above ground fire pump

7/23/2019 Above Ground Fire Pump

http://slidepdf.com/reader/full/above-ground-fire-pump 1/61

PA ABOVE GROUND FIRE PUMP (Please change this description to suit your job)

PA.1 GENERAL :

PA.1.1 DESCRIPTION

The work require u!er "hi# Co!"r$%" wi&& 'e (or "he )$!u($%"ure* ($%"or+ "e#"i!,*e&i-er+ "o Si"e* o((&o$i!,* #"or$,e i( !e%e##$r+/* i!#"$&&$"io!* #i"e "e#"i!, $!%o))i##io!i!, o( "wo "re$"e w$"er 0u)0# $! )o"or#* o!e o%ke+ 0u)0*$##o%i$"e 0i0ework* -$&-e#* e"%. wi"hi! "he 0u)0i!, #"$"io! "o 1) ou"#ie "he0u)0i!, #"$"io! "o,e"her wi"h $&& "he !e%e##$r+ e&e%"ri%# $! %o!"ro&#.

PA.1.2 PUMP C2ARICTERISTIC CURVES

Within as short a time as possible but not later than 2 weeks after the award of the

ontract! the ontractor shall supply to the "ngineer! the proposed pump characteristiccur#e and suppliers data sheet for appro#al.

PA.1.$ PLANT DRA3INGS

Within as short a time as possible but not later than 2 weeks after the award of theontract! the ontractor shall supply to the "ngineer! in triplicate! fully dimensioneddrawings of the plant and e%uipment to be supplied by him and details of the positions of all foundations! bolt holes! openings in walls or floors and other special features affectingthe construction of the works so that the "ngineer can appro#e such details and si&e.

PA.1.' INSTALLATION PROGRAMME

Within 1 week after the award of the ontract the ontractor shall furnish! in triplicate! aconsolidated programme in the form of a bar chart or other suitable format showingseparately! in sufficient detail! each major operation with critical operations clearlyidentified. All future re#isions of the programme shall be of the same format as of thatinitially submitted. n preparing his programme the ontractor shall make due allowancefor the fact that work under the i#il "ngineering aspects of the ontract! will beproceeding simultaneously.

PA. 1. DELIVER4 AND STORAGE

mmediately any consignment of plant or materials under the Pumping Plant aspect of the ontract is despatched! and four days prior to despatch by road transport! the"ngineer*s +epresentati#e must be notified and an additional ad#ice note shall beforwarded to the "ngineer! gi#ing a full description of the plant and materials despatched!date of consignment and details of the transportation.

,o co#ered storage is a#ailable on site for the plant and e%uipment to be supplied. -heontractor will! howe#er! be permitted to store nonperishable items on site in the openair at his own risk. Apart from any materials stored thus! all plant and materials to besupplied under this ontract shall be stored at the ontractor*s e/pense! either in his ownstores or in stores arranged by the ontractor nearer to site and deli#ered to site onlywhen installation is re%uired. All costs of storage and deli#ery to site shall be deemed toha#e been included in the 0chedule of Prices.

All plant! e%uipment! apparatus and pipework likely to be damaged in loading or unloading! or through chafing or through being subjected to pressure! or likely to

2$ 001



deteriorate through e/posure to the atmosphere whilst in storage! is to be suitablypacked so as to pre#ent such damage.

PA.1. STANDARDISATION

n order to simplify maintenance and minimise stocks of spares! the ontractor shallstandardise components supplied under this ontract as far as is reasonably practicable.

PA. 5 MATERIALS AND 3OR6MANS2IP :

PA. 2.1 MATERIALS 7 GENERAL

PA.2.1.1 All materials used and plant supplied shall be of ade%uate %uality and the mostappropriate of their kind in accordance with the best accepted modern practice3 theyshall be suitable for working at the pressures and temperatures in#ol#ed! under alloperating conditions! without distortion or deterioration or the setting up of undue

stresses in any part.

PA.2.2 STANDARDS AND SAMPLES

PA.2.2.1 STANDARDS:

-he latest editions and amendments of the following 0tandards and odes shall beconsidered a minimum re%uirement! and the entire installation shall comply with these0tandards and odes of Practice unless otherwise specified elsewhere in this documentor dictated by 4o#ernment! 0upply Authority or 5ocal Authority 6y5aws and Pro#isions 7

(i) -he 0A60 ode of Practice for the Wiring of Premises.

(ii) -he 8ccupational 9ealth : 0afety Act ; of 1<<$.

(iii) 0outh African 6ureau of 0tandards 0pecifications and odes of Practice(0A60).

(i#) 6ritish 0tandards and 0pecifications and odes of Practice (600=P).

(#) " 0tandards and odes of Practice.

.-i/ ASIB Au"o)$"i% S0ri!k&er I!#0e%"io! Bure$u P"+/ L" Ru&e#

,ational 0tandards and odes of Practice take priority o#er foreign 0tandards andodes! and where ,ational 0tandards and odes do not e/ist! the rele#ant 600 and "odes shall apply in that order of preference.

,otwithstanding anything to the contrary! the most onerous condition will be deemed toapply! in the e#ent of any ambiguity or conflict between applicable 0tandards!0pecifications and=or odes of Practice which could arise.

PA.2.2.2 SAMPLES:

0amples of e%uipment and material intended for use in the installations may bere%uested by the "ngineer before work is commenced and such samples may beretained until completion of the ontract. opies of the rele#ant standard test reportsshall be submitted to the "ngineer on re%uest.

2$ 002



,otwithstanding the foregoing! the ontractor shall satisfy himself as to the suitability of all materials supplied by him for the purpose re%uired. t shall be deemed that the pricesincluded in the 0chedule of >uantities=Prices ha#e allowed for the pro#ision of suchsamples! tests and test reports unless otherwise stated in the 0pecification.

PA.$. STRUCTURAL STEEL3OR6

PA.$.1 -he structural steel used in this ontract shall be to 0A60 1'$1 4rade $ W.

PA.$.2 6lack bolts and nuts shall be in accordance with 0A60 1$.

PA.$.$ 6lack metal washers shall be in accordance with 60 $'1.

PA.$.' 9igh strength friction grip! bolts! nuts and washers shall be in accordance with0A60 12;2! and their application shall conform to 0A60 <'! tor%ue wrenches or impacttools where used shall be recalibrated before each shift.

PA.$. All fabrication and erection procedures shall be in accordance with 0A60 12 as

amended! Part 2! hapter .

PA.$. 6efore commencing the fi/ing of the steelwork the ontractor shall check the seating for line! le#el and bolt setting! and any errors which cannot be accommodated shall beimmediately reported to the "mployer.

PA.'. STEEL FABRICATION AND BASEPLATES

PA.'.1 -he manufacture of all fabricated items of plant shall be generally in accordance with0A60 12.

PA.'.2 -he fabrication and manufacture of the plant and e%uipment shall be completed in theontractor*s workshops before deli#ery to site.

PA.'.$ ,o fabrication of complete units shall take place on site. 0ite work shall be confined onlyto such alterations and adjustments as are found to be necessary during erection.

PA.'.' f major alterations are found necessary! the items of plant concerned shall be returned tothe ontractor*s workshops for modification or replacement and shall be tested andchecked before redeli#ery to site.

PA.'. ?ri#e baseplates shall be robustly constructed and ade%uately stiffened to pre#enttwisting and distortion.

PA.'. Any fabricated baseplates shall be of allwelded construction and formed of hot rolledmild steel plates and sections.

PA.'.@ Where dri#ing units are directly coupled to the dri#en component all mounting surfacesshall be machined to ensure correct alignment. 0hims may be pro#ided to aid finalalignment. After final shop assembly and testing! the indi#idual items of plant shall beaccurately dowelled and bolted in position on the baseplate to pre#ent any misalignmentduring transportation and installation or during operation.

PA.'.; -he ontractor shall include in the design for any measures re%uired to counter theeffects of #ibration which might be caused by the operation of the e%uipment3 such#ibration should howe#er be minimal and in accordance with the appropriate standard.

PA.'.< -he baseplates shall be designed in a manner which will enable the ontractor to ramgrout under the support frame without cutting of the baseplate such that the baseplatesupport faces are in full contact with the grout.

2$ 00$



PA.'.1 A stainless steel ($+12) drip tray must be pro#ided under the pump=motor shaft tocollect any water passing the gland.

2$ 00'



PA.. STEEL PIPES :

PA..1 STEEL PIPES AND COATINGS

"/cept in cases where steel pipes and fittings are to be used in compliance with 0ection aterials and Workmanship! lause PA ; hereof! all steel pipes and fittings shall belined and coated and shall be in compliance with 0A60 @1< or 60 $'. -he lining andcoating of such pipes and fittings shall be set out in 0ection aterials andWorkmanship! lause PA 2.

PA..2 STEEL PIPES ARC 3ELDING PROCEDURE:

A&& we&i!, i# "o 'e %$rrie ou" '+ Cer"i(i%$"e or Coe we&er#.

-he welders shall possess one or more of the following certificates of competency 7

(a) A0" 0ection < for Position .g

(b) Welding certificate for positional welding in accordance with 0A60 ode of

Practice.

(c) Welding certificate for positional welding in accordance with 60 ';@2 Part 1.

PA..2.1 Fir#" 3e&# o! S"ee& Pi0i!,:

All first welds on steel piping shall be Argon Arc welds followed by arc welding. 0mallbore piping with diameter less than 2mm shall be totally Argon Arc welded. etal Arcwelding shall be in accordance with -echnical emorandum -.$ issued by the 6ritishWelding +esearch Association.

PA..2.2 I!$equ$"e Pe!e"r$"io! $! L$%k o( Fu#io!:

Any indi#idual defect due to inade%uate penetration or lack of fusion shall not e/ceed12mm in length. -he total length of any such defects in any $mm length of weld shallnot e/ceed 12mm. ndi#idual defects shall be separated by at least 1mm of soundweld metal. f the weld is less than $mm then the total length of such defects shall note/ceed B of the total weld length.

PA..2.$ S&$, I!%&u#io!# 7 3e&#:

-he ma/imum width of any isolated slag inclusions shall not e/ceed 1!mm and the totallength of any such inclusions shall not e/ceed one and a half times the nominal wallthickness. Adjacent inclusions shall be separated by a minimum of mm of sound weld

metal.

PA..2.' Poro#i"+:

-he ma/imum dimensions of any indi#idual gas pocket shall not e/ceed 1!mm.lustered or scattered porosity throughout the weld will be adjudicated on its merits bythe "ngineer! whose decisions will be final.

areful consideration must be gi#en to temperatures and pressures.

,o weld containing cracks! regardless of shape! si&e or location will be accepted.

2$ 00



PA..2. U!er%u""i!,:

Cndercutting shall not be Dshaped! nor shall it e/ceed !@mm or 12EB of the pipe wallthickness! whiche#er is the smaller in depth! nor shall it e/ceed mm in length or 1=thof the length of the weld! whiche#er is the smaller.

Cndercutting adjacent to the root bead on the inside of the pipe shall not e/ceed mm inlength! or 1=th of the length of the weld! whiche#er is the smaller.

PA..2. Re0$ir o( Re)o-$& o( De(e%"#:

?efects! e/cept cracks! in the root and filler beads may be repaired only with the prior consent of the "ngineer. A butt weld containing any form of cracks shall be remo#ed inits entirety. All repairs to welds must meet the specified standards of acceptability.

6efore a repair is made! injurious defects shall be entirely remo#ed down to clean metal. All slag and scale shall be remo#ed by grinding or wire brushing. Preheating of a localrepair area may be called for by the "ngineer. Any repaired areas shall be reradiographed! or inspected by the same means pre#iously used.

-he "mployer reser#es the right to reinspect the whole of any repaired weld.

PA..2.@ Pi0e Be!# or S0e%i$&#:

Where reducers! bends or tees are re%uired! suitably drawn and formed fittings!compatible with the pipes! may be used. All fabricated fittings shall be appro#ed by the

"ngineer and the wall thickness of the bends or specials increased to the ne/tstandard wall thickness of the adjacent piping (#i&. '! mm thick 4rade A steel pipe bends or specials therefor shall be mm thick 4rade A steel pipe etc.)

PA..$ STEEL PIPE 7 GAS 3ELDING PROCEDURE

PA..$.1 8/yacetylene welding shall generally be carried out in accordance with theF+ecommended practice of o/yacetylene welds in ild 0teel PipelinesF published by the9eating and Dentilation ontractors Association.

PA..$.2 -he ontractor shall obtain from the manufacturers test certificates representati#e of welding rods and electrodes used in accordance with 60 1'$ or 60 $< respecti#ely.

PA..$.$ All welded joints! whether produced by o/yacetylene flame or metalarc processes shallbe of firstclass %uality. -he butts shall be slightly con#e/ with regular ripples and no

undercutting washing away or surface ca#ities shall be present. ,otches at the rootindicating incomplete penetration and e/cessi#e weld protruding into the pipe bore ine/cess of 1!mm will not be accepted and the e/ternal reinforcement shall run outsmoothly to the pipe surface on either side. All slag shall be remo#ed after each run.Cndercut edges! slag pockets! unsound metal and blowholes shall be chipped out as thework proceeds.

PA.8. POL4PROP4LENE PIPE 3ELDING PROCEDURE

PA..1 P"! PP and uPD pipes shall comply with 0A60 $$ Part ! 0A60 1$1 or 0A60 <respecti#ely for water supply purposes and shall be weather resistant and CD 0tabili&edwhere installed abo#e ground. Goints and fittings for unplastici&ed PD pipes shall be to60 '$'.

PA..2 Cnplastici&ed PD pipes for drainage purposes shall be to 0A60 @<1 and 0A60 <@ for underground and abo#e ground systems respecti#ely.

2$ 00



PA.9 VALVES

[email protected] SLUICE VALVES:

-hese shall be cast iron standard waterworks pattern #al#es double flanged for steel

pipes and plainended for uPD mounted pipes.

-he #al#e wheels or handles shall be clockwise closing with nonrising stainless steelspindles. ?irection of closing shall be clearly marked on the handwheel.

-he sluice #al#es shall comply with the re%uirements of 0A60 ' for Waterworks 4ateDal#es up to lass 2! 0A60 for ndustrial 4ate Dal#es up to lass 2! 0A60 1<1for 0teel 9igh Pressure 4ate Dal#es for both Waterworks Pattern and ndustrial Patterngreater than lass 2.

[email protected] BUTTERFL4 VALVES:

-hese shall be cast iron double flanged #al#es of perfect closure. -he #al#es shall befitted with stainless steel shafts and discs and natural rubber or neoprene seats andshaft seals.-he #al#es shall comply with 60 1 1<;'.

PA@.$ REFLU VALVES:

-hese shall be double flanged and shall comply with the re%uirements of 0A60 1'' for swing check types.

+eflu/ #al#es shall be so designed that when mounted hori&ontally the flap restsagainst the seat in the absence of flow or pressure without the aid of springs or

counterweights

PA;. FLANGES

PA;.1 Hlanges for pipes and specials shall be parallel faced truly at right angles to the bore or branch and machined o#er the full width of the contract face. ?imensions and drillingshall be in accordance with 0A60 112$ unless otherwise specified and where used shallbe bonded at three places on the circumference of the pipeline to the adjacent pipeline.

Puddle flanges shall be of similar dimensions as standard flanges but undrilled and unmachined.

PA.< =OINTING MATERIALS

PA<.1 Hlanged joints shall be supplied complete with full face $mm reinforced butyl rubber for low pressure or AH for high pressures or other appro#ed joint rings and with all bolts!nuts and washers and of ade%uate strength to withstand the local stresses and pressuresof the pipeline! fitting or special at its position in the system. -he physical properties of the gasket material shall be appropriately chosen for the type of fluid to be transportedand shall be chemically stable.

PA1>. FLEIBLE PIPE COUPLINGS

PA1.1 -he ontractor is at liberty to pro#ide any type of fle/ible coupling for the pipes specifiedabo#e subject to the appro#al of the "mployer. ouplings shall generally howe#er! be of a type without a central register and shall be capable of being assembled withoutdistorting or damaging the joint ring3 all necessary bolts! nuts and rings shall be

2$ 00@



pro#ided. "ach coupling shall ha#e a test rating e%ual to or greater than that of the pipeswhich it connects. Hle/ible couplings in the ground shall be encased in corrosionprotecti#e material and bonded in three places on its circumference to the adjacentpipeline on both sides of the coupling.

PA11. 3ATER PIPE TESTING

PA11.1 Water piping shall be tested as re%uired with a water pressure of not less than 1E timesthe ma/imum working pressure or the ma/imum surge pressure whiche#er is the greater.

are shall be taken to a#oid putting e/cessi#e pressures on mechanical seals! safetyde#ices! etc. -he system shall be filled and all air #ented at least 2' hours before theactual test pressure is applied. -est pressure shall be maintained for not less than $minutes and must hold its pressure to the satisfaction of the "mployer after the forcepump has been disconnected. 5eaks in screwed fittings shall be corrected by remakingthe joints. Welded joints shall be cut out and rewelded if leaks occur from them.aulking of leaks will not be permitted.

PA15. METAL 3AL63A4S

PA12.1 All metal walkways shall be made of s%uare pattern gratings with I $mm openings!' / mm bearer bars and a mass of not less than kg per s%uare metre. he%uer plate shall not be used for walkways. -he gratings shall be gal#anised and further treated as re%uired in accordance with lause 1 of this 0pecification.

PA1?. BOLTS* NUTS @ 3AS2ERS

PA1$.1 All bolts and nuts shall ha#e preferably metric threads of coarse pitch series but thosesupplied as part of proprietary e%uipment will be accepted in accordance with themanufacturers 0tandard. Washers shall be pro#ided at each nut and shall be of the

same materials or coating where applicable to match the bolt and nut.

0ingle coil spring washers shall be fitted to all bolts subject to #ibration. All bolts shallproject not more than mm and not less than $mm from the heads of the nuts when fi/edand shall ha#e not more than four threads within the thickness to be bolted up.

All anchor bolts for machinery shall be gal#anised or of similar metal resistant tocorrosion attack but not painted. -hey shall be protected so as not to set up electrolyticaction between the bolts and the surrounding e%uipment.

PA.1 GALVANISING

PA.1'.1 All hotdip gal#anising shall be e/ecuted in accordance with the ode of Practice0A60 21' 1<;@ go#erning the design! fabrication and inspection of steel for hotdipgal#anising in conjunction with 0A60 <$' and 0A60 @$ go#erning the %uality of hotdipgal#anising! with particular reference to the following re%uirements. 0A60 <$' for hot dipgal#anised &inc coatings on steel sheet and strip. 0A60 <$ for hot dip gal#anised &inccoatings on steel wire.

PA.1'.2 ild steel plate and sections shall be of good commercial %uality! or higher grades! bestsuited for gal#anising! The )$"eri$& #h$&& 'e (ree (ro) #&$, or %o$r#e &$)i!$"io!#*(i!e (i##ure# $! ro&&e7i! i)0uri"ie#.

PA.1'.$ astings shall be sound! dense and clean and free from distortion! porosity! carbon andslab enclosures! blowholes and other injurious conditions.

PA.1'.' Fo&e* ri-e""e or #i)i&$r&+ oi!"e )e"$& %o!#"ru%"io!# #h$&& !o" 'e $%%e0"$'&e.

2$ 00;



PA.1'. Welding flu/ shall be chipped away and all welds wire brushed before gal#anising.

PA.1'. -he surfaces to be gal#anised shall be free from paint! oil! grease! rust and similar impurities.

PA.1'.@ All e/posed surfaces including welds shall be thoroughly sand blasted prior togal#anising.

PA.1'.; -he "ngineer shall ha#e the right to inspect all steel components before gal#anising! andto reject or ask for remedial treatment of any material which is considered to beunsuitable. -his applies particularly to welds.

PA.1'.< -he gal#anised coating shall be smooth! adherent! continuous and free from black spotsor flu/ stains.

PA.1'.1 4lobular e/tra hea#y deposits of &inc which interfere with the intended use of the materialshall not be acceptable. "/cessi#ely protuberant lumps and nodules shall be remo#edby hot wiping or by the skilful application of mechanical means. 9owe#er! there shall

remain a sufficient minimum thickness of unbroken &inc coating. Hlaws on small partsand working surfaces shall be repaired only by stripping and redipping. -he &inc bathshall contain not less than <;!B pure &inc.

PA.1'.11 nstallation in areas which are not classified as hygiene areas! are subject to lessstringent re%uirements.

PA.1'.12 -he deposits from gal#anised coatings shall be as follows 7

A-"+A5-9J,"00

8A-,4 4+A0 P"+mK

APP+8LA-"-9J,"00

mm and o#er @ !1; mm

mm to 2 mm $ !@ mm

2 mm to 1!2 mm ' ! mm

6olts and ,uts 2@ $!$$ mm M!$ mm

PA.1. PAINTING :

PA.1.1 GENERAL CLAUSES

All preparation and painting shall be in accordance with 0A60 0tandards.

3here 0$i!"i!, "$ke# 0&$%e* #urrou!i!, (&oor#* w$&&#* #"ru%"ure#* 0&$!" $!equi0)e!" #h$&& 'e 0ro"e%"e $,$i!#" #0i&&$,e $! i! %$#e o( $%%ie!"$& #0i&&i!,*"horou,h&+ %&e$!e.

0uch work is to be properly super#ised throughout the contract.

All painting is to be undertaken in accordance with the appropriate 0A60 0tandards andthe following directi#es must be considered 7

PA.1.1.1 Paint shall not be applied o#er any surfaces containing traces of grit! grease! oil! looserust! loose millscale or corrosion products of any kind.

2$ 00<



PA.1.1.2 All metal surfaces to which paint is applied shall be moisture free. Paint surfaces whichare to be o#ercoated shall be hard dry before o#ercoating! unless the specification statesotherwise.

PA.1.1.$ All traces of soluble salts and corrosi#e airborne contaminants shall be thoroughlywashed from the surface prior to painting! and the surfaces dried and repaintedimmediately thereafter.

PA.1.1.' Cnless otherwise stated! no paint shall be applied within mm of areas which are to bewelded.

PA.1.1. Welds and adjacent parent metal shall be deslagged! inspected and appro#ed and allspatter shall be remo#ed prior to painting.

PA.1.1. -he weld areas shall be abrasi#e blasted and=or ground and all contaminants shall beremo#ed prior to painting. Wire brushing of the weld shall only be allowed if the Paint0pecification calls for wire brushing. -he weld area shall then be flushed with fresh water and allowed to dry before recei#ing the full specified paint system.

PA.1.1.@ Sur($%e# whi%h $re "o re#" o! %o!%re"e or o"her (&oor# #h$&& re%ei-e "he (u&& 0$i!"#+#"e) 0rior "o ere%"io!.

PA.1.1.; Areas where the paint coating has been damaged during transportation! erection or byany means whatsoe#er! shall be repaired as follows 7

+ust spots shall be remo#ed by means of a wire brush or emery paper and thesurrounding paint which is still intact shall be feathered for a distance of 2mm beyondthe damaged area. 0pot priming shall consist of all the coats pre#iously applied! andshall o#erlap the damaged area by 2 mm.

PA.1.1.< Where the shop coat has been allowed to age for a few months before painting! it shall

be light sanded or rubbed with steel wool or scrubbed with clean water! using a bristlebrush.

PA.1.1.1 ating of contact surfaces shall be protected from corrosion by ensuring that the twosurfaces brought into contact with each other shall be prepared and primed inaccordance with the specification. -he primed surfaces shall be brought together whilethe paint is still wet.

PA.1.1.11 Areas which will be inaccessible after erection shall recei#e the full appro#ed coatingsystem! before erection or assembly.

PA.1.1.12 Cnless otherwise specified! steel embedded within concrete shall not be painted e/cept

to within mm below the concrete=air interface.

PA.1.1.1$ All sharp edges and cut ends shall recei#e the specified dry film thickness of paint.

PA.1.1.1' All air used for blast cleaning or spraying shall be free from all traces of water and oil.

PA.1.1.1 When blastcleaning! a satisfactory blast profile (i.e. anchor pattern) shall be achie#ed. f the abrasi#e used for blastcleaning is sand! it shall be free of clay.

-he abrasi#e shall comply with 0A60 ' Fode of PracticeF and shall be free from oiland grease and corrosi#e contaminants such as chlorides and the like.

PA.1.1.1 -he ontractor shall ensure that the manufacturer*s recommended thinners are used for any particular paint.

PA.1.1.1@ -he ontractor shall ensure that the final finishing coat obscures the pre#ious coat.

2$ 001



PA.1.1.1; -he ontractor shall ensure that primed steelwork which is to be deli#ered to site isstacked on bearers and is clear of the ground. Where#er possible channels! angles! etc!shall be stacked so that water cannot collect on steel.

PA.1.1.1< 0urfaces which are to be friction bolted! shall be prepared in accordance with thespecification (i.e. blast cleaned or wire brushed)! but shall recei#e no paint coating.

PA.1.1.2 Paint dry film thickness shall be measured using a nondestructi#e thickness gauge suchas the FikrotestF or e%ui#alent.

PA.1.1.21 -he paint manufacturer*s instructions shall be strictly adhered to.

PA.1.2 PAINTING OF STEEL SURFACES 3IT2 POL4URET2ANE

-his system is based on a polyurethane which is cured with an Aliphatic ?isocyanate.,o polyurethane products which are cured with Aromatic ?isocyanate curing agents willbe acceptable. Thi# #+#"e) #h$&& 'e u#e i! hi,h&+ %orro#i-e %o!i"io!# $! where$ hi,h qu$&i"+ (i!i#h i# require.

PA.1.2.1 I! F$'ri%$"or# Pre)i#e#:

(a) 0urface Preparation7

All steel surfaces shall be abrasi#e blastcleaned to an 0A 2E (near white) finish to0wedish 0tandard =<=.

(b) Primer7

Apply one full coat by spray of norganic "thyl 0ilicate Ninc +ich Primer to gi#e ainimum dry film thickness of ' microns.

(c) Cndercoat7

Apply one coat of icaceous ron 8/ide 9igh 6uild "po/y (?ark 4rey) to gi#e aminimum dry film thickness of ' microns.

PA.1.2.2 O!7#i"e P$i!"i!, o( S"ee&work7

(a) Cndercoat7

Cnless the undercoat has already been applied it shall be applied before erection asdescribed in 0ubclause (c) abo#e.

(b) Hinishing7

-wo (2) finishing coats of appro#ed polyurethane enamel in the appro#ed colour!shall be applied go gi#e a minimum dry film thickness of 2 microns per coat. -hetwo coats shall be distinguishable in colour and the second coat shall be appliedwithin 2' hours of the first.

The "o"$& )i!i)u) r+ (i&) "hi%k!e## (or "he %o)0&e"e 0$i!" #+#"e) #h$&& 'e 1>)i%ro!#.

PA.1.$ PAINTING OF MOTORS* GEAR BOES* PUMPS AND OT2ER EUIPMENT:

PA.1.$.1 Sur($%e Pre0$r$"io!:

-his paint system shall apply to areas in low corrosi#e conditions.

2$ 0011



-he surfaces to be painted shall be wire brushed to an 0t $ finish to 00 =<= andshall be completely free from oil! grease! rust and foreign matter of any kind.

PA.1.$.2 Pri)i!,:

8ne (1) coat of an appro#ed norganic Ninc "po/y Primer shall be applied to form auniform coat with a minimum dry film thickness of microns and to fill all porosities inthe castings. After 2' hours the primer shall be wet sanded to produce a uniform!smooth surface.

PA.1.$.$ U!er%o$"7

8ne (1) coat of a suitable undercoat to a minimum dry film thickness of $ microns inaccordance with 0A60 ;1! -ype 2! tinted to a shade just lighter than the finishing colour with a suitable staining agent compatible with the paints shall be applied.

PA.1.$.' Fi!i#hi!,:

8ne coat of appro#ed high gloss enamel to a minimum dry film thickness of $ microns

in the appro#ed colour shall be applied in accordance with 0A60 $.

The "o"$& r+ (i&) "hi%k!e## (or "he %o$"i!, #+#"e) #h$&& !o" 'e &e## "h$! 15>)i%ro!#.

PA.1.' PAINTING OF PIPES* VALVES AND FITTINGS

-his paint system shall be used in areas of low corrosi#e conditions.

PA.1.'.1 Sur($%e Pre0$r$"io!:

-he surfaces shall be wirebrushed to an 0t $ finish to 0wedish 0tandard 00 =<= toremo#e loose rust and millscale.

PA.1.'.2 Pri)i!,:

8ne appro#ed coat of primer in accordance with 0A60 @<! -ype ! shall be applied to aminimum dry film thickness of $ microns.

PA.1.'.$ U!er%o$":

Cndercoat shall be as specified in 21.'.$.

PA.1.'.' Fi!i#hi!,7

-he finishing coat shall be as specified in lause 21.'.'.

The "o"$& r+ "hi%k!e## (or "he %o$"i!, #+#"e) #h$&& !o" 'e &e## "h$! <> )i%ro!#.

PA.1. PAINTING OF GALVANISED SURFACES

A setting time of one week must be allowed before the application of the final coat.

PA.1..1 Sur($%e Pre0$r$"io!:

-he surfaces shall be cleaned using a gal#anic iron cleaner.

PA.1..2 Pri)i!,

2$ 0012



-o the cleaned surfaces apply a base coat of Prolu/ ? 1<$;$< or appro#ed alternati#eto a minimum dry film thickness of 2 microns.

PA.1..$ U!er%o$":

Apply one coat of high build chlorinated rubber! Prolu/ $2 or appro#ed alternati#e! to aminimum dry film thickness of @ microns and tinted to a shade just lighter than thefinishing colour with a suitable tinting agent which shall be compatible with the paint.

PA.1..' Fi!i#hi!,:

Apply one coat of Jemrist hlorinated rubber enamel (Prolu/ $1 or similar appro#ed) toa minimum dry film thickness of $ microns.

The "o"$& r+ "hi%k!e## (or "he %o$"i!, #+#"e) #h$&& !o" 'e &e## "h$! 1? )i%ro!#.

PA.1. PAINTING OF C2EUER PLATE OR OPEN GRATING FLOORING ANDSUPPORTING FRAMES 3IT2 EPO4 TAR S4STEM

-his paint shall apply to steel flooring! che%uer plate and open grating flooring.

PA.1..1 Sur($%e Pre0$r$"io!:

0urfaces shall be abrasi#e blastcleaned to an 0A 2E finish to 0wedish 0tandard 00=<=1 or acid pickled and passi#ated.

PA.1..2 Fi!i#hi!,:

-hree e%ual coats of appro#ed "po/y -ar to 0A60 ;1! -ype ! shall be applied.onsecuti#e coats shall be in distinguishing colours.

The "o"$& r+ "hi%k!e## (or "he 0$i!"i!, #+#"e) #h$&& !o" 'e &e## "h$! 1> )i%ro!#.

PA.1.@ PROTECTION OF UNPAINTED SURFACES :

[email protected] Bri,h" M$%hi!e P$r"#:

All bright machined parts shall ha#e a protecti#e treatment applied by the manufacturer before despatch and this treatment shall be kept intact up to the time of hando#er unlessit has to be remo#ed for installation. f the surface is e/posed after installation a further

protecti#e coating shall be applied in accordance with the manufacturer*s re%uirements.

[email protected] No!7(errou#7

All e/posed copper piping shall be cleaned down! degreased and all adhering materialscleaned off without damage to the installation.

PA.1.; FINAL INSPECTION

-he "ngineer may subject surface preparation and the completed paintwork to 0A60 or other inspection3 the findings of such inspection being binding on the ontractor. -hecost of such inspection will be borne by the "mployer. n the e#ent of workmanshipfailing to meet the re%uirements of the 0pecification! the cost of the inspection shall beborne by the ontractor.

2$ 001$



PA.1. ELECTRIC MOTORS

PA.1.1 Fie S0ee Mo"or# (or No!72$$rou# Are$#:

PA.1.1.1 -he motor shall comply with the information stated on the data sheet.

PA.1.1.2 -he motor shall be of cast iron frame! totally enclosed fan cooled! three phase with anP degree of protection and a chemical works finish. -he paint colour shall be id6runswick 4reen! ,umber 22 to 60 $;1 .

PA.1.1.$ -erminal bo/es shall be pro#ided with purpose drilled and tapped holes to suit cableglands manufactured to 60 121 7 1<@$! a knock out is not acceptable. -he tappedholes shall be fitted with plugs (with a screw dri#er slot to facilitate remo#al) for transit.-he holes shall be at the bottom of the bo/ for hori&ontal shaft motors.

-erminal bo/es shall be manufactured in cast iron or steel and arranged to suit theenclosure! classification re%uirements. Plastic bo/es and co#ers are not acceptable.

-erminal bo/es shall be suitable for turning through <O or 1;O so that a side or top entry

is possible.

PA.1.1.' Where specified the motors shall be fitted with Positi#e -emperature coefficient (P-)thermistors for integration with the starter. -he ends shall be brought out to terminalslocated in the motor terminal bo/. Accordingly! the motor terminal bo/ is to include adedicated suitable si&ed standard 08 thread to accommodate the glanding arrangementfor the thermistor cable.

PA.1.1. Pro#ision shall be made for an earthing stud facility within the terminal bo/ of themachine! as well as the standard e/ternal frame earthing termination feature.

PA.1.1. 6earings shall be of ball or roller type and shall be packed with lithium base grease.

PA.1.1.@ All motors abo#e ! kW rating shall ha#e si/ leads brought from the motor windings toterminals in the terminal bo/ complete with fitted copper links to make the motor suitablefor direct on line starting. All terminals and stator leads shall be clearly marked.

PA.1.1.; nsulation of motors shall be to lass *H* with lass *6* temperature rise (;O).

PA.1.1.< -he ontractor must ensure that ade%uate tor%ue is a#ailable to accelerate the dri#e tofull load speed for all types of starters! with a FrunupF time of ($ I .1$ / kW) seconds.

PA.1.1.1 -he starting tor%ue when switched directonline at rated #oltage shall not be less than1B full load tor%ue.

PA.1.1.11 A stainless steel nameplate! stamped with the following information! shall be permanentlyattached to the housing of the motor7

(i) anufacturer*s name and address(ii) Dolts=phase(iii) kW rating(i#) Hull load current(#) anufacturer*s model and serial number (#i) +ated speed(#ii) lass of insulation and permissible temperature rise(#iii) Power factor (i/) otor windings configuration(/) Hrame si&e(/i) ?egree of protection.

2$ 001'



PA.1.2 8n completion at the manufacturer*s works the motors shall be subjected to +outine-ests outlined in 0A60 <'; or 60.'<<< as applicable. Hor motors with a rating of 12kW and abo#e! -ype -ests shall be carried out on each batch of motors of the samesi&e.

A batch certificate! if not more than si/ () months old! will be acceptable.

f a full -ype -est certificate is not a#ailable! then the manufacturer shall carry out a full -ype-est and +outine -est on one motor of each design for which a -ype -est is not a#ailable.,o additional costs will be accepted for any factory tests.

-ype test certificates will include the results of tests at rated #oltage and fre%uency of thefollowing7

(i) -emperature rise(ii) omentary load(iii) "fficiency at B! @B and 1B full load(i#) Power factor at B! @B and 1B full load(#) 0tarting tor%ue (,)(#i) 0tarting current (A)(#ii) 5ight running current (A)(#iii) ,oise le#el of d6(A) at one metre(i/) Permissible acceleration time on starting up(/) Area classification certificates by appropriate appro#ing authority (if applicable)

After installation site tests should be performed at a #oltage that is ;B of the appropriatetest #oltage gi#en in -able 2' of 0A60 <';. All test certificates for each motor shall besubmitted in triplicate to the "ngineer.

NOTE: Hactory test certificates shall be submitted to the "ngineer prior to despatch of themotors etc. from the factory.

PA.1.$ DATA TO BE SPECIFIED AND GUARANTEED B4 T2E CONTRACTOR

Any figure %uoted in respect of full load output! tor%ue output! efficiency! power factor andtemperature rise shall be subject to a guarantee.

PA.1.' UALIT4 ASSURANCE

-he ontractor shall submit at the time of tender their standard works >uality AssuranceProgramme stipulating the #arious stages of production and inhouse tests carried out during

the course of manufacture.

PA.1. PAC6ING

PA.1..1 -he ontractor shall supply information on their standard packing techni%ues for thee%uipment as per this en%uiry at time of tender.

PA.1..2 -he ontractor shall be totally responsible for the ade%uacy of the packing and protectionpro#ided against climatic conditions! damage! and mishandling of the goods! during transitfrom the works to the final deli#ery point! as indicated on the en%uiry=order.

PA.1. MAR6ING

2$ 001



PA.1..1 All packaged! bundled and loose items shall carry the Plant reference number (if applicable)! ontract number and project number.

PA.1@. COUPLINGS FOR PO3ER TRANSMISSION :

[email protected] COUPLINGS

Cnless specified otherwise! all pumpsets shall be directly coupled (shaft to shaft) to thedri#e motor by means of a fle/ible type coupling only. All couplings shall comprise of thetwo cast iron flanges connected by means of a resilient! fle/ible component! the deflectioncapability which shall be a prime design consideration. -he fle/ible components shall alsobe able to absorb transient peak loads and reduce #ibrations and torsional oscillations onthe dri#e shafts.

All fle/ible couplings shall include for taper lock fi/ing and keys and keyways with topclearance shall be allowed for on applications where load fluctuations are e/pected.

-he fle/ible component shall be manufactured from neoprene rubber compounds suitable

for operating temperatures up to @O and be resistant to oil and grease contamination.

All fle/ible couplings shall be able to accommodate the following incidental misalignmentsor displacements 7

Parallel or a/ial up to ! mm Angular up to '!O0haft end float up to ;! mm

All fle/ible couplings shall be easily remo#able by withdrawal towards the indi#idual shaftstub ends. ouplings shall be si&ed and selected with due consideration for the ma/imumpower transmitted! shaft speed! the type of dri#en machine! the type of dri#ing unit!

diameters of connecting shafts and the operational hours per day.

Where pump dri#e shafts re%uire withdrawal for maintenance purposes! spacer couplings of ade%uate dimensions shall be pro#ided or allowed for as necessary unless specificallye/cluded.

All keys and keyways and taper pins shall conform to 60 ' 7 Part 1 7 1<; (as amended).

5imits : tolerances for shafts and holes shall conform to 60 1<1.

PA.1; ERECTION AND INSTALLATION :

PA.1;.1 GENERAL :

PA.1;.1.1 -he construction of the pumpset and=or motor plinths! of the pipe ducts and cabletrenches=drainage ducts as necessary will be carried out under the i#il aspects of theontract generally but not always wholly in ad#ance of erection of the Plant and e%uipmentto be supplied under this ontract. 9oles should be left in walls and foundations whene#er practicable to accommodate pipes! foundation bolts and other e%uipment to be erectedunder this ontract.

PA.1;.1.2 t shall be the responsibility under the echanical and "lectrical Portions of this ontract tosupply and set in position any steel columns and wedges forming a permanent part of theworks to support pipework! #al#es and e%uipment and to install and align any puddle pipes."/ca#ation and backfilling of pipe trenches and casting of concrete anchor blocks and piersto pipework and the grouting or concreting of pipes etc.! will be measured and carried outunder the i#il "ngineering aspects of the ontract

2$ 001



PA.1;.1.$ t shall be the responsibility under the echanical and "lectrical Portions of this ontract topro#ide the necessary specials! pipe fittings! joints! pipework supports etc. and manifold for the connection of suction pipework! manifolds and deli#ery pipework to the new dischargepipework for the operation of the plant pro#ided.

PA.1;.2 PROGRAMME OF 3OR6 :

PA.1;.2.1 n carrying out erection! the ontractor shall conform to his appro#ed erection programmeunless otherwise agreed with and appro#ed by the "ngineer.

PA.1;.2.2 -he "mployer may! from time to time! by order in writing! without in any way #itiating theontract! re%uire the ontractor to proceed with the installation of the Works in such order as in his opinion may be necessary.

PA.1;.$ ERECTION* AD=USTMENT* OPERATION* COMMISSIONING @ TESTING :

PA.1;.$.1 -he ontractor shall make his own arrangements for handling and transporting all material

to and on the 0ite in a proper and careful manner to a#oid damage! and shall beresponsible for properly storing and protecting all plant and e%uipment against damage bywater! weather! fire and any other interference before and during erection. n particular! theontractor shall ensure that all necessary precautions are taken to ob#iate the possibility of motors being damaged by water.

PA.1;.$.2 -his ontract is to include for the erection! adjustment! putting into proper working order!testing and maintaining of all plant! e%uipment and materials supplied or refurbished by theontractor. -he erection of the plant is to be carried out by skilled and e/perienced erectorsand the plant! when erected! is to be of neat and workmanlike appearance! solidly ande#enly supported! true to line and le#el! plumb and in proper working order. -he erection isto include for the proper lining up of all bolts! pipes! pipework supports! fittings in holes left

by the i#il "ngineering ontractor for the reception of the e%uipment and pipes3 positi#esupport for such bolts! pipes and fittings shall be pro#ided to a#oid any mo#ement of themduring concreting operations.

PA.1;.$.$ 8n completion of erection! installation! unless otherwise specified! the ontractor is to cleanall e/posed metalwork! polish parts to be left bright and paint all other parts! as specifiedelsewhere. All motors! pumps! baseplates! #al#es! pipework! etc.! shall be painted in acolour as instructed by the "ngineer.

PA.1;.$.' -he ontractor is to finish off neatly all grouting and pointing carried out by him! and isgenerally to lea#e all his work under the ontract clean! neat! tidy and in efficient workingorder.

PA.1;.$. After completion of erection and after completion by others of electrical work and ha#ing putall e%uipment into proper adjustment and working order! the ontractor shall operate hisplant for at least @2 hours or such longer time as may be necessary for the purpose of thewitnessing of performance tests on site and of commissioning of the plant3 the water andelectricity for the latter purposes will be pro#ided free of charge by the "mployer.

PA.1;.$. 6efore handing o#er the plant! the ontractor is to ensure that e#ery part of the e%uipmentis operating satisfactorily. -he ontract will not be deemed to be completed for -aking 8#er purposes until the "ngineer is fully satisfied in this regard.

PA.1;.$.@ n the e#ent of the ontractor being unable to complete the installations or adjust and testthe plant and e%uipment at the time of installation through circumstances beyond hiscontrol! it may be necessary for him to return to site at a later date to undertake this work.tems ha#e been pro#ided in an anne/ure to the 0chedule of >uantities=Prices to co#er thecost of returning to site! if ordered by the "mployer to do so.

2$ 001@



PA.1;.'. OPERATING INSTRUCTIONS :

PA.1;.'.1 8perating and maintenance instructions! hereinafter referred to as nstructions! are re%uiredfor all plant and e%uipment supplied and=or installed under this ontract. 0uch nstructionsshall be prepared and supplied against the item included in the 0chedule of Prices.-riplicate copies of nstructions shall be prepared and supplied by the ontractor.

PA.1;.'.2 -he nstructions shall be made up in the form of books with a rear pocket enclosing prints of all the FAsbuiltF ?rawings rele#ant to the echanical and "lectrical Portions of theontract.

PA.1;.'.$ -he nstructions are to be prepared by the ontractor and three copies are to be deli#eredto NA onsultants ! ;<2 Cmgeni +oad! ?urban! '! two weeks before thecommissioning of the plant and e%uipment. NA onsultants will send one copy to the"mployer and one is to be kept at the Works.

PA.1;.'.' 8n the co#er of each set of nstructions! the following information shall be indelibly printedin bold lettering 7

DEPARTMENT OF PUBLIC 3OR6SCONTRACT NO 3CS : 3IMS>>5;9<

OPERATING AND MAINTENANCE INSTRUCTIONS FOR T2EFIRE PUMPS AT T2E NE3 LABOUR AND NEO7NATAL 3ARDS

(Print name! address and telephone number of ontractor)

-he first page of each set of nstructions shall be an inde/ to the nstructions and shall

include a list of the numbers and descriptions of all drawings and pamphlets included in theset.

PA.1;.'. -he nstructions shall be carefully prepared so as to pro#ide in detail and with clarity acomplete description of all components of the plant and e%uipment and all information anddrawings re%uired to gi#e complete guidance to operators and maintenance staff on allmatters relating to the proper and safe operation and maintenance of the plant ande%uipment and on all matters relating to the future ordering of spare parts which may bere%uired for maintenance purposes.

PA.1;.'. nter alia! the nstructions shall include the following 7

(a) 5ist of spare parts supplied under the ontract.-his list shall include the full details referred to in the ontract relating to pump andmotor spares and similar full details relating to #al#e and control e%uipment. -he"ngineer on behalf of the "mployer reser#es the right to accept or reject all or part of the list pro#ided by the ontractor at the time of tender and accept only the spares thatare considered essential.

(b) 5ist of spare parts which are not supplied under the ontract but which may bere%uired for future major o#erhaul of mechanical plant and motor e%uipment.

(c) 5ist of Fname plate dataF gi#ing full particulars of serial numbers and other descripti#edata pertaining to the plant and e%uipment installed.

(d) 5ist of points re%uiring lubrication and fre%uency of lubrication! stating for each pointthe type and grade of lubricant recommended and full details as to %uantity! the periodof time after which the lubricant is to be renewed and the manner in which it is to becarried out.

2$ 001;



(e) Particulars of bearings! contacts and other mo#ing parts with instructions relating toany special attention which may be re%uired.

(f) Precautions to be taken in starting! running and stopping the plant or e%uipment.

(g) +outine tests which the supplier would suggest be carried out on the plant to ensurethat it is kept in good repair.

(h) ?rawings depicting7

(i) All dimensions as installed of pumps! motors! couplings! guards! bedplates andconnecting pipework! #al#es! specials etc.

(ii) opies of all pump test sheets and characteristic cur#es.

(iii) anufacturers* pamphlets and catalogues edited and clearly marked so as todescribe the particular e%uipment and plant supplied under the ontract.

NOTE: Pamphlets and printed catalogue data shall be bound into the nstructionsrather than pocketed with the drawings and all information in suchpamphlets and catalogues which is rele#ant to this ontract shall be clearlymarked.)

PA.1;. INSTRUCTING OPERATORS DURING INITIAL PERIOD OF OPERATION :

PA.1;..1 "/perienced representati#es of the ontractor and! where applicable! of all the 0ubcontractors shall attend the commissioning and performance testing of all e%uipment andshall e/plain in detail and demonstrate! to the "mployer*s staff and operators! the contentsof the nstructions referred to abo#e and the correct methods of operating and maintaining

the plant and e%uipment. -he prices and rates tendered will be deemed to includeallowances for such e/planation and demonstration as may be re%uired to be pro#ided bythe ontractor to ensure that the operating staff is fully informed as to how the plant ande%uipment is to be cared for! operated! maintained and safeguarded. -he ontractor shallbe solely responsible for filling with the recommended oil all gearbo/es and other apparatusand for lubricating all bearings and components before commissioning performance testingor demonstrations.

PA.1< DETAILED SPECIFICATION :

PA.1<.1 GENERAL :

PA.1<.1.1 -he ontractor shall guarantee and shall be deemed to guarantee that all plant ande%uipment supplied under this ontract shall be capable of meeting the performance asspecified or otherwise appro#ed under the ontract when operating under the re%uiredconditions.

PA.1<.1.2 -he ontractor shall be re%uired to perform the necessary tests to demonstrate that thecapacity of any item of plant or e%uipment meets that specified. -he cost of such tests andany necessary retests shall be borne by the ontractor. Where#er e%uipment or materialsare specified as being to appro#al then the ontractor shall be responsible for obtainingsuch appro#al from the "ngineer.

PA.1<.2.1 SCOPE OF 3OR6 :

2$ 001<



PA.1<.2.1 As specified elsewhere in this document the ontractor shall supply! pro#ide interim storageas necessary! deli#er and install! albeit as appropriate when the programme of the i#il"ngineering aspects of this ontract permits! (such programme ha#ing been drawn up bythe ontractor with the appro#al of the "mployer) and then test! commission and maintainthe pumpset! associated pipework! #al#es! etc. all as specified herein! or appro#ed under the ontract. -he pump set being re%uired to deli#er at the proposed rate of appro/imately95*> )Hhr 5> &#/ against the dynamic head for one pump of appro/imately ??*>) water gauge.

PA.1<.2.2 n relation to the foregoing the ontract shall include and the prices shall be deemed toinclude inter alia for 7

PA.1<.2.2.1 All pump units as scheduled or otherwise appro#ed including electric dri#e motors!baseplates! couplings! pressure gauges! gland drains! guards! packers and holding downbolts including the le#elling and grouting up of baseplates and holding down foundationbolts! #al#es! special fitting supports as re%uired by the manufacturer but not including theconstruction of necessary thrust blocks and pipe support blocks! although details of suchblocks and supports shall be pro#ided for the appro#al of the "mployer.

PA.1<.2.2.2 All pipework! specials! fittings! joints! #al#es as scheduled or otherwise appro#ed includingpipe brackets=supports! straps and holding down bolts.

PA.1<.2.2.$ All the necessary e/ternally mounted noflow switches! pressure switches and cablingwithin the pump station! temperature switches! pressure gauges! re%uired for the effecti#eoperation of the pumpsets and control e%uipment.

PA.1<.2.2.' All the necessary electrical starter panels for all pumpsets and associated electrics.

+efer particular specification P6 7 0tandard 0pecifications for 5D 0witchboards! ?istribution6oards and otor ontrol entres for the supply! installation! testing and commissioning of the for this contract.

-he minimum international protection rating of P ' (internal) or P (e/ternal) shall beapplied.

0witchboards! distribution boards and motor control centres shall be designed!manufactured and installed in strict compliance with 0A,0 11'2 regarding type testing =self certification depending on kA rating.

-he enclosure shall be manufactured of $+12 stainless steel. -he enclosure shall beepo/y powder coated (colour orange). Hor recommended manufacturers refer 0tandard0pecification P6.1@.

"ach enclosure shall be pro#ided with the following 7

1. 5ockable main isolator.

2. ontractor! o#erload combination for ?85 starting! up to @!kW! star delta starting or other appro#ed method for motors abo#e @!kW.

$. Doltmeter

'. Pump selector switch.

. A hand = off = auto selector switch (0afety and o#erload de#ices must be functional inthe hand mode.

. 8ne 1 Amp single phase 2$ #olt switch socket and waterproof light supplied througha $ mA earth leakage unit and separate distribution board.

2$ 002



"ach pump shall be pro#ided with the following instruments and indicator lights7

1. 0ub isolation.2. Ammeter (not less than @mm dial diameter).$. 9oursrun meter with digit nonresettable run hour meter.'. Pump start button. Pump stop button. 8#erload reset button@. 5"? indicating lights for7

a) ains power Q8,R M greenb) -o show which pump is Q8, ?C-SR M bluec) -o show when pump is Q+C,,,4R M greend) -o show when pump has QHA5"? ?C" -8 8D"+58A?R for each pump M amber e) -o show when pump Q"A+-9 5"AJA4" 9A0 -+PP"? 8C-R amber

;. "arth leakage protection for nonsubmersible water pumps in terms of 0A,011'2.5ine monitoring relay for motors e/ceeding @!kW (single phase #oltage! under #oltage! o#er #oltage and phase failure protection)......................................

<. 5ine monitoring relay for motors e/ceeding @!kW (single phase #oltage! under #oltage! o#er #oltage and phase failure protection)......................................

1. Tr$!#(er #wi"%h (or (u"ure e)er,e!%+ ,e!er$"or.

The #+#"e) o0er$"io!* %o!"ro&* #$(e"+ $! $&$r)# $# require #h$&& 'e $##0e%i(ie i! "he ASIB Ru&e#

PA.1<.2.2. All painting and necessary corrosion and weather protection to the e%uipment and pipeworkinstallations.

PA.1<.2.2. All special tools and e%uipment re%uired for the normal operation and maintenance of theplant and e%uipment including the lubricants and grease re%uired for the first filling of allplant and e%uipment and for $ months operation of the plant and e%uipment.

PA.1<.2.2.@ -he pro#ision of FnstructionsF as specified elsewhere.

PA.1<.$ 3ATER UALIT4 7

PA.1<.$.1 -he water obtained to be pumped is treated water.

PA.1<.' OUTLINE DESIGN PARAMETERS :

PA.1<.'.1 Altitude of pump station 7 J ;1 m abo#e 05

PA.1<.'.2 Ambient -emperature 70ummer a/. at 12h T 'OWinter in. at h T $O

PA.1<.'.$ Plant 8peration 7

8ne duty pumpset alternating with the standby pump

PA.1<.'.' -he motor shall be suitable for a coastal en#ironment and e#ery allowance must be madefor corrosion protection.

2$ 0021



PA.1<.'. ncoming "lectrical 0upply ' #olt (I 1B) $ phase! ' wire(0upply Authority) 9& (I 1B)

PA.1<..8 Fu"ure e)er,e!%+ ,e!er$"or #u00&+

PA.1<. LUBRICATION :

PA.1<..1 -he ontractor shall be responsible for filling all gearbo/es and lubricating all bearings tothe manufacturer*s re%uirements initially and before commissioning.

PA.1<..2 -he pump and shaft bearings shall be pro#ided with a separate prelubrication system.

PA.1<..$ All grease used shall be free of acid and resin and should not tend to harden or crumble.4reases of differing characteristics shall not be mi/ed. -he grease for bearing lubricationshall ha#e a drop point of 1O.

PA.1<. PIPE3OR6* VALVES* COUPLINGS* ETC. :

All pipework! #al#es! couplings! flanges! bolts! nuts! joints pro#ided under this aspect of theontract shall be in accordance with that 0pecified under lauses P".2 to P".2$ inclusi#e!aterials and Workmanship of this 0pecification and shall be! to the appropriate 4rade or lass indicated in the 0chedule of Pipes! Dal#es and Hittings so as to be capable of withstanding the pressures that will be de#eloped under operating conditions and in thee#ent of emergency stoppages without the operation of any surge attenuation facilities.

PA.1<.@ PAINTING :

-he ontractor shall allow for all necessary painting of all pumping e%uipment! motors!pipework! #al#es! fittings! etc! included in this ontract both internally and e/ternally. Allsuch paintwork shall be of an epo/y enamel finish e/ternally and opon shall be used for

internal lining of pipework unless otherwise indicated on the drawings or specified. -hepaint and painting system shall be in accordance with that re%uired for highly corrosi#econditions.

PA.1<.; SPARES :

Cnder the heading spares shall be included sufficient lubricants and grease for threemonths operation of the plant and e%uipment.

PA.1<.< TESTING :

-he prices entered in the 0chedule of >uantities=Prices shall and shall be deemed toinclude for all necessary factory and site testing and the pro#ision of all necessarye%uipment and labour including test pumps! connections! gauges! blank flanges! thrustblocks! supports! the isolation of apparatus! where necessary from the applied pressuresand for making good defects unless otherwise specified.

PA.1<.<.1 Pu)0 7 F$%"or+ Te#"#:

-he pumps shall be subjected to the specified hydraulic pressure test which will be to apressure e%ual to one and a half times the ma/imum head the pump will generate at noflow or to the ma/imum surge pressure which will obtain whiche#er is the greater.

"ach pump set shall be subjected to performance tests in accordance with 60 $1 at themanufacturer*s works or in appro#ed testing premises3 which tests shall include as follows7

2$ 0022



(a) the pumpsets shall be tested at sufficient points to define the pump characteristics3one point being as close to the duty point as practicable and one point closely on either side of that point.

(b) n addition to the test report re%uired after completion of the tests3 the following cur#esshall be certified and witnessed and submitted with comparisons of cur#es submitted atthe times of -ender to the "ngineer in triplication before erection of the pumps on site7

(i) -est ur#e 7 -otal Pumping 9ead (metre of water)#s ?ischarge (mU=hour)

(ii) -est ur#e 7 Pump "fficiency (B) #s ?ischarge (mU=hour)

(iii) -est ur#e 7 nput Power (kW) #s ?ischarge (mU=hour)

(i#) -est ur#e 7 Amps per phase #s ?ischarge (mU=hour)

NOTE: -he abo#e test cur#es shall be calculated on the basis of the pumptests in conjunction with the results of simultaneous or separate

tests on the appropriate motor without allowance being made for power factor correction capacitors which shall be installed andassuming a $;D! 9N! power supply).

f the performance of any of the pumpsets is outside the limits of tolerance the ontractor shall rectify the fault or shall pro#ide a new pumpset for testing. Alternati#ely! the "ngineer may re%uire the ontractor to supply the pumpset at a reduction in price determined by the"ngineer.

PA.1<.<.2 Mo"or 7 F$%"or+ Te#"#:

+outine tests shall be carried out on motors in accordance with 0A60 0pecification and

tests shall be carried out to pro#e the performance of the motors against the data sheets.opies of the certified tests shall be forwarded in triplicate to the "mployer.

PA.1<.<.$ Pu)0#e"# 7 Per(or)$!%e Te#"# o! Si"e:

6y running the pumpset after commissioning the ontractor shall carry out sufficientperformance tests in the presence of the "mployer! or his +epresentati#e! to #erify that theplant is operating satisfactorily in accordance with the Hactory test certificates.

6ecause the rate of discharge may not be readily measurable on site the efficiencies of pumps and motors need not necessarily be rechecked but the following performance testsshall be carried out.

(NOTE: 0peed and #oltage shall be measured during such tests).

(i) losed deli#ery #al#e check head de#eloped by pump and current taken againstfactory test cur#es (deli#ery noflow limit switch deacti#ated for this test).

(ii) a/imum head de#eloped.

(iii) ?uty point check head and motor current.

(i#) ?eli#ery #al#e full open check that power (kW) absorbed does not e/ceed full loadcontinuous current of motor.

-/ Che%k o0er$"io! o( "he &ow 0re##ure 0u)0 #"$r" #wi"%h $! e&i-er+ !o7(&ow %u"7o(( #wi"%h.

PA.1<.<.' Pi0ework 7 Pre##ure Te#"i!, o! Si"e:

2$ 002$



8n completion of erection and at least se#en days after all necessary pipework! supports!struts and thrust blocks ha#e been constructed! the pumps and interconnecting pipeworkand #al#es shall be filled with water and tested to not less than one and a half times thema/imum operating pressure or to the surge pressure which could obtain whiche#er is thegreater.

PA.1<.1. PUMPING PLANT :

PA.1<.1.1 De#%ri0"io!

There #h$&& 'e i!#"$&&e "wo !ew 0u)0 #e"# $! o!e o%ke+ 0u)0 i! "he '$#e)e!" o( "he !ew w$r. The !ew 0u)0 #e" '$#e# "o "$ke "he !ew 0u)0 #e"# wi&& 'e 0ro-ie$! %o!#"ru%"e u!er "hi# Co!"r$%" '+ o"her#.

The !ew 0u)0 #e"# i!&e" #h$&& %o!!e%" ire%"&+ i!"o $ %o))o! 1>)) NB #u%"io!)$!i(o& $""$%he "o "he w$&&.

The !ew 0u)0 #e"# ou" #h$&& %o!!e%" ire%"&+ i!"o $ %o))o! 1>>)) NB e&i-er+

)$!i(o& $""$%he "o "he w$&&.

-he flow #elocity in the suction and discharge manifolds shall not e/ceed 1! m=s and2! m=s respectfully.

PA.1<.1.2 Pu)0# $! A!%i&&$rie# :

PA.1<.1.2.1 -he pumps pro#ided shall be of the self priming type or other appro#ed alternati#e to suitthe pumphouse structural constraints and the configuration proposed for the suction anddeli#ery manifolds. -he pump units shall comply with the duties identified in theaccompanying 0ystem ur#e or appro#ed duties. -he efficiency of the pump should be as

high as possible at the system duty=operating point.

-he speed of the pump should preferably be 1' r.p.m. but should not e/ceed2< r.p.m. -he pump is to be directly coupled to suitable s%uirrel cage induction motor.

-he pump casing shall be manufactured from high grade cast iron or cast steel and shall beproperly designed and rigidly secured to a baseplate. -he pump casing shall be tested tothe specified test pressures.

mpellers shall be manufactured from bron&e! or other appro#ed material.

-he pump shaft shall be of high tensile stainless steel with protecting slee#es (where

applicable) of bron&e or other suitable metal! the diameter being sufficient to withstand andtransmit without whip and with ample margin of safety all torsional and bending stresses towhich it may be subjected.

6earings are to be of the selected hea#y duty cylindrical roller type at the suction side andangular contact ball bearings at the discharge ends. -he bearings shall be accessible anddustproof and waterproof with suitable pro#ision for continuous lubrication! robust! freerunning! readily replaceable seals and corrosion resistant shaft slee#es shall be fitted to thepump. Packed glands are preferred to mechanical seals.

All parts shall be of ample dimension and strength and hardness! free from flaws!accurately machined! properly assembled and fitted so as to a#oid the setting up of initialstresses in construction or erection and to ensure perfectly free running.

-he pump shall be pro#ided and fitted with a suitable and ade%uate hydraulic balancingde#ice to absorb the unbalanced a/ial thrust of the rotating assembly. -he de#ice shallconsist of back #anes and balancing holes or e%ui#alent and appro#ed alternati#e.

2$ 002'



Pro#ision must be made to protect the balancing de#ice when operating at deli#erypressures below the pump manufacturer*s recommendations. -he balancing and counter balancing discs shall be manufactured from hardened bron&e and cast iron or appro#edalternati#es.

-he pump housing tie bolts shall be of the high tensile steel type! si&ed for the duty of thepump.

An air release #al#e! pro#ided with a lead off pipe for waste water shall be fitted to theuppermost point of the pump casing. A 12mm dia. drain #al#e and drain pipe shall bepro#ided on each pump and run to discharge. 4land water collectors together with pipes todrain therefrom shall be pro#ided.

"ach pump is to be fully e%uipped with all necessary air cocks for remo#al of air together with suitable copper bleed pipes. An airbleed cock and drain pipe shall also be pro#ided athigh points on the deli#ery mains.

Pressure gauges shall conform to 60 1@; wallmounted concentric scale industrial type1mm dial diameter! graduated in kilopascals. "ach gauge to register at appro/imately

B of full scale reading during normal operation.

-he suction and deli#ery pressure gauges for each pump shall be rigidly mounted ona wall near to the pumps with all dials at the same ele#ation! and labelled as to whichpump and which pressure they apply.

"ach gauge shall be e%uipped with a bron&e isolating cock and detachable porous metaldamper of appro#ed design and connected to the pipework by means of copper tubingneatly laid and securely fi/ed.

-he prices for all pump accessories and gauges shall include and shall be deemed toinclude allowances to co#er the cost of e#erything! such as brackets and fi/ings! necessary

for setting up this part of the plant in a neat and workmanlike fashion! all so arranged as tofacilitate reading of gauges and clearing of drainage tubing without dismantling.

PA.1<.1.2.2 Dri-e Mo"or:

-he pump shall be dri#en by a #ertical or hori&ontal -.".H.. s%uirrel cage induction! ' pole$;D! 9&! $ Ph connection electric motor fitted with anticondensation heaters and

facilities for motor temperature monitoring by an electronic motor protection unit. -he pumpshaft is to be fitted with a fle/ible half coupling complete with pins and bushes! the bushesare to be of the cone ring type.

-he thrust assembly shall cater for both the thrust conditions of the pump and none of thatthrust transmitted shall be imposed on the electric motor.

-he motors shall be suitable for direct on line starting against the full system hydraulicpressure. -he motor shall be ade%uately si&ed to the appro#al of the "mployer! to be nono#erloading and shall ha#e a continuous rating of at least 1B abo#e the pump input power at the duty point.

-he motors shall be suitable for continuous operation at the altitude of the treatment worksle#el and at the ambient temperatures. otors shall be designed in accordance with there%uirements of 60 . Part << or 0A60! similar for a full load speed not e/ceeding$ r.p.m.

2$ 002



otor windings shall be thoroughly moistureresistant and insulated in accordance with 602@@ or similar for lass H insulating materials. a/imum temperature rise abo#e theambient temperature shall be limited to ;O.

otors shall be pro#ided with appro#ed terminal bo/es and glands of ample dimensions toaccommodate the cables to be connected to them by the ontractor.

An appro#ed earthing terminal shall be pro#ided on the frame of each motor so that eachmachine may be earthed in accordance with local regulations by the ontractor.

8n completion in the manufacturer*s works the motors shall be subjected to high #oltagetests in accordance with the re%uirements of 60 Part <<. n addition routine tests aslaid down by 60 Part <<! shall be carried out and test certificates in triplicate gi#ingrecords of all such tests shall be submitted for appro#al before deli#ery to site isundertaken. After installation on site the necessary high #oltage test shall be carried out.

PA.1<.1.2.$ Dri-e Cou0&i!,:

-he coupling will be of the positi#e transmission type with sufficient resilience to absorbstarting tor%ue and shock. t shall be possible to remo#e and replace the motor dri#e fromthe pump unit without remo#al of motor=pump half couplings from their respecti#e shafts.-he coupling will be installed complete with a suitable guard as appro#ed by the "mployer.

PA.1<.1.2.' Pu)0 O0er$"i!, Co!"ro&# :

(a) F,oHlowF Protection7 A paddle type noflow switch shall be installed on the deli#ery pipe of each pump. Atimer is to be installed in the switchboard to pre#ent the pump from running more thanone minute if there is no flow from its indi#idual outlet. -he flow switch! connection

points and the interconnecting cable are to be pro#ided under this ontract.

'/ Pre##ure #wi"%hA 0re##ure #wi"%h #h$&& 'e )ou!"e o! "he e&i-er+ 0i0e. The 0re##ure #wi"%hwi&& %$u#e "he u"+ 0u)0 "o #"$r" o! e"e%"io! o( &ow 0re##ure %$u#e '+ $ (ireh+r$!" %o)i!, i!"o o0er$"io!.

2$ 002



SECTION PB

STANDARD SPECIFICATION FOR LV S3ITC2BOARDS*DISTRIBUTION BOARDS @ MOTOR CONTROL CENTRES

PB.1 SCOPE OF 3OR6

-his specification co#ers the supply! installation! testing and commissioning of low #oltageswitchboards! distribution boards and motor control centres! for use at phase to phase #oltagesup to D.

PB.5 GENERAL

PB.5.1 E-er+"hi!, !e%e##$r+

-he supply and installation of plant or e%uipment re%uired by adherence to the following Act and+egulation may not ha#e been further detailed in other parts of the specification! but shall

ne#ertheless be considered as forming part of the contract. -he installation should includee#erything necessary and installed to the appro#al of the "mployer.

PB.5.5 S"$!$r#

-he e%uipment shall be designed! manufactured! tested and installed in accordance with there%uirements of the latest edition of7

(a) -he 8ccupational 9ealth and 0afety Act ; of 1<<$ and subse%uent amendments andregulations issued thereunder.

(b) 0outh African 6ureau of 0tandards 0pecification 0A60 " ''3 '$<=13 <'@='3

1'$=1

(c) 0outh African 6ureau of 0tandards ode of Practice 0A,0 11'2.

(d) 0outh African 6ureau of 0tandards 0pecification 0A60 12! 1! 1@2! 1222! 11<! 1'@$!1'@'! 1@.

(e) 0outh African 6ureau of 0tandards ompulsory 0pecification 0A60 D ;$! ;$.

(f) 6ritish 0tandard nstitution 60 1'$$! 1<! ';.

-he e%uipment shall in addition comply with the following re%uirements which shall supersede

the pro#isions of the abo#e specification in the e#ent of differing re%uirements.

PB.? S2EET METAL ENCLOSURES

PB.?.1 Ge!er$&

P6.$.1.1 0heet metal enclosures for switchboards! distribution boards and motor control panels shallbe wall or floor mounting as indicated on the drawings or described in the ?etailed or 0tandard 0pecification.

P6.$.1.2 n general! the enclosure is to be fabricated from a welded steel frame! to which the doorsand other co#ers are to be fitted. -he use of pop ri#ets in any of the frame construction is notpermitted.

P6.$.1.$ All welds are to be ground smooth and all e/ternal #oids to be filled.

2$ 002@



P6.$.1.' 5ap welding of panels and bo/ing of sections shall be a#oided in the construction to ob#iatecorrosion of the unpainted surfaces and facilitate the cleaning of the boards. 6olted stiffeningchannels and braces are acceptable.

P6.$.1. ompleted sheet metal enclosures shall be free internally and e/ternally from burrs! sharpedges and blemishes. -he metal enclosures shall be dust and #erminproof throughout andconstructed to meet ambient conditions. A remo#able steel base frame shall be allowed for floor mounting boards and be constructed of at least $ mm channel with a clearance of atleast 1 mm abo#e the floor. +emo#able lifting eyes shall be pro#ided for hea#y panels.

P6.$.1. -he sheet metal enclosures shall be designed to accommodate the electrical distribution andcontrol e%uipment shown in the diagrams and comply with the constructional re%uirements of this specification.

P6.$.1.@ -he construction of the 5D switchboard enclosures shall allow for the board to be e/tendedon both sides by the addition of panels without the need of cutting openings for busbars.

P6.$.1.; 6olts! nuts and washers used throughout shall be suitably plated to pre#ent corrosion!preferably cadmium plated with the e/ception of busbar bolts! which shall be of high tensile

steel.

P6.$.1.< 0crewed knobs used for securing doors or hinged co#ers shall be pro#ided with retainingwashers to pre#ent the screwed knob falling out when the door or co#er is opened.

P6.$.1.1 -he use of selftapping screws is unacceptable (e/cept for the securing of labels). -he useof double sided or FmirrorF tape or self adhesi#e components for the fi/ing of any e%uipmentis not acceptable.

P6.$.1.11 All e%uipment! co#ers! wireways and ducting shall be bolted to the enclosure with threadedrod or welded bolt. ,o loose nuts are acceptable. All tapped holes in metal work shall ha#ea minimum tapped thread length e%ual to the diameter of the tapped hole and the e/posed

metal work shall be protected against corrosion by the application of a suitable inhibitor o#er the tapped area.

PB.?.5 Mi& S"ee&

P6.$.2.1 Cnless otherwise specified! the metal enclosures! internal panels and all e%uipment supportframes shall be manufactured from FNinte/F steel plate. When re%uired! glass panels may bespecified for #iewing indication e%uipment.

P6.$.2.2 -he minimum thickness of the FNinte/F sheets used shall be 1! mm for panels note/ceeding ! mK or 2 mm for larger panels. -hicker sheets shall be used for #ery large

panels and where the weight of the e%uipment would cause buckling or #ibration.

P6.$.2.$ All metal used for the fabrication of the board! i.e. internally and e/ternally! shall be painted.-he steel plates and e/trusions used in the fabrication shall be thoroughly descaled anddegreased on completion of the manufacturing operations and treated with a corrosioninhibiting process before painting.

P6.$.2.' -he corrosion inhibiting process shall be suitable for the en#ironmental conditions to beencountered on site and full details shall be pro#ided at the time of tendering. ?etails of thechemical process employed and the method of application shall also be pro#ided at the timeof tendering.

As a minimum re%uirement! the painting process shall consist of the following7

(a) ?egrease and clean metal with trichloroethylene.

2$ 002;



(b) Apply twopack wet primer Plascon "P6 1 (base) with "P6 $2(catalyst) to 1 microns! allow to air dry for $ minutes and low bake ino#en at ;V to 1V for 2 minutes. Alternati#ely! allow primer to air dryfor 2' hours. 0hould primer re%uire thinning! use Plascon -9 12@ sol#ent.

(c) Apply epo/y polyester powder coating with electrostatic gun to thickness' microns minimum and ; microns ma/imum and bake in o#en at 1;Vfor 12 minutes. Hinal colour to be Plascon ?PH 1<1 8range (600 @) or unless otherwise indicated on the drawings.

PB. PROTECTION CLASS

P6.'.1 -he protection class for the assembly as a whole shall be with all co#ers in place and alldoors secure and locked.

P6.'.2 -he minimum protection class of the assembly shall be as follows unless otherwisespecified 7

P6.'.2.1 f the assembly is installed outdoors and subject to rain then the class shall be P$.

P6.'.2.2 -he protection between the cable and feeder compartments in Horm $ or ' assemblies is tobe pro#ided by means of neoprene grommets or -ufnol sheets cut to fit around theconductors.

P6.'.2.$ f the assembly is wall mounted! surface or flush! where switch toggles protrude and theassembly is installed in a clean area for e/ample an office then the enclosure class shall beP '.

P6.'.2.' Any #entilation lou#res are to be fitted with a 1 mm anti#ermin mesh.

PB. 2INGES* LOC6S AND ACCESSORIES

P6..1 9inges and door handles shall be manufactured from nonferrous materials! suitably finishedand treated against corrosion by an electroplating process. Pewter components or insufficiently resilient materials will be rejected.

P6..2 9inges and door locks of the weldon type will not be acceptable. FPianoF type hinges are alsonot acceptable.

P6..$ 9inges and door locks shall be well designed to ensure satisfactory operation and a pleasantappearance.

P6..' -he repeated opening and closing of the hinged panels or the operation of the door locks shallnot cause chipping or scratching of the painted surfaces or other blemishes to the finishedboards.

P6.. Jey operated! lockable door handles shall be mm s%uare dri#e locks and fitted only if specifically re%uested. n general! door latches which may be operated by electrician*s toolssuch as screwdri#ers and panel keys! are preferred to those re%uiring special keys or handles!which may be remo#ed or lost. All doors must be fitted with a handle.

P6.. All doors shall be fitted with F6arker and ,elsonF or other e%uipment type door locks with a 1;Vmo#ement or otherwise appro#ed.

2$ 002<



P6..@ ?oor latching and delatching operations shall be smooth and %uick! whilst ensuring proper compression of the sealing gaskets without damaging or marking the paintwork or corrosionresistant surface of the board.

P6..; 0ealing strips and gaskets shall be made of durable! nonhardening rubber! neoprene or other synthetic material. are must be taken to ensure that e#en pressure is e/erted along the entirelength of the gasket and that neither deflection or buckling of panel occurs when the gasket iscompressed.

P6..< -o a#oid damage to the paintwork! screws! bolts! door locks! etc.! must not be in direct contactwith painted surfaces.

PB.8 ASSEMBLIES

PB.8.1 Swi"%h'o$r#

P6..1.1 0witchboards are defined as assemblies which are floor standing! e/cept where the circuitsare predominately single phase and the designed fault le#el is not more than 1 kA! in which

case the assembly is classed as a distribution board.

P6..1.2 0witchboards shall consist of a sheet steel enclosure! free standing on a supporting baseframe. -he base frame shall be pro#ided with predrilled holes for fi/ing the board to thefloor. onduit and cable entries shall be pro#ided on the top and bottom panels and frontand=or rear access shall be pro#ided! as indicated on the drawings.

P6..1.$ 6usbars shall be installed at the top or bottom of the board and along its full length. 6usbar droppers shall be pro#ided either behind or alongside the feeder cubicles as specifiedelsewhere.

P6..1.' -he incoming main switch shall be mounted in its own cubicle! be easily accessible at all

times and shall be easily distinguishable from the other switchgear.

P6..1. -he distribution e%uipment installed within the board (i.e. A6! H0 or 6)! shall bemounted in #ertical parallel rows unless the arrangement calls for the hori&ontal placing of thee%uipment and pro#ided the e%uipment manufacturer warrants operation in this direction.

P6..1. 5arge withdrawable air circuit breakers and switch fuse units shall not be positioned at highle#el unless facilities are pro#ided to assist maintenance staff in withdrawing these units.

P6..1.@ -he arrangement shall be such that ample space e/ists between adjacent items of e%uipment for the installation of incoming and outgoing conductors and the e/pansion of theionised gas generated during circuit interruption.

P6..1.; -he incoming busbars to the board*s main switch shall be either heat shrunk PD insulatedor co#ered with a remo#able insulated barrier. All li#e parts must be protected to P $irrespecti#e of the form of separation. Where applicable! the incoming isolator is to be fittedwith a shroud o#er the incoming terminals.

P6..1.< Hlash barriers shall be interposed between items of e%uipment which! by #irtue of their designor arrangement in the board! are likely to cause the breakdown of the dielectric insulation toadjacent items of e%uipment during operation.

P6..1.1 -he board shall be of sufficient dimensions to allow the installation of all e%uipment specifiedand any future e%uipment indicated on the drawings without unduly restricting the access toand the clearance between the #arious items.

P6..1.11Particular attention shall be paid to the accommodation and bending of incoming and outgoingconductors within the enclosure and the working space necessary for making off the cables!

2$ 00$



installing the lugs and connecting into the e%uipment. 0uitable pro#ision shall be made for #erminproofing the cable entries and earthing the armouring.

P6..1.12 Any part of the distribution board metalwork shall be electrically continuous and a suitableearth bar shall be pro#ided for the earthing of the enclosure. Particular attention shall be paidto the earth continuity of remo#able and hinged access panels! particularly those carryingsuper#isory and control e%uipment. Hle/ible copper straps may be used for the purpose of ensuring the earth continuity between the board and the panels.

P6..1.1$ -he minimum form of separation as depicted in 0A60 " '$< Part 1! shall be Horm 2 inwhich the busbars are separated from the functional units and from the feeder outgoingterminals. omponents within a functional unit! which may consist of a number of feeders!are not re%uired to be separated.

P6..1.1' n the case of Horm $ or ' assemblies! the neutral bars need not be run through the feeder compartments! but need only be pro#ided in the cable compartment. -he neutral busbar mustbe clearly distinguishable from the earth busbar.

P6..1.1 n Horm $ or ' assemblies the protecti#e de#ices must be operated #ia door mountedhandles.

P6..1.1 Where busbar stubs are connected to protecti#e de#ices to accommodate other e%uipment!such as -*s! then these busbars must be supported on standoff insulators near the cabletermination point. n the case of parallel connected outgoing cables! sufficient space mustalso be pro#ided on the busbar to permit a lug to be bolted to each side of the busbar.

PB.8.5 Di#"ri'u"io! Bo$r#

P6..2.1 ?istribution boards are defined as assemblies which are wall mounted or which are floor standing! in which case the outgoing circuits are predominately single phase and thedesigned fault le#el of the board is not more than 1 kA.

P6..2.2 ?istribution boards may be flush! semi recessed or surface installed! as indicated on thedrawings. onduit and cable entries shall be pro#ided on the top and bottom panels.

P6..2.$ ?istribution busbars which are predrilled and fully tinned and mounted on suitable standoff insulators shall be pro#ided in all $phase boards. t is desirable that if busbars are notinstalled within a sheet or e/panded metal enclosure! then a clear perspe/ safety co#er shallbe supplied to pre#ent accidental contact.

P6..2.' All wall mounting boards! unless differently indicated on the drawings! shall be front accessonly and shall be manufactured in two parts 7 a rear chassis! which is either built into or attached to the supporting wall! and an outer panel secured to the chassis on completion of the work and readily remo#able from it.

P6..2. -he arrangement is sought in order that chassis may be supplied at an early stage! whilstbuilding and installation work are in progress! without the risk of damage to the outer panel or e%uipment installed therein.

P6..2. -he chassis shall be manufactured from gal#anised mild steel plates! in order that they maywithstand the rough handling and dirty ambient conditions pre#ailing during construction.0urface wall mounted panels may alternati#ely be supplied with chassis finished in att6lack.

P6..2.@ hassis shall ha#e suitable knockouts along the top and bottom panels for the terminations of all conduits in not more than two rows. A feeder cable entry knockout shall also be pro#ided!

suitable for the feeder cable rating indicated on the drawings.

P6..2.; -he outer panel! secured to the chassis by means of adjustable bolts! shall support thee%uipment trays! the busbars and the wiring harness.

2$ 00$1



P6..2.< 0ingle phase sections of three phase boards shall be arranged in three hori&ontal parallelrows! directly abo#e one another and in the phase se%uence +ed White 6lue from top tobottom.

P6..2.1 $phase 6*s! where these are not used for subdistribution! may be installed at the righthand end of the single phase row. f more than three ($) $phase 6*s are re%uired in any?6 (i.e. more than 1 per row) then a separate $phase section must be pro#ided. -hesearrangements are illustrated in the standard layout drawings.

P6..2.115ighting and power circuits shall be separated by a blank space along the hori&ontal rows."/tra space for future circuits shall be allowed for at the right hand side of each single phaselighting and power row of e%uipment! in the ratio of one spare space for each four lighting or power circuit installed. A minimum of one space shall be allowed to each lighting and power row.

?ummy co#ers are to be pro#ided o#er spare spaces. 0imilar pro#ision for future circuitsshall be made on the busbars! neutral and earth bars.

P6..2.12 -he phase! neutral and earth bars must be positioned so that it is possible to connectadditional circuits to the bars without ha#ing to remo#e any other e%uipment. -he earth bar must be bonded to the chassis and the incoming earth conductor must connect directly to theearth bar.

P6..2.1$ n the case of single phase ?6*s! the incoming isolator may be of the same type and si&e asthe rest of the 6*s in the ?6. 9owe#er! in the case of $phase ?6*s! the incoming isolator must be of the large frame (6) type! e#en if the outgoing feeders are small frame 6*s.-he large frame isolator must be fitted with a shroud o#er the incoming terminals.

P6..2.1' Any part of the distribution board metalwork shall be electrically continuous and a suitable

earth bar shall be pro#ided for the earthing of the enclosure. Particular attention shall be paidto the earth continuity of remo#able and hinged access panels! particularly those carryingsuper#isory and control e%uipment.

Hle/ible copper straps may be used for the purpose of ensuring the earth continuity betweenthe board and the panels.

P6..2.1 A remo#able escutcheon plate shall be pro#ided! behind a hinged door! through whichtoggles and other operating handles shall project. All wiring terminations and connectionsshall be made behind the escutcheon and shall not be accessible without its prior remo#al.-he board shall be designed so that the switch toggles! instruments! etc.! are easily

accessible to operators of a#erage height (i.e. upper edge of e%uipment not higher than 2 mor lower than !2 m abo#e floor le#el)! unless otherwise specified.

PB.8.? S0e%i$& Require)e!"# (or Mo"or Co!"ro& Ce!"re#

P6..$.1 otor ontrol entres (*s) are defined as assemblies where at least either B of thefeeders or B of the total load is de#oted to motor dri#es.

P6..$.2 -he general re%uirements of switchboards apply irrespecti#e of whether the is floor or wall mounted.

P6..$.$ Cnless otherwise specified! the form of separation shall be Horm '. "ach motor dri#e is to beconsidered a functional unit and is to be in its own compartment.

P6..$.' -he following will be the minimum pro#isions on each motor dri#e! unless otherwise specified 7 All components must be in compliant with -ype 2 coordination (")

2$ 00$2



(a) ain protecti#e de#ice! either 6 or H0! as specified.

(b) ontrol protecti#e de#ice either 6 or fuse! connected downstream of the mainprotecti#e de#ice.

(c) ?oor mounted interlocked operating handle with padlockable facility.

(d) ontractor and o#erload relay = electronic motor protection relay.

(e) ,umbered outgoing connection terminals.

(f) - and instantaneous ammeter.f

(g) "arth leakage de#ice with - if specified.

(h) ?oor mounted control de#ices 7

0top = 0tart push buttons. +un = 0top = -rip indicator lights.

8#erload reset. 5ocal = +emote switch! if specified. "arth leakage test and reset.

PB.9 BUSBAR AND BUS C2AMBERS

[email protected] -he busbars and their supports shall be 7

(a) "lectrically and mechanically designed to withstand the short circuit stresses which mayoccur with the fault le#el specified for a period of not less than one second. (Attention of tenderers and manufacturers is drawn to the re%uirement for type test results of the shortcircuit capability of the busbars.)

(b) 8f uniform crosssection throughout the busbar run.

(c) anufactured from copper.

(d) ?esigned to accommodate e/pansion and deflection due to thermal and mechanicalstresses without damage or distortion occurring to the busbars or the e%uipment connectedto them.

(e) 0hall comply with 600 1'$$ and 1< and 0A60 1'@$2 and 11<! where applicable.

[email protected] 6usbars on the incoming side of the main switch=breakers are to be insulated with heat shrinkslee#ing with distincti#e phase colours. -he earth bar and busbar joints and cable terminationsmust not be insulated.

P6.@.$ f the busbar is close to areas where cable terminations and connections are carried out whilstthe busbar is energised and if the busbar is not housed in a chamber then a clear perspe/safety co#er shall be supplied.

P6.@.' 6usbar chamber co#ers to be bolted in the four corners and e%uispaced at least e#ery mmaround the periphery. ,uts welded to the co#er frame may be used for fi/ing or the frame maybe tapped as specified. 5oose or capti#e nuts may not be used.

P6.@. -he construction of the enclosure shall allow for the e/tension on both sides by the addition of panels without the need of cutting openings for busbars.

P6.@. Phase identification colours are to be fi/ed to the bars at regular inter#als and shall be +ed!White : 6lue (+W6) from top to bottom! from left to right! from back to front when facing thefront of the board! unless otherwise specified. 6oth main and secondary bars must be identified.

2$ 00$$



P6.@.@ -he minimum clearance between li#e conductors or li#e conductors and earth shall be 2 mmfor systems up to D.

P6.@.; 6usbars shall be ade%uately and continuously rated for the specified current with a ma/imumtemperature rise of 'V relati#e to a peak ambient temperature of 'V gi#ing a ma/imumpeak busbar temperature of ;V.

n the case of fault le#els of 2 kA or higher! the manufacturer shall produce type test results of the proposed busbar arrangement! in the enclosure intended! to pro#e the correct si&ing of thebars and that the temperature rise is within the limits specified.

n the absence of such type tests the following minimum criteria will be used in determining therating of rectangular bars with the larger side in a #ertical plane 7

urrent rating of multiple bars relati#e to single bar rating 7

2 bars 7 1!$ bars 7 2!<' bars 7 2!$

?erating of current carrying capacity within steel enclosure relati#e to freeair rating 7..................................................................................................!;

?erating of capacity for 'V temperature rise instead of V 7..................................!;;

n this case the ratings gi#en in the publication Fopper for 6usbarsF by the opper ?e#elopment Association are to be used.

P6.@.< ,eutral busbars in three phase! four wire! supplies shall ha#e a crosssection of at least B of the crosssection of the phase busbars and shall be predrilled.

Where multiple busbars are used per phase! the current rating of the neutral bar shall be atleast B of the rating of the phase bar combination.

[email protected] "arth bars are to be run the full length of the switchboard and must be continuous. -he bar is tobe positioned near the gland plate top or bottom or both as necessary. "arth bars are to ha#ethe following minimum crosssectional area with a minimum thickness of !$ mm 7

S0e%i(ie Three Ph$#e S+))e"ri%$&F$u&" Le-e& : kA/

E$r"h B$r Sie#q.))/

Cp to and including

Abo#e and up to 1

Abo#e 1 and up to 2

Abo#e 2 and up to $

Abo#e $ and up to '

Abo#e '

$

@

1

2

$

'

[email protected] n main switchboards! which deri#e a supply directly from a transformer! the neutral of thetransformer is to be bonded to earth at a point inside the switchboard.

-his point of bonding shall be close to the point of entry of the incoming conductors into theswitchboard and is to be in a conspicuous place. -he bonding conductor is to be at least of the same area as the earth bar and is to be insulated in green or green=yellow PD for

identification.

2$ 00$'



[email protected] ncoming and outgoing connections from the busbars shall be designed for the specified faultconditions and shall be rigidly supported by brackets to support their mass from the busbar stack or the e%uipment terminals.

[email protected]$ Pinch screw terminals must not be used on any of the busbars. -erminals must be of theclamping plate type or else the connections must be lugged and bolted.

[email protected]' ain and subsidiary busbars shall be of the same material and all bolted joints shall be tinnedor sil#er plated. -he joints shall be tightened to the correct bolt tor%ue and shall be lockedinto position to pre#ent connections becoming loose due to thermal cycling or mechanical#ibrations.

[email protected] 0witchboards with incomers and=or buscouplers shall be constructed so that the buscouplers are each in a segregated compartment and that the busbars associated with eachincomer are also segregated. -he main and secondary busbar chambers must also besegregated from each other. Hurthermore! in long switchboards! the main busbar chamber isto ha#e segregating barriers pro#ided at inter#als of not more than metres. -he degree of protection between the abo#e busbar compartment is to be at least P$.

PB.; CABLING AND 3IRING

P6.;.1 All wiring and cabling shall be carried out and be readily accessible from the front of theenclosure unless otherwise stipulated.

P6.;.2 -he re%uirements of 0A60 1'2 must be complied with.

P6.;.$ -he minimum conductor area of any power circuit shall not be less than 1!mmK. 0uitablyprotected control circuits may be wired with no less than 1!mmK fle/ible conductors. 2!mmKwiring shall be used for the secondary circuits of current transformers.

P6.;.' f the current rating dictates that multiple fle/ible conductors are to be connected to a

protecti#e de#ice! then the conductors are to be connected to the de#ice #ia stub busbars.

P6.;. -he connections between the incoming supply and the busbars or between the busbars andthe incoming side of the outgoing power circuit protecti#e de#ices! shall be made withconductors ha#ing a fault capacity e%ual or higher than the fault le#el indicated for the board.Hle/ible conductors may not be used to connect to the incoming side of the power circuitprotecti#e de#ices at specified fault le#els of 2 kA or higher! in which case only solid busbarsmay be used.

P6.;. ontrol wiring connected to the main or secondary busbars shall be protected with 9+fuses! preferably mounted directly on the busbars! but otherwise with no more than a 1 mmlong li#e conductor from the busbar. Cnprotected wiring may not be run into a compartment of

a switchboard which is separated from the compartment in which the tapoff is made. ngeneral! where control supplies are obtained directly from the busbars! upstream of anyfeeder protecti#e de#ices! the instruments so supplied are to be protected #ia 2 fuses in serieswith a collecti#e 1 A busbar mounted fuse for all instruments and an indi#idual 2 A fuse for each instrument.

P6.;.@ 0ubdistribution circuits protected by 9+ fuses need only be rated for the ma/imumprospecti#e asymmetrical fault le#el possible when the largest fusible link is installed in thefuse base.

P6.;.; ultistranded conductors shall be used in preference to solid conductors. 0olid conductorsmay not be used for control wiring.

P6.;.< nsulated conductors shall not be bunched in large numbers! to a#oid heat accumulationwithin the core of the bunch or damage to healthy circuits in the e#ent of fault.

2$ 00$



P6.;.1 f bunching of conductors is una#oidable! the conductors should be derated in accordancewith the rele#ant table of the 0A60 ode of Practice for the Wiring of Premises.

P6.;.11 onductors must be rated for an ambient temperature of at least 'V.

P6.;.12 -he insulation of the conductor shall not be stripped beyond the leading edge of the terminal inwhich it has to be accommodated. 0tripping shall be carried out without damage to theconductor! preferably by means of a cable stripper.

P6.;.1$ All cable and wire ends to be terminated on bolted connections to ha#e crimping lugs andferrules fitted and crimping shall be carried out using the proprietary tool. 9e/agonal crimpsmust be employed for conductors ' s%.mm or larger. able : wire ends due for termination oncircuit breaker! contactor and nonlugged type terminations shall ha#e the e/posed copper strands bound with copper wire to pre#ent splaying when the connection is tightened.

P6.;.1' -he wiring shall be carried out neatly along perpendicular lines and it shall be accommodatedin enclosed wireways or trunking which upon completion of wiring shall ha#e a 2B sparecapacity. -he wireways are to be positioned so that wiring is taken into the wireways within ashort distance of the terminals on the de#ice. f a loom is necessary! suitable metal standoffs

will be re%uired for fi/ing and forming of the loom. 0tandoffs shall either be screwed or epo/yglued to the board M double sided FmirrorF tape will not be acceptable.

P6.;.1 -he wiring shall not preclude the remo#al or block the access to any component. -he wiringmust be arranged and the de#ices spaced so that the labels which are fi/ed to the mountingplate are not obscured by the wiring.

P6.;.1 All cables and wiring is to be identified by numbered ferrules at e#ery termination according tothe schematic diagram and tables. Wrap around or Fstick onF ferrules are not acceptable.

P6.;.1@ ,eutrals shall be numbered so as to clearly and easily identify each neutral with itscorresponding phase conductor.

P6.;.1; able colours for wiring purposes shall be as indicated in the following. olour coding shall bediscussed with the "mployer! when foreign e%uipment! wired to different standards! is to beincorporated in the installation 7

(a) 0ingle phase distribution boards shall be wired in red and black PDinsulated conductors.

(b) -hree phase distribution boards shall be wired in red! white and blue PDinsulated conductors.

(c) 4eneral control wiring shall be orange and be taken from the blue phase.

Phase sensiti#e control wiring is to be wired in the phase colour.

(d) Cnearthed and ? control wiring shall be grey for negati#e and purple for positi#e.

(e) ,eutral connections shall be black and this colour must not be used for anyother connection.

(f) "arth connections only shall be striped greenyellow PD insulatedconductors.

P6.;.1< A terminal strip of the FJlipponF or similar type! if re%uired for e/ternal connections! shall becon#eniently and hori&ontally positioned and located no less than 1 mm abo#e the glandplate. -he terminal mounting rails shall be made longer than re%uired to allow a 2 Bfuture e/pansion. Wiring connected to such a terminal must be fitted with pin ferrules. 6areconductors are not to be directly inserted into the terminal connectors.

2$ 00$



P6.;.2 All ? and instrument terminals shall be separated from other terminals.

P6.;.21 Plastic Fchocolate blockF terminals with pinch screws will not be acceptable.

PB.< T4PICAL ARRANGEMENT DRA3INGS

P6.<.1 -he following typical arrangement drawings are included as a guide and illustrate the desiredarrangement concepts.

n pricing and engineering the boards! cognisance must be taken of the actual constraintsimposed due to the location of the board within the building! manner of installation! number and si&e of the circuits! cable entries and access and routing limitations within the building.

P6.<.1.1 0-?"=?@ 7 $phase distribution board with subdistribution.

P6.<.1.2 0-?"=?; 7 $phase distribution board without subdistribution.

P6.<.2 ,otwithstanding anything to the contrary! where the successful tenderer has tenderedon main and subdistribution boards manufactured by nonrecommended suppliers!acceptance of the tender shall be subject to the nonrecommended supplier pro#idinge%uipment! material! workmanship and standards e%ual to or better than therecommended suppliers and to the appro#al of the "mployer.

2$ 00$@



FUSES, TIME SWITCH

AND CONTROL GEAR

MAIN SWITCH

FRONT ELEVATION

SIDE ELEVATION

E

N

N

N

WITH DOORS REMOVED

FRONT ELEVATION WITH DOORS IN PLACE

SECTION

ISOLATOR

SINGLE PHASE

SECTION

SUB-

DISTRIBUTION

SECTION

MDC/PP

N.T.S.

5/5/94

STDE/D007

TYPICAL SURFACE WALL MOUNTED

3 PHASE DISTRIBUTION BOARD

WITH SUB-DISTRIBUTION

MAIN SWITCH

LABEL

DRAWN :

SCALE :

DATE :

DRAWING No :

REV :

2P 1P BLANKS

MAIN DB

DESIGNATION LABEL

SECTION LABELS

0

LARGE FRAME

ISOLATOR

2$ 00$;



MAIN

SWITCH

FRONT ELEVATION

WITH DOOR REMOVED

DESIGNATION

LABEL

MAIN SWITCH

LABEL

OUTER VIEW WITH DOOR CLOSED

E

N

N

N

SIDE ELEVATION

DRAWN :

SCALE :

DATE :

DRAWING No :

REV :

MDC/PP

N.T.S.

5/5/94

STDE/D008

TYPICAL FLUSH WALL MOUNTED

3 PHASE DISTRIBUTION BOARD

WITHOUT SUB-DISTRIBUTION

1P

3P

0

LARGE FRAME

ISOLATOR

2P BLANKS 3P

2$ 00$<



PB.1> MAR6ING AND LABELLING

P6.1.1 -he re%uirements of 0A,0 11'2 must be complied with.

P6.1.2 -he assemblies shall be fitted with identification labels engra#ed with the reference logosindicated on the wiring diagrams. -he labels shall be affi/ed to the front of the panels or ina similar prominent position! by dri#e screws or other appro#ed method.

P6.1.$ All components shall be identified as per their designation on the schematic diagrams byengra#ed plastic laminated labels mounted abo#e the component. -he letters should be atleast ; mm high! black on white background.

P6.1.' All busbar chambers to be clearly marked with the following information7 ser#ice #oltage!current carrying capacity and fault le#el and duration.

P6.1. "ach indi#idual item of e%uipment installed in the panels shall be identified by a labelengra#ed with the corresponding diagram reference. -he label is to be securedimmediately below or close to the de#ice it is identifying! but not on the de#ice itself. -he

label must not be co#ered by the wiring. 0elfadhesi#e tape labels will not be consideredsuitable for this purpose.

P6.1. "ach wiring termination of a motor control panel and all control wiring in other assembliesshall be fitted with a solid concentric cable marker engra#ed with the correspondingdiagram reference number. lipon and stickon cable markers will not be consideredsuitable for this purpose.

P6.1.@ Where an outgoing terminal block is pro#ided! each indi#idual terminal shall be marked withthe corresponding diagram reference number.

P6.1.; Purposemade labels shall describe the #arious sections or functions of the panels! to

facilitate the identification of the e%uipment and relate it to the diagrams.

P6.1.< -he usual warning labels! marker*s label and rating plate shall be affi/ed in suitablepositions. A copy of the wiring diagram and spare parts list shall be stored in a plasticen#elope within the enclosure! unless otherwise directed by the "mployer.

P6.1.1 5egend card holders are to be made of metal with a clear PD front and welded to the frontof the board (without doors) in a suitable position or to the inside of a door.

P6.1.11 -he description on the legend card must clearly indicate the location of the circuit as well asthe circuit type! e.g. FPlugs 7 ,orth lassroomF.

P6.1.12 All switchboards and distribution boards shall be fitted with a standard bilingual label

F, A0" 8H A?",-A5 8,-A- 085A-" A, 0W-9F

mounted directly below the main isolating switch and the si&e of the cable supply.

P6.1.1$ All subdistribution boards shall ha#e a label fi/ed below the main switch which shallindicate the source of the main feeder cable supply and the si&e=cores of the cable.

2$ 00'



PB.11 S3ITC2GEAR @ PROTECTIVE DEVICES

PB.11.1 Air Cir%ui" Bre$ker# ACB#/

P6.11.1.1 Air circuit breakers must comply with " <'@2. -he rated ser#ice short circuit breakingcapacity (cs) shall be e%ual to! or greater than! the specified re%uired fault le#el of theswitchboard in which it is to be used.

P6.11.1.2 A6*s shall be of utilisation category FAF and ha#e a short circuit withstand capacity of onesecond.

P6.11.1.$ Withdrawable A6*s must be pro#ided with an interlock on the cradle which pre#ents aclosed A6 from being withdrawn from! or inserted into! the power circuit. -he cradle mustclearly indicate F0er#iceF! F+acked 8utF and F-estF positions.

P6.11.1.' A6*s must be pro#ided with at least the following o#erloads 7

(a) An adjustable thermal o#erload with at least a range of ! to 1! of therated current.

(b) A short circuit o#ercurrent delay! adjustable both in time in at least stepsof ! !1! !2 and !$ seconds and in current up to 1 times the ratedfull load current of the A6.

PB.11.5 Mou&e C$#e Cir%ui" Bre$ker# MCCB#/

P6.11.2.1 A 6 is defined in this specification as a large frame circuit breaker with at least $ polesand with a breaking capacity of greater than 1 kA at ' D.

P6.11.2.2 6*s must at least comply with 0A60 1. n addition! for breaking capacities of $ kA

at ' D! or higher! the de#ices must also comply with " <'@2. -he rated ser#ice shortcircuit breaking capacity (cs) shall be at least e%ual to B of the specified re%uired faultle#el of the assembly in which it is to be used.

PB.11.? Mi!i$"ure %ir%ui" 're$ker )%'/

P6.11.$.1 cb*s are defined! in terms of this specification! as small frame circuit breakers of 1! 2! $ or 'pole type with breaking capacities up to 1 kA at ' D or up to kA at ' D for currentlimiting types.

P6.11.$.2 cb*s shall at least comply with 0A60 1.

PB.11. E$r"h &e$k$,e %ir%ui" 're$ker# ELCB#/

P6.11.'.1 -he earth leakage personnel protecti#e relays and circuit breakers shall operate on thecore balance principle and energi&e the trip coil by means of a static switching de#ice of simple design.

P6.11.'.2 -he sensiti#ity and response of the relay shall cause the instantaneous tripping of theisolator when the earth leakage current reaches $ mA.

P6.11.'.$ -he relay is to be fitted with integral test facilities and shall be compensated for ambienttemperature #ariations and se#ere earth fault currents.

P6.11.'.' "arth leakage relays protecting installations against earth leakage damage shall be of similar design and cause the isolator to trip when the total earth leakage current reaches2 mA.

2$ 00'1



P6.11.'. "arth leakage relays supplying $phase! 'wire supplies! shall be of the 'pole type.

P6.11.'. "arth leakage relays shall comply in all respects with 0A60 @@.

P6.11.'.@ An earth leakage relay shall be fitted to all circuits that feed socket outlets! e/cept those for special applications! and all circuits that supply water pumping e%uipment.

PB.11. Co)'i!$"io! Fu#e Swi"%he# CFS#/

P6.11..1 ombination fuse switch units shall be triple pole de#ices fitted with neutral links and shallcomply fully with 0A60 12 or 60 ", <'@.

P6.11..2 -he fuse switches shall be of the onload type capable of carrying the rated currentcontinuously! making and breaking rated current and tested to " <'@ for making andbreaking capacity.

P6.11..$ -he units shall be of the double airbreak! %uickmake! %uickbreak type with an arcchamber. -he mechanism shall be dri#en by springs on both sides.

P6.11..' -he unit shall consist of a fi/ed contact assembly! hea#y duty mechanism! mo#ing contactcarriage and a retractable operating handle mounted on a rigid frame. -he contacts shallbe of high %uality material! e.g. sil#er plated.

P6.11.. -he fi/ed contacts shall be shrouded.

P6.11.. When the fuse switch is in the open position! the double air break shall fully isolate the9+ fuse links! permitting fuse replacement in safety.

P6.11..@ nterlocks shall be pro#ided to pre#ent the co#er from being opened when the switch isF8,F and to pre#ent the switch from being operated when the co#er is open! unlesspurposely defeated.

P6.11..; -he cartridge fuses used in the units shall comply with 0A60 1@2 or 60 ;; or thee%ui#alent ?, and D?" 0tandards. -he category of the duty shall be suitable for the#oltage le#el and the fault le#el at the point where the fuses are installed. -ime=currentcharacteristics shall be matched to the e%uipment supplied and protected by the switch.

P6.11..< Huse gear carrying the 9+ fuses on the co#er! the co#er also forming the operating le#er!is regarded as a fuse isolator and is not acceptable.

PB.11.8 C$r"ri,e Fu#e# $! Fu#e 2o&er#

-his section co#ers cartridge fuses and holders used for the protection of distribution and

power system e%uipment up to D 7

P6.11..1 T+0e#

-he following fuse and fuse holder types are acceptable for use in distribution and power systems 7

(a) A cartridge type fuse link which fits into a fuse carrier together with a fuse base withfi/ed terminals. -he fuse can be remo#ed by taking out the fuse carrier and thenremo#ing the fuse from the carrier.

(b) A cartridge type fuse link which fits into a fuse base with fi/ed terminals. n thiscase a fuse puller is re%uired to disengage the fuse from the base. -hese fuses are

only acceptable on e%uipment imported with these fuses as a standard item. 8nepuller shall be supplied for each board or bo/ in which these fuses are used. -hefuse puller shall be mounted in a spring clamp inside the board.

2$ 00'2



+ewirable fuses are not acceptable and shall not be used.

Huses shall normally be installed in moulded plastic fuse holders or rigid isolatingbarriers shall be installed between the fuses. 0ufficient spacing to pre#entaccidental contact when inserting or withdrawing fuses shall be maintained. -heco#ers or barriers shall be manufactured for the specific fuses to be used.

0triker pin fuses shall be e%uipped with an alarm contact so that the contact closesand remains closed when the striker pin operates.

P6.11..2 S"$!$r#

All fuses used for distribution systems shall comply with the following standards 7

(a) Huses 7 0A60 1@2 or 60 ;;! Parts 1 and 2.

(b) 9olders 7 0A60 1@$.

(c) Huses of the types described in para P6.11..1 abo#e and complying with the

rele#ant ?, ('<1! '<11! '<1! '<22! '<$! '<$@) and D?" ($!) 0tandards are also acceptable.

P6.11..$ R$"i!,#

(a) Huse ratings shall be accurate to within TB of the published #alue for unused fusesand shall not #ary significantly after long periods of ser#ice.

(b) Huses shall be derated for ambient temperatures abo#e 2V in accordance with themanufacturer*s recommendation. f no such recommendation e/ists! a derating factor of 1B per V abo#e 2V shall be applied.

(c) Huses shall be derated for ele#ations of more than 1 m abo#e sea le#el inaccordance with the manufacturer*s recommendation. f no such recommendatione/ists! a derating factor of 1B per $ m abo#e 1 m abo#e sea le#el shall beapplied.

(d) -ime=current characteristics shall be chosen to suit the application 7

able Protection 7 -he fusing shall not e/ceed 1!.

otor ircuits 7 -ime lag characteristic so that the starting currentswill not cause deterioration of the fuse.

apacitor ircuits 7 Huses shall be chosen to withstand a higher thannormal fullload current (1! times rated capacitor current) to allow for harmonics and shall notdeteriorate due to the high transients at switchon.

?istribution 0ystems 7 -he total operating 2t let through by secondary(minor) fuses shall be less than that of primary(major) fuses in any specific branch.

(e) t shall be ensured that the rupturing capacity of a fuse chosen for a specific applicationshall be ade%uate! both as far as short circuit current and applied #oltage areconcerned.

2$ 00'$



PB.11.9 Tri0&e Po&e O!7Lo$ Swi"%he#

[email protected] -his section co#ers switches suitable for panel mounting for use in power distributionsystems up to D! 9&. 0witches for motor isolation are included.

[email protected] -he switches shall be of the triplepole! hand operated type! complying with 0A60 12.

P6.11.@.$ -he switches shall ha#e a high speed closing and opening feature.

P6.11.@.' -he switches shall be suitably rated for the continuous carrying! making and breaking of therated current specified. -he throughfault current capacity must be at least e%ual to thespecified prospecti#e fault le#el for one second.

P6.11.@. -o distinguish the switches from circuit breakers the operating handles shall ha#e adistincti#e colour and=or the switch shall be clearly and indelibly labelled F085A-8+F.

PB.11.; Co!"$%"or#

P6.11.;.1 ontactors shall be of the totally enclosed! four! three or two pole! electromechanically

operated air break type! suitable for ' D = 2$ D supplies and comply with 0A60"<'@='.

P6.11.;.2 ontactors shall be of modern design with the following characteristics 7

(a) "nclosed coil easily replaceable.(b) A permanent air gap in the magnetic circuit to pre#ent sticky operation.(c) Pro#ision for %uick and simple inspection of contacts.(d) learly marked main and au/iliary terminals.

All parts shall be accessible from the front.

P6.11.;.$ ontactors which are not located in switchboards shall be housed in enclosures whichcomply with P.' of 0A60 1222.

P6.11.;.' -he current rating of the contactor shall be as specified for the circuit with a switching dutyin accordance with the following utilisation categories of 0A60" <'@=' 7

(a) A 1 7 +esisti#e heating.

(b) A $ 7 0tarting indication motors37 0witching fluorescent and incandescent lighting circuits.

(c) A (b) 7 apacitor switching.

P6.11.;. n *s or switchboards where the prospecti#e fault le#el is 2 kA or higher! contactorsmust be selected to gi#e lass 2 coordination to 0A60" <'@='.

P6.11.;. -he magnetic system of the contactor shall be carefully designed and all laminations tightlyclamped to ensure that when the armature is closed and full #oltage at normal fre%uency isapplied to the coil! the contactor will not emit more noise than the hum associated with anyproperly constructed laminated core with tightly clamped laminations. ,oisy contactors willnot be accepted.

P6.11.;.@ 5atched contactors shall be pro#ided with a trip coil and a closing coil. -he contactor shallremain closed after deenergising the closing coil and shall only trip on energising the tripcoil.

P6.11.;.; ontactor operating coils shall ha#e a #oltage rating as re%uired by the control circuitry andshall ha#e the limits of operation and temperature rise as specified by 0A60" <'@='.

2$ 00''



5atched contactors shall be capable of being tripped at B of the rated coil #oltage. oilsoperating on 2$ #olts would be preferred.

P6.11.;.< ontactors for normal=standby changeo#er circuits shall be electrically and mechanicallyinterlocked. ontactors shall also be electrically interlocked in stardelta starters.

P6.11.;.1 ontactors shall ha#e the pro#ision to add au/iliary contacts and con#ert au/iliary contactson site. ontactors with permanently fi/ed au/iliary contacts shall ha#e at least 1 / ,=8and 1 / ,= spare au/iliary contact in addition to the contacts specified for control purposesand in addition to contacts re%uired for selfholding operations or economy resistances.Where the number of au/iliary contacts re%uired is greater than the contacts that can beaccommodated on the contactor! an au/iliary relay or additional contactor shall be pro#idedto supply the additional contacts.

P6.11.;.11 t shall be possible to replace main contacts without disconnecting wiring.

P6.11.;.12 Au/iliary contacts shall be capable of making! carrying continuously and breaking A at2$ D A! unity power factor for contactors used on ' = 2$ D systems.

P6.11.;.1$ Au/iliary contact functions re%uired! e.g. Fla&yF contacts! latemake! latebreak!makebeforebreak! etc.! shall be inherent in the contact design. Cnder no circumstancesmay these functions be impro#ised by bending contacts! loading contacts! etc. -hesefunctions shall be a#ailable in all contactors.

P6.11.;.1' 0pare au/iliary contacts shall be wired to numbered terminal strips in the switchboard andshall appear on the switchboard drawings.

PB.11.< O-er&o$ Re&$+# (or Co!"$%"or#

P6.11.<.1 All o#erload relays are to comply with 0A60" <'@='1 and must pro#ide protection

against both o#erload and single phasing conditions.

P6.11.<.2 -hermal o#erload relays must be temperature compensated and pro#ide gal#anicallyisolated au/iliary contacts for tripping and indication. 6oth manual and autoreset facilitiesmust be pro#ided.

P6.11.<.$ "lectronic o#erload relays must be used for motors of kW and larger! unless otherwisespecified. -he relay must ha#e the facility to set the starting time of the dri#e and must tripinstantaneously in the case of single phasing.

PB.11.1> E&e%"ro!i% Mo"or Pro"e%"io! Re&$+#

P6.11.1.1 "lectronic motor protection relays must comply with 0A60" <'@=' as applicable andbe suitable for use on '=2$ D systems.

P6.11.1.2 -he relay must be pro#ided with a sealable co#er! behind which the settings of the unitare made. A reset button must be accessible without remo#ing the co#er.

P6.11.1.$ -he relay must pro#ide indication by means of 5"?*s! of the cause of the trip out andalso indicate the operational readiness of the unit.

P6.11.1.' At least the following protection facilities must be pro#ided 7

P6.11.1.'.1 -hermal o#erload

P6.11.1.'.2 Anti0ingle phasing

P6.11.1.'.$ 0tall protection

2$ 00'



P6.11.1.'.' Phase se%uence protection

PB.15 INDICATING INSTRUMENTS

P6.12.1.1 All electrical e%uipment for a particular application shall be supplied from the samemanufacturer! shall be splashproof and dustproof and ha#e the same face dimensions.-he face dimensions shall be s%uare and not less than < / < mm. Antistatic impactresistance glass shall be used on the face.

P6.12.1.2 All instruments shall conform to 60.;< and=or ".1.

P6.12.1.$ nstruments shall be rated for 2 kD insulation resistance to earth.

P6.12.1.' nstruments shall be capable of withstanding o#erloads of continuous or short duration inaccordance with ".1 (1!2L = 1L ).

P6.12.1. nstruments shall be pro#ided with either recessed or shrouded studs for rear connection. All rear connections shall conform to at least P 2.

P6.12.1. nstruments shall be sufficiently resistant to #ibration that may be encountered.

PB.15.5 6i&ow$""72our )e"er#

P6.12.2.1 Cnless specified to the contrary! kilowatthour meters shall be suitable for operation on22=2 D! 9&! systems.

P6.12.2.2 eter elements shall be of the inductor disc type and designed to carry the rated currentcontinuously.

P6.12.2.$ Jilowatthour meters shall comply with the rele#ant parts of 60 ;$. -he integrating

period on ma/imum demand meters shall be $ minutes unless specified to the contrary.

P6.12.2.' -he registering mechanism shall be of the cyclometer type! pro#iding a si/ digit readoutwith the si/th digit indicating one tenth of a unit.

P6.12.2. Cnless specified to the contrary! the meters shall conform to accuracy lass 1! as specifiedin ".1.

P6.12.2. Jilowatthour meters shall be graded and calibrated for the specific application to a#oid theapplication of multiplication factors where possible. Where multiplication factors areuna#oidable this shall be clearly indicated in unit form and not as a combination of se#eralfactors. urrent transformer ratios shall be incorporated in the factor.

P6.12.2.@ -he kilowatthour meter shall preferably be pro#ided with a magnetic type of bearing for thedisc spindle.

P6.12.2.; Hacilities for a security seal shall be pro#ided on the fi/ing screws of the co#er.

P6.12.2.< kWh meters with pulsed output are to be single or $phase units as applicable. A digitcyclometer display is to be pro#ided and the onetenth digit may be omitted. A ma/imumerror of 2B is to be pro#ided. -he pulse output! which is to be pro#ided by #oltage freecontacts! must correspond to 1 kWh=pulse.

PB.15.? Vo&")e"er# $! #e&e%"or #wi"%he#

P6.12.$.1 Hor 5D applications! all #oltmeters shall be scaled from #olts! unless otherwisespecified.

2$ 00'



P6.12.$.2 Doltmeters shall be of the mo#ing iron type! lass 1. accuracy as specified in ".1.Nero adjustment screws shall be pro#ided.

P6.12.$.$ Cnless otherwise specified! a single #oltmeter shall be used with a selector switch. -he#oltage selector switch shall ha#e an F8HHF position and positions for indicating readingsbetween each phase and neutral and between phase and phase.

P6.12.$.' -he #oltage selector switch shall be cam actuated or of the air break type with two breaksper pole.

PB.15. A))e"er#

P6.12.'.1 Ammeters shall ha#e a mo#ing iron element to indicate instantaneous #alues as well as a&ero adjustment screw for the indicating arm.

P6.12.'.2 Ammeters may be direct reading up to a ma/imum of amps. urrent transformer operated ammeters shall ha#e the - ratio indicated on the face plate and shall be ratedfor amps full scale reading actual primary circuit currents.

P6.12.'.$ Where combined ma/imum demand and indicating ammeters are detailed! a bimetallicspiral element shall be pro#ided in the same housing to indicate mean #alue o#er a 1minute period.

P6.12.'.' -he bimetal element shall dri#e a residual pointer to indicate ma/imum mean currentbetween resettings. -his pointer shall operate on the main scale and shall be of adistincti#e colour. -he pointer shall be resettable from the face of the meter.

P6.12.'. -he bimetal element shall be designed to compensate for limits of ambient temperaturebetween ()2 and @ .

P6.12.'. Hull load or rated current shall be clearly indicated! preferably with a red line. Cnless

specified to the contrary! a 1B condensed o#erscale shall be pro#ided for instantaneousreading instruments and no o#erscale for combined ma/imum demand ammeters.

P6.12.'.@ -he intrinsic error! e/pressed in terms of the fiducial #alue in accordance with ".1shall be lass 1. for the instantaneous readings and lass 2. for the mean ma/ima.

P6.12.'.; Where saturation current transformers are re%uired! these shall be an integral part of themeter. 0eparate saturation current transformers will not be permitted.

PB.15. Freque!%+ )e"er#

P6.12..1 Hre%uency meters may be of the #ibrating reed type or the direct indicating type consistingof a mo#ing coil milliammeter and a current=fre%uency transducer.

P6.12..2 Cnless specified to the contrary! the indicating range shall be ' 9& 9&.

P6.12..$ -he accuracy class shall be lass ! in accordance with " 1 unless otherwisespecified.

P6.12..' Where re%uired! an adjustable speed alarm contact shall be pro#ided! adjustable o#er thecomplete scale length.

PB.15.8 Ru!!i!, hour )e"er#

P6.12..1 +unning hour meters shall be of the electrically operated cyclometer type! suitable for flushmounting.

P6.12..2 ,umerals shall be clearly defined White on a 6lack background.

2$ 00'@



P6.12..$ -he range of hour meters shall be fi#e digits! the fifth digit indicating onetenth of an hour!i.e! from to <<<<!< hours.

P6.12..' -he accuracy class shall be lass 1 in accordance with ".1 unless otherwisespecified.

PB.15.9 Curre!" "r$!#(or)er#

[email protected] Ge!er$&

urrent transformers shall comply with the re%uirements of 0A60 " ''1.

[email protected] R$"i!,#

(a) urrent transformers shall be suitable for the primary currents listed hereunder and their decimal multiples 7

1! 12.! 1! 2! 2! $! '! ! and @

-he preferred #alues are 7

1! 1! 2! $! and @

(b) urrent transformers shall ha#e secondary ratings of 1 A or A! with A beingpreferred.

(c) urrent transformers shall ha#e standard outputs of 2.! ! 1! 1 or $ DAas applicable! in terms of the burden of the instruments and interconnectingwiring. -he current transformer output shall match the actual instrument burdenas closely as possible in order not to introduce unnecessary errors.

P6.12.@.$ A%%ur$%+ %&$##

(a) Hor metering applications! accuracy classes . or 1 are applicable. Where noaccuracy class has been specified! the following table is to be adhered to7

A00&i%$"io! C&$##

ndicating instruments 1

etering applications 1

Precision metering applications !

and bulk metering

(b) Where ring type current transformers are specified! the aperture shall not beunnecessarily large as accuracy is thereby reduced.

(c) -he classes for protection are P! 1P! 1P! 2P or $P with P and 1Pbeing standard. -urns compensation shall not be employed on protectioncurrent transformers for ratios greater than 1=.

P6.12.@.' All current transformers shall come complete with a label on which the following informationis indelibly stamped 7

anufacturer 0erial ,umber or -ype+ated primary and secondary current+ated fre%uency+ated output and accuracy class

2$ 00';



9ighest system #oltage+ated insulation le#el

P6.12.@. urrent transformers shall be capable of withstanding the dynamic forces and thermalstress resulting from the ma/imum throughfault current which may be encountered at thepoint where they are installed. -he short time current rating of current transformers shallcorrespond to the ma/imum short circuit current at the point of connection flowing for aperiod of 1 second.

P6.12.@. mpulse le#els for current transformers used in system #oltages up to D shall complywith 0A60 " ''.

PB.1? MISCELLANEOUS CONTROL EUIPMENT

PB.1?.1 I!i%$"or &i,h"#

P6.1$.1.1 ndicator lights may only be of the neon or 5"? types. 5amp #oltages shall suit the supplyor control #oltage. 5amps shall be derated for continuous duty by using economy resistorsor using input #oltages at least 2B lower than the rated lamp #oltages.

P6.1$.1.2 Where 5"?*s are used as indicators on main supply #oltages a suitable current limitingcapacitor and re#erse #oltage protection diode must be used. Hor low A or ? #oltages(I 2' D ) a current limiting resistor will suffice.

P6.1$.1.$ ndicator lights shall conform to 60.1 where applicable.

P6.1$.1.' ndicator lamps shall consist of interchangeable lenses! lamp base! suitably rated andaccessible terminals and a chromed screwon retaining ring. All indicator lights for aspecific application or switchboard shall be from the range of one manufacturer and shallpreferably be of the same si&e and shall use the same lamp types. Plastic lenses shall notbe used.

P6.1$.1. t shall be possible to replace lamps from the front of the panel without the use of tools.

P6.1$.1. 0urface mounted indicator lights shall be housed in purposemade bo/es with suitableco#er plates.

P6.1$.1.@ ndicator lights shall be e%uipped with standard remo#able legend plates. Alternati#ely! thefunction shall be clearly indicated by means of labels or by engra#ing on the lenses.

P6.1$.1.; All indicator lights for a specific application or switchboard shall be from the range of onemanufacturer and shall preferably be of the same si&e and shall use the same lamp types.

P6.1$.1.< -he following are the preferred colours for indicator lights 7

(a)+"? Abnormal 0tate or otor 8ff

(b)S"558W (or Amber)7 Attention! or aution! or otor -ripped

(c)4+"", 7 otor +unning

(d)W9-" (or lear) 7 ircuit 5i#e or ircuit 8perating ,ormally

(e)65C" Any function not co#ered by the abo#e colours.

PB.1?.5 P$!e& )ou!"e 0u#h 'u""o!#

P6.1$.2.1 All push buttons on a specific switchboard shall be of the same physical dimension (roundor s%uare) and shall be fully interchangeable as far as possible. Push buttons mustpreferably be interchangeable with indicator lamps! key switches! etc.

2$ 00'<



P6.1$.2.2 Push buttons shall be designed for long life! low contact bounce and constant contactresistance. echanisms may be of the mechanical type with spring control and a clutch or catch frame or of the solid state type operating on the principle of a noncontacting!inducti#e pro/imity switch.

P6.1$.2.$ All push buttons shall be pro#ided with replaceable lenses with a #ariety of symbols for insertion and for remo#able and inter changeable legend plates. 5egend plates shall beclear and #ersatile.

P6.1$.2.' Push button terminals shall be suitable for the application with regard to spacing! conductor capacity! etc.

P6.1$.2. 0crew type! soldered or connector type terminals shall be chosen to suit the specificapplication with regard to good contact! ease of remo#al or alteration! rigidity! etc. -erminalsshall be suitable for conductor si&es to be used. Push button assemblies mounted ondoors of control boards shall be enclosed to pre#ent inad#ertent contact with the terminals.

P6.1$.2. Push buttons shall be suitable for the en#ironmental conditions to be encountered! e.g.moisture! e/cessi#e temperatures! mechanical shock! #ibration! etc.

P6.1$.2.@ ontact duty shall be chosen to suit the application. Wiping contacts shall be used for low#oltages and currents and snapaction contacts for high #oltages and currents. ontactsshall be constructed of high %uality material such as sil#ertipped or gold laminatedcontacts.

P6.1$.2.; lluminated push buttons may employ neon or 5"? lamps. 5amp #oltages shall suit systemcontrol #oltages. 5amps shall be derated when used for continuous duty! e.g. using 2 Dsupply on 2; D rated lamps. "/ternal resistors shall be used with 5"? lamps to a#oide/cessi#e current.

P6.1$.2.< Push buttons may be grouped together in purposemade stations! suitable for the

en#ironment in which it is to be installed.

P6.1$.2.1 Jeylock push buttons shall be supplied with duplicate keys. -he remo#al action of the keyshall suit the application.

P6.1$.2.11 Push buttons shall comply with the applicable re%uirements of 60.$< Part $ and".<'@.

PB.1?.? Ro"$r+ CAM #wi"%he#

P6.1$.$.1 -his section co#ers rotary cam switches used for control functions in switchboards! motor control circuits! etc.! up to 1 kD A.

P6.1$.$.2 -he switches shall be e%ui#alent to J58J,"+8"55"+ -ype - rotary cam switchesand shall conform to ".<'@1 and D?".11$! where applicable.

P6.1$.$.$ -he switches shall be of the cam actuated type with two breaks per pole! the re%uirednumber of poles and number of control functions pro#ided by the assembly of switchingunits on a common spindle.

P6.1$.$.' -he spindle shall be operated by a control handle suitable for the method of installation of the switch. -he control handle shall be located by a keyway on the spindle.

P6.1$.$. -he switches shall be pro#ided with a suitable face place! indicating the angle of throw andthe switch positions. -he latching mechanism shall ensure positi#e positioning in accuraterelation to the positions indicated on the face plate.

2$ 00



P6.1$.$. -he switches shall be suitable for use with the supply #oltage le#el. -he contacts shall besil#er plated or gold laminated and shall be suitably rated for the switching functionsintended.

P6.1$.$.@ Hor normal applications the making capacity of the switch shall be at least three times thenormal current rating. Hor A.' duties (inching! re#ersing! plugging)! the rated current of the switch shall be at least e%ual to the stalled rotor current of the motor.

P6.1$.$.; 0pecial contacts! e.g. latemaking! earlybreaking! etc.! shall be inherent in the design andshall not be impro#ised by loading or bending contacts! etc.

PB.1?. Mo"ori#e Ti)e Swi"%he#

P6.1$.'.1 -ime switches shall be of the single pole type! suitable for 2$ D systems! with contactsrated for the duty to be performed with a minimum A1 rating of 1 A. ontacts shall be of high %uality material! e.g. sil#er plated or solid sil#er. -he time switch shall be rated for operation in the temperature range 1V to TV

P6.1$.'.2 -he clock shall be dri#en by a crystal controlled stepping motor! keeping accurate mains

time. All clocks shall ha#e a @2hour rechargeable battery reser#e in the e#ent of mainsfailure.

P6.1$.'.$ -he motor shall be separately protected by a correctly rated single pole 6.

P6.1$.'.' A manual bypass switch shall be pro#ided to permit the circuit to be switched F8,F or F8HHF manually without affecting the operation of the time switch.

P6.1$.'. ?aily timeswitches shall ha#e a 2' hour dial! with day and night indication! that can be setwith a minimum accuracy of $ minutes unless specified otherwise.

P6.1$.'. Weekly timeswitches shall ha#e a @day dial! with clear indication of the days of the week

that can be set to a minimum accuracy of ' hours.

P6.1$.'.@ 0witches intended for incorporation into distribution boards must be suitable for railmounting.

P6.1$.'.; -he switch intended for wall mounting shall be housed in a dusttight moulded plastic or metal case! consisting of a plastic clipon front co#er and a moulded plastic or metal baseand be pro#ided with a suitable positioned 2 mm conduit knockout.

P6.1$.'.< When re%uired! motorised timeswitches are indicated as either F-F or F-F on theschematics or schedules.

PB.1?. Di,i"$& Ti)e Swi"%he#

P6.1$..1 ?igital time switches shall be of the single channel type! suitable for 2$ D systems withcontacts rated at least 1 A! 2$ D! A1.

P6.1$..2 -he switch shall be microprocessor based with at least a 1 hour battery reser#e. -heoperating temperature range shall be at least M1V to T'V.

P6.1$..$ -he switch is to be pro#ided with a li%uid crystal display for indicating time and=or thesettings. -he time stability shall be at least 1 second=day. -he display must also indicatethe operating condition (8,=8HH) of the switch.

P6.1$..' ?aily time switches shall ha#e a setting capacity of 12 programme steps ( programmepairs).

P6.1$.. Weekly time switches shall ha#e a setting capacity of at least 12; switching times.

2$ 001



P6.1$.. -he minimum switching time is to be not more than 1 minute.

P6.1$..@ 0witches are to be pro#ided with a clip for ?, rail mounting and must be enclosed in anP 2 bo/! if wall mounted.

PB.1?.8 Pro,r$))$'&e E&e%"ro!i% Ti)er#

P6.1$..1 -imers must be of the plugin module construction. "ach timer is to be housed in a dusttight housing with the timing range clearly marked on the front and must be pro#ided with acalibrated setting knob.

P6.1$..2 -he timer must be suitable for either 2$ or ' D operation! as applicable! and ha#e acontact rating of 1 A=2$ D A1 for single pole or A=2$ D A1 for double pole. ontactlife is to be at least 1 operations at full load.

P6.1$..$ -he operating temperature range is to be at least M1V to TV.

P6.1$..' -he time adjustment range must be at least 1271.

P6.1$.. -he front of the timer must be pro#ided with a small indicating light to show the relay isenergised.

PB.1?.9 Mi%ro7,$0 #wi"%he#

[email protected] icrogap switches shall be suitable for ratings up to ' A at D (triple pole) and maybe used for main and distribution switches in domestic applications! offices! small factoriesand similar applications.

[email protected] ?ouble pole switches shall be suitable for #oltages up to 2 D.

P6.1$.@.$ -he switches shall comply with 0A60 12.

P6.1$.@.' icrogap switches may be used on A circuits only.

P6.1$.@. etal clad and moulded casings are acceptable.

P6.1$.@. icrogap switches shall be capable of carrying rated current continuously and making andbreaking rated current.

P6.1$.@.@ 9ea#y! fully accessible! brass terminals with two screws each shall be pro#ided to facilitateeasy wiring. ontacts shall ha#e large contact surfaces! made from high %uality materialsuch as solid sil#er.

P6.1$.@.; -he F8,F and F8HHF positions and the rating of the switch shall be clearly and indeliblymarked.

PB.1?.; I!oor Sur,e Arre#"or#

P6.1$.;.1 0urge arrestors shall be of the gapless metal o/ide type and shall comply with there%uirements of 0A60" <<' or 0A60" 1'$1 or D?" @.

5ow #oltage surge protection de#ices shall be fitted to each phase and neutral of all maindistribution boards and motor control boards! irrespecti#e of the lightning ground flashdensity of the area.

P6.1$.;.2 Arrestors intended for use on 2$ D systems must ha#e a rated #oltage of not less than2@ D.

P6.1$.;.$ Arrestors shall at least ha#e a rated nominal discharge current of kA. -he residual #oltageat a kA discharge current shall be less than 1 kD.

2$ 002



P6.1$.;.' 0urge arrestors shall be suitable for installation at altitudes of up to 1; m abo#e seale#el.

P6.1$.;. -he unit shall be supplied complete with a gal#anised steel mounting bracket for con#enient mounting onto the metalwork or tray of a switchboard.

P6.1$.;. Alternati#ely! the unit shall be of the type which can be mounted into the clip tray of aswitchboard or for ?, rail mounting.

P6.1$.;.@ 0urge arrestors shall be pro#ided in all cases where a switchboard is supplied directly froman o#erhead line.

P6.1$.;.; n other cases! surge arrestors! if re%uired! will be specified in the F?etailed -echnical0pecificationF.

PB.1?.< Ter)i!$& Co!!e%"or#

P6.1$.<.1 -erminal connectors shall hold the conductor by means of a clamping plate held down bythe securing screw.

P6.1$.<.2 onnectors shall be of the indi#idual #ariety which are assembled on to a mounting rail andheld in place by means of a securing plate at each end.

P6.1$.<.$ -he minimum si&e used must be able to accommodate a conductor in the range 1! to s%.mm.

P6.1$.<.' All connectors and the wires connected to them must be numbered and these numbersreflected on the Fas builtF drawings.

PB.1 INSTALLATION

P6.1'.1 5D switchboards and distribution boards and motor control panels shall be erected!installed and commissioned in the positions shown on the drawings. -he installation shallbe arranged to suit the general installation programme. All floor mounted switchboardsmust be bolted securely to the floor.

P6.1'.2 ?uring transport to site and installation! the boards shall be protected against mechanicaldamage and #ibration.

P6.1'.$ 6oards shall not be mo#ed onto site nor installed until all building ser#ices and finishingtrade work has been completed in the room or #icinity of where the boards are to beinstalled.

P6.1'.' -he boards shall be installed in such a manner as to facilitate e/tensions! maintenance!testing and repair work with easy access to cable entries= terminations! currenttransformers! potential transformers! small wiring terminal boards and relays! and busbar connections.

P6.1'. Prior to the onsite tests! all screws! bolts! joints and cable terminations shall be checkedfor tightness. 6usbar joints and cable terminations must be tor%ued to the correct tension.

PB.1 INSTALLATION S2OP DRA3INGS* MANUALS AND SAMPLES

PB.1.1 Ge!er$&

P6.1.1.1 -he ontractor shall pro#ide all drawings! manuals and samples as specified below.

2$ 00$



P6.1.1.2 ?etailed drawings of all e%uipment shall be submitted to the "mployer in triplicate for appro#al well in ad#ance of the latest ordering date and in all cases at least 2 weeks inad#ance of the latest manufacturing commencement date.

P6.1.1.$ Cnder no circumstances will the these re%uirements be wai#ed. Any delays or increasedcosts due to noncompliance with these re%uirements will be for the contractor*s account.

P6.1.1.' -he appro#al of the drawings shall not relie#e the manufacturer of his responsibility to theemployer to supply the e%uipment according to the re%uirements of this specification.

P6.1.1. -he ontractor is to submit two (2) copies of shop and installation drawings to the"mployer for re#iew.

PB.1.5 Sho0 r$wi!,#

As a minimum! the shop drawings shall indicate schematic wiring diagrams! symbol legend!e%uipment schedule and engineering construction drawings showing7

P6.1.2.1 ?etails of construction! front #iew! side #iew and section through board and e%uipment!

dustproofing! access and cable terminations! etc.

P6.1.2.2 -he internal arrangement to show details of the housing o#er! indicating door positions! roof line! etc.

P6.1.2.$ A schedule crossreferenced listing all e%uipment within the board with the total %uantities!manufacturer*s names! current ratings and time settings.

P6.1.2.' 6usbar and dropper bracing and support details including specimen calculations or testreports in substantiation of short circuit capacity of the system.

P6.1.2. 6usbar section and si&e including selection=si&ing criteria and calculations in substantiation

of the full load rating.

P6.1.2. All labelling information in both official languages on a separate sheet.

PB.1.? I!#"$&&$"io! r$wi!,#

As a minimum! the dimensioned installation drawings shall indicate7

P6.1.$.1 Position of switchboard relati#e to cable trenches! cable trays! adjacent walls ande%uipment.

P6.1.$.2 0urrounding clear space between walls and adjacent e%uipment for access and

maintenance purposes.

P6.1.$.$ able entry details! and cable routing and crosso#er aspects when entering the board.

P6.1.$.' ?etails of supports across trenches and the interface between the cable trench co#ersand switchboard.

PB.1. S$)0&e#

P6.1.'.1 Where switchboards and subdistribution boards are to be pro#ided by manufacturers other than those recommended! the contractor shall pro#ide samples of the e%uipment! material!%uality and workmanship to be inspected for appro#al.

P6.1.'.2 -hese samples may take the form of e/isting e%uipment pro#ided by the particular supplier for pre#ious contracts! pro#iding the location of the e%uipment is local to and within 1kilometres of the "mployer*s offices.

2$ 00'



P6.1.'.$ -he "mployer may also re%uest physical samples of items of e%uipment be submitted for appro#al during the detailed engineering phase.

PB.1. KA# Bui&"K Dr$wi!,# $! M$!u$&#

P6.1..1 -he FAs 6uiltF ?rawings and anuals shall comprise the rele#ant final as appro#ed andinstalled installation and shop drawings. -he maintenance and fault finding manuals shallbe e/plicit! shall crossreference to the drawings! schematics and control logic diagramsand shall pro#ide full maintenance details! re%uirements! methods and schedules for eachand e#ery type of de#ice employed. Hurthermore! the manual shall contain spare parts listsand numbers for all e%uipment and the names of the suppliers from whom the e%uipment isto be obtained.

P6.1..2 anuals must also include all test results and the settings of all protecti#e! control andindicating de#ices as applicable.

P6.1..$ anuals must be pro#ided in a hard co#er looseleaf file! properly inde/ed with full pageseparators between each section.

P6.1..' Hull and detailed -echnical literature and operating procedures must be pro#ided for allitems of e%uipment. At least one original manual must be pro#ided for each correspondingitem of e%uipment! up to the re%uired number of three ($).

P6.1.. -hree ($) copies of the FAs 6uiltF drawings and anuals shall be submitted to the "mployer within two weeks after deli#ery of the e%uipment.

PB.18 INSPECTIONS* T4PE TESTS* TESTS AND COMMISSIONING

P6.1.1 At the time of tender the manufacturer is to demonstrate compliance with item @..1 of 0A60" '$< part 1! that assemblies shall be so constructed as to be capable of withstanding

the thermal and dynamic stresses resulting from short circuit currents up to the rated #alues.-his will take the form of type test results on similar arrangements or e/trapolation from typetested arrangements or agreement to conduct short circuit tests on the completed assembly.

P6.1.2 Prior to commencement of manufacture! the contractor shall pro#ide typical samples of the%uality of work and finish to be e/pected from the board manufacturer.

P6.1.$ -he contractor shall keep the "mployer informed of the manufacturing progress and shallarrange periodic works and site inspections and tests as re%uired.

P6.1.' As a minimum! the final inspections and tests shall include 7

P6.1.'.1 -he pro#isions of 0A60 " '$< part 1

P6.1.'.2 Disual inspection of the board! busbar! joint tightness! switchgear operation! etc.

P6.1.'.$ 2 kD A = 1 min test of all control and power circuits.

P6.1.'.' Primary injection test of all -*s for use in protection! indication and metering circuits. -histest current must be of sufficient magnitude to #erify the correct ratio of the - and theindicating=metering de#ice. "lectronic o#erloads used in A6*s and 6*s may be testedusing secondary injection from a specialised tester pro#ided by the anufacturer=0upplier.

P6.1.'. 8peration and testing of all control! indication! metering and protection systems.

P6.1.'. Hinal check of all protection system settings and the coordination and discriminationbetween associated de#ices.

P6.1.'.@ "nergisation of the board.

2$ 00



P6.1.'.; heck on phase rotation! #oltage drop! load balance! earth continuity and resistance.

P6.1. All test results must be recorded by the ontractor and included in the manuals.

2$ 00



PB.19 RECOMMENDED MANUFACTURERS AND SUPPLIERS

-he following list of manufacturers and suppliers of electrical e%uipment is enclosed for theinformation of -enderers. 8ther makes and suppliers of electrical e%uipment may beconsidered by the onsulting "mployer but the tender shall include the following e%uipmentand any other makes must be quoted as an alternative offer:

2$ 00@



A+ +C- 6+"AJ"+0 (A6) erlin 4erin M 0chneider "lectric0A" 6 itsubishi

8C5?"? A0" 6+"AJ"+0 (6) 6 M itsubishierlin 4erin M 0chneider "lectric

86,A-8, HC0" 0W-9"0(H0) 0tromberg0iemens

9+ HC0"0 A,? A+-+?4"0 4 " 6rush

8,-A-8+0 A,? 8D"+58A?+"5AS0

A66 "lec. 0ystems0precher : 0chuh-elemecani%ue0iemens

0trombergJlockner oXller

+"5AS0 A,? -"+0 A66 "lec. 0ystems0precher : 0chuh8mron0iemens-elemecani%ue

-"+,A5 658J0 Jlippon-elemecani%ue0precher : 0chuh

PC09 6C--8,0! 0"5"-8+0W-9"0! P58- 549-0

A66 "lec. 0ystems8mron-elemecani%ue0iemens0precher : 0chuh

"5"-+ -"+0 8rbis9einemann?uotron8mron+homberg6rYsler

45A00H6+" 0W-968A+?0 A,?

?0-+6C-8, J80J0

0witchboard anufacturers

4olni/Sork

0W-968A+?0 0iemens! Pinetown4amma Panels! ?urban0witchboard anufacturers! Phoeni/! ?bn

agnol "lectrical! ?urban

8-8+ 8,-+85 68A+?0 A66 "lec. 0ystems! ?urban4amma Panels! ?urban"lectron "lectrical ontractors! ?urban

2$ 00;



ELECTRICAL SYMBOLS FOR SINGLE LINE DIAGRAMS

DELAYED ACTION

MECHANICAL INTERLOCK BETWEEN TWO DEVICES

LATCHING DEVICE DISENGAGED

LATCHING DEVICE ENGAGED

OPERATED BY PULLING

OPERATED BY PUSHING

EMERGENCY SWITCH (MUSHROOM HEAD SAFETY

FEATURE)

OPERATED BY KEY

OPERATED BY THERMAL ACTUATOR,FOR EXAMPLE THERMAL

RELAY,THERMAL OVERCURRENT PROTECTION

DELAY WHEN OPENING & CLOSING

THERMAL SWITCH

TERMINAL FOR REMOTE CONNECTION

OPERATING DEVICE

RELAY COIL OF A SLOW OPERATING RELAY

DIRECT ON LINE MOTOR STARTER

STAR DELTA STARTER

HEATER

CURRENT TRANSFORMER 3 PHASE WITH FOUR

THREE PHASE TRANSFORMER

RECTIFIER IN FULL WAVE (BRIDGE)CONNECTION

EARTH

1 CONDUCTOR

2 CONDUCTOR

3 CONDUCTOR

PLUG & SOCKET (MALE & FEMALE)

CONNECTING LINK CLOSED

CAPACITOR

BATTERY OF PRIMARY CELLS OR ACCUMULATORS

INDUCTION MOTOR,THREE PHASE

SQUIRREL CAGE

TRANSFORMER

CIRCUIT BREAKER

FUSE

SURGE ARRESTOR

VOLTMETER

AMMETER

POWER FACTOR METER

FREQUENCY METER

RECORDING WATTMETER

KILO-WATT HOUR METER

PULSE METER (ELECTRICALLY OPERATED COUNTING DEVICE)

CLOCK

SIGNAL LAMP

HORN

BELL

SIREN

INCORPORATED

CONDUCTORS

PANEL MOUNTED PUSH BUTTON

EARTH LEAKAGE WITH THERMAL OVERLOAD

EARTH LEAKAGE WITHOUT THERMAL DEVICE

SWITCH DISCONNECTOR (ON LOAD ISOLATING SWITCH)

FUSE SWITCH)

FUSE SWITCH-DISCONNECTOR (ON LOAD ISOLATING

DURBAN EMPANGENILADYSMITH ULUNDI

3

M

E/L

E/L

kWh

W

Hz

fcos

2$ 00<



ELECTRICAL SYMBOLS FOR

SINGLE LINE DIAGRAMS

INCORPORATED

MAKE CONTACT

BREAK CONTACT

DELAYED MAKE CONTACT

WHEN CLOSING

(NON LOCKING)

PUSH BUTTON SWITCH

WHEN RE-OPENING

DELAYED MAKE CONTACT

EMERGENCY KEYED

LOCKED-OUT STOP

WHEN RE-CLOSING

DELAYED BREAK CONTACT

POSITION SWITCH, BREAK CONTACT

LIMIT SWITCH, BREAK CONTACT

POSITION SWITCH, MAKE CONTACT

LIMIT SWITCH, MAKE CONTACT

MAKE CONTACT WITH SPRING RETURN

BREAK CONTACT WITH SPRING RETURN

CONTACTOR (CONTACT OPEN IN THE

UNOPENED POSITION)

UNOPENED POSITION)

CONTACTOR (CONTACT CLOSED IN

BREAK CONTACT OF OVERLOAD

RELAY

THERMAL OVERLOAD RELAY

DURBAN EMPANGENI LADYSMITH ULUNDI

2$ 00



MAIN LV DISTRIBUTION SC2EDULE

ITEMS SUB=ECT TO AGREEMENT BET3EEN MANUFACTURER AND USER

0ubclause of 0A60 " '$< ?"0+P-8, 0P"H +">C+"",-

.1.$ (,8-")

Cse of electronic e%uipment at

altitudes abo#e 1m.2 0pecial ser#ice conditions

.2.1"lectrical and radiatedinterferences

.$.1onditions during transport!storage and erection

@.1.$.2eans of connecting foraluminium conductors

@.1.$.'urrent carrying capacities ofterminals for neutral conductors

@.2.1.1 ?egree of protection re%uired

@.'.2hoice of protecti#e measuresagainst direct contact

@.'.$hoice of protecti#e measuresagainst indirect contact

@.'. Accessibility in ser#ice byauthorised personnel

@.'..1 Accessibility for inspection andsimilar operations

@.'..2 Accessibility for maintenance

@.'..$ Accessibility for e/tension under #oltage

@..2.$Dalues of prospecti#e shortcircuit current for high powerrotating machines

@..'oordination of short circuitprotecti#e de#ices

@..'.$?egree of protection afterremo#al of a remo#able orwithdrawable part

@.@ Horm of separation

@.<.1nput #oltage #ariations forelectronic e%uipment supply

@.<.'(b) 0upply fre%uency de#iation

;.2.1.$.'-emperature rise test for #aluesof test current higher than$1 A

above ground fire pump

Documents