HBL Power Systems Ltd.

REF.NO.PSE/P 2603-1 List

REV:1,DT: 20.02.08
SHEET NO: 1 OF 2
HBL POWER SYSTEMS LIMITED
RECTIFIER DIVISION
LIST OF DRAWINGS / DOCUMENTS

CUSTOMER : M/S. BHUSHAN ENERGY LIMITED.,

PROJECT : 2X150MW POWER PLANT, MERAMANDALI, ORISSA

CONSULTANT : DESEIN PRIVATE LIMITED, NEW DELHI

CUST. P.O. NO : 8-4006-BEL-86 DT: 29.12.07

JOB NO : TP-07-3-2603-1

TYPE OF UNIT : 220 TP 150 FC & 220 TP 150 FCBC

QUANTITY : 1 No.

PREPARED BY: CHECKED BY : PPROVED BY :

SL NO. DESCRIPTION DOC. NO. NO OF REV.
SHEET

1. SYSTEM DESCRIPTION PSE/P86828 2 1

2. TECHNICAL SPECIFICATION PSE/P87828 3 1

3. BILL OF MATERIAL FOR CHARGER PSE/P80828 4 1

4. GENERAL ARRANGEMENT DRAWING PSE/P70033 6 1

5. ELECTRICAL SCHEMATIC FOR CHARGER PSE/P50828 8 1

 HBL Power Systems Ltd.
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RECTIFIER DIVISION
SYSTEM DESCRIPTION

CUSTOMER : M/S. BHUSHAN ENERGY LIMITED.,

PROJECT : 2X150 MW POWER PLANT, MERAMANDALI, ORISSA

CONSULTANT : DESEIN PRIVATE LIMITED, NEW DELHI

CUST. P.O. NO : 8-4006-BEL-86 DT: 29.12.07

JOB NO : TP-07-3-2603-1

TYPE OF UNIT : 220 TP 150 FC & 220 TP 150 FCBC

QUANTITY : 1 No.

PRPD BY: CHECKED BY: APPRD BY:

SYSTEM CONFIGURATION

The system consists the following:

1) 220 TP 150 Float charger – 1 No

2) 220 TP 150 Float cum Boost charger-1 No

Both the chargers are connected to input feeder connected to the ON/OFF MCCB through
input change over switch with ON/OFF Switch + Fuse +Contactor + TOV. The charger
consists of three-phase full wave full controlled thyristor bridge with fast acting
semiconductor fuses.

On the DC side, both chargers are provided with out put ON/OFF Switch + Fuse. Battery is
made parallel during normal condition to both the chargers. A battery to load contactor (K3)
is provided to operate both the chargers parallel.

All the alarms are annunciated by HBL make WINDOW Annunciator with associated Alarm
ACK, Reset and Test push buttons provided on the front panel with audible hooters. One
pair of potential free summary contact terminals is provided in each charger for common
fault.

FCBC is provided with two positions Auto/Manual (SW6) and Mode select switches (SW7)
whose positions are as follows
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SW6: Auto/Manual select switch SW7: Mode select switch

Position 1: AUTO Position 1: FLOAT

Position 2: MANUAL Position 2: BOOST

The function of the switches is as below

If Auto/Manual switch is selected in AUTO position the charger automatically turns into Float
or Boost modes depending on the battery conditions. In this position the functioning of Mode
select switches will be disabled.

If Auto/Manual switch is selected in MANUAL position the functioning of the charger

depends upon the selection of FLOAT/BOOST switch.

OPERATION

1) NORMAL CONDITION:

Under normal conditions the contactor K3 is in ON. Condition, it is assumed that the battery
is fully charged. Both float charger and boost charger will operate in parallel, sharing the
load and also keep the battery on float or fed by running by one charger.

2) IN CASE OF MAINS FAILURE:

In case main’s failure the battery will take over the load through battery to load contactor.

3) UPON RESUMPTION OF MAINS POWER

On resumption of the mains, both the chargers will supply the load and float charges the
battery. Depending on the condition of the battery FCBC goes to boost mode automatically
and come back to Float mode automatically if the AUTO/MANUAL switch is in AUTO
position. If the switch is in MANUAL mode, BOOST mode need to be selected manually.
During FCBC in boost mode load to battery contactor is in OFF position.

4) IN CASE OF CHARGER FAILURE OF FC DURING BOOST CHARGING OF FCBC

The FCBC returns back to float and supplies to load and trickle charge the battery. The
momentary supply is supplied through tapcell diode

5) IN CASE OF FCBC FAILS DURING BOOST CHARGING

FC which is supply load will trickle charge the battery through K3 contactor.
 HBL Power Systems Ltd.
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RECTIFIER DIVISION
TECHNICAL SPECIFICATION

CUSTOMER : M/S. BHUSHAN ENERGY LIMITED.,

PROJECT : 2 X 150 MW POWER PLANT, MERAMANDALI, ORISSA

CONSULTANT : DESEIN PRIVATE LIMITED, NEW DELHI

CUST. P.O. NO : 8-4006-BEL-86 DT: 29.12.07

JOB NO : TP-07-3-2603-1

TYPE OF UNIT : 220 TP 150 FC & 220 TP 150 FCBC

QUANTITY : 1 No.

PRPD BY: CHECKED BY: APPRD BY:

1. AC input voltage: 415V, 3 phase, 3 wire, permissible variation: ±10%

2. AC input frequency: 50 Hz, permissible variation: ±5%

3. DC output voltage settings:

Nominal: 220 Volts DC

Float: 240.8 Volts DC (Adjustable)
Boos: 292.4 Volts DC (Adjustable)

4. Total Current Limit: 150A FC & 150A FCBC

5. Power Conversion: AC to DC by means of a three phase full wave

Controlled bridge consisting of Thyristors.

6. Output Voltage Regulation: ±1% of set voltage for ±10% input variations, and
0-100% load variations

7. Efficiency: 80% (At full load)

8. Ripple voltage: < 1% RMS

9. Power factor 0.8 lag at rated load

9. Switchgear:

a) Input side : MCCB + Switch + Fuse + Con + TOV

b) Output side : Switch + Fuse
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10. Protection:
a) Surge suppressors
b) Soft start
c) Total current limit
d) Control circuit & voltmeter fuses
e) Rectifier protection fuses
f) I/p phase failure
g) I/P voltage Unbalance protection

11. Digital Meters (48X96 mm, Acc 1.0%) 1) AC input Voltmeter (0-500V)
2) DC output Voltmeter (0-400V)
3) DC output Ammeter (0-200A)
4) Battery Voltmeter (0-400V)
5) Battery Ammeter (300A-0-300A)

12. Indications: AC Power ON (R, Y, B)

Output ON
Charger ON Float
Charger ON Boost
13. Alarms:

FC FCBC

Mains AC Failure DC under voltage

AC Under Voltage DC over voltage
DC under voltage DC earth fault
DC over voltage DC over load
DC earth fault Battery under voltage
DC overload SCR fuse fail
SCR fuse fail
Filter fuse fail Filter fuse fail
Charger fail Battery on discharge
Surge suppressor fuse fail Charger fail
Surge suppressor fuse fail

All visual alarms will be provided through HBL make window type annunciator. Audio alarm
through buzzer. Alarm ack, reset and LED test provision through Push Buttons. One pair of
potential free summary contacts terminals is provided grouping all the faults for remote
annunciation.
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14. Operating Temperature: 0- 50° C

15. Panel: a) 2200 (H) x 1400 (W) X 800 (D)- FC

b) 2200 (H) x 1400 (W) x 800 (D)- FCBC
c) Protection grade: IP-42
d) Natural air-cooling for ventilation
e) Paint shade: RAL 7035
Paint thickness: 50 microns

16. MAGNETICS

a) Average winding temp. Rise over ambient: 70 Deg.C

b) Insulation class: F
c) Insulation break down voltage: 2KV for 1 Min.

17. CABLES

650/1100V grade PVC insulated, copper, Multistrand. Ferrules will be provided at both ends of
each wire for identification.
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RECTIFIER DIVISION
BILL OF MATERIAL

CUSTOMER : M/S. BHUSHAN ENERGY LIMITED.,

PROJECT : 2 X 150 MW POWER PLANT, MERAMANDALI, ORISSA

CONSULTANT : DESEIN PRIVATE LIMITED, NEW DELHI

CUST. P.O. NO : 8-4006-BEL-86 DT: 29.12.07

JOB NO : TP-07-3-2603-1

TYPE OF UNIT : 220 TP 150 FC & 220 TP 150 FCBC

QUANTITY : 1 No.

PRPD BY: CHECKED BY: APPRD BY:

SL. PART NO. DESCRIPTION SEPCIFICATION MAKE QTY
NO.
1. CONSOLE 2200HX1400WX800D (FC) HBL 1
2200HX1400WX800D (FCBC)
2. T1 MAIN XMER(FC) 57.75 KVA HBL 1
PRI: 415V ±10%
SEC: 227 V
3. T6 MAIN XMER 69.3 KVA HBL 1
(FCBC) PRI: 415V ±10%
SEC: 271 V
4. T2 (FC), CONTROL XMER 50 VA HBL 2
T7(FCBC) PRI: 415V ±15%
SEC1: 18V, 1A
SEC2 & SEC3: 15V, 1A
5. T3-5 (FC), SYNCH.XMER 10VA HBL 6
T8-10 (FCBC) PRI: 230V ±15%
SEC: 0-10V, 1A
6. L1 CHOKE (FC) 0.6263 mH AT 150A DC HBL 1
7. L2 CHOKE (FCBC) 0.7484 mH AT 150A DC HBL 1
8. C1,C2 FILTER 4700MFD/450V RESCON/ 10
CAPACITORS (5 IN PARALLEL) ALCON
9. V1-6, THYRISTORS 200A, 1200V PIV HIRECT/ 12
V9-14 SEMIKRON
10. V7,8, 15, 16,17, F.W/BLOCKING/ 250A, 1200V PIV HIRECT/ 15
17A, 17B TAPCELL DIODES 3 IN PARALLEL SEMIKRON
11. HS1-6, HS9-14 HEAT SINKS EIA1717 150MM EIA 12
12. HS7, 8,15-17, HEAT SINKS EIA1717 150 MM EIA 15
17A, 17B
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SL. PART NO. DESCRIPTION SEPCIFICATION MAKE QTY
NO.
13. Q1-Q2 (FC) I/P ON/OFF MCCB 3P, 415V AC, 200A, 30KA ABB 2
14. SW1 CHANGE OVER 200A, 3P, 2W, 415V AC KAYCEE 1
SWITCH SWITCH
15. S1, S3 I/P ON/OFF SWITCH 150A, 3P, 415V AC KAYCEE 2
16. S2, S4 O/P ON/OFF 200A, 2P, 240V DC KAYCEE 2
SWITCH
17. VS1 I/P VOLTAGE 10A, 4 POSITION WITH KAYCEE 1
SELECT SWITCH OFF
18. TH1 THERMAL 54-81A, 415VAC, ABB 1
OVERLOAD RELAY
19. TH2 THERMAL 66-99A, 415VAC ABB 1
OVERLOAD RELAY
20. K1 I/P CONTACTOR 3P, 110A, 415V AC COIL, ABB 1
(FC) AUX. 1NO+1 NC
21. K2 I/P CONTACTOR 3P, 150A, 415V AC COIL ABB 1
(FCBC) AUX. 1NO+1 NC
22. K3 BATTERY TO LOAD 3P, 300A, 220 V DC COIL ABB 1
CONTACTOR AUX. 1NO+1 NC, 3poles
connected in series
23. K3A AUX. CONTACTOR 2P, 16A, 220V DC ABB 1
AUX. 1 NO
24. SW2, 4 PANEL LTG. 6A, ON/OFF TOGGLE IEC 2
ON/OFF SWITCH TYPE TS 610
25. SW3, SW5, I/P ON/OFF 6A,1P, 2W CAM TYPE KAYCEE 3
SW7 SWITCH, MODE ISI6B
SELECT SWITCH
26. SW6 AUTO/MANUAL, 6A,2P, 2W CAM TYPE KAYCEE 1
SWITCH 2S26B
27. RL5, 9 SUMMARY 5A, 220V, DC, 3C/O PLA/OEN 2
CONTACT RELAYS TYPE WITH 11 PIN BASE 2
28. RL10 BOOST RELAY 5A, 24V, DC, 3C/O PLA/OEN 1
TYPE WITH 11 PIN BASE 1
29. RL12 VOLT SENSING 5A, 110V DC, 3C/O PLA/OEN 1
RELAY TYPE WITH 11 PIN BASE 1
30. CT1-6 CURRENT TXR 100/5A, 5VA AE/KAPPA 6
31. F1-3 I/P FUSES (FC) 125A TSF 125 GEC/BUSMAN 3
WITH SM 125H BASE
32. F24-26 I/P FUSES (FCBC) 160A TSF 160 GEC/BUSMAN 3
WITH SM 160H BASE
33. F23-23, O/P FUSES 200A TSF 200 GEC/BUSMAN 3
F42-43 (FC & FCBC) WITH SM 160H BASE
34. F11-16 RECTIFIER FUSES 200A, GSG1000/200 GEC/BUSMANN 12
F31-36
35. F20, 40 CAPACITOR FUSES 80A, VSB80 WITH ISG160 GEC/BUSMANN 2
36. F4, 27 PANEL LTG. 6 A, TIA 6 WITH SM 32H GEC 2
CKT.FUSES BASE GEC 2
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SL. PART NO. DESCRIPTION SEPCIFICATION MAKE QTY
NO.
37. F5-10, F17- CONTROL CKT & 1A GLASS FUSE WITH C.W 24
19,F21,F28- V.METER FUSES HOLDER
30, F37-39,
F41, F36,
F8A-10A,
F28A-30A
38. P1 I/P VOLMETER 0-500V AC, AE/ IMP/ 1
48X96 Sq.mm, 1.0%ACC RISHABH/MECO/
AUX. SUP. 180-300V DC CADDLE
39. P2, 4 O/P VOLTMETERS 0-400VDC,48X96 Sqmm. AE/ IMP/ 2
1.0% ACC RISHABH/MECO/
AUX. SUP. 180-300V DC CADDLE
40. P3, 5 O/P AMMETERS 0-200A, 48X96 Sq.mm., AE/ IMP/ 2
75MV 1.0% ACC RISHABH/MECO/
AUX. SUP. 180-300V DC CADDLE
41. P6 BATTERY 0-400VDC,48X96 Sqmm. AE/ IMP/ 1
VOLTMETER 1.0% ACC RISHABH/MECO/
AUX. SUP. 180-300V DC CADDLE
42. P7 BATTERY AMMETER 300-0-300ADC, AE/ IMP/ 1
48X96 Sq.mm 1.0%ACC RISHABH/MECO/
AUX. SUP. 180-300V DC CADDLE
43. SH1-2 CHARGER SHUNT 200A, 75m V AE/IMP 2
44. SH3 BATTERY SHUNT 300A, 75Mv AE/IMP 1
45. VD1-3 INPUT ON LEDS 22.5mm 240V AC ESBEE/L&T/ 6
21-23 CLUSTER LEDS SIEMENS
46. VD4, 24 O/P ON LEDS 22.5mm 220V DC ESBEE/L&T/ 2
CLUSTER LEDS SIEMENS
47. VD25, 26 CHARGER ON FLOAT 10MM RED LED REPUTED 2
& BOOST LED’S WITH HOLDER
48. VD1A-4A, MIMIC PLATE LED’S 5 MM RED LED’D WITH REPUTED 10
21A-26A METAL HOLDER
49. PS1, 2 POWER SOCKET 5A, 240V AC REPUTED 2
50. DS1-4 DOOR SWITCHES 1NC REPUTED 4
51. IL1-2, IL3, 4 ILLUMINATING LAMP 60W, 240V AC BULB REPUTED 4
WITH HOLDER
52. BZ1, 2 HOOTER 12V DC REPUTED 2
53. SPH1-2 SPACEHEATER 240V, 80W REPUTED 2
54. TSC1-2 THERMOSTAT 0-85 DEG.C REPUTED 2
55. PT1-5 POTENTIOMETERS 20K,MULTITURNS BOURNS 5
56. A1, 21 MOTHER BOARD 69-00242 HBL 2
57. A2, 22 FIRING CARD 69-00319 HBL 2
58. A3, 23 CONTROL CARD 69-00118 HBL 2
59. A4, 24 POWER SUP. CARD 69-00120 HBL 2
60. A5, 25 AUX.CARD 69-00141 (220V) HBL 2
61. A6, 26 R C CARD 69-00003 (220V) HBL 2
62. A7, 7A, PULSE XMER CARD 69-00140 HBL 4
27,27A
63. A13 MAINS FAIL CARD 69-00251 HBL 1
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SL. PART NO. DESCRIPTION SEPCIFICATION MAKE QTY
NO.
64. A11, 12, GEN. RELAY CARDS 69-00333 HBL 3
31
65. A10, 30 WINDOW 3R X 4C HBL 2
ANNUNCIATOR
66. A9, 29 DC-DC CONVERTER 69-00076(220V) HBL 2
67. A14, 15, 34, 35 FUSE FAIL CARD 69-00123 HBL 4
68. A8, 28 TIME DELAY CARD 69-00169 HBL 2
69. A17, 37 RELAY CARD 69-00215 HBL 2
70. A36 VOLT SENSING CARD 69-00325 (220V) HBL 1
71. CABLES INPUT WIRING (FC) 25 Sqmm
INPUT WIRING (FCBC) 35 Sqmm
CAPACITOR WIRING 25 Sqmm
OUTPUT WIRING 75 Sqmm CU BUS BAR
BTY.TO LOAD WIRING 75 Sqmm CU BUS BAR
CONTROL WIRING 2.5 Sqmm CU (GREY) Reputed
CONTROL WIRING 2.5 Sqmm CU (BLACK)
PCB WIRING 0.5 Sqmm CU (GREY)
PCB WIRING 0.5 Sqmm CU (BLACK)
EARTHING BUSBAR 25x5 CU BUS BAR
72. TERMINALS
X/1-3, X/31-33, INPUT TERMINALS M8 X 60 L 12
X/35-37,41-43
X/5-6 LOAD TERMINALS M10 X 70 L 2
X/7-8,9 BATTERY, TAPCELL M12 X 70 L 3
TERMINALS
X10-11(FC), INTERLOCK TERMINALS M10 X 70 L Reputed 4
X/12-13 (FCBC) (POWER)
X15-16 (FC), SUMMARY CONTACT CTS 2.5 4
X17-18 (FCBC) TERMINALS
X/19-24(FC) INTERLOCK TERMINALS CTS 2.5 12
X/25-30 (FCBC) (CONTROL)
BOM FOR RS 485
A20, 40 PORT CARD RS 485 COM.PORT HBL 2
T12-17 SYNCH.XMER 10VA HBL 6
PRI: 240V ±10%
SEC: 0-10V, 1A
SL1-6 CT SHORT LINKS 6 Sq.mm CDTTU C.W 6
73. HARDWARE
74. ENGRAVING
75. PACKING