PGL / STD / Switchyard / 07

MAHARASHTRA INDUSTRIAL DEVELOPMENT

( A GOVT. OF MAHARASHTRA UNDERTAKING)

ITEM NO. 8Bay Marshalling Box.

Providing, erecting, testing and commissioning of following types of Bay Marshalling Boxes complete as per detail technical specification.

Item No. 8.1120 terminal Bay Marshalling Box.

Item No. 8.2 60 Terminal Bay Marshalling Box

TECHNICAL SPECIFICATION1.0SCOPE

The scope of this specification covers the design, manufacture, galvanising or painting as specified, inspection & testing before dispatch, packing & forwarding to site Marshalling Kiosks for use in EHV switchyard for connection of control cables coming form various switchyard equipment and the control room.

2.0STANDARDS

The marshalling Kiosk offered shall conform to the latest revisions of relevant standards, rules and codes. Some of these standards are listed below:

Sr. No.Standard NoT I T L E

1IS : 13947Degree of protection provided by enclosure for low voltage switchgear and control gear

2IS : 4007Terminals for equipment

3IS : 13703HRC cartridge fuse links

4IS : 6005Code of phosphating for Iron and Steel

5IS : 5Colour of ready mix paints

6IE Rule - 1956

3.0PRINCIPAL PARAMETERS

The equipment covered in this specification shall meet the following technical particulars and the general technical requirement of the marshalling box furnished at 4.0 below:Sr. NoParticularsRequirement

120 Ways60 Ways

1.InstallationPedestal mountedPedestal mounted

2.TypeOut door typeOut door type

3.Electrical clearancesAS per IE ruleAS per IE rule

4.Minimum inside dimensions

4.1Height1200800

4.2Width750750

4.3Depth300300

5.Thickness of sheet steel2.5 mm (min)2.5 mm (min)

6.Degree of protectionIP - 55IP - 55

7.Terminal Block

7.1SizeSuitable to connect 10 sq. mm aluminum or 2.5 sq. mm. copper conductorSuitable to connect 10 sq. mm aluminum or 2.5 sq. mm. copper conductor

7.2TypeM5 Clip on with melamine body and poly carbonate cover. Elmex/ConnectwelM5 Clip on with melamine body and poly carbonate cover. Elmex/Connectwel

7.3Normal Current30 A30 A

7.4Rated voltage1100 V1100 V

Sr. NoParticularsRequirement

120 Ways60 Ways

7.5Insulation Level3.5 kv for 1 minute3.5 kv for 1 minute

7.6Minimum clearance between terminal block and cable gland150 mm150 mm

7.7Minimum clearance between two rows of terminal blocks150 mm150 mm

8.Fuses

8.1TypeHRC NS cartridgeHRC NS cartridge

8.2Normal current16 A16 A

8.3Rated voltage415 V415 V

8.4Insulation Level3.5 kV for one minute3.5 kV for one minute

4.0GENERAL TECHNICAL REQUIREMENT

4.1The marshalling box shall have the arrangement of terminal columns as under:

4.1.1120 Way marshalling box shall have three columns of terminal blocks each with 40 terminals.

4.1.260 Way marshalling box shall have three columns of terminal blocks each with 20 terminals.

4.1.3The installation of terminal blocks shall commence from top of the column, bottom side of the column shall be kept without terminals for installation of additional terminal blocks if required, in future.

4.2The marshalling kiosk shall be sheet steel enclosed, dust, vermin weather proof suitable for installation outdoors. Cold rolled sheet steel shall be used for the box.4.3The box shall stand on base angle frame with a door, switchboard type handle and locking arrangement & hooks for padlocking industrial lock at top and bottom of the door. The door shall have three hinges for 120 way and two hinges for 6o way box.

Holes of 23 mm diameter shall be provided for the foundation pad for fixing it on the foundation. Foundation bolts of adequate size shall also be provided along with each box.

4.4Cable entry shall be from bottom. Removable steel sheet gland plate of at least 3.5 mm thick shall be provided for this purpose.4.5A switch, HRC fuse, socket and holder suitable for 230 V lamp shall be provided.

4.6A sloping rain hood shall be provided to cover all the sides of the box. All doors / covers shall be designed with special shape and sections and provided with adequate size of neoprene gaskets to prevent ingress of moisture and achieve the degree of protection of IP 55.

4.7Two nos. of earthing terminals shall be provided on the two sides of the marshalling box for connection to the earth mat.

4.8Gaskets shall be provided all round the doors and gland plates. Neoprene anti vibration gasket of size 18 mm x 5 mm thk on door and 15 mm x 2 mm thk on gland plate shall be provided.

4.9All nuts and bolts including foundation bolts shall be electro galvanised in white shade.

4.10Terminal Blocks4.10.1The terminal block shall be M 5 clip on type, one piece moulded complete with insulated barriers, stud type brass terminals, washers, brass nuts, brass lock nuts and identification strips. Studs, screws and washers etc. shall be made of brass and shall be nickel plated. The springs shall be made of non magnetic stainless steel. The washer shall be of brass having minimum thickness of 0.5 mm and shall be nickel plated. The connectors shall be rated for 1100 V at 30 A continuous current.

4.10.2The terminal blocks shall be mounted on electro galvanised C shaped steel section at least 2 mm thick. Zinc coating shall be at least 20 microns. Each column shall have provision for addition of at least five terminals if required.4.10.3Steel end clamps shall be provided to fix the terminal blocks in position at each end of the row.

4.10.4Heavy duty transparent unbreakable good quality clip on type polycarbonate or equivalent covers shall be provided on the terminal block to prevent contact with the terminals unless the cover is removed.

4.10.5Each terminal block shall be so arranged that any individual terminal can be connected / removed / replaced without disturbing the other.4.10.6Four PVC troughs shall be provided between columns of the terminal blocks to receive wires for connection to individual terminals. The trough shall have PVC cover.

4.11Painting

4.11.1All sheet steel work shall be phosphated by seven tank process in accordance with IS 6005. Oil, grease, dirt shall be thoroughly removed by emulsion cleaning.

4.11.2Rust and scale shall be removed by pickling with dilute acid followed by washing with running water, rinsing with slightly alkaline hot water and drying.

4.11.3After phosphating, thorough rinsing shall be carried out with clean water followed by final rinsing with dilute dichromate solution and oven drying.

4.11.4Phosphate coating shall be sealed by the application of the two coats of stoving type epoxy primer. The first coat may be flash dried while the second coat shall be stoved.4.11.5After application of the primer, two coats of finishing epoxy paint shall be applied. The second finishing coat shall be applied after the completion of tests. The panel shall have colour confirming to shade 631 as per IS 5 for out side and inside of the box. Base frame shall be coloured black. Thickness of paint shall not be less than 50 microns.5.0TESTS

5.1The equipment offered should have been successfully type tested in line with the relevant Indian Standards and technical specification. The successful bidder shall submit two copies of the type test report for review and record along with the submission drawings.

5.2All acceptance and routine tests as stipulated in the relevant standards shall be carried out in presence of purchasers representative.

6.0INSPECTION

6.1The inspection may be carried out by MIDC at any stage of manufacture and also after the equipment is ready at manufacturers works. The manufacturer shall grant free access to the purchasers representative at any reasonable time when the work is in progress.

6.2The supplier shall keep the purchaser informed of the time of starting and of the progress of manufacture of the equipment in its various stages.

6.3No material shall be dispatched from its point of manufacture unless the material has been satisfactorily inspected and tested.

6.4Advance information of the readiness of the equipment shall be given to MIDC for arranging visit to manufacturers works for inspection.

7.0Quality Assurance Plan

7.1The successful bidder shall submit a detail quality assurance plan for procurement of raw material, manufacturing and testing of the equipment within a fortnight of receipt of Letter of Intent.

7.2It shall also include following information :

a) Statement of Raw materials, names of sub-suppliers, standards according to which raw material is tested, List of tests normally carried out on raw materials in the form of a quality assurance plan.

b) Copies of test certificates of all bought out items.

c) List of manufacturing facilities available.

d) List of testing equipments

8.0Performance Guarantee

The equipment shall be guaranteed for satisfactory performance for a period of 24 months from the date of receipt of material at site or 18 months from the date of commissioning whichever is earlier. In case of failure of the equipment within this period, the supplier shall make good the faulty equipment at no extra cost to the purchaser.

9.0Drawings and documents

9.1All the drawings shall conform to the international standards organization (ISO) A series of drawing sheet. All drawings shall be Auto cad generated. All the dimensions shall be in system international units.

9.2The successful bidder shall on receipt of LOI submit four sets of following minimum drawings along with bill of material and packing list for purchasers approval. After receipt of purchasers approval, the supplier shall submit four prints and a soft copy of the approved drawings.

9.2.1General outline drawing showing outside dimensions, shipping dimensions, weights and such other prominent details.

9.2.2Sectional views showing the general constructional features of the marshalling kiosk including door details and fixing of gaskets to achieve IP 55 feature .

9.2.4Foundation plan including pedestal details.

9.3Guaranteed technical particulars of the equipment in the format acceptable to M S E B.

9.4Approval of drawings by the purchaser shall not relieve the supplier of any of his responsibility and liability for ensuring correctness and correct interpretation of the drawings for meeting the requirements of the applicable standards, rules and code of practice.

10.0Packing & Forwarding

10.1The equipment shall be packed in suitable crates so as to withstand handling during transport and out door storage. The supplier shall be responsible for any damage to the equipment during transit, due to improper and inadequate packing.

10.2Each consignment shall accompany a detailed packing list.

11.0Installation

11.1The contractor shall arrange to transport the marshalling box to its location & mount the marshalling boxes on steel frames as per MSEB norms & approved drawings.

11.8Following preliminary checks shall be conducted before commissioning of circuit breakers.

1.Check the tightness of bolts, clamps and connecting terminals.

2.Check earthing connections.

3.Check control wiring for correctness of connections , continuity and IR values.

4.Ensure doors are properly aligned .

12.0Mode of Measurement

The measurement shall be made on per box basis.

CONTRACTOREXECUTIVE ENGINEER