions that calls for its
operation and to remain either passive or biased against operation under all other
conditions.
There are several types of relays being used for protection systems
- Electromagnetic relays
- Static relays
- Numerical relays
The old conventional electromagnetic relays are now being replaced with static relays
with are much faster and maintenance free. These relays are more reliable and sensitive.
These microprocessor based relays have different protections elements and therefore a
separate relay for each protection is not required. A list of protections generally available in
these microprocessor based relays is enclosed as Annexure-II. The numerical relays are
having LED indications for power ON, trip status for different protection elements, time /
current characteristics selected and contacts for trip signals. However, some individual
electromagnetic conventional / static relays for few important protections are recommended
to be provided as standby relays.
It has been a practice to use electro-mechanical / solid state relays for all above
protections. The present trend is to use numerical relays which offer many advantages as
follows, over the earlier technology.
The user’s worry that numerical relays are very expensive is now removed due to
continuous production, improvement in techniques which have made numerical relays above
all, with features listed as above. Numerical relays are more user friendly and are gaining
popularity everywhere.
21
• Annexure-I - List of SHP Generator panel indications & relays
• Annexure-II - List of protection elements in Microprocessor based relays
The designer must balance the expense of applying a particular relay against the
consequences of losing a generator. The total loss of generator may not be catastrophic if it
represents a small percentage of the investment in an installation. However, the impact on
service reliability and upset to loads supplied must be considered. Damage to equipment and
loss of product in continuous processes can be dominating concern rather than generating
unit. Accordingly there is no standard solution based on MW-rating. However, it is rather
expected that a 500 kW, 415 V hydro machine will have less protection as compared to 25
MW base load hydro electric machine.
Immediate tripping is required for a, c, i, and j. While for item b, d, e, f, g and h only
alarm and annunciation is required to alert the operator and take corrective action, but in case
corrective action is not taken, tripping will eventually follow. Applying brakes at a particular
speed (30% of full speed) is done to reduce time to achieve stand still position of machine.
It is recommended two independent devices must be provided for over speed shut
down on larger machines. One for alarm mostly at 110% and other for tripping at 140%,
specially for machines which are not designed for continuous run away speed.
22
a. Stator temperature
b. Over current (stator and rotor)
c. Earth fault with current limits (stators & rotor)
d. Maximum and minimum voltage
e. Power reversal
f. Over/ under frequency
g. Oil level in bearing sumps
h. Pad & oil temperature of bearings
i. Cooling air temperature
Immediate tripping is required for items b, c, d, e & f while for items a, g, h and i first
alarm and annunciation is required for taking correcting measure and then tripping if
correcting measure is not taken within permissible time.
In view of the economy and plant requirements generator protection for small
hydropower stations is categorized a follows:
1.5.3.5.3 Minimum protection for a small machine with low resistance grounding are
proposed as follows:
Options
27 Under voltage relay
32 Reverse power relay
40 Loss of excitation relay
46 Negative phase sequence relay
49R Stator over temperature relay
50GS Ground sensor over current relay
51VC Voltage controlled over current relay
23
64B Generator ground over voltage relay (in place of 51GN
where generator is ungrounded)
81 L/H Under / over frequency relay
86G Lockout auxiliary relay
87G Self-balancing current differential relay
12 Over speed relay
7.3.5.4 Minimum protection for a large machine with high resistance grounding
Basic Package
21 Distance
24 Over excitation
27 Under voltage
27TN Third harmonic under voltage
32 Reverse power
40 Loss-of-excitation
46 Current unbalance (negative sequence)
51GN Ground over current (backup to 64G)
51V Voltage-restrained over current
59 Over voltage
60V VT fuse failure detection
64G Stator ground
64F Ground (field)-I
81L/H Under/ Over frequency
24
87G Percentage differential
50/27 Accidental energisation protection
95 Trip circuit monitoring
86G Lockout auxiliary relay
12 Over speed relay
Options
21G System backup distance relay (in place of 51V)
49R Stator over temperature relay (RTD)
60V2 Voltage ground relay-II
78 Out-off step relay
With increasing complications in the power system, utility regulations, stress on cost
reduction and trend towards automation, generator protection has become a high focus area.
State of the art, microcontroller based protection schemes from various manufactures offer a
range of solutions to customers to address the basic protection and control requirements
depending upon the size and plant requirements.
25
1.5.3.5.6 Generators-size less than 300 kVA
Normally these generators are controlled by MCCBs, which offer O/C and short
circuit protections. It is advisable to have following protections in addition to MCCB.
E/F protection (51 N): This will protect the generator from hazardous leakages and
ensure operator safety. Many organizations have already made E/F protection as mandatory.
Since these units are very remotely located and less manpower is available for operation and
maintenance, the system needs more automation and fool proof protections. Therefore,
recently several optional protections are also being used for micro/mini units including over
speed (12) protections.
There are two major differences when compared with the small machines considered
above.
• IDMT over current + E/F relay will be required in addition to normal MCCB or ACB
releases – since the generator may need shorter trip time for faults in the range 100%
to 400% level.
26
• By virtue or larger power level, any faults inside the stator or fault between the neutral
of the machine and the breaker terminals can reach very high intensity.
Such internal faults must be cleared instantaneously. Normal IDMT over current E/F
relays are not adequate to monitor this internal fault status-otherwise the machine can
circulate very high fault currents resulting in severe damage.
A high impedance differential relay scheme, is the best suited for this purpose. If the
neutral is formed inside the machine, the differential relay scheme will not be
possible. In this case a restricted E/F scheme is the solution. Care should be taken to
provide adequate number of CTs.
• Machine of this size are likely to have external controls for frequency and excitation –
so that they can be run in parallel with other power sources (other generators on the
same bus or the local grid). This necessitates voltage and frequency related
protections as well.
27
When reverse power happens, the generator along with prime mover will
undergo violent mechanical shock – hence reverse power protection is
necessary.
This protection is very impartment since the machines of this size have to be
protected for severe damages that may occur due to internal faults.
Considering the large power levels, it is necessary to have a percentage biased,
low impedance differential relay. These relays generally have following
advantages.
28
• Rotor side protections
Generators of this size will need rotor side protections listed below:
29
FIELD
EXCITER
FIELD
BREAKER
BRUSH
C1 C2
AC
64F
R
R
For large generators above 10 MVA size, the philosophy of main protection and back
up protection has to be followed. In addition to the protections listed above following extra
protections are to be considered.
30
o 100% earth fault protection
This will help in sensing earth faults close to neutral. Third harmonic content
in the zero sequence voltage will be detected by the replay for the above
protection.
o Under impedance
This will be required as a backup protection for the whole system including
the generator transformer and the associated transmission line. If the distance
relay fails to pick for some reason, this under impedance function will pick up
and save the generator.
o Over excitation
This will protection the generator from over fluxing conditions
• Grid disturbances
9 Under-voltage / Over-voltages
9 Under-frequency/Over-frequency
9 Rapid fall/ rise of frequency (df / dt),
9 Grid failure or other faults
Generator may not be able to operate below a certain power-factor. At low power-
factor, reverse reactive power flow may damage the generator.
Whenever more than one generator is operating in parallel, it is necessary to see that
the plant load is equally shared by the generators in parallel. If there is unequal sharing, there
would be sever hunting amongst the generators and eventually this will lead to cascaded
tripping of all generators, causing a total black out. Specific load sharing relays are available
in the market which provide the most effective, online load sharing system for generators in
parallel.
31
1.8 PROTECTION GROUPS
The protective relays and devices of generator and turbine are proposed to be grouped
into following four categories for an orderly shutdown of the affected unit with the remaining
generating units and auxiliaries continue to operate.
Immediate action shut down will be initiated by any of the following conditions
32
¾ Trip generator breaker
¾ Trip field breaker
¾ Initiates controlled action shut down stop turbine by governor action
¾ Trip annunciation in control room
I. Fuses
II. Sudden pressure protection (Buchholtz Relay)
III. Oil temperature high
IV. Winding temperature high
V. Over current/ earth fault
VI. Over frequency
VII. Differential protection
VIII. Restricted earth fault protection
IX. Over flux protection (in large grid)
X. Over all differential protection (Gen. Trans. Both in large machines)
XI. Fire protection system
9 Fire extinguishers
9 Mulsyfire protection
9 Fire buckets-sand filled
For large generators, fire protections system will use CO2 as the quenching medium
which will operate automatically. Hot spot/ smoke detectors are provided all around the
periphery of generator winding. Bank of CO2 cylinders with control panel etc. are provided
common for all the generators. The individual pipes let the CO2 enter in the faulty generator
and quench the fire. Generator is isolator from the bus bar and machine stopped. The system
is more effective in closed cycle cooling systems of generators.
33
ANNEXURE-I
34
ANNEXURE-II
Symbol Description
21 Under Impedance
24 Over Fluxing
26 Field Winding Temp
27 Under Voltage
27NT 100% Stator E/F
32 Reverse Power
38 Bearing Temp
40 Loss of Field
46 Negative Phase Sequence
49 Stator Winding Temp
50BF Breaker Failure
50P Instantaneous Phase Over Current
50N Instantaneous Neutral Over Current
50/27 Unintentional Energisation at Stand Still
51P Time Delayed Phase Over Current
51N Time Delayed Neutral Over Current
51N Voltage Controlled Over Current
59 Over Voltage
59N Residual Over Voltage
64R Restricted E/F
78 Pole Slipping Protection
81 Over/ Under Frequency
87G Generator Differential
CTS Current Transformer Supervision
VTS Voltage Transformer Supervision
35
SECTION II
TECHNICAL SPECIFICATIONS FOR
CONTROL, PROTECTION & METERING
( MICRO HYDEL UPTO 100 KW)
2.1. Scope
The scope includes design, manufacture, shop testing, delivery erection, testing,
commissioning and training of purchaser personnel for PLC/ computer based
automation system with manual control facility for the operation of power plant from
power house. The scope also includes protection, annunciation, synchronization,
metering and other components for making the system complete and to ensure a
trouble free and safe operation on turnkey basis.
For Turbine –Generator unit one Panel shall be provided. The Panel shall incorporate
components for generator protection, indication & alarm devises and meters for
metering various parameters. The requisite functions for ELC can also be
incorporated in this control panel. The Air Circuit Breaker for generator may also be
incorporated in this panel.
2.2.Applicable Standards
(i ) ANSI / IEEE 1010-1987- IEEE Guide for Control of Hydroelectric Power
Plants
(ii) IS/IEC/ISO Standards mentioned in the text
36
2.4. PROTECTION AND METERING
Electrical control, protection and metering system will be based on state of art
technologies. PLC based automation systems for the operation of power plant will be
adopted. The complete metering and protection scheme is shown in Drawing (to be
enclosed by Purchaser0. This protection scheme is tentative and is for the general
guidance of the tenderer and does not restrict the tender to give offer for better
scheme.
A. Generator Protections
• Voltage restraint over current (51V)
• Stator earth fault relay (64 S)
• Over speed electrical/Mech. (12)
• Over Voltage Protection (59)
• Under voltage protection (27)
B. Metering System
The power generated shall be metered at generator terminal through metering CT and PT.
Following metering instruments shall be provided on relevant panels.
1. kW Meter
2. kWH Meter
3. kV Meter
4. Ampere Meter
5. PF Meter
6. Frequency/Speed Meter
7. Temperature Meter for (To be provided only on generator panel)
a. Stator
b. Turbine bearing
c. Generator bearing
C. Annunciation System
37
A multipoint microprocessor based annunciator with suitable number of ways for projecting
visual signals and audible alarm in case of fault shall be provided on the control panels
suitably. The annunciator shall be back connected flush mounting, dust tight and tropicalised
and shall be complete with audible warning device, and apparatus as required to complete the
annunciator system. It shall be suitable for operation on 24 V.D.C. supply.
D. Indication System
The control panel shall incorporate the visual indication such as Breaker on, Breaker off,
Breaker Trip, B/F Valve open, B/F Valve close, D.C on, D.C. off etc. The indication lamps
should be 24 V D.C. operated, interchangeable and replaceable from the front of the panel.
E. Potential Transformers
The potential transformers to be used for metering & protection circuits shall be epoxy cast
resin, class ‘F’ insulation dry type units. The potential transformers shall be protected on
primary and secondary side by current limiting fuses. The potential transformers shall
confirm to the latest Indian standard. IS-3156 (1992)
F. Current Transformers
The current transformers should be suitable for metering & protection circuits shall be epoxy
cast resin, class ‘F’ insulation dry type units. The current transformer will be wound primary
or bar primary as the case may be. The current transformers shall confirm to the latest Indian
standard. IS–2705 (1992)
G. Surge Arrestors
The L.T surge arrestors shall be provided in the control panel. The L.T. surge arrestors shall
confirm to the latest Indian standard.
Following components shall be provided on UCB (the list is tentative). Bidder shall have to
provide additional component, if required for proper operation of unit.
i 415 V --- A Circuit Breaker for generator (MCCB with shunt trip may 1 No.
be used.)
ii Voltmeter 0 – 500V & Voltmeter S/S 1 No.
iii Relays
Voltage restraint over current (51V) 1 No. Each
Stator earth fault relay (64 S)
Over speed electrical/Mech. (12)
Over Voltage Protection (59)
Under voltage protection (27)
38
Ammeter (0-50 A) & Ammeter Selector Switch 1 No.
Kilo-Wattmeter ( 0-30 kW) 1 No.
Energy Meter (kWH meter), 1 No.
Indication Lamps Generator Breaker OFF/ON/TRIP 3 No.
Indication Lamps D.C.ON / OFF ( if provided) 2 Nos.
Indication Lamps for B/F Valve open/close 2 Nos.
Potential Transformer for protection, metering and AVR 3 Nos.
Current Transformers for Protection & Metering 7 Nos.
Frequency meter 45-50-45 HZ 1 No.
Auto manual change over switch
Power Factor meter 1 No.
Emergency Push Button 1 No.
Annunciation Window for faults & Buzzer/alarm 1 No.
Electronic load controller. 1No.
2.5 Tests
Routine and type test certificate of CTs, PTs, LAs, Relays, Metering instruments as per
IS shall be submitted for approval of the purchaser.
39
SECTION - III
TECHNICAL SPECIFICATIONS
CONTROL, PROTECTION AND METERING
(FOR SHP ABOVE 100KW TO 1000KW)
3.1 SCOPE
The scope includes design, manufacture, shop testing, delivery, erection, testing,
commissioning and training of purchasers’ personnel for computer based automation systems
for the operation of power plant from powerhouse. The scope also includes protection,
annunciation and synchronization, metering and other components for making the system
complete and to ensure a trouble free and safe operation on turn key basis. The power
station will comprise the following major components:
Following drawings show tentatively the main scheme (to be supplied by the
Purchaser) :
Single Line Diagram
Metering and Protection System
The control equipment shall comprise of the following:
Generating Units Control
3.3 SYNCHRONIZATION
40
3.4 ALARM AND ANNUNCIATION
Window annunciation shall be provided on the unit control board and the same shall
be complete with audio and video alarm system. The system shall be designed to have low
DC power consumption.
3.5 METERING
i. All panel meters shall be digital with at least 2 cm digit size, at least three-and-
a-half digit LED display and accuracy class of 1.0 or better.
ii. Energy metering shall be provided on the 11 kV feeders and generators with
electronic energy meter of an accuracy class of 1.0 or better.
iii. Digital Multi-functions Meter alongwith analogue type three ammeter and
voltmeter with selector switch shall be required for each generator circuit.
i. Each generator shall be provided with static digital numeric type of relays for
the protection system.
ii. Digital relays shall be provided for the protection of 11 kV feeders and ---
kVA 415 V/11 kV Generator Transformers.
3.8 COMPLETENESS
The contractor shall ensure supply of the spares for all the offered
equipment/components (at least one module of every type) for use for 5 years and any special
tools & plants, spanners etc. required for site assembly, erection, testing, commissioning,
operation & maintenance of the equipment.
41
3.10 DOCUMENTATION
The contractor shall provide all necessary drawings, diagrams and documentation of
equipment and software. The documentation in original shall also include six hard copies and
a. Hardware:
The necessary user, reference and service manuals along with the technical
specifications for all the hardware systems/sub-systems shall be supplied by the contractor.
b. Software:
User and reference manuals related to complete software shall be supplied by the
contractor. The extent of the documentation to be furnished shall be to the satisfaction of the
Purchaser.
3.11 STANDARDS
Standard and codes to which the equipment must conform are given below.
42
IEC 68 Environmental testing
43
Computer-based automation systems shall permit operation of the power plant from
local (Machine hall). Local manual control shall also be provided in the equipment as a
backup.
For each generating unit, there will be an independent PLC based unit controller.
Back up manual control shall also be provided for each unit.
Each PLC/computer based controller system will have a dual power unit. The main
power unit will work on 24 V d.c. and the hot-standby power unit will take power from a
UPS at 240 V a.c.
3.13.1 Unit Control
44
The equipment controlled and monitored during the start/stop sequence will generally
include the following:
a. Main inlet valve;
b. Governor hydraulic oil system; (If provided)
c. Guide Vane limit positions;
d. Guide Vane positions;
e. Cooling water system; (If provided)
f. Excitation equipment;
g. Unit speed;
h. Protective relaying status;
i. Unit alarms;
j. Unit breaker status;
3.13.1.3 Diagnostic Information
Standard control scheme of turbine suitable for mini hydro plants will be adopted.
Back up control including black start should be provided as per IEEE-1249. The black
start shall be accomplished by providing manual pumping of the oil pressure system.
The auxiliary power at 415 V shall be taken from the 415 V generator bus and
15 KW 3 φ diesel generating set as shown in drawing No. -----.
3.13.1.7 D.C. Supply
The D.C. power at 24 V for all controls, circuit breakers, relays and meters etc. shall
be obtained from one set of station battery. The battery bank shall have 200 AH capacity
tentatively and shall be float and boost charged from rectifier units. Calculations for the
capacity of batteries shall be submitted by the bidder for the consideration of the purchaser.
All the protective relays will be housed on the unit control board.
45
The final drawings for the protection & metering shall be submitted by the contractor
and will be subject to the approval by the Purchaser.
3.14.2 CTs/VTs
All current and voltage transformers required for protection system of the unit shall
have adequate VA burdens, knee point voltage, saturation factor and characteristics suitable
for the application, and shall be subject to approval of the Owner.
ii. Wide setting ranges with fine setting steps for each protection shall be
available.
iii. The offered system shall have proven record of satisfactory performance for
at least 2 years and in two power stations. Necessary certificates to this effect
shall be a part of the offer.
iv. The protective relays shall preferably be housed in draw out type of cases with
tropical finish.
v. Common tripping relays (each for similar functions) will be provided with
lock-out facilities. All these relays shall have potential free contacts for trip and
alarm purposes and externally hand reset type of flag indicators.
vi. The relays shall be static/digital/numeric type.
3.14.4.1 Following generator protection relays shall be provided for each generator:
46
3.14.5 Generator Protection(mechanical)
3.14.5.1 Following mechanical protections shall be provided for each unit.
Over current/earth fault protection for this transformer shall be provided on generator
bus side. It is presumed that diesel generator protection shall be provided on control panel of
the set.
The power generated shall be metered at generator terminal through metering CTs and
PT. The power transferred to 11 kV feeder shall also be metered through CTs and PT.
47
3.15.2 11 kV Feeder Panels
1. kW meter
2. kWh meter
3. Voltmeter with selector switch
4. Ampere meters with selector switch
5. Power factor meter
6. Frequency meter
1. kWh meter
2. Voltmeter with selector switch
3. Ampere meters with selector switch
The unit control board for each generating unit shall accommodate necessary relays,
measuring instruments, indicators, control unit, control switches, annunciator, temperature
scanner etc. for the operation of the generating units. The generating units shall be controlled
from this control panel during starting, stopping and normal running in manual and auto
modes.
48
Synchronising switch shall be mounted near each generator circuit breaker control
switch on the respective unit control panel. Contacts provided in each switch shall be
connected in the closing circuit of the respective breaker so that the breaker can not be closed
until the switch is turned to the “Synchronising” position. Switches shall be arranged so that
the handle will be locked only in the ‘OFF’ position and check synchronizing relay shall be
provided, so that the breaker could be closed only when voltage, frequency and phases are
properly matched.
Provision for closing the breaker without synchronising check should also be made
with the check synchronising switch in OFF position.
(i) When an external initiating contact is closed, the audible warning shall sound
continuously and the appropriate facia shall be illuminated by flashing light.
(ii) An “acknowledge” push button shall be provided on the annunciator unit
which when pressed shall stop the audible signal and cause the facia to remain
illuminated steadily.
(iii) The annunciator facia illumination shall normally be designed to retain the
indication after the re-opening of the initiating contact. A “reset” push buttom
shall restore the annunciator to the normal condition.
(iv) A “test” button shall be provided close to the “acknowledge” and “reset”
buttons to illuminate all the facias on the associated display unit for as long as
the test button is held in pressed condition.
(v) In case there is a second fault on a system when the first is already being
shown by the facia, the annunicator shall show the second fault also even
when the first is existing on facia.
The following facility shall be provided with each of the annunciator points: -
It shall be possible to use “Normally open” type contacts as initiating contacts for the
annunciator. It shall also be possible to use a few “Normally closed” type of initiating
contacts, if required.
49
It will be the responsibility of the contractor to provide all the alarms and
annunciations required for the safe and efficient operation of the power station.
An A.C. operated relay with A.C. buzzer and A.C. indicating lamp with reset push
button shall be supplied for annunication of D.C. supply failure.
Alarm horns, flicker light relays, necessary hardware and any other auxiliary
equipment required to complete the annunciation system shall be provided.
Each individual equipment shall be routine tested as per IEC/IS at the work’s of
supplier in presence of Owner.
The contractor shall organize and execute a complete factory test of the system. The
system shall be erected in his workshop in the engineered configuration and shall be tested
for the following:
i. Operation requirements
ii. Operating characteristics
iii. Response times
iv. Software functions used in PLC based unit controller.
v. Deficiencies
Various process signals shall be simulated for carrying out above system tests. The
Supplier shall submit routine test reports of each equipment and the total system.
The contractor shall carryout tests at site as per relevant IEC/IS standards as follows
in the presence of and to the entire satisfaction of the owner:
i. Calibration checks (on sample basis) on all factory calibrated meters and
transducers.
ii. Acceptance tests on all other devices fitted on the unit control boards and earlier
tested in factory.
iii. IR tests on panels.
iv. Continuing and IR tests on external cablings.
v. Calibration checks/acceptance tests on all devices and equipment connected to the
unit control boards.
vi. Functional checks on each equipment/object controlled from unit controllers with
control circuits de-energised.
vii. Functional checks on unit controllers with power circuits de-energised.
viii. Verification of all manual control functions from unit control board.
ix. Verification of all control sequences from unit controllers with power and control
circuits energised.
x. Watch up each generating unit and perform all start/stop sequences on it.
50
3.21 DRAWINGS
(i) The tenderer shall submit three sets of drawings of the equipment offered
along with illustrated and descriptive literature for scrutiny and record.
(ii) Certified copies of type test certificates.
(iii) Detailed dimensions drawings along with mounting details.
The tenderer shall supply spares required for maintenance for a period of five years
and special tools required for site assembly, erection, testing and commissioning,
operation and maintenance.
51
SECTION -IV
4.0 SCOPE
The Contractor shall design, fabricate, assemble, test at manufacturers works, supply,
deliver, erect, test at site, Commission and train owner’s operating personnel for the
Control, Protection and Metering Equipment and System for power generation,
transformation and transmission and comprising of following.
(i) Unit control, metering and protection relay panels (For units 1 & 2).
(ii) 33 kV Feeders and bus sectionaliser C.B. control, metering and protective
relay panels.
General Considerations
Considerations involved in providing control and monitoring systems for the power plant
and the switchyard are as follows:
52
e) The turbines, generators, transformer and other equipment proposed for the
unit will be provided with necessary sensors and actuators. Control shall meet
the operational requirement of Butterfly valve which is closed by weight under
emergency.
f) The generators are proposed to be provided with static excitation system.
g) Two number 3.3/33 kV unit transformers of -- MVA capacity each are
proposed to step up the generated power to 33 kV.
j) A single 33 kV bus is proposed.
The scheme will be designed in accordance with ANS/IEEE – 1020 and will be
subject to approval by owner.
The generation units of power plant are proposed to be controlled by push button
from the main centralized control Board in the power Station with provision of
control from SCADA system in the control room. Suitable interlocks shall be
provided to safe guard the machine against inadvertant faulty operations and to ensure
correct operation of all sequences when starting the machine from the power stations
or from remote station.
Normal Starting
The normal starting and stopping of each unit is proposed effected through local
remote switches to energize a sequence controller installed on the control panel of
each unit.
The master controller switch in the first step of its sequence, shall open-turbine inlet
valve and start unit auxiliaries.
In the second step of the sequence the turbine shall be started and field breaker is
closed.
Loading of generating unit shall be in the fourth by remote control of the limiter
motor and speed level motor.
53
Automatic protective devices shall be provided to detect failures in normal operating
conditions of the various equipments and secure an emergency stop of the unit
whenever necessary and actuate alarms.
It is tentatively proposed that emergency stopping of the units should occur in the
following cases:-
Hydraulic Control
It is proposed to provide a system of water level controls based the for transmission of
storage reservoir laves to the power plant and actuate alarms/shutdown whenever the
levels goes beyond abnormal values and trail-race level by means of sensor installed
in tailrace well for actuating runner blade angle.
4.3.1 General
The control system shall receive input signals from main equipment such as the
turbine or the generator, and from various other equipment, such as the governor,
exciter, etc. Status inputs shall be obtained from control switches, level and function
switches indicative of pressure, position etc, throughout the plant. The proper
combination of these inputs to the control system logic will provide outputs to the
governor, the exciter, and other equipment to start or shutdown the unit. Any
abnormalities in the inputs must prevent the unit’s startup, or if already on-line,
provide an alarm or initiate its shutdown, depending upon the magnitude of
abnormality.
The unit control boards should be designed to perform the following functions:
54
(iv) Temperature information monitoring
(v) Metering and instrumentation signals display
(vi) Event recording, when required
(vii) Synchronizing and connecting the unit to the system
The unit control board is the central control means and communicates with the main
and associated equipment through hard wire or multiplexing.
Manual remote control of the 33 kV Vaccum/ SF6 breaker is proposed in the powerhouse
in the centralized control room.
The unit auxiliaries are proposed to be provided automatic control to suit the unit control
as proposed for manual/supervisory control room centralized control room.
4.3.1.3 Annunciation
Annunciation system is proposed to be designed for control of the unit from the
powerhouse in centralized control. The normal annunciators consisting of indicating
lamp and relay assembly is proposed to be provided on the unit control boards in the
powerhouse.
Data logging – Data will be stored in hard disc and printed every half an hour for which
printer will be provide at centralized control room.
Centralized controls of the power distribution and control boards is proposed for attended
automatic operation. Automatic switching of selected standby and emergency auxiliaries
on failure of running auxiliaries is proposed. Automatic change over of entire unit
auxiliaries to alternate source of supply is also proposed.
Air break switchgear is proposed to reduce fire hazard. The opening/closing time of
switchgear may not exceed 8 cycles so that stalling of motors on change over does not
take place. All motors will be direct on line starting and are therefore high starting
torque.
55
Control and status data to be transmitted from various equipment to Unit Control
Board and from Unit Control Board to the equipment etc is detailed below. This is
tentative and may be increased or decreased as required with owner’s approval.
Information and control signals will be needed between the control board and each of the
following:
1 Turbine Table – 1.1 to 1.3
2 Turbine speed governor Table – 2.1 to 2.3
3 Generator Table – 3.1 to 3.4
4 Generator excitation system Table – 4.1 to 4.3
5 Unit transformer Table – 5.1 to 5.2
6 Circuit breaker and switches Table – 6.1 to 6.2
7 Intake valve and draft tube gate Table - 6.3
8 U/S and D/S water level
Additionally, control signal shall also be from Auxiliary equipment, Fire Protection,
Auxiliary AC Power Supply, DC Power supply, Service Water, Service Air shall be
provided as per IEEE – 1020.
These equipment blocks represent auxiliary service equipment needed for the proper
operation of the generating plant. Abnormal conditions of this equipment will be alarmed.
56
33SP Wicked gate shear pin A Shear pin failure while closing
failure wicket gates due to obstruction
71WTH Turbine pit water high level A, C Senses excessive water level in
turbine pit due to plugged drains or
major seal failure. One contact
operates submersible pump.
TYPE C = Control
P = Protection Trip
A = Annunciation/Event Recording
T = Temperature Monitoring
I = Indication (analog, digital, status lamps)
57
Table- 1.2 - Control and Status D a t a T r a n s m i t t e d f ro m U n i t
Control Sw itchboard to Turbine
Type
C = Control
P = Protection Trip
A = Annunc iation/Ev ent Recording
T = Temperature Monitoring
I = Indication (analog, digital, status lamps)
58
Table‐1.3 ‐ Operating Power, Air and Water from Service Equipment to Turbine
Power supply for Lubricating oil system AC May be alternately fed from
for bearing DC.
Type
AC = AC Power
DC = DC Power
A = Air
W = Water
Table 2.1 – Control and Status Data Transmitted from Governor to Unit Control
Switchboard
59
12-X Over-speed C, P Over-Speed Switch should be actuated
mechanically by means of a centrifugal device
mounted on the turbine shaft.
12-X1 Over-speed, C, P Electrically actuated speed relays by comparing
13-X Synchronous the speed signal to a reference signal
14-X speed and under
speed switches
65SF Speed signal A,C,P Loss of speed signal may initiate control action
failure i.e. shutdown of the unit and annunciation.
39C Creep detector A,C Control action upon detection of shaft movement
operation after shutdown may include any or all of the
following :
- Start thrust/guide bearing HP oil pump
- Release brakes
- Drop intake gates
- Alarm
- Start turbine guide bearing oil pump
33WG Wicket gate C,P,I Typical uses of gate position switches for control
position switches and indication:
- Generator brake application (that is, apply
brakes at low speed if gates at 0%)
- Turbine gate lock (apply at 0% gate
position)
- Trip generator breaker as gates pass
through speed-no-load position (auto-stop,
protective shutdowns without overspeed)
- Incomplete stop detection
- Unit running detection
- Initiate time delay for stopping auxiliaries
- Reenergize starting relays to provide
restart after momentary loss of power
60
71 QP Governor Oil A, P Alarms for high, low and extreme low levels.
Pressure Unit – oil Shutdown for extreme low level, air admission
level switches in for high level.
Pressure Vessel
63Q Governor Oil A, P Pump control, alarms for low and extreme low
Pressure Unit - pressures, shutdown for extreme low pressure.
pressure switches
on Pressure Vessel
65WGLF Wicket gate A Indicates that the gate lock has not been fully
automatic lock applied on shutdown
failure
61
C = Control
P = Protection trip
A = Annunciation/Event Recording
T = Temperature Monitoring
I = Indication (analog, digital, status lamps)
Table 2.2 – Control and Status Data Transmitted from Unit Control Switchboard to Governor
62
3SS On-off C,P The start/stop solenoid 65SS typically operates as
command to follows :
start/stop - Energized to allow wicket gates to open and
solenoid 65SS close under control of the electric governor,
or gate limiter gate limit or manual gate control, that is,
motor “energized to start and run”
- De-energized to initiate complete closure of
the wicket gates at maximum rate and block
subsequent opening of the gates, i.e. “de-
energized to stop”
3SNL On/off C,P The partial shutdown solenoid 65SNL (if used) is
command to typically de-energized to limit the opening of the
partial wicket gates, or return them, to a position slightly
shutdown above the speed-no-load position and is controlled
(speed-no-load) as follows :
solenoid - Energized when unit circuit breaker closes to
allow generator to be loaded
- De-energized whenever unit circuit breaker
trips to restore unit to near rated speed;
provides backup to the electric governor
- De-energized to unload the unit for certain
protection operations (that is over speed to
112% during opening of unit circuit breaker)
63
speed and power references
Type
C = Control
P = Protection Trip
A = Annunciation/Event Recording
T = Temperature Monitoring
I = Indication analog, digital, status lamps)
Table 2.3 – Operating Power, Air and Water from Service Equipment to Governor
Description Type
Notes
Power supply for Oil Pressure AC One or more separate supplies depending on
Unit pumps number of pumps and required redundancy.
Type
AC = AC Power
DC = DC Power
A = Air
W = Water
64
Table 3.1 – Control and status data Transmitted from Generator to
unit control
Switchboard
33AB Air brake position C, I Start interlock indicating all brake shoes
indication have cleared runner plate.
TYPE
C = Control
P = Protection trip
A = Annunciation/Event Recording
65
T = Temperature Monitoring
I = Indication (analog, digital, status lamps)
Switchboard
1GL Generator lube oil system C Enables generator lubrication prior to unit
start/stop command. run.
TYPE
C = Control
P = Protection trip
A = Annunciation/Event Recording
T = Temperature Monitoring
I = Indication (analog, digital, status lamps)
T a b l e 3 . 3 – O p e r a t i n g P o we r , A i r a n d W a t e r f r o m S e r v i c e E q u i p m e n t
t o G e n e rat o r
Air supply for brakes and rotor jacking A Control valve may be located in governor
system cubicle/ generator brake panel.
TYPE
C = Control
66
P = Protection trip
A = Annunciation/Event Recording
T = Temperature Monitoring
I = Indication (analog, digital, status lamps)
Table 3.4 – Control and Status Data Transmitted from Generator Terminal
Equipment to Unit Control Switchboard
F Frequency indication I
V Voltage indication I
AVR Voltage signal for automatic voltage C Analog signal from a VT.
regulator (AVR)
TYPE
C = Control
P = Protection Trip
A = Annunciation/Event Recording
T = Temperature Monitoring
I = Indication, analog, digital, status
lamps)
67
Table 4.1 – C o n t r o l a n d S t a t u s D a t a T r a n s m i t t e d f r o m e xc i t a t i o n s y st e m
t o u n i t c on t r o l s wi t c h b o a r d
68
58-1 Rectier transformer temperature A Thyristor fuse, conduction, or gating failure.
-
58-2 Rectifer failure –Stage 2 P
49 HE Heat exchanger failure A Various heat exchanger arrangements are
possible Once-through, closed system, etc
26RTD Exciter transformer temperature I Temperature detectors . Quantity variable
indication depending on number of secondary winding
and whether transformer is 3 phase or 3 x 1
phase.
70V Manual voltage adjuster with I Signal generated by potentiometer coupled to
70V motor drive.
70V/LSI, 70V End-of travel indication I Signal generated by limit switches coupled to
2 70V motor drive
90V Auto voltage adujster with I Same as 70V.
position
90V/LSI, 90 V End-of –travel indication I Same as 70V/LSI,2.
2
70V/LS3 70V preset position C Interlock in start sequence
90V/LS3 90V preset position C Interlock in start sequence.
89LS Station service A.C test supply I Optional
switch position
MAN Indication mismatch between I To ensure bumpless transfer from AUTO to
auto & manual Manual
AUTO Voltage regulator output and I MAN and MAN to AUTO
manual
Balanc e Voltage setpoint
Balanc e Voltage setpoint
TYPE
C = Control
P = Protection Trip
A = Annunciation /Event recording
T= temperature Monitoring
69
I = indication (analog, digital, status lamps)
Table 4.2 – Control and Status Data transmitted from unit control Switchboard
to excitation
70
90 V lower Lower auto voltage adjuster C
52G/a Generator CB Auxiliary C De- excite control, disable
switch power system stabilizer of-line.
Wicket Analog signal representing C Used to develop accelerating
gate wicket power input to PSS if required
position
TYPE
C = Control
P = Protection Trip
A = Annunciation /Event recording
T = temperature Monitoring
I = indication (analog, digital, status lamps)
Table 4.3– Operating Power, Air and Water from Service Equipment to
Excitation system
TYPE
C = Control
P = Protection Trip
A = Annunciation /Event recording
T = Temperature Monitoring
I = Indication (analog, digital, status lamps)
71
71G Gas accumulation detection A Event recording (optional).
63G Gas pressure device A, P Event recording
63Q Main tank sudden pressure relief A, P Hand reset contact (local). Event
recording
device
63T Main tank over pressure switch A, P Trip generator breaker
49-1W Transformer winding temperature A, T, P Temperature detectors embedded
49-2W thermal device in each separate in each separate winding for first
winding stage temperature control. RTD
are in each winding because of
the possibility of unbalanced
loading.
26Q Top oil temperature indicator A, T Dial type oil temperature
indicator at the transformer. First
stage annunciation, tripping
optional. Second stage tripping
71QC Conservator tank oil level indicator A Dial type indicator with
maximum and minimum
indicating levels. Tripping
optional.
T a b l e 5 . 2 – O p e r a t i n g P o we r , A i r a n d W a t e r f r o m S e r v i c e
Equipment to transformer
Description Type
Notes
Power supply for DC control DC For uninterruptible systems.
circuits
Power supply for fans, pumps, AC For FA, FOA transformers. If an FOW
ac control circuits transformer is used, additional
information and control signals may be
needed, such as monitoring of the
pressure difference between the oil and
water systems.
Water supply for fire W
extinguishing system
Type
AC =AC Power
DC =DC Power
A =Air
72
1XJ Breaker control switch, trip/close C
12G Generator overspeed P
25 Synchronizing equipment C
33 Wicket gate position switch C Permissive switch
38GB Generator bearing temperature P
38TB Turbine bearing temperature P
43XJ Breaker test switch C
49T Step-up transformer over temperature P
63T Step-up transformer sudden pressure P
71K Kaplan low oil P
80TBQ Turbine bearing oil P
38G Generator winding temperature P
43S Unit synchronizing selector switch C Permissive switch
Type
C =Control
P =Protection Trip
A =Annunciation/Event Recording
T =Temperature Monitoring
I =Indication (analog, digital, status lamps)
73
Table 6.3 – Inlet Valve and Draft Gate
74
4.4 MANUAL CONTROL, METERING AND PROTECTION SYSTEM
4.4.2 Standards
All materials and equipments shall comply in every respect with the requirements of the
latest edition of the relevant Indian, British equivalent N.E. M.A. I.E.C. Standards or any
other recognized International standards, except in so far as modified by this
specification. Where standards offered are other than the Indian or British standards,
copies of the relevant standard specification in English language must be attached.
The control will have provision for start, stop,, manual synchronizing and emergency
stop. Sequencing will be as per control of unit operation as given below: -
Common tripping relays for similar functions have been provided with lockout
facilities. All these relays shall have potential free contacts for trip and alarm purposes
and externally hand reset type of flag indicators. They should preferable be housed in
drawout type of cases with tropical finish.
All the protective equipment will be housed in the Power Plant main control room.
The details of C.T.’s for all the unit protection and metering are given in Drawings
No-----. The secondary current of C.T.’s located in switchyard is proposed as 1 amp.
because of long leads so as to ensure efficient and accurate operation of their
protective scheme.
3.3 kV C.T.s and P.T. may be mounted on 3.3 kV switchgear panels’ alongwith
relays.
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4.4.5 Protective Relays
The relay operation actuates lockout relay for complete shutdown of the unit
Drawing No. -----.
The relay operation actuates lockout relay for complete shutdown of the unit.
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transformer and resistor can
be housed in same container
with metallic partition.
A set of single phase relays is proposed with suitable time delay setting so that
operation of relay under transient conditions is avoided. The relay setting
range is proposed from 110% to 150%. The relays shall be immune to
frequency variation. Provision of instantaneous tripping element at some
suitable setting is also proposed.
The relay is set to operate lockout relay for partial shutdown to speed no load
position.
Protection will detect unbalance in the outgoing lines which will be detected
and operate the relay. The current transformer for this protection is proposed
to be located on the generator neutral side.
The relay is set to operate the lockout relay for partial shutdown to speed no
load position.
This backup protection for the generator operates for over current which are
accompanied by dip in voltage so that false tripping due to through faults are
avoided. The relay is set to trip lockout relay for partial shutdown to speed no
load position.
Suitable voltage balance relays are proposed to monitor the fuse failure of 3
sets of potential transformers and to block the relays (50/51 V or 40) or other
devices that may operate incorrectly on the voltage due to fuse failure of
potential transformers. The relay is set to give an alarm only.
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x) Mechanical Protections
The tripping of the relay is set to open the excitation breaker main generator
C.B., 33 kV trans. C.B. & UAT breaker and shut down the turbine on
immediate shut down mode.
The protection shall consist of two stages. The first stage with a lower range
shall be arranged to give alarm and annunciation. The second stage with a
higher range shall carry out tripping of the gen. C.B., UAT breaker, field
breaker and shut down the turbine on immediate shut down mode.
This over current instantaneous relay in the excitation circuit before the
excitation transformer will cater to rectifier transformer faults and other
excitation system faults. This relay is set to trip excitation circuit breaker and
bring the unit to rated speed at no load.
iv) Over excitation relay (OER) in the DC circuit and excitation relay (31) in the
field flashing circuit are other relays proposed in the excitation system.
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Suitable relays are proposed to be provided for unit auxiliary transformers
over load protections. The relay will operate from the three current
transformers on the Low Voltage side of the transformer and will be arranged
to trip the Low Voltage breaker.
An instantaneous time over current relay is proposed from the CT’s on the 3.3
kV side of the auxiliary transformer. This relay at a higher setting will cater to
transformer faults and the tripping of the relay is set to bring the unit to rated
speed at no load.
This relay on the station service system trips the LV circuit breaker so as to
prevent operation of the three phase motors in the reverse direction
.
The C.T.’s on 3.3 kV side are proposed be located in the Generator neutral
side and on 33 kV side in the switchyard. The auxiliary/interposing current
transformers as required for the protection shall also be provided.
For this protection Inverse Definite Minimum Time Lag type relay having
suitable setting range and operating time is proposed. This relay is proposed to
trip the unit circuit breaker and bring the unit to speed no load. The relay will
be co-ordinated with line earth fault protection.
iii) Bucholz gas pressure relay for first stage alarm and second stage trip.
iv) Transformer oil level and temperature for alarm & trip
v) Winding temperature for alarm & trip
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4.4.5.4 Bus Bar Protection
The supervision relay will be capable of detecting open: Cross or broken C.T.
secondary and pilots by employing sensitive alarm relay, which shall be connected
across the bus wires of each protected zone. It shall be capable of taking the
protection of the effected zone out of service by shorting the appropriate bus-wires.
`No volt’ relays to indicate failure of D.C. alarm and trip supply to the bus-bar
protection scheme is also proposed to be provided.
High speed tripping relays shall be provided to trip the connected circuit breakers
connected to the faulty bus bar.
Protective relay design for the 33 kV line is important because of high fault power
from 33 kV grid sub-stations. Main features of fast acting protection system is
tentatively proposed as follows:
This relay shall be provided on the line and the bus to indicate grid failure conditions.
4.4.6 Metering
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i. 3 ammeters (each phase)
ii. Power factor and kW meter
iii. kVAR
iv. Voltmeter with voltmeter switch
v. kWH meter
vi. Frequency Meter
i. kWh meter
ii. Ammeters (3 No.)
4.4.7 Annunciation
Conventional 16 window annunciator for each generator turbine faults; 12 window each for
feeder faults and Bus Coupler is proposed for important faults. Schedule for these windows may
be proposed for approval by purchaser. All other annunciation will be on SCADA system.
4.4.8 Recorder
4.4.9.1 All current and voltage transformers required for protection system of the unit are
detailed in generator specifications shall have adequate VA burdens, knee point
voltage, instrument safety factor and characteristics suitable for the application, and
shall be subject to approval of the Owner. 33 kV CTs are detailed in separate
section.9.1.1.
CTs/PTs used for different applications shall have following accuracy class:
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i) PTs for performance testing and low forward power relays Class 0.2
CTs and PTs details proposed will be submitted for approval by purchaser.
The technical requirement and location of the CTs are given in the unit metering
and relaying drawing (enclosed). The generator suppliers shall supply suitable
current transformers for the protection scheme and these shall be in the neutral
grounding cubicles.
The potential transformers should be suitable for metering and protection scheme
enclosed.
Floor mounted, sheet steel simplex type control and relay panels with the following
equipment mounted on them shall be as follows. The details of the panel and
equipment will be supplied for approval by purchaser.
Test blocks shall be provided on switchboards where test facilities are required but are
not provided by use of drawout type meters or relays. The test blocks shall be of the
back connected semi-flush mounted switchboard type with removable covers. All test
blocks shall be provided with suitable circuit identification. The cases shall be dust
tight. Test blocks shall be rated not less than 250V at 10 amps and shall be capable of
withstanding a di-electric test of 1500 V, 50c/s for one minute. All test blocks shall be
arranged to isolate completely the instruments or relays from the instrument
transformers and other external circuits so that no other device will be affected and
provide means for testing either from an external source of energy or from the
instrument transformers by means of multiple test plugs. The test blocks and plugs
shall be arranged so that the C.T. secondary circuits cannot be open circuited in any
position, while the test plugs are being inserted removed.
1. Review front and rear elevations versus the final approved drawings. Check each
item of equipment for proper location and verify the instrument/catalog number is
correct per the specification.
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2. Review the interior of the UCS in the same manner as the elevations. In addition,
verify the lighting is adequate and grounding connections are provided.
3. Check anchor channels and cable entrances. Confirm they are in accordance with
the drawings.
4. Review test certificate or witness the insulation resistance test of all wiring,
current transformers, and potential transformers.
5. Check approximately 5 to 10 percent of the internal cabling. Verify that the
following items conform to the drawings :
• Cable numbers;
• Terminal block designations;
• Terminal designations on individual components such as control switches
and lockout relay;
• Raceway layouts; and
• Equipment identification nameplates.
6. Activate all protective relays. Confirm that the appropriate lockout relay is
energized and the correct annunciation and/or printout occur.
7. Confirm that settings of all protective relays are in accordance with approved
documents.
8. Check all annunciation points.
9. Check factory calibration of all devices possible, including electronic speed
relays, current and potential transformers, and vibration monitors.
10. PLC checks:
• Check the I/O racks for type and number of analog and digital I/O cards;
• Check for future expansion capabilities on the I/O racks;
• Check for surge protection provided on the I/O rack and I/O cards;
• Identify grounding connections for the PLC and the I/O rack; determine
whether chassis and logic grounds are the same or separate (this will affect
the type and quantity of external surge protection required);
• Review the PLC ladder diagram viewed on the video display terminal
versus the final approved PLC software coding documentation; and
• Verify that modem connections are provided and functional.
11. Perform the function checks listed below with the final approved schematics, PLC
software coding, and control block logic diagrams in front of you. All premissives
and interlocks should be provided by using the “dummy” toggle switchboard to
provide these inputs.
• Manual start/stop sequence (does not apply to redundant PLC control
schemes);
• Auto start/stop sequence;
• Manual emergency stop sequence;
• Automatic emergency stop sequence (usually performed by activating one
of the lockout relays while in the “normal running” mode );
• Change position of all control switches as follows (typically done while in
the normal running mode);
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- Manual control to automatic control
- Headwater level control “OFF” to “ON”
- Headwater level control “ON” to “OFF”
- Excitation manual control to excitation automatic control
- Excitation automatic control to excitation manual control; and
• Verify the performance of the automatic synchronizing circuit and the
manual sync-check relay (if provided).
section 7.0 and control in grid mode and isolated mode operation of the Hydel Power
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♦ Automatic startup, on-load control and shutdown of the units by the control
system
♦ Control of auxiliary equipment
♦ Remote monitoring of all plant status and alarm information
♦ Remote normal startup, on-load control and shutdown of units by operators.
♦ Unit Controller.
♦ Common Plant Controller/Supervisory Controller at Power House control
room
The SCADA to be supplied shall be of proven design; operation in at least four power
house for more than 3 years and will be subject to approval by purchaser and will
consist of following.
The SCADA system shall be capable of performing the following functions in real
time.
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h) Application software including state estimation, bad data detection, and on
line power flow.
i) Data logging and report generation.
j) Report alarms.
k) Predict need for shut down and maintenance of equipment.
l) Software shall be such that the monitoring system will take care of the
transient parameters during system run-up and shut down.
m) Software shall be modular and upgradable.
n) The SCADA software shall run in co-ordination with SCADA software for
gate control operation. It can receive data of Gate positions etc. from it and
send generation etc. data to it.
Fast response time of computer system is required. Bidder will intimate following:
(a) Time duration required to update a graphical display from the instant a field
contact changes state.
(b) Time duration from the instant a control is activated at the operator station
until the command is implemented at the field device.
(c) Overall time duration to process and lag an alarm once it is received at the
computer.
Open architecture system shall be followed. Interface or operating standards for the
following shall be intimated and should comply with ISO/IEC 12119.
• Communications
• Operating system
• User Interface
• Data base
The normal, start-up, shut down and emergency operations of the hydro turbine
generator, auxiliaries and feeders shall be performed in three different ways as
follows:
(i) PLC based governor control panel for unit and plant control
(ii) Control from Power House control room
(iii) Manual control panel
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The Control Engineer shall be able to perform the following operations from the CRT
through keyboards.
e) The control engineer shall be able to set the interlocks to start the unit from the
CRT/key board and once the start command is given following sequence shall
take place through the SCADA system.
f) The control engineer shall be able to shut down the unit during normal condition in
the following sequence.
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g) The control engineer shall also be able to trip the unit during emergency condition
with the following sequence.
The SCADA system shall be complete with all primary sensors, cables, analyzers/
transmitters, monitors, system hardware/ software and peripherals etc. to monitor/ control
the parameters for control, protection, annunciation, event recording etc different equipments
including.
Bidder shall provide suggestions relating to measurement points and sensors. If in his
opinion, an enhancement in condition monitoring capability can be attained by use of
additional sensors these should be provided and details to be indicated in the bid.
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♦ Standardized hardware technology
♦ Highly modular design
♦ Expandable
♦ Operation over a wide voltage range
♦ Intelligent I/O modules
♦ Central and distributed I/O
♦ Communication with other controllers and computers
♦ Remote fault diagnostics
It should include all transient suppression, filtering and optical isolation necessary to
operate in a power plant environment. The type of controllers to be used in the
SCADA system should be selected to meet specific plant requirements described
below including availability, number of plant I/O, cycle time and type of
communications link. The modular design of the controllers should be such that they
are easily integrated into the control system requiring the minimum of engineering.
The controller should have a conventional relay logic shutdown circuit. This circuit
should include start and stop relays for controlling the turbine. The start relay
circuitry should provide for auto and manual control capability. A controller fail relay
should drop out the start relay when the auto relay is on. All shutdown hardware
should be powered by the station battery. The stop relay should drop the start relay
whenever a contact input which is strapped for shutdown on a digital input module is
closed.
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4.5.6.4 DC Analog Inputs
The controller should accept 0-1ma, 0-5V, 4-20ma or 1-5V DC analog signals. The
controller should be able to measure DC analog signals with as much as 5 volts
common mode signal with differential inputs. The controller should provide ground
straps that can be inserted on the negative lead of any input signal that should be
grounded at the controller. The controller should also provide selective terminating
resistors for 1ma and 20ma signals. The DC analog signals should be converted to
digital signals using at minimum 12 bit analog to digital converter in the controller
with all conversion errors considered the controller should maintain an accuracy of
0.1% or better of full scale and a resolution of 1 part or less in 2000. All DC analog
inputs should be protected from transient spikes and voltages with circuitry that meets
the IEEE surge withstand test.
The controller should connect directly to current transformers. The controller should
accurately measure all current inputs from 0-6.25 amps. It should withstand 10 amps
continuously and 50 amps for 1 second. The controller should be able to measure
magnitude of the current with a true RMS to DC converter and its phase shift with
respect voltage. The current measuring accuracy should be to .1% and the phase shift
accuracy should be to .1 degree. The controller should induce a burden of less than
.5VA on each current transformer it connects to.
The controller should connect directly to the potential transformers. The controller
should accurately measure voltage inputs from 80 to 150V AC. It should withstand
up to 200V AC continuously. The controller should be able to measure the magnitude
of the voltage with a true RMS to DC converter and measure the phase shift of the
voltage with respect to current. The voltage measuring accuracy should be to .1% and
the phase shift accuracy should be to .1 degree. The controller should induce a
burden of less than 1 VA in each potential transformer that it connects to.
4.5.6.7 Control outputs
The controller should provide control relays to operate the circuit breaker, voltage
regulator, and other equipment. The contacts should be DPDT rated 125 VDC at
0.5 A. Two contacts should be available from the DPDT relay and either should be
strappable as normally closed or normally open. An optional high-powered relay
should be available that provides one normally open contact rate 150 VDC at 10A.
Each relay should have an LED indicator mounted on a manual control panel to
indicate the status of the relay, on or off. Next to the indicating LED should be a
switch to operate the relay manually. Each switch/LED should be clearly marked as
to its function.
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4.5.6.8 RTD inputs
The controller should have provisions to connect directly to RTDs. RTD readings
should be corrected for nonlinearly and readings should be accurate to + 0.25oC. The
temperature range should be 0-160oC. The controller must have a 10, 100 and 120
ohms 8 input RTD module. The correct linearizing curve should be selected by
configuring. The controller should be capable of reading temperatures from eight
RTDs. If eight RTDs are not required, any of the RTD inputs should be able to be
used as a 4-20 mA analog input. Each of the eight inputs should be assigned three
alarm set points; two high alarm set points and one low alarm set point.
4.5.6.9 Analog outputs
The controller should output 4-20ma signals for calculated signals such as kW,
kVARS, power factor, frequency, voltage, and current. The signals should be isolated
outputs with 1000 common mode voltage capability. The accuracy of these outputs
should be better than .25%.
The controller should be capable of outputting contacts for alarms that it generates
internally. The contact rating for these alarms should be 1 Amp. at 24 VDC.
All digital inputs should be capable of meeting the surge withstand capability in
accordance with ANSI/IEEE C37.90.
The controller should connect directly to current transformers (CTs) and potential
transformers (PTs). The controller should be capable of deriving the generator voltage
(line to line and line to neutral), generator amps, generator WATTS, generator VARS,
generator Power factor, generator kVA, generator frequency and bus frequency from
the CTs and PTs: The controller should be configurable for open delta (line to line)
or star (line to neutral) connected CTs and PTs.
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It should comprise of LVDT mounted on hydraulic cylinder for actuating wicket gate.
Two level sensors, one for Headwater and one for Tail water should be provided.
4.5.11 Speed switches
Speed switches should be provided for application of brake, overspeed tripping and
creep at 30%, 112% and 5% of the rated speed respectively.
4.5.12 Printers
Printer/Hard copy units must be provided with supervisory and unit controllers.
4.5.13 Recorders
The plant control system should include video recording system of selected parameters i.e.
Generator temperature etc.
1. Review front and rear elevations versus the final approved drawings. Check each
item of equipment for proper location and verify the instrument/catalog number is
correct per the specification.
2. Review the interior of the UCS in the same manner as the elevations. In addition,
verify the lighting is adequate and grounding connections are provided.
3. Check anchor channels and cable entrances. Confirm they are in accordance with
the drawings.
4. Review test certificate or witness the insulation resistance test of all wiring,
current transformers, and potential transformers.
5. Check approximately 5 to 10 percent of the internal cabling. Verify that the
following items conform to the drawings :
• Cable numbers;
• Terminal block designations;
• Terminal designations on individual components such as control switches
and lockout relay;
• Raceway layouts; and
• Equipment identification nameplates.
6. Activate all protective relays. Confirm that the appropriate lockout relay is
energized and the correct annunciation and/or printout occur.
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7. Confirm that settings of all protective relays are in accordance with approved
documents.
8. Check all annunciation points.
9. Check factory calibration of all devices possible, including electronic speed
relays, current and potential transformers, and vibration monitors.
10. PLC checks:
• Check the I/O racks for type and number of analog and digital I/O cards;
• Check for future expansion capabilities on the I/O racks;
• Check for surge protection provided on the I/O rack and I/O cards;
• Identify grounding connections for the PLC and the I/O rack; determine
whether chassis and logic grounds are the same or separate (this will affect
the type and quantity of external surge protection required);
• Review the PLC ladder diagram viewed on the video display terminal
versus the final approved PLC software coding documentation; and
• Verify that modem connections are provided and functional.
11. Perform the function checks listed below with the final approved schematics, PLC
software coding, and control block logic diagrams in front of you. All premissives
and interlocks should be provided by using the “dummy” toggle switchboard to
provide these inputs.
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3. Perform point-to-point continuity and megger tests on all external cabling.
4. Calibrate all remaining instrumentation devices.
5. “Bench test” all protective relays to ensure proper settings.
6. Perform functional checks tests on all unit and station auxiliary equipment
controlled from the UCS to verify proper operation.
7. Perform functional checks on unit start/stop sequences, duplicating the factory
sequences. These checks should be performed first with the associated power
circuits de-energized, and then with both power and control circuits energized.
8. Methodically document steps 1 through 7 to ensure that no cables, instrumentation
devices, protective relays, or control systems have been overlooked.
9. Water-up the unit and perform all start/stop sequences.
4.5.16 Additional Factory and Field Tests for Distributed Control Systems
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SECTION -V
5.0 SCOPE
The Contractor shall design, fabricate, assemble, test at manufacturers’ works, supply,
deliver, erect, test at site, Commission and train owner’s operating personnel for the
Control, Protection and Monitoring Equipment and System for power generation,
transformation and transmission and comprising of following.
(iii) Unit control, metering and protection relay panels (For each unit).
(iv) --- kV Feeders control, metering and Protective relay panels.
(v) --- kV Bus coupler control and relay panel.
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5.2 CONTROL AND MONITORING SYSTEM
General Considerations
Considerations involved in providing control and monitoring systems for the power plant and the
switchyard are as follows:
The scheme will be designed in accordance with ANS/IEEE – 1010 and will be
subject to approval by owner.
5.3.1General
The control system shall receive input signals from main equipment such as the
turbine or the generator, and from various other equipment, such as the governor,
exciter, etc. Status inputs shall be obtained from control switches, level and function
switches indicative of pressure, position etc, throughout the plant. The proper
combination of these inputs to the control system logic will provide outputs to the
governor, the exciter, and other equipment to start or shutdown the unit. Any
abnormalities in the inputs must prevent the unit’s startup, or if already on-line,
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provide an alarm or initiate its shutdown, depending upon the magnitude of
abnormality.
The unit control boards should be designed to perform the following functions:
The unit control board is the central control means and communicates with the main
and associated equipment through hard wire or multiplexing.
The power units operation is proposed to be level controlled so that in case of variation in
canal/HRC water level due to discharge variation, loading on the power units is
automatically adjusted to available water and energy output is optimised, unnecessary
gate operation avoided and canal water level maintained between permissible limits.
Redundant level monitoring system – one float operated and the other non float operated
shall be provided.
Manual control of the --- kV SF6 breaker is proposed in the power house and supervisory
control in the centralized control room as well as at offsite control centre.
The unit auxiliaries are proposed to be provided automatic control to suit the unit control
as proposed for manual/supervisory control centralized control room and off- site control.
5.3.1.4 Annunciation
Annunciation system is proposed to be designed for control of the unit from the
powerhouse as well as supervisory control in centralized control and offsite control. The
normal annunciators consisting of indicating lamp and relay assembly is proposed to be
provided on the unit control boards in the power house. The remote annunciation for
supervisory control will be part of digital control system.
Data logging – Data will be stored in hard disc and printed every half an hour for which
printer will be provide at centralized control room as well as off-site.
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5.3.1.5 Auxiliaries Control
Centralized controls of the power distribution and control boards is proposed for
unattended automatic operation and for remote control from power house no. 4.
Automatic switching of selected standby and emergency auxiliaries on failure of running
auxiliaries is proposed. Automatic change over of entire unit auxiliaries to alternate
source of supply is also proposed.
Air break switchgear is proposed to reduce fire hazard. The opening/closing time of
switchgear may not exceed 8 cycles so that stalling of motors on change over does not
take place. All motors are direct on line starting and are therefore high starting torque.
Control and status data to be transmitted from various equipment to Unit Control
Board and from Unit Control Board to the equipment etc is detailed below. This is
tentative and may be increased or decreased as required with owner’s approval.
Information and control signals will be needed between the control board and each of the
following:
Canal/HRC water level
Turbine Table – 5.1.1 to 5.1.3
Turbine speed governor Table – 5.2.1 to 5.2.3
Generator Table – 5.3.1 to 5.3.7
Generator excitation system Table – 5.4.1 to 5.4.3
Unit transformer Table – 5.5.1 to 5.5.3
Circuit breaker and switches Table – 5.6.1 to 5.6.2
Intake gate/MIV and draft gate Table - 5.7
Additionally, control signal shall also be from Auxiliary equipment, Fire Protection,
Auxiliary AC Power Supply, DC Power supply, Service Water, Service Air shall be
provided as per IEEE – 1010.
These equipment blocks represent auxiliary service equipment needed for the proper
operation of the generating plant. Abnormal conditions of this equipment will be alarmed.
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Table- 5.1.1 - Control and Status Data Transmitted form Turbine to
U n i t C o n t r o l S wi t c h b o a r d
33SP Wicked gate shear pin A Shear pin failure while closing
failure wicket gates due to obstruction
71WTH Turbine pit water high level A, C Senses excessive water level in
turbine pit due to plugged drains or
major seal failure. One contact
operates submersible pump.
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74TG Turbine greasing system low A Detects failure of power supply to
voltage( if greasing system solenoid valve used to control
provided ) greasing cycle.
TYPE C = Control
P = Protection Trip
A = Annunciation/Event Recording
T = Temperature Monitoring
I = Indication (analog, digital, status lamps)
Type
C = Control
P = Protection Trip
A = Annunc ia tion/Eve nt Re c or ding
T = Temperature Monitoring
I = Indication (analog, digital, status lamps)
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Table-5.1.3 - Operating Power, Air and Water from Service Equipment to Turbine
Power supply for Lubricating oil system AC May be alternately fed from
for bearing DC.
Type
AC = AC Power
DC = DC Power
A = Air
W = Water
Table 5.2.1 – Control and Status Data Transmitted from Governor to Unit Control
Switchboard
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13-X Synchronous the speed signal to a reference signal
14-X speed and under
speed switches
65SF Speed signal A,C,P Loss of speed signal may initiate control action
failure i.e. shutdown of the unit and annunciation.
39C Creep detector A,C Control action upon detection of shaft movement
operation after shutdown may include any or all of the
following :
- Start thrust/guide bearing HP oil pump
- Release brakes
- Drop intake gates
- Alarm
- Start turbine guide bearing oil pump
33WG Wicket gate C,P,I Typical uses of gate position switches for control
position switches and indication:
- Generator brake application (that is, apply
brakes at low speed if gates at 0%)
- Turbine gate lock (apply at 0% gate
position)
- Trip generator breaker as gates pass
through speed-no-load position (auto-stop,
protective shutdowns without overspeed)
- Incomplete stop detection
- Unit running detection
- Initiate time delay for stopping auxiliaries
- Reenergize starting relays to provide
restart after momentary loss of power
71 QP Governor Oil A, P Alarms for high, low and extreme low levels.
Pressure Unit – oil Shutdown for extreme low level, air admission
level switches in for high level.
Pressure Vessel
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63Q Governor Oil A, P Pump control, alarms for low, and extreme low
Pressure Unit - pressures, shutdown for extreme low pressure.
pressure switches
on Pressure Vessel
65WG Wicket gate A Indicates that the gate lock has not been fully
LF automatic lock applied on shutdown.
failure
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BAL Governor balance I For electric governors, indication of electric-
indication hydraulic transducer input voltage.
Type
C = Control
P = Protection trip
A = Annunciation/Event Recording
T = Temperature Monitoring
I = Indication (analog, digital, status lamps)
Table 5.2.2 – Control and Status Data Transmitted from Unit Control Switchboard
to Governor
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3SS On-off C,P The start/stop solenoid 65SS typically operates as
command to follows :
start/stop - Energized to allow wicket gates to open and
solenoid 65SS close under control of the electric governor,
or gate limiter gate limit or manual gate control, that is,
motor “energized to start and run”
- De-energized to initiate complete closure of
the wicket gates at maximum rate and block
subsequent opening of the gates, i.e. “de-
energized to stop”
3SNL On/off C,P The partial shutdown solenoid 65SNL (if used) is
command to typically de-energized to limit the opening of the
partial wicket gates, or return them, to a position slightly
shutdown above the speed-no-load position and is controlled
(speed-no-load) as follows :
solenoid - Energized when unit circuit breaker closes
to allow generator to be loaded.
- De-energized whenever unit circuit breaker
trips to restore unit to near rated speed;
provides backup to the electric governor
- De-energized to unload the unit for certain
protection operations (that is over speed to
112% during opening of unit circuit breaker)
105
speed and power references.
Type
C = Control
P = Protection Trip
A = Annunciation/Event Recording
T = Temperature Monitoring
I = Indication analog, digital, status lamps)
Table 5.2.3 – Operating Power, Air and Water from Service Equipment to
Governor
Description Type
Notes
Power supply for Oil Pressure AC One or more separate supplies depending on
Unit pumps number of pumps and required redundancy.
106
Type
AC = AC Power
DC = DC Powe r
A = Air
W = Water
107
Ta b l e 5 . 3.1 – C on trol an d st at us dat a Tr ansm it t e d f r om Ge ne r at or t o
unit control board
38QW Bearing water A One sensor for each separate oil reservoir,
contamination for detection of water buildup or emulsified.
detector
108
conjunction with probes on turbine guide
bearing.
63QTH Thrust bearing high C, A, I Pressure switch provides confirmation that
pressure oil system the oil pump motor has established
start interlock/failure sufficient pressure to allow the start
alarm. sequence to proceed. Used also to generate
alarm if pressure fail to establish after pump
is commanded to start.
33AB Air brake position C, I Start interlock indicating all brake shoes
indication have cleared runner plate.
80CW Cooling water flow A, P Pump Failure, supply valve closed, pipe
low obstruction, pipe rupture
TYPE
C = Control
P = Protection trip
A = Annunciation/Event Recording
T = Temperature Monitoring
I = Indication (analog, digital, status lamps)
109
Ta b l e 5 . 3.2 – C on trol an d st at us dat a Tr ansm it t e d f r om Ge ne r at or t o
unit controlbord
20CWS Generator cooling water C Open valve or start pump prior to starting
system start/ stop unit. Confirmation of water flow via 33CW
command. or 80CW (Table 3A-1).
20AL Air louver operate C, P Close discharge and inlet air louvers in
command generator housing in event of a fire.
1GL Generator lube oil system C Enables generator lubrication prior to unit
start/stop command. run.
TYPE
C = Control
P = Protection trip
A = Annunciation/Event Recording
T = Temperature Monitoring
I = Indication (analog, digital, status lamps)
110
T a b l e 5 . 3 . 3 – O p e r a t i n g P o we r , A i r a n d W a t e r f r o m S e r v i c e E q u i p m e n t
t o G e n e ra t o r
Power supply for thrust bearing high- AC 415 volts 3 phase AC.
pressure oil pump.
Power supply for DC control circuits. DC For uninterruptible systems such as air
cooler temperature control system, fire
protection.
Air supply for brakes and rotor jacking A Control valve may be located in governor
system cubicle/ generator brake panel.
Power supply for generator lube oil AC May be fed alternatively from DC source.
system.
TYPE
C = Control
P = Protection trip
A = Annunciation/Event Recording
T = Temperature Monitoring
I = Indication (analog, digital, status lamps)
111
Table 5.3.4 – Control and Status Data Transmitted from Generator Terminal
Equipment to Unit Control Switchboard
F Frequency indication I
V Voltage indication I
AVR Voltage signal for automatic voltage C Analog signal from a VT.
regulator (AVR)
TYPE
C = Control
P = Protection Trip
A = Annunciation/Event Recording
T = Temperature Monitoring
I = Indication analog, digital, status
lamps)
112
Table 5.3.5 – Control and Status Data Transmitted from Unit Control Switchboard
to Generator Terminal Equipment
TYPE
C = Control
P = Protection Trip
A = Annunciation/Event Recording
T = Temperature Monitoring
I = Indication analog, digital, status lamps)
Table 5.3.6 – Operating Power, Air and Water from Service Equipment to
Generator Terminal Equipment
TYPE
AC = AC Power
DC = DC Power
A = Air
W = Water
113
Table 5.3.7- Control and Status Data Transmitted to and from the Cooling System
and Unit Control System
Conventional
Type
A = Annunciation
C = Control
P = protective trip
T = temperature monitoring
114
Table 5.4.1 – C ontrol an d S tatus Dat a Tr a n s m i t t e d f r o m e x c i t a t i o n s y s t e m
t o u n i t c o n t r o l s wi t c h b o a r d
115
26ET-2 Exciter transformer temperature P
–Stage 2
58-1 Rectifier transformer A Thyristor fuse, conduction, or gating failure.
temperature -
58-2 Rectifier failure –Stage 2 P
49 HE Heat exchanger failure A Various heat exchanger arrangements are
possible Once-through, closed system, etc
26RTD Exciter transformer temperature I Temperature detectors. Quantity variable
indication depending on number of secondary winding
and whether transformer is 3 phase or 3 x 1
phase.
70V Manual voltage adjuster with I Signal generated by potentiometer coupled to
70V motor drive.
70V/LSI, 70V End-of travel indication I Signal generated by limit switches coupled to
2 70V motor drive
90V Auto voltage adjuster with I Same as 70V.
position
90V/LSI, 90 V End-of –travel indication I Same as 70V/LSI,2.
2
70V/LS3 70V preset position C Interlock in start sequence
90V/LS3 90V preset position C Interlock in start sequence.
89LS Station service A.C test supply I Optional
switch position
MAN Indication mismatch between I To ensure bumpless transfer from AUTO to
auto
AUTO Voltage regulator output and I MAN and MAN to AUTO
manual
Balanc e Voltage setpoint
Balanc e Voltage setpoint
116
TYPE
C = Control
P = Protection Trip
A = Annunciation /Event recording
T= temperature Monitoring
I = indication (analog, digital, status lamps)
Table 5.4.2 – Control and Status Data transmitted from unit control Switchboard
to excitation
117
70 V lower Lower manual voltage C
adjuster
90 V raise Raise auto voltage adjuster C
90 V lower Lower auto voltage adjuster C
52G/a Generator CB Auxiliary C De- excite control, disable
switch power system stabilizer of-line.
Wicket Analog signal representing C Used to develop accelerating
gate wicket power input to PSS if required
position
TYPE
C = Control
P = Protection Trip
A = Annunciation /Event recording
T = temperature Monitoring
I = indication (analog, digital, status lamps)
118
Table 5.4.3– Operating Power, Air and Water from Service Equipment to
Excitation system
Station service as test supply AC Used for exciter testing and emergency
operation if exciter transformer out of service
(optional)
TYPE
C = Control
P = Protection Trip
A = Annunciation /Event recording
T = Temperature Monitoring
I = Indication (analog, digital, status lamps)
119
Table 5.5.1 – Control and Status Data Transmitted from
T r a n s f o r m e r t o U n i t C o n t r o l S wi t c h b o a r d
P =Protection Trip
A =Annunciation/Event Recording
T =Temperature Monitoring
I =Indication (analog, digital, status lamps)
120
T a b l e 5 . 5 . 3 – O p e r a t i n g P o we r , A i r a n d W a t e r f r o m S e r v i c e E q u i p m e n t
to transformer
Description Type
Notes
Power supply for DC control DC For uninterruptible systems such as fire
circuits protection.
Power supply for fans, pumps, AC For FA, FOA transformers. If an FOW
ac control circuits transformer is used, additional
information and control signals may be
needed, such as monitoring of the
pressure difference between the oil and
water systems.
Water supply for fire W
extinguishing system
Water supply for cooling W
Type
AC =AC Power
DC =DC Power
A =Air
W =Water
T a b l e 5 . 6 . 1 – S i g n a l s T r a n s m i t t e d f r o m P l a n t E q u i p m e n t t o G e ne r a t o r
Breaker
121
T a b l e 5 . 6 . 2 – S i g n a l s T r a n s m i t t e d f ro m g e n e r a t o r B r e a k e r t o U n i t
C o n t r o l S wi t c h b o a r d
Signal Description Type
Notes
52a, b Breaker open-close C, I
27CB Generator breaker loss of dc control A
power
61 Generator breaker pole failure P, A Trip is isolate breaker.
63a Breaker air pressure switch C Permissive switch.
63A Generator breaker low air pressure P, A
Type
C =Control
P =Protection Trip
A =Annunciation/Event Recording
T =Temperature Monitoring
I =Indication (analog, digital, status lamps)
Table 5.7 – Intake Gate/MIV and Draft Gate
122
5.4 MANUAL CONTROL, METERING AND PROTECTION SYSTEM
Design, manufacture, testing, commissioning of manual control, metering and
protection system which includes Electrical protection by conventional relay; manual
control and metering of the Power House.
5.4.2 Standards
All materials and equipments shall comply in every respect with the requirements of the
latest edition of the relevant Indian, British equivalent N.E. M.A. I.E.C. Standards or any
other recognized International standards, except in so far as modified by this
specification. Where standards offered are other than the Indian or British standards,
copies of the relevant standard specification in English language must be attached.
The control will have provision for start, stop, manual synchronizing and emergency stop.
Sequencing will be as following tentative Drawings (to be enclosed by Purchaser).
Common tripping relays for similar functions have been provided with lock-out
facilities. All these relays shall have potential free contacts for trip and alarm purposes
and externally hand reset type of flag indicators. They should preferable be housed in
drawout type of cases with tropical finish.
All the protective equipment will be housed in the Power Plant main control room.
The details of C.T.’s for all the unit protection and metering are given in Drawings
123
No. ----. The secondary current of C.T.’s located in switchyard is proposed as 1 amp.
because of long leads so as to ensure efficient and accurate operation of their
protective scheme.
The drawings for the proposed system will be subject to approval by the Purchaser.
The relay operation actuates lockout relay for complete shutdown of the unit
including release of CO2 as shown in Drawing No. ----.
The relay operation actuates lockout relay for complete shutdown of the unit.
124
single phase.
b. Connection Between generator neutral
and ground
Loading Resistor
a. Construction Non-ageing, corrosion
resistant, punched stainless
steel grid elements provided
with necessary installations,
and temperature rise not
exceeding 300 deg. C.
b. Housing Enclosure with IP:22 degree
of protection. However,
transformer and resistor can
be housed in same container
with metallic partition.
A set of single phase relays is proposed with suitable time delay setting so that
operation of relay under transient conditions is avoided. The relay setting
range is proposed from 110% to 150%. The relays shall be immune to
frequency variation. Provision of instantaneous tripping element at some
suitable setting is also proposed.
The relay is set to operate lockout relay for partial shutdown to speed no load
position.
A two stage protection complete with filter network is proposed for this
purpose. The first stage with a lower suitable range shall be instantaneous and
shall be arranged to give alarm and annunciation and the second stage with
higher range will energise a timer which shall perform the various tripping
functions in two stages at different time settings, as shown in the drawing E-
230-3. The current transformer for this protection is proposed to be located on
the generator line side.
The relay is set to operate the lockout relay for partial shutdown to speed no
load position.
This backup protection for the generator operates for over current which are
accompanied by dip in voltage so that false tripping due to through faults are
avoided. The relay is set to trip lockout relay for partial shutdown to speed no
load position.
125
Reverse power relay (32)
Suitable voltage balance relays are proposed to monitor the fuse failure of 3
sets of potential transformers and to block the relays (50/51 V or 40) or other
devices that may operate incorrectly on the voltage due to fuse failure of
potential transformers. The relay is set to give an alarm only.
Mechanical Protections
An offset mho type of relay having its circular characteristics adjustable both
in offset and diameter, along the X-axis of the R-X plane, is proposed for this
purpose.
126
The protection shall consist of two stages. The first stage with a lower range
shall be arranged to give alarm and annunication. The second stage with a
higher range shall carry out the tripping functions as shown in the Drawing --.
Direct current injection type of protection is proposed for this purpose. The
relay will be suitable for the field system voltage and be capable of detecting
deterioration of insulation level below about 0.2 Mega-ohms. 110 Alternating
current potential transformer auxiliary supply will be available but the relay
will have its own internal rectifiers etc. to drive the D.C. injection supply.
Failure of A.C. auxiliary supply will not totally incapacitate the protection.
The tripping of the relay is set to open the excitation breaker and bring the unit
to speed no load.
This over current instantaneous relay in the excitation circuit before the
excitation transformer will cater to rectifier transformer faults and other
excitation system faults. This relay is set to trip excitation circuit breaker and
bring the unit to speed no load.
Over excitation relay (OER) in the DC circuit and excitation relay (31) in the
field flashing circuit are other relays proposed in the excitation system.
An instantaneous time over current relay is proposed from the CT’s on the 11
kV side of the auxiliary transformer. This relay at a higher setting will cater to
transformer faults and the tripping of the relay is set to bring the unit to speed
no load as shown in Drawing E-230-5.
127
Under voltage relay (27)
These relays have been provided to trip the LV circuit breaker (Refer Drg. ----
---).
The C.T.’s on 11 kV side are proposed be located in the Generator neutral side
and on ----- kV side in the switchyard. The auxiliary/interposing current
transformers as required for the protection shall also be provided.
The relay is set to operate lockout relay for shutdown as shown in Drawing
No.-----.
For this protection Inverse Definite Minimum Time Lag type relay having
suitable setting range and operating time is proposed. The relay shall be
energized by zero sequence current supplied to it through current transformer
in the power transformer neutral. This relay is proposed to trip the unit circuit
breaker and bring the unit to speed no load. The relay will be co-ordinated
with line earth fault protection.
Bucholz gas pressure relay for first stage alarm and second stage trip.
Winding temperature
Necessary separate C.T. cores shall be provided at the incoming and outgoing
128
circuits for check features. The main zonal relay and check relay scheme will have
their contacts connected in series in the trip circuit.
The protection will be capable of detecting all type of faults on the bus-bar. The
sensitivity of protection shall be such that it does not operate for faults on the C.T.
secondary wiring of the most heavily loaded circuit. C.T.’s on one side of the bus
coupler/section breaker are proposed and inter-locked overcurrent relay will be
provided.
The supervision relay will be capable of detecting open: Cross or broken C.T.
secondaries and pilots by employing sensitive alarm relay, which shall be connected
across the bus wires of each protected zone. It shall be capable of taking the
protection of the effected zone out of service by shorting the appropriate bus-wires.
`No volt’ relays to indicate failure of D.C. alarm and trip supply to the bus-bar
protection scheme is also proposed to be provided.
High speed tripping relays shall be provided to trip the connected circuit breakers
Protective relay design for the --- kV line is important because of high fault power
from 66 kV grid sub-stations. Main features of fast acting protection system are
tentatively proposed as follows:
Under voltage relay shall be provided on the line and the bus to indicate live line
conditions. Relays with separate flush/semi-flush drawout cases and having individual
in-built testing facilities shall be preferred. But modular drawout construction and
equivalent facilities would also be accepted. The panels shall be complete and all
necessary name plates, device identification, terminals blocks, fuses etc. shall be
provided.
129
The protection requirement with respect to characteristics operating principle, tripping
schedule and type of relays shall be discussed during detailed engineering stage, and
Bidder shall provide the same to the satisfaction of the Owner.
5.4.6 Metering
5.4.7 Annunciation
Conventional 16 window annunciator for each generator turbine faults; 12 window each for feeder
faults and Bus Coupler is proposed for important faults. Schedule for these windows may be
proposed for approval by purchaser. All other annunciation will be on SCADA system.
5.4.8 Recorder
5.4.9.1 All current and voltage transformers required for protection system of the unit are
detailed in generator specifications shall have adequate VA burdens, knee point
130
voltage, instrument safety factor and characteristics suitable for the application, and
shall be subject to approval of the Owner. Details of --- kV(Feeder) CTs are to be
given by the Purchase .
CTs/VTs used for different applications shall have following accuracy class:
5.4.9.4 The technical requirement and location of the CTs are given in the unit metering and
relaying drawing (enclosed). The generator suppliers shall supply suitable current
transformers for the protection scheme and these shall be in the neutral grounding
cubicles.
The current transformers should be suitable for metering and protection scheme
attached .
11 kV Current Transformers
131
Generator Transformer 87GT with three Nos.
interposing CTs
.
(b)Generator Transformer side – Two core -6 Nos.
Single core 5P10 class for over current protection of Rectifier Transformer
circuit 51EX relay
.
Single core 5P10 class for over current protection of Unit Aux. T/F
50/51 relay.
5.4.11.1 G e n e r a t or t r a n s f or m e r c o nt r o l a n d r e l a y p a n e l s
Floor mounted, sheet steel simplex type control and relay panels with the following
equipment mounted on them shall be supplied for Generator Transformer control and
protection.
Control panels
132
S. N o m e n c l at u Quantity Description
No. re
1. - - Mimic diagram of bus –bars and connections.
2. BI 1 set Semphore indicators for isolators.
3. CB 1 set Semphore indicators for circuit breakers.
4. AG 3 Nos. Dial type A.C. ammeters for measuring
generator current in Amperes range 0-800A
5. VG 1No. Dial type A.C. voltmeter for measuring
generator voltage in kV range 0-15 kV
6. VS 1No. Voltmeter selector switch.
7. PF 1No Polyphase indicating power factor meter
range – 0.5 to 0 to +0.5
8. KW 1 No. Polyphase indicating kW meter of range 0 to
15000 kW
9. KVAR 1No. Polyphase indicating KVAR meter of range
0-6000 kVAR
10. FM 1 No. Frequency meter 0-75 Hz
11. AF 1 No. Field current meter 0-200 A
12. VF 1 No. Field voltage meter 0-300 V
13. SI 1 No. Speed indicator 0-1000 rpm
14. SL 1No Gate limit indicator
15 SW 1 no. Remote/ local selector switch
16. A/M 1 No. Auto/manual selector switch
17 S1 1No. C.B. control switch with indicating lamps
including healthy trip supply indication.
18 S2 1 set Bus Isolator control switch with indicating
lamps
19 S4 1No. Gate limiter control switch (Raise/lower )
20 S5 1 No. Speed level control switch (Raise/lower).
21. SS 1No. Synchronising switch with locking key
22. T 1 No. Temp. indicator with selector switch
23 86 G 1 No. High speed tripping relay
24 30 X 1No Emergency stop switch with cover
25 30 Y 1N. Stop reset push Button
26. KWH 1 No. Energy meter with test block
1 Set Annunciation block with 16 windows
complete with alarm cancellation lamps reset
and lamp test push buttons
133
Relay panels
S. N o m e n c l at u Quantity Description
No. re
1 87 G 1 Set Tripple pole generator differential protection
relay including auxiliary relay etc.
2 50/51T 1 No. Overcurrent Earth fault relay for Generator
transformer.
3 51 V 1 No. Backup protection relay ( over current voltage
restraint.
4 64 G 1No. Generator ground protection relay.
5 64T 1No. Transformer ground protection relay
6 59 1No Over voltage relay
7 25 1 No. Check synchronising relay
8 32 1 No, Reverse power relay
9 46 1No. Negative phase sequence relay
10 40 1 No. Field failure relay
11 87 GT 3 Set. Generator Transformer differential protection
relay including auxiliary relay etc.
12 64 F 1No. Rotor earth fault relay
13 12 G 1No. Over speed relay (electrical)
14 27 1No. Under voltage relay
15 47 1No. Phase sequence voltage relay
16 84 1No. Generator trip relay
17 Auxiliary and locking relays
Floor mounted, sheet steel simplex type control and relay panels with the following
equipment mounted on each of them shall be supplied for Mukerian stage I and
Dasuya feeders control and protection.
Control panels
134
9. KVAR 1No. Polyphase indicating KVAR meter of range 0
to------ kVAR
10. S1 1No. C.B. control switch with indicating lamps
including healthy trip supply indication.
11. S2 1 set Bus Isolator control switch with indicating
lamps
12. S3 1set Line Isolator control switch with indicating
lamps
13. SS 1No. Synchronising switch with locking key
14. 86 G 1 No. High speed tripping relay
15. KWH 1 No. Export/ Import Energy meter with test block
16. 1 Set Annunciation block with 16 windows
complete with alarm cancellation lamps reset
and lamp test push buttons
Relay panels
S. N o m e n c l at u Quantity Description
No. re
1. 51D 1 No. Directional overcurrent Earth fault relay
2. 27 1set Under voltage relay
3. 185 1set Phase comparison relay
4. 81H/L 1 set High / Low frequency relay
5. Auxiliary relays as per actual requirement.
Other protections relays as decided by feeder
protection designer .
Floor mounted, sheet steel simplex type control and relay panels with the following
equipment mounted there on shall be supplied for Bus Coupler control and protection.
Control panel
S. N o m e n c l at u Quantity Description
No. re
1. - - Mimic diagram of bus –bars and connections.
2. BI 2 sets Semaphore indicators for isolators.
3. CB 1 set Semaphore indicator for circuit breaker.
4. AB 3 Nos. Dial type A.C. ammeters for measuring
current in Amperes range 0-500A
5. S1 1No. C.B. control switch with indicating lamps
including healthy trip supply indication.
6. S2 A/B 2 sets Bus Isolator control switch with indicating
lamps
135
7. 86 G 1 No. High speed tripping relay
8. 1 Set Annunciation block with 16 windows
complete with alarm cancellation lamps reset
and lamp test push buttons
Relay panel
S. N o m e n c l at u Quantity Description
No. re
1.-- 87 B1/B2 2 Sets Triple pole Bus Bar differential protection relay
including check and auxiliary relays etc.
2. 51 I No. Interlocked overcurrent relay
3. Other Auxiliary relays as per requirement
Sheet steel swinging panel mounted on the side of the switchboard complete with internal
wiring connections equipped as synchronizing panel with the following equipment
mounted there on.
Quantity Description
2 Nos. Dial type A.C. voltmeter of suitable range for measuring
voltage in kV.
2 Nos. Dial type frequency meters of suitable range.
1No. Synchro-scope.
1No. Synchronizing lamps control switch (ON/OFF)
2Nos Synchronizing lamps.
1 No. Synchronization selector switch (Auto / Manual).
Test blocks shall be provided on switchboards whore test facilities are required but
are not provided by use of drawout type meters or relays. The test blocks shall be of
the back connected semi-flush mounted switchboard type with removable covers. All
test blocks shall be provided with suitable circuit identification. The cases shall be
dust tight. Test blocks shall be rated not less than 250V. at 10 amps and shall be
capable of withstanding a di-electric test of 1500 V, 50c/s for one minute. All test
blocks shall be arranged to isolate completely the instruments or relays from the
instrument transformers and other external circuits so that no other device will be
affected and provide means for testing either from an external source of energy or
from the instrument transformers by means of multiple test plugs. The test blocks and
plugs shall be arranged so that the C.T. secondary circuits cannot be open circuited in
any position , while the test plugs are being inserted removed.
136
12. Review front and rear elevations versus the final approved drawings. Check each
item of equipment for proper location and verify the instrument/catalog number is
correct per the specification.
13. Review the interior of the UCS in the same manner as the elevations. In addition,
verify the lighting is adequate and grounding connections are provided.
14. Check anchor channels and cable entrances. Confirm they are in accordance with
the drawings.
15. Review test certificate or witness the insulation resistance test of all wiring,
current transformers, and potential transformers.
16. Check approximately 5 to 10 percent of the internal cabling. Verify that the
following items conform to the drawings :
• Cable numbers;
• Terminal block designations;
• Terminal designations on individual components such as control switches
and lockout relay;
• Raceway layouts; and
• Equipment identification nameplates.
17. Activate all protective relays. Confirm that the appropriate lockout relay is
energized and the correct annunciation and/or printout occurs.
18. Confirm that settings of all protective relays are in accordance with approved
documents.
19. Check all annunciation points.
20. Check factory calibration of all devices possible, including electronic speed
relays, current and potential transformers, and vibration monitors.
21. PLC checks:
• Check the I/O racks for type and number of analog and digital I/O cards;
• Check for future expansion capabilities on the I/O racks;
• Check for surge protection provided on the I/O rack and I/O cards;
• Identify grounding connections for the PLC and the I/O rack; determine
whether chassis and logic grounds are the same or separate (this will affect
the type and quantity of external surge protection required);
• Review the PLC ladder diagram viewed on the video display terminal
versus the final approved PLC software coding documentation; and
• Verify that modem connections are provided and functional.
22. Perform the function checks listed below with the final approved schematics, PLC
software coding, and control block logic diagrams in front of you. All premissives
and interlocks should be provided by using the “dummy” toggle switchboard to
provide these inputs.
• Manual start/stop sequence (does not apply to redundant PLC control
schemes);
• Auto start/stop sequence;
• Manual emergency stop sequence;
• Automatic emergency stop sequence (usually performed by activating one
of the lockout relays while in the “normal running” mode );
137
• Change position of all control switches as follows (typically done while in
the normal running mode);
12. Perform point-to-point continuity and megger tests on all external cabling.
13. Calibrate all remaining instrumentation devices.
14. “Bench test” all protective relays to ensure proper settings.
15. Perform functional checks tests on all unit and station auxiliary equipment
controlled from the UCS to verify proper operation.
16. Perform functional checks on unit start/stop sequences, duplicating the factory
sequences. These checks should be performed first with the associated power
circuits de-energized, and then with both power and control circuits energized.
17. Methodically document steps 1 through 7 to ensure that no cables, instrumentation
devices, protective relays, or control systems have been overlooked.
18. Water-up the unit and perform all start/stop sequences.
138
station centralized control room at EL 246.0 m. It should also provide remote
monitoring and control of the Power House from Mukerian stage I power house 7 km
from this power plant. through dedicated fibre optic cable and redundant power line
carrier communication (PLCC) system. This SCADA system should have following
features:
♦ Unit Controller.
♦ Common Plant Controller/Supervisory Controller at Power House control
room
♦ Remote Supervisory Controller
The SCADA to be supplied shall be of proven design; operation in at least six power
house for more than 5 years and will be subject to approval by purchaser and will
consist of following.
139
The SCADA system shall be capable of performing the following functions in real
time.
Fast response time of computer system is required. Bidder will intimate following:
(d) Time duration required to update a graphical display from the instant a field
contact changes state.
(e) Time duration from the instant a control is activated at the operator station
until the command is implemented at the field device.
(f) Overall time duration to process and lag an alarm once it is received at the
computer.
140
5.5.4 Equipment Architecture and Protocol
Open architecture system shall be followed. Interface or operating standards for the
following shall be intimated and should comply with ISO/IEC 12119.
Communications
Operating system
User Interface
Data base
The normal, start-up, shut down and emergency operations of the hydro turbine
generator, auxiliaries and feeders shall be performed in three different ways as
follows:
(j) Redundant PLC based governor control panel for unit and plant control
(iv) Remote Control from Power House control room
(v) Manual control panel
The Control Engineer shall be able to perform the following operations from the CRT
through keyboards.
j) The control engineer shall be able to set the interlocks to start the unit from the
CRT/key board and once the start command is given following sequence shall
take place through the SCADA system.
141
3) When the oil pressure is established in the governor circuit, blades shall set at
the starting position.
4) Release generator brakes.
5) After having ensured that the bakes are released and blades are in starting
position command shall be given to open the wicket gates.
6) With opening of wicket gate unit speed shall rise.
7) At 90% unit speed, generator shall be excited, wicket gate shall be stopped
and its position maintained by energizing governor relays speed adjustment,
blades/movements shall be achieved.
8) When unit frequency and phase voltage is matched to that of existing power
system, unit circuit breaker shall be closed.
9) After unit breaker is connected to the system, governor parameters shall be
set to automatic mode.
f) The control engineer shall be able to shut down the unit during normal condition in
the following sequence. .
g) The control engineer shall also be able to trip the unit during emergency condition
with the following sequence. .
The SCADA system shall be complete with all primary sensors, cables, analyzers/
transmitters, monitors, system hardware/ software and peripherals etc. to monitor/ control
the parameters for control, protection, annunciation, event recording etc different equipments
detailed in 7.1 and including.
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• Turbine blade tip clearance
• Governor control monitoring of turbine speed.
• Generator terminal voltage, current, KW, KVAR, KVA, KWH,
Frequency, power factor, field voltage and field current.
• Annunciation for violation of permissible limits of the above
parameters.
• Turbine bearing temperature.
• Guide bearing temperature.
• Guide bearing oil level.
• Guide vane bearing oil temperature.
• Generator bearing temperature.
• Generator winding temperature.
• Turbine speed.
• Generator speed.
• Governor oil pumps, oil pressure indicator and low pressure switch.
• Cooling water pumps, suction and discharge pressure switch/ gauge.
• Inlet pressure gauge at inlet of turbine.
• Vacuum gauge for draft tube pressure.
• Level indicator for level in the forebay.
• Weir type flowmeter for measurement of flow.
• Annunciation
Bidder shall provide suggestions relating to measurement points and sensors. If in his
opinion, an enhancement in condition monitoring capability can be attained by use of
additional sensors these should be provided and details to be indicated in the bid.
It should include all transient suppression, filtering and optical isolation necessary to
operate in a power plant environment. The type of controllers to be used in the
SCADA system should be selected to meet specific plant requirements described
below including availability, number of plant I/O, cycle time and type of
communications link. The modular design of the controllers should be such that they
are easily integrated into the control system requiring the minimum of engineering.
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Redundant microprocessor based/PLC based governor system control should be
interfaced with SCADA powerful enough to perform all the required functions
mentioned above. It should have capability to implement closed loop PID function for
governing. The scan time of the complete sequence for each process should be less
than 100 msec. It should have lock to prevent unauthorised modification and be
capable of detecting hardware and software failures. It may also have digital relays for
over current, over-voltage and differential generator protection. It should have
following hardware features. It should have a console and keyboard to program the
controller as well as communicate with Supervisory controller. Unit controller should
support remote management and remote programming for supervisory controller.
The controller should have a conventional relay logic shutdown circuit. This circuit
should include start and stop relays for controlling the turbine. The start relay
circuitry should provide for auto and manual control capability. A controller fail relay
should drop out the start relay when the auto relay is on. All shutdown hardware
should be powered by the station battery. The stop relay should drop the start relay
whenever a contact input which is strapped for shutdown on a digital input module is
closed.
5.5.7.1.3 DC Analog Inputs
The controller should accept 0-1ma, 0-5V, 4-20ma or 1-5V DC analog signals. The
controller should be able to measure DC analog signals with as much as 5 volts
common mode signal with differential inputs. The controller should provide ground
straps that can be inserted on the negative lead of any input signal that should be
grounded at the controller. The controller should also provide selective terminating
resistors for 1ma and 20ma signals. The DC analog signals should be converted to
digital signals using at minimum 12 bit analog to digital converter in the controller
with all conversion errors considered the controller should maintain an accuracy of
0.1% or better of full scale and a resolution of 1 part or less in 2000. All DC analog
inputs should be protected from transient spikes and voltages with circuitry that meets
the IEEE surge withstand test.
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5.5.7.1.4 AC current inputs
The controller should connect directly to current transformers. The controller should
accurately measure all current inputs from 0-6.25 amps. It should withstand 10 amps
continuously and 50 amps for 1 second. The controller should be able to measure
magnitude of the current with a true RMS to DC converter and its phase shift with
respect voltage. The current measuring accuracy should be to .1% and the phase shift
accuracy should be to .1 degree. The controller should induce a burden of less than
.5VA on each current transformer it connects to.
The controller should connect directly to the potential transformers. The controller
should accurately measure voltage inputs from 80 to 150 VAC. It should withstand
up to 200 VAC continuously. The controller should be able to measure the magnitude
of the voltage with a true RMS to DC converter and measure the phase shift of the
voltage with respect to current. The voltage measuring accuracy should be to .1% and
the phase shift accuracy should be to .1 degree. The controller should induce a
burden of less than 1 VA in each potential transformer that it connects to.
5.5.7.1.6 Control outputs
The controller should provide control relays to operate the circuit breaker, voltage
regulator, and other equipment. The contacts should be DPDT rated 125 VDC at
0.5 A. Two contacts should be available from the DPDT relay and either should be
strappable as normally closed or normally open. An optional high-powered relay
should be available that provides one normally open contact rate 150 VDC at 10A.
Each relay should have an LED indicator mounted on a manual control panel to
indicate the status of the relay, on or off. Next to the indicating LED should be a
switch to operate the relay manually. Each switch/LED should be clearly marked as
to its function.
5.5.7.1.7 RTD inputs
The controller should have provisions to connect directly to RTDs. RTD readings
should be corrected for nonlinearly and readings should be accurate to + 0.25oC. The
temperature range should be 0-160oC. The controller must have a 10, 100 and 120
ohms 8 input RTD module. The correct linearizing curve should be selected by
configuring. The controller should be capable of reading temperatures from eight
RTDs. If eight RTDs are not required, any of the RTD inputs should be able to be
used as a 4-20 mA analog input. Each of the eight inputs should be assigned three
alarm set points; two high alarm set points and one low alarm set point.
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5.5.7.1.8 Analog outputs
The controller should output 4-20ma signals for calculated signals such as KW,
KVARS, power factor, frequency, voltage, and current. The signals should be
isolated outputs with 1000 common mode voltage capability. The accuracy of these
outputs should be better than .25%.
The controller should be capable of outputting contacts for alarms that it generates
internally. The contact rating for these alarms should be 1 Amps. at 120 VDC.
All digital inputs should be capable of meeting the surge withstand capability in
accordance with ANSI/IEEE C37.90.
The controller should connect directly to current transformers (CTs) and potential
transformers (PTs). The controller should be capable of deriving the generator voltage
(line to line and line to neutral), generator amps, generator WATTS, generator
VARS, generator Power factor, generator kVA, generator frequency and bus
frequency from the CTs and PTs: The controller should be configurable for open
delta (line to line) or star (line to neutral) connected CTs and PTs.
Intel Pentium IV Processor 500 MHz (or more recent) / Desktop Mini computer with
support for running windows 2000.
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It should comprise of LVDT mounted on hydraulic cylinder for actuating wicket gate.
Two level sensors, one float operated and other non-floated should be provided for level
controlled operation of the machine. The level controller should be redundant to each other. One
level transducer may consist of a diaphragm type sensor and internal signal conditioning system
and should be able to provide standard output such as 4 to 20 mA/0-5 V DC.
Speed switches should be provided for application of brake, overspeed tripping and
creep at 30%, 112% and 5% of the rated speed respectively.
The Console should permit software development and operator training while providing
backup hardware for use where the manual operator interface is out of service.
Interlocking should be provided to permit only one console to be in control at a time.
5.5.14 Printers
Printer/Hard copy units must be provided with supervisory and unit controllers.
5.5.15 Recorders
The plant control system should include video recording system of selected parameters
i.e. Generator temperature etc.
i) Scope
Design, supply, delivery, Site, erection, communication and training of personnel for
communication links between the power house and Mukerian Stage I for off-site
control and communication and between power house and dasuya grid substation
(interlinking points) for voice communication.
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ii) Code Standards
The contractor shall furnish detailed design and calculation for approval by purchaser.
Govt. regulatory requirement and sanctions for the communication system shall be
obtained by Contractor. Necessary assistance will be provided by Purchaser.
Dedicated communication system for SCADA, voice communication and code call
paging system from power house to offsite control at Power House IV of stage I shall be
by Fiber optic cable. Code call facility shall be provided for paging key personnel.
The Fiber optic cable shall be laid along the canal bank and no right of way problem is
anticipated.
Repeaters
Repeaters if needed shall be provided. Necessary equipment at sending and receiving and
for interfacing remote supervisory controller at Power House IV with SCADA.
Centralized SCADA system to remote supervisory control in the control room of Power
House No. IV of stage I shall be provided by the dedicated Fiber optic couple. The
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design will be subject to approval by purchaser and will confirm to latest relevant
standard.
Local area network if proposed inside the Power House for distributed control otherwise
shall also connected by Fiber optic cable.
Two sets of PLCC system, line matching units and protective device shall also to be
supplied, installed and commissioned for communication and control between Power
House (emergency link) and Grid Substation for voice communication. Coupling
voltage transformer and Wave trap have been covered in switchyard equipment.
The equipment to be supplied should have got the facility of transmission of speech
and data simultaneously. Data transmission speed should be 9600 bps. To design the
PLCC system following line parameters are to be taken for a single circuit ---- kV
line.
b) Line impedances
i) L = -------- ohm/km per phase
ii) Inductive Reactive = -------- ohm/km per phase
iii) A.C. Resistance = --------- ohm/km at 20o C
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5.7 Factory Tests for Unit Control Switchboards
12. Review front and rear elevations versus the final approved drawings. Check each
item of equipment for proper location and verify the instrument/catalog number is
correct per the specification.
13. Review the interior of the UCS in the same manner as the elevations. In addition,
verify the lighting is adequate and grounding connections are provided.
14. Check anchor channels and cable entrances. Confirm they are in accordance with
the drawings.
15. Review test certificate or witness the insulation resistance test of all wiring,
current transformers, and potential transformers.
16. Check approximately 5 to 10 percent of the internal cabling. Verify that the
following items conform to the drawings :
• Cable numbers;
• Terminal block designations;
• Terminal designations on individual components such as control switches
and lockout relay;
• Raceway layouts; and
• Equipment identification nameplates.
17. Activate all protective relays. Confirm that the appropriate lockout relay is
energized and the correct annunciation and/or printout occurs.
18. Confirm that settings of all protective relays are in accordance with approved
documents.
19. Check all annunciation points.
20. Check factory calibration of all devices possible, including electronic speed
relays, current and potential transformers, and vibration monitors.
21. PLC checks:
• Check the I/O racks for type and number of analog and digital I/O cards;
• Check for future expansion capabilities on the I/O racks;
• Check for surge protection provided on the I/O rack and I/O cards;
• Identify grounding connections for the PLC and the I/O rack; determine
whether chassis and logic grounds are the same or separate (this will affect
the type and quantity of external surge protection required);
• Review the PLC ladder diagram viewed on the video display terminal
versus the final approved PLC software coding documentation; and
• Verify that modem connections are provided and functional.
22. Perform the function checks listed below with the final approved schematics, PLC
software coding, and control block logic diagrams in front of you. All premissives
and interlocks should be provided by using the “dummy” toggle switchboard to
provide these inputs.
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• Manual emergency stop sequence;
• Automatic emergency stop sequence (usually performed by activating one
of the lockout relays while in the “normal running” mode );
• Change position of all control switches as follows (typically done while in
the normal running mode);
11. Perform point-to-point continuity and megger tests on all external cabling.
12. Calibrate all remaining instrumentation devices.
13. “Bench test” all protective relays to ensure proper settings.
14. Perform functional checks tests on all unit and station auxiliary equipment
controlled from the UCS to verify proper operation.
15. Perform functional checks on unit start/stop sequences, duplicating the factory
sequences. These checks should be performed first with the associated power
circuits de-energized, and then with both power and control circuits energized.
16. Methodically document steps 1 through 7 to ensure that no cables, instrumentation
devices, protective relays, or control systems have been overlooked.
17. Water-up the unit and perform all start/stop sequences.
5.9 Additional Factory and Field Tests for Distributed Control Systems
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5.10 Data/ Document to be furnished by the Bidder
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