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KUDREMUKH IRON ORE COMPANY LTD

TURNKEY TECHNICAL SPECIFICATION FORDUCTILE IRON SPUN PIPE PLANT

AT MANGALORE

MEC/S/196G/01/PJ/01 Chapter 8, Sheet 1 of 213“© 2008 MECON Limited. All rights reserved”

8.0 SHOP ELECTRICS AND ILLUMINATION FACILITIES

8.1 Shop Electrics

Relates to shop electrics scheme for the project. The electrical equipment envisaged for procurement and installations are transformers, MCCs PDB, LT power and control cables etc as detailed in this specification.

8.1.1 Scope of work

The scope of work for electrics shall comprise design, engineering, manufacture, shop testing, arranging Owner’s/Consultant’s inspection, packing & forwarding, delivery at site, storage at site, erection, testing & commissioning of complete shop electrics for the Ductile Iron Spun Pipe Plant project of KIOCL.

8.1.2 The major equipment covered in the scope of the tenderer shall include but not be limited to the following:

LT Motor control centres (MCCs)/PDB/VFD for control of drives of project

Solid state soft start with energy saving device shall be adopted preferably wherever energy saving is of major consideration for all LT AC motors.

LT and control cables internal to the package including termination at both ends.

GI/GRP cable trays required to enable cabling as per battery limits of the package.

Fabricated, epoxy painted steel structures including cable stockade, required to facilitate the erection of cable trays, push button stations etc.

Cable laying and termination accessories viz. double compression brass cable glands, cable ties, saddles, clamps, printed aluminium cable tags etc.

Provision of earthing grid for the Plant comprising of earth pits, GI flats and duplicate earthing connection to the earthing grid by GI wires and flats for equipment supply in tenderer's scope. Scope shall also include duplicate earthing connection from tenderer supplied Plant earth main grid to the existing plant main earth grid.



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Lightning protection system as per IS 2309 for the plant comprising of GI flats, downcomers, earth pits, air terminations etc

Field devices such as mounted electrics, motors for technological / utility equipment, limit switches, brakes, motor operated valves etc. (A motor and feeder list with kWs and analogue / digital input and output list indicated against each item / equipment shall be furnished).

Controls- PLC, Control desks, Local push button stations, Soft starters.

Power Sockets- 63 A welding receptacles, 15A convenience outlets etc.

All ECR (Electrical Control Room) shall have pressurized ventilation system in MCC / PDB portion of ECR and VVVF/PLC/Soft Start portion of the ECR shall have air conditioning system.

The ECRs layout considerations shall be in line with that of electrical sub stations given under specification for Power Distribution.

Intelligent fire detection and alarm system shall be provided for all electrical and other control rooms.

Main control room housing PLC, computer shall be air conditioned for temperature of 25 Deg. C + 1.

The tenderer’s scope of work shall also include the following :

Liasion with statutory bodies including Karnataka State Electrical Inspectorate on behalf of the Owner and obtaining all necessary clearances/approvals as per requirement without contractual implications to the Owner

Civil works pertaining to laying of buried cables, earthling pits, installation of equipment viz MCC etc.

Preparation of drawings and documents along with calculations, cable schedules for approval and as built drawings, O&M manuals etc.

8.1.3 Standards

Equipment to be supplied by the tenderer shall conform to the requirements of latest revisions of IEC, Indian Standards, IE Rules, local rules and regulations. In case of conflict, the most stringent one shall govern.



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8.1.4 Voltage levels

Motors over 160 kW and above

: 6.6KV, TP, 50 Hz,40 KA Non-effectively earthed

Direct-on-line start motors up to 160 kW

: 415V, TPN, 50 Hz, 50KA solidly grounded

MCC Control Supply : 110V, AC, Single phase obtained through transformer

Space heaters : 240V, AC, Single phase

8.1.5 Operating conditions

Power Supply Variations

Voltage level Voltage Variation Frequency Variation

415 V ± 10 % ± 5%6.6 Kv ± 10 % ± 5%

Combined voltage and frequency variation

: ± 10 %

Reference ambient temperature : 450C

Relative humidity : 100% not occurring Simultaneously with maximum temperature

Height above Mean Sea level : Less than 1000 M

8.1.6 Equipment specification

8.1.6.1 Technical specification for LT switchboards/MCC

Design Criteria

Power supply conditions

Nominal voltage : 415 V, TPN

Variation in voltage : + / - 10 %



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Nominal voltage : 415 V, TPN

Nominal Frequency : 50 Hz

Variation in Frequency : + / - 5 %

System Earthing : Solidly grounded

Fault level (1 sec) : 50 KA

Control supply for O/G feeders : 110V, 1 –Ph

Auxiliary supply for space heaters etc. : 240V, 1 – Ph

Constructional features

Construction : Single/double front, single incomer, fully draw out/non draw out floor mounted, compartmentalized, multi-tiered type.

Enclosure class of protection

: IP 52

Sheet steel thickness : 1.6mm (min.) CRCA, for non-load bearing members and 2.0 mm (min.), CRCA for load – bearing members

Tier formation : Two tier for ACB feeders and multi tier for others

Incoming termination : Cable

Incoming entry : Top

Outgoing entry : Top cable

Minimum clearances in air

a) between phases : 25.4 mm

b) between live parts and ground

: 19mm for solidly earthed system

1 minute PF withstand for main circuits

: 2.5 KV r.m.s

Paint shade : As per approved drawing



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Busbars

Material for phase and neutral busbars

: E91E Aluminium

Continuous rating at specified design ambient

:

a) Main busbars : As per requirement

b) Bus connections to circuit breakers

: As per rated currents of circuit breakers

Final temperature at rated continuous current of busbars in busbar chambers

: 85 C

PVC shrouds : At all joints

Materials of earth busbar : Al, 50 x 6 mm (min.)

Breakers

Type of breaker : Fully drawout, air break

No. of poles : 3

Rated current at :

Specified design ambient temperature

: As per specification

In panel breaker rating : As per busbar rating

Rated ultimate short circuit breaking capacity

: 50 KA

Rated short-circuit making capacity

: 105 KA (peak)

Rated service short-circuit breaking capacity

50 KA

Utilisation category : B

Rated short time withstand current (1 sec)

: 50 KA

Type of release : micro processor based



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Protection functions to be provided in release

- Over current : Yes, inverse-time type

- Short circuit : Yes, with options for both inverse time and definite time

- Earth fault : - do -

Under voltage release with independently adjustable voltage range and time setting range

: Preferable

Operating mechanism : Trip free, motorised, stored energy

Requirement of electrical/manual operation

: Electrical

Auxiliary voltages for

a) closing coil : 240 V, ACRange : 80 – 110 %

b) Trip coil : 240 V, ACRange : 50 – 110 %

c) Spring changing motor : 240 V, ACRange : 80 – 110 %

MCCB

Type : Air break

No. of poles : 3

Utilisation category : A


: 50 kA

Rated service short circuit breaking capacity

: 105kA

Protective releases : Microprocessor based releases.



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Contactors

Type : Electromechanical, double air break

No. of poles : 3

Utilisation category : AC-3

Rated current : 150 % of motor rated current with 16A min at AC3 duty

Coil voltages

Pick-up : 80 – 100% of rated

Drop-off : 40 - 60% of rated

Overload relays

Type : Thermal, ambient temperature compensated (As per Component Selection Chart of MCC)

No. of poles : 3

Reset : Hand/Auto site selectable

Other features

Mechanical trip position indicator

: Required

Test button : Required

Auxiliary contacts : 1 NO + 1 NC

Protective cover : Required

Single phasing preventer

: Inbuilt

Current transformers

Type : Dry Resin cast

CT secondary : 5A

Accuracy

Metering : 1.0, ISF < 5

Protection : 5P 10

One minute p.f. Withstand voltage

: 2.5 kV r.m.s



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Indicating instruments

Ammeter

Type : Taut band, square dial

Accuracy class : 1.5

Size

For I/C & B/C : 144 x 144 mm

For other feeders : 96 x 96 mm

Zero adjust : Required

CT operation : For continuous running drives rated above 11 kW & for feeders rated 100A & above.

List of applicable standards for LT Switchboards with Reaffirmed (R.a) year.

IS : 8623 (1993) : Specification for low-voltage switchgear and control gear assemblies

Part 1

(R.a : 1998)

: Requirements for type – tested and partially type tested assemblies

Part 3(R.a : 1998)

: Particular requirement for equipment where unskilled persons have access for their use

IS : 11353 (1985)(R.a: Not Available)

: Guide for uniform system of marking and identification of conductors and apparatus terminals

IS : 7118 (1973)

(R.a: 2003)

: Recommendations for direction of movement for control devices operating electrical apparatus

IS : 9409 (1980)

(R.a: 2002)

: Classification of electrical and electronic equipment with regard to protection against electrical shock.

IS : 12063 (1987)

(R.a: 2004)

: Classification of degrees of protection provided by enclosures of electrical equipment.



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IS : 12083 (1986) : Electrical relays

Part 1(R.a: 2001) : Contact performance

Part 2(R.a: 2001) : Insulation tests

IS : 13947 (1993) : Low voltage switchgear and control gear

Part 1 (R.a: 1998) : General Rules

Part 2 (R.a: 1998) : Circuit breakers

Part 3 (R.a: 1998) : Switches, disconnectors, switch disconnectors and fuse combination units

Part 4 (R.a: 1998) : Contactors and motor-starters

Part 5 (R.a: Not Available)

: Control circuit devices and switching elements

SP 39 (1987) (R.a: Not Found)

: Indian standard guide for insulation coordination within low voltage systems

IS : 2147 (1962) : Degrees of protection provided by enclosures for low voltage switchgear and control gear.

IS : 13703 (1993) : Low voltage fuses for voltage not exceeding 1000V AC or 1500 V DC

Part 1 (R.a:2004) : General requirements

Part 2 / sec 1(R.a:2004)

: Fuses for use by authorised persons –supplementary requirements

Part 2 / sec 2 (R.a:2004)

: Fuses for use by authorised persons –examples of standardised fuses

IS : 2705 (1992) : Current transformers

Part 1 (R.a: 2002) : General requirements

Part 2 (R.a: 2002) : Measuring current transformers

Part 3 (R.a: 2002) : Protective current transformers

Part 4 (R.a: 2002) : Protective current transformers special purpose applications

IS : 3156 (1992) : Voltage transformers

Part 1 (R.a: 2002) : General requirements

Part 2 (R.a: 2002) : Measuring voltage transformers

Part 3 (R.a: 2002) : Protective voltage transformers



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IS : 4146 (1983)

(R.a: 2001)

: Application guide for voltage transformers

IS : 4201 (1983)

(R.a: 2001)

: Application guide for current transformers

IS : 8530 (1977)

(R.a:2000)

: Maximum demand indicators

IS : 1248

(R.a:2003)

: Direct acting indicating analogue electrical measuring instruments and their accessories.

IS : 13947 (Part 5 Sec 1-1993)

(R.a: 1998)

: Specification for control switches (Switching devices for control and auxiliary circuitsincluding contactor relays) for voltages up to and including 1000V AC and 1200 V DC

: General requirements and tests

: Push buttons and related control switches

: Rotary control switches

Equipment specification

LT switchboard/MCC shall comprise equipment for power supply and control and protection of equipment. Feeder requirement and type of switching equipment shall be as per approved schematic diagram and control schemes of feeders

LT switchboard/MCC with all its components mounted in the cubicle shall carry continuously specified rated current without exceeding the final temperature applicable to various equipment, corresponding to the design ambient temperature.

Final temperature shall be as per relevant IS adjusted to design ambient specified. Where final temperatures are specified, the same shall be applicable.

LT switchboard with breakers, CTs, busbars shall have breaking dynamic withstand and short time rating corresponding to those specified for the LT breaker.



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Breakers shall be capable of operating satisfactorily under symmetrical and all asymmetrical faults corresponding to breaking capacity specified.

Each cubicle shall have provision to terminate required number of cables considering multi-tier arrangement. Two-tier arrangement shall be preferable. Design of breaker cubicles shall be such as to provide inter changeability of breaker carriages of same rating at site.

Constructional features

The LT switchgear units shall be indoor, self supported, floor mounting, dead front, fully compartmentalised to conform to Form 3 requirement of IS 8623(R.a:1998), multi- tiered, air insulated, natural air cooled, metal clad factory assembled, fully wired, type tested assemblies. The switchgear shall allow extension at either end.

The switchgear when erected shall form a continuous single line-up of panels. Each shipping section shall comprise not more than three verticals and shall be provided with lifting arrangement.

ACB panels shall be restricted to two-tier formation. The maximumand minimum working height for switchboard shall be not more than 1800 mm and not less than 350mm respectively.

The switchgear shall be single front/double front, draw-out/fixed type as specified in the Design Criteria/bill of material. The enclosure class of protection shall be IP- 42 or as indicated in Design Criteria/bill of material.

The enclosure shall be fabricated from CRCA sheet steel whose thickness shall be min. 2mm for load bearing members and min. 1.6 mm for non-load bearing members.

All doors and covers shall be provided with synthetic rubber gaskets. All hinges shall be concealed type.

Feeder module doors and cable alley doors shall open in opposite directions. For single front type switchgear, the vertical panels shall be provided with rear lift-off doors in two sections. Each lift off section shall be provided with handles.



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The switchgear shall be suitable for top/bottom incoming busduct/cable entry and top/bottom outgoing cable entry as specified in Design Criteria.

LT switch board/ MCC shall be provided with 30% spare cubicles/ modules. These spare cubicles / modules shall be complete with all devices with the standard module design of the corresponding MCC.

The switchgear shall be provided with an integral base channel.

Each vertical shall be provided with anti-condensation heater and lamp.

Where ACBs are provided, breaker handling trucks shall be included in supply.

Requirements for draw-out construction.

Withdrawable modules shall be provided with 3 distinct positions:

a) Service : Both power and control circuit connections to be made.

b) Test : Power circuit shall be off while control circuit shall remain connected and can be tested by means of "Test Push Buttons"

c) Isolated : Both power and control circuit shall be disconnected.

Means shall be provided to identify each position.

Each withdrawable unit shall be provided with its own door. The door shall be jumpered to the main structure to provide earth continuity.

Each withdrawal unit shall be mounted on guide rails and shall be provided with rollers. The units shall be self-aligning.

Power contacts shall be spring loaded, stab-in type. Control contacts shall be spring loaded, self-aligning type. Each withdrawal unit shall be provided with double scraping type earth connections, which shall be first to make and last to break type.



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Safety shutters shall be provided to ensure that no live parts are accessible once the module is withdrawn.

Identical draw out modules shall be interchangeable

Main Busbars and connections

Busbars shall be made of E91E grade Aluminum alloy. Cross section of busbars selected shall ensure temperature of busbars and joints is limited to 850C at rated currents. In addition, it shall withstand mechanical forces for specified peak short circuit current and have 1 sec. short circuit thermal rating at specified short circuit current. Horizontal busbars shall be housed in totally enclosed compartments with removable bolted covers.

Busbars shall be tinned at joints. High tensile cadmium plated bolts with suitable spring washers shall be used for busbar joints. Prior to joining, oxide-inhibiting grease shall be applied after cleaning the surfaces.

Busbars shall be fully insulated for working voltage with specified phase and ground clearances. Heat shrunk PVC sleeves for busbars and shrouds for joints shall be provided. Further busbars shall be colour coded for phase identification.

Busbars shall be supported on non-hygroscopic anti-tracking, flame retardant insulating supports. Busbar chamber of each panel shall be segregated from the busbar chamber of adjacent panels.

All busbars and main current carrying connections shall have the same cross sectional area throughout their lengths.

The busbar supports and their terminal connections shall be designed to permit expansion and contraction of the buses with variations in temperature which may occur in actual service.

The connecting busbars for the incoming line circuit breaker shall have continuous current capacity same as specified for main busbars. For the outgoing feeders, the connecting busbars shall have the continuous current capacity not less than the rated current of the circuit breaker, irrespective of the release settings.



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The neutral busbars shall be designed to carry 50% of the continuous current rating of the main busbars.

Earth bus shall be provided running continuously at the bottom of the switchgear with a bolted link to the neutral busbar. Horizontal busbar shall be extensible on both sides.

Auxiliary busbars

Auxiliary busbars shall be provided for control supply, space heater supply. These busbars shall be segregated from the main busbars and adequately sized to meet the specific requirement. Material of busbars shall be electrolytic tough pitch copper. The busbars shall be adequately supported and due clearances shall be observed.

Make up of Modules

(i) Incoming feeder:

- Shall be MCCB unit of adequate rating in fixed module. Where rating is 630 Amp or above the same shall be air circuit breaker in draw out execution. MCCB/ACB shall be with microprocessor based direct acting self powered adjustable O/C, E/F, S/C release . ACB release shall be provided with separate LED indication for each fault and a fault reset button. Self-diagnostic feature shall be provided in the release as a standard feature.

- Provided with voltmeter and ammeter having accuracy class 1.0 and size 144 x 144 sq. mm. Ammeters shall be provided for all the three phases without selector switch.

- Provided with microprocessor based metering system with RS 485 communication port and pulse energy output.

- Provided with R,Y,B phase indication lamps and ON/OFF/TRIP lamps

- MCCB shall have 1 NO + 1 NC contacts rated for 6A, AC 11 duty. ACB shall have minimum 4 NO = 4 NC auxiliary contacts rated for 6A, AC 11 duty.



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- ACB shall be provided with mechanical and electrical anti pumping arrangement and trip circuit supervision through lamp and test push button.

(ii) Control supply feeder

- Each MCC shall have adequately rated control transformers at each bus section with MCCB at primary side and SPMCB on secondary side with one leg of secondary earthed

- Provided with dry type control transformer of 415/110V with + 2.5, + 5%primary taps

- “Control supply on" lamp and voltmeter to be provided.

- Manual selector scheme for providing selection “ individual / transformer 1/ transformer 2”

(iii) MCCB feeders

- With microprocessor based adjustable, self powered release for O/C, S/C and E/F.

- With 1 NO + 1 NC auxiliary contacts rated for 6A at AC11 duty.

- Provided with ON, OFF and Trip lamps, ammeter for all feeders rated 100 A and above.

(iv) Motor feeders

- Provided with MPCB / MCCB with 2 NO + 2 NC auxiliary contacts rated for 6A at AC 11 duty.

- MCCB / MPCB shall be interlocked with control circuit

- Main contactor shall be suitable for AC 3 duty with minimum rating of 16A. Selection shall be as per component selection chart. The contactor shall have minimum 2 NO + 2 NC auxiliary contacts rated for 6A at AC 11 duty.



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- Interposing relays for remote PLC control shall be provided in individual feeder module. Coil voltage for these relays shall be 24 V DC.

- MCC module shall be provided with a relay to operate with thermistors in motors above 55Kw.

- Transducer shall be provided in the MCC module with 4-20 mA signal output for current indication/measurement as required by the process.

- Overload relays to be provided for motors rated up to less than 55 kW. Overload relay shall be 3 element bimetallic type, ambient temperature compensated with in-built single phasing preventer. It shall be manual reset type. Drives of 11 kW and above shall be provided with CT operated O/L relays with protection Class 10P10.Drives rated 55 kW and above shall be provided with motor protection relay type as specified in the component selection table with thermistor/RTD input for motor protection.

- Drives upto 11 kW shall be provided with direct reading ammeters on Y phase.

- Motor feeders rated 11Kw and above shall be provided with 3 Nos. CTs with Ammeter selector switch.

- Ammeter shall have acc. class 1.5 and shall be of size 96 X 96 mm. They shall be suitable to read starting current.

- Reversible drives shall be provided with mechanically and electrically interlocked contactors.

- SP MCB (9 kA) shall be provided for control supply to module.

- ON/FORWARD/REVERSE/OPEN/CLOSE, OFF, TRIP indication lamps (LED clustered) shall be provided.



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- Provision shall be kept in the module for winding heating at 240 V AC for motor space heaters for motors above 30 kW.

- All pumps shall be provided with dry running protections.

- All emergency conditions like stop push button, emergency stop command, level switches, end switches, torque switches etc. will be directly hard wired to the main power contactors of the drives, so that the drives are stopped irrespective of mode of controls (and by by-passing operation). All these emergency conditions will be displayed in control desk (in the VDUs also).

- Selection of components shall be so as to provide Type 2 discrimination as per IS-13947(R.a:1998)

L.T. Circuit breaker

The circuit breakers shall be triple pole, trip free, air break, fully drawout shunt trip and selective type for achieving discrimination. All current carrying contacts of the breaker shall be silver plated. The main contacts shall have ample area and contact pressure for carrying the rated current of the circuit breaker, to avoid excessive temperature and the resultant pitting. The tips of the arcing contact shall be made out of suitable arc resisting material. Arc chute shall be provided on each pole and so fitted that it can be easily removed for inspection of the main contacts. The contacts shall meet against spring pressure with a self-cleaning action. Interphase barriers of proper design shall also be incorporated.

The connections of main power and auxiliary control circuits shall be fitted with self-aligning contacts. The fixed portions of the sliding contacts shall be easily accessible for maintenance and checking. If plug and socket are used for auxiliary control circuit connection, mechanical interlock shall be provided to ensure the following :

i) Remove the plug before the breaker is withdrawn from the test position and

ii) Movement of breaker from test to service position shall be possible only after connecting plug and socket.



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The breaker shall have the following three distinct positions:

a) Service position: Normal service position with main and auxiliary control circuits remaining connected.

b) Test position: In this position, main power contacts of the breaker are fully disconnected while the auxiliary control circuits remain connected.

c) Isolated/maintenance position: In this position the breaker shall be fully out of the cubicle and both the main power and auxiliary control circuits are disconnected.

These three positions shall be possible with door closed. An automatic mechanical indicator shall be provided to indicate these positions, visible from outside. It shall be possible to lock the breaker in test and isolated position.

The circuit breaker, together with its operating mechanism isolating and interlocking gears, contacts and wiring, shall be fixed on a withdrawable carriage. Each carriage shall have a dead front panel. Mechanical interlocking shall be provided on each carriage to prevent mal-operation and in particular to ensure that

a) The carriage cannot be moved in or out of its cubicle with the circuit breaker closed.

b) The circuit breaker can only be closed when the carriage is in one of the three positions viz. the service position or fully out of the cubicle in the maintenance position.

c) Inadvertent withdrawal of a circuit breaker carriage too far beyond its supports shall be prevented by suitable mechanical stopper.

d) Interlocked rigid clamping and anti lifting arrangements shall be provided for circuit breaker trucks in the service and test positions.



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The circuit breaker shall be capable of carrying continuously and interrupting satisfactorily the currents specified without undue heating or wear of the contacts, under the specified site conditions.

Automatically operated shutters shall be provided to screen the fixed portion of the contacts assembly when the breaker is fully withdrawn from the cubicle.

Circuit breakers of identical rating shall be physically and electrically interchangeable.

Operating Mechanism

Circuit breaker shall be provided with either a power operated mechanism or a manual operating mechanism as specified in Design Criteria.

Manually operated mechanism shall be of independent spring charging, stored energy type. Power operated mechanism shall be of motor wound, spring charging, stored energy type.

The operating mechanism shall be trip free and designed to reduce mechanical shocks to a minimum during operation. The operating mechanism shall operate normally even when circuit breaker is closed on fault.

The mechanism shall be provided with mechanical indicators to indicate spring condition i.e., CHARGED, DISCHARGED.

The operating mechanism shall be provided with following features:

It shall not be possible to close the breaker unless spring is fully charged.

Closing of the breaker shall immediately and automatically initiate spring charging to ready for the next closing stroke.

Failure of the spring shall not initiate closing or prevents intentional tripping.

Means shall be provided for manual charging with motor supply being cut-off automatically when charging handle is inserted.



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Spring charging motor shall be suitable for AC or DC supply as per Design Criteria with variation from 85% to 110% of rated voltage.

Provided with a shrouded mechanical trip button accessible from outside.

Electrical and mechanical anti-pumping protection

One open-close-open operation of the circuit breaker shall be possible after power supply failure to motor.

Protection Releases

The circuit breakers shall be provided with microprocessor based direct acting protection releases for overload, short circuit and earth fault protections. The release shall be ambient temperature compensated for ambient temperature up to 60 C and shall be self powered type requiring no auxiliary supply. The performance of the release shall not be affected by the magnitude of the fault current.

The release shall be provided in a separate case and shall be tested in accordance with IS /IEC for mechanical stresses (shocks and vibrations), dielectric strength etc.

The overload function shall be inverse-time type whereas for short circuit and earth fault it shall be possible to choose between inverse time and definite time characteristics. For all the three protections it shall be possible to set the fault current and time separately. Individual indications shall be provided for each type of fault.

The release shall also be provided with the following features:

Self-monitoring for microprocessor mal function. An indication shall be available for the healthiness or otherwise.

Manual reset pushbutton for trip resetting

An external contact for signaling the trip/microprocessor malfunction. Individual contact for each type of fault shall be preferred



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Function blocking for the three protections separately.

Zone selectivity so that in the case of two or more breakers connected in series, the breaker nearest to the fault clears the fault first while informing the upstream breaker of the occurrence of the fault. This selectivity shall be available on short circuit and ground fault protections when definite time characteristic has been selected for these protections

Self-test facility for the release when breaker is isolated. Auxiliary supply/power pack required being included in scope.

Communication facility on RS – 485 serial link interface.

Circuit breaker for incomers, bus couplers and motor feeders shall be provided with adjustable under voltage release. It shall be possible to adjust both voltage and time settings.

Auxiliary contacts

All contacts shall have adequate capacity to make, carry and interrupt the current in their circuits. Minimum rating shall be 5A at 415 V AC 2A at 220 V DC. Each circuit breaker shall be provided with 6 NO + 6 NC auxiliary contacts. Out of these, 3 NO + 3 NC shall be spare auxiliary contacts for owner’s exclusive use at site. The design of the contacts shall be such that they can be easily converted from normally open to normally closed type and vice versa. All the auxiliary contacts shall be wired internally upto the terminal blocks in the fixed portion of the breaker cubicle. In case multiplication of contacts are required, the same shall be done using electrically reset latched type relays.

Interlocks

The switchgear shall be provided with all necessary interlocks designed to prevent incorrect operation and to ensure safety of operating personnel and also the equipment. Each breaker shall have door interlocking mechanism and interlock defeat facility. Castle-key interlock shall be provided for incomers and bus sectionaliser to prevent parallel operation where specified.



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Moulded Case Circuit Breakers (MCCBs)

MCCBs shall be of triple pole construction suitable for panel mounting, Operating mechanism shall be trip free, quick make, quick break type.

The MCCBs shall be provided with front operating handles and mechanical ON/OFF indicators. In case of trip, the handles shall rest in an intermediate position.

MCCBs shall be provided with microprocessor based release for O/C, S/C, E/F, which shall be fully adjustable.

Where MCCBs are used in the motor starter modules in conjunction with contactor and thermal overload relay, type 2 coordination shall be provided.

MCCBs shall have following accessories and features :

a) Shunt trip release

b) Auxiliary contact set of 1 NO + 1 NC contacts

c) Fault signaling contact set of 1 NO + 1 NC contacts

d) Insulation shields to isolate the connections between each pole

e) Finger protection plate to prevent accidental contact

The compartment door shall be interlocked with the handle of the MCCB

Contactors

The contactors shall be electro-mechanical triple pole, air-break type with the coil operating voltage as specified in the control scheme. The coil shall be suitable for operation in the range of 85% to 110% of the rated coil voltage.

The utilization category of the contactors AC 3 / AC 4 to match with the load requirements. The contactor rating shall be chosen to provide type 2discrimination; however, the minimum rating shall be 16A at AC 3 utilisation category.



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The contactor shall be provided with adequate no. of NO and NC auxiliary contacts. The auxiliary contacts shall be such that NO contacts close after the main poles have closed and NC contacts open before the main poles have closed. Further, it shall be possible to change NO contacts to NC and NC contacts to NO at site.

Directional contactors shall be electrically and mechanically interlocked.

The closed state of the contactor shall be visually identifiable by means of a mechanical indicator.

Overload relays

Overload relays shall be thermal, triple pole, manually reset, ambient temperature compensated, and positive acting type with in-built single phasing preventer.

The range selection shall be such that the setting ranges overlap. Relays may be direct acting or CT operated depending on current rating. In the latter case, CTs shall be in tenderer's scope.

The relays shall have following features

i) It shall be possible to change from manual reset to auto-reset at site.

ii) Resetting the relay shall be possible from the front with the compartment door closed

iii) Mechanical trip position indicator shall be provided.

iv) Test button shall be provided

v) Protective cover shall be provided to avoid intentional tampering of settings, auto/manual reset and test button

vi) Provided with 1 NO + NC auxiliary contacts.

The trip class of the thermal overload relays shall be chosen based on the type of load and shall be subject to approval. In general for applications such as pumps etc. where starting time is less than 10



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seconds, the trip class shall be 10. For high inertia loads, the trip class shall suit the starting time.

Relays

All protection relays shall be drawout flush mounted in dust proof cases control circuits shall be automatically broken and current transformer secondary circuits shorted when a protection relay is withdrawn from its case. A marking strip shall be provided in front of each terminal block and a diagram plate at the back of each case to identify connections.

All spare contacts shall also be wired upon the externals. Relay coils shall carry their normal currents indefinitely and such currents than can occur under fault conditions. Relay mechanism shall not be affected by normal vibrations or external magnetic fields.

All indicating and protection relays shall have mechanically operated hand reset flag indicators. Indicators shall be capable of being reset without opening the relay case. It shall not be possible to operate any relay by hand or to alter its setting, without opening the case.

Means shall be provided for testing relays from the front of the panel, preferably by test plugs for insertion between the finger contacts of drawout relays.

Current transformer

Protection and measuring current transformer shall be of cast resin, bar type primary, with 5A or 1A secondary as per enclosed single line diagrams. The minimum burden shall be 15 VA. Measuring current transformers shall conform to accuracy class I and burden of CTs shall be as required by the associated measuring instruments and connecting leads. The CTs shall have saturation factor of 5.

Protection current transformers shall have their accuracy as minimum 5P and burden as required by the protection circuit in which they are used and shall have minimum saturation factor not less than 10.

CTs for restricted earth fault protection shall conform to Class 'PS', Part IV of IS 2705. (R.a:2002) All CTs shall withstand without



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injury dynamic stability and thermal stability currents specified for the switchboard.

The current transformer ratios specified are provisional and are subject to alteration and confirmation later at the time of approval of manufacturer's drawings.

Current transformers shall have a short time withstand rating equal to the short time withstand rating of the associated switchgear for one second for breaker feeders; for fuse backed feeders, the CTs shall have a withstand capacity not less than that of the let through on isolating link.

The CT pointing shall be marked indelibly on the CT as well as the leads wiring it to the terminal block.

Voltage Transformers

Voltage transformers shall be dry, cast resin type with accuracy class 1.0 for measuring VTs and class 3.0 for protection VTs. The high voltage side of VTs shall be protected with current limiting fuses. The secondary side of VTs shall be protected by means of fuses sized to prevent overload. Fuses shall be so located that it shall be possible to replace the same with the switchgear in energised condition.

VTs shall have a continuous over voltage factor of 1.2 with short time over-voltage factors as below

i) 1.5 for 30 seconds in case of effectively earthed systemsii) 1.9 for 8 hours in case of non-effectively earthed systems

VT polarity shall be marked indelibly on the VT as well as the lead terminals at the terminal block.

In case the secondary windings of the VT are required to be earthed, the same shall be done with an isolating link.



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Control Transformers

LT board/MCC shall be provided with a dual control transformer with manual change over scheme/switch rated to cater to the control supply requirement of the entire switchboard. The primary side of the control transformer shall be protected by switch fuse unit, secondary sides of the transformer shall be provided with fuse and rental link. One secondary leg of the transformer shall be connects to earth bus through link.

Control transformer shall be dry type, double wound, having insulation class B. The primary shall be provided with + 10% taps. Each control transformer module shall be provided with voltmeter of accuracy class 1.5 and ON indicating lamp.

Separate transformers shall be provided in each bus-section for space heater, panel lighting load etc.

Control and selector switches

Control and selector switches shall be rotary type with enclosed contacts. The various positions shall be identified through escutcheon plates.

Control switches shall be spring return type and selector switches shall be stay put type. Control switches shall be provided with pistol grip handle whereas handles for selector switches shall be oval/wing knob type.

The rated operational current of the switches shall be not less than 4A (AC-11) at 240 V AC and 1A (DC-11) at 220 V DC.

Breaker control switch shall have 3 positions-trip, neutral and close. To close the breaker the switch shall be turned clockwise, to trip the breaker the switch shall be such that the breaker shall be tripped before closing. Lost motion contacts shall be provided.

Voltmeter selector switches shall be seven position type capable of reading both phase and line voltages and with OFF position. Ammeter selector switches shall be four-position type with OFF position and shall have make before break contacts.



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Pushbuttons

Pushbuttons shall be oil tight type and provided with escutcheon plates marking the function. All pushbuttons shall be provided with 2 NO + 2 NC contacts; each contact shall have rated operational current of not less than 4A (AC – 11) at 240V AC and 1A (DC – 11) at 220V DC

Pushbuttons for 'START', ‘OPEN’, 'CLOSE', 'LEFT', 'RIGHT', 'FORWARD', 'REVERSE' etc. shall be flush type with spring aided self-reset contacts and shall be coloured green.

Pushbuttons for 'STOP' shall be flush type with spring aided self reset contacts and shall be of red colour. Pushbuttons for 'EMERGENCY STOP" shall be mushroom headed type with stayout contacts and shall be of red colour. Further the operation of the button shall be press to lock and twist to release.

Indicating lamps

Indicating lamps shall be cluster LED type. It shall be possible to replace the lamp from without opening the compartment door.

Breaker modules shall be provided with ON, OFF AUTOTRIP indications. Incomer modules shall be provided with R, Y and B phase indication lamps. DOL starter modules shall be provided with ON, OFF and TRIP lamps. RDOL starters shall be provided with OPEN/CLOSE, FORWARD/REVERSE, LEFT/RIGHT, UP/DOWN indication lamps as applicable in addition to OFF and TRIP indications. SFU/MCCB power modules shall be provided with ON and OFF indications. Transformer modules shall have ON indications

The colours of indication lamps for various applications shall be as follows

ON, OPEN/CLOSE, FORWARD/REVERSE etc. : RedOFF : GreenTRIP : Amber

Each indication lamp shall be provided with an escutcheon plate indicating its function.



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Indicating instruments

All indicating instruments (voltmeters/ammeters) shall be of taut band, square dial, flush mounting type, suitable for vertical mounting and back connection and conform to IS 1248. The accuracy class of instruments shall be class 1.5 Ammeters shall be graduated to read min. 1% of full-scale reading. Instruments for all feeders shall have sizes as per Design Criteria. All indicating instruments offered shall be of the best make and shall have non-reflecting bezels, clearly divided and indelibly marked scales and sharply outlined pointer. All instruments shall be provided with a zero adjusting device for external operation. Ammeters shall be suitable for operation on CT and scaled to read actual currents flowing in the circuit.

Internal wiring and ferrules

Wiring inside the cubicles shall be carried out using 1100/650 V grade, PVC insulated, stranded, single core conductor wires. For power circuits, the minimum size shall be 4 sq.mm copper. For control circuits the minimum size shall be 1.5 sq.mm copper; for CT circuits the minimum size shall be 2.5 sq.mm copper.

Spare auxiliary contacts shall be wired up to the terminal block.

Not more than two connections shall be made at any one terminal.

Wires for interpanel wiring shall be taken through the bottom-most tier of the switchgear, which shall be kept vacant for this purpose.

All metal cutouts provided for facilitating wiring shall be pushed.

Each wire shall be identified at both sides by ferrules. Ferrules shall be of interlocking type of yellow colour with black engraved lettering. Equipotential ferrules shall carry the same identification number.

Terminal Blocks

Terminal blocks shall be 650V grade, of non-hygroscopic, non-tracking moulded plastic type. Terminal blocks shall be segregated based on the circuit voltage. Individual terminals shall be numberedwith engraved black-on-white labels. Where it is necessary to duplicate terminals, same shall be done with solid links.



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Power terminals shall be stud type with phase separation barriers control terminals shall be rated for 10A min. and they shall be suitable for 2.5 sq.mm conductor. At least 20% spare control terminals shall be provided in each block.

Terminals for CT secondary leads shall be provided with shorting and disconnecting / earthing facilities and shall be similar to CATD M4 design of Elmex.

Power and control terminals shall be shrouded. It shall be possible to carry out work on any module separately without coming into accidental contact with the immediately located modules.

Labeling and Nameplate

Labels shall be provided for each component of each module of the switchgear. These shall be white engraved on block, PVC type. Paper labels are not acceptable. Labeling shall be done as per approved scheme drawings.

Nameplates shall be provided for each feeder each vertical and for the switchgear as a whole. These shall be of anodised aluminium with engraved lettering on a black background.

In addition, danger plates shall be provided for each switchboard. In case of single front switchgear, the rear side of each panel shall be marked with the panel number.

Cable termination accessories

Undrilled G.I gland plates of minimum 3 mm thickness and double compression type brass glands shall be provided for termination of cables. The gland plates shall have gaskets. Required number of tinned, crimping type copper lugs shall be provided. Provision for terminating ½ core on to earth bus and neutral bus shall be made.

Earthing

Two earth terminals shall be provided on each cubicle, at back. An earth bar of specified cross section shall be fixed to the terminals. The earth bar shall be electrically continuous and shall run the full extent of each board. Terminals shall be provided for external earth



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connections. All relay and meter bodies shall be earthed by one separate green earth conductor.

Special tools

A set of special tools required for the normal operation and maintenance shall be supplied with each switchboard. The tenderer shall include along with each switchboard one-height adjustable circuit breaker trolley for removal and replacement of the withdrawable circuit breaker carriage as well as one no. Fuse puller.

Painting

Painting shall be done as per approved painting procedure. Specification. Colour shade for finish paint shall be indicated to successful tenderer.

TEST REQUIREMENTS

The switchboards shall be tested as per approved Quality Assurance Plan.

The low voltage switchboards shall be subjected to routine tests as per IS: 8623 (1993) (R.a:1998) at the manufacture's works. These tests shall include the following as a minima

Checking for correctness of wiring

Checking for electrical operation

One minute power frequency withstand test for power and auxiliary circuits

Measurement of IR value for power and auxiliary circuits.

Test for interchangeability of identical feeders

Test to prove the operating range of control components viz contactors, spring charging motor, trip and close coils etc.

Test to measure the millivolt – drop between the incoming and outgoing jumpers at air circuit breakers with the breakers in closed condition.

Physical inspection and check for components as per approved bill of material.



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The vendor shall furnish test and calibration certificates for all major bought out items viz relays, meters, instrument transformers etc.

The vendor shall furnish type test certificates along with the offer covering all the type test as indicated in IS: 8623(1993) (R.a:1998)

DOCUMENTATION REQUIREMENTS

The vendor shall furnish following drawings and documents

Along with the bid

Filled up Questionnaire

General arrangement drawings for the switchboard indicating the overall dimensions, clearances to be provided, mounting arrangement, cable/Busduct entry details, weight etc.

Detailed literature, technical catalogues for various components viz air circuit breakers, MCCBs, breaker release, overload relays, switches contactors etc.

Type test certificates

Single line diagram

Signed list of deviations from the technical specification

After award of order

Final G.A. drawings of the switchboards indicating constructional details of the switchboard, the dimensional data, typical cross –sectional details, requirement of floor cut-outs, busduct flanges etc. single line diagrams indicating the ratings of equipment.

Feeder - wise bill of material indicating the make type, catalogue no., rating, quantity etc of components

Terminal plan

Power layout drawings

Door layout drawings

Inscription plate details/Name plate list for the various feeders.



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Component selection chart for MCC

Sl No

Motor kW

MPCB/ MCCB(A)

Contactor(A)

CT Ammeter Cable sizeCable type

1 0.1-0.75 16A MPCB 16 - - 4 x 2.5 YRY

2 1.1-1.5 16A MPCB 16 - 0-5/30 4 x 2.5 YRY

3 2.2 16A MPCB 16 - 0-7.5/45 4 x 2.5 YRY

4 3.7 16A MPCB 16 - 0-10/60 4 x 2.5 YRY

5 5.5 16A MPCB 16 - 0-15/90 4 x 4 YRY

6 7.5 32A MPCB 32 - 0-20/120 4 X 4 YRY

7 9.3 32A MPCB 32 - 0-20/120 4 x 10 AYFY

8 11 32A MPCB 32 25/5 0-25/150 4 x10 AYFY

9 15 63A MPCB 63 30/5 0-30/180 4 x 16 AYFY

10 18.5 63A MPCB 63 40/5 0-40/240 4 x 25 AYFY

11 22 100A MCCB 63 50/5 0-50/300 3.5x35 AYFY

12 30 100A MCCB 105 60/5 0-60/360 3.5x50 AYFY

13 37 250A MCCB 105 75/5 0-75/450 3.5x70 AYFY

14 45 250A MCCB 170 100/5 0-100/600 3.5x70 AYFY

15 55 250A MCCB 170 125/5 0-125/750 3.5 x 120 AYFY

16 75 250A MCCB 250 150/5 0-150/900 3.5 x 185 AYFY

17 90 400A MCCB 400 200/5 0-200/1200 2(3.5 x 95) AYFY

18 110 400A MCCB 400 250/5 0-250/1500 2(3.5x 120) AYFY

19 132 400A MCCB 400 300/5 0-300/1800 2(3.5x120) AYFY

20 150 630A MCCB 400 300/5 0-300/1800 2(3.5x185) AYFY

Note: 1. Components shall be selected to provide Type 2 discrimination as

per IS 1394(R.a:1998) 7. However, the minimum ratings of switches and contactors shall comply with the above table.

2. Motor feeders up to 18.5 Kw shall be provided with O/L relays and earth fault relays and the MPCBs shall have only S/C element. For motors rated above 18.5 kW and up to 37 kW the feeder shall be equipped with MCCBs with S/C element, thermal O/L relays and earth fault relays. For motors 55 kw and above, the feeder shall be equipped with MCCBs with microprocessor based adjustable releases for O/C, S/C, E/F and comprehensive motor protection relays of L & T (MM30)/ Multilin 239/Schneider (SEPAM20).



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3. Cable sizes indicated are tentative. Cables shall be selected considering the allowable voltage drop, derating factors for temperature, grouping etc.

8.1.7 Local control stations / Push button station

- Die-cast aluminium alloy construction, dust and vermin proof, wall/structure mounting.

- Canopy for out door installation.

- Control switches, push buttons and indication lamps mounted on front

- Suitable drilled holes with glands on the bottom for cable entry.

- Terminals to be suitable for copper conductor of 2.5 sq mm with 20% spare terminals.

- Wiring with extra flexible wires.

- Emergency Stop push button to be stay put type with mushroom head press to lock and twist to unlock type. Emergency stop push button hard wired to MCC.

- All indicating lamps shall be LED clustered type.

- Inscription in English on corrosion resistant metal strips.

- Enclosure conforming to IP-65.

- Shall be provided with following devices

- For DOL drives : STOP,EMERGENCY STOP and START pushbuttons, LOCAL ENABLED lamp

- For RDOL drives : FORWARD/REVERSE, STOP and EMERGENCY STOP pushbuttons, LOCAL ENABLED lamp

- For VFD drives : START (FORWARD/REVERSE), STOP,EMERGENCY STOP, SPEED INCREASE, SPEED DECREASE pushbuttons, LOCAL ENABLED lamp, milli-ammeters for speed and current indication

- All pushbuttons shall have 2 NO + 2 NC contacts rated for 5 A at 220VAC/ 1A at 110 VDC

BRAKES:

DC electromagnetic type suitable for 220V DC.



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Floor mounting, two shoes, self-aligning, quick acting with self-lubricating robust bearings.

Electrically released and spring applied for fail-safe operation (gravity operated counter weight type are not applicable).

Brake release sensing limit switch for interlocks.

Necessary rectifier and brake forcing equipment/ circuit in IP: 54 enclosure shall be included for DC electromagnet brakes used with AC system

8.1.8 HT Motors

8.1.8.1 Scope

This specification covers the requirements of design, manufacture, performance and factory testing of three-phase, high voltage squirrel cage induction motor for general applications.

Applicable standards

Motors covered under this specification shall conform to the Indian Standards/IEC Publications as listed below for design, manufacture performance & testing as listed below : with their reaffirmation (R.a) year.

IS: 325 (1996) (R.a: 2002) -Three Phase Induction Motor –Specification.

IS: 4722 (2001) - Rotating electrical machines.

IS: 12075 (1986) (R..a:2002) - Mechanical vibration of rotating electrical machines with shaft height 56 mm and higher –measurement, evaluation and limits of vibration intensity.

IS: 12065 (1987) (R.a:2004) - Permissible limits of noise level for rotating electrical machines.

IS: 4691 (1985) (R.a:2004) - Degrees of protection provided by enclosures for rotating electrical machinery.

IS: 4728 (1975) (R.a:2002) - Terminal marking and direction of rotation for rotating electrical machinery.



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IS: 6362 (1995) (R.a:2002) - Designation of methods of cooling for rotating electrical machines.

IS: 4029 (1967) (R.a:2002) - Guide for testing three - phase induction motors.

IS: 12802 (1989) (R.a:2004) - Temperature - rise measurement of rotating electrical machines.

IS: 4889 (1968) (R.a:2002) - Method of determination of efficiency of rotating electrical machines.

IS: 12824 (1989) (R.a:2004) - Type of duty and classes of rating assigned.

IS: 14122 (1995) – Impulse voltage withstand levels of rotating A.C machines with form wound stator coils.

IS: 11723 (1992) - Mechanical vibrations - balance quality requirements of rigid rotors, Part I: Determination of permissible residential unbalance.

IEC 72 - Dimensions and output series for rotating electrical machines

8.1.8.2 Operating conditions

8.1.8.3 The motors shall be rated for following power supply conditions :

Voltage : 6.6 kV Frequency : 50 HZ Voltage variation : + 10%Frequency variation : + 5%Combined voltage and frequency variation : + 10%Voltage unbalance : 5%

8.1.8.4 The motor shall be designed for following operational conditions

Ambient temperature: as specified in ordering data sheet

Altitude : not exceeding 1000M above Mean Sea Level (MSL)

8.1.8.5 Design features

8.1.8.6 Mechanical construction features

8.1.8.7 The stator and rotor cores shall be laminated steel stampings punched out of magnetic silicon steel sheets of small thickness, low hysteresis loss and high magnetic permeability. These core



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stampings shall be varnished subsequently to reduce eddy current losses. Care shall be taken to ensure that these stampings are burr-free. The magnetic steel shall be to grade A260 of IS: 648(R.a:1998).

8.1.8.8 The stator stampings shall have circular outer periphery with a punched slot to accommodate a key. The inner periphery shall be slotted for accommodating the stator windings.

Stator core stack may be built up any of the following ways:

i) Prebuilt on separate mandrel.

Subsequently the core stack shall be hydraulically pressed to consolidate and then clamped either by steel wedges or clamping plates. The stator windings are then built into the slot and the complete capsule is inserted into the stator shell by hydraulic press and locked in position.

ii) Built into the stator frame

The stator stampings are assembled in the stator frame and locked in position by a steel guide rod fitted inside the frame. The stampings are clamped together by steel end plates, which in turn are clamped by numerous keyways machines in the stator bore. The stampings are hydraulically pressed prior to insertion of keys. The slots shall be aligned and filed if necessary to prevent damage to insulation of the winding while inserting.

8.1.8.9 The rotor core stampings shall have a circular inner edge with slots to accommodate a key. The stampings shall be built-up on the shaft and keyed to the shaft with a large steel key. End clamping plates of steel shall be provided and shall be firmly enclosed on the shaft and secured against axial displacement.

8.1.8.10 The motor shaft shall be made from forged high carbon steel and of adequate cross-section to ensure high torsional strength and minimum deflection. The shaft shall be finely machined to ensure fit and eccentricity shall be minimized. Generally, the shaft shall be cylindrical, single extension type with slotted keyway. Tapered shaft/stepped shaft/double extension shall be provided if specifically indicated in Ordering data sheet.



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8.1.8.11 The motor shall be Totally Enclosed Tube Ventilated (TETV) type, preferably, with two internal and one external axial fan. The fan shall be suitable for bi-directional rotation.

8.1.8.12 The motor out door type shall be provided with additional hood over to avoid rusting cover to avoid rusting

8.1.8.13 The motor shall be provided with grease lubricated, anti-friction ball/roller bearings. Regressing nipples and grease drain plugs shall be provided as a standard feature. Bearings shall be suitable for bi-directional rotation. Bearings shall be insulated to prevent circulating currents. Generally, the NDE side bearing shall be insulated.

8.1.8.14 Following terminal boxes shall be provided for the motor:

Phase segregated terminal box for stator leads – This shall be of cast iron/fabricated steel. Pressure relief diaphragm and silica gel desiccator shall be included. The P.S.T.B. shall be suitable for Aluminum conductor, armoured XLPE cable of size indicated in Ordering data sheet. A trifurcating box shall be included with PSTB. It shall be possible to rotate the PSTB through 3600 in steps of 900

Neutral terminal box – This shall be inter changeable with the PSTB.

Space heater T.B. - This shall be of cast iron and provided with stud type terminals.

ETD/BTD T.B – A common TB for ETDs and BTDs shall be provided. This shall be of cast iron and provided with clip on terminals as required with 20% spare. The terminals shall be suitable for 2.5-sq.mm-conductor size.

8.1.8.15 The rotor shall be dynamically balanced with half key. Other shaft mounted components viz internal and external fans, coupling half etc shall be separately balanced. Balancing shall be carried out at rated speed of the motor. Residual imbalance shall conform to class " G 2.5 " as per IS – 11723, Part I (1992)

8.1.8.16 The motor shall be provided with following additional accessories

i) Lifting and jacking arrangement

ii) Stainless steel nameplate with punched markings. Markings shall be provided as per Cl.Nos. 20.1 and 20.2 of IS : 325 (1996) (R.a:2002)



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8.1.8.17 The painting for motor shall be epoxy – powder coating type. Final paint shade shall be as per Ordering data sheet or as per approved drawings.

8.1.8.18 All fasteners used shall be metric sized.

8.1.8.19 The rated speed of motors shall be limited 1500 rpm max. where it is inevitable to use 3000 rpm motors, the bearing shall be sleeve bearing

8.1.8.20 Electrical construction features

8.1.8.21 Motor shall be suitable for DOL start/VFD start as specified in Ordering data sheet.

8.1.8.22 Motor insulation shall be class ‘F’ with temperature rise restricted to class ‘B’. Stator coils shall be fabricated from ETP copper strips of rectangular cross-section duly pre-insulated with polyester amideenamel. The stator winding coils shall be inserted in the open slot of stator core and slots closed off by a magnetic wedge to reduce pulsation, surface losses and noise.

The stator insulation shall be provided tropical, fungicidal and corona suppression treatment. The stator winding shall be vacuum dried and then subjected to vacuum pressure impregnation of resin to form void free insulation system.

The end windings shall be securely lashed and braced using fiberglass tape.

8.1.8.23 Rotor shall be of rigid cage design, Rotor bars shall be of high conductivity ETP copper and shall be firmly wedged in the rotor core slots. The portion of rotor bars in the slot shall be non-insulated. The rotor bars shall be brazed to the end short-circuiting rings which shall be of annealed high conductivity copper. Retaining rings, if included in vendor's design, shall be of non-magnetic material preferably brass.



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8.1.8.24 Motor shall be provided with following

i) Anti-condensation heaters – these shall be placed in the lower part of the motor and shall be easily accessible for replacement/maintenance. The heater terminals shall be brought out to a separate TB.

ii) Embedded temperature detectors – six nos. simplex type 3 wire, Pt-100 ETDs shall be provided @ two nos. per phase. The ETDs shall be subjected to IR test and HV test.

iii) Bearing temperature detectors – two nos Duplex type, 3 wire, Pt-100 BTDs shall be provided @ one no for each bearing.

A common TB for ETDs and BTDs shall be provided.

8.1.8.25 The motor frame shall be provided with two earthing points along with associated hardware. In addition, two nos. vibration measuring pads shall be provided, one at DE and the other at NDE side.

8.1.8.26 The PSTB shall be suitable for short circuit rating of 40KA for 0.25 sec.

8.1.8.27 Performance requirement

8.1.8.28 Motor shall be able to start and accelerate under rated load at 80% of rated voltage, without exceeding the specified temperature.

8.1.8.29 If while running, the voltage drops to 70% the motor shall be capable of delivering rated torque and continue to run without stalling for 5 minutes.

8.1.8.30 The motor shall be capable of withstanding 150% of rated voltage for 2 minutes without damage.

8.1.8.31 The motor shall be designed to provide the required starting torque where speed-torque characteristics of load are included in the specification. Where the specification does not contain the load characteristics, motor shall be designed to provide minimum 160% starting torque.

The pull-out torque of the motor shall not be less than 250% at rated voltage and frequency.



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8.1.8.32 Motor shall be suitable for following starting requirements

a) 3 successive cold starts

b) 2 successive hot starts

c) 6 equally spread starts/hour

8.1.8.33 The locked rotor current shall not exceed 600% of rated current including IS tolerance.

8.1.8.34 For defining the safe stall time, the rotor temperature shall be limited to 375C.

8.1.8.35 The motor vibration in all three axes shall conform to the requirement of ‘Normal” class as per IS: 12075(1986). (R.a:2002) Vibration severity shall be preferably measured as vibration velocity.

8.1.8.36 The motor shall be capable of running at 120% of rated speed for 2 minutes.

8.1.8.37 The mean sound power level for motor when tested and measured in conformance to IS : 12065 (1987) (R.a:2004) shall be limited to class “Reduced Sound Power’ as defined in the standard.

8.1.8.38 The motor shall be capable of withstanding 1.5 times rated current for 2 minutes.

8.1.8.39 Test requirement

8.1.8.40 All tests shall be carried out at the manufacturing works. Test methods shall comply with IS: 4029 (1967) (R.a:2002)

8.1.8.41 Vendor shall furnish Type Test Certificates along with the bid. Type tests shall include following optional type tests as per IS : 325 (1996).

a) Test for vibration severity.

b) Test for noise level

c) Temperature rise test at limiting values of voltage and frequency variation as per this specification.

d) Over speed test.



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e) Impulse voltage withstand test for inter-turn insulation and main insulation.

8.1.8.42 Routine tests shall be carried out on all motors as per clause 22.3.2 of IS : 325 (1996) (R.a:2002)

In addition, PI value measurement shall also be carried out on each motor.

Note: Impulse voltage tests for H.T motors shall be as follows:

Main insulation

i) 1.2/50 micro-second lightning impulse at (4UN +5) peak voltage. Five impulses to be applied.

ii) 175/2500 micro-second switching surge voltage test on main insulation at (4UN +5) peak voltage. Five surges to be applied.

Inter – turn insulation

0.3/3.0 microsecond inter turn impulse test between successive turns, after cutting and flaring out the coil, at a value of 0.25 (4UN+5) KV peak.

8.1.8.43 Documentation requirement along with bid

Overall dimensional drawing of motor

Data sheet for motor (Appendix A2)

Signed list of clause-by-clause deviations

Write-up on insulation system

Type test certificates

Internal Quality Assurance Plan

Test certificates from CMRS, Dhanbad and approval from CCE, Nagpur in case of motors for use in hazardous area.

List of recommended spares for 2 years normal operation

8.1.8.44 After award of order

Overall dimensional drawing of motor indicating locations of stator TB, neutral TB, space heater TB, ETD/BTD TB, shaft details, keyway details, vibration pads, earthing connections etc.



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General arrangement drawing for stator TB, neutral TB, space heater TB, ETD/BTD T.B

Motor data sheet (Appendix A1)

Routine test certificates

Test Certificate for residual unbalance

Motor characteristic curves

Quality Assurance Plan for Client’s inspection

8.1.8.45 Ordering data sheet

8.1.8.46 Site conditions

i) Installation : Indoor/Outdoor as applicable

ii) Hazardous Area classification

: As applicable

iii) Altitude : Not exceeding 1000M above MSL

iv) Ambient air temperature

a) Maximum dry bulb :

b) Maximum daily average :

c) Reference temperature for electrical design

: 45 deg C

d) Relative Humidity : 100% (not occurring simultaneously with maximum temperature)

8.1.8.47 Power supply conditions

i) Rated voltage & variation : 6.6 kV +/- 10 %ii) Rated frequency & variation : 50 Hz +/- 5 %iii) Combined variation : 10%iv) System grounding : Resistance grounded

8.1.8.48 Motor design details

i) Design Ambient Temperature : 45 0 C

ii) Enclosure :

a) Class of protection : IP - 55



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b) Type : TETV/TEFC/CACA

c) Hazardous Area Classification : As applicable

iii) Insulation class : F

iv) Temperature rise above design ambient

: Restricted to class B

v) Type of cooling : Internal radial fan for DOL start and external axial fan for VFD controlled

vi) Duty type and designation : Continuous, S1vii) Starting requirements

a) Equally spread / hour : 6 starts

b) Successive cold : 3 starts

c) Successive hot : 2 starts

viii) Method of starting : DOL starter / VFD

ix) Switching element : Vacuum CB/SF6CB/Vacuum contactor( for 6.6 kV)

x) Mounting requirements :

a) Shaft Orientation : Horizontal / vertical

b) Mounting : Foot / Flange

xi) No. of poles : Not to exceed 1500 rpm

xii) Direction of rotation : Bi directional

xiii) a) Starting torque/rated torque : 1.6

b) Pull out torque/rated torque : 2.5

c) Locked rotor current / rated current

: 6.0 (incl. Tolerance)

xiv) Vibration severity : Limited to "Normal Class" as per IS : 12075 (1986) (R.a:2002)

xv) Noise level : Limited to " Reduced Sound Power" as per IS : 12065 (1987) (R.a:2004)



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xvi) Accessories

a) Stator TB : Phase segregated type with fault level of 40KA, 0.25 sec at rated voltage

b) Neutral TB : Phase segregated, inter changeable with stator TB

c) ETDs : 6 Nos. Pt – 100, Simplex, 3 wire

d) BTDs : 2 Nos. Pt-100, Duplex, 3 wire

e) ETD/BTD TB : Common TB to be provided

f) Space heaters : Required Separate TB to be provided

g) Vibration pads : 2 Nos.

h) Duplicate earthing : To be provided with necessary electrogalvanised hardware

i) Cable glands and lugs : To be provided for power cable, space heater cable & RTD/BTD cable.

xvii) Bearing insulation : Required

xviii) a) Shaft extension : Single/double

b) Shaft type : Cylindrical/tapered/step

xix a) Motor painting : Epoxy based

b) Final paint shade : As per approved drg

Xx Cable sizes

a) Power : XLPE as per approval

b) Space Heater :

c) ETD/BTD :

8.1.8.49 General purpose LT motors



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8.1.8.50 Motors rated up to & including 160kw shall be LT motors as per detailed specification given below

Design Criteria for Low Voltage Three Phase Squirrel Cage Induction Motors

SITE CONDITIONS

i) Installation : Indoor

ii) Altitude : Not exceeding 1000M above MSL

iii) Ambient air temperature

a) Maximum bulb : 40C

b) Maximum daily average :

c) Reference temperature for electrical design

: 45C

d) Relative humidity : 100%(not occurring simultaneously with maximum temperature)

DRIVEN EQUIPMENT DETAILS

i) Application :

ii) Coupling Type : Direct flexible/rigid/Belt-pulley

iii) Moment of inertia :

iv) Speed –Characteristics

enclosed

: Yes/No

v) Absorbed KW :

POWER SUPPLY DETAILS

i) Nominal voltage (V) : 415, TPNii) Variation in Voltage (%) : +/- 10Iii) Nominal frequency (Hz) : 50iv) Variation in frequency (%) : +/- 5v) System grounding : Solidly groundedvi) Combined voltage &

frequency variation: +/- 10%

vii) Voltage imbalance : +/- 5%



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MOTOR DETAILS

i) Design Ambient Temperature

: 45 0 C

ii) Enclosure :

a) Class of protection : IP 54 for indoor and IP 55 for outdoor application with additional hood cover

b) Hazardous Area Classification

: As applicable

iii) Class of insulation : Class F

iv) Temperature rise above design ambient

: Limited to class B

v) Type of cooling : IC 410 (TEFC)

vi) a) Duty type and designation

: As per application

b) Minimum over load capacity for main drive motors

: 160% frequently repeated load for 15 seconds

vii) Starting requirements For crane duty motors as per crane clearance diagram or as specified below for continuous duty motors

a) Equally spread / hour : 6 starts

b) Successive cold : 3 starts

c) Successive hot : 2 starts

viii) Method of starting : DOL / VFD

ix) Mounting requirements

a) Shaft Orientation : Horizontal / vertical (As per mechanical equipment requirement)

b) Mounting : Foot / Flange (As per mechanical equipment requirement)



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x) Speed

a) No. of poles : As per application. However preferred synchronous speed shall be 1500 rpm.

b) Speed range (for VFD oprn)

: As per application

xi) Terminal box

a) Location of main TB (when viewed from DE)

: R.H.S (preferably)

b) Rating of TB : 40 kA (0.25 secs) at 415V

xii) Anti-condensation heaters : Required for motors rated 30 kW and higher. Additional TB to be provided.

xiii) Temperature sensing elements

a) Thermistors : For DOL start, 6 Nos to be provided in series for ratings 55 kw and above.

: For VFD start 6 Nos. to be provided @ 2 per winding

xiv) Bearing type : Re-greasable ball / roller anti friction

xv) Bearing insulation : On NDE side for motors rated 75 kW and above fed by VFDs

xvi) Vibration Severity : Limited to “Normal class” as per IS : 12075 (1986) (R.a:2002)

xvii) Noise level : Limited to "Reduced sound Power as per IS : 12065 (1987) (R.a:2004)

xviii) Final paint shade : As per approved drawing

Note : Painting shall be epoxy resin based.

xix) Torque

a) Ratio of starting torque to rated torque

: 1.6

b) Ratio of pull out torque to rated torque

: 2.5



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c) Ratio of locked rotor current to rated current

: 6.0

xx) Over-speed : 1.2 times rated speed for 2 minutes

xxi) Direction of rotation : Bi-directional

8.1.8.51 Technical specification for Low Voltage Three Phase Squirrel Cage Induction Motors

Design features

Mechanical construction features

The stator frame and end shields shall be preferably made from cast iron of high quality conforming to IS: 210(1993) (R.a:1999) , They shall be ribbed externally to maximize heat dissipation. The feet shall be integrally cast with the stator frame. Bolted feet construction is not acceptable.

The stator and rotor cores shall be of low loss, high permeability electrical steel stampings duly treated to reduce eddy current losses.

The motor shaft shall be of cylindrical design made of suitable high grade steel. The cross – section shall be chosen to provide high tensional strength and minimize deflection. The shaft shall be finely machined to ensure fit and eccentricity shall be minimized. Unless specified otherwise, the motor shall be with single shaft extension with keyway and key. Motor shall be with half key.

The motor shall be cooled by means of an external fan mounted on the rotor shaft. The fan shall be protected by a cowl, which shall be bolted to the stator frame. The fan shall be of cast iron preferably. The body of the fan shall be provided with 2 numbers, diametrically opposite drilled holes for jacked bolts to enable removal of fan without breakage. The fan shall be designed to ensure low noise and adequate ventilation. The form should be suitable for bi-directional operation.

The motor shall be provided with ball/roller bearings with grease lubrication. Greasing nipples and arrangement for drainage of excess/old grease shall be provided as a standard feature. Seals shall be provided to ensure that excess grease does not reach the windings. The L10 life of bearings shall not be less than 40000 hours under



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rated conditions. Bearings shall be suitable for bi-directional rotation.

For vertical motors, bearings shall suitably conform to mechanical design of motor.

The terminal box for motor shall be of cast-iron and shall be mounted on R.H.S when viewed from DE side. The terminal box shall be suitable for rotation in steps of 900. The design of terminal box shall be spacious to suit termination of armoured aluminium conductor cable. Six ends of windings shall be brought to the terminal box and shorting links shall be provided.

The terminal box shall be provided with gland plate. If required, cable spreader box/trifurcation box shall be provided additionally to facilitate termination of large size cables. Double compression brass cable glands shall be provided along with the motor.

One No. Internal earthing terminal shall also be provided in the terminal box as a standard feature.

The terminal box shall have a cover plate. The cover plate shall be bolted to the terminal box with Allen bolts.

Where space heaters / thermistors / RTDs are specified, separate TBs shall be provided for these accessories.

Terminal marketing shall conform to IS: 4728 (1975) (R.a:2002)

Phase terminals shall be stud type of FRP material. Terminals for space heaters shall be stud type; terminals for thermistor / RTDs may be clip-on type suitable for 2.5 sq.mm conductor.

The rotor shall be dynamically balanced with key. Other shaft mounted components viz fan, coupling half etc., shall be balanced separately. Balancing shall be carried out at rated r.p.m. of the motor. The balancing weights shall be firmly secured to the rotor. The balance quality grade shall conform to class “G2.5” as per IS: 11723, Part I (1992).

The motor shall be provided with lifting lugs/eye bolts to facilitate erection/ maintenance requirements.



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All nuts, bolts, studs shall be based on metric units.

The motor shall be provided with a rating plate, stainless with punched markings. Markings shall be provided as per clause no 20.1 and 20.2 of IS: 325 (1996) (R.a:2002)

The painting of motor shall be epoxy-powder-coated type. Final paint shade shall be as indicated in Ordering Data Sheet.

ELECTRICAL CONSTRUCTION REQUIREMENT

Motor shall be suitable for DOL/VFD, start as specified.

Motor insulation shall be class ‘F’ with temperature rise restricted to class ‘B’. The motor winding shall be given special tropical and fungicidal treatment to ensure protection against tropical weather. Fungus, oil, abrasive /conductive dust.

The motor insulation shall be given any of the following treatments to brace the coils:

Powerhouse treatment – At least 3 cycles of dip and bake shall be allowed.

Trickle impregnation.

Vacuum pressure impregnation (VPI)

VPI method shall be preferred.

The overhang of the stator windings shall be given an additional coat of epoxy gel to minimize the effect of end turn forces at switch-on. The vendor shall furnish the details of bracing method employed.

Stator slot wedges shall be of non-magnetic material.

Rotors shall be state of the art high pressure aluminium die cast design as per manufacturers norms.

Motor rated 30 kW and above shall be provided with single phase anti-condensation heaters as a standard feature. The heaters shall be placed in the lower part of the motor and shall be accessible for easy replacement/maintenance.



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The motor frame shall be provided with two diagonally opposite earthing bolts along with required hardware viz. bolts/screws, plain and spring washers. The hardware shall electro-galvanized type.

SPECIAL REQUIREMENTS FOR MOTORS FED FROM VARIABLE SPEED DRIVES (VFD)

For motors fed from VFDs the insulation system shall be strengthened as follows:

Stator end turns shall be suitably braced by providing coat of epoxy gel. Additional mechanical bracing if any considered by the vendor shall be brought out.

Stator winding insulation system shall be by VPI method.

Stator magnet wires shall be provided with an additional coat of polyamide/polyester over and above the enamel paint to increase their PDIV rating, Triple build magnet wires shall be provided for stator wires.

Phase insulation shall be provided for all the ratings.

Motors shall be provided with 6 PTC thermistors @ 2 nos. per phase winding.

The critical speed of motor should be well above the required speed range of operation where super-synchronous operation is envisaged.

Motors shall be provided with insulated bearings on NDE side.

PERFORMANCE REQUIREMENT

Motor shall be able to start and accelerate under rated load at 80% of rated voltage, without exceeding the specified temperature.

If while running, the voltage drops to 70% the motor shall be capable of delivering rated torque and continue to run without stalling for 5 minutes.



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The motor shall be capable of withstanding 150% of rated voltage for 2 minutes without damage.

The motor shall be designed to provide the required starting torque where speed-torque characteristics of load are included in the specification. Where the specification does not contain the load characteristics, motor shall be designed to provide minimum 160% starting torque.

The pull-out torque of the motor shall not be less than 250% at rated voltage and frequency.

Continuous duty motor shall be suitable for following starting requirements

3 successive cold starts2 successive hot starts6 equally spread starts/hour

Crane duty motors shall be suitable for number of starts as specified in the crane clearance diagrams.

The locked rotor current shall not exceed 600% of rated current subject to IS tolerance.

For defining the safe stall time, the rotor temperature shall be limited to 375C.

The motor vibration in all three axes shall conform to the requirement of Normal class as per IS 12075 (1986) (R.a:2002) . Vibration severity shall be preferably measured as vibration velocity.

The motor shall be capable of running at 120% of rated speed for 2 minutes.

The mean sound power level for motor when tested and measured in conformance to IS: 12065 (1987) (R.a:2004) shall be limited to class “Reduced Sound Power’ as defined in the standard.

The motor shall be capable of withstanding 1.5 times rated current for 2 minutes.



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The value of full load speed, full load current and efficiency shall be as set out in IS : 8789 (1996) with tolerances as per Table I of IS : 325 (1996)

TEST REQUIREMENT

All tests shall be carried out at the manufacturing works. Test methods shall be in accordance IS : 4029 (1967) (R.a:2002)

Vendor shall furnish Type Test Certificates along with the bid. Type tests shall include following optional type tests as per IS: 325 (1996) (R.a:2002) .

Test for vibration severity.Test for noise level

Temperature rise test at limiting values of voltage and frequency variation as given in this specification.

Overspeed test.

Routine tests as per IS: 325 (1996) shall be carried out on all motors.

DOCUMENTATION REQUIREMENT

Along with Bid

- G.A. drawing of motor, main terminal box, space heater TB, thermistor/RTD T.B.

- Type test certificates

- Test certificates from CMRS, Dhanbad and approval from CCE, Nagpur in case of motors for use in hazardous area wherever required.

- List of recommended spares for 2 years normal operation

After award of order

- G.A. drawings of motor, main terminal box, space heater TB, thermistor / RTD T.B.



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- Wiring diagram for space heater TB, thermistor/RTD T.B.

- Motor questionnaire duly filled up. (Appendix A1)

- Routine test certificates

- Certificate for residual unbalance

- Quality Assurance Plan for Client’s inspection

- Motor characteristic curves:

Speed-torque Current-time Thermal withstand P.F. vs loadEfficiency vs loadCurrent-speedSpeed-time

APPLICABLE STANDARDS

Motors covered under this specification shall conform to the Indian Standards for design, manufacture, performance & testing as listed below with their reaffirmation (R.a) year.

IS: 325 (1996)(R.a:2002)-Three Phase Induction Motor –Specification.

IS : 2223 (1983) (R.a:2002) - Dimensions of flange mounted A.C. induction motors.

IS : 4722 (2001) - Rotating electrical machines.

IS : 1231 (1974)(R.a:2003) - Dimensions of three-phase foot mounted induction motors.

IS : 8789 (1996) (R.a:2003) - Values of performance characteristics for three-phase induction motors.

IS : 12075 (1986) (R.a:2002) - Mechanical vibration of rotating electrical machines with shaft height 56 mm and higher –measurement, evaluation and limits of vibration intensity.

IS : 12065 (1987) (R.a:2004) - Permissible limits of noise level for rotating electrical machines.

IS : 4691 (1985) (R.a:2004) - Degrees of protection provided by enclosures for rotating electrical machinery.



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IS : 4728 (1975) (R.a:2002) - Terminal marking and direction of rotation for rotating electrical machinery.

IS : 6362 (1995) (R.a:2002) - Designation of methods of cooling for rotating electrical machines.

IS : 4029 (1967) (R.a:2002) - Guide for testing three - phase induction motors.

IS : 12802 (1989) (R.a:2004) - Temperature - rise measurement of rotating electrical machines.

IS : 4889 (1968) (R.a:2002) - Method of determination of efficiency of rotating electrical machines.

IS : 12824 (1989) (R.a:2004) - Type of duty and classes of rating assigned.

IS : 8223 (1999) (R.a:2004) - Dimensions and output ratings for foot mounted rotating electrical machines with frame number 355 to 1000.

IS : 9628 (1980) (R.a:2004) - Three phase induction motors with type of protection ‘n’.

IS : 3682 (1966) (R.a:2002) - Flameproof ac motors for use in mines.

IS : 12615 (1989) (R.a:2004) - Energy efficient three-phase squirrel cage induction motors.

IS : 9283 (1995) (R.a:2002) - Motors for submersible pump sets.

IS : 14122 (1994) - Built - in thermal protection for electric motors rated up to 660V AC.

IS : 11723, (1992) - Mechanical vibrations - balance quality requirements of rigid rotors, Part I: Determination of permissible residential unbalance.

8.1.8.52 Preferred list of makes

LT motor KEC/Siemens/Bharat Bijilee/Alstom/ABB/CGL



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8.2 Variable frequency drives

8.2.1 Scope of work

The scope of work involves design, manufacture, shop assembly, performance testing at manufacturer’s works, supply of equipment to site inclusive of proper packing and transportation, receiving at site, storing, unpacking, erection, cabling, testing and commissioning of all the electrical equipment required for the VFD system equipment.

The items involved are:

a) 415V, 3phase, 50HZ VFD of suitable rating-Converter & Inverter equipment with associated switch gear & protections devices on the input & output side, power, controls and regulation units.

b) The VFD system having interface for PLC for Control, protection, supervision and Engineering with Software as per the technical requirement.

c) Interconnecting power, control and instrumentation cables between converter / inverter unit, sensors, including all cable terminations in the VFD equipment.

d) Erection accessories.

8.2.2 General

a) Modification of schemes/changes in components, if any suggested during scrutiny/approval of drawings and execution of work, shall be carried out by successful contractor at no extra cost.

b) Equipment offered shall be of best quality to ensure smooth, efficient and trouble free operation of the system.

c) Make of all bought out items shall be as per the List of preferred makes enclosed.

d) No equipment shall be dispatched without inspection and/or clearance by Owner/Consultant.

e) The scope of Contractor includes all electrical equipment/sensors/ interlocks required for smooth and efficient working of system and required during installation, testing & commissioning. All



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such items are deemed to have been included in the contractor’s scope

f) Electrical:

415V, 3ph 50Hz, 3 phase will be made available by the Owner.

Safety interlocks, necessary to ensure maintenance operation shall be provided.

Party may indicate additional information to be provided by the Owner to suit the system offered.

Software/hardware required as per the technical requirement shall be included in the scope. The system offered shall be complete in terms of hardware.

8.2.3 VFD unit

- VFD unit shall mainly consist of a three phase rectifier bridge, voltage source, D.C. link with capacitors, inverter bridge, microprocessor based control system & capacitor pre-charging circuit.

- The VFD shall be pulse width modulation (PWM) type with flux vector control for closed loop speed control with or without tacho feedback for high accuracy and good dynamic performance. Necessary tacho shall be provided at motor shaft. Tacho shall be with IP-65 degree of protection enclosure.

- The unit shall comprise of an incoming microprocessor based MCCB with suitable over current, short circuit & earth fault releases, reactor, three phase 6 pulse thyristor bridge rectifier acting as the line converter and three phase inverter as the load converter interconnected through DC link reactor and capacitor unit. The MCCB incomer shall be fully rated having short circuit withstand capability as indicated under Design Criteria/ System data of the specification. For the inverter unit IGBT’s shall be used. The outgoing of the unit shall be comprise of reactor, contactor with over current, short circuit and earth fault releases. Regenerative braking shall be provided. In addition line side filter shall be provided to contain line side voltage harmonics within the limits of IEEE/IEC standards. The unit shall be equipped with Thermister relay.



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- Contactors shall be 3pole air break, electro-magnetically operated. The contacts shall be made of special silver alloy suitable for higher switching frequency. The contacts shall have minimum bounce. The contactor shall have mechanical ON/OFF indication. The coil shall be rated at 110V AC and operate satisfactorily from 50 to 110% of rated voltage. Minimum size of contactor shall be 16A.

- All the busbar works of VFD system shall be of copper only.

- VFD shall be provided with RS-485 serial bus interface for control and monitoring by PLC.

The unit shall have the following regulation, control, communication & protective features:

- The unit shall have fully digital microprocessor based regulation and control system with suitable interfaces for communication with the PLC as well as the required instruments and signals. The microprocessor shall carry out all the functions required from the unit including triggering, protection, self-diagnostics, operator & various parameterisations Interface.

- Suitable programming and debugging unit shall be provided. Display of faults, alarms as well as diagnostic messages will be available in plain text on the operator panel in the cubicle. It shall be sealed type with membrane switches & LED/LCD display unit. It shall be normally plugged onto the cubicle board with the possibility of detachment. Besides the requirement mentioned above, the operator interface shall have following additional features.

START switch STOP switch Speed raise switch Speed lower switch Function/control/reset switches LED/LCD seven segment display unit

- The converter shall be capable of operating normally under AC system voltage and frequency fluctuations as indicated in the design criteria & system data of this specification on a continuous basis. It shall be designed to withstand momentary dips in supply voltage without damage to the IGBT’s / Thyristors / diodes and blowing of fuses.



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Converter

High speed electronic protection comprises:

- Self-diagnostic for microprocessor faults- Over current instantaneous trip- Short circuit protection for converter/ inverter- Adjustable current limit- Earth fault protection- Over temperature at heat sink- DC bus under voltage & over voltage- Control & regulated power supply failure- Phase reversal protection

Motor

- Thermal overload- Over temperature using thermistor relay- Stall- Loss of phase/phase guard- Current imbalance- Critical frequency lock out

Any other converter or inverter protection as required. The devices shall be clearly stated in this offer.

All the above protective features shall be processed & upon sensing abnormality alarm shall be initiated & drive shut down based on the nature of the fault.

Indication and monitoring:

Features shall generally include but not limited to the following:

Instruments

i) Input voltageii) Ammeter output currentiii) Voltmeter output voltageiv) Speed Indication in rpm.



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All meters shall be of identical type and fed through buffer amplifier so that the system is not affected due to defects in the instrument. All meters shall have minimum 270 deg full-scale deflection

Metering

The panel-mounted instruments shall be of the following types and accuracy class.

METER TYPE ACCURACY CLASS

AC ammeter

Moving iron/rectifier type permanent magnet moving coil

1.5

AC voltmeter


1.0

Indication / Status bar screens

i ) Main power on/offii) Control supply on iii) Auxiliary oniv) Contactor on

Alarm/Annunciation on Panel & to PLC

This shall generally include, but not be limited to the following: i) Over current

ii) Over voltageiii) Any specific converter faults as requirediv) Transformer faults as applicablev) Fuse failurevi) Fan failure for convertervii) Any specific regulation and control system faults as requiredviii) Incoming breaker trip where applicableix) Phase lossxi) Surge suppressor failurexii) Any other specific faults as required xiii) Out put voltage out of limitxiv) Output frequency out of limit



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VFD unit shall have the following operational features:

- Auto tuning- Parameter lock- Power loss ride through- Programmable analog (4-20 mA), – /+10 v inputs/outputs.- Indication on cubicle for converter ready, converter running &

converter fault.- Local/remote selection- Adjustable acceleration / deceleration time - Auto restart- Suitable for Constant torque / squared torque application as per

requirement.- Torque boost at start (adjustable)- Adjustable switching frequency- Programmable U/ F curve- Programmable digital inputs/outputs- Analog inputs/outputs

Analog inputs/outputs of the converter shall be galvanically isolated type. Digital outputs shall be potential free type.

Components for the same function and rating shall be of identical design and of modular construction to reduce the inventory.

Each cubicle shall be provided with panel illumination lamp, panel space heaters and 15A, 3 pin socket with switch. 230V AC supply for this shall be obtained through separate control transformer with fuses on the primary and MCB at the secondary side.

Auxiliary contactors for contact multiplication, indication, interlock, control etc., shall be mounted in the cubicle and shall be suitable for 110V AC .Control supply shall be obtained through a separate control transformer with fuses on the primary and MCB at the secondary side.

Control transformers shall have one leg of secondary earthed and shall be provided with + / - 2.5 % and 5 % primary tappings.

Relays shall be provided for interfacing with plant PLC. These shall have 24 V DC coil supply and shall be provided with surge arresting devices across the coil.



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Incoming MCCB / ACB feeder shall be provided with R, Y, B phase indication lamps, voltmeter with selector switch and ammeter with selector switch.

Starters for auxiliary cooling fans and motor space heater supply for motors rated 30 kW and above at 240 V AC shall be provided in the panel.

Components for the same function and rating shall be of identical design and of modular construction to reduce the inventory.

Each cubicle shall be provided with panel illumination lamp, 15A, 3 pin socket with switch. 230V AC supply for this shall be tapped from incoming side.

Auxiliary contactors for contact multiplication, indication, interlock, control etc., shall be mounted in the cubicle and shall be suitable for 110V AC control.

CONTROL PHILOSOPHY

Control of the VFD shall be possible from following three locations (any one)

From PLC: This shall be through analog / digital signals. Following digital / analog signals shall be output from PLC. (DO & AO)

- PLC Start.- PLC Stop.- Local enable / Local permissive.- 4-20 mA speed reference.

Following digital / analog signals shall be input to PLC.(DI & AI)

- DRIVE READY.- DRIVE RUN.- DRIVE TRIP.- THERMISTOR TRIP.- THERMISTOR RELAY (at VFD from motor).- 4-20 mA signals for SPEED.- 4-20 mA signals for current.



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From cubicle through operator interface.

From local control station mounted near motor, following signals shall be input from this control station.

- START- STOP- EMERGENCY STOP- SPEED INCREASE- SPEED DECREASE

Following signals shall be output to control station:

- LOCAL ENABLED for indication- READY TO START for indication- 4-20 mA signals for SPEED and CURRENT for meter indication.

Design Criteria

Input voltage : 415V (+10%, -10%), TPN

Input frequency : 50 Hz 5%

Ambient temperature : 45 deg C

Output voltage : 0 – input voltage, 3 phase

Resolution : 0.01 Hz

Short time overload capacity (for auxiliary loads like pumps, fans etc.)

: 150% for 1 min./ every 10 min. (constant torque)

110% for 1 min./ every 10 min. (squared torque) and meet the requirement of the driven equipment.

Switching frequency : Adjustable to 15 kHz



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b) Overload capacity (for main drives of the process / plant)

: 100% continuous

: 125% for 2 hours

: 200% for 10 seconds

: The VFDs shall be suitable for actual motor overloads, i.e. incase the actual drive overload requirement is worse than the above recommendation, then VFDs shall be adequately designed for actual overload conditions.Also, the VFDs shall be suitable for 5 minutes operation on 100% load following the fan failure.

The unit shall be housed in enclosed in single front non compartmentalised self supporting floor mounted, dust and vermin proof cubicles having minimum IP42 degree of protection for the enclosure. The cubicles shall be fabricated from CRCA sheets of minimum 2.0mm thickness. The control electronics unit shall be accommodated in subrack. The cubicle shall be fixed to the ISMC 75 base channel. Lifting and earthing lugs shall be provided. Three phase busbars shall be provided. Bus bars shall be of Aluminium E91E grade. The allowable temperature rise of busbars shall be 40 °C over ambient of 45 °C. Continuous Aluminium earth bus shall run through out the length of the board. Painting shall be epoxy based as indicated in the over all Tender specification of the main equipment under the heading Electrical equipment.

TESTS

Following tests shall be performed as part of testing requirements for VFD units.

Factory test:

Insulation resistance Light load test Checking of auxiliary devices Control system test



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Site tests:

Insulation Light load test Rated current test

Checking of auxiliary devices Control system test

Details/Drawings/Documents

i) The tenderer shall furnish the following drawings/ documents along with the tender.

Drawing showing the front view, overall dimensions and mounting arrangement.

Make, type and ratings of all components.

Technical literature, detailed catalogues.

ii) On placement of order, the contractor shall furnish within fortnight 6 (Six) sets of the following drawings/details for approval.


Make/type and ratings of all components along with catalogues.

After approval 6 (Six) sets of the above drawings/details duly approved shall be furnished within a fortnight.

8.3 Soft starter units

8.3.1 Scope of Work

The scope of work involves design, manufacture, shop assembly, performance testing at manufacturer’s works, supply of equipment to site inclusive of proper packing and transportation, receiving at site, storing, unpacking, erection, cabling, testing and commissioning of all the electrical equipment required for the Soft Start system equipment.



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The items involved are:

a) 415V, 3phase, 50HZ Soft Starter with suitably rated electronic and power devices with associated switch gear & protections devices on the input & output side, power, controls and regulation units.

b) The Soft Start system having interface for PLC for Control, protection, supervision and Engineering with Software as per the technical requirement.

c) Interconnecting power, control and instrumentation cables between converter / inverter unit, sensors, including all cable terminations in the Soft Starter equipment.

d) Erection accessories.

8.3.2 General

Modification of schemes/changes in components, if any suggested during scrutiny/approval of drawings and execution of work, shall be carried out by successful contractor at no extra cost.

Equipment offered shall be of best quality to ensure smooth, efficient and trouble free operation of the system.

Make of all bought out items shall be as per the List of preferred makes enclosed.

No equipment shall be dispatched without inspection and/or clearance by Owner/Consultant.

The scope of Contractor includes all electrical equipment/sensors/ interlocks required for smooth and efficient working of system and required during installation, testing & commissioning. All such items are deemed to have been included in the contractor’s scope

Electrical

415V, 3ph 50Hz, 3 phase will be made available by the Owner.



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Safety interlocks, necessary to ensure maintenance operation shall be provided.

Party may indicate additional information to be provided by the Owner to suit the system offered.

Software/hardware required as per the technical requirement shall be included in the scope. The system offered shall be complete in terms of hardware.

8.3.3 Selection Criteria

Soft starter shall be provided for specific motors as indicated in the Motor and Feeder list. Design and selection of soft starters shall be done taking into consideration the fact that the soft starters are to operate (with bypass contactor) and with all reasonable precautions and provisions for the safety of operating and maintenance personnel. The soft starter rating shall be at least equal to motor KW rating at 500C for continuous operation and other specified site conditions.

For the motor, the incoming AC voltage to soft starter shall be 415V, 3 phase, 50 Hz neutral earthed system.

The soft starters have digital control using microprocessor based digital regulation & control. This shall be provided with six thyristors in power circuit and shall have all controls suitable for energy saving also.

Individual soft starter module for each motor shall be with MCCB with microprocessor based releases, 3 core CTs for connection to energy meter, Energy Meter, surge suppressor, soft starter, Contactors (to connect Soft Starter) and Overload relay. The digital regulation and control system shall be compatible for operation from PLC (provided separately. Not in the scope of this package). Potential free contacts shall be made available for interfacing the soft start unit with PLC for start, stop. Potential free contact shall be provided at soft start unit for trip signal to PLC.

The unit shall be housed in enclosed, self supporting, floor mounted, dust and vermin proof cubicles having minimum IP 41degree of protection for the enclosure. Painting shall be epoxy based. A maximum of two soft start modules shall be accommodated per vertical.



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8.3.4 Salient Features

Soft Starter for AC drives shall comprise of following features:

1) The other protective features for the Soft starter shall include following :

Electronic type AC surge suppresser with fuse monitoring device

AC incomer under voltage & over load Negative Phase sequence protection & monitoring

2) Suitable for soft start / current limit / full voltage mode of operation

3) Built in energy saver feature when motor is lightly loaded or is running on no load.

4) Regulation & control equipment

The digital drive regulation shall be considered and speed and torque accuracy of drives shall be as required for the process.

The regulation equipment shall be able to carry out all the control functions including following important features:

Current feedback & controller Adjustable acceleration / deceleration time. Adjustable starting torque

5) Pulse transformers & trigger models

6) Protection, indication & annunciation devices.

7) Load side filter

Protection Features

Protection, Indication and Annunciation



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The protection of the soft starter are to be provided as per the clauses stipulated in IEEE-444 as suitable and required for each case and shall generally include the following.

Control power supply failure Ventilation failure Wrong phase sequence Motor stalling monitor Any other protection as required for particular application. The indications shall be provided as listed but not limited to

the following: The alarm and annunciation on the panel and to PLC shall be

provided as listed but not limited to the following: Main power ON Control supply ON Incoming breaker trip Phase loss Microprocessor healthy System faulty Over Current Over Voltage Any specific regulation and control system faults as required Surge suppressor failure Any other specific fault as required.

The unit shall have the following regulation and control.

- The unit shall have fully digital microprocessor based regulation and control system with suitable interfaces for communication with the PLC.

- The unit shall be sealed type with membrane switches & LED/LCD display unit. Besides the requirement mentioned above, the operator interface shall have following additional features.

START switch STOP switch Settable ramp feature Setting voltage Setting time Function/control/reset switches Key Pad LED/LCD seven segment display unit.



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Indication and monitoring:

Features shall generally include but not limited to the following:

Instruments

VoltmeterAmmeter

All meters shall be of identical type and shall have minimum 270 deg full-scale deflection

Metering

The panel-mounted instruments shall be of the following types and accuracy class.

METER TYPE ACCURACY CLASS

AC ammeter


1.5

AC voltmeter


1.0

Indication / Status bar screens

Main power on/offControl supply on Contactor on

Control philosophy

Control of the Soft Starter shall be possible from following three locations (any one)

From PLC: This shall be through digital signals. Following digital signals shall be output from PLC. (DO)

- PLC Start.- PLC Stop.- Local enable/Local Permissive.



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Following digital signals shall input to PLC (DI).

- DRIVE READY- DRIVE RUN- DRIVE TRIP- THERMISTOR TRIP

- THERMISTOR RELAY (At VFD from motor)

From cubicle through operator interface.

From local control station mounted near motor, following signals shall be input from this control station.

- START- STOP- EMERGENCY STOP

Following signals shall be output to control station:

- LOCAL ENABLED for indication- READY TO START for indication

Following shall also be annunciated.

Motor Faults

Over load relay or Thermistor relay Over current Earth fault

Soft Starter status

Readiness Fault Run / Start Stop

Design Criteria

1 Nominal voltage rating : 415 V, 50Hz2 Voltage range (AC output) : 0-415 VAC3 Supply variations (voltage) : +/- 10%



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4 Supply variations (frequency) : +/- 5%5 Settable ramp feature : Required6 Setting Voltage : Vendor to indicate7 Setting Time : Vendor to indicate

TESTS

Following tests shall be performed as part of testing requirements for VFD units.

Factory test:

Insulation resistanceLight load testChecking of auxiliary devicesControl system test

Site tests:

InsulationLight load testRated current testChecking of auxiliary devicesControl system test






ii) On placement of order, the contractor shall furnish withinfortnight 6 (Six) sets of the following drawings/details for approval.



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Make/type and ratings of all components alongwith catalogues.


8.4 Power distribution boards

8.4.1 General

i) The power distribution boards shall be designed to carry continuously without overheating, the rated current specified in the schedule of quantities.

ii) The busbars shall be rated to limit the temperature rise within 40 deg.c over the specified ambient temperature of 45 deg.c (total temperature: 85 deg.c)

iii) The power distribution boards shall comply with IS 8623(R.a:1998) Part I&II, IEC 439 and other relevant Indian/International Standards.

iv) The ratings of incomer and feeders shall be as indicated in schedule of items/ single line diagrams enclosed.

8.4.2 Construction

i) The power distribution boards shall have sheet steel enclosure cubicle type and shall be

Floor mounted, self standing/supporting type

Totally enclosed, dust, damp and vermin proof

Single front, dead front and preferably without rear access.

With IP 54/52 enclosure as per IS 2147(1962)



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Fully compartmentalised, fixed type, in tier formation with Aluminium busbars

Easily extensible on both sides at site

The power distribution shall have MCCB acting as incomer while the outgoing feeders shall be with MCCBs as indicated in the enclosed single line diagram.

The power distribution boards shall be of indoor, factory assembled, continuous boards suitable for cable entry from bottom.

The boards shall be provided with lifting eye bolts for each shipping section.

The cubicles shall be manufactured using high quality CRCA sheet steel of at least 2 mm thick.

Suitable neoprene gaskets shall be adequately provided on all doors and covers for making the boards dust proof.

All operating handles shall be accessible from the front side of the cubicle. The operating handles shall be suitably interlocked mechanically with the door such that the door can be opened or closed only with the switch in OFF position. Provision for defeating the door interlock also shall be provided.

The number of accepted tier formation shall be subject to the condition that the operating handles shall be above 400 mm from floor level and shall not exceed 1800 mm from floor level for convenience of the operating personnel.

Each unit compartment shall have full metal barrier on all sides except front which shall be a hinged door. All hinges shall be concealed.

Each vertical section shall have a busbar alley on one side for tap off to feeders and cable alley on the other side and shall be provided with door/removable covers at the front.



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The clearances required at the back and front side, shall be indicated.

There shall not be more than 6 compartments in a vertical section.

A base channel/frame of minimum 50 mm height and 2.5 mm thickness shall be provided.

xiii) All inscriptions shall be on traffolite/� crutini aluminium sheets with white letters on black background.

xiv) PDB shall be provided with 30% spare cubicles/ modules. These spare cubicles / modules shall be complete with all devices with the standard module design of the corresponding PDB.

8.4.3 Feeder details

Distribution boards shall have MCCBs as incomer and outgoing feeders conforming to the detailed specifications given below :

All incomer feeders shall have 3 indicating lamps, red ,yellow, blue in colour, to announce power supply ‘ON’.

All incomer feeders shall have voltmeters and ammeters with selector switches with off position. All outgoing feeders shall be provided with � crutini with selector switches.

Incomers of PDBs shall have specially designed termination arrangements to accommodate multiple cables (as indicated in schedule of items).

Number and ratings/details of feeders are given in schedule of items/SLD

8.4.4 Busbars, busbar supports, connections

Power distribution board shall have metal enclosed chamber for main busbars at the top running throughout the length of the board.The busbar chamber shall have removable covers for easy maintenance.



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Outgoing feeders shall be connected to the main busbars through vertical busbars provided in the busbar alley. Vertical bus bars shall be easily accessible for maintenance. Vertical bus bars for TP&N shall be arranged to run full height of the vertical section irrespective of whether the bottom most section is used or left as empty feeder.

Busbars (triple pole and neutral) shall be

Aluminium conductor

Uniform in cross section through out the length of the bus and identified by colour code throughout.

Selected giving due consideration to proximity effect.

iv) All the busbars shall have dynamic stability for the peak current and thermal stability for the specified symmetrical short circuit current for 1 second without any deformation, deterioration or damage.

Busbars shall be provided with heat shrunk insulation.

An earth bar of adequate cross section for terminating fourth core of outgoing cable shall be provided running throughout the length of the power distribution board at the bottom with provision to connect to shop earth grid at either end of the board. Size of earth bar shall however be not less than neutral bus size. Removable bus link shall be provided between neutral and earth bus bars.

Bus bar support shallhave high dielectric strength and high impact strength capable of withstanding dynamic stability currents.

Be of non-hygroscopic type

Be with antitracking barriers

Be self extinguishing and fire retardant insulators with ribbed construction to prevent tracking due to dust accumulation and to have larger creepage distance.



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Size of the neutral bus shall not be less than half of the size of main busbar.

The busbars shall be rated to limit the temperature rise within 40 deg.C over the specified ambient temperature as indicated in the design criteria.

Allowance shall be made for reduction in section by bolt holes.

Busbar, connecting fish plates, zinc bichromated bolts, nuts and washers shall be provided at each end of a shipping section to facilitate connection at site.

The clearance between bare phase power busbars and between phase and earth in air shall not be less than 25 mm and 19 mm respectively.

All busbar joints shall be of bolted type. Belleville/ spring washers shall be used for joints to prevent loosening.

Busbars shall be phase identified by colour code.

8.4.5 Cable alley

Each vertical section shall have a cable alley along side

Cable alley shall have adequate space for terminating copper power cables.

Barriers running complete height of the board shall effectively isolate the cable alley from horizontal and vertical busbars.

Bottom cable chamber shall be left free completely for accommodating power cables and shall be completely isolated from vertical busbars.

Removable, undrilled gland plates shall be provided for each cubicle/vertical.

There shall be no horizontal cross bracings within 250 mm of gland plates where the cables enter.



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All power outgoing terminals shall be brought out to a separate terminal block/strip through solid links with bellows and located in the cable alley.

8.4.6 Interchangeability

All identical equipment and corresponding parts, accessories shall be fully interchangeable without any modification.

Components and equipment that are not fully interchangeable are liable for rejection and the supplier shall replace all such items by fully interchangeable ones free of cost.

8.4.7 Make up of Modules

Incoming feeder :

- Shall be MCCB unit of adequate rating in fixed module. Where rating is 630 Amp or above the same shall be air circuit breaker in draw out execution. MCCB shall be with microprocessor based direct acting self powered adjustable O/C, E/F, S/C release.

- Provided with voltmeter and ammeter with selector switches. Meters to have accuracy class 1.0 and size 144 x 144 sq. mm.

- Provided with microprocessor based metering system with RS 485 communication port and pulse energy output.

- Provided with R,Y,B phase indication lamps and ON/OFF/TRIP lamps

- MCCB shall have 1 NO + 1 NC contacts rated for 6A, AC 11 duty. ACB shall have minimum 4 NO = 4 NC auxiliary contacts rated for 6A, AC 11 duty.

MCCB feeders :

- With microprocessor based adjustable, self powered release for O/C, S/C and E/F.

- With 1 NO + 1 NC auxiliary contacts rated for 6A at AC11 duty.



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- Provided with ON, OFF and Trip lamps, ammeter for all feeders rated 100 A and above

Moulded Case Circuit Breakers (MCCBs) :

MCCBs shall be of triple pole construction suitable for panel mounting, Operating mechanism shall be trip free, quick make, quick break type.

The MCCBs shall be provided with front operating handles and mechanical ON/OFF indicators. In case of trip, the handles shall rest in an intermediate position.

MCCBs shall be provided with microprocessor based release for O/C, S/C, E/F which shall be fully adjustable.

Where MCCBs are used in the motor starter modules in conjunction with contactor and thermal overload relay, type 2 coordination shall be provided.

MCCBs shall have following accessories and features:

Shunt trip release

Auxiliary contact set of 1 NO + 1 NC contacts

Fault signaling contact set of 1 NO + 1 NC contacts

Insulation shields to isolate the connections between each pole

Finger protection plate to prevent accidental contact

The compartment door shall be interlocked with the handle of the MCCB

8.4.8 Indicating instruments and current transformers

All indicating instruments (voltmeters and ammeters) shall conform to IS 1248(R.a:2003) .

All indicating instruments shall be of taut band flush mounting type size 96 mm x 96 mm and shall conform to 1.5 accuracy class.



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All instruments shall be provided with zero adjusting device for external operation.

Ammeters shall be suitable for operation on CT and scaled to read actual currents flowing in the circuits.

All measuring current transformers shall conform to IS 2705 (R.a:2002). The current transformers shall be of cast resin/bakelite housing type, with bar primary, 5A secondary current and class 1 accuracy. The burden of CTs shall be as required by the associated measuring instruments and connecting leads.

8.4.9 Indicating lamps

All indicating lamps shall be of low wattage cluster LED type. Red, Yellow and Blue colour lenses shall be provided for the lamps of the incomer.

8.4.10 Wiring and terminations

The PDB shall be completely factory assembled and wired.

Power connections shall be done by 1100 V grade single core pvc insulated copper conductor or by aluminium strips of sizes adequate for the respective ratings. Control / Aux. Wiring shall be by 650 V/1100V grade pvc single core copper conductor of min. cross section 2.5sq.mm.

Each wire shall be identified by ferrules at each end in accordance with schematics.

Wiring to the door shall be done by flexible cable and the cables shall be bunched, sleeved and cleared so that no mechanical damage can occur to the cables during door movements. All terminations shall be of adequate current rating and size to suit individual feeder rating.

Outgoing power terminals shall be designed for connecting PVC copper cables of sizes indicated in schedule of items

Not more than 2 wires shall be connected at one control terminal.



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Required number of heavy duty double compression type brass cable glands suitable for the outgoing cables, projected nipple type complete with two locknuts and earthing washer (provided with earth studs) shall be supplied.

Edge of cable glands shall have threaded projection to enable the locknut to fit from inside of the equipment.

Terminals, crimping type cable lugs and glands shall be suitable for the cable sizes to be indicated by the Owner during the execution of order.

8.4.11 Painting

Final outer surface colour shall be Owners preferred shade as per IS – 5

For detailed specification on painting, refer to special instruction to tenderer.

The designation of the board shall be painted using stencils and white coloured 50 mm high letters. The designations shall be as indicated in schedule of quantities

8.4.12 Tests

All routine tests as per IS 8623(R.a:1998) shall be conducted at the manufacturer’s works in the presence of owner/consultants and test certificates shall be furnished. Copies of type test certificates shall also be furnished.

8.5 Welding receptacles & power sockets

8.5.1 General

The plug and socket units shall be suitable for operation at 415 volts, 50 Hz, 3 phase, 4 wire system with earthed neutral having symmetrical fault capacity as specified in the design criteria.



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The plug and socket units shall be designed for the satisfactory operation for the climatic and site conditions specified in the design criteria.

The plug and socket units shall comply with the relevant Indian Standards.

iv) The ratings of plug and socket units shall be as indicated in schedule of items

8.5.2 Construction

The contacts of plug shall be adequately shrouded and contacts in sockets shall be sufficiently deep recessed to ensure safety for operating personnel against risk of accidental contact to live parts.

The socket and plug assembly shall be non reversible.

The earthing pin shall be long enough to ensure that earth connection is made first and broken last.

The units shall be complete with compression type cable glands.

The units shall be painted brilliant green as per IS-5 shade 221.

Each unit shall be provided with inscription plates made of traffolite sheets with white letters on black background.

The plug and socket assembly shall be provided with integral interlocked rotary switch. It should ensure that the plug can be inserted or removed only with the switch in the OFF position. The unit shall be provided with HRC fuses for short circuit protection. The components shall be enclosed in dust proof enclosure conforming to IP 54 degree of protection. The switch shall be AC 23 rated/heavy duty type.

The unit shall be suitable for wall/column mounting

The units shall have the following standard ratings.

415volts, 200 Amps, 100 Amps, 63 Amps and 32 Amps with 3 pole, neutral and earth.

240 volts. 15 Amps. 3 pin.

24V, AC 2pin



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8.5.3 Tests

All routine tests as per relevant Indian Standards shall be conducted at manufacturer’s works in the presence of owner/consultant and test certificates shall be furnished. Copies of type test certificates shall also be furnished.

8.5.4 Details/Drawings/Documents





ii) On placement of order, the contractor shall furnish within fortnight 6 (Six) sets of the following drawings/details for approval.


Make/type and ratings of all components along with catalogues.


8.6 LT Power & Control cables

LT power and control cables shall be 1100 V grade, heavy duty, Aluminium/copper conductor, multi core, PVC insulated, armoured, extruded PVC sheathed cables complying with IS 1554(R.a:2005) , Part 2. Heat Resistant (HR) cables shall be considered in heat zones of DISP Plant. All control and power cables (6 sq.mm and above) shall be of stranded type. All LT power cables shall be 3.5/4 core, outer sheath shall be of PVC type.



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Outer Sheath

The outer sheath shall be of an extruded layer of PVC type ST1/ST2. The sheath shall be resistant to water, ultra – violet radiation, fungus, termite and rodent attacks. The colour of the outer sheath shall be black.

Inner sheath

The inner sheath shall be of extruded PVC type ST1 as per IS-5831(1984) (R.a:2001) .

Armour

The armouring for cables shall comprise a single layer of GI strip/round wire as per IS – 3975 (1999) (R.a:2004) .

Insulation

Conductors shall be insulated with extruded PVC Type A/Type C as per IS – 5831.

Conductor

Aluminium conductor shall be stranded, grade H4, class 2 as per IS –8130 for LT power cables 16 mm2 and above. For core size of 10 mm2 and lesser, the conductor shall be stranded, copper of grade H4, class 2.

Copper conductor shall be annealed, stranded copper conductor class 2 as per IS – 8130(1984) (R.a:2001) for control cables below 4.0 mm2 and shall have 7 strands for the conductors.

Identification of cores

Colour coding shall be acceptable for all cables up to 5 cores. Cable with more than 5 cores shall have Hindu Arabic numerals printed on each core. The printing shall be reversible.

Where colour coding is used for cables with up to 5 cores, the choice of colours shall be red, yellow, blue, black and gray.

Cable drums

Cable shall be supplied in non-returnable wooden drum. The wood used for construction of the drum shall be properly seasoned and free from defects. Wood preservative shall be applied on the entire drum. All ferrous parts shall be treated with a suitable rust preventive coating to prevent rusting during transit or storage. Cable drums shall



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conform to IS – 10418, 1991(R.a:2001) . Cable ends shall be sealed with non – hygroscopic cap.

Minimum drum length shall be indicated by the tenderer in his offer. The actual length supplied on each drum shall be within the tolerance limit of 5% with an overall tolerance of 5% on total ordered quantity for each size of cable. However the maximum drum length for the largest power & control cable shall not be less than 1000 m in order to avoid joints.

Incremental cable lengths in meters shall be embossed on the outer sheath at every 1m interval.

Cable Identification for HT, LT and control cables

The outer sheath of the cable shall be embossed/ stamped with the following details at regular intervals:

Name of manufacturer / trade mark

Voltage grade

Year of manufacture

Number of cores and nominal cross-sectional area of conductor

Tests

Cables shall be subjected to routine, type, and acceptance tests in accordance with IS: 7098 (part II) 1985(R.a:2005) and IS – 1554 (part I) 1988(R.a:2005) . Test method shall conform to IS: 10810(R.a:2001) (methods of test for cables).

8.7 GI Cable Trays

GI Cable trays shall be of 3000 mm standard length and shall be fabricated from minimum 2 mm thick CRCA sheet steel. The tray shall be ladder type with folded rungs and side rails. The side rails shall have an inner lip formed by folding the sheet. The trays shall be hot dip galvanized to a minimum thickness of 85 microns. Supply of GI trays coupler plates and electro-galvanised hardware shall be part of supply of trays. The tray shall be suitable of withstanding a load of 70 kg at the center and UDL of 70 kg with a support span of 3000 mm without exceeding the deflection limit.


Cable schedule shall be furnished for both power and control cable. Cable schedule shall include inter plant cable layout drawing of



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various routes and summary quantity of different cable sizes. Termination diagrams shall be furnished as required .

8.7.1 Control Pulpits

SCOPE OF WORK

The scope of work shall cover design, preparation of fabrication drawings, fabrication/ procurement, supply, erection, assembly and commissioning of control pulpits including illumination as elaborated in this specification/enclosed drawings.

The scope of work shall extend to staircase along with entry platform, platform for air-conditioner and gallery alround the control pulpit as shown in the drawings.

The scope of work shall also include submission of fabrication drawings for approval.

During erection of the control pulpit, the contractor shall co-ordinate with erectors of electrical equipment and service facilities viz. pipelines, conduits, air-conditioning etc., and shall be responsible for the completeness of the pulpits.

8.7.1.1 Technical specification

General

The overall dimension and design of control pulpits shall be as required.

The pulpits will house various equipments such as control desks, CCTV, processors, printers, monitors, main computers etc. However, the pulpit is manned to oversee the operation of the plant. The pulpit shall be designed and fabricated in accordance with relevant Indian Standards as well as ergonomical rules/aspects. The pulpit shall confirm to the rules for design of modern working places. The pulpit shall be aesthetically good. Each pulpit shall consist of a fabricated steel structure supported on steel columns, or combination of steel columns and concrete walls as shown in the drawings. Pulpits shall be self supported and isolated from main building columns. The front and a portion of the sides shall have



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glass window panels. The side and rear walls and roof shall be double walled sheet steel with thermal insulation packing. The pulpit shall be provided with false ceiling and false flooring.

8.7.1.2 Wall and Wall Sheeting

Wall structures shall consist of several standard elements of modular construction. The elements shall be suitable for bolted connections for easy assembly at site. The wall elements shall have a thermal insulation of 80 mm highly compressed mineral wool mats. The outer sheeting shall consist of cold rolled non-scaling sheet steel of 2.0 mm thickness. The inner sheeting shall consist of stainless steel 304 gr. Sheet of not less than 1.0 mm thickness.

8.7.1.3 Roof and false ceiling

The roof structures shall consist of several standard elements of modular system. The elements shall be suitable for bolted connections for easy assembly at site.

The roof element shall have a thermal insulation of 100 mm highly compressed mineral wool mats. The junction between wall and roof elements shall be thoroughly sealed against any atmospheric influence with weather resistant permanent elastic PVC ribbon. The false ceiling shall consist of luxalun type supported from the roof at sufficient number of points. The false ceiling panels of 12 mm/19 mm thick particle board or semi perforated anchor white tiles or equivalent shall be suitably fixed to the underside of this grid. The boards shall be of noise proof. Complete details of the false ceiling grid suspension method, ceiling panels etc., shall be furnished.

The roof shall be designed considering the weight of air-conditioners as shown in drawings and movement of service personnel etc. Air-conditioning ducts shall be run between the roof and false ceiling. Cold air outlets and return air passage shall be provided. The location of air-conditioner will be shown in the drawings. The false ceiling shall also be designed to accommodate electrical conduits and light fixtures.



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8.7.1.4 Pulpit floor / Cable floor

The pulpit cable floor shall consist of structural steel grid designed to withstand static and line load. The pulpit floor shall be designed for floor loadings and equipment weights as indicated in the respective pulpit drawings during drawing approval.

The floor shall be covered with removable false flooring units. The portion of the floor below control desks are to be suitably modified as required and necessary openings will be indicated. The size of cover plates shall be of the order of 600 x 600 mm, after finalizing the equipment. The surface of false floor units shall be pasted with a minimum of 2.0 mm thick PVC vinyl sheet. The colour of the false floor will be indicated later. The floor will be supported on special adjustable jacks where cable duct is located and fixed jacks at other places. The false floor details shall be furnished with all fixing and leveling arrangement by the tenderer.

8.7.1.5 Glass windows

The front and side wall of pulpits are provided with glass windows. The location and size of the windows shall be provided as indicated in the drawings. The window glass shall consist of two glass sheets of 6 mm thick hermetically sealed together with an air gap of 12 mm. The outer glass shall be of heat resistant toughened quality while the inner can be plain toughened glass. The glasses shall be of shatter proof safety design with uniform thickness and a flat surface. The quality shall be such that light transmission is not less than 80%. The entire screen unit shall be mounted on to the pulpit structure in an encircling special section gasket, made from “NEOPRENE”, fixed with suitable clamping device. The aluminium frame for vertical joints shall be of standard anodized natural colour. No horizontal joints are permitted.

Tenderer may quote tinted glass non-reflective type as an optional for front view glass of furnace and down coiler control pulpits. Moisture absorbing chemicals shall be suitably placed between glass panes to absorb any moisture and prevent the window from clouding. The make of glass shall be preferably Hindustan Safety Glass Works Limited brand name penguin pane insulating glass.



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Doors

Standard anodized natural colour aluminium glazed door from extruded sections shall be provided at entrance of the pulpit. Door to be provided with double action floor spring and pivot or door closure of standard make. Door to be provided with lock and butterfly type handles on inside and outside. Special neoprene gasket for cushioning 6 mm glass safety or equivalent to be provided.

8.7.1.6 Thermal insulation

The insulation material inside the double wall, floor and roof panels shall be highly compressed mineral wool mats. The density of mineral wool mats shall be about 150 kg/m3 with a max. co-efficient thermal transmission of 0.5 W / m2 0 k. Noise transmission co-efficient shall be very low. The recommended thickness of the highly compressed mineral wool mat for wall shall be 80 mm thick and that of roof and floor shall be 100 m thick. The make shall be of Lloyds of equivalent. The noise insulation shall be of “SPINTEX” make.

8.7.1.7 Illumination

The pulpit shall be illuminated by using decorative fittings with a combination of fluorescent tubes and incandescent lamps controlled from flush type decorative switches. All fittings shall be of flush type and fixed flush with the false ceiling. The decorative tubelight fittings preferably of diffused nature. The locations of the fittings with respect to the equipment location and operators position shall be such that no glare will be experience by the operator. The illumination level at the working height shall be of 350 lux. Emergency light in case of power failure shall be provided 240V, 15/5A socket for maintance purpose and 24V low voltage socket whall be provided for use of hand lamps. Power supply of 240Vand 24V will be made available at the nearest column. Light fittings of reputed manufacturers viz., Philips/Genelec/Bajaj shall be used.

8.7.1.8 Brackets / supports for monitor equipment

Brackets / supports suspended from roof shall be provided to support various video monitors etc. The exact location of the above supports



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/ hangers will be indicated after finalisation of the equipment by electrical supplier.

8.7.1.9 Heat shield & handling facilities

Heat shield shall be provided in front and bottom of control pulpits located in furnace area . Handling facilities if any required shall be provided underneath the pulpit for mainteance of equipment located in the furnace area. The details for the same will be furnished later.

8.7.1.10 Architecture

The bidder shall give specific importance to architectural and aesthetic aspects and furnish all such details separately. Architectural drawings of pulpit supplied by the bidder may also be included in the bid.

8.7.1.11 Pulpit shall be designed to withstand wind pressures as per latest IS 875 Part-III standards.

8.7.1.12 Painting

1. Surface preparation on sand blasting.2. Primer – Epoxy Zinc rich primer one coat 25 M OFT.3. Intermediate coat – Epoxy high built micacaus iron oxide one

coat 75 M OFT4. Final coat – Expoxy high built enamel two coats 40 M OFT

8.7.1.13 Inspection and testing

Visual inspection, checking of dimensions of various prefabricated sections / assemblies with reference to approved drawings shall be done at suppliers work by the customer ‘s representative. After final erection and finishing at site, inspection shall be carried out for conformation to the contract standards and final acceptance. The supplier shall produce test certificates for all materials used including but no limited to structural steel, false ceiling and floor, illumination fixtures etc.

The supplier shall also bear responsibility for getting the structures approved by statutory authorities.



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8.7.1.14 Drawings and Documentation

The following documentation shall be furnished by the supplier along with offer :

- Structural drawing for each pulpit (Preliminary).

- Wiring diagram for illumination and wall sockets (Preliminary)

- Bill of Materials

Documentation shall be furnished after placement of order as follows:

- Final structural G.S drawings with detail of connection and Bill of Material.

- Detailed design calculations

- Final wiring diagram for illumination and wall sockets.

- Foundation loading diagrams.

- Operation and Maintenance instruction.

- Catalogues and pamphlets

- Reproducible tracing films of structural drawings, assembly drawings and Bill of Materials.

No. of sets and time schedule for the above will be mutually agreed.

8.7.1.15 General terms and Conditions

The tenderers shall quote for complete supply and installation / erection of the control pulpits. Prices shall be quoted as follows :

- Price for complete installation, erection and commissioning pulpit wise. (in case it is more than one).

All civil works connected with the erection shall be within the scope of contract.

Tenderer shall furnish along with the offer a list of similar jobs so far executed along with names of the customers.

The contractor shall make his own arrangements for transport and storage of the materials at site.



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Contractor shall make his own arrangement for transport of his personnel and their facilitate during erection.

Contractor shall take necessary insurance coverage of his own personnel.

All safety rules and regulations prevailing in the area and as desired by the ultimate customer shall be observed by the contractor.

Electrical power shall be supplied at 415V 3 phase 50 HZ .

Necessary tools and tackles for the execution of the work shall be arranged by the contractor.

Contractor shall hold necessary licenses for carrying out such type of jobs.

For any material the contractor intends to bring inside the customer’s premises or intends to take out from the customers premises, the customer’s factory regulations shall be strictly followed.

Manufacture of pulpits in suitable prefabricated sizes which can be easily transported and erected at site.

Complete erection, and finishing (final painting, false ceiling and flooring etc.) at site, of all items under tenderers scope of supply.

8.8 Earthing and Lightning protection

Earthing

The principal requirements of the grounding are:

Low resistance and adequate current carrying capacity.

Uniform and near uniform ground potential on all structural metal work on all metal enclosures and/or supports of equipment and apparatus.

The earthing network shall be as per actual site conditions. The combined grid resistance shall be less than 1 ohm. Earthing network of all LT substations and Main sub-station shall be interconnected.



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The tenderer shall measure soil resistivity at different locations of site which will be the basis for designing the earthing system.The earthing system to be installed shall conform to IS 3043(1987) (R.a:2001), Indian Electricity Rules and Regulations of CEI of the state. The installation contractor’s scope also include all the civil work associated with complete earthing network. Installation rates quoted for all equipment shall include earthing of equipment also. All earth connection shall ensure a permanent low resistance contact. Earth connections required to be removed for the purpose of testing of equipment/earthing network shall have bolted connection and joints fastened. All earthing connections shall be visible for inspection. All electrical equipment (indoor and outdoor) shall have 2 separate distinct earth connections. Air termination rods of lightning protection systems shall be connected to earthing network as per IS 3043. The grounding connection to the lightning arresters, air termination points of lightning protection system shall be as short as possible. Sharp turns in these conductors shall be avoided. It has to be ensured that main earth bus in the installation as well as earth buses in individual sections/areas shall form complete ring and they shall be interconnected. Duplicate earthing (two separate and distinct connections with earth) shall be employed for all equipment.

As far as possible earthing conductors shall be neatly taken along with the power cable route which may be on the cable trays/racks/risers or buried cable run way. Wherever earth conductors are taken on racks/trays/risers, they shall be neatly clamped at every 3 meters interval on the horizontal racks and at every 750mm interval on the vertical racks/risers/ bends/ take off points etc.



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Wherever burying of earth conductors are specified, they shall be buried as per approved drawings. Wherever earth conductor crosses the road, it shall be taken through GI pipes. At all terminations of earth conductors or equipment, sufficient length shall be left for easy movement of the equipment from its position for alignment purposes. Wherever not detailed, the route of the conducting and location of the earth pit shall be arranged, so as to avoid obstructions, crossing etc., according to convenience at site and shall be got approved by the owner’s representative in-charge of the work.

General requirements

Entire system shall be earthed in accordance with the provisions of the relevant IEC recommendations / IS:3043 – 1987(R.a:2001) (Code of practice for earthing) and Indian Electricity Rules, so that the values of the step and contact potentials in case of fault are kept within safe permissible limits.

Parts of all electrical equipment and machinery not intended to be alive shall have two separate and distinct earth connections.

Plant Building and electrical room housing tenderer’s MCC shall be provided with a ring main earthing system each. Individual ring main earthing systems shall again be inter-connected to each other and to existing plant earth grid as a network.

The ring earthing system around building shall be laid at a distance of approximately 1.5m from the building and at a depth of approximately 0.8m. The ring shall be bonded at intervals to the building steel structures and also to pipes, wherever they are cross-ing. The earthing shall further be connected at intervals to deep earthing electrodes to achieve a combined earth resistance of one ohm value or less.

For the purpose of dimensioning the main earthing lines/conductors, the duration of the earth fault current shall be taken as 1 second.



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For different floors in a building, localized ground mats shall be formed and connected to the ground-earthing ring through vertical risers. The earthing mat shall be common to both power and lighting installations.


Earthing and lightning layout drawings with calculation for no. of earthing stations and GI strip quantity etc. shall be furnished.

Earthing Stations

The earthing station shall comprise of earth electrode, layers of salt and charcoal, civil masonry work, cast iron frame and cover, cast iron pit marker etc as per IS 3043(R.a:2001) .The earthing electrode shall be of C.I. of 100 mm dia & 3.5 mtr. Length provided with GI funnel and wire mesh. Earthing system for computers and microprocessor-based equipment/PCs shall be distinct and separate from the power and lighting equipment-earthing system. For earthing of individual equipment’s and interconnection between earth pits GI wires and flats shall be used. The sizes of earthing cables shall be as below:

The sizes of earth conductors for various equipment shall be as follows:

Main earthing ring 75 X 10 mm GI flatHT motors and switchgear 50 X 6 mm GI flatLT PMCC / MCC 50 X 6 mm GI flatLT motors up to 2.2 kW 6 sq. mm stranded GI wireLT motors 3.7 kW to 15 kW 16 sq. mm stranded GI wireLT motors 15 kW to 45 kW 25 X 3 mm GI flatLT motors above 45 kW 50 X 6 mm GI flatLocal control stations, safety Switches, lighting fixtures etc.

6 sq mm stranded GI wire

Joints/terminations All joints of earth conductor shall be through approved termination method so as to form rigid earth ring. All such joints shall be given necessary coating of cold galvanized paint as per relevant standards



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and a coat of suitable bitumen compound to prevent corrosion. Joints shall form part of laying of earth conductors and they shall not be considered as terminations for payment purposes. No extra costs shall be applicable for joints of all the earth conductors.

In case joints are made by using suitable connectors the entire joint shall be fully sealed by suitable compound so that no metallic part is exposed. The contractor shall make his own arrangements for the necessary crimping tools, soldering equipment, drilling machines and other tools and tackles which are necessary for completing the installation.

The number of earth electrodes and size of earth conductor indicated is tentative. The contractor shall provide adequate number of earth electrodes and equipment earthing conductor as per site requirements based on unit rates quoted. The overall resistance of the grid to be considered shall be about 1 ohm.

Any modifications suggested by CEI of Government of Kerala on the grounding/earthing work done by the contractor shall be carried out at no extra cost However, provision of additional earth electrodes/ conductors or changing type and size of electrodes/conductors by CEI will be paid extra at unit rates quoted.

Lightning protection

All buildings, plant structures and lighting towers vulnerable to lightning strokes owing to their height or exposed situation shall be protected against atmospheric flash-over and lightning strokes in such manner as to eliminate any danger to the personnel employed therein, stipulations of IS : 2309-1989(R.a:2005) shall be followed.The lightning system shall consist of ai terminations, horizontal roof conductors and down comers of 25 X 3 mm GI flats. All roof conductors and downcomers shall be cleated at every 2-M intervals and 1-M intervals on roof slab and columns respectively. All connectors, cleats, clamps, anchors etc shall be of � crutinize steel. Normally joints ans sharp projections shall be avoided in downcomers.



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Air termination network should cover all salient points of the structure. All metallic chimneys, ducts and the like above the main surface of the roof of the structure shall be bonded to and form part of the air termination network. Vertical air termination points shall project at least 30 cm above the object on which it is fixed.

Down conductors shall follow the most direct path possible between air termination and earth termination avoiding sharp bends. Down conductor shall have a testing point adjacent to the earth electrode. Each con� cruti shall have an independent earth termination. All earth termination shall be interconnected. The lightning protection system shall be further interconnected to the plant earthing system.


Lightning protection system layout drawings and details with calculation and summary of quantity of earthing stations GI strips, sizes etc. shall be furnished.

8.9 Erection

8.9.1 Scope of work

The scope of work includes erection, testing and commissioning of complete electrics for the Plant being supplied by the tenderer viz. MCCs, PDBs, cables, cable trays etc., equipment mounted motors & electrics/system supplied by others.

Scope of work also includes :

Liasioning with statutory bodies and other contractors, preparation of site sketches/drawings to enable cable laying and inter-connections, preparation of as built drawings

Loading/unloading and transportation to site of Owner supplied equipment civil works associated with the erection of electrical equipment like grouting of insert plates, � crutini, chipping, grouting, making/closing openings

Supply and erection of erection accessories like anchor / grip bolts, fasteners, cable clamps and ties, cable markers etc



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8.9.2 Installation of IT Switch boards /MCCs

The board number shall be verified with equipment number and single line schematic drawing for the correctness of the panels. Minimum clearances in air between phases, phase and ground shall be checked. In case, if clearances do not meet the specified requirements, live parts shall be insulated to rated voltage after obtaining necessary approval from engineer/owner. Each panel and total switchboards shall be aligned and leveled along both axes. Free movement of breaker truck in each cubicle and interchangeability of breaker trucks shall be checked before final fixing of cubicles. The frames for the switchgear shall be secured to the foundations by means of anchor bolts or welding to embedded plates. The grouting and patching of anchor bolts shall be done by the electrical installation contractor. Any minor civil works like chipping foundations, leveling and finishing shall be a part of electrical installation contract. Before fixing up switchboard, the bus duct shall be connected and checked for alignment. Any adjustment for proper alignment shall be carried out by the contractor. Check the name plate details as per approved drawings. After the base frames are properly secured in foundation, all the panels of the switchboard shall be installed as per general arrangement drawing and ensure that all the panels are in the sequence. Tightness of all bolts, clamps and connecting terminals shall be checked. The connecting links between the transportable sections of the main switchboard shall be connected properly. While joining shipping sections, bus ducts, Aluminum fish plates and bus bars shall be cleaned and contact grease shall be applied wherever required, by the contractor. Outgoing cables shall be connected at the switch gear panels as explained under “installation of cables”. The drilling of gland plates at site shall be done by the contractor after checking the suitability for termination, laying of cables at site. The continuity of all the bus bars and earth continuity conductor provided in the switchgear shall be checked after installation is complete. All bus bars points shall be tightened using torque wrench as per manufacturer’s specification.



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Before final commissioning of units, the switchboard shall be painted neatly at the points where there are scratches and peeling off of paint during transit. Suppliers/engineer’s instructions shall be followed for installation, testing etc. Earthing for the equipment shall be carried out with two suitable earthing conductors. 2 Nos. earthing conductors from the equipment shall be connected to the earth grid.

The contractor shall follow the following sequence of erection of switchgears. 1. Transportation to the place of installation from contractor’s

stores/owner’s stores.

2. Unpacking the cases and physical inspection of switchgear for breakages, missing parts or damages as compared with the packing list.

3. Erection of base channel and alignment.

4. Erection on foundation.

5. Assembly.

6. Alignment.

7. Connection of bus bars.

8. Welding and anchoring.

9. Installation and wiring of relays, meters etc.

10. Laying, meggering, termination, dressing and clamping of power and control cables.

11. Tagging and marking of cables.

12. Earthing station, earthing strips, earthing equipment and measurement of earth resistance as per IER 1956/IS 3043 with the latest revision.



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13. Connection of power and control cables.

14. Checking and testing of all relays, meters, other protective accessories and control and power circuit wiring, phase sequence connection, checking of all circuit breakers for proper alignment of handles with doors. Ensure movement of handle, check for opening, closing and draw out operations.

15. Using a vacuum cleaner, remove dust, small particles etc.

16. Clean all insulating surfaces with dry cloth or as indicated by the manufacturer.

17. Heating of panels by anti-condensation heaters.

18. HT and other tests on power and control cables.

19. Tests on switchgear as per supplier / engineer’s instructions and as indicated in the specification.

20. Submission of preliminary completion report.

21. Connection of DC control supply to switch gear and checking of manual and electrical operation of breakers, control circuits and interlocks, operation of protection relays.

22. Charging of switchgear.

23. Functional tests.

24. Painting of all accessories, structures etc.

25. Submission of completion report in format.

26. Handing over to engineers/owners.

NOTE : All works connected with switch gear shall comply with IS 3427-1997 Amendment 1973 and as per engineer/owner’s instructions and IS 2147(1962).



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8.9.3 Installation of prefabricated Cable trays

The contractor shall install cable trays/troughs complete with all associated accessories like coupler plates, dropout trays, horizontal elbows vertical elbows, tees, reducers, hangers, tray supports as per approved layout drawings. Cable trays shall be supported at every 3.0m lengths for horizontal and 1.5m for vertical run. Wherever cable tray route requires to be changed/altered, contractor shall carry out such alterations after obtaining the permission of engineer. Modifications in the cable tray routings at site shall be in the scope of the contractor and the contractor shall not be entitled for any extra charges on this account.

Constructional details and supporting arrangement for the cable trays shall be as shown in the drawings to be furnished during installation, or as per contractor’s drawing approved by owner/consultant.

Cable trays shall not be used as walkways. Cable trays shall be earthed as specified.

8.9.4 Installation of Cables

Scope under cabling shall include –

Cable and cable drum inspection and handling

Laying, meggering, termination, dressing and clamping of cables.

Tagging and marking of cables

HT/LT tests on cable

Identification of phases

Connection of equipment

Marking of cables tray ready for charging after completing all associated work.

Important note

For cable installation/laying, if cutting of foundations or structures is required, prior permission shall be obtained from the owner/engineer.



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Cabling shall not be carried out in areas of excessive temperatures. Wherever a cable crosses a temperature expansion joint in structure, sufficient sag shall be provided. Cables of different voltage levels and noise classification if any, shall be taken on in the trays/racks (or other means specified) indifferent trays as per standards and drawings. In no case instrument cables are to be run along with power cables. Cable trays/racks shall not be used as a walkway, either, during installation or while cable pulling or at any other time of installation.

Cable inspection and handling On receipt of cable drums, the contractor shall inspect each cable drum and check for size, length, and type with respect to supplier’s seal and making/documents. Loading and unloading of cable drums shall be done by crane and drums shall be carefully lifted and deposited on ground. If crane is not available then the drum shall be carefully rolled down on a suitable ramp of rails. The drum shall be rolled as per the direction indicated by the arrow on the drum in order to prevent the turns of the cable from loosening on the drum. Under no circumstances shall a drum be dropped to the ground as the shock may cause serious damages to the inner layer of cables. No cable drum shall be slung except by a bar or spindle through the � cruti of the drum. In no case the drum be stored with the flanges horizontal. Only cable jacks shall be employed for removing the cable from the drum. For removing the cables from the drum, the drum should be properly mounted on jacks on a cable wheel, making sure that the spindle is strong enough to carry the weight without bending and that it is lying horizontally in the bearings so as to prevent the drum creeping to the one side or the other while it is rotating. The drums should be mounted such that when the drum is turned against the direction of arrow, the cable is paved out from the top of the drum to



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avoid any danger of bending and breaking the cable if unreeled from the bottom.

Cable pulling and laying

Cable rollers shall be used for pulling and laying of cables. Cables shall be properly handled while laying to avoid any damage to the cables. Cables may be pulled by hand or by the use of pulling eye securely clamped to the conductors. Jacket, armour or outer jacket shall be secured to the clamp to prevent relative movement. If mechanical means are used to pull on the conductors, force must not exceed values recommended by the manufacturer. The pulling eye shall be securely fastened to the ends of all the conductors so that the load is evenly distributed. The ends of all cables to which pulling eyes are attached shall be cut off before terminations are made. Bending radius for permanent bends shall not be less than those specified by manufacturer. When pulling cables, the bending radius, pulling tensions and wall pressure at bends shall be strictly in accordance with manufacturer’s recommendations. Cable cutting/splicing Cables cut from the drums and distributed for various route lengths shall be carefully planned bearing in mind that splices shall not be allowed except on specified approval for larger lengths (cable splices are not permitted normally). All cables shall be cut to required lengths only after assessment of correct lengths required, by actual measurement at site. Contractor shall take extra care while cutting and terminating the cables to ensure that wastage of cables as short lengths is � crutiniz, by resorting to most economical cable cutting schedule as approved (so as to keep the cutting wastage of cable to minimum possible extent). The cables shall be arranged on trays/racks/arms etc., as per approved cable layout and cable rack layout drawings.



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Cabling on trays / racks Most of the cabling may have to be carried on ladder type cabletrays having a rung spacing of 250mm except: When installed in rigid steel conduits, In case of individual equipment feeder on drops to device when properly supported on channels or run in trays, When installed in duct banks or embedded conduits or buried underground. Cable tray/rack system to be provided for cabling installation has been explained elsewhere in this specification. A clearance equal to one diameter of the bigger cable shall be maintained between two adjacent higher rated power cables on the trays/racks/risers and clamped by separate clamps, which shall follow the profile of the cable. Common clamping/strapping shall be done for a bunch of control cables and small power cables. Cables shall be clamped at every 3.0 meters on the horizontal trays/racks and at 750/1000mm at bends, take off points and on vertical trays/racks.

Cable leading to cable box of an equipment shall be supported at a distance of 0.450 meters from cable gland/cable box and cable gland shall be suitably earthed. Cable shall be clamped only after the cables are neatly arranged, dressed, tailored and kept in position. Type of cable clamps/straps, fixing bolts/nuts/washers and materials of cable clamps shall be as specified elsewhere in the specification. Cable drops to equipment shall be as per standards.



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Cabling in conduits/pipes Cables through floor slabs/walls are to be passed through rigid, steel conduit sleeves in accordance with the standards. Wherever sleeves have not been cast in slabs the latter is to be core drilled for a suitable sleeve. Except where otherwise shown on the drawings, sleeves to extend 150mm above and 100mm below slab to provide mechanical protection for cables. Cables entering or leaving the conduits shall be sealed with non-hardening silicon compounds. It is also contractor’s responsibility to satisfy himself regarding the conditions of the embedded conduits. Prior to pulling cables each duct shall be rodded by suitable means. After rodding an 8 gauge pulling wire is to be left in each duct. Embedded conduits will be identified in Accordance with the drawing. The ends of the conduits shall be plugged when work is halted for any period of time.

Cable laying direct in ground For cable laying direct in ground if any specified, suitable trenches shall be excavated in the ground to the required sizes and at locations shown in approved drawings. Cable shall be laid directly in the excavated trench on the sand bed. This sand shall be � crutin and cables laid over it. The cable shall be covered with sand. After laying of cables as per layout drawings, the excavated trenches shall be back filled with layers of sand, well burnt bricks and riddled soil respectively as per standards. On top of bricks the earth shall be back filled, rammed and leveled. Suitable separation shall be provided if more than one run of cable is taken in the same trench and between cables of different voltage grades. There shall not be any crossover of cables when laid in the ground. Necessary cable marker plates as per Indian Standards made out of cast iron shall be fixed at every 30 meters interval and at all bends along the route of buried cable trench on central line of the trench. Voltage rating of the cables shall be engraved on the marker plates. The cost of marker plates shall be included in the cost of cable laying/trench work.



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Cable entry at buildings Pressure seals and fire barriers shall be provided at the places where cables enter � crutinize� electrical rooms as per standards. Cable transits and tray installation at buildings entry shall be in accordance with approved drawings. All wall openings shall be effectively sealed after installation of cables to avoid water leakage. Wherever buried cables enters the building the same shall be taken through medium duty GI pipes embedded at the entry portion. After taking cables through the above pipes, the same shall be sealed by using suitable compound so as to avoid ingress of water.

Cable jointing During the preliminary stage of laying the cable, consideration should be given to proper location of the joint position so that when the cable is actually laid, the joints if any, are made in the most suitable places. Joints shall not be made at passageways and at road crossings. On cable trays/racks or in any other route where there are two or more cables laid together, the joints if any, shall be arranged to be staggered by two or more meters so as to reduce the possibility of one joint failure effecting the other. Before jointing is commenced, the insulation resistance of both sections of the cable to be jointed shall be checked by using suitable megger. In jointing of armoured PVC cables, hot pouring compound shall not be used. Only cold sealing compound shall be used.

Individual conductors in cables shall always be jointed number to number or colour to colour of the insulation over the conductors. Suitable marking with identification to be provided wherever cable joint is buried in ground.



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All materials required for cable jointing such as jointing kit, compounds, insulation tape, cable lugs, glands, fittings etc., and other consumable materials shall be arranged by the contractor wherever necessary. Cable termination Cable shall enter switchgear panels from the bottom /top. Cables to individual cubicle shall be neatly laid out and may be supported on channel type trays. Conductors of control cables where applicable shall be carefully and neatly arranged in compact group. The entire group shall be placed and tied with nylon straps to the points of pass out for connection of individual conductors to terminal blocks. Spare conductors shall be terminated with sufficient length to permit future connection to the terminal block associated with the control cable. Conductors of control cable where applicable shall be carefully and neatly arranged in a compact group at point of termination. The entire group shall be laced and tied with nylon strips to the point of fan out for connection of individual conductors to terminal blocks. Spare conductors shall be terminated with sufficient length to permit future connection to the terminal block associated with the control cable.

Conduit and cable identification All conduits and PVC cable runs shall be identified at all terminations, including junction boxes, exposed points etc., in accordance with approved conduit and cable schedules. Each conductor termination shall have an identification number in accordance with standards. Where cables are laid in trays identification tags shall be provided at least once in every 30 meters.

8.10 Testing at site

The intention of specifying the procedure for installation, testing and commissioning and different tests to be conducted are to give guidelines to the contractor. The contractor shall not restrict himself in carrying out only the tests specified, but all tests as per relevant



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Indian Standards shall satisfactorily be conducted on each equipment. In case owner / consultant desire to conduct tests specifically not mentioned in this specification, to ascertain the quality of work done/performance of equipment installed, the same shall be conducted by the contractor at no extra cost. In case if some of the tests are to be repeated, at the request of owner/consultant, the same shall be carried out by the contractor at no extra cost.

The contractor shall provide consultant/owner with complete test certificates on format approved by the consultant/owner. The certificates shall be signed by both the contractor and the consultant/owner and the tests shall be completed under supervision of the consultant/owner.

The contractor shall check and test all electrical equipment and systems installed and supplied by him including equipment supplied by others if any in conformity with the test procedures outlined by the manufacturers.

The contractor shall ensure that no tests are applied which may stress equipment above the limits for field-testing recommended by the manufacturer. The contractor shall be responsible for any damage to personnel or equipment resulting from improper test procedure.

All defective materials supplied by the contractor and defects due to poor workmanship revealed through field-testing, shall be corrected at the contractor’s expense without affecting the milestone agreed upon.

The contractor shall bring his own testing equipment for testing and commissioning of equipment / items. List of such testing equipment shall be furnished along with the Quotation.

The following minimum tests shall be carried out at site.

8.10.1 LT Switch board/MCC

The boards shall be subjected to standard tests and to the routine tests as per applicable standards.



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Tests at site shall include the following:

For Switchboard/MCC/PDB

a) Physical inspection and check the components for rating as per approved drawing and bill of material.

b) Tightness check for Power and control of busbars and individual feeders,

c) Checking for correctness of control wiring.

d) Check of control circuits for individual feeders.

e) Insulation resistance test for power, auxiliary and control circuits.

f) One minute PF withstand voltage between phases, phase to earth and between open poles as well as for the auxiliary/control circuit.

g) Milli volt drop across incoming and outgoing jumper connections with breaker closed and in service position.

h) Checking for electrical operation for Phase sequence

i) Operational tests

j) Test to prove the operating range of control components viz. Relays, contactors, spring charging motor, trip and close coils, alarms and indicating lamps etc.

k) Tests to prove inter changeability of breakers with same current rating

l) Tests to prove correct wiring/operation of Isolating contacts, plug and sockets etc.

m) Calibration of meters (if supplier is to commission the equipment, this can be done at site)

n) Heat run test on the switchboard, at extra cost if required by the customer.



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For circuit breaker

Breaker shall be subjected to standard tests and to the routine tests specified in standards. However, the routine test shall include as minimum.

Insulation resistance test

Power frequency high voltage test for 1 minute for all CB.

Tests to prove correct operation of closing and tripping coils at 80% and 50% rated control voltage respectively.

Operational and functional tests.

Tests to prove interchangeability of similar parts.

Instrument transformers (CTs and PTs)

Current transformers and potential transformers shall be subjected to the standard tests and to routine tests specified in standards. The routine tests shall include as minimum the following :

Current transformers

Insulation resistance test.

Power frequency withstand test for 1 minute.

Ratio test.

Measurement of terminal marking and polarity.

Measurement of knee point voltage and secondary winding resistance.

Potential transformers

Insulation resistance test.

Power frequency HV test for 1 minute.

Verification of terminal markings and polarity.

Ratio test.

The vendor shall furnish test and calibration certificates for all major bought out items viz relays, meters, instrument transformers etc.



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8.11 Cables

All the tests as per relevant standards and as per manufacturer’s standard practices shall be carried out on all the type of cables. The following minimum tests shall be carried out on all the types of cables:

High voltage test Insulation resistance test by megger continuity test

8.11.1 Motors

Measurement of winding resistance. High voltage test. IR test before and after H.V test. No load run till attainment of steady final temperature. Load run

8.11.2 Safety items / equipments

Rubber mat

Front and rear of all switch boards/SF6/ VCB/ panels where daily routine operation are done shall be provided with 12 mm /6 mm thick rubber mat of 11 kV grade/1 kV grade as applicable.

CO2 Fire Extinguisher

Each substation & switch room shall be provided with minimum 2 numbers of CO2 fire extinguishers.

Fire Sand Buckets

Each substation will additionally be provided with 4 Nos. Fire river sand filled buckets with stand.

Shock Treatment Chart

Each substation & switch room shall be provided with minimum two numbers of nicely framed shock treatment charts at easily viewable and readable place.



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Caution Boards & Danger Plates

The substation panels, and switch board panels shall be provided with caution boards & danger plate to avoid � crutinize� � entries.

Single Line Diagram

All the substation shall be provided with nicely framed as built Single Line Diagram indicating system voltage, current rating, fault level, feeder no and capacity, fuse rating, connected equipment tag no etc.,

Qestionnaire

Questionnaire for LT Switchboards/MCC

(To be filled up and submitted by bidder along with offer)

SWITCHBOARD

Manufacture’s name :Type Designation :Rated operational voltage :Rated insulation voltage :Rated short time withstand current :Rated current :Enclosure type :Degree of protection for enclosure :Compartementalised to Form 4 requirement

: Yes / No

Design Ambient temperature :Incoming Entry : Cable/Duct, Top/BottomOutgoing cable entries : Top/BottomDimensions (L x B x H) :Approx. weight :Point shade :Operating clearancesRear :Front :Sides :Paint Shade as per IS 5 :



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BUSBARS

Material for main busbar :Cross – section of main busbar :Continuous current rating at design ambient temperature of main busbarTemperature rise of main busbar over design ambient at(i) rated current :(ii) rated short circuit current :

Busbars provided with colour coded PVC sleeves

: Yes/No

Rated insulation voltage for PVC sleeves

:

Material of main busbar supports :Auxiliary busbars provided material and c/s of aux. Busbars

:

CIRCUIT BREAKERS

Make :Type :No. of poles :Rated operational voltage :Rated insulation voltage :Rated current (free air) :In panel rated current :Rated short circuit making capacity

:


:

Rated service short circuit breaking capacity

:

Rated short time withstand current :Utilisation category :Pollution degree :Type of over current trip device offered

: Thermo-magnetic /solid state/ micro processor based



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Rated current of over current trip device

:

Features of o/c trip deviceFunction blocking selection : Yes/NoIndividual fault visual indication : Yes/NoIndividual signaling contact for each fault type

: Yes/No

Self test facility with breaker in isolated position

: Yes/No

Visual indication for self check : Yes/NoSite selectable inverse/definite time characteristic for E/F and S/C

: Yes/No

Whether U/V release provided or U/V relay provided

:

If U/V release provided, then Voltage setting range :Time setting range :If U/V relay provided, thenRelay type :Aux. Supply :Contact configuration :Operating mechanismType for I/c & B/C feeders : Manual/MotorisedType for O/G feeders : Manual/MotorisedTrip free design : Yes/NoStored energy type : Yes/NoElectrical and mechanical anti-pumping feature provided

: Yes/No

Auxiliary supplyVoltage & permissible range for spring charging motor

:

Voltage & permissible range for closing coil

:

Voltage & permissible range for shunt trip coil

:

Mechanical indicator provided forSpring charged / discharged :Breaker status (On/OFF/TRIP)Position (Service/isolated)



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MCCB

Make :Type :No. of poles :Rated operating voltage :Rated insulation voltage :Rated impulse withstand voltage :Utilisation category :Rated service breaking capacity :Rated ultimate breaking capacity :Rated short time withstand current :Rated un interrupted current :

Protective device type : Thermo-magnetic/staticAuxiliaries providedDoor interlock : Yes/NoFault signalling contact : Yes (1 C.O./1 NO + 1

NC) / NoShunt trip : Yes / NoU/V release : Yes / NoVisual indication for status (ON/OFF/TRIP)

: Yes / No

STARTERSContactors

Type :No. of poles :Rated operational voltage :Rated Insulation voltage :Utilisation category :Coil pickup voltage :Coil drop off voltage :Auxiliary contact arrangement :

Thermal Overload Relay

Type :No. of poles :Trip class :



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Ambient temperature compensated for 600 C

:

Reset arrangement : Hand / AutoProtective cover provided : Yes / NoAuxiliary contact arrangement :Coordination with short circuit protective device – type 2 provided Heating : Direct / Indirect

INDICATING METERS

Make :Type :Accuracy class :Size : For I/C & B/C : For other feeders :Enclosure protection class :Environment category :Burden :

8.13.2 Questionaire for HT MotorAPPENDIX A1 (HT Motor Technical Data Sheet)(To be submitted by vendor after award of contract)

A) GENERAL PARTICULARS1. Project description :2. Application :3. Connected equipment tag no :4. Manufacturer’s Name :5. Manufacturer’s Model /Catalogue

no:

B) PRODUCT PARTICULARS1. Applicable standards :2. Frame size :3. Duty designation :4. No. of poles :5. Installation : Outdoor / Indoor6. Mounting class : IM -7. Class of Cooling : IC -



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8. Enclosure class of protection : IP -9. Hazardous area classification :10. Enclosure type :

C) GUARANTEED PARTICULARS

:

1.0. Supply of conditions :1.1 Rated voltage/No. Of phases :1.2 Rated frequency :1.3 Allowable variations in

a) Voltage :b) Frequency :c) Combined :

1.4 Allowable supply voltage unbalance

:

2.1 Motor KW at _ 0 C ambient :2.2 Motor KW at 400 C :3.1 Rated speed :3.2 Rated slip :4.1 Class of insulation :4.2 Temperature rise at _ 0 C ambient :5.1 No load current :5.2 Rated current :5.3 Locked rotor current/rated current :6.0 Rated efficiency :7.0 Rated p.f :8.1 Rated torque :8.2 Starting torque/rated torque :8.3 Pull out torque/rated torque :9.0 Minimum voltage required to start

and accelerate under rated load:

10.0 Safe stall time at rated voltage :i) Cold condition :ii) Hot condition :

10.1 Rotor temperature considered :11.0 Starting requirements :11.1 Equally spread/hour :11.2 Cold successive :11.3 Hot successive :12.0 Noise level at 1 m :13.0 Vibration severity :



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14.0 Residual unbalance :15.0 Max. value of shaft induced

voltage:

16.0 Total guaranteed losses :16.1 Iron loss :16.2 Copper loss :16.3 Friction, wind age and stray losses :

D) OTHER PARTICULARS1.0 Direction of rotation :2.0 Stator thermal time constant :3.0 Motor GD2 :4.0 Accelerating time at rated load4.1 Rated voltage :4.2 110% rated voltage :4.3 Minimum voltage :5.1 Slip at 90% rated voltage :6.0 Safe stall time :6.1 At 110% rated voltage :

i) Hot :ii) Cold :

6.2 At minimum voltagei) Hot :ii) Cold :

7.0 Insulation7.1 Tropical and fungicide treatment : Yes/No7.2 Method of insulation :8.0 Epoxy based painting : Yes/No9.0 External paint shade :10.0 Motor weight :11.0 Reactance/phase :11.1 Steady state :11.2 Transient :12.0 Resistance / phase :13.0 Normal winding connection :14.0 Stator terminal box :14.1 Type :14.2 Fault level at rated voltage :14.3 Fault duration :14.4 Location (viewed from DE side) : RHS/LHS14.5 Tinned copper lugs and brass :



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double compression gland provided

14.6 Cable type and size :15.0 Neutral terminal box :15.1 Type :15.2 Inter chargeable with stator TB : Yes/No16.0 Space heater TB :16.1 No. of space heaters :16.2 Rating of each element :16.3 Total space heater KW :16.4 Tinned copper lugs and brass

double compression gland provided

:

16.5 Cable type and size :

17.0 RTD/BTD T.B17.1 RTDs for windings :

i) Type : Simplex/Duplexii) leads : 2 wire / 3 wireIii) No. per phase winding :

17.2 RTDs for bearingsi) Type : Simplex/Duplexii) Leads : 2 wire/ 3 wireIii) No per bearing :

18.0 Bearings18.1 Type on DE side :18.2 Type on NDE side :18.3 Expected bearing life (L10) :18.4 Design Ambient Temperature for

bearings:

18.5 Allowed temperature rise :18.6 If water cooled bearings, then

cooling water required :

18.7 Bearing insulation provided : Yes/No19.0 Bearing lubrication system : Grease/Oil19.1 If Grease lubricated

i) Regreasing nipple and excess drain plug provided

: Yes/No

ii) Recommended grease :Iii) Lubrication interval :iv) Grease quantity :

19.2 If oil lubricated



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i) Type : Self/Forcedii) Residual oil drain plug and oil level sight provided

: Yes/No

Iii) Oil type and specification :

19.3 If forced oil lubricatedi) Compatible with lubrication system of driven equipment.

:

ii) Flow rate :Iii) Pressure :iv) Lube oil sump capacity :v) Lube pump motor rating :vi) Lube system control panel : Included/Not includedVii) Heat exchanger type & MOC :Viii) Filter type :

20.0 Double earthing provision with electrogalavanised fasteners

: Yes/No

21.0 Lifting and jacking lugs provided : Yes/No22.0 Vibration pads22.1 No. of pads :22.2 Location :

8.13.4 APPENDIX A2 : HT Motor Technical Data Sheet(To be submitted along with offer)

1. Name of manufacturer :2. Supply conditions :2.1 Rated voltage No. of phases :2.2. Rated frequency :2.3 Allowable variations :

i) Voltage :. ii) Frequency :

iii) Combined :3.0 Applicable ambient temperature :4.1 Design Ambient Temperature :4.2 Motor KW at 4.1 :4.3 Motor KW at 400 :5.0 Frame size :6.0 No. of poles :7.0 Enclosure class of protection :8.0 Enclosure type :9.0 Installation : Out door/indoor



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10.0 Hazardous area classification :11.0 Mounting class : IM-12.0 Cooling class : IC-13.0 Class of insulation :14.0 Temperature rise at _ 0 C ambient :15.0 Insulation treatment method :16.1 No load current :16.2 Rated current16.3 Locked rotor current/rated current :17.0 Rated efficiency :18.0 Rated slip :19.1 Rated torque :19.2 Starting torque/rated torque :19.3 Pull out torque/rated torque :20.1 No. of equally spread starts/hour :20.2 No. of successive cold starts :20.3 No. of successive hot starts :21.1 Stator T.B. Type :21.2 Neutral T.B. Type :21.3 Stator and neutral T.B. Inter

chargeable:

21.4 Fault level for stator T.B :22.1 Winding RTD type : Pt – 100, Simplex/Duplex, 2/3

wire22.2 No. of winding RTDs :22.3 Bearing RTD type : Pt-100, Simplex/Duplex, 2/3

wire22.4 Combined T.B. For ETDs/BTDs : Yes/No23.1 Anticondensation heater provided : Yes/No23.2 Separate space heater TB provided : Yes/No24.0 Cable glands and lugs provided : Yes/No25.0 Cable size and type

8.13.5 Questionaire: Data to be furnished by Tenderer for Low Voltage Three Phase Squirrel Cage Induction Motors

Motor and feeder list shall be provided along with details like Motor Kw rating, motor rpm, Digital Input, Digital Output, Analog input and Analog output as required.



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Questionnaire to be submitted after award of order (Appendix A1)

A) GENERAL PARTICULARS

1. Project description :2. Application :3. Connected equipment tag no :4. Manufacturer’s Name :5. Manufacturer’s Model no :

B) PRODUCT PARTICULARS1. Applicable standards :2. Frame size :3. Duty designation :4. No. of poles :5. Installation : Outdoor / Indoor6. Mounting class : IM -7. Class of Cooling : IC -8. Enclosure class of protection : IP -9. Hazardous area suitability :

C) GUARANTEED PARTICULARS :1. Rated voltage no of phases :2. Allowable voltage variation :3. Rated frequency :4. Allowable frequency variation :5. Allowable supply voltage unbalance :6. i) Rated r.p.m

ii) Rated slip :7. Method of starting :8 i) Kw at 45 0 C ambient

ii) Kw at 40 0 C :9. Class of insulation :10. Temperature rise at 45 0 C ambient :11. Currents :

i) Rated current :ii) Locked rotor / rated current :iii) No load current at rated voltage :

12. Rated Efficiency :13. Rated power factor :14. Torque :

i) Rated torque :ii) Starting / rated torque :



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iii) Pull out / rated torque :15. Minimum voltage required to start

and accelerate under rated load:

16. Starting requirements :i) Equally spread / hourii) Cold successiveiii) Hot successiveiv) Minimum over load capacity for

main drive motors17. Locked rotor current withstand time

at rated voltage:

i) Hot :ii) Cold :

18. Noise level at 1 m (d BA) :19. Vibration level :

D) OTHER PARTICULARS1. Winding connection :2. Direction of rotation :3. Accelerating time at rated load

i) At rated voltage :ii) At 110% rated voltage :iii) At minimum voltage :

4. Motor thermal time constant :5. Slip at :

i) 110% rated voltage :ii) 90% rated voltage :

6. Safe stall time :i) At 110% rated voltage

- Hot :- Cold :

ii) At minimum voltage- Hot :- Cold :

7. Motor inertia time constant :8. Motor main T.B :

i) No. of terminals : 3/6ii) Short circuit level :iii) Location when viewed from DE side : RHS/LHSiv) Cable type & size (As per

Component Selection Chart for MCC under MCC spec.)

:



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9. i) Space heaters provided : Yes / Noii) Space heater rating (kw) :iii) Space heater voltage :iv) No. of elements :v) Space heater TB provided separately

: Yes / No

10 i) Winding temperature sensing element: Thermistor / RTDii) Total no of elements :iii) If RTDs, specify type :iv) Separate TB provided : Yes / No

11 i) Bearing RTDs provided : Yes / Noii) If yes, specify type :iii) Total no of elements

- DE side :- NDE side :

12. Insulation :i)Tropical & fungicidal treatment : YES / NO

ii)Method : Powerhouse / Trickle impregnation / VPI

13. Bearings :i) Type on DE side :ii) Type on NDE side :iii) Grease lubrication : YES / NOiv) Regreasing nipples provided : YES / NOv) Recommended grease type :vi) Greasing interval :vii) Grense Quantity :viii) Expected bearing life (L 10) :

14 External paint shade :15. Epoxy based painting : YES / NO16. Tinned copper lugs and

double compression brass cable glands for power cable, space heater cable, RTD / BTD cable

: YES / NO

17. Double earthing provision with electro galvanised screws / bolts plain and spring washers

: YES / NO

18. Approx. total weight :19. Rating of Terminal box20. One no. internal earthing terminal

provided in the terminal box: YES/NO



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8.13.6 Questionnaire to be submitted along with offer (Appendix A2)

MOTOR DETAILS1. Name of manufacturer :2. a) Rated voltage :

b) Voltage variation :3. a) Rated frequency :

b) Variation in frequency :4. No. of phases :5. a) Motor kw at 450 c ambient :

b) Motor kw at 40 0 c :6. Frame size :7. Rated speed :8. Enclosure class of protection : IP -9. Hazardous area suitability :10. Class of Insulation :11. Temperature rise above 450 C

ambient:

12. a) Locked rotor current / rated current:b) Starting torque / Rated torque :c) Pull out torque / rated torque :

13. a) No. of equally spread starts / hour :b) No. of successive starts from cold condition

:

c) No. of successive starts from hot condition

:

d) Minimum over load capacity for main drive motors

14. External paint shade :15. Epoxy based painting : YES / NO16. Terminal Box location (viewed from

DE side): R.H.S / LHS

b) Rating of Terminal box c) One no. internal earthing terminal provided in the terminal box

: YES/NO

17. Space heaters provided : YES / NO18. Temperature detectors provided

If YES, thenYES / NO

a) Type : PTC / Pt-100b) No.of detectors :

19. Cable sizes : (As per Component Selection Chart for MCC under MCC specn.)



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B. CONNECTED LOAD DETAILS1. Connected load type :2. Connected load tag no :3. Shaft absorbed kw :4. Coupling type :

8.13.7 Questionnaire for VFD

General

1. Is the equipment being a regular product or the latest model / type.

2. Whether type of equipment offered has been supplied and is in

continuous operation for the last five years. (List of such supplies made indicating year of supply, customers' name, and year of commissioning to be enclosed)

3. Whether the list of recommended spare parts with itemised prices

for 2 years of operation have been enclosed?

4. Whether clause wise acceptance/ deviations from Owner’s technical specifications have been enclosed?

8.13.8 Questionnaire for VFD unit

1. Drive No.2. Drive Rating3. VFD Make4. VFD cat. No./type No.5. VFD Rating6. Control principle7. Number & rating of devices

provided in parallel8. No. of power devices in parallel

- Line: :- output side :- Safety factor :- Operating temperature :- Ventilation arrangement :



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10 Following accessories providedi) Line side Ac reactor/isolation

trafo:

Yes/No

ii) RF Filter : Yes/Noiii) Load Side reactor : Yes/Noiv) Sinusoidal filter : Yes/No

11 Power Circuit Devices Providedi) Line side :ii) Output side :

12 EMC compliance : Yes/No13 Short time overload capacity

125 % _______ Hours/sec150 % _______ Hours/sec200 % _______ Hours/sec300 % _______ Hours/sec

14 Nominal voltage rating 415v, 50 Hza) Voltage range (AC output)b) Frequency range

15 Supply variations a) Votlage +10%, -15%

b) Frequency +5%16 Ambient Temeprature O C17 Operational features

i) Power loss ride through duration

____ sec.

ii) Auto restart No. of Attempts Yes/No

v) Parameter lock Yes/Novi) Load optimisation for light

load operationYes/No

vii) Adjustable switchingFrequency Yes/NoMax. switching freq. ______ Hz

viii)a) Max No. of digital I/p (std):b) Max No. of digital o/p

(std):c) Max No. of analog i/p (std)d) o/p & i/p programmablee) Max. No. of analog o/p

(std):



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ix) Voltage control accuracy - Static ………..- Dynamic (100% load step)

x) Frequency Control accuracy- Resolution …………- Stability (% of max. freq.)

…………Hz

xi) Fundamental p.f. …………xii) Total p.f. …………xiii) Harmonics (THD) …………%

- Current …………%- Voltage …………%

xiv) Noise level (1.5M) …………dB (A)xv) Efficiency …………%

18 Protective Featuresi) Self diagnostic Yes/Noii) O/C instantaneous trip

-% In (max)Yes/No

iii) S/C protection Yes/Noiv) Max. adjustable current

limit……….% in

v) E/F protection Yes/Novi) Heat sink over temperature Yes/Novii) d.c bus -

Over voltage Yes/NoUnder voltage Yes/No

19 PANELS 1. Line up configuration Yes/No2. Enclosure class of IP41 Yes/No3. Limiting dimension

(LxBxH)

4. Paint shade5. Floor cut out detailsi) VFD Unit6. Heat lossi) VFD Unit7. Tier formation Yes/No



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8. Power cable entryi) VFD with top i/c and o/g

cable entriesYes/No

9. Control cable entry top for all VFD

Yes/No

10. Control possibility from Local/Console / individual control station/ Engg. PC

Yes/No

11. Communication / external interfaces (list)

Yes/No

12. Control voltage 240V AC Yes/No13. Control bus provided Yes/No14. Incoming & Outgoing

feeders equipped with MCCB/ACB, line Contactor etc.,

Yes/No

15. Makes of all components as per preferred list

Yes/No

16. MCCB ratings In panel / free Air17. All breakers equipped with

static release direct acting type

Yes/No

18. Double compression brass cable glands considered for power & control cables along with lugs

Yes/No

19 All cubicles equipped with air filter fan starter for fan light

Yes/No

20 Cooling Air cooled/closed circuit water cooled

20 Recommendation regarding.

i) Type of cable for digital signals.

ii) Type of cable for analog signals.

21 Weight of VFD unit



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8.13.9 Questionnaire for Soft Starter

SOFT STARTER1 Soft Starter Make2 Soft Starter cat. No./type No.

3Soft Starter Rating of enclosed version at 500C ambient

Tenderer mark rating on SLD to be enclosed with offer

4. Control principle

5.Converter devices, no. of pulses, Controlled / uncontrolled

6. EMC compliance :7. Short time overload capacity

125 % _______ Hours/sec150 % _______ Hours/sec200 % _______ Hours/sec300 % _______ Hours/sec

8. Supply variationsa) Voltage +10%, -15%b) Frequency +5%

9. Ambient Temperature 50 0 C10 a) Operational features

i) Torque boost requiredii) Load optimization for light

load operationb) i) Protection features for the

soft starter (Built in)ii) Protection features for the

motor built in the soft starter

iii) Other external protection provided

12 PANELS: -1. Line up configuration2. Enclosure class of IP543. Limiting dimension

(LxBxH)4. Paint shade5. Floor cut out detailsi) Soft Starter Unit



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6. Heat lossi) Soft Starter Unit7. Tier formation8. Power cable entryi) Soft starter with i/c and o/g

cable entries9. Control cable entry 10. Control possibility from

Local/Console / individual control station/ Engg. PC

11. Communication / external interfaces (list)

12. Control voltage 110V AC13. Control bus provided14. Incoming feeders equipped

with MCCB 15. Outgoing feeders equipped

with MCCB, line Contactor etc.,

16. Makes of all components as per preferred list

17. MCCB ratings In panel / free Air18. All breakers equipped with

micro processor release direct acting type

19 Double compression brass cable glands considered for power & control cables along with tinned copper lugs

20 All cubicles equipped with air filter fan, starter for fan/ light

21 Cooling Air cooled/closed circuit water cooled

20Recommendation regarding.

i) Type of cable for digital signals.

ii) Type of cable for analog signals.



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21 Weight of Soft Starter module

22Weight of self standing panel with soft starter panel

8.13.10 Questionnaire for PDB

The data called for below are to be furnished by the tenderer and in case the tenderer becomes the supplier, the data shall form part of the contract covering the work.

POWER DISTRIBUITON BOARDS

i) Generala) Conforming to IS/IECb) Makec) Typed) type of service Indoor/Outdoore) Rated voltage and frequencyf) Rated currentg) System earthingh) Ambient temperaturei) 3 Phase symmetrical fault level-KA (RMS)

ii) Enclosurea) Mounting type YES/NOb) Compartmentalised YES/NOc) Provision of hinged door for

Individual compartmentsYES/NO

d) Enclosure IP-54 YES/NOe) Sheet steel grade CRCA and 2 mm

thicknessYES/NO

f) Bottom cable entry YES/NOg) Neoprene gasket YES/NOh) Provision of cable alley and busbar

YES/NO

i) Provision of intercompartmentAnd interpanel partition

YES/NO

j) Provision of undrilled removalble gland plate, double compression cable glands and lugs.

YES/NO

k) Painting as per technical specification YES/NO



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l) Overall dimensions and weight of individual cubicles.

m) Shipping sectionsn) Total number of cubicleso) Clearances required

- at front- at back

iii) MCCBMakeTypeNo. of polesRated operating voltageRated insulation voltageRated impulse withstand voltageUtilisation categoryRated service breaking capacityRated ultimate breaking capacityRated short time withstand currentRated un interrupted current

Protective device typeThermo-magnetic/ static

Auxiliaries providedDoor interlock Yes/NoFault signalling contact Yes

(1 C.O./1 NO + 1 NC) / No

Shunt trip Yes / NoU/V release Yes / NoVisual indication for status (ON/OFF/TRIP)

Yes / No

iv) Bus barsa) Ratingb) Material c) Grade-high conductivity

Electrical grade copperYES/NO

d) No. & Cross section- Main bus bars- Vertical droppers- Earth bus



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e) Insulation-support insulation and material of sleeving

f) Thermal ratingg) Temperature rise over the specified

ambient temperatureh) Dynamic withstand capacityi) Short time rating for 1 sec.j) Colour codingk) Clearances 1) Phase to Phase 2) Phase to earth l) Provision and material of interphase barriers.m) Provision of continuous earth bus YES/NOn) Provision of removable neutral earth link

YES/NO

v) Indicating instrumentsa) Voltmeter

1) Reference Standard2) Make3) Type4) Accuracy class5) Size6) Type of mounting7) Provision of selector switch (for phase and line voltage measurements)

b) Ammeter1) Reference standard2) Make3) Type4) Accuracy class 5) Size6) Type of mounting7) Provision of suppressed scale8) Provision of selector switch YES/NO

c) Indicating Lamps1) Make2) Type3) Wattage4) Voltage5) Material of lens6) Colour



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vi) Current transformers1) Reference standard2) Make3) Type 4) Accuracy class5) Burden6) Secondary current

vii) Wiring and terminationsa) Power wiring :1) Grade, type & size of conductor (feeder rating wise)2) Material and size of strip (feeder rating wise)b) Control / Auxiliary wiring1) Grade, type and size of conductorc) Make & type of terminals :- Power- Control d) Make & type of cable gladse) Make & type of cable lugs

viii) Drawings / documents :a) Furnished drawings/details as per technical specification

YES/NO

b) Furnished schedule of items YES/NOc) Furnished catalogues and Test Certificate for various components used

YES/NO

8.13.11 Questionnaire for welding plug & sockets

The data called for below is to be furnished by the tenderer and in case the tenderer becomes the supplier, the data shall form part of the contract covering the work.

i) Conforming to ISii) Makeiii) Typeiv) Ratingv) Enclosure materialvi) Enclosure IP-54 YES/NOvii) Provision of integral interlocked switch YES/NOviii) Switch-AC 23 rated / heavy duty YES/NO



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ix) Provision of sliding earthing contact with first to make and last to break

YES/NO

x) Shade of final finishxi) Provision of HRC fuse YES/NO

8.13.12 Preferred list of makes

Micro processor based meters Enercon/Swift/Neptune/ABB/ SiemensIndicating meters AE/IMP/MECO/RishabhCTs/PTs Pragati/Kappa/Precise/AEControl/Selector switches Kaycee / SalzerLT motor KEC/Siemens/Bharat

Bijilee/Alstom/ABB/CGLHT motor BHEL/Imported (ABB/Siemens/Alstom)LT MCCs & PDB Schneider/L & T / SiemensVFDs / Soft Starters ABB/ L&T/ SiemensACBs Schneider/Siemens/L & TMCCBs Merlin Gerin/L & T/Siemens/ABBMPCBs Siemens / Telemechanique / Sprecher and

SchuhContactors, O / L relays with SPP

Telemecanique/L & T / Siemens

SFU, Load break switches, Fuses,

SIEMENS / L & T / GEPC / Schnieder/ ABB

Control voltage Transformer Southern Electric / KAPPA / Automatic Electric / Kalpa / Pragathi Electrics.

MCB / ELCB MDS/Hager/Siemens

Motor protection relaysL & T (MM-30) / Schneider (SEPAM)/Multilin (239)

Cables NICCO/Polycab)/Fort Gloster/Universal/RPG (LT power & control)/Delton (control)

Push buttons Vaishno / Siemens / L & T / BCH / GEPC Indicating lamps (LED type) Siemens/Raas Controls/L&T

Industrial Plugs & SocketsBest & Crompton/Schneider Electrics/ Bharatia Industries

Local push button station BLEP/Flexpro/Flameproof Equipment/Pushtron

GI cable Trays ERCON/General composites/Densons

Note: Items for which preferred makes are not indicated shall be provided only after approval of the make by owner / consultant



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8.13.13 Schedule of Quantities (typical)

Sl. No.

Item Qty Unit Remarks

PART - B SHOP ELECTRICS:

A SECTION- A – MCC,PDB,LOCAL CONT.STN. SOCKETS:

A.1.0 Supply of breaker handling trucks for LT switchgear Nos.A.2.0 415V, 50Hz, TPN , 50kA (1sec ) indoor, type tested, compartmentalised

MCC/PDB having aluminium bus bars with ACB/MCCB incoming and MCCB/MPCB out goings as per single line diagram, termination of cable including supply of double compression brass cable gland, tinned crimping type copper lugs. Single front fully Non-drawout type MCC with top cable entry for I/C & O/G feeders

SetSingle front fully Non-drawout type PDB with top cable entry for I/C & O/G feeders

Set

A 2.1 Control Pulpits with heat resistant glass window. No.

A.3.0 The following Unit Rates shall be applicable for addition & deletion for MCC/PDB

A.3.1 a) Full height vertical incomer panel for MCC with bus bars interconnections etc to accommodate incomer drawout modules of different sizes with protective release, meters, CTs, Lamps etc.

i) 100A MCCB Nosii) 250A MCCB Nosiii) 400A MCCB Nosiv) 630A MCCB Nosv) 800A ACB Nosvi) 1000A ACB Nosvii) 1250A ACB Nosviii) 1600A ACB Nosb)Full height vertical outgoing panel for MCC with

bus bars interconnections etc to accommodate outgoing drawout modules of different sizes with protective release, meters, CTs, Lamps etc.

Nos



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c) MCC drawout O/G modules for motors of following KW rating with components including CTs & Transducers as required.

0.1 – 18.5KW Nos22 - 30 KW Nos37 – 75 KW Nos90 - 132 KW Nos150 - 200 KW Nosd) MCC drawout O/G modules for feeders with

protective release, meters, CTs, Lamps etc.i) 400 A MCCB Nosii) 250 A MCCB Nosiii) 100A MCCB Nos

A.3.2 a) Full height vertical incomer panel for PDB with bus bars interconnections etc. to accommodate modules of different sizes with protective release, meters, CTs, Lamps etc.

i) 630A MCCB Nosii) 400A MCCB Nosiii) 250A MCCB Nosb) Full height vertical outgoing panel for PDB with bus bars

interconnections etc to accommodate modules of different sizes with protective release, meters, CTs, Lamps etc.

c) Full height vertical outgoing non drawout module for PDB with bus bars interconnections etc to accommodate modules of different sizes with protective release, meters, CTs, Lamps etc.

i) 16A MCCB Nosii) 32A MCCB Nosiii) 63A MCCB Nosiv) 100A MCCB Nosiv) 250A MCCB Nosv) 400A MCCB Nos

A 3.3 Elecrics to suite operation with DCS / PLCa) CTs & Transducers with mounting arrangment,wiring & terminal block as

required in expansion MCCs for following KW rating of motors0.1 – 18.5KW Nos22 - 30 KW Nos37 – 75 KW Nos90 - 132 KW Nos150 - 200 KW NosHT motors Nos



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A.3.4

AuxilLary relay /contactor panel for interfacing DCS / PLC & MCC complete with control transformer & wiring to the terminal block etc.Floor mounted selfstanding type, IP-54 enclosure made of high quality CRCA sheet steei of at least 2mm thick

Nos

A.3.5 Power socketsa) 415V ,TPNE ,200 A Power socket Nosb) 415V ,TPNE ,100 A Power socket Nosc) 415V ,TPNE ,63 A welding receptacles Nosd) 415V ,TPNE ,32 A welding receptacles Nose) Industrial sockets

i) 240 V 3 pin, 1 phase, 15 A Nosii) 24 V AC ,2 pin Nos

f) 415V ,TPNE ,100 A Power socket ( flame proof) Nosg) 415V ,TPNE ,63 A welding receptacles ( flame

proof)Nos

h) 415V ,TPNE ,32 A welding receptacles ( flame proof)

Nos

i) Industrial sockets (flame proof)j) 240 V 3 pin, 1 phase, 15 A Nosk) 24 V AC 2 pin Nos

A.3.6 Local control stations i) Cast aluminium alloy IP 65 enclosure as per

specificationNos

ii) Flame proof control station with cast aluminium enclosure as per IS-2148/81 suitable for hazardous area with certification from CRMS/CCOU features as per specification

Nos

A.4.0 Variable Frequency Drive (VFD) A.4.1 The following VFDs of different rating ranges, as per

specifications shall be applicable for addition / deletion.a) With short time overload capacity of 150% for 1

min.i) 1.5 – 5.5KW Setii) 7.5 – 15KW Setiii) 18.5 – 22KW Setiv) 30 – 45KW Setv) 55 – 90KW Setvi) 110 – 160KW Set



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b) With short time overload capacity of 110% for 1 mini) 1.5 – 5.5KW Setii) 7.5 – 15KW Setiii) 18.5 – 22KW Setiv) 30 – 45KW Setv) 55 – 90KW Setvi) 110 – 160KW Set

c) With over load capacity of 100% continuous, 125% for 2 hours and 200% for 10 secondsi) 1.5 – 5.5KW Setii) 7.5 – 15KW Setiii) 18.5 – 22KW Setiv) 30 – 45KW Setv) 55 – 90KW Setvi) 110 – 160KW Set

A.5.0 Soft Starters A.5.1 The following soft starters of different rating ranges,

as per specifications shall be applicable for addition / deletion.a) With short time overload capacity of 150% for 1

min.i) 1.5 – 5.5KW Setii) 7.5 – 15KW Setiii) 18.5 – 22KW Setiv) 30 – 45KW Setv) 55 – 90KW Setvi) 110 – 160KW Set

b) With short time overload capacity of 110% for 1 mini) 1.5 – 5.5KW Setii) 7.5 – 15KW Setiii) 18.5 – 22KW Setiv) 30 – 45KW Setv) 55 – 90KW Setvi) 110 – 160KW Set

A.6.0 LT Motors (Ratings as per component selection chart for MCC in the specification for MCCs.)

Nos.



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A.6.1 Auxiliary motors Nos.A.6.2 Main motors Nos.A.7.0 HT Motors of different ratings as required. Nos.

B SECTION-B: LT POWER & CONTROL CABLES

B.1.0

1.1kV grade, heavy duty, stranded, grade H-4, class 2, aluminium conductor, PVC type A insulated, extruded PVC type ST-1 inner sheathed, single layer galvanised steel strip armoured, extruded PVC type ST-1 overall sheathed power cable as per specification and IS-1554, Part-I of following sizes.a) 3.5 x 240 Sq.mm AYFY Mtsb) 3.5 x 185 Sq.mm AYFY Mtsc) 3.5 x 120 Sq.mm AYFY Mtsd) 3.5 x 95 Sq.mm AYFY Mtse) 3.5 x 70 Sq.mm AYFY Mtsf) 3.5 x 50 Sq.mm AYFY Mtsg) 3.5 x 35 Sq.mm AYFY Mtsh) 4 x 25 Sq.mm AYFY Mtsi) 4 x 16 Sq.mm AYFY Mtsj) 4 x 10 Sq.mm AYFY Mtsk) 4 x 6 Sq.mm AYRY Mtsl) 4 x4 sq.mm YRY (Copper Cable) Mtsm) 4 x 2.5 sq.mm YRY (Copper Cable) Mts

B.2.0Supply, storage laying and termination of 1100 grade PVC insulated, PVC sheathed, multistrand flexible cord with copper conductor of following equivalent conductor area including copper lugs.a) 27x1.5 Sq.mm YRY Mtsb) 19x1.5 Sq.mm YRY Mtsc) 14x1.5 Sq.mm YRY Mtsd) 7 x 1.5 Sq.mm YRY Mtse) 5 x 1.5 Sq.mm YRY Mtsf) 4 x 1.5 Sq.mm YRY Mts

B.3.0

1.1kV grade, heavy duty, stranded, class 2 annealed copper conductor PVC type A insulated, extruded PVC type ST-1 inner sheathed, single layer galvanised steel wire / strip armoured, extruded PVC type ST-1 overall sheathed control cable as per specification and IS – 1554, Part-1 of following sizes : a) 27x1.5 Sq.mm YRY Mtsb) 19x1.5 Sq.mm YRY Mtsc) 14x1.5 Sq.mm YRY Mtsd) 7 x 1.5 Sq.mm YRY Mts



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e) 5 x 1.5 Sq.mm YRY Mtsf) 4 x 1.5 Sq.mm YRY Mtsg) 3x1.5 Sq.mm YRY Mtsh) 2x1.5 Sq.mm YRY Mts

B 3.1 Heat resistant cables : Similar sizes as above.B.4.0 CABLE TERMINATIONB.4.1 LT 1.1 KV Power Cable termination including supply of cable

lugs (tinned copper) etci) 3 ½ x 240 Sq.mm AYFY Nosii) 3 ½ x 185 Sq.mm AYFY Nosiii) 3 ½ x 120 Sq.mm AYFY Nosiv) 3 ½ x 95 Sq.mm AYFY Nosv) 3 ½ x 70 Sq.mm AYFY Nosvi) 3 ½ x 50 Sq.mm AYFY Nosvii) 3 ½ x 35 Sq.mm AYFY Nosviii) 4 x 25 Sq.mm AYFY Nosix) 4 x 16 Sq.mm AYFY Nosx) 4 x 10 Sq.mm AYFY Nosxii) 4 x 4 Sq.mm YRY Nosxiii) 4 x 2.5 Sq.mm YRY Nos

B.4.21.1kV control cable termination including supply of tinned copper cable lugs etci) 27x1.5 Sq.mm YRY Nosii) 19x1.5 Sq.mm YRY Nosiii) 14x1.5 Sq.mm YRY Nosiv) 7 x 1.5 Sq.mm YRY Nosv) 5 x 1.5 Sq.mm YRY Nosvi) 4 x 1.5 Sq.mm YRY Nosvii) 3x1.5 Sq.mm YRY Nosviii) 2x1.5 Sq.mm YRY Nos

B.5.0 Out door cable straight through jointing kits LT 1.1 kV Power Cablei) 3 1/2 x 240 Sq.mm AYFY Nosii) 3 1/2 x 185 Sq.mm AYFY Nosiii) 3 1/2 x 120 Sq.mm AYFY Nosiv) 3 1/2 x 95 Sq.mm AYFY Nosv) 3 1/2 x 70 Sq.mm AYFY NosNote : Cable jointing for LT smaller size cables not allowed



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C SECTION - C - ERECTION ACCESSORIES:C.1.0 GI pipe class ‘B’ as per IS – 1239 threaded at both ends with coupling at one

end without internal burrs suitable for cable laying,surface laying / concealed laying / road crossing,burried in the floor as Pipe inserts in the Foundation of following dia.*a) 100 mm dia Mtsb) 80 mm dia Mtsc) 65 mm dia Mtsd) 50 mm dia Mtse) 40 mm dia Mts*The scope of erection work also includes supply and installation of all erection accessories like tees, collars, bends, clamps saddles etc, which is required for installation and making necessary bends as per site requirement and ceiling both ends to avoid water entry. The scope work also includes digging the earth and back filling wherever pipes are buried in the ground / road crossing

C.2.0 NP-3 Hume pipesa) 300 mm dia Mtsb) 600 mm dia Mts

C.3.0 PVC pipe as per IS 4985 Class 3a) 100 mm dia Mtsb) 80 mm dia Mtsc) 65 mm dia Mtsd) 50 mm dia Mtse) 40 mm dia MtsThe scope of erection work also includes supply and installation of all erection accessories like tees, collars, bends, clamps saddles etc, which is required for installation as per site requirement and ceiling both ends.

C.4.0 Junction box/ Terminal boxes & Pull boxesC.4.1 Junction box/ Terminal boxes & Pull boxes IP-54 enclosure for indoor

application.Enclosure shall be of CRCA sheet of at least 2mm thicknessa) Junction box/ Terminal boxes & Pull boxes

i) TB-10(10 terminals) Nosii) TB-20(20 terminals) Nosiii) TB-35(35 terminals) Nosiv) TB-40(40 terminals) Nos

b) Pull boxesi) PB-1 (200x200x100) Nosii) PB-2 (400x400x350) Nosiii) PB-3 (600x600x350) Nos



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iv) PB-4 (800x800x350) Nosv) PB-5 (800x1200x350) Nos

C.4.2 Junction box/ Terminal boxes & pull boxes IP-55 with canopy for outdoor application.Enclosure shall be of CRCA sheet of at least 2mm thicknessc) Junction box/ Terminal boxes & Pull boxes

i) TB-10(10 terminals) Nosii) TB-20(20 terminals) Nosiii) TB-35(35 terminals) Nosiv) TB-40(40 terminals) Nos

d) Pull boxesi) PB-1 (200x200x100) Nosii) PB-2 (400x400x350) Nosiii) PB-3 (600x600x350) Nosiv) PB-4 (800x800x350) Nosv) PB-5 (800x1200x350) Nos

C.5.0 MS Flexible pipesi) 100 mm dia Mtsii) 80 mm dia Mtsiii) 65 mm dia Mtsiv) 50 mm dia Mtsv) 40 mm dia Mts

C.6.0 PVC Flexible pipesi) 100 mm dia Mtsii) 80 mm dia Mtsiii) 65 mm dia Mtsiv) 50 mm dia Mtsv) 40 mm dia Mts

C.7.0 EarthingEarth pit confirming to IS 3043 latest version installation connecting to earthing main, testing and commissioning of earthing station conforming to tender specification , inclusive of associated components, materials like electrode assembly with GI funnel wire mesh , charcoal, salt sand, CI or RCC lifting covers,earth pit markers and civil works involved in excavation, back filling and construction of brick chamber as per specification.a) 100 mm dia class-B GI pipe electrode 3.5 Mt long Nosb) CI plate 1200 x 1200 x 12 mm electrode Nosc) Copper plate 600 x 600 x 6 mm electrode Nosd) GI flat for earthing & lightning protection.

i) 75x10 mm GI flat Mtsii) 50 X 6 mm GI flat Mts



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iii) 25 X 3 mm GI flat Mtsiv) 16 sq. mm stranded GI wire Mtsv) 6 sq mm stranded GI wire Mts

C.8.0 Pre-fabricated, ladder type GI cable trays including accessories like coupler plates, L clamps, bolt and nuts etc (all stainless steel suitable for use in corrosive areas) for cable trays as indicated belowi) 600 mm ST wide tray Mtsii) 300 mm ST wide tray Mtsiii) 150 mm ST wide tray Mtsiv) 100 mm ST wide tray Mts

C.9.0 Fabricated supports using structural steel like angles, channel, I section etc for cable trays, on stockade /channel/coloumns/structural beam /RCC, including supports for control station and other works with two coats primer and final coat of epoxy painting,fabrication & Erection works as required.

Ton-nes

D SECTION – D- Safety Equipment:a) Danger boards conforming to IS 2551 - 415 V Danger boards Nosb) Safety charts conforming to IE rules Nosc) First aid box with all accessories Nosd) Rubber mats of 2000 x 1000 mm conforming to IS

1524 – 1969- for 415 V – 6 mm thick Nos

e) Hand gloves as per IS - 4770- for 415 V system Pairs

f) Stand with 4 Nos, galvanised round bottom fire buckets of 2 gallon capacity with sand filling

Nos

g) Teak wood key box Nosh) Carbon dioxide fire extinguisher

- 2 Kg capacity Nos- 4.5 Kg capacity Nos

i) Caution boards Nos

Notes :

1 Installation of LT cables includes pulling of cables through pipes, laying in buried trench/concrete cable channel, laying in overhead trays invertical/horizontal fashion, fixing on columns/walls, termination of cables at both ends, supply and fixing of nylon cable ties/ aluminium tags/ GI saddles / GI clamps.



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2 Installation of cable trays includes supply of fixing hardware and anchor /grip bolts.

3 Supply of cable trays includes supply of coupler plates and hardware etc.

4 Obtaining clearance from statutory bodies viz Karnataka state electrical inspectorate etc. is deemed to be included.

5 Commissioning spares as required shall be included .

8.14 Illumination system

8.14.1 Scope of work

The scope of work covers design, manufacture, inspection / testing, transportation to site, loading and unloading, storage at site, transportation to place of work. Erection, testing and commissioning of all the equipment and the necessary accessories, statutory approvals, whether covered separately in this specification or not, but required for electrics of lighting system for the DUCTILE IRON SPUN PIPE PLANT PROJECT of KIOCL. The scope also includes designing of the lighting system based on the level of illumination indicated and getting approval from owner/consultant.

The scope of illumination work starts from the outgoing terminal of feeder reserved for power supply to lighting system in the MCC/LT Switchboard and further distribution of power through necessary lighting distribution boards to light fittings, fans, socket outlets (5A & 15A 1Ph, 240V), power supply to A/C points etc.

The following are the items likely to be included but not limited to these :

a) Main lighting distribution boards, Outdoor Feeder Pillars, Lighting distribution boards and sub-distribution boards with 30% spares of each rating.

b) Flood light poles / street light poles including supply of all materials for making foundations and earthwork for buried pipes, cable trenches, earth pits etc.

c) Cables / wires for complete wiring of buildings and power supply to distribution boards.

d) Wires / strips for complete earthing interconnection including erection of earth pits.



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e) GI / PVC conduits, GI pipes and supporting structures, cable trenches, tag route markers etc.

f) Light fixtures including Bay fittings, Well glass fitting, Aviation lights, lamps, switches, sockets, ceiling fan, exhaust fan etc.

g) All accessories like branch/pull/junction boxes, cross arms brackets for supporting light fixtures, distribution board etc., saddle / clamps and other

Miscellaneous items required for the completeness and efficient working of the system whether explicitly specified or not in thisspecification.

The following additional information may be noted and taken care.

The building drawing supplied by owner/consultant during tender shall be used for planning the type, location and number of fittings for supply and erection of the lighting system of the building. Based on the drawings for buildings supplied by owner/consultant, the contractor shall prepare the lighting design drawings along with conduit layout and the wiring /cabling layout drawings and submitted for approval. The illumination level and type of fittings for each area indicated elsewhere in the specification shall be the basis for design of the illumination system. The design of all lighting distribution /sub distribution boards including the main lighting board shall be carried out by the contractor. Minimum 20%spare feeders of each rating shall be provided in each board. These drawings shall be got approved by owner/consultant. The installation work shall be carried out as per approved drawing and as per the directions of the site engineer / owner.

The following drawings shall be prepared by the successful tenderer and got approved by owner / consultant before procurement / site execution :

a) Lighting design calculation, area wise, to establish the number of fittings required to achieve the desired level of illumination.

b) The layout of DBs, lighting fixtures & controls, power socket outlets, concealed / surface wiring routing drawings, equipment list for each type of building drawings.



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c) SLD, GA drawings and component list for all the equipment like boards, fixtures etc.

d) As built drawings.

8.14.2 Design philosophy

The Illumination system shall cater to the following:

Normal cum Emergency Lighting.

Normal cum Emergency Lighting shall be provided through Light fixtures distributed throughout the plant.

Normal power shall be from Electricity Board power.

In case of failure of normal supply the D.G set shall be started automatically (AMF operation) and take over lighting load of the plant until the normal power Supply gets restored.

Road lighting and area lighting is envisaged using High mast or HPSV/HPMV flood light fittings mounted on swaged and welded steel tubular poles.

HPSV street light fittings are envisaged on the entry of all the civil buildings.

All the civil buildings shall be provided with fluorescent tube light fittings using colour designation – 86 fluorescent lamp (Similar to Philips truelite type) or decorative CFL light fittings controlled through decorative control switches. Adequate Number of Ceiling fans, 5A & 5/15A socket outlets with control switches shall be provided. All toilet blocks and Sub- station building shall be provided with exhaust fans. Surface/concealed wiring using PVC casing N capping / MS conduit / PVC conduit with multi strand PVC insulated copper wires shall be carried out in all the buildings in building area.

For industrial building Well glass / Bulk head / Bay fittings with HPMV/MH / HPSV / fluorescent lamps.



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Surface wiring using multi strand PVC insulated copper cable in GI conduit shall be provided in plant area with suitable junction boxes, cable glands etc.

In addition portable wall mounted emergency light fixtures with 18W CFL lamps with in built chargeable battery, which has minimum of 1 hr. backup, with charging facility from nearby single phase power supply source. Emergency light MCC Room, DG Room.

The tenderer / contractor shall consider Guide lines/data as per Table ‘A’ for design of the lighting system.

TABLE- A

Sl.No.

Area Illumination level (lux)

Maintenancefactor

Type of light fittings

1 Electrical room /LT substations, Amenities Block, Control Pulpit, Security Complex

250-300 0.7 Decorative Mirror Optics / Rail / Trough type fluorescent tube light fittings

2 Offices 300 0.7 Decorative type fluorescent tube light fittings or CFL fittings

3 Periphery of buildings

20 0.5 70W/150 W, HPSV Street Light Fittings

4 Gate Complex and any other open area within the battery Limits

AS PER RELEVANT NORMS

5 Industrial Building

100-150 0.5 Well Glass, Bulk Head,Bay Fittings (HPSV, MH)

NOTE :

Based on the area of different premises indicated in the above table, depending on illumination levels specified and taking into account various design factors, the tenderer shall estimate and indicate (with



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back up calculations building wise) quantity of various types of fittings/Switches/sockets/fans and other Accessories required as per Schedule of Quantity.

The coefficient of utilization for each area shall be arrived at based on the type of fitting and area to be illuminated.

The level of illumination indicated above shall be measured and shown after installation of Light fixtures.

8.14.3 Equipment specification

8.14.3.1 Main lighting distribution board

a) Design criteria

All equipment shall be designed for operation based on the following site conditions and system.

i) Site conditions

a) Installation Indoor

b)Design Ambient Temperature

45 Deg. C.Both not likely to occur

c) Relative humidity 100% simultaneously

d) Mounting Suitable for Floor Mounting

e) IP Classification IP-52 for indoor

ii) System data

a) Supply voltage 415 Volts. +/- 10%b) Rated frequency 50 Hz. +/- 5%

c) Combined voltage and frequency variation

+/- 10%

d) Phase and wires 3 Phase, 4 wire.e) System grounding Solidly earthed.

f) Expected fault level at the LT S/S Busbar

25 kA symmetrical Max.

g) A base channel of shall be provided.

Minimum 50mm height.



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h) Thickness of sheet steel The thickness shall be selected based on rigidity and design requirements. However the thickness shall not be less than1.6 mm.

iii) Feeder details

a) Main lighting distribution boards shall have 4P MCCB / TPN SFU as incomer and outgoing feeders as per requirement. There shall be two Nos. 4 pole MCCB on the incomer side to receive power from normal and emergency source. These feeders shall be electrically and mechanically interlocked such that only one breaker will be ON at a time.

b) MLDBs should have cable chambers and specially designed termination arrangements to accommodate multiple cables asrequired for both incoming and outgoings.

c) Number and rating/details of feeders are to be provided by the contractor as required

d) The board shall be provided with LED indicating lamps, Ammeter with necessary CT, Voltmeter and Energymeter.

iv) Busbars, Busbar supports, Connections

a) Main lighting distribution board shall have isolated/shrouded, metal enclosed chamber for main bus bars.

The busbar chamber shall have removable covers for easy maintenance.

b) Outgoing feeders shall be connected to the main busbar. Bus bars shall be easily accessible for maintenance. Bus bars for TP&N shall be arranged to run full height of the vertical section irrespective of whether the bottom most section is used or left as empty feeder.



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c) Bus bars (triple pole and neutral) shall be

i) of high conductivity, electrolytic grade Aluminum (E91E) conforming to IS 5082(1998) (R.a:2003) .

ii) Uniform in cross section through out the length of the bus and identified by colour code throughout. PVC Sleeves shall be provided.

iii) Selected giving the consideration to proximity effect.

iv) Suitable for current carrying capacity of 1 (one) Amp/mm² or less.

d) All the bus bars shall have dynamic stability for the peak current and thermal stability for the specified symmetrical short circuit current without any deformation, deterioration or damage. All necessary calculations to substantiate the selection of bus bars shall be submitted along with GA drawings for approval.

e) An earth bus of adequate cross section for terminating earth connections shall be provided running throughout the length of the main lighting distribution board at the bottom with provision to connect to earth grid at either end of the board. Size of earth bus shall however be not less than neutral bus size. Removable bus link shall be provided between neutral and earth bus bars. Provision will be made for connecting earth continuity conductor of all out going cables on the earth bus.

f) Bus bar support shall

i) Have high dielectric strength and high impact strength capable of withstanding dynamic stability currents.

ii) Be of non-hygroscopic type

iii) Be with anti-tracking barriers

iv) Be self extinguishing and fire retardant insulators with ribbed construction to prevent tracking due to dust accumulation and to have larger creepage distance.

v) Be designed to permit expansion and contraction of buses with variation in ambient temperature.



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g) Size of the neutral bus shall not be less than half of the size of main busbar for boards above 100A & shall be same as phase bus bars up to 100A boards.

h) The bus bars shall be rated to limit the temperature rise within 40°C over the specified ambient temperature.

i) Allowance shall be made for reduction in section by bolt holes.

j) The clearance between phase to phase and phase and earth in air shall not be less than 25 mm and 19 mm respectively.

k) Aluminium to aluminium joints shall be done by cleaning the surface and coating it with oxide inhibiting grease.

l) All bus bar joints shall be of bolted type. Relleville/spring washers shall be used for joints to prevent loosening.

m) In case more than two verticals are required based on the number of outgoings a bus bar chamber shall be provided at the top running throughout the length of the board for providing the main bus bars.

v) Miniature circuit breakers (MCB)

a) The MCB shall conform to IS 8828(1996) (R.a:2006) or International Standards.

b) The MCB’s shall have a breaking capacity of not less than 9 kA rms.

c) The MCB’s offered shall be ‘L’ series or ‘G’ series having an instantaneous tripping current of 5 or 7 times the rated current respectively.

vi) Moulded case circuit breaker (MCCB)

Moulded Case Circuit Breakers shall be electrically operated to feed power feeders. Magnetic release and over load protections, ON/OFF/Tripped on fault lamp indications, 3 CTs for ammeter and Ammeter 96x96, taut band circular scale with selector switch to read line currents with OFF position.



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1. Type : Feeder duty as required

2. Reference standard : IS:13947 (Part-3), 1993, IS:2516

3. Rated current : As per approved SLD

4. Feature required : Adjustable inverse time (O/L) and/or instantaneous magnetic releases as per approved SLD

5 Operating handle : Yes

6 Door interlock : Yes

Padlocking in ON/OFF

7 Position : Yes

8. Withstand capability : Symmetrical breaking capacity not less than the system short circuit level specified.

9. Auxiliary contacts : 1 NO + 1 NC

10. Performance : P2category

Over load, short circuit and E/F releases shall be independently continuously adjustable.

vii) Cable alley

a) Each vertical section shall have a cable alley along side with removable front cover.

b) Cable alley shall have adequate space for terminating aluminium power cables.

c) Barriers running complete height of the board shall effectively isolate the cable alley from horizontal and vertical bus bars.

d) Bottom cable chamber shall be left free completely for accommodating power cables and shall be completely isolated from vertical bus bars.

e) Removable, un-drilled gland plates shall be provided at top & bottom for each cable alley and incomer cubicle.



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f) There shall be no horizontal cross bracings within 250 mm of gland plates where the cables enter.

g) All power outgoing terminals shall be brought out to a separate terminal block/strip through solid links with bellows and located in the cable alley, if necessary.

viii) Switches

a) The switches shall have quick make, quick break, fault make, load break mechanism operated by an external insulated and earthed handle compile with ON/OFF position indicator / dial plates.

b) The switches shall be heavy duty conforming to IS 13947(Part3) (R.a:1998) and capable of interrupting three times the rated current at 0.3 p.f. at rated voltage for switches rates above 315 amps.

c) All switch contacts shall be silver plated.

d) In combination with series current limiting fuses, the switches shall be capable of making all currents up to the system short circuit level specified.

e) The load break switch shall be provided with a through door operating mechanism with visible blades or a visible means of determining the disconnected position when the door is opened and mechanically interlocked with the door so that switch must be in OFF – position before the door can be opened. Provision shall also be there to defeat the door interlock.

f) It shall be possible to padlock the load break switch handle in the OFF position. Integral padlocking discs shall be provided.

g) The load break switch shall be TPN.

h) Bolted type removable aluminium / copper links of adequate size shall be provided for neutral in all in-comer feeders and outgoing feeders with TPN switch fuse units.



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i) Solid links shall be used for connections between switches and fuses and such links shall be PVC Sleeved / Taped

ix) Fuses

a) All fuses shall be HRC link type (knife edge but not bolted type) conforming to IS:13703:Part I:1993(R.a:2004) . The HRC fuses shall be current limiting, non-deteriorating type having breaking capacity of not less than the rated short circuit capacity of the board.

b) Fuse holders shall be selected based on the highest fuse rating for the given load break switch and specified lower size fuses shall be fitted by means of suitable links if required.

c) All fuses shall be provided with distinct type operating indicators, to show whether they have operated or not.

d) Fuse holders and fuse bases shall be made of unbreakable, non-inflammable and non-hygroscopic material like phenolic mouldings.

e) 2 sets of fuse pullers required for inserting and removing HRC fuses shall be supplied for each MLB.

x) Cable glands, Cable sizes and Lugs

a) Required number of heavy duty double compression type brass cable glands of projected nipple type complete with two lock nuts and earthing waster (provided with earth studs) shall be supplied.

b) Edge of cable glands shall have threaded projecting to enable the lock-nut to fit from inside of the equipment.

c) Terminals, crimping type cable lugs, glands etc., shall be suitable for the cable sizes and numbers to be indicated by the Owner during the execution of order.



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xi) Painting for Panel boards

Board shall be treated before painting by seven tank process and two coats of corrosion resistance spray painting shall be given over two coats suitable primer. The colour of final finished paint will be indicated during the approval of drawing.

xii) Name plate, Danger board etc.

a) Anodised aluminium nameplate indicating designation of the board and details of feeders shall be fixed on the front door.

b) Standard danger board of suitable size shall be provided.

8.14.3.2 Lighting distribution and Sub distribution boards

A) Design criteria

The lighting distribution and sub distribution boards shall be sheet steel enclosed, wall / recess mounting type conforming to IP : 52 suitable for use on 415V, 50 Hz., 3 phase, 4 wire AC system. The board shall have TPN / DP isolator / switch fuse unit / MCB as incoming and TPN / SP MCB as outgoing feeders. These boards are meant for use in plant area buildings. These shall be factory built standardized boards or fabricated based on specification and approved drawing.

B) Constructional details

1. The lighting distribution and sub distribution boards shall be wall / recess mounted type made of minimum 1.6 mm thick sheet steel totally enclosed, dust and vermin proof construction having separate chambers for incoming and outgoing feeders.

2. The board shall conform to IP : 52 class of protection as per IS : 13947:Part I:1993(R.a:1998) .

3. The board shall be fabricated using high quality CRCA sheet steel.

4. Suitable neoprene gaskets shall be provided for all doors and covers for making the board dust proof.

5. The incomer chamber shall have TPN / DP, switch-fuse unit / MCCB / MCB along with suitable ELCB. Outgoing shall be 4/8 way / 12 way MCBs of 9kA having required current rating as detailed in SLD suitably mounted on DIN Rail / channel.



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6. The operating handle of the incoming switch fuse unit shall be accessible from the front side. The operating handle shall be suitably interlocked mechanically with the door of the incomer chamber so that the door can be opened or closed only when the switch is in ‘OFF’ position. A manual interlock defeat shall also be provided.

7. The outgoing MCB’s shall be housed in a separate chamber. The chamber shall have provision for mounting Timer and Contactor wherever necessary. The operating knobs of the MCB’s shall be accessible only after opening the front door. The outgoings chamber shall be covered completely with Hylum / FRP sheet, and only the operating knob of the MCB shall project outside. The 4mm thick Hylum / FRP sheet provided shall effectively shroud all the live parts against accidental contact. The door shall have pad locking facility.

8. Bus bars shall be of Tinned copper. Bus bars shall be shrouded and phase and neutral Bus bars shall have the same cross sections up to 100A rating.

9. The incoming compartment door shall have 3 Nos. (for 3 phase) 1 No. (for single phase) Neon indicating lamps (red colour).

10. In case of boards where MCBs fed from different phases are mounted side by side FRP / Hylum barriers / separators shall be placed between each MCB or required spacing shall be provided.

11. The board shall have knockout holes / un-drilled gland plates at top and bottom for cable entries.

12. All the incoming and outgoing feeders shall have specially designed termination arrangements to accommodate multiple cables or higher size cables required as per schedule of items / approved drawings.

13. MCB switch, fuse etc., shall confirm to the requirements as specified under lighting boards.

14. Safety clearances as per IE rules shall be provided for various components in the board.

15. Board shall have continuous earth bus of size same as that of neutral.

16. Link between neutral and earth shall be provided.



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17. For details of SFU's, MCB's refer to specification given elsewhere.

18. Necessary Mounting Bracket.

C) Miniature circuit breakers (MCB)

a) The MCB shall conform to IS 8828 or International Standards.



D) Moulded case circuit breaker (MCCB)

Moulded Case Circuit Breakers shall be electrically operated to feed power feeders. Magnetic release and over load protections, ON/OFF/Tripped on fault lamp indications, 3 CTs for ammeter and Ammeter 96x96, taut band circular scale with selector switch to read line currents with OFF position.


2. Reference standard : IS:13947 (Pt-3), 1993, IS:2516


4. Feature required : Adjustable inverse time (O/L)and/or instantaneous magneticreleases as per approved SLD


6 Door interlock : Yes

7 Padlocking in : YesON/OFF Position



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8. Withstand capability: Symmetrical breaking capacity not less than the system short circuit level specified.




E) Painting

Board shall be treated before painting by seven tank process and two coats of corrosion resistance epoxy spray painting shall be given over two coats suitable primer. The colour of final finished paint will be indicated during the approval of drawing

F) Testing

All the boards viz., L.T switch board, lighting meter and distribution boards shall be tested as per IS : 8623 at factory site. Testing shall be done for LT switch board and lighting meter board for visual, IR, HV and functional checks.

G) Drawings

The following drawings shall be submitted for approval.

a) GA drawing, SLD and Component list.

8.14.3.3 Feeder Pillar

A) Design criteria

All equipments shall be designed for operation with following system



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i) Site conditions

a) Installation Outdoor

b)Design Ambient Temperature

45 °C.Both not likely to occur

c) Relative humidity 100% Simultaneously

d) Mounting Suitable for outdoor

e) IP ClassificationIP-55 with canopy for rain water protection.

ii) System data

a. Supply voltage 415 volts + 10% or – 10%b. Rated frequency 50 Hz + 5% or – 5%c. Combined voltage

frequency variation10% or – 10%

d. Phase and wires 3 phase, 4 wiree. System grounding Solidly earthedf. Expected fault level

at the pillar15 kA symmetrical (max)

g. A base channel of 50 mm height shall be provided

h. Thickness of cold and rolled sheet steel

The thickness shall be selected based on rigidity design requirement. However the thickness shall not be less than 2.00 mm for frame work and 1.6 mm thick for door shutter with double door arrangement.

B) Construction

a) The feeder pillars shall be out door, pedestal mounted type made of sheet steel totally enclosed with protection class of IP –55 construction having separate chambers for incoming and outgoing feeders.

b) The board shall be fabricated using high quality 2 mm minimum thick CRCA sheet steel.

c) Suitable canopy for rain water protection shall be provided.



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d) Suitable neoprene gaskets shall be provided for all doors and covers for making FP dust proof.

e) The board shall have cable entry and exit from bottom removable undrilled gland plate of not less than 3mm thick shall be provided.

f) The incomer shall have separate chamber for having TPN SFU / MCCB and provision for terminating multicore cables of required numbers.

g) The outgoings shall be TPN SFU / FP MCCB/ELCB or MCB /TP MCCB or MCB with N-Link as indicated in the Single Line Diagram. The feeders with Timer / Contactor shall be housed in the same chamber having hinged door with pad locking facility.

h) Incomer and outgoing chamber shall be provided with 5-mm hylum or FRP separator/ metal partition.

i) Incomer switch handle shall be inter locked with incomer chamber door manual inter lock defeat facility.

j) Floor level. Minimum height shall not be less than 450 mm.

k) The front door of the feeder pillar shall not have any meter switch handle etc. all these shall be mounted on the inner door provided for incoming / outgoing feeders. All doors, inner and outdoor, shall be provided with gasket to make the feeder pillar dust proof.

l) All live part shall be shrouded.

m) FP shall have earth bus with extended earthing stud link between neutral and earth bus.

n) Suitable brick/concrete pedestal shall be provided for mounting FP

o) Two Nos. lifting hooks shall be provided on top FP canopy.

C) Busbars, Busbar supports, Connections

a) Feeder Pillar shall have isolated shrouded, metal enclosed chamber for main busbars. The busbar chamber shall have removable covers for easy maintenance.



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b) Outgoing feeders shall be connected to the main busbar. Bus bars shall be easily accessible for maintenance. Bus bars for TP&N shall be arranged to run full height of the vertical section irrespective of whether any section is not used or left as empty feeder.

c) Busbars (triple pole and neutral) shall be

i) of high conductivity, electrolytic copper/Aluminium grade E91E conforming to IS 1897 – 1983 (R.a:2006)

ii) Uniform in cross section through out the length of the bus and identified by colour coded PVC sleeves throughout the length.

iii) Selected giving due consideration to proximity effect.

iv) Current density of busbars shall be as per requirements of permissible maximum temperature at rated loading.

d) All the busbars shall have dynamic stability for the peak

current and thermal stability for the specified symmetrical short circuit current without any deformation, deterioration or damage. All necessary calculations to substantiate the selection of bus bars shall be submitted along with GA drawings for approval.

e) An earth bus of adequate cross section for terminating

connections shall be provided running throughout the length of the main lighting distribution board at the top / bottom with provision to connect to earth grid at either end of the board. Size of earth bus shall however be not less than neutral bus size. Removable bus link shall be provided between neutral and earth bus bars. Provision will be made for connecting earth continuity conductor of all out going cables on the earth bus.

f) Bus bar support shall

i) Have high dielectric strength and high impact strength capable of withstanding dynamic stability currents.

ii) Be of non-hygroscopic type

iii) Be with antitracking barriers



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iv) Be self extinguishing and fire retardant insulators with ribbed construction to prevent tracking due to dustaccumulation and to have

v) larger creepage distance.

vi) be designed to permit expansion and contraction of buses with variation in ambient temperature.

vii) Size of the neutral bus shall not be less than half of the size of main busbar.

viii) The busbars shall be rated to limit the temperature rise within 400C over the design ambient temperature of 450C.

ix) Allowance shall be made for reduction in section by bolt holes.

x) The clearance between phase busbars and between phase and earth in air shall not be less than 25 mm and 19 mm respectively.

xi) Aluminium to aluminium joints shall be done by cleaning the surface and coating it with oxide inhibiting grease.

xii) All busbar joints shall be of bolted type. Belleville/spring washers shall be used for joints to prevent loosening.

xiii) In case more than two verticals are required based on the number of outgoings a busbar chamber shall be provided at the top / bottom running throughout the length of the board for providing the main bus bars.

D) Cable alley

a) Each vertical section shall have a cable alley along side with removable front cover.

b) Cable alley shall have adequate space for terminating aluminium power cables.

c) Barriers running complete height of the board shall effectively isolate the cable alley from horizontal and vertical busbars.



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d) Bottom cable chamber shall be left free completely for accommodating power cables and shall be completely isolated from vertical busbars.

e) Removable, undrilled gland plates shall be provided for each cable alley and incomer cubicle.

f) There shall be no horizontal cross bracings within 250 mm of gland plates where the cables enter.

g) All power outgoing terminals shall be brought out to a separate terminal block/strip through solid links with bellows and located in the cable alley, if necessary.

E) Interchangeability

a) All identical equipment and corresponding parts, accessories shall be fully interchangeable without any modification.

b) Components and equipment that are not fully interchangeable are liable for rejection and the supplier shall replace all such items by fully interchangable ones free of cost.

F) Miniature circuit breakers (MCB)

a) The MCB shall conform to IS 8828(1996) (R.a:2006) or International Standards.



G) Moulded case circuit breaker (MCCB)

Moulded Case Circuit Breakers shall be electrically operated to feed power feeders. Magnetic release and over load protections, ON/OFF/Tripped on fault lamp indications, 3 CTs for ammeter



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and Ammeter 96x96, taut band circular scale with selectorswitch to read line currents with OFF position.


2. Reference standard : IS:13947 (Pt-3), 1993, IS:2516


4. Feature required : Adjustable inverse time (O/L) and/or instantaneous magnetic

releases as per approved SLD


6 Door interlock : YesPadlocking in ON/OFF

7 Position : Yes

8. Withstand capability : Symmetrical breaking capacity not less than the system short circuit level specified.




H) Switches

a) The switches shall have quick make, quick break, fault make, load break mechanism operated by an external insulated and earthed handle complete with ON/OFF position indicator/dial plates.



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b) The switches shall be heavy duty conforming to IS 13947(Part 3)(R.a:1998) and capable of interrupting three times the rated current at 0.3 p.f at rated voltage for switches rated above 315 amps.

c) All switch contacts shall be silver plated.

d) In combination with series current limiting fuses, the switches shall be capable of making all currents upto the system short circuit level specified.

e) The load break switch shall be provided with a through door operating mechanism with visible blades or a visible means of determining the disconnected position (when the door is opened) and mechanically interlocked with the door so that switch must be in OFF-position before the door can be opened. Provision shall also be there to defeat the door interlock.

f) It shall be possible to padlock the load break switch handle in the OFF position. Integral padlocking discs shall be provided.

g) The load break switch shall be TPN.

h) Bolted type removable copper links of adequate size shall be provided for neutral in all incomer feeders and outgoing feeders with TPN switch fuse units.

i) Solid links shall be used for connections between switches and

j) fuses and such links shall be PVC sleeved/taped.

I) Fuses

a) All fuses shall be HRC link type (knife edge but not bolted type) conforming to IS:9224-1979. The HRC fuses shall be current limiting, non-deteriorating type having breaking capacity of not less than the rated short circuit capacity of the board.



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b) Fuse holders shall be selected based on the highest fuse rating for the given load break switch and specified lower size fuses shall be fitted by means of suitable links if required.

c) All fuses shall be provided with distinct type operating indicators, to show whether they have operated or not.

d) Fuse holders and fuse bases shall be made of unbreakable, non-inflammable and non-hygroscopic material like phenolic moldings.

e) 2 sets of fuse pullers required for inserting and removing HRC fuses shall be supplied for each MLB.

f) Current Vs. time and I characteristics of all fuses shall be furnished along with the tender.

J) Cable gland and Cable sizes

a) Required number of heavy duty double compression type brass cable gland of projected nipple type complete with two lock nuts and earthing washer. (Provided with studs) shall be supplied.

b) Edge of cable gland shall have threaded projection to enable the locknut to fit from inside of the equpt.

c) Terminals, crimping type lugs, glands etc, shall be suitable for the cable sizes and number to be indicated by the Owner during the execution of order.

K) Painting for feeder pillar

The finished colour of the boards will be indicated while approving the general arrangement drg.

L) Foundation for feeder pillar

Suitable brick/concrete foundation shall be designed by the contractor and got approved before construction.



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M) Name plate, Danger board etc.

a) Anodized aluminium nameplate indicating designation of the board and designation of each feeder shall be fixed on the front doors.

b) Standard danger board of suitable size shall be provided.

c) Single line diagram of distribution shall be etched on a metallic plate and fixed inside the door.

N) Timer

Timer (Time Switch) shall be accurate & quartz driven multi program. Units shall be with one or two dials double dial unit shall offer daily and weekly time sequences. The timer shall have a built-in chargeable Ni-Cd cells for 150 hours continuous operation in the event of power failure. The timer shall be suitable for switching street lights, open area lights, boundary wall lights etc.

The timer shall be supplied with enclosure as indicated in the bill of quantities.

8.14.3.4 Light fixtures, Lamps and Accessories

General

a) All the luminaries shall be designed, suitable for coastal area manufactured and tested in accordance with relevant IS specifications so far as they are applicable.

b) All the luminaries shall be commercial / industrial / decorative type as per specific requirement. All the lighting fixtures shall be complete with all parts, including earthing arrangement and accessories for efficient performance whether specifically asked in the specification or not.

c) Individual light fittings shall be provided with suitable arrangements for GI threaded conduit entry of 19 mm dia. unless otherwise specified. Terminals of all fittings shall be suitable for taking 2.5 sq.mm flexible, copper conductor PVC insulated, PVC sheathed cable. The earthing terminal provided shall effectively earth the entire luminaries.



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d) The clearance between the live parts and the enclosures earthing and other safety factors shall be governed by the latest revisions of the IS specification and IE rules.

e) The luminaries shall be suitably designed to provide economically the required level of illumination on the working plane when mounted at normal standard height in accordance with the type of fixtures.

f) The luminaries shall be suitable for operating at normal supply voltage of 240 V, single phase, 50 Hz with voltage variation of +/- 10% or at voltages as specified. Ballast’s of copper conductor shall be used for all fittings. P.F correction capacitor to improve P.F up to 0.95, electronic igniter, necessary connectors etc., shall also be provided where required.

g) The lamp holders of the fittings shall be suitable to take the lamp supplied.

h) Mounting accessories like chain, for fittings mounted in false ceilings anchor bolt and all erection accessories required for complete installation is in the scope of the contractor.

i) Down rods / chains for mounting light fittings and fans and GI / MS conduits, brackets, flats, hooks, channels, etc., also to be supplied and installed as required.

j) All luminaries are to be supplied with required lamps as indicated in the drawings / specifications.

k) All fixtures supplied shall be as per type / specification as specified in the drawing including necessary control gears mounting brackets/accessories hardware consumables required for wall ceiling suspension/recess including down rod/chain/Anchor bolts.

l) All discharge lamp fittings shall be supplied with suitable ballast, power factor improvement capacitor, igniter, etc. The ballast terminals shall be made for various tapings for use on a wide range of mains voltage making it versatile in application.



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8.14.3.5 Light fixtures

A) Fluorescent/ PL type luminaire

Fluorescent light fitting shall be made of CRCA sheet steel housing white epoxy stove enameled incorporating all electrical accessories such as spring loaded rotor lamp holders, starter holders, copper wire wound polyester filled ballast, p.f improvement capacitor with provision to improve the p.f up to 0.95, reflectors/louvers, etc.,

B) Bulk head luminaire (GLS, PL)

The body of the fitting shall be made of epoxy Grey powder coated die cast aluminium fitted with heat resistant glass cover, anodised aluminium reflector and galvanized wire guard made of suitable dia to ensure protection to glass. Proper sealing of inside against outside influences like water vapour etc., is to be achieved with the help of a neoprene gasket glued to the housing and positioned between ring and housing. The fitting shall be provided with control gear and ceramic BC/ES lamp holder suitable for HPSV lamps pre wired up to the terminal block. The housing shall have suitable conduit threaded entry and fixing lugs shall be provided for mounting on wall / ceiling. All MS hardware parts shall be cadmium plated and passivated to withstand corrosion. The fitting shall be weather proof.

C) Well glass fitting ( HPSV, MH)

The body of the fitting shall be made of epoxy Grey powder coated die cast aluminium fitted with heat resistant well glass cover, galvanized wire guard and anodised aluminium reflector. Proper sealing of inside against outside influences like water vapour etc., is to be achieved with the help of a neoprene gasket glued to the housing and positioned between ring and housing. The fitting shall be provided with built in control gear and ceramic BC/ES lamp holder suitable for HPSV lamps pre wired up to the terminal block. The housing shall have suitable conduit threaded entry and eye bolt on top for suspension. All MS hardware parts shall be cadmium plated and passivated to withstand corrosion. The fitting shall be weather proof.



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D) Medium / High bay luminaire (HPSV, MH)

The body of the fitting shall be made of epoxy Grey powder coated die cast aluminium housing for control gear, with anodised aluminium reflector. The fitting shall be provided with adjustable GES lamp holder pre wired up to the terminal block. One no. earth terminal shall be provided near the terminal block. The fitting shall be provided with epoxy grey powder coated MS suspension bracket with an eyebolt.

E) Street light luminaire (HPSV)

Integral type street light fitting shall be of single piece die cast aluminium construction. The housing shall be finished with paint of stove enameled gray out sides and white inside the lamp compartment. The lamp compartment shall have suitable reflectors, porcelain lamp holders with E40 brass holder having very good mechanical strength. The fitting shall be provided with acrylic cover stabilized to avoid yellowing. The fitting shall be supplied with necessary ballast, igniter, p.f improvement capacitor suitable for 70/150 V, necessary connector block, GI pipe bracket to support the bracket for mounting the light fitting. The fitting shall be completely wired up with wires suitable to withstand the higher temperature, the fitting shall be gasketed to make it rain water proof. One No. earthing terminal shall also be provided. The fitting shall be supplied with the necessary lamp and GI pipe arm of not less than 1500mm.

F) Flood light luminaire for HPSV, MH lamps

The flood light fittings shall be of integral / non integral type as specified in the schedule. The Luminaire comprising of die cast aluminium housing with heat resist toughened glass, complete with ballast, power factor improvement capacitor, igniter, etc suitable for mounting on pole/wall/column including necessary brackets.

G) Aviation obstruction luminaire (suitable for neon lamp)

Aviation obstruction lights shall consist of yellow painted cast alumnium body housing, with built-in 75VA step up transformer and heat resistant, clear, toughened, thick glass



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dome mounted on hinged die cast aluminium ring secured to the body. The luminaire shall be provided with Neon spiral plugged into spring loaded high tension nylon socket and wired up to the terminal block. The luminaire shall be suitable for mounting on a pipe bracket.

H) Timer

Timer (Time switch) shall be accurate & quartz driven. The timer shall have an built in chargeable Ni-Cd cells for 150 hours continuous operation in the event of power failure. The timer shall be suitable for switching ON / OFF street lights, open area lights, boundary wall lights etc., at predetermined time.

The timer shall be supplied with enclosure or panel mounted as required.

I) Street light pole/ Flood light pole

Steel tubular street light pole shall be swaged and welded construction as indicated in the schedule. Each pole shall be comprising of a looping/terminal box clamped with top level 550mm above ground level along with a suitable earth terminal. A base plate 300 x 300 x 10mm welded to the bottom of the pole. The looping box shall be provided with a suitable bus bar arrangement to loop 3 to 4 cables (type and size shall be as per schedule of items/drawings). 5A fuse cutout and an earthing terminal shall be provided.

The pole shall be provided with a cap having 3 nos. fixing bolts at 120 degrees apart, pipe arm with suitable stiffeners shall be provided to mount the street high fitting. The dia of the pipe shall be suitable to carry the weight of fitting etc and suitable for mounting the fitting.

The pole shall be provided with necessary cross arms as per schedule of items for mounting one or more numbers of flood light fittings where required. Both underground cable and earth cable shall be terminated at the terminal/looping box. Further wiring to the light fixture shall be done by three core flexible copper wire (2 core for power supply and third core for



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earthing). The earth terminal at the terminal box shall be further connected to the earth terminal on the pole by aluminium cable.

Steel tubular pole cap, terminal box and all other MS material shall be epoxy painted hot dip galvanized to 80 micron thickness. All hardwares like nuts, bolts, etc shall be of stainless steel or zinc passivated.

The steel tubular pole shall be suitable for mounting on concrete foundation. The civil work for street light pole foundation forms a part of erection.

The depth of concrete foundation made of cement concrete 1:3:6 (1 part cement: 3 part sand: 6 parts stone aggregate) laid on top of a mud mat of 100 mm thickness shall be 2000 mm below the ground level for poles having 8m to 11m length and 2200mm below the ground level for poles having 12m to 14.5 m length. The concrete foundation below the ground level shall be 450 mm x 450 mm square for poles having length 8m to 11m and 600 mm x 600mm for poles having length 12m to 14.5m. Concrete coping of dia 350 mm and 450 mm respectively shall be provided for the above poles for a height of 600 mm above the ground level. For any poles having length other than that indicated above the foundation shall be suitably designed by the contractor and got approved by consultant.

The terminal box shall be embedded in the coping (part of foundation above ground above ground level) so that the front of the box is accessible and slightly below the top level of foundation. GI pipes to be given as inserts to guide the cables from cable trench to terminal box

Steel tubular poles shall conform to IS 2713 Part II – 1980 (R.a:1998) with designation as specified in the BOQ.

8.14.3.6 Lamps

A) Incandescent lamp

These shall be gas filled, clear glass shell with coiled coil tungsten filament supported on Molybdenum wires. The bulb



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caps shall be of brass and screw type with ES/GES threads. The incandescent lamps shall be suitable for operation on 240V, 50 Hz AC supply.

B) Fluorescent lamp

All fluorescent lamps shall be cool day light and shall be suitable for switch start. Fluorescent lamps wherever specifically indicated shall be of TLF type (built-in reflector type). The lamp shall have high luminous efficiency, high lumen output.

C) Sodium vapour lamp

The lamps shall be suitable for universal burning position and shall be colour corrected and shall have caps E-40 with ES/GES threads. All the lamps shall be suitable for external igniter. Lamps shall be ovoid or tubular type as specified.

D) Compact fluorescent lamps

The lamp shall be designed for low energy consumption, cool day light appearance, excellent colour rendering with longer life. The lamp shall be suitable for use with wall or ceiling mounting fittings suitable for compact fluorescent lamp.

E) ML Lamps

ML lamps shall be of colour rendered and shall consist of quartz mercury discharge tube connected in series with tungsten filament should function as incandescent light source as well as ballast for mercury tube by limiting the lamp current.

8.14.4 Sockets, switches, fans and other installation accessories

8.14.4.1 Socket outlets

a) Flush/surface mounting socket outlets (decorative type)

6A / 16A, 6A, 240V, single phase, 3 pin (two pole and one earth) socket outlet shall be flush / surface mounting type along with decorative type switch. The socket shall be 6A / 16A combined



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(universal type) having 6 pin, or 16A, 3 pin with suitable piano type switch, Fuse & indicating lamp.

b) Industrial type plug socket outlet

10A/20A, 240V, single phase, 3 pin (two pole and one earth) industrial type socket outlet with interlocked switch and MCB. The outer casing shall be made of non-corroding die cast aluminium alloy, moulded of superior grade phenolic /polyester compound.

8.14.4.2 Junction and outlet boxes

Junction and outlet boxes fabricated with sheet steel shall have a minimum thickness of 1.6 mm unless otherwise specified in schedule of items. All these items shall be painted whether indicated specifically in the BOQ or not. The JB shall have earthing terminals & terminal block, required no. of knockouts for cable entry etc.,

The exact size and number of knockouts & cable glands shall be decided by the Contractor as per actual requirement.

8.14.4.3 Control switches

A) Decorative type

Single pole decorative type, 6A or 16A switches shall be used for light point wiring in control rooms, office premises/non plant buildings

All branch switches shall be placed in line conductor of the circuit and no single switch or fuse shall be inserted in the neutral conductor of the circuit.

B) Switch boards (for decorative switches and sockets)

The switch board shall be made of 1.6 mm thick sheet steel and painted including supports for switches, sockets, fan regulator etc., but excluding front cover in case of decorative switches & sockets which will be of FRP sheet of approved quality, design and colour. Clear depth of the box shall not be less than 60 mm,



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but adequate for easy mounting of fan regulators. All fittings shall be in flush pattern in case of concealed wiring. The FRP cover sheet thickness shall not be less than 4 mm. No separate payment will be made for switch boards as the cost of this has to be included along with the rate quoted for socket, point wiring, switches and fans. In case of more numbers of sockets / switches / regulators are to mounted in one location, these can be mounted in a bigger size switch board with necessary clearance etc., between switches instead of individual switch board for each switch. Sheet steel enclosure shall be painted with two coats of epoxy paint above two coats of epoxy based primer.

C) Bolts & nuts / brackets / downrods / chain

All screws, bolts nuts and washers used for Illumination work shall be of brass or cadmium passivated MS to resist corrosions. All brackets, down rods, chains used for suspension of tube light, well-glass fittings shall be made of MS Conduits / channels / angles / strips as approved by site engineer. Two coats of epoxy spray painting shall be applied over two coat of epoxy based primer for all accessories.

D) Ceiling roses / lamp holders

Ceiling rose may be used in the house wiring, if required.

a) Normally only one flexible cord shall be attached to a ceiling rose. Specially designed ceiling roses shall be used for multiple pendants.

b) All ceiling roses shall be of three plate pattern.

c) All lamp holders shall be of brass and batten or angle type as required with shrouding.

E) Ceiling fan fans and regulators

a) All ceiling fans supplied shall be conforming to relevant IS and with capacitor starting, class 1 type suitable for voltage range of not less than 220 V to 240 V AC single phase supply.



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b) Fans shall be supplied complete with fan motor, fan blade, insulated hangers canopy and regulator along-with a down rod of suitable length as required. The speed regulators shall be of electronic type for steeples variation from zero to 100%. All ceiling fans supplied shall have double ball bearings.

c) All ceiling fans shall be wired to a junction box and suspended from a hook in shackle and insulated from the same. All joints in the suspended rod shall be screwed and all joints or bolts in connection there with shall in addition be secured by means of split pin.

d) The canopy at the top of the suspension rod shall effectively hide the suspension.

e) The lead-in wires shall not be smaller than 0.75 Sq.mm (24/0.2 mm) PVC insulated flexible copper conductor cable and shall be protected from abrasion.

f) Unless otherwise stated, all ceiling fans shall be hung at 150mm above the light fitting level or as directed by the Engineer in-charge. The length of the down rod supplied shall be suitable for this purpose.

g) Generally the ceiling fans shall be mounted 2500/3000, above FFL. The down rod length shall be considered based on roof profile (slope or flat)

F) Exhaust fan

Exhaust fan shall have totally enclosed with highly efficient heavy duty motor mounted on ball bearing, precisely and dynamically balanced blades/impeller to ensure smooth and trouble free operation, rigid frame with rubber pads for silent operation finished with epoxy based painting for better chemical, mechanical and corrosion resistant. The exhaust fan shall be supplied with wire guard/bird mesh screen as required.

The exhaust fan shall be provided with earthing terminal.

8.14.5 Cables & wires

8.14.5.1 Cables

Cables shall be used for power supply to lighting boards and all outdoor installations. For specification of cables refer to details in electrics.



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8.14.5.2 Wires

i) Conductor shall be composed of plain annealed high conductivity copper or aluminium conductor as specified.

ii) Wires up to 1.5 Sq.mm shall be either solid or stranded in case of copper conductor and solid in case of aluminium conductor. Wires above 1.5 Sq.mm shall have stranded conductors.

Aluminium conductor up to 10 sq.mm shall be solid for cables and stranded for higher size.

iii) Conductors having cross sectional area up to 25 Sq.mm shall be circular

iv) For flexible cords the conductor formation shall be according to IS : 8130 (1984) (R.a:2001) .

8.14.5.3 Insulation

The insulation shall consist of an extruded layer of suitably compounded high quality PVC.

The insulation shall be so applied that it fits closely on the conductor and it shall be easily removable without damage to the conductor.

8.14.5.4 Core identification

The individual cores of single core and multi-core cables shall be identified by different colour of PVC insulation as indicated below :

Sl. No.

Cables for fixed wiring Flexible cords

1 Single Core : Red, Black, Yellow,blue, white or grey

Red, Black, Yellow, Blue,

2 Cores : Red & Black Red & Black

3 Cores : Red, Yellow & Blue Red, Black & Yellow /Green

4 Cores : Red, Yellow, Blue & Black :

Red, Yellow, Blue, & Yellow / Green



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8.14.5.5 Tests

All tests conducted shall be as per IS amended up to date. Type test certificates shall be submitted at the time of approval of specific makes.

8.14.5.6 Conduits

A) MS/GI CONDUIT

Electrical conduit shall conform to relevant IS. Rigid metal conduits shall be threadable with heavy protection. The internal bore of all conduits must be suitable for cable drawing and the ends free from burrs.

B) PVC CONDUIT

Rigid medium / heavy duty PVC conduit as per IS : suitable for electrical wiring may also be used wherever indicated in the approved drawings or specifically approved by Engineer. It shall be of approved make.

C) PVC CASING, CAPPING & ACCESSORIES

PVC casing, capping & accessories like Tees, elbows, JB’s shall be of heavy duty fire retardant self extinguishing, Acid & Alkali resistant, PVC toughness that will not dent, snap-fit covering, desired colour.

8.14.5.7 GI Pipes

All the pipes supplied shall be suitable for cable drawing, without any internal burrs, smooth internal surface and threaded at both ends with coupling at one end.

Class ‘B’ type GI pipes as per IS shall be used for the following cable routes:

a) Cables running on floor shall be laid in buried pipes.

b) All cables laid upto a level +200mm from floor level shall be in GI pipes.



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c) Cables crossing road, entering building from outside through wall/foundations etc. shall be laid in GI pipes.

d) All GI pipes shall have a suitable fish wire for drawing cable.

8.14.5.8 Earthing

Earthing shall confirm to IS 3043 – 1987.

8.14.5.9 Earthing of lighting distribution boards

The lighting board shall be provided with two separate earth terminals. An earth bus bar of appropriate cross section shall be provided inside the lighting board and connected to the earth terminals provided on either side of the board.

Adequate number of holes / terminals shall be provided on earth bus with suitable provision for terminating the earth wire.

GI strip / GI wire insulated single core cable of suitable size shall be used for earthing the lighting board, by connecting the two earth terminals separately to the earthing main in the shop / earth pit.

8.14.5.10 Earthing of light fixtures and socket outlets

The single core PVC insulated / bare copper wire or 14 SWG GI wire and the third core of the flexible wiring cable shall be used for earthing the light fixtures and single phase socket outlets etc.,

8.14.5.11 Earthing of metal boxes and brackets

Not less than 14 SWG GI wire or suitable size PVC insulated copper wire shall be used for earthing all metal boxes and brackets.

8.14.5.12 Earthing of street light poles / flood lighting poles

At every 5th pole including end poles a separate earth station shall be provided. The poles will be earthed by connecting its earth terminal to the junction box through 8 SWG GI wire. Apart from the above, continuous earthing connection from pole to pole shall be carried out using copper wire.



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The earth terminal at the junction box shall be connected to the main earthing ring through 8 SWG GI wire.

8.14.6 Erection, Testing and Commissioning

General

The scope includes receiving and storage of equipment at site, transportation, handling, installation, testing and commissioning of all units/items under the scope of supply of the contractor, his scope also includes installation and termination of cables to / between owner's electrical equipment and sealing of cable conduits, floor / slab openings, minor civil works required for erection etc.,

8.14.7 Procedures for installation of items covered in schedule of quantities

The contractor shall follow general procedure for installation of the equipment / items implicitly covered in this section read with special instruction to contractors. Equipment/cabling / earthing and other electrical system installation shall be carried out in accordance with the latest editions of relevant Indian Standards and codes of practice and the installation shall fully comply with the requirement of the Indian Electricity Rules and statutory regulations that are in force at the place of installation.

8.14.8 Lighting boards

A) Main lighting board

The main lighting distribution board shall be floor-mounting type. Suitable base channel shall be supplied and the floor inserts, if necessary, incorporated in the civil works. G.A drawings shall indicate foundation details and insert requirement also along with arrangement of panel boards. Installation of equipment includes supply and installation of necessary hooks/arms for cable support and all other connected works.



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B) Lighting distribution boards

The lighting distribution boards/sub-distribution boards will be generally mounted on a wall or structural column. The distribution board shall be mounted in such a way that the operating handle of the incomer and outgoing switchgears shall not exceed 1800 mm from the finished floor level for easy operation. The panel will be fixed on the wall/column securely by means of suitable bracket and fixing clamps/bolts etc. The contractor shall also design and incorporate in the civil works necessary pipe inserts etc., for cabling to the board.

C) Light fixtures, fans etc.

All light fittings such as bulk head, well glass, fluorescent tube light fittings, street light fixtures, flood light fixtures etc., are to be installed as per given/ approved layout drawings, and direction of site engineer conforming to Standard installation norms and practices. Apart from the technical requirements, aesthetic requirement also to be satisfied while designing supporting arrangements and fitting layout.

Brackets / down rods / chains for suspension of light fixtures and fans irrespective of length are to be included in the scope of work for supply & installation of respective fixtures / fans.

D) Control switches, socket outlets and switchboards

All the control switches, sockets and switchboards are to be installed as per given drawing. When no drawings are given, they will be installed as per specification, standard norms and direction of site engineer.

The switch controlling the socket shall be connected to live side of the socket.

E) Junction box, outlet box, anchor box etc.

All junction boxes including terminal blocks wherever required outlet boxes are firmly fixed to walls/ceiling/structures using MS bracket and bolt and nuts. The front cover of these boxes



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shall be flush with the wall/roof finish in case of concealed mounted type. The location of these boxes shall be selected insuch a way that easy accessibility is available for maintenance. All these boxes shall be of minimum 1.6mm thick duly painted as per specification given else where in this document.

8.14.9 Electrical wiring

A) Definitions for wiring :

The definition of terms shall be in accordance with Indian standard code of practice for electrical wiring installation IS 732-1989(R.a:2005) except for the definition of “Point”.

The following shall be deemed to the included in the point wiring, starting from D.B. to fitting via switch / push button :

a) Switch & socket of required type and rating.

b) Metal Junction box, shrouded brass batten holder, ceiling rose or connector as required.

c) Fan hooks and in case of concealed wiring suitable sheet steel box for neatly housing the connector and covering the fan hook in case of fan point.

d) Metal box, bushed conduit or porcelain tubing where cables pass through walls / floors etc.,

e) Heavy/Medium class GI/PVC conduit / PVC casing ‘N’ capping as required including intermediate metal junction / looping boxes / pull boxes, & accessories like tees, elbows, bends collers charges etc.,

f) All metal boards and boxes sunk or surface type for mounting control switches, sockets etc., including those required for mounting fan regulator but excluding those under the main and sub distribution switchgears. The face plate of control switchboard should be decorative plastic type / hylam type as per relevant IS.

g) All fixing accessories, such as nuts, bolts, check-nuts, bushes, clips, nails, screws, fill plug, rawl plug, etc., as required.



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h) Connections to ceiling rose, connector, socket outlet, lamps holder, switch, fan regulator etc.,

i) Earth wire from light / fan points to the common earth including connections.

j) Looping, interconnections and end-terminations with socket / ferrules etc., wherever required.

k) Earth wire from three pin socket outlet point / fan regulator to the common earth including connections.

l) Fish wire in case of concealed wiring.

m) Painting / varnishing as required.

n) Required length of wiring including reasonable spare length of cables at termination points.

o) Where ever light fitting is not indicated in the drawing and point wiring shall be terminated in the lamp holder, necessary lamp, as indicated in the drawing, shall be provided as part of point wiring.

B) Wiring other than point wiring :

The cost of electrics include the cost of materials and installation charges for the complete wiring length as detailed below :

a) Cables/wires as specified

b) The cost of electrics also includes all fixing accessories such as clips, nails, screws, saddles, plug etc.,

c) Interconnections with switch/switch boards or any electrical item including all accessories cable glands & lugs required for terminations.

C) System of wiring

Distribution

a) The wiring shall be carried out on each system as may be specified in the tender schedules. "Power and Heating" wiring shall be kept separate and distinct from "Lighting"/"Fan" wiring. All conductors shall be run as far as possible along the walls and ceiling, so as to be accessible and capable of being thoroughly inspected.



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b) Light and fans may be wired on a common circuit.

However, such circuit shall not have more than 10 points of light/fan, 5A socket outlets in a single-phase circuit or 1000-Watts whichever is less.

c) The balancing of circuits in the poly-phase installations

shall be ensured in each lighting boards. In large rooms, light and socket outlet points shall be distributed over more than one circuit.

D) Joints and looping back

Unless otherwise specified the wiring shall be done in the "Looping" system. Both the phase and the neutral conductors shall be looped at the switch box/junction box nearest to the point of entry. Jointing of cables at junction boxes located onceiling are not allowed. No bare or twisted joints are allowed at any point. Looping of neutrals between different circuits for point wiring are not allowed. No joints in conductors shall be made at intermediate points in the through run of cables unless the length of a final sub-circuit, sub-main or main is more than the length of the standard coil.

E) Positions of wiring runs and points

All runs of wiring and the exact positions of all points and switch boxes shall be first marked on the building and approved by the engineer before actual commencement of the work.

F) Size of wires

Wires to be used for wiring to light fittings, sockets etc. shall be

G) Wiring terminations

Wiring shall be terminated in junction box/ceiling rose/brass batten holder as directed by owner/engineer where no fitting is mentioned. In case of house wiring, wiring shall be terminated in brass batten holder for all tube light, decorative light, (single pendent fitting) and at locations where no fittings are specified.



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H) Provision for maximum load

All conductors, switches and accessories etc., shall be suitably rated so as to be capable of carrying, without their respective ratings being exceeded, the maximum current which will normally flow through them.

I) Fixing to walls and ceiling

Rawl plugs on ordinary walls or ceiling for conduit, hooks etc., may be used. The plugs shall be fixed into the walls/ceiling with necessary special tools. The holes drilled and the screws used shall be of the correct size as specified by the manufacturer of Rawl plugs. Where the equipment to be fixed are heavy suitable insert shall be embedded in the civil works and the equipment suitably fixed to these inserts. Wooden plugs shall not be used for fixing the equipments/ junction boxes / fittings.

J) Damage to wall/floor

Conduits/switch boards/junction boxes shall be placed in position before finishing the wall/flooring and before concreting the roof. However in unavoidable cases, the wall/floor etc., shall be cut to accommodate switch boards, conduit etc., and made good at no extra cost.

8.14.10 Conduit wiring

General

The installation shall generally be carried out in conformity with IE rules and IS 732(R.a: 2005) as amended up to date and also the relevant regulations of the Electric supply authority concerned. Normally concealed conduiting is envisaged for the civil buildings and surface wiring in conduit for structural buildings. The conduit wiring shall be done in accordance with the specification laid down in the following paragraphs.

At all the switch and socket positions or where the conduit terminates at ceiling or wall points, a metal box shall be provided.



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Provisions must be made to enable cables to be withdrawn and new ones drawn without interfering with the conduit system throughout the life of the installation.

Therefore, all inspection box and draw-in boxes must be installed in positions where they will remain accessible.

Cable shall be drawn into the conduit only when the site engineer has given his consent and has satisfied himself that the conduit work has been properly carried out. Suitable means shall be taken to prevent entry of insects inside conduit. A draw wire shall be used for drawing cables in conduit. When drawing-in a number of cables, they must be fed-in very carefully at the delivery end. Cable reels should be used for this purpose. In hot weather when the insulation on the cable is liable to become soft, the drawing-in can be assisted by rubbing French chalk on the cables.

As much slack cable as possible shall be left in all draw-in and inspection boxes, switch boxes, and distribution boards to facilitate alterations or repairs when necessary. The rate quoted for conduit shall be deemed to be inclusive of supporting saddles/brackets, supporting structures etc., (excluding cable trays), supply & installation of accessories like collars, tees, elbows, bends, junction box/pull box / ceiling rose, consumables etc.,

A) Surface conduit system (using conduits / casing ‘N’ capping)

The conduit casing ‘N’ capping must be arranged in a fashion to avoid crossing at points where they take different directions.

All conduit accessories shall be of threaded type and under no circumstances pin grip type or clamp grip type accessories shall be used.

Inspection elbows and inspection tees may not be used if there is insufficient room for drawing in cables and if it presents a shoddy appearance. A standard round box or rectangular box will be used in this case. For conduits upto 25 mm diameter, the small circular boxes may be used for conduits larger than 25 mm, rectangular boxes of suitable size shall be used.



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The conduits should be run as straight as possible and in drops they should be vertical.

The conduits shall be supported using saddles at every 1M on the vertical run and 0.5M on the horizontal run.

B) Concealed conduit system

The conduits will be installed during building construction and must be buried in floors, walls and ceiling in such a manner that the cables can be drawn in at any time after the completion of the building.

When the conduit is run to switch and other positions in wall, it will be run in a chase out into the wall. The chases must be deep enough to allow atleast 10 mm of cement and plaster covering. At ceiling point, the conduit boxes will be flush with the finish of concrete ceiling. Extension rings may be used to suit the thickness of plaster.

At the position of ceiling points, metal box shall be provided. Suitable junction box/ceiling rose shall be fixed to the box for connecting light/fan fitting etc., Suitable outlets will be provided in the fittings for concealed wiring.

For other technical particulars specification for surface conduit system shall be referred to. To facilitate drawing of wires in the conduit, a suitable GI fish wire shall be laid and kept inside the conduit.

8.14.11 Earthing

A) Installation of earthing circuit

All exposed metal parts such as Lighting boards/feeder pillar enclosure, metal clad switches enclosure, lamps brackets, lamp holder, plug sockets enclosure, lighting poles, junction box, etc., shall be properly earthed by connecting these to the earth electrode by means of bare GI wire/flat or single core cable of approved size to pass the fault current safely to earth in case of leakage at the apparatus or in the system. The minimum size of earthing wire unless specified otherwise is indicated below :



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a) Loop earthing ring for LDB/ sub distribution board earthing -minimum size of 25 x 6 mm GI strip buried in floor/wall/trench etc., in side the shop.

b) Light point earthing - same size as point wiring single core PVC insulated copper wire / bare copper wire in case of GI conduit wiring of same size or equivalent.

B) Earthing of MLDB/FEEDER PILLAR/LDB/ etc.,

The Distribution board shall be provided with two separate earth terminals. An earth bus bar of appropriate cross section shall be provided inside the distribution board and connected to the earth terminals provided on either side of the board.

Adequate number of holes/terminals shall be provided on earth bus with suitable provision for terminating the earth wire.

GI strip / Armoured copper conductor single core cable of same size of phase / neutral up to 6 sq. mm shall be used for earthing of equipment by connecting the two earth terminals separately to the earthing main in the shop.

C) Earthing of light fixtures and socket outlets

The single core PVC insulated/bare copper wire of same size as the phase conductor or 14 SWG GI wire and the third core of the flexible wiring cable shall be used for earthing the light fixtures and single phase socket outlets etc. as per drg /specific approval of owner / consultant

D) Earthing of metal boxes and brackets

Not less than 14 SWG GI wire shall be used for earthing all metal boxes and brackets.

8.14.12 Testing and commissioning

General

The successful tenderer, based on the broad outline procedure indicated in this specification, shall finalise with owner/engineer, the detailed procedure for testing and commissioning along with time schedules for both.



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The contractor shall adhere to the general guidelines given for testing and commissioning of the equipments/items implicitly covered under heading special instructions to contractor general condition of contract and technical specification.

The intention of specifying below, the procedure for testing and commissioning and different tests to be conducted, are only to give guideline to the contractor.

The contractor shall not restrict himself in carrying out only the tests specified here, but all tests as per relevant Indian Standards shall satisfactorily be conducted on each equipment. On successful completion of erection of each item/equipment, a final inspection will be carried out at site by owner/engineer, for correctness and completeness of erection.

A) Mechanical inspection and check up of the equipment

After installation, but before any power supply is connected, the contractor shall make a complete mechanical check and clean all installed electrical equipment and systems. This shall include, but not restricted, to the following: i) Visually inspect all equipment/item for defects if any, and

check equipment numbers against drawings to ensure that equipment has been correctly located and proper installation is done.

ii) Check name plates of individual feeders and others,

distribution boards, distribution fuse boards etc., for conformity with the data given on the supplier's drawings/ standards and specification sheets.

iii) Check connections to all equipments for tightness. iv) Check correctness of cabling and its terminations.

v) Check phasing, polarity.



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vi) Check all electrical and mechanical interlocks and other equipments for safety and to ascertain that those are functioning as per intention and accomplish their purposes.

vii) Check all plug in contacts for alignment and grip.

viii) Check all contactors for free manual operation ix) Remove all blocking devise installed for shipment. x) Check all the coils for their continuity and proper

voltage. xi) Check that the fuses are correctly rated and installed

are clean undamaged and fit for operation. xii) Check that all disconnect switches are clean, undamaged

and operate properly. Ensure that all contacts are tight and the joints, linkages and contacts properly lubricated (where applicable). Check interlocks and auxiliary devices and also the operation of the circuit breakers with the protection relay circuit connected.

xiii) Vacuum clean before energizing of power distribution

boards, MLDB, LDB/SDB, plug and sockets, switch fuse and like equipments

All interconnected wiring shall be checked thoroughly for correct connections with the wiring and schematic drawings of the manufacturer and the drawings supplied by the owner before energizing. All cable/bus bar connections shall also be thoroughly inspected and checked for corrections, foreign materials, tightness etc., before energizing the equipment. All labeling shall be checked against drawings. All components within the main equipments shall be tested for proper performance and correct operation before commissioning the equipment.



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Continuity and insulation tests shall be conducted. Switchgear rated 415 volts shall be tested with a 1000 volts megger. Auxiliary wiring rated less than 415 volts shall be tested with 500 volts megger. Equipment giving insulation resistance readings of less than 10 meg Ohms shall not be energized. Necessary steps shall be taken for improving the I.R value. All protective relays shall be tested at sufficient points to establish their proper functioning in accordance with the manufacturer's specification.

B) Pre-commissioning tests

All pre-commissioning tests at site on all the equipments/items shall be carried out as per relevant standards and as directed by the owner/ engineer. High voltage tests and primary and secondary injection tests on all components/ equipments shall form part of pre-commissioning tests.

All cables, heating cable units, immersion type heaters, correction type unit heaters and metallic conduits shall be tested to ensure electrical continuity.

Circuit breakers, contactors, relays, remote devices and other electrical operation equipment shall be functionally tested.

Relays, thermisters, photo-cells and other equipment requiring operational setting shall be set and checked.

C) Operational testing

Upon completion of the electrical installation and at such time as the owner/ engineer may direct, the contractor shall conduct apparatus and system operating tests for approval and acceptance purposes.



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All apparatus control schemes, interlocking safety and protective devices etc., shall be demonstrated to operate and function in accordance with the requirements of this specification.

All malfunctions and improper operations disclosed through these tests, shall be corrected to the satisfaction of the owner/ engineer. All necessary corrections to the contractor supplied equipment shall be at the contractor's expense.

The contractor shall employ skilled persons and laborers

required during the course of this operational testing.

D) Insulation resistance test for lighting installation

The insulation resistance shall be measured by applying 500 V DC between earth and the whole system of conductor or any section thereof (with all fuses in place, all switches closed and all lamps in position) by a megger of suitable range.

The insulation resistance of the installation shall be not less

than 50.0 meg ohms divided by the number of outlets on the circuit except that it need not exceed 1 meg ohm for the whole installation.

The insulation resistance shall also be measured between all

conductors connected to one phase conductor of the supply and all the conductors connected to the neutrals or other phase conductors of the supply with all lamps in position and switch off and its value shall be not less than that specified above.

E) Testing of polarity of non-linked single pole switches

In a two wire installation, test shall be made at each point to verify that cutouts and all non-linked single pole switches have been fitted in the same conductor throughout and such conductor shall be labeled or marked for connection to the phase conductor only and not on the neutral or earthed conductor.



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In a three wire or a four wire installation a test shall be made to verify that every non-linked single pole switch or cutout is fitted in a conductor which is labeled or marked for connection to the phase conductors of the supply. Acceptance of the electrical contractor's work described herein is contingent upon the successful testing of all electrical apparatus, systems and associated wiring, (testing methods shall be in accordance with procedures readily recognizable by the owner/engineer and the contractor). All tests shall be performed in the presence of the contractor and the owner/ engineer. For all types of visual inspections, checking, pre-commissioning, commissioning tests and acceptance tests, relevant IS for the tests given therein shall be followed in addition to the instructions of engineer/owner for such tests.

F) Testing and Commissioning of Earthing and Cabling systems

1.0 EARTHING SYSTEM

The contractor shall inspect and test all earthing works carried out by him, including all interconnections between group loops, earthing of electrical rooms and grounding of equipment and ensure that the connections are permanent and that the earthing circuit is continuous. The contractor shall test the buried earth grids supplied by him and others within the zone assigned to him.

The contractor shall measure and record earth resistance at various earth connection points. Equipment earthing internal to each equipment such as fourth core earthing in the motor terminal boxes shall be shown to the owner/engineer. Only after checking of such connection by the owner/engineer, the terminal boxes shall be closed.

Earthing system and connections shall be tested as follows : -

a) Resistance of individual earth electrode shall be measured after disconnecting it from the grid.



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b) Earthing resistance of the grid shall be measured after connecting all the electrodes to the grid and generally the test value shall conform to IS code of practice unless otherwise specified. The earth resistance shall be less than 1 Ohms for the grids constructed by the Contractor.

The resistance to earth shall be measured at the following :-

a) At each electrical electrode independently. b) At each earth system provided for structure lightning

protection c) Combined earthing system used to earth electrical

equipment enclosures, metal structures etc.,

2.0 CABLING SYSTEM

The contractor shall inspect and test all cabling works carried out by him. All cables shall be tested before and after jointing/termination as per relevant Indian Standards. Jointing/ termination shall be redone, if found unsatisfactory without any extra cost to the owner. For testing, all cables shall be megger tested before jointing. After completion of jointing, all LV cables shall be megger tested. The cable cores should be tested for continuity absence of cross phasing, insulation resistance to earth and insulation resistance between conductors. Before energising, the insulation resistance of every circuit, circuit cable shall be measured from phase to phase and from phase to ground.

Where splices or terminations are required in circuits measure insulation resistance of each length of cable before splicing and/or terminating. Repeat measurements after splices and/or terminations are complete.



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Measure the insulation resistance of directly buried cable circuits before trenches are back filled. Repeat measurement after back filling.

DC high voltage test shall be made after installation of the following :

a) All 1100 volts grade cables in which straight through joints have been made.

b) All cables above 1100 V grade.

For record purposes test data shall include the measured values of leakage current.

The DC high voltage test shall be performed as detailed below :

Cable shall be installed in final position with all the straight through joints complete. Termination shall be kept unfinished so that motors switchgear, transformer etc., are not subjected to test voltage.

The test voltage and duration shall be as per relevant codes and practice of Indian Standard Institution.

The result of all the tests conducted at site shall be furnished in a tabulated form given below, to the Owner for their approval. All tests shall be performed with genuine instruments. The Tenderer shall, therefore, submit a list of all such instruments proposed to be used for testing the installation.

8.14.13 Applicable codes and standards

General

Latest revision of all applicable Indian and IE codes, regulations and standards shall govern the design, manufacture, installation, testing and commissioning of individual equipments and total installation even when the requirement of the specification is less stringent than the codes, regulations and standards. In the event of requirement of the specification exceeds the corresponding codes, regulations or standards, the specification shall govern. Wherever Indian Standards are not available, relevant International Standards are to be followed.



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Conflict of different specification

In the event of conflict between codes, regulations and standards referred in this specification, the most stringent one shall govern.

List of some indian standards

A few Indian Standards which need reference more frequently are listed below (for all these specifications, the latest revision will be referred to).

1. IS 6665-1972 (R.a:2005)

: Industrial lighting code of practice.

2. IS 3043-1987(R.a:2001)

: Earthing-Code of Practice

3. IS 732-1989 (R.a:2005)

: Electrical wiring and installations

4. IS 5216-1982(R.a:2005)

: Guide for safety procedures and practice in electrical work

5. IS 4160-2005 : Industrial type Interlocking switch socket

6 IS 1293-2005 : Plug & socket outlets

7. IS 2667-1988(R.a:2000)

: Fittings for rigid steel conduits for electrical wiring

8. IS 9537

Part 1 – 1980 (R.a:2000)

Part 2 – 1981

(R.a:2001)

Part 3 –1983(R.a:2001)

Part 4 – 1983

(R.a:2001)

: Conduits for Electrical installation

General requirements

Rigid steel conduits

Rigid conduits of insulating material

Pliable self recovering

Conduits



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9. IS 6946-1973 (R.a:2001)

: Flexible non metallic conduits for electrical Installation

10. IS 3419-1989(R.a:2001)

: Fittings for regid non metallic conduits.

11. IS 3837-1976(R.a:2001)

: Rigid steel conduits for electrical wiring and accessories.

12. IS 1913 Part I (R.a:2003)

: General and safety requirement of lighting fittings Tubular Fluorescent lamps.

13. IS 374 – 1979(R.a:2000)

: Fans and regulators, ceiling type

14. IS 8623 Part-II1983 (R.a:1998)

: Factory built assemblies of switchgear for voltages up to & including 1000V.AC and 1200V. DC Particular requirement for busbar trunking systems.

15. IS 13947:Part I:1993(R.a:1998)

: General requirements for switchgear and control gear for voltages not exceeding 1000 V. A.C.

16. IS 13947:Part II:1993(R.a:1998)

:

:

:

Requirements and tests, voltages not exceeding 1000VAC or 1200V DC General and definitions for voltage above 1000V AC

Informations to be given with enquiries, tenders and orders and rules for transport,erection and maintenance, for voltage above 1000V AC.

17. IS 10118-1982 Part 1 to 4 (R.a: 2006)

: Code of practice for selection, installation And maintenance switch gear and control gear.

18. IS 13947:Part I:1993(R.a:1998)

: Degrees of protection provided by enclosure for low voltage switch gear and control gear.



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19. IS 13703:Part I:1993(R.a:2004)

: HRC cartridge fuse links.

20. IS 1554(1988) Part I (R.a:2005)Part II 1988(R.a:2005)

: PVC insulated (heavy duty) electric cables for working voltage up to and including1100V.

21. IS 9511-1980(R.a:1999)

: Earthing knobs for neutral conductors.

22. IS 5578-1985 (R.a:2006)

: Guide for marking of insulated conductors.

23. IS 13234:1992 (R.a: 2002)

: Guide for short circuit calculations.

24. IS 2551-1982 (R.a: 2005)

: Danger boards

25. IS 9676-1980(R.a: 2004)

: Reference ambient temperature for electrical equipment.

26. S 8923-1978(R.a: 2005)

: Warning symbols for dangerous voltages.

27. IS 5-2004 : Colours for paints.

28. IS 8289-1976(R.a: 2001)

: Electrical Equipment with type of protection ‘n’

29. IS 2713 Part-I to III (R.a: 1998)

: Street light pole

30. IS 3854-1997(R.a: 2002)

: Switches to domestic and similar purposes.

31. IS 3480-1966(R.a: 2001)

: Flexible steel conduits for electrical wiring.



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32. IS 5133-1969 Part-I (R.a: 1996)Part-II (R.a: 1996)

:

:

Boxes for enclosure of elect. accessoriesSteel & cost iron boxes.Boxes made of insulating materials

33. IS 371-1999 Reaffirmed-1990

: Ceiling roses.

34. IS 3722-1983 (R.a: 2002)

: Letter symbols and signs used in electrical technology.

35. IS 7752-Part I – 1975(R.a: 2006)

: Guide for improvement of power factor in consumers installation.

36. IS 12943-1990(R.a: 2005)

: Brass Glands for PVC cables.

37. IS 4615-1968(R.a: 2000)

: Switch socket outlets.

38. IS 5082-1998(R.a: 2003)

: Wrought Aluminium & Aluminium Alloy Bars, Rods, Tubes & Sections for Electrical Purposes.

39. IS 8828-1996(R.a: 2006)

: Circuit Breakers for Over current protection for household & similar installation.

40. IS 694 –1990(R.a: 2005)

: PVC insulated cables for working voltages up to and including 1100V (Third Revision).

41. IS 3480-1966(R.a: 2001)

: Flexible steel conduits for Electrical wiring.

42. IS 1777 – 1978(R.a: 2005)

: Industrial Lighting Fittings with metal reflector.



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43. IS 2309 (1989) (R.a: 2005)

: Lightning protection.

44. IS 3646 : Code of practicePart I –1992(R.a: 2003)

Interior Illumination General requirement and recommendation for working interiors

Part II – 1966(R.a: 2003)

: Schedule of illumination and glare index

Part III – 1968(R.a: 2003)

: Calculation of coefficients of utilization by the BZ method

45 IS – 1569 – 1976(R.a: 2001)

: Capacitors for electric discharge lamps (fluorescent and mercury lamps)

46 IS – 10322 : Luminaries for streetlight fittingsPart I – 1982(R.a: 2005) : General RequirementsPart II – 1982(R.a: 2005)

: Constructional requirement

Part – III – 1984(R.a: 2005)

: Screw and screw less terminations

Part IV – 1984(R.a: 2005)

: Methods of test

47 IS – 418 – 2004 : Specification for tungstem filament general lighting service electric lamp

48 IS – 1258 – 2005 : Boynet lamp holders

49 IS – 1534 (Part I) 1977(R.a: 2001)

Ballast for fluorescent lamps for switch start circuits.

50 IS – 3323 – 1980(R.a: 2002)

: Bipin lamp holder for TL lamps

51 IS – 2215 – 1984(R.a: 2003)

: Starter for TL lamps



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52 IS – 3324 – 1982(R.a: 2003)

: Holders for starters for TL lamps

53 IS – 2418 – 1977 TL lamps for general lighting service

Part - I(R.a: 2000) Requirements ad testsPart – II(R.a: 2001) Standard lamp data sheetsPart – III(R.a: 2001) Dimensions of Bipin capPart – IV(R.a: 2002) Ganges of Bipin cap

54 IS – 5077 – 1969(R.a: 2005)

Decorative light fittings

55 IS – 9974 – 1981 High pressure sodium vapour lamps

Part – I(R.a: 2002) General Requirements and testsPart – II(R.a: 2002) Standard lamp data sheets

56 IS – 10276 – 1982(R.a: 1998)

Edison Screw lamp holders

57 IS – 1569 – 1981(R.a: 2001)

Cast acrylic sheets for use in luminaries

58 IS – 2268 – 1994 (R.a: 2004)

Electric call bells and buzzers for indoor use

59 IS – 5081 – 1990(R.a: 2001)

Glass tubes for fluorescent lamps for general lighting service.

60 IS – 2148 – 2004 Flame proof enclosure for electrical apparatus

61 IS – 2206 – 1962 Part – I(R.a: 2005)

Flame proof electrical fittings part I well glass and bulk head type

Part – II(R.a: 2003) Flame proof electrical fitting part II using gas tubes

62 S – 4013 – 1967(R.a: 2005)

Dust tight electrical light fittings

63 IS – 8239 – 1976 Classification of maximum surface



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(R.a: 1991) temperatures of electrical equipment for use in explosive atmosphere

64 IS – 5572 – 1994Part I(R.a: 1999)

Classification of hazardous area (other than mines) for electrical installation Part – I areas having flamable gases and vapour.

65 IS – 8240 – 1976(R.a: 1999)

Guide for electrical equipment for explosive atmospheres

66 IS – 5780 – 2002 Intrinsically safe elsectrical apparatus and circuits

67 IS – 7689 – 1989(R.a: 2005)

Guide for control of undesirable static electricity.

8.14.14 Preferred makes of equipment

Makes of the equipment offered shall generally limited to the following only. However, while offering the make shall be selected justifying the quality and economy.

1. a) Light fittings & lamps Philips/ Crompton/ Bajaj/GE2. Decorative switches &

socketsAnchor / Lisha / MK Electric India Ltd/MDS/vinay carol Modular switch

3. PVC conduits/casing & capping

Modi/Universal / Atul / Bajaj Plast

4. PVC insulated copper wires

Ravicab/Rajnigandha / Finolex / Kalinga

5. Ceiling fan/Exhaust fan Bajaj/Crompton/Khaitan / Usha

6. MCCB GEPC / L&T / Siemens7. SFU - Changeover

SwitchesSiemens/ L&T/C&S/Havels

8. ELCB/ MCB/ MCB Distribution board

MDS/ Indo Asian / Havels/ Standard

9. Energy Meter BHEL / Havels/HPL / L & T10. Indicating lamps L&T/Siemens/Vaishno/Essen11. Indicating meters AE/IMP/MECO



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12. CT AE/Kappa/Pragati/Kalpa13. Cables Polycab/CCI/NICCO / RPG/

universal / Finolex / Fort Gloster / ASIAN/INCAB

14. Synchronous Timers L&T/Minilec/Indo Asian/MDS15. Push Buttons / Control

SelectorL&T/Siemens/Vaishno/Essen Switch

16. 17. GI/ Pipes Jindal Pipes Ltd.,/Omega/Kalinga / GST/ Surya / Khandelwal

18. Lighting Boards / LMB's As approved by Owner / Consultant

19. GS tubular Street light pole

As approved by Owner / Consultant

Items for which preferred makes are not indicated shall be procured only after approval of the make by owner/consultant.

8.14.15 Drawings and documentation

General

The scope of contractor includes supply of all drawings for elect. equipment GA & cable routing & cable schedule, earthings etc., documents, operation and maintenance manuals, catalogues, as built drawings of the plant, equipment supplied and work done for comments / approval / information / reference of Owner / consultant at no extra cost.

All drawings, specifications, furnished by the consultant shall be treated as strictly confidential property of the owner. All drawings and information furnished by the contractor shall become property of the owner.

8.14.16 List of drawings

Within 15 days from the effective date of contract, the contractor shall submit requisite copies of a list of all drawings and documents he proposes to submit for the contract. The drawings shall be categorised into (a) For approval of Owner (b) For Owner'’ information (c) As built drawings (d) Catalogue (e) Manufacturing drawings.



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The list shall be approved by the Owner and may be revised or extended if necessary for proper execution of work / documentation.

8.14.17 Approval of drawings / documents / manuals

The contractor shall furnish drawings as indicated in technical specification for each item for approval of the Owner / consultant according to agreed time schedule.

Contractor shall furnish, if requested, additional drawings, calculations, information to the consultant / Owner to enable him to examine / study the drawings for approval.

If incomplete drawings / documents not meeting the consultants requirements are sent, the responsibility for any delay in approval shall be that of contractor.

Where drawings are returned to the contractor with marking “Commented”, the contractor shall resubmit the revised drawings for approval.

Where the drawings are returned to the contractor with marking “Approved as Noted”, contractor shall make the necessary modifications / changes and resubmit revised drawings for final approval.

If any subsequent alternations are found necessary and approved by the consultant / owner, all drawings and data affected by such alterations shall be duly revised and re-submitted for the approval of the engineer as said above.

Owner / his consultant will scrutinise drawings / data furnished by contractor and comments, if any, will be communicated to the supplier within 2 weeks from the date of receipt.

In order to expedite the approval of drawings related to procurement / manufacture, contractor shall present the drawings to the Owner / consultant and incorporate the necessary changes after discussions and obtain the approval.



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Contractor shall be responsible for correctly incorporating all the points conveyed to him and resubmit the drawings to the Owner for final approval.

If the contractor is unable to incorporate some of the comments, such non-compliance shall be clearly stated in a forwarding letter with reasons without delay. However, it shall be Owner’s / his consultant’s discretion to accept or reject the non-compliance.

Work shall be carried out exactly as indicated on the approved drawings and data and no alternations shall be made without consent of the Engineer / Owner.

Approval of drawings by Owner / his consultant shall not relieve the supplier of his contractual obligations and responsibility for engineering, design, workmanship, materials and performance of the equipment.

8.14.18 As built drawings

All the drawings / documents supplied by the contractor for Owner’s comments / approval, if required, shall be revised / modified, after Owner / consultant’s approval, to incorporate all the modifications / changes necessitated at various stages of execution of contract viz.,

During inspection & testing at works and site. During erection, commissioning of individual equipment. During integrated commissioning of total system. Due to changes in associated connecting equipment not supplied

by the contractor (based on the information furnished by the Owner / consultant).

All the approved drawings, manufacturer’s drawings, installation drawings are included in as-built drawing.

8.14.19 Documents and test reports

Contractor shall furnish any relevant calculations asked for.

Contractor shall furnish of copies of factory routine and type test certificates wherever specified for all equipment. All statutory approval certificates shall also be furnished.



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After completion of site testing of all the equipment, contractor shall furnish the site test results of all equipment. This shall also indicate clearly the rectification carried out during testing, in case site test results vary very widely with factory test results, commissioning engineer’s observations shall be clearly indicated against corresponding equipment, identified by manufacturer’s serial numbers.

Contractor shall furnish indicating list of spares supplied for each equipment. The volume shall contain, manufacturer’s catalogue number of components with description. It shall also indicate precautions to be taken for storing.

8.14.20 Operation, instruction and maintenance manuals / catalogues

All relevant drawings, catalogues of equipment supplied and its operation and maintenance manuals as required shall be supplied.

8.14.21 Number of copies

The contractor shall submit drawings, documents ‘As built’ drawings, instruction manuals etc., in following number of copies to the Owner / consultant.

- For approval/resubmission for approval : 4 Copies- After approval : 6 Copies - As built drawings : 6 Copies and 1 set

of soft copy/RTF.- Operating and maintenance manuals,

equipment and system, catalogues, factory and site test certificate volumes, list of spares volumes.

: 6 Sets.

8.15 Drawings and Documentation for Power distribution, Shop Electrics and Illumination.

8.15.1 General

The scope of contractor includes supply of all drawings, documents, operation and maintenance manuals, catalogues, as built drawings of the plant, equipment supplied and work done, for comments/



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approval / information/ reference of Owner / consultant at no extra cost.

All drawings, specifications, furnished by the consultant shall be treated as strictly confidential property of the owner. All drawings and informations furnished by the contractor shall become property of the owner.

Drawings, specifications and schedule of quantities shall be treated as supplementary to each other and should anything appear in one that is not described in the other, no advantage shall be taken by the contractor for any such omission. For such discrepancy / inconsistency, the contractor shall seek the instructions from the consultant before proceeding with the work and the clarifications/ decisions given by the consultant shall be treated as final and binding on the contractor.

List of drawings

Alongwith the offer, the tenderer shall submit the following documents:

Calculation for equipment selectionSLD of all swithchboardsLayout of Sub-station/switchgear Room/MCC RoomBill of Quantities

Within 15 days from the effective date of contract, the contractor shall submit requisite copies of a list of all drawings and documents he proposes to submit for the contract. The drawings shall be scrutinized� into (a) For approval of Owner (b) For Owner’s information (c) As built drawings (d) Operation and maintenance manuals and catalogue (e) Manufacturing drawings.

The list shall be approved by the Owner and may be revised or extended if necessary for proper execution of work / documentation.

Each drawing and document in the list shall be identified as follows:

a) Serial numberb) Descriptive titlec) Proposed date of submission.



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Approval of drawings/ documents/ manuals

The contractor shall furnish drawings as indicated in technical specification for each item for approval of the Owner / consultant according to agreed time schedule.

Contractor shall furnish, if requested, additional drawings, calculations, information to the consultant/ Owner to enable him to examine / study the drawings for approval.

If incomplete drawings/ documents not meeting the consultants requirements are sent the responsibility for any delay in approval shall be that of contractor.

Where drawings are returned to the contractor with marking not approved. The contractor shall resubmit the revised drawings for approval.

Where the drawings are returned to the contractor with marking “ Approved as Noted” , contractor shall make the necessary modifications/ changes and resubmit revised drawings for final approval.

If any subsequent alterations are found necessary and approved by the consultant/ owner, all drawings and data are affected by such alterations shall be duly revised and re-submitted for the approval of the engineer as said above.

Owner/his consultant will � crutinize drawings/ data furnished by contractor and comments, if any, will be communicated to the supplier within 2 weeks from the date of receipt.

In order to expedite the approval of drawings related to procurement / manufacture, contractor shall present the drawings to the Owner / consultant and incorporate the necessary changes after discussions and obtain the approval.

Contractor shall be responsible for correctly incorporating all the points conveyed to him and resubmit the drawings to the Owner for final approval.



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If the contractor is unable to incorporate some of the comments, such non-compliance shall be clearly stated in a forwarding letter with reasons without delay. However it shall be Owner’s / his consultant’s discretion to accept or reject the non-compliance.

Work shall be carried out exactly as indicated on the approved drawings and data and no alterations shall be made without the written approval of the Engineer/ Owner.

Approval of drawings by Owner / his consultant shall not relieve the supplier of his contractual obligations and responsibility for engineering, design, workmanship, materials and performance of the equipment.

As built drawings

All the drawings/ documents supplied by the contractor for Owner’s comments/ approval, if required, shall be revised / modified, after Owner/ consultant’s approval, to incorporate all the modifications / changes necessitated at various stages of execution of contract viz.,

During inspection & testing at works and site During erection, commissioning of individual equipmentDuring integrated commissioning of total systemDue to changes in associated connecting equipment not supplied by the contractor (based on the information furnished by the Owner/ consultant)

Contractor shall furnish as-built drawings required for normal operations, maintenance, testing of all equipments in specified number of copies. All the approved drawings, manufacturer’s drawings, installation drawings are included in as-built drawing.

Documents and Test reports

Contractor shall furnish any relevant calculations asked for. It shall also contain manufacturer’s catalogues, operation and maintenance manuals for all types of relays used.

Contractor shall furnish bound volumes of copies of factory routine and type test certificates for all equipment.



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After completion of site testing of all the equipment, contractor shall furnish the site test results of all equipment. This shall also indicate clearly reifications carried out during testing, in case site test results vary very widely with factory test results, commissioning engineer’s observations shall be clearly indicated against corresponding equipment, identified by manufacturer’s serial number.

Contractor shall furnish bound volume indicating list of spares supplied for each equipment. The volume shall contain, manufacturer’s catalogue number of components with description. It shall also indicate precautions to be taken for storing.

Drawings and Documents

Instruction manual shall give step by step procedure for

Erection, testing and commissioningOperationMaintenance Repair

Instruction manual shall also contain ;

List of spare parts with ordering specifications and manufacturer’s cataloguesList of consumables with specifications, brand names and annual consumption figures.Drawings relevant for erection, operation, maintenance and repair of the equipment.Procedure for ordering spares.

Contractor shall submit the following data / documents in specified number of copies and reproduceable prior to handing over the installation to the owner, whichever is earlier.

All drawings approved by consultant / owner.

Equipment manufacturing drawings submitted for information of consultant / owner.

Equipment drawings required for operation and maintenance.



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Inspection reports, factory and site test certificates in bounded volume

As built drawings incorporating all site modifications

Instruction manuals and catalogues

List of spares

Number of copies

The contractor shall submit drawings, documents, ‘As Built’ drawings, instruction manuals etc. in following number of copies to the Owner / consultant :

- For approval / resubmission For approval : 5 copies- After approval : 6 copies- As built drawings : 8 copies &

1 soft copy on CD

��8. . Operating & maintenance manuals, equipment & system catalogues, factory & site test certificate volumes, list of spares

: 10 sets.

chap shop electrics illumination,r1

Documents

electrical equipment

plant earth main grid

control of drives

control desks

lt power

cable laying

control rooms

standards equipment