spec for 415v mcc, mldb

LPG BOTTLING PLANT , BATHINDA

Doc. No. 266763-000-SP-4004 Rev: B of 37

P:\Kolkata\Engineering\JOBS\OGO-269323-HPCL Bathinda-LPG\ELECTRICAL\03. Issued to client\PMCC MCC PDB MLDB\266763-000-SP-4004.doc

Specification for 415 V PMCC, BUS DUCT, MCC, PDB & MLDB

Hindustan Petroleum Corporation Ltd

8 S.V. Marg, Ballard Estate

Mumbai- 400 001

Mott MacDonald Consultants (India) Pvt. Ltd.

Kothari House, CTS No. 185

Off Andheri - Kurla Road

Andheri (East)

Mumbai 400 059


Doc. No. 266763-000-SP-4004 Rev: B of 37


List of Content Page No

1 Introduction 5

2 Location and Environmental Conditions 6

2.1 Plant Location 6

2.2 Environmental Conditions 6

2.3 Electrical System Data 6

3 Scope of Supply 6

3.1 Electrical Equipment & Material: 6

3.2 Engineering Services 9

3.3 Exclusions 9

4 Codes and Standards 10

4.1 General 10

4.2 Conflicting Requirements 10

5 Technical Particulars: 10

5.1 Operating Philosophy: 10

5.1.1 415 V PMCC(000-PMCC-001) 10

5.1.2 415 V BPMCC (000-BPMCC-001) 11

5.1.3 415 V PDB (000-PDB-001) 11

5.1.4 415 V MLDB (000-MLDB-001) 11

5.1.5 Motor Control philosophy. 11

5.2 Motor Feeder Requirement: 11

5.3 Construction: 12

5.4 Busbars: 13

5.5 Air Circuit Breakers (ACB): 14

5.6 Moulded Case Circuit Breakers (MCCB): 15

5.7 Contactors: 16

5.8 Over Load Relays & Timers: 16

5.9 Control Switches, Indication Lamps, Push Buttons & Control Fuses: 16

5.10 Indicating Instruments & Meters: 17

5.11 Current Transformers: 18

5.12 Potential Transformers: 18

5.13 Wiring and Identification: 19

5.14 Control Supply: 20

5.15 Space Heaters and Cubicle Illumination: 20

5.16 Earthing: 21

5.17 Busduct Terminations: 21

5.18 Cable Entry and Terminations: 21


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5.19 Capacitor Bank : 21

5.20 Nameplates: 21

5.21 Makes of Components 22

5.22 Tropical Protection 22

5.23 Painting 22

5.24 Quality assurance: 22

6 Inspection and testing: 23

7 Vendor documentation: 24

8 Spares and special tools: 25

8.1 Spares 25

8.2 Special tools 25

9 Installation and commissioning: 25

10 Packing and transportation: 25

11 Statutory Approval: 25

12 Guarantee: 26

Appendix-A: Table of Compliance. 27

Appendix-B: Electrical System Data 30

Appendix-C: Codes & Standards. 31

Appendix-D: Requisition for Engineering Documents 32

Appendix-E: Guaranteed Technical Particulars 34

Appendix-F: Electrical Drawings. 35

Appendix-G: Control Schematics drawings. 36

Appendix-H: Technical Specification for 415 V Bus Duct. 37


Doc. No. 266763-000-SP-4004 Rev: B of 37


1 Introduction

This specification is intended to cover the design, manufacture, assembly, testing at manufacturer's works,

supply & delivery, properly packed for transport F.O.R. site of 415V PMCC, MCC, Bus Duct, PDB & MLDB

complete with all accessories for efficient and trouble-free operation for the LPG Bottling Plant project at

Bathinda of Hindustan Petroleum Corporation Limited, India.

The scope of work shall also include, the supervision of erection, testing, commissioning and putting into

successful commercial operation of the switchgear furnished under this specification

Following are the definitions:

Company/Client/Owner

Shall mean Hindustan Petroleum Corporation Limited

(HPCL),

Consultant Shall mean Mott MacDonald Consultants India Pvt. Ltd.

(MMCI).

Manufacturer / Vendor Supplier of 415V PMCC, MCC,Bus duct, PDB, MLDB

etc.

Shall This is to be understood as mandatory in relation to the

requirements of this document.

Should This is to be understood as a strong recommendation to

comply with the requirements of this document.

Equipment This is to be understood as vendor supplied equipment

with all accessories.

The Vendor shall ensure that the design complies with the requirements of this specification and its

referenced specifications, data sheets & standards. The Guaranteed Technical Particulars, Appendix F,

which forms part of this specification, shall be completed by the Vendor. Deviation if any should be

specifically brought out at the offer stage in the Table of Compliance, Appendix A. Without the compliance

table and Guaranteed Technical Particulars can cause rejection of the offer. Failure to clearly identify

specific deviations if any shall be assumed by the Purchaser to be total compliance with the specification.

This specification does not relieve the Vendor from final guarantee as to materials, apparatus,

workmanship and performance of the equipment supplied.


Doc. No. 266763-000-SP-4004 Rev: B of 37


2 Location and Environmental Conditions

2.1 Plant Location

The Plant is situated at Village Phulo Khari, Taluka – Talwandi Sabo, District Bathinda Punjab.

PMCC/MCC/Bus Duct /MLDB listed in scope of supply shall be located in the MCC Room within plant

complex.

2.2 Environmental Conditions

Design ambient temperature for Electrical Equipment (Indoor): 50 0 C

Design ambient temperature for Electrical Equipment (Outdoor): 55 0 C

For other details Refer EIA Report for Site Enviormental condition.

2.3 Electrical System Data

Refer Doc No.: 266763-000-SP-4004BX [in Appendix – B] for details.

3 Scope of Supply

The following equipments shall be supplied, in accordance with this specification; standards stated herein

& enclosed appendices.

3.1 Electrical Equipment & Material:

Sr. No. Item Description Unit Quantity Remarks

415V PMCC/MCC/Bus duct/ PDB/MLDB as per following details:

1.0 000-PMCC 001 ( 415 V PMCC)

415V, Double Front, Compartmentalised Draw out

type, floor mounted, AL Bus bar PMCC as per

following details & attached Single Line diagram

Dwg. No 266763-000-410-002D.

Rated voltage 415 V

Highest system voltage 433 V

Rated Bus-bar current 1600 A

Short time withstands current 50 kA for 1 Sec.

No. of outgoing feeders As per SLD

Control supply Voltage Refer Appendix B

Set

1

2.0 000-BPMCC 001 ( 415 V MCC)

415V, Double Front, Compartmentalised Draw out


Doc. No. 266763-000-SP-4004 Rev: B of 37


type, floor mounted, AL Bus bar; Bottling Plant

MCC as per following details & attached

Single Line diagram Dwg. No 266763-000-410-

003D.

Rated voltage 415 V





Control supply Voltage Refer Appendix B

Set 1

3.0 000-BD 001( 415 V Bus Duct )

415V AL, non-segregated phase Bus Duct as per

following details & attached Annexure H for

specification of LV Bus Duct :

Rated voltage 415 V



Short time withstands current 50 kA for 1Sec.

Ref. Dwg. No. 266763-000-425-006D.

set

1

Exact bus duct

length will be

finalized during

detail engineering

stage. Vendor is

advised to quote

as on unit rate

basis.

4.0 000-PDB-001( 415 V PDB )

415V, Compartmentalized, Floor mounting, single

Front, and Fixed type auxiliary PDB as per

following details & attached Single Line diagram

Dwg. No. 269323-000-410-049D.

Rated voltage 415 V





Set

1

4.0 000-MLDB-001( 415 V MLDB )


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415V, Compartmentalized, Floor mounting,

Double Front, and Fixed type Main Lighting

Distribution Board as per following details &

attached Single Line Diagram Drawing No.

266763-000-410-004B.

Rated voltage 415 V





Set 1

Dummy Panel of following widths to account for

floor beams that may foul with the cable entries:

800mm wide No. Quote

unit rate


unit rate

5.0


unit rate

6.0 Unit rates for addition / deletion of::

6.1 Incomer Breaker Panel of each rating Quote

unit rate

6.2 Outgoing Motor feeder ( DOL) of each rating &

each scheme type

Quote

unit rate

6.3 Outgoing Motor feeder ( STAR/DELTA) of each

rating & each scheme type

Quote

unit rate

6.4 Outgoing Power feeders of each rating & each

scheme type

Quote

unit rate

Empty Panel without feeders but complete with

horizontal & vertical Busbars.

Main Busbars rated for

1600A

400A

250A


Doc. No. 266763-000-SP-4004 Rev: B of 37


Extension Box if required, for termination of

cables shall be included at no extra cost.

• Inspection and Testing as specified.

• Submission of documents as specified.

• Painting as specified.

• Preservation, preparation of shipment and delivery to site.

• List of Spares for two years normal operation.

• Start-up spares and commissioning spares.

• List of special tools required (Vendor to provide list with the bid).

• Any other items, required to make system complete.

3.2 Engineering Services

The Vendor shall provide engineering services, which shall include, but not necessarily be limited to, the

following:

• Providing/coordinating detailed design of all equipment and components within the scope of

supply. This will also include providing engineering/design layout of PMCC & Bus Duct matching

the customer’s general arrangement of the substation.

• Resolving engineering queries related to the equipment and components within the scope of

supply.

• Performing all relevant calculations pertaining to the equipment and components within the scope

of supply.

• Providing progress reports etc.

• Providing expediting services for all sub-vendors, if any.

• Providing quality assurance, including all sub-vendors if any with respect to ISO 9000 or

equivalent.

• Quality Assurance.

• Supervision of Installation/erection and commissioning.

• Training of client’s personnel at site / Vendor’s shop.

3.3 Exclusions

Installation/Erection & commissioning.


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4 Codes and Standards

4.1 General

The LV Switchgears shall meet the requirements of this specification and latest edition of applicable

standards listed in enclosed Appendix-C

4.2 Conflicting Requirements

In case of conflict between documents relating to the enquiry or purchase order, the following priority of

documents shall apply.

First priority : This engineering specification along with attached drawings/ data sheets

and subsequent purchase order & variations thereto.

Second priority : Relevant Indian /International standards.

Note: Should any conflict arise either before or after order placement the Vendor shall immediately

inform the Purchaser for technical resolution of the conflict.

5 Technical Particulars:

5.1 Operating Philosophy:

5.1.1 415 V PMCC(000-PMCC-001)

a) PMCC located in the MCC Room, will have two incomers; One from Grid Source through 1 MVA

distribution transformer via bus duct and other from DG AMF cum Control Panel (Common for 2

nos. 500KVA DG Sets) by single core cables. For details Refer 415 V PMCC single Line diagram

Dwg. No. 266763-000-410-002D.

Under Normal condition, Incomer -I will be energized independently from Grid Source and feeding

power supply to PMCC Loads. In case of failure of power supply at –I, Incomer –II will be fed from

DG Panel & will supply the entire plant load.

b) There shall be electrical interlocking among two incomers such that only one circuit breaker out of

two shall be closed at a time.

c) Under loss of grid mains power supply, DG-1 (500KVA) & DG-2 (500KVA) will start on AMF signal

from Line PT. DG Incoming breaker at PMCC will be closed manually after getting close permisive

from DG AMF Cum Control Panel. The running of DG-1 & /or DG-2 shall depend on the total load

connected to PMCC which will be sensed & controlled by DG AMF Cum Control Panel. The two

DGs will be synchronised at DG AMF Cum Control Panel.

d) On resumption of grid power, Changeover from ‘DG-Incomer’ to grid main power supply shall be

done manually, with break in power supply (i.e. DGs shall not be paralleled with the grid at any

time). However provision to be kept at the PMCC panel for automatic changeover by momentary

paralleling between the two incomers on resumption of grid power without break in power supply.

e) In case of loss of supply on both the incomers, the breaker status shall be maintained.


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5.1.2 415 V BPMCC (000-BPMCC-001)

a) Bottling Plant MCC (130-BPMCC-001) located in the MCC Room, will have one incomer feeding

from PMCC supplying to the Bottling Plant loads. Refer Dwg. No 266763-000-410-003D for details.

5.1.3 415 V PDB (000-PDB-001)

a) Auxiliary power distribution board (130-PDB-001) located in the MCC Room, will have one incomer

feeding from PMCC, supplying to the auxiliary 415 V & 240V loads. Refer Dwg. No 266763-000-

410-049 for details.

5.1.4 415 V MLDB (000-MLDB-001)

a) Main Lighting Distribution board shall have two incomers. One Incomer form 415 V PMCC & Other

from the 250 kVA Emergency DG set (DG-3). Refer Dwg. No. 266763-000-410-004B for details.

b) Critical loads (viz. Jockey Air Compressor/Jockey pump motors) also will be fed from this

distribution board.

c) During normal operating condition it will be fed from the PMCC. In case loss of grid mains power

supply and DG-1 &/or DG-2 fail to start, DG-3 shall be started manually & feed the critical loads

including entire lighting loads.

5.1.5 Motor Control philosophy.

Refer control Schematic drawing no. 269323-000-410-050D. However above control schematic as referred

above is indicative only. Vendor shall develop the detail control circuits as required. Vendor is advised to

ensure that the following control philosophy will be taken care during their detail design.

a) The Start and normal Stop operation for all motors except VFD drives will be done from the local

control station manually by actuation of Start and Stop push buttons of the respective equipment.

The indications of “Motor overload”, “Motor ON”, “Motor OFF” will be displayed on the respective

MCC feeder with “Amber” “Red”, “Green” colored indicating lamps respectively.

b) PMCC/MCC /MLDB will have the emergency Stop Push button for all the drives.

c) Standby motors shall come in service manually during outage of working motors or as and when

required as per process requirements.

d) VFD fed motors shall be controlled from local control stations through contactor provided at VFD.

5.2 Motor Feeder Requirement:

5.2.1 The manufacturer shall consider feeder rating, feeder type (Schematic), busbar rating, SFU rating,

CT & ammeter requirements etc., from the respective Single Line Diagram & Schematic drawings.

Manufacturer shall obtain the motor tag number and description from the feeder list for nameplates

on each feeder. The SLD depict the minimum ratings of each equipment. The final rating will be as

per Type -2 coordination as per IEC 60947 .

5.2.2 Motor starters

a) The manufacturer shall wire the starters as per enclosed Motor starter schematic drawings.


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b) Motors up to and including 22 kW shall be with DOL starter and motors above 22kW shall be with

star delta starter unless otherwise specified. All motor feeders shall have electronic over current

relays except VFD Feeders.

c) Current transformers shall be provided for current indication in Local Control Station for all motors

rated 7.5 kW and above.

d) Circuit for motor space heating shall be provided for all outgoing motor feeder modules rated 30kW

and above. Separate 240 V AC busbar shall be considered which will be fed from a separate

source.

e) Feeders with Forward – reverse motors shall have suitable control logic.

5.3 Construction:

5.3.1 Switchgears shall be totally enclosed, metal clad, sheet steel fabricated, dust & Vermin proof, free

standing, floor mounted type with self-supporting structure and provided with integral base frame

at bottom. Switchgears shall be in double-front, draw-out execution & fully compartmentalized. The

Panels shall have IP 4X degree of protection with gasketed doors. All doors shall be fastened to

the vertical section by means of concealed hinges. The sides, top & bottom of each vertical section

shall be covered with removable screw-on plates with formed edges all around.

5.3.2 The Switchgears shall be easily extensible on either side by the addition of vertical sections. It

shall be possible to extent the Switchgears, irrespective of the type of end panel and design shall

be such as to permit addition of extension panels of a type other than the type of end panel. It shall

be of unit construction suitable for splitting into sections for shipping to site and to be correctly re-

erected on prepared foundations without skilled supervision. The individual shipping section shall

comprise not more than three verticals. For each shipping section adequate lifting facilities such as

hooks for ease of handling on site shall be provided. These hooks when removed shall not affect

the degree of protection of Panels. Vendor shall supply accessories such as bus links, etc. for

connecting various shipping sections at site.

5.3.3 The Switchgears shall be fabricated preferably from CRCA sheet steel of minimum thickness

2mm. for load bearing members, 1.6 mm for non-load bearing members & 3mm for gland plates.

Removable type undrilled gland plates shall be provided at bottom of the panel.

5.3.4 The height of Switchgears shall be constant throughout the length, but not exceeding 2500mm.

The arrangement of feeders shall ensure that operating height of components shall be above

350mm & below 1800mm from finished floor level. Cable alley width shall be 300mm.

5.3.5 Busbars shall not be exposed when CB / Starter module is removed. Insulated and isolated

vertical busbars are required. Barriers shall be provided to separate the bus compartment from

wiring space at top, bottom and sides of each section and shall be adequate to prevent accidental

contact and restrict propagation of unit originated arc into the busbar compartment.

5.3.6 Starter Unit / CB shall be draw-out type. Each starter/CB compartment door shall be interlocked

with door mechanically so that it cannot be opened unless the Switch operating handle is moved to

the "OFF" position. However, the handle mechanisms of the Switch shall be so designed that a

qualified person can defeat the door interlock for purpose of inspection without interrupting power.


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5.3.7 Each draw-out unit shall be equipped with a mechanical safety interlock such that:

a) A withdrawn unit with the Switch in the 'ON' position cannot be inserted into the vertical structure

and make contact with the vertical bus.

b) Units in the fully inserted position shall not be able to be withdrawn with the Switch in the 'ON'

(closed) position.

5.3.8 Front access shall be available to all components in each cubicle, which require adjustment,

maintenance or replacement. Checking & removal of components shall be possible without

disturbing adjacent equipment. All auxiliary equipment shall be easily accessible. Setting of relays

shall be possible without de-energizing other equipment. Access shall be available to all cable

glands & multicore terminal blocks by means of sheet steel hinged doors, designed to give the

maximum possible access to the cable terminations. The cable alley door shall be provided with

bolts, which can be opened with special keys but by authorized person. Plug-in stab construction

shall assure positive electrical and mechanical contact to the bus under all loads and rated fault

conditions.

5.3.9 All incomers, bus couplers & outgoing feeder shall be designated as per feeder list. Incoming

feeder shall be mounted in separate vertical section. The arrangement of feeders in the panel shall

take into consideration the number & size of cables required for the feeders. Extension box if

required for termination of cables shall be included.

5.3.10 Vendor shall provide partition between two power cable terminations of outgoing feeders. Vendor

shall provide FRP shrouds on outgoing feeder terminations.

5.3.11 Base frame:

Switchgears shall be provided with integral base frame which shall be bolted/welded on the cross

members provided by owner. Amply dimensioned oblong holes shall be provided on the base

frame. The base frame shall be of standard sections, re-rolled sections will not be acceptable.

Vendor shall give base frame details in foundation drawing. Cross members or foundation on

which base frame is mounted is excluded from Vendor’s Scope of supply.

5.4 Busbars:

5.4.1 The Busbars shall be made of Electrolytic grade high conductivity Aluminum with continuous rating

as required. All busbars & their main current carrying connections shall have same cross sectional

area throughout the length. All busbars shall be insulated with heat shrinkable PVC sleeves. All

busbars shall be colour coded such that on removal of any door the phases shall be identifiable.

All busbars shall be accessible for inspection & easily replaceable. Control & earth bus bar shall

be of copper bus.

5.4.2 Busbar size shall be determined by taking into consideration the specified continuous current

rating & fault level for 1 sec, without exceeding the busbar final temperature of 95ºC. The busbars

shall be supported by insulators of non-carbonizing material resistant to acid and alkali and having

non-hygroscopic characteristics and braced to withstand fault level specified. The main horizontal

busbars shall be located at the top. Size of neutral busbar may be half the size of main busbars.

Neutral busbar shall include taps for each outgoing cable connection in each vertical section. The

clearance between live parts & earth shall be as per IS/IEC.

5.4.3 Busbars and connections shall be secured in such a manner that the insulators are not subjected

to bending forces under short circuit conditions. Dynamic stresses shall be calculated on the basis

of peak short circuit current. For long Busbars, suitable expansion joints shall be provided.


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5.4.4 Separate set of vertical busbars shall be provided for front and rear sections. The vertical busbars

shall be sized to carry continuously at least the sum of rated currents of the connected circuit

breakers. Short time rating of vertical busbars shall be same as main busbars.

5.4.5 It shall be possible to extend the busbars at either end of the switchboard for addition of future

units. Both ends of busbars must be suitably drilled for this purpose.

5.4.6 Where busbars are taken through the partitions of adjacent cubicles, fireproof shrouding shall be

provided to prevent spread of fire from one unit to the next.

5.4.7 Thermal design of the busbars shall be based on installation of the switchgear in poorly ventilated

conditions. The cooling air volume shall take into account only the bus enclosure.

5.5 Air Circuit Breakers (ACB):

5.5.1 The Circuit Breaker shall be manually & electrically operated, triple pole, air break, and draw-out

type with solid manually detachable type neutral. Short circuit withstands capacity for ACBs shall

be same as that of switchgear. Breaker continuous current ratings shall be in panel ratings. No

external mean shall be provided for limiting temperature rise in panel box.

5.5.2 The charging mechanism of the circuit breaker shall be motor operated. The close / trip control

switch to be interlocked to trip before close. The closing and tripping circuits shall be self-opening

on completion of their respective functions irrespective of the position of the control switch.

Manual closing devices shall also be provided. Operating handle shall be provided for charging the

spring manually.

5.5.3 The Circuit Breaker shall be provided with mechanical ON/OFF, TRIP and SPRING CHARGED,

DISCHARGED indication, T/N/C control switch, mechanical trip push button, mechanical ‘close'

push button, and padlocking facility.

5.5.4 The circuit breaker shall be electrically and mechanically trip free, with anti-pumping feature.

5.5.5 The breaker shall be provided with minimum 6 NO + 6 NC auxiliary contacts. However, the exact

requirement shall be as per the details given in the Scheme Specific Requirements. 20% auxiliary

contacts (Min. 3 NO + 3 NC) shall be provided for Owner's exclusive use. All spare contacts shall

be wired up to terminal blocks. Auxiliary contactor or relay shall be used to multiply contacts.

5.5.6 The auxiliary contact for the shunt trip shall be of advanced nature such that the auxiliary contact

close before main contacts.

5.5.7 The main and secondary isolating contacts of the circuit breaker shall be of self-aligning type. The

main isolating contact shall have continuous rating equal to the rating of the breaker. The

secondary isolating contact shall be of wiping contact type.

5.5.8 The fixed portion of the circuit breaker shall have slide rail arrangement over which the chassis can

move smoothly. The breaker shall have 3 distinct positions, such as "SERVICE", "TEST" and

"ISOLATED", with padlocking facility in ‘Test’ & ‘Isolated’ position. Proper mechanical indication

shall be provided to locate these three positions without opening the compartment door. It shall be

possible to bring the circuit breaker to isolated position with the help of external lever without

opening the compartment door. A stop block shall be provided on the slide rails to prevent the

movement of the circuit breaker out of the compartment when it reaches the isolated position so

that any accidental fall can be avoided.

5.5.9 Wherever cut-outs are provided for the circuit breaker control box, proper continuous gaskets shall

be provided. Provision shall be made for closing the cut-out provided for the control boxes when

the C.B. is taken out of the compartment.


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5.5.10 The circuit breaker shall be provided with automatic safety shutters, so that before the breaker

reaches `isolated' position the main isolating contacts are completely shrouded. When the circuit

breaker compartment door is open it must not be possible to touch the live parts. All removable

covers protecting live parts shall be clearly labelled with warning notices reading LIVE PARTS.

ISOLATE ELSEWHERE BEFORE REMOVING COVER”.

5.5.11 The circuit breaker compartment shall be so designed that hot gases produced during fault shall

be lead away from the operator.

5.5.12 It shall be possible to readily remove the arc chutes for routine inspection of the contacts with the

circuit breaker in the “withdrawn” position.

5.5.13 The protective relays and instruments shall be mounted in separate compartment. This

compartment shall be along side and immediately next to the controlled breaker.

5.5.14 The CB shall be provided with microprocessor based direct acting protection releases for overload,

short circuit & earth fault. The releases shall be programmable & adjustable type.

5.5.15 Circuit breakers shall be with communication unit for :

a) Breaker status, alarm and maintenance information.

b) Control commands & configuration settings.

5.5.16 The following interlocks shall be provided on the circuit breaker :

a) It shall not be possible to withdraw the circuit breaker from the service position with the contacts of

the breaker closed.

b) It shall not be possible to close the circuit breaker unless any one of the three positions is located,

the service position, a definitely located test position, or isolated position.

c) It shall not be possible to open the compartment door when the circuit breaker is ON.

d) The circuit breaker can be padlocked in OFF position with door interlock defeat facility.

e) Castle key interlock shall be provided for incomers & bus couplers to prevent parallel operation

where specified.

5.5.17 All the non-conducting metal parts of the circuit breaker trolley shall be bonded together and shall

make perfect electrical connection to earth through substantial sliding contacts, at service and test

positions. Such sliding contacts shall be arranged to make before power plug in and interrupt after

power draw out.

5.5.18 All circuit breakers of same rating shall be identical in all respects and shall be interchangeable.

However, breakers of different ratings shall not be interchangeable.

5.5.19 Breaker handling trucks / trolleys shall be included in the scope.

5.6 Moulded Case Circuit Breakers (MCCB):

5.6.1 MCCBs shall be of triple pole construction for panel mounting, operating mechanism shall be trip

free, quick make quick break type. Short Circuit withstand capacity for MCCBs shall be same as

that of switchgear.

5.6.2 The MCCBs shall be provided with front operating handles & mechanical ON/OFF indicators. In

case of trip handles shall remain in an intermediate position.


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5.6.3 MCCBs shall be provided with releases as per schematic drawings. The releases shall be

adjustable type.

5.6.4 MCCBs in individual motor circuits shall be designed for application, in combination with motor

starter units. They shall operate on the magnetic principle with accurate sensing element in each

pole to provide short circuit protection.

5.6.5 MCCBs shall have following accessories & features:

a) Auxiliary contact set of 1 NO + 1NC

b) Fault signalling contact set of 1 NO + 1NC

c) Insulation shields to isolate the connection between each pole.

d) Finger protection plate to prevent accidental contact.

e) The compartment door shall be interlocked with handle of MCCB.

5.7 Contactors:

5.7.1 The air break contactors shall be of electromechanical, triple pole type conforming to AC3 category

of duty. However for motors in inching or reversing rotating service, utilization category AC4 shall

be used. Contactors used for Capacitor bank application shall be suitable for Capacitor switching

compitable.

5.7.2 The auxiliary contactors shall have 4 NO + 4 NC contacts with at least 2 NO + 2 NC auxiliary

contacts for owner's exclusive use. The spare contacts shall be wired up to the terminal block.

5.7.3 The contactor coil shall be suitable for the specified control voltage. The coils shall have grade ‘E’

insulation and shall be suitable for use in the ambient temperature specified elsewhere. The

design of the contactor shall ensure easy access to auxiliary contacts and coil. Mechanical ON-

OFF indication shall be provided for the contactors. Wherever mechanical indications are not

provided, indicating lamps shall be provided for ON indication of the contactor. The contactor shall

pick up at 85% to 110 % of the control voltage and shall not drop out for voltage up to 45%.

5.7.4 The contactor rating shall be chosen to provide Type-2 co-ordination as per IEC 60947. In case of

Star-delta starter feeder, rating of all three contactors shall be identical.

5.8 Over Load Relays & Timers:

5.8.1 Motor Overload Protection Relays

Overload protection relays shall be of Electronic type to be installed in all phases & shall have in-built Single Phasing Protection feature. Relay shall be temperature compensated type with manually reset facility on the front of the compartment door.

Overload protection relays shall be direct line mounted upto 50A rating. Higher ratings shall utilize CTs. Relays shall be with adjustable trip class -10, 20, 30 as per IEC 60947.

5.8.2 Timers

Timers shall have adjustable time setting of 0 - 60 secs. The time settings, where specified shall be accurately set before dispatch of the switchboard for all ‘ON’ delay & ‘OFF’ delay timers.

5.9 Control Switches, Indication Lamps, Push Buttons & Control Fuses:

5.9.1 Each Air circuit breaker shall be provided with trip-neutral-close control switch and local remote

selector switch.


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5.9.2 All circuit breaker operating switches shall be of the pistol grip type, spring return to neutral and

lockable in neutral position. They shall be arranged to close the breaker by being turned

clockwise. The trip, neutral and close positions shall be clearly indicated. The movement shall be

such that the switch cannot be operated inadvertently and that it is mechanically interlocked to trip

before close. The operating switch shall be located on the centre line at about 1.5 meters from the

floor level. Two spare ways shall be provided on these switches.

5.9.3 Ammeter selector switches shall have `make` before break feature on its contacts. The selector

switch shall generally have four positions for reading three phase currents and the neutral current.

5.9.4 The voltmeter selector switch shall also have four positions. Three shall be used to measure

phase to phase voltages and the fourth shall be ‘OFF’ position.

5.9.5 Based on operational philosophy, if required, Auto / Manual selector switch shall be provided.

5.9.5 Indication lamps shall be cluster of LEDs. Voltage rating of LED shall be equal to rating of control

circuit voltage. The covers of the lamp shall be heat resistant.

5.9.6 Indication lamps shall be provided for each feeder in Switchgear as per feeder schematics.

5.9.7 Emergency Stop push buttons shall be mushroom headed, stayput type, with press to lock & twist

to unlock (release) operation.

5.9.8 Colour coding of Push Buttons & Indication Lamps shall be as follows:-

Push Buttons Lamps (LED Type) Push Buttons Lamps (LED Type)

Start or On - Green Running or On - Red

Stop or Off - Red Stop or Off - Green

Alarm Reset - Yellow Fault - Amber

Acknowledge - Black Trip coil healthy - White

O/L Reset - Blue Spring charged - Blue

Trip circuit healthy check - Black Breaker in Service - Blue

DC Failure - Red

Control supply healthy - White

5.10 Indicating Instruments & Meters:

5.10.1 All indicating instruments and meters shall be capable of carrying continuously their full load

currents and full voltage across their pressure coils. They shall not be damaged by the passage of

fault currents or the existence of over pressure on the primary side of their instrument transformers

for the maximum permitted duration of fault conditions, which may occur during normal operation.

All instruments and meters shall be back connected.

5.10.2 The type and quantity of the measuring instruments shall be as specified in schematic drawings.

5.10.3 All instruments shall be of the flush mounting type and shall have an enclosure with a degree of

protection of at least IP 52.

5.10.4 They shall be equipped with non-glare, non-reflecting windows. Standardized dimensions shall be

used in accordance with IEC 60473.


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5.10.5 Indicating instruments shall be in accordance with the relevant IEC standards and have an

accuracy class 1. Analogue meters should be of the square pattern type 96 x 96 mm, and

mounted at a suitable height for easy reading from the front. Scales shall be in actual values.

5.10.6 Meters shall be installed on the door of the respective functional units.

5.10.7 Ammeters for motor current indication shall have suitable suppressed scale corresponding to

motor starting current.

5.11 Current Transformers:

5.11.1 The CTs shall be Resin cast bar type. CT secondary shall be 1A. The minimum burden shall be

15VA. However, current transformers shall have sufficient capacity to operate with the burden

imposed by the devices shown on drawings with their accuracy classification. Separate cores

shall be used for metering and protection.

5.11.2 CTs for measuring instruments shall have an accuracy class 1.0 and accuracy limit factor less than

5.0. If a metering load is fed from a protection CT, suitable 1/1 or 5/5 ratio saturable interposing

CTs shall be use. CTs for Protection shall have an accuracy class 5P and saturation factor less

than 0. CTs for restricted earth fault protection shall confirm to class X.

5.11.3 The CTs shall be capable to withstand dynamic and thermal stresses originated by the fault

current.

5.11.4 The CTs shall be suitably insulated and the mounting of the CTs shall facilitate easy maintenance.

The CTs shall be mounted in stationary part of switchgear.

5.11.5 Shorting links shall be provided for the secondary of the CTs when wired to terminals.

5.11.5 One side of current transformer secondary shall be grounded in the compartment with the meters

or relays which they serve and each CT group shall be grounded with a separate identified lead

which may be disconnected for testing.

5.11.6 All motors rated 7.5 kW and above, the CT signal shall be brought out as shown in schematics for

current indication at Local Control Station. CT terminals shall be suitable for termination of 4

sq.mm cable.

5.11.7 CT parameters shall be verified by vendor, based on connected relay make & relay manufacturers

recommendation.

5.12 Potential Transformers:

5.12.1 The Potential Transformers shall be epoxy cast resin type. Potential transformers shall have

sufficient capacity to operate with the burden imposed by the devices shown on the schematic

drawings with their accuracy classification.

5.12.2 The Potential Transformers shall have an accuracy class 1.0 for voltmeter only. For energy

management / others, it shall have accuracy class of 3.0

5.12.3 The primary of the Potential Transformers shall be rated for 412 volts and the secondary for 110

volts. PT’s shall have a continuous voltage factor of 1.2 with short time over voltage factors as

below:

a) 1.5 for 30 seconds in case of effectively earthed systems.

b) 1.9 for 8 hours in case of non-effectively earthed systems.

5.12.4 The PT shall be provided with HRC fuse on the primary side and MCB on secondary side.


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5.12.5 For proper relaying, one side of PT secondary shall be grounded at the transformer and the

ground connection shall be identified and removable for testing.

5.12.6 Test terminals shall be provided for PT circuits.

5.13 Wiring and Identification:

5.13.1 All wiring for control signal, protection and metering shall be by PVC insulated, 650 Volt grade,

copper stranded conductor wires of minimum 1.5 sq.mm section. For CT secondary circuit wires

of 2.5 sq.mm copper conductors minimum shall be used. Wiring shall run in enclosed channel and

shall leave at least 25% spare space for future use. Wires for connection between moving parts

shall be flexible stranded copper conductors and the same shall be soldered at the ends before

connections are made.

5.13.2 Terminal strips for connecting incoming control cables shall be channel mounted type of adequate

size and shall be located conveniently for easy accessibility, without danger of contact with live

part, ease of connection and shall be separated by barriers from power circuits. At least 20% spare

terminals shall be provided in each terminal strips. CT secondary lead terminals shall be provided

with shorting links.

5.13.3 All spare contacts of auxiliary relays, timers, contactors etc. shall be wired up to terminals block.

Terminal Block shall be 600V grade 10 Amps rated.

5.13.4 Sufficient terminals shall be provided on each terminal strip to ensure that not more than one

outgoing wire is connected per terminal. The wire shall be identified by numbered ferrules at each

end, in accordance with the connection diagram. All ferrules shall be made of non-deteriorating

materials. The ferrules shall be firmly located on each wire so that they cannot move or turn freely

on the wire.

5.13.5 All inter-panel control wiring shall be done by the switchgear vendor. All wiring shall be properly

bunched, cleated, & supported on a panel frame and shall run in plastic wire ducts. The inter panel

wiring shall be taken through PVC sleeves or suitable rubber grommets.

Colour Coding for internal panel wiring shall be as follows:

Power Wires - Red, Yellow, Blue for Phases.

Control Wires - Grey.

Neutral Wires - Black.

Ground Wires - Yellow & Green.

5.13.7 Each shipping section of each Switchgear shall be provided with one marshalling box. Wiring

between individual modules to marshalling box shall be done by Vendor. Wiring from Switchgear

to field controls like local PB Stations / Panels will be done directly from individual modules,

however, interconnection between Switchgear and control room panels like DCS / PLC / Relay

Panel will be done through this marshalling box. Vendor shall refer attached scheme drawings to

estimate number of signals per module, up to marshalling box. Actual number of signals shall be

confirmed at the time of drawing approval. Each marshalling box shall have two separate terminal

blocks, one for outgoing signals to DCS / PLC / Relay Panel and other for incoming signals from

DCS / PLC / Relay Panel. Vendor shall provide 25% spare terminals in each terminal block in

marshalling box.


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5.14 Control Supply:

5.14.1 Control supply for control, indication, space heater etc. shall be derived within the switchgear by

vendor. Vendors shall provide auxiliary / control supply bus in the switchgear throughout its length

for further distribution inside the switchgear. Vendors shall also provide suitable MCB for receiving,

distributing & in each sub-circuit as per requirement.

5.14.2 Auxiliary Busbars of thick electrolytic tough pitch copper shall be provided for following

applications. Exact number of bus bars shall depend on various controls, metering and auxiliary

power distribution requirements.

5.14.3 ACB [spring charging motors], Panel / Motor space heater supply – 240V AC, 1 ph, 50Hz, to be

derived by vendor.

5.14.4 Control supply for Annunciators, ACB [indications, closing & tripping coils] – 110V DC, from clients

DC UPS.

5.14.5 Control supply for motor starter control circuits – 110V AC via control transformer, to be derived by

vendor.

5.14.6 Space Heaters – 240 AC derived from Lighting DB.

5.14.7 Two number 110V DC power supply feeders shall be provided for each switchgear from owners

DC UPS. Suitable DC control supply monitoring & selection scheme shall be developed by vendor.

Any other intermediate voltage required in the panel shall be derived by providing suitable control

transformer.

5.14.8 Control Transformer & Control Circuits:

a) Control transformer shall be double wound, air cooled type with one leg of secondary earthed unl-

ess otherwise specified.

b) VA rating of the Control transformer to be adequate to supply about 150% of the control loads of

the switchgear. Voltage regulation of the Control transformer shall be limited to 4%.

c) The control supply in Switchgear shall be derived from control transformer with 100% standby. The

control transformers in each panel shall have power supply from each of the incomer. Out of the

two control transformers one shall be working and other will be standby.

d) Auto-change over system shall be provided for control supply from working control transformer to

standby control transformer and vice versa as per schematic drawings attached.

5.15 Space Heaters and Cubicle Illumination:

5.15.1 Adequately rated anti-condensation space heaters shall be provided in each breaker panel and in

cable alleys of the MCC to maintain MCC inside temperature, 5°C above outside ambient

temperature.

5.15.2 Space heater shall be strip type, rated for operation on 240V, single phase, 50 Hz. A.C. supply

unless otherwise specified.

5.15.3 Each space heater shall be complete with a rotary type ON/OFF switch, MCB in the phase, neutral

link in neutral and a control thermostat.

5.15.4 A separate DP isolator and MCB shall be provided in motor feeders for control of space heaters of

motors. These shall be wired through a 'NC' contact of the contactor / circuit breaker for motor

control.


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5.15.5 Each vertical panel shall have fluorescent light fittings for internal cubicle illumination with door

switch.

5.15.6 240V, 15A SPN Industrial socket outlet, complete with MCB & earth leakage protection shall be

provided in each vertical panel.

5.16 Earthing:

5.16.1 An earth bus of at least 50mm x 10mm aluminium shall be provided. The earth bus shall be

electrically continuous and shall run the full extent of each board. The earth bus shall be of same

material as the main busbars. Each unit shall be constructed to ensure satisfactory electrical

continuity between all metal parts not intended to be live and the earth terminals of the unit.

5.16.2 At each end of switchgear, suitable slots shall be provided on main earth bus for connection to

Owner's Earth. The earth bus shall be accessible in each cable compartment either directly or

through a branch extension to ground the cable armour and shields.

5.16.3 All doors and movable parts shall be connected to the earth bus with flexible copper connections.

All non-current carrying metallic parts of the equipment shall be earthed. Earth bus shall be

brought back to cable compartment and earthing bolts shall be provided to ground cable armours.

5.17 Busduct Terminations:

5.17.1 PMCC Incomer will be connected to Transformers by Non segregated Busducts (with Aluminum

Busbars) from top. Vendor shall furnish flange details for Busduct connection.

5.18 Cable Entry and Terminations:

5.18.1 For Switchgears, opening with removable gland plate for cable entry shall be provided at the

bottom for both incoming and outgoing cables. Terminals shall be located sufficiently away from

gland plate to facilitate easy connection. Gland plate shall be minimum 3 mm thick.

5.18.2 All terminal blocks shall be furnished with white marking strips marked with terminal numbers in

accordance with the wiring diagrams. The terminal blocks shall be physically grouped and located

suitably for termination of the cables. Terminal block in all drawout units shall be furnished with

pull apart terminals to connect all outgoing wires and shall be furnished with 20% spare terminals

at least.

5.18.3 Suitable arrangement shall be made in cable alley for supporting incoming & outgoing cables.

Terminal blocks shall not be used to support cables.

5.19 Capacitor Bank :

PMCC shall have capacitor bank for power factor correction. 300 kvAR Capacitor bank with

suitable combination of basic unit size will be housed in the PMCC Panel along with the APFC

(automatic power factor correction) relay. For Details, refer technical specification for Capacitor

bank Document No. 266763-000-SP-4006.

5.20 Nameplates:

5.20.1 Permanent non-corrosive nameplate with engraved white letters on black background indicating

the switchgear designation shall be fixed at the top of the central panel. A separate nameplate

giving feeder details shall be provided for each feeder.

5.20.2 Name plates shall contain the following information:


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a) Manufacturer

b) Basic technical data such as rated voltage, rated current, etc.

c) Country of origin.

d) Certification data such as UL certificate number etc.

e) Each feeder shall be labelled giving following details

- Equipment number as per feeder list

- Description as per feeder list

- Feeder No. as per manufactures GA

- KW Rating as per feeder list

- Scheme reference.

5.20.3 Nameplates shall be provided for each equipment (lamps, push button stations, switches, relays,

Auxiliary contactors etc.) mounted on the switchgear. Special warning plates shall be provided on

all removable covers or doors giving access to high voltage cables / busbars and inside the

switchgear wherever considered necessary. Danger labels shall have black letters on a yellow

background.

5.20.4 Internal labels and components identifications shall correspond with identities or circuit references

as shown on the schematic diagrams. All external labels shall be attached by screws or rivets only

and not by adhesive.

5.21 Makes of Components

5.21.1 Manufacturer shall furnish standard list of components makes for the complete the 415V

switchgear assembly. This list must be included with the offer.

5.21.2 Make of Numerical Relays shall be Areva / Siemens / ABB. Electronic overload relay shall be

EOCR or equivalent type.

5.22 Tropical Protection

5.22.1 All equipment, accessories and wiring shall have fungus protection, involving special treatment of

insulation and metal against fungus, insects & corrosion.

5.22.2 Screens of corrosion resistant material shall be furnished on all ventilating louvers to prevent the

entrance of insects.

5.23 Painting

5.23.1 All metal surfaces shall be thoroughly cleaned and degreased, pickled and phosphatised.

Thereafter, a coat of phosphate paint and a coat of zinc chromate primer shall be applied. After

removing all imperfections, all metal surfaces shall be sprayed with two coats of final paint as per

colour shade RAL 7032. Final coat shall be of epoxy based. All unpainted parts shall be plated to

prevent corrosion.

5.24 Quality assurance:

5.24.1 The Manufacturer is expected to demonstrate that he has working Quality Assurance System

which complies with ISO 9001 or may be appropriate to the type of contract and his product.

5.24.2 If the Vendor elects to sub-contract part of the work he shall ensure that only those sub-contractors

or suppliers are used who can demonstrate that they operate Quality Systems based on ISO 9001


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or ISO 9002 as applicable. The Vendor shall give his sub-contractors or suppliers assistance in

attaining the required standard, if necessary. This shall not relieve the Vendor of his responsibility

for the quality of the finished work. The Owner reserves the right to audit the Vendor’s Quality

System.

5.24.3 The Vendor shall assign sufficient full time personnel to the Project to ensure the Quality

Assurance / Quality Control System, documented in a Quality Assurance / Control Manual, is

maintained and kept up-to-date throughout the duration of any purchase order. The Vendor’s

Quality Assurance / Control System shall become an integral part of any Purchase Order. Vendor

shall organize a prefabrication / inspection meeting with the Owner.

Within 3 weeks from the date of Purchase Order the Manufacturer shall submit a “Quality

Assurance Plan” for the review of the Owner.

6 Inspection and testing:

6.1 The responsibility for inspection, certification, etc. of all materials, parts lies with the Vendor.

6.2 The Vendor shall specify all of the inspection and testing requirements in the quality plan which

shall identify the activities requiring the Owner’s approval, review, witnessing etc.

Inspection and testing requirements shall be in accordance with this specification, other All

Equipment shall be inspected for compliances with:

a) Requirement of Owner’s specification & correspondence therefore.

b) Applicable codes, standards and specifications, which shall also include sub- referenced

standards therein.

c) Test and Inspection Plans produced by the vendor.

6.3 Inspectors have the right to request additional inspections or tests to ensure that the equipment

complies with the specification and all relevant codes & standards.

6.4 Manufacturer shall furnish valid Type Test Certificates of similar models along with the offer. Fresh

type tests for the equipment are not needed, provided the Manufacturer can submit certificates

that the equipment complies with all type tests as prescribed by IEC/IS Standard specifying the

test requirements for that equipment.

6.5 The routine tests shall include but not necessarily limited to the following:

a) Operation under simulated service condition to ensure accuracy of wiring, correctness of control

scheme & proper functioning of the equipment.

b) All wiring and current carrying part shall be given appropriate High Voltage test.

c) Primary current and voltage shall be applied to all instrument transformers.

d) Routine test shall be carried out on all equipment such as circuit breakers, instrument

transformers, relays, meters etc.

6.6 Routine tests on the equipment shall be carried out as per the relevant IS/IEC. Equipment offered

for final inspection shall be complete and ready for shipment, with the possible exception of the

final paint finish.

6.7 Routine Test certificates to be submitted for Equipment and its all auxiliaries. Type test certificate

of similar equipment shall be submitted.


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6.8 Vendor to furnish required copies of test certificates, Ref Documents, Drawings, and Instruction

Manuals before Equipment are dispatched.

6.9 Factory acceptance test (FAT) is required to be done at no extra cost to the purchaser. The

purchaser or his representative shall be advised of the tentative date for FAT at least 3 weeks in

advance prior to the test date.

6.10 Any defects found by the TPI or the Owner’s appointed Inspector shall be rectified in his presence.

Where this is not possible or practical, check lists shall be prepared and signed by the Third Party

Inspector stating all “pending items”. Copies of these lists shall be sent to the Owner to enable

their subsequent checking. The equipment shall not leave the Vendor factory before all defects

have been rectified and without the written permission of the Owner.

6.11 All spare parts shall be subjected to the same inspection standards and full material certification as

the main order.

6.12 The equipment shall not leave the Vendor / Sub-Vendor’s factory before all discovered defects

have been rectified and without the written permission of the Owner/Purchaser.

6.13 Any acceptance or release of equipment following an inspection or test activity shall in no way

relieve the Vendor of his contractual responsibility to provide guarantees as to the suitability of the

materials, workmanship and performance of the equipment in accordance with this Specification.

6.14 Owner/Consultant reserves the right to waive the inspection at any stage. Inspection shall be

carried out only on receipt of Vendor's internal test report of the equipment offered and scrutiny of

the same. In the event, on receipt of inspection call, the Owner/Consultant’s representative

reaches the Vendor's works and finds the material not ready for inspection/incomplete/has short

supply, the inspector will return to his base station and all expenses incurred by the inspector

including to and from travelling expenses from his base station to place of inspection, boarding

and lodging etc shall be reimbursed by Vendor.

7 Vendor documentation:

7.1 All information listed here is to be furnished along with the offer as a minimum.

a) Clause wise comments / deviations on specification in `Table of Compliance’ [enclosed Appendix

A]. If not furnished, compliance to all requirements in specifications will be binding on the Vendor.

b) Duly filled up Guaranteed Technical Particulars [enclosed Appendix-F].

c) List of components & accessories with Makes.

d) List of recommended spares for two years normal operation with itemised rates.

e) Type test certificates.

f) Technical Catalogues and brochures of major Components.

g) List of clientele for similar equipment in last 5 years.

h) Complete list of special tools (if required)

i) Documents as per RED.

7.2 The Manufacturer shall furnish the drawings and documents as per enclosed Requisition for

Engineering Documents - RED Form [Appendix-D].


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7.3 The Owner/Consultant will review drawings submitted by Vendor & return to the Vendor one copy

of drawings with comments to carry out necessary changes, if any, during the engineering /

manufacturing stage.

7.4 The documents required by the Third Party Inspection Agency are not covered under this

specification. The Vendor shall provide all the drawings and documents required by the Third Party

Inspection agency in compliance with the applicable codes and standards.

8 Spares and special tools:

8.1 Spares

The Manufacturer shall furnish list of spares and provide all necessary spares for testing, pre-

commissioning, commissioning. Any of the spares if used during testing/commissioning must be

replenished at no extra cost to the purchaser.

The Manufacturer shall also provide all consumables required during erection up to commissioning.

In addition to above, Manufacturer shall quote separately for Spares required for two years of operation.

8.2 Special tools

The Manufacturer shall include any special tools, which are required for the installation, commissioning,

operation and maintenance of the equipment being supplied. A list of special tools shall be supplied along

with the offer

9 Installation and commissioning:

Vendor shall dispatch Installation and Commissioning instructions at least 2 weeks before the arrival of the

equipment.

Vendor shall provide qualified personnel to supervise the installation and carryout site testing and

commissioning of all equipment supplied under this contract. Prices for these services shall be given

separately.

10 Packing and transportation:

Packing, shipping and delivery of equipment at site and unloading requirements shall be as per relevant

Standard. Vendor to submit the procedure & all the relevant necessary datas / informations along with

offer.

Preparation of the skids for shipment is a crucial step in the completion of this contract. The Vendor must

take in to consideration that all equipment and the skid itself shall be prepared for land transportation.

11 Statutory Approval:

The Equipment supplied shall be acceptable to local Electrical Inspectorate and changes required, if any,

shall be carried out by the vendor without any extra cost.


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12 Guarantee:

Equipment shall be guaranteed to meet the specified performance at specified conditions in terms of

power, air flow, thermal performance, design conditions etc.

Equipment and its components shall be guaranteed against faulty design, defective / improper materials

poor workmanship or failure from normal use during the guarantee period.

Vendor shall make all necessary and desirable alterations, repairs and replacement free of charge in the

even of mal performance or defects occurring in the equipment during guarantee period.

Also refer to guarantee clause under Purchase Order.


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Appendix-A: Table of Compliance.

The Vendor shall confirm that clauses of the specification have been complied with/accepted or further clarifications are desired, or Vendor has taken a deviation with reason thereto.

CLIENT :

M/s. Hindustan Petroleum Corporation Ltd

LPG Bottling Plant project at Bhatinda.

VENDOR REF.

Spec. Clause No.

Conforms Yes/No

Alternative Yes/No

Clarification

1

2

2.1

2.2

2.3

3

3.1

3.2

3.3

4

4.1

4.2

5

5.1

5.2

5.3

5.4

5.5

5.6

5.7

5.8

5.9

5.10

5.11


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CLIENT :



VENDOR REF.

Spec. Clause No.

Conforms Yes/No

Alternative Yes/No

Clarification

5.12

5.13

5.14

5.15

5.16

5.17

5.18

5.19

5.20

5.21

5.22

5.23

5.24

6

7

8

8.1

8.2

9

9.1

9.2

10

11

12

Appendix A:

Appendix B:

Appendix C:

Appendix D:


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CLIENT :



VENDOR REF.

Spec. Clause No.

Conforms Yes/No

Alternative Yes/No

Clarification

Appendix E:

Appendix F:

Appendix G:

Appendix H:


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Appendix-B: Electrical System Data

[Doc. No. 266763-000-SP-4004BX]


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Appendix-B: Electrical System Data

1.0 System Voltages

Nominal system voltage 11 KV 0.415kV

Highest system voltage 12 KV 440 V

Frequency 50 Hz 50 Hz

Lightning Impulse withstand voltage 75 KV (peak) --

Power frequency withstand voltage

for 1 minute 28 KV (rms) 2 KV (rms)

2.0 Supply variations

System voltage 11 KV 0.415 kV

Steady state voltage ± 10 % (*) ± 10 %

Steady state frequency ± 5 % (*) ± 5 %

Combined Voltage Frequency ± 10 % ( *) ± 5 % (*)

System fault level at rated voltage 31.5 KA for 3s

( Hold (*)) 50 KA for 1s

System Earthing Resistance

Earthed

Solidly

Earthed

( *) HPCL to advice. Vendor to take confirmation from HPCL before final design.

3.0 Control Supply for Electrical System

HV Circuit Breakers for Incomer feeders Voltage ( in Volts)

Spring Charging Motors : 110V DC

Closing Circuit : 110V DC

Trip Coil : 110V DC

Alarm : 110V DC

Indication : 110V DC


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Relay Auxiliary Supply : 110V DC

Heaters in Panels : 240V AC, SPN

LV Air Circuit Breakers (Applicable for Incomers & Bus coupler as applicable)

Spring Charging Motors : 240V AC, SPN

Closing Circuit : 110V DC

Trip Coil : 110V DC

Alarm : 110V DC

Indication : 110V DC

Relay Auxiliary Supply : 110V DC

Heaters in Panels : 240V AC, SPN

LV Motor Starters (Contactor controlled)

Control Voltage : 110V AC, SPN derived through control transformer.

Indications 110V AC, SPN

Space Heater Circuit : 240V AC, SPN ( From MLDB Bus)

Indications

PMCC/BPMCC : 110V AC, SPN

Local Control Panel : 110V AC, SPN


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Appendix-C: Codes & Standards.

IS-1248 ( Part I to IX) :2003

: Direct acting indicating analogue electrical measuring instruments and their accessories

IS-2419 :1979 : Dimensions for panel mounting indicating and recording electrical instruments

IS-2705 ( Part I to IV) : 1992

: Current Transformer

IS-3156 (Part I to IV)

: 1992

: Voltage Transformer

IS-3231 : 1986 (Part I) / (Part II) : 1987

: Electrical Relays for Power System Protection

IS-4146 : 1983 : Application guide for Voltage Transformers

IS-4201 :1983 : Application guide for Current Transformers

IS-4237 :1982 : General Requirements for Switchgear and Control Gear for Voltages not exceeding 1000V AC or 1200V DC

IS 4691 :1985 : Degree of Protection provided by enclosures

IS-4794 ( Part I & II) : 1968

: Push Button Switches

IS-5082 :1998 : Wrought aluminium & aluminium alloy bars, rode, tubes and sections for electrical purposes.

IS-6236:1971 : Direct recording electrical measuring instruments.

IS-6875 : Part I : 1973 : Control switches (switching devices for control and auxiliary circuits including contactor relays) for voltages up to and including 1000V AC and 1200V DC.

IS 8623 : ( Part I to II) :1983

: Specification for Low-Voltage Switchgear and Control gear Assemblies

IS-9224: Part I ( 1979) : Low Voltage Fuses

IS 10118 :1982 : Code of Practice for Selection, Installation and Maintenance of

Switchgear and Controlgear

IS-11353 : 1985 : Guide for uniform system of marking and identification of conductors and apparatus terminals

IS 13947 : 1993 : Specification for Low-voltage Switchgear and Controlgear

IEC 60947 :2007 : Low Voltage Switchgear & Controlgear- Part 1 - General rules

IEC 61439 :2009 : Low voltage switchgear and control gear Assemblies Part 1: Type-tested and partially type-tested assemblies.


Doc. No. 266763-000-SP-4004 Rev: B

Page 32 of 37


Appendix-D: Requisition for Engineering Documents

RED Form

Owner/Purchaser’s Office Distribution Office

Hindustan Petroleum Corporation Ltd

8 S.V. Marg, Ballard Estate

Mumbai- 400 001




Andheri (East)

Mumbai 400 059

SPECIAL INSTRUCTIONS Prints Documents shall be sent to:

Production Schedule 4 The Purchasing Office via courier service

Manufacturing, inspection & testing sequence plan 4 The Purchasing Office via courier service

DRAWINGS Required number for TIMING FOR SUBMITTAL

OFFER

APPROVAL

FINAL - for approval 2 weeks after order date

Approval drawings / Final drawings to be submitted under cover of an ADS form / FDS form respectively

Prints Prints Disk Prints - final issue 2 weeks after approval date

Documents shall be submitted to:

Submission of Following for each L V Switchgear, but not limited to:

Guaranteed Technical Particulars 2 4 2 4

General Arrangement Drawing showing masses, main dimensions

2 4 2 4

Panel cross section details showing arrangement of auxiliary components, etc.

- 4 2 4

Foundation Plan & Loading details 2 4 2 4

Single line diagram, Feeder list - 4 2 4

Block Logic, Schematic & Connection Diagrams

- 4 2 4

Bill of Material - 4 2 4

Soft starter schematic, component details, Block Logic diagram, connection diagrams, etc.

- 4 2 4

Bus-bar sizing calculations - 4 2 4

Name Plate Drawing - 4 2 4

Make of Each Components 2 4 2 4

Type Test, Routine Test Certificates 2 4 2 4

Spares List for two Years Operation 2 4 2 4

As Built Drawing - 4 2 4 Purchasing Office via courier service

SPARE PARTS DOCUMENTS 2 4

ESPIR forms including 1 transparency

TEST AND INSPECTION DOCUMENTS Prints

Documents to be submitted under transmittal Documents shall be submitted to:

Manufacturing report 1 4

Test Report / Data Curves 1 4

Calibration Certificates for testing Instruments. 1 4

Bought out Equipments Certificates. 1 4 Purchasing Office via courier service within 4 weeks

of relevant test / inspection.


Doc. No. 266763-000-SP-4004 Rev: B

Page 33 of 37


OPERATING DOCUMENTS Purchasing Office via courier service not later than at time of dispatch of equipment.

Installation instructions 1 4

Operating instructions 1 4 Combine into one manual

Maintenance instructions 1 4

ADDITIONAL REQUIREMENTS

1. Referenced standards / codes shall be the latest issue unless otherwise stated.

REMARKS

Invoice must certify that the drawings and engineering documents specified above have been dispatched to all parties concerned.

Any deviation from the timing for submittal of documents shall be notified to the Approval / Distribution Offices by fax or E mail.

Shop fabrication shall not be started before the required approval drawings have been released for construction by the party concerned, unless otherwise stated on the "Approval Drawing Specification".

Each document shall bear the item / tag and order reference number and be dispatched by air mail, unless other instructions are stated on the RED.

Units / dimensions to be used on Engineering documents shall be SI.

The documents shall be in English. Description on drawings and similar documents may be in other languages provided English translations are also given.

Drawings and documents shall be suitable for microfilming and comply with accepted national or international standards for the preparation of technical drawings. Only the following standard sizes should be used: A4, A3, A2, and A1.


Doc. No. 266763-000-SP-4004 Rev: B

Page 34 of 37


Appendix-E: Guaranteed Technical Particulars

[Doc. No. 266763-000-SP-4004EX]


Doc No: 266763-000-SP-4004EX Rev: B Page 1 of 6

P:\Kolkata\Engineering\JOBS\OGO-269323-HPCL Bathinda-LPG\ELECTRICAL\03. Issued to client\PMCC MCC PDB MLDB\266763-000-SP-4004EX.doc

Appendix- E : GUARANTEED TECHNICAL PARTICULARS (* To be filled in by the Vendor)

Note: Vendor shall submit guaranteed technical particulars separately for each L V Switchgear. It includes 000-PMCC-001 (415 V PMCC), 000-BPMCC 001 (Bottling Plant MCC), 000-PDB-001(415 V PDB) & 000-MLDB-001(415 V MLDB)

Sr No

Description To be filled in by Vendor

A) GENERAL

1) Manufacturer *

2) Place of Manufacture *

3) Applicable codes & standards *

4) IAC classification for switchgear [as per latest IEC 62271-200]

*

5) Type test certificate furnished *

6) Documents as per Specification furnished? *

B) ENCLOSURE

1) Enclosure material *

2) Type & Execution *

3) Thickness of sheet metal mm *

4) Degree of Protection *

5) Paint Shade Inside Outside

*

6) PMCC suitable for Busduct Incomer from Top

*

7) Cable entry (Incoming & Outgoing) *

8) Minimum Cable alley width mm

9) Material & thickness of gland plates mm *

10) Mounting height of components Minimum Maximum

mm *

11) Overall dimension of Switchgear mm *

12) Busduct Entry

13) Switchgear Heat Load for HVAC Watts *

C) BUSBARS

1) Rated continuous current [Main & Vertical]

kA *

2) Short circuit rating [1 sec] kA *

3) Main Busbar location *

4) Busbar material *

5) Bus with insulating sleeves [Material of sleeves]

*

6) Clearances Ph/Ph, Ph/n & Ph/earth mm *

7) Short circuit current rating for 1 sec kA *




Sr No


8) Final Temperature of Busbars ºC *

9) Horizontal Busbar size Phase Neutral

mm *

10) Vertical Busbar size Phase Neutral

mm *

11) Busbars support insulator make & voltage class

*

12) Spacing between Busbar supports mm *

13) Shrouds on Joints & Tap-offs *

14) Inter panel barrier *

D) AIR CIRCUIT BREAKER

1) Make *

2) Type *

3) Voltage, frequency & poles *

4) Rated current A *

5) Short circuit rating kA *

6) Sym. interrupting capacity kA *

7) Total interrupting time ms *

8) Making current (Peak) kA *

9) Power Frequency Withstand Voltage kV *

10) Lightning Impulse Withstand Voltage kV *

11) Anti pumping feature provided *

12) Trip-free feature *

Provision for pad locking facility in the “OFF” position

*

13) No. of auxiliary contacts for owners use *

14) Spring charging motor rating at 240V AC VA *

15) Time required to charge spring from fully discharged condition

ms *

16) Control Supply voltage(DC) V *

17) Maximum tripping coil consumption /ACB VA *

18) Maximum closing coil consumption /ACB VA *

E) MCCB

1) Make *

2) Voltage, frequency & poles *

3) Rated current A *

4) Short circuit rating kA *

5) Sym. interrupting capacity kA *

6) Total interrupting time ms *




Sr No


7) Making current (Peak) kA *

8) Operating mechanism *

9) Trip - free feature *

10) Provision for pad locking facility in the “OFF” position

*

11) No. of auxiliary contacts for owners use *

F) SWITCHES

1) Make *

2) Type *

3) Duty *

4) Rating A *

5) Interlocking with Door + Defect Interlocking facility

*

6) Padlocking in OFF position *

7) Shrouding of Incoming Terminal *

8) Rotary / Link Type *

9) Single Break / Double Break *

G) FUSES

1) Make *

2) Type *

3) Rupturing Capacity *

4) Rating A *

5) Control Fuse Make *

H) CONTACTORS

1) Make *

2) Type *

3) Service *

4) Rating A *

5) Duty *

I) OVERLOAD PROTECTION RELAY

1) Make *

2) Type *

3) SPPR feature *

4) Trip class *

5) Reset facility *

6) CT operated from which rating onwards? *

J) EART FAULT PROTECTION RELAY

1) Make *




Sr No


2) Type *

3) Rating A *

4) CBCT provided *

5) Timer provided *

6) Reset facility *

K) CURRENT TRANSFORMER

1) Make *

2) Type & services *

3) Voltage & frequency *

4) Ratio *

5) Rated burden VA *

6) Accuracy class *

7) Short circuit current rating kA *

8) Class of Insulation *

9) Shorting link for secondary *

L) POTENTIAL TRANSFORMER

1) Make *

2) Type & services *

3) Voltage & frequency *

4) Ratio *

5) Rated burden VA *

6) Accuracy class *

7) Short circuit current rating kA *

8) Class of Insulation *

M) PROTECTIVE RELAYS

1) Make *

2) Type *

3) Control voltage V *

N) INDICATING INSTRUMENTS [To be filled for each type of instruments]

1) Make *

2) Size *

3) Type *

4) Range for Incoming & Outgoing *

5) Burden VA *

O) WIRING

1) Insulation *

2) Voltage class V *




Sr No


3) Size & Colour code Power Circuits CT secondary Control circuits

*

P) ANNUNCIATION SYSTEM

1) Make *

2) Applicable standard *

3) Type *

4) System Voltage [DC] V *

5) No. of windows, Display device, Facia type and LED colour etc.,

*

6) Flash rate *

7) Response time *

8) Operational sequence (Alarm sequence) *

9) Power consumption VA *

10) Dimensions mm *

Q) CONTROL SUPPLY

1) Auxiliary Busbar size 110V DC 110V AC 240V AC

mm *

2) Control transformer Ratio Rating Nos/Swgr

*

3) Provision of standby control Transformer in each switchgear?

*

4) Auto-change over provided between Control Transformers?

*

5) Sleeving for control Busbars [Material of sleeves]

*

R) SOFT STARTER

1) Make *

2) Type of Solid state Soft Starter *

3) Frequency Range *

4) Starting capacity at maximum rated full load current Ir [* times Ir for * secs].

*

5) Allowable no. of starts per hour *

6) Overload capacity & duration *

7) Selectable Overload Class range *

8) Selectable Start/stop mode [Voltage / Torque ramp]

*

9) Selectable range of Start Ramp *

10) Selectable range of Stop Ramp *

11) Control Type *




Sr No


12) Selectable Torque limit range *

13) Control of Soft starter with field bus provided

*

14) Power circuit continuous Rating [SCRS] A *

15) SCR peak inverse voltage V *

16) SCR protection fuse rating A *

17) Power Factor *

18) Efficiency (Converter with Output Filter) % *

19) Transient voltage protection *

20) Total Harmonic Distortion (THD) *

21) Noise Level *

22) Type of cooling *

23) Bypass Contactor provided *

24) Protection provided For the Soft starter *

25) Requirement of Air-conditioning *

S) EARTHING

1) Earth Bus Size *

2) Material *

3) Location *

4) Provision for Connection to Grid *

T) LOAD ON BATTERY

1) ACB Closing Coils VA *

2) ACB Tripping Coils VA *

3) Burden of Auxiliary Relays (which will be on Battery)

VA *

4) Annunciation system VA *


Doc. No. 266763-000-SP-4004 Rev: B

Page 35 of 37


Appendix-F: Electrical Drawings.

01. Dwg. No. 266763-000-410-001B:- Overall Key Single Line diagram. 02. Dwg. No. 266763-000-410-002B:- Single Line diagram for PMCC

03. Dwg. No. 266763-000-410-003B:- Single Line diagram for Bottling Plant MCC 04. Dwg. No. 266763-000-410-004D:- Overall Lighting Distribution Single Line Diagram

05. Dwg. No. 266763-000-410-049D:- Single Line diagram for Power Distribution board.

06. Dwg. No. 266763-000-425-006D:- Equipment Layout of MCC room & Transformer Cell.


Doc. No. 266763-000-SP-4004 Rev: B

Page 36 of 37


Appendix-G: Control Schematics drawings.

01. Dwg. No. 266763-000-410-050D:- Typical Control Schematics.-DOL ( Sheet 1) 02. Dwg. No. 266763-000-410-050D:- Typical Control Schematics.-R-DOL ( Sheet 2) 03. Dwg. No. 266763-000-410-050D:- Typical Control Schematics.- STAR-DELTA ( Sheet 3)


Doc. No. 266763-000-SP-4004 Rev: B

Page 37 of 37


Appendix-H: Technical Specification for 415 V Bus Duct.


Doc. No. 266763-000-SP-4004HX

Rev: B Page 1 of 13

P:\Kolkata\Engineering\JOBS\OGO-269323-HPCL Bathinda-LPG\ELECTRICAL\03. Issued to client\PMCC MCC PDB MLDB\266763-000-SP-4004 HX, Rev-0.doc

Specification for LV Busduct

(Appendix H to Specification for 415V PMCC, Bus duct, Aux. PDB, MLDB, Spec No. 266763-000-SP-4004)

List of Contents Pages

1. Introduction 2

2. Scope of Supply 2

3. Bill of Material for Busducts 2

4. Technical Particulars: 4

4.1. Construction 4

4.2. Busbars 5

4.3. Busbar Supports 6

4.4. Space Heater: 6

4.5. Earth Bus: 6

4.6. Termination at the ends of Busduct 6

4.7. Special Chambers 6

4.8. Marking for Reassembly 7

4.9. Name Plates 7

4.10. Busduct Supporting Arrangement 7

4.11. Makes of Component 7

4.12. Painting 8

5. Codes & Standards 9

6. Requisition for Engineering Documents 10

7. Guaranteed Technical particulars 12


Doc. No. 266763-000-SP-4004HX

Rev: B Page 2 of 13


1 Introduction

This specification covers the minimum requirements for the Design, Manufacture, Material procurement,

Assembly, Painting, Inspection at manufacturer’s works, and Delivery to site, supervision of Erection of

Non-Segregated Metal Enclosed three Phase Neutral Busduct

This specification is to be read in conjunction with Specification for 415V PMCC, Bus duct, MCC, PDB,

MLDB, Spec No. 266763-000-SP-4004.

2 Scope of Supply

The following LV Bus duct shall be supplied, in accordance with this specification; standards stated

herein.

1. Busduct No. 000 -BD-001

2. Voltage Grade (Volts) 415

3. Rating (Amp) 1600

4. PMCC 000-PMCC-001

5. Transformer No. 000-DT-001

6 Location MCC Room

3 Bill of Material for Busducts

3.1 The 415V Bus ducts shall be supplied with Materials listed below:

Sl No.

Description of Parts Quantity (approximate)

a. Straight Length (Indoor) 4 Meter.

b. Straight Length (Outdoor) 10 Metre.

c. 90 Degree Bend - Horizontal / Vertical 5 Sets.

d. Adaptor Chamber (at Switchboard End) 1 No.

e. Adaptor Chamber (at Transformer End) 1 No.

f. TPN Copper Flexible Set for Transformer End Connection

1 Set

g. TPN Copper Flexible Set for Switchboard End 1 Set


Doc. No. 266763-000-SP-4004HX

Rev: B Page 3 of 13


Connection

h. Phase-cross over assembly (as required by manufacturer)

1 Set

i. Aluminium Flexible (if required) 1 Set

j. Rubber Bellow at transformer end (if recommended by manufacturer)

1 Set

k. Wall Frame Assembly with Seal of Bushing 1 Set.

l. Silica gel Breather (if recommended by manufacturer)

1 No.

m. Fire Barrier As required.

n. 240V Space heater +Thermostat Set with junction box

1 Set

o. Supporting Structure (galvanized) with hardware as required

1 Lot

• Vendor to Estimate the actual quantities during execution

3.1.1 Notes to Vendor:

a) Indoor and Outdoor Lengths indicated are tentative. These lengths are given only to give an idea

about approximate length of Busduct. Vendor shall accept the changes in Busduct route, length &

accessories till final drawing approval. To arrive at the total length of Busduct, it will be measured

along the centre line of the Busduct which will include bends and phase cross over chambers.

b) Vendor shall manufacture Busducts as per final approved drawings and bill of material shall be

treated as basis for final invoice

c) Following drawings shall be furnished to successful vendor for Busduct engineering in the event

of order. i. Equipment Layout ii. Vendor Drawing for Transformer

The Scope shall also include

• Inspection and Testing at manufacturer’s works, as specified.

• Submission of documents as specified.

• Painting as specified.

• Preservation, preparation of shipment and delivery to site.

• Supervision of Erection at site.

• List of Spares for two years normal operation.

• Start-up spares and commissioning spares.

• List of special tools required (Vendor to provide list with the offer).

• Any other items, required to make system complete.

3.1.2 Exclusions

• Installation/Erection & commissioning.


Doc. No. 266763-000-SP-4004HX

Rev: B Page 4 of 13


4 Technical Particulars:

4.1 Construction

4.1.1 The Busduct shall be of box frame construction of Sheet Steel enclosure suitably braced to

withstand the maximum mechanical and electrodynamic forces.

4.1.2 The Busduct enclosure shall be fabricated from 2 mm thick Sheet Steel. Eddy current heating, if

applicable, shall be taken into account.

4.1.3 The section of the Busduct shall be rectangle & non-phase segregated. The degree of protection

shall be IP-55.The Busduct shall have fire barriers inside.

4.1.4 The Busduct enclosure shall be suitable for indoor/outdoor installation as specified. The outdoor

portion of Busduct shall be suitable for outdoor installation without any additional protection from

owner’s end. However, rain hood shall be provided as an additional protection for outdoor

installation. Canopy and proper fixing arrangements shall be provided for the same.

4.1.5 The Busduct shall be provided with removable top covers fitted with gaskets secured by sufficient

number of nuts, bolts to ensure that these covers are dustproof. All joints and covers shall be

provided with non-deteriorating type gaskets of neoprene between joints. These covers shall be

of suitable length for ease of removal and shall be arranged to give complete accessibility to the

busbars, joints, bends and supports, etc. The entire busduct shall be dust and vermin proof.

Louvers shall not be provided.

4.1.6 The design of Busduct enclosure shall be such that it will withstand the operating conditions

arising out of the following:

(a) Normal operating conditions

(b) Momentary short circuit currents

(c) Rigours of adverse weather conditions, and

(d) Combinations of above.

4.1.7 The busduct shall be provided with flanged ends to connect the busduct to transformer at one

end and switchgear at other end. These flanges shall match with corresponding flanges in the

equipment to which these are connected.

Vendor shall provide suitable termination arrangement at 415V switchgear and transformer ends. Proper alignment and co-ordination between the busduct and power transformer / switchgear terminations shall be the responsibility of the busduct supplier. The purchaser will furnish the drawings required by the vendor. The busduct shall be supplied complete with all the hardware necessary for making the terminations

4.1.8 All hardware shall be hot dip galvanised/Cadmium Plated. The bolts shall be full threaded and

high tensile quality. Belleville washers for all current carrying conducting parts of the busbars and

plain washers for enclosure and covers shall be provided for every bolt.


Doc. No. 266763-000-SP-4004HX

Rev: B Page 5 of 13


4.1.9 Filter type drain holes shall be provided for draining out condensed moisture. The filter element

shall be such that it will allow escape of moisture but prevent ingress of dust. This shall be

removable type for cleaning purposes.

4.1.10 Bolted inspection cover shall be provided throughout length of Busduct. At the wall crossing of

the busduct, there should not be removable type inspection cover.

4.1.11 Proper wall sealing arrangements shall be provided at the wall where bus duct enters the

substation building. Busduct with wall mounting flange will be acceptable for the sealing

arrangement.

4.1.12 Top covers of the busduct shall be so located that they will not fall within the wall crossing section.

Busduct shall be supported from overhead hangers inside the substation.

4.1.13 The enclosure shall be provided with suitable mounting lugs at suitable interval. The mounting

lugs shall be suitable for hanger type supports. Vendor shall design and indicate the supporting

arrangement for busduct.

4.1.14 The Busduct shall be designed for an ambient temperature of 50 Deg Centigrade. (For indoor) &

550 C for outdoor. Under Normal operating conditions, the surface temperature of the enclosure

shall not exceed 80°C (i.e., the temperature rise shall be limited to 30 Deg centigrade.)

4.2 Busbars

4.2.1 The busbars shall be of electrical grade Aluminium flats adequately sized to carry maximum

specified continuous current & short circuit current for 1sec, at maximum site temperature

specified. The final temperature of busbars and connectors at joints between connector and

busbar should not exceed 95°C when carrying rated currents. Also the final busbar temperature

shall not exceed 250°C when specified short circuit current for 1sec duration flows through.

Current density of Busbars shall be 0.8 Amp/mm2 max.

4.2.2 All busbars shall be insulated with heat shrinkable PVC sleeves. All busbars shall be colour

coded such that on removal of any inspection cover the phases shall be identifiable.

4.2.3 Busbar clamps shall be provided to maintain the busbars in position. These clamps shall be

made out of fully heat treated magnesium silicate aluminium alloy to IS: 5082, 1998. The clamp

design shall be such that it holds the busbar firmly and also allow sliding movement of busbars

without generating internal stresses to accommodate expansion during operation at rated current.

For fixing the busbars to the busbar supports, cadmium plated bolts, nuts and washers shall be

employed.

4.2.4 Wherever required for long run of busduct, expansion joints with flexible strips shall be provided

to allow for expansion and contraction due to temperature variations arising out of normal

continuous current flow and short circuit current flow for specified duration. Minimum one

expansion joint shall be provided for each 3000 mm long straight length of busduct. In case this

is not provided, Vendor shall substantiate the same with Calculations.


Doc. No. 266763-000-SP-4004HX

Rev: B Page 6 of 13


4.2.5 Suitable Bimetallic strips shall be provided wherever copper to aluminium connections are

envisaged.(For flexible jumpers at expansion joint & end terminations)

4.2.6 All the hardware for connections both at transformer end & the PMCC end shall be in scope of

supply.

4.3 Busbar Supports

4.3.1 The busbars shall be supported by non-deteriorating type (non-hygroscopic, non-carbonising,

Corrosion resistance) Solid core resin cast epoxy insulators of requisite electrical / mechanical

strength. The mechanical strength shall be sufficient to withstand forces arising out of peak short

circuit current. Each shipping section shall meet this requirement separately.

4.3.2 Adequate Creepage distance shall be available on insulator to operate under high humid

conditions and effects of condensed moisture due to variations in temperature within busduct due

to different conditions of loading.

4.3.3 The spacing of the insulating supports shall be decided on the basis of the fault withstand

capacity

4.4 Space Heater:

Busduct shall be provided with anti-condensation space heaters with controlling thermostats of

adequate capacity to maintain internal temperature above dew point to prevent moisture

condensation in busduct. Space heaters shall be rated for 240V, single phase, 50 Hz AC supply.

Space heater shall be provided on both sides of the fire barrier.

4.5 Earth Bus:

Earth bus of 50 mm x 8 mm aluminium shall run on the external side of the busduct through the

whole length of the busduct and shall be positively connected to the body of the busduct

enclosure. At both ends of the earth bus provision shall be made to connect it to main earthing

system.

4.6 Termination at the ends of Busduct

4.6.1 The busduct shall be provided with flexible at both ends for connecting it with transformer at one

end and 415V switchgear at other end.

4.6.2 The Flexibles shall be made of thin copper strips. The ends of the flexible shall be clamped by

copper plate. The ends of flexible shall be tin plated.

4.7 Special Chambers

To match the phase sequence of the two equipments connected by busduct, a suitable phase

cross over chamber shall be provided; if required, at suitable location. This chamber shall

generally be located in transformer yard.


Doc. No. 266763-000-SP-4004HX

Rev: B Page 7 of 13


4.8 Marking for Reassembly

All busduct parts like enclosure, adaptor box, rain hoods, enclosure covers, supports, busbar and

busbar fish plates shall be identified distinctly by clear numbers. These shall be indicated in

drawing.

4.9 Name Plates

Permanent non-corrosive nameplate with engraved white letters on black background shall be

fixed on each Busduct with its designation & service description. The nameplate shall indicate the

following:

First line : Equipment Item No.

Second line: Equipment Description

Third line: System voltage.

Fourth Line: Equipment Continuous & short Circuit Rating.

4.10 Busduct Supporting Arrangement

4.10.1 Busduct supplier shall quote separately unit rate for busduct supports with details of the

supporting members and quantity being offered.

4.10.2 The supports offered shall be as specified below.

(a) Supporting structure shall be fabricated from standard steel sections and shall be hot dip galvanised after fabrication.

(b) Support structures shall be designed to withstand the dead weight of the busduct and the short circuit forces under maximum fault conditions.

(c) Support structures shall include support members like brackets, hangers, vertical / longitudinal beams, channels, nuts, bolts, washers and other hardware required for erection and support of entire busduct.

(d) Indoor portion of the busduct may be supported from wall or ceiling as per layout furnished. Outdoor portion of the busduct shall be supported from ground below on suitable foundations in

ground.

4.11 Makes of Component

4.10.2 Manufacturer shall furnish standard list of components makes for the complete the 415V

Busduct assembly. This list must be included with the offer.


Doc. No. 266763-000-SP-4004HX

Rev: B Page 8 of 13


4.12 Painting

All metal surfaces shall be thoroughly cleaned and degreased, pickled and phosphatised.

Thereafter, a coat of phosphate paint and a coat of zinc chromate primer shall be applied. After

removing all imperfections, all metal surfaces shall be sprayed with two coats of final paint as per

colour shade RAL 7032. Paint thickness shall be 100 microns. Final coat shall be of epoxy based.

All unpainted parts shall be plated to prevent corrosion. Inside surface of Busduct enclosure shall

be painted with black matt colour for heat dissipation.


Doc. No. 266763-000-SP-4004HX

Rev: B Page 9 of 13


Codes & Standards

IS-8623 (Part 2), 1993 : Specification for Low Voltage Switchgear and Control gear Assemblies: Particular Requirements for Busbar Trunking Systems.

IS-13947, 1993 : Specification for Low Voltage Switchgear and Control gear

IS-5082, 1998 : Wrought Aluminium and Aluminium alloy bars, rods, tubes and sections for electrical purposes.

IS-5578, 1984 : Guide for making of Insulated Conductors.

IS-4237, 1982 : General Requirements for Switchgear and Control Gear for Voltages not exceeding 1000V AC or 1200V DC

IS -4691, 1985 : Degree of Protection provided by enclosures


Doc. No. 266763-000-SP-4004HX

Rev: B Page 10 of

13


Requisition for Engineering Documents

RED Form

Owner/Purchaser’s Office Distribution Office

HI-TECH CARBON,

(A unit of Aditya Birla Nuva Ltd.)

Murdhwa Indl. Area, P.O. Renukoot,

Dist. Sonebhadra (U.P.),

Pin-231 2127




Andheri (East)

Mumbai 400 059

SPECIAL INSTRUCTIONS Prints Documents shall be sent to:

Production Schedule 4 The Purchasing Office via courier service

Manufacturing, inspection & testing sequence plan 4 The Purchasing Office via courier service

Required number for TIMING FOR SUBMITTAL

DRAWINGS OFFER

APPROVAL

FINAL - for approval 2 weeks after order date

Prints Prints Disk Prints - final issue 2 weeks after approval date

Documents shall be submitted to:

Submission of Following for each 415V Busduct, but not limited to:

Guaranteed Technical Particulars with values filled up.

2 4 2 4

General Arrangement Drawing with cross sectional view of bus duct with details of Insulator, busbar clamps, spacing of busbar phases and spacing of Insulators and cross section & length of flexible

2 4 2 4

Plan View of busduct connecting two equipments with dimensions from centre to centre equipments

- 4 2 4

Side elevation of busduct with all levels or dimensions marked.

- 4 2 4

End View of busduct with busbars and flexible connecting the transformer with clearances between bolt/Nut of adjacent phases and same for PMCC End.

- 4 2 4 Purchasing Office via courier service

Design Calculation for:

(i) Busbar sizing

(ii) Final Temp.of busbars when carrying rated current

Continuously in still air.

(iii) Final Temp.of busbars when 3 phase SC Current

flow for one second

(iv) Final Temp.of busbar enclosure for conditions (ii) & (iii)

- 4 2 4


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(v) Temp. rise Calculation

(vi) Busbar Support Calculations under short circuit conditions.

(vii) Surface Temp.of enclosure under normal operating conditions.

Flange details of connecting adaptors at both ends

- 4 2 4

Wall sealing frame - 4 2 4

Name Plate Drawing - 4 2 4

Make of Each Components 2 4 2 4

Type Test, Routine Test Certificates 2 4 2 4

Spares List for two Years Operation 2 4 2 4

As Built Drawing - 4 2 4

SPARE PARTS DOCUMENTS 2 4

TEST AND INSPECTION DOCUMENTS Prints

Documents to be submitted under transmittal Documents shall be submitted to:

Manufacturing report 1 4

Test Report / Data Curves 1 4

Calibration Certificates for testing Instruments. 1 4

Bought out Equipments Certificates. 1 4 Purchasing Office via courier service within 4 weeks

Of relevant test / inspection.

OPERATING DOCUMENTS Purchasing Office via courier service not later than at time of dispatch of equipment.

Installation instructions 1 4

Operating instructions 1 4 Combine into one manual

Maintenance instructions 1 4

ADDITIONAL REQUIREMENTS

1. Referenced standards / codes shall be the latest issue unless otherwise stated.

REMARKS

Invoice must certify that the drawings and engineering documents specified above have been dispatched to all parties concerned.

Any deviation from the timing for submittal of documents shall be notified to the Approval / Distribution Offices by fax or E mail.

Shop fabrication shall not be started before the required approval drawings have been released for construction by the party concerned, unless otherwise stated on the "Approval Drawing Specification".

Each document shall bear the item / tag and order reference number and be dispatched by air mail, unless other instructions are stated on the RED.

Units / dimensions to be used on Engineering documents shall be SI.

The documents shall be in English. Description on drawings and similar documents may be in other languages provided English translations are also given.

Drawings and documents shall be suitable for microfilming and comply with accepted national or international standards for the preparation of technical drawings. Only the following standard sizes should be used: A4, A3, A2, and A1.


Doc. No. 266763-000-SP-4004HX

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Guaranteed Technical particulars

(* To be filled in by the Vendor)

Sr. No


A) GENERAL

1) Manufacturer *

2) Country of Manufacture *

3) Applicable codes & standards *

4) List of Type test certificates furnished *

5) List of Routine tests offered *

6) Documents as per Cl. 5 of Specification furnished?

*

B) CONSTRUCTION

1) Busduct Enclosure

a) Enclosure material *

b) Thickness of Enclosure mm *

c) Degree of Protection

Indoor / Outdoor[without canopy] *

2) Type & Execution *

3) Paint Shade

a) External Paint Shade *

b) Internal Paint Shade *

4) Dimensions: Width x Length x Height

mm *

5) Slopping Canopy for outdoor portion

a) Material of Canopy *

b) Thickness of Canopy *

6) Number of Bends *

7) Provision for phase Crossover Chamber *

8) Location of phase Crossover Chamber mm *

9) Type of Gasket used for Joints and Covers *

10) Wall Frame Assembly(for Sealing) *

11) Provision of drain plug to remove condensated moisture

*

12) Busduct Top Cover removal provision *

13) Provision of Space Heaters *

14) Provision of Fire Barrier *

C) RATINGS

1) Continuous current rating Amps *

2) Fault Current withstand capacity for 1 sec. kA *

3) Voltage Grade Volts *

4) Design Ambient Temperature Deg.C *

5) Maximum Temperature rise above Design Ambient Temperature of

Deg.C

a) Busbar *

At rated continuous current *

At rated short circuit current *

b) Enclosure *

6) Derating Factors considered for busbar sizing *


Doc. No. 266763-000-SP-4004HX

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13


Sr. No


D) BUSBARS

1) Busbar Material mm *

2) Busbar Type (Cross-Section) *

3) Number of Busbars per Phase *

4) Size of Busbar mm *

5) Current Density of Busbars A/ mm2 *

6) Neutral Busbar Cross Sectional Area Sq.mm *

7) Earth Busbar Material *

8) Earth Busbar Size mm *

9) Earth Busbar Location w.r.t. Enclosure *

10) Busbar Insulation:

a) Material *

b) Thickness *

c) Class *

11) Busbar Colour Identification *

12) Heat shrinkable sleeves for Busbars *

13) Minimum Air Clearance Between

a) Phase - Phase *

b) Phase - Neutral *

c) Phase - Enclosure *

14) Provision for Busbar Expansion Joints *

15) Internal of Busbar Expansion Joints *

16) Flexible Connections provided at *

a) Number of Flexible Connections per phase *

b) Material of Flexible Connections *

E) BUSBAR SUPPORTS

1) Type of Busbar Supports (Material) *

2) Distance between Busbar supports mm *

F) BUS DUCT SUPPORTS

1) Type of Busbar Supports (Material) *

2) Distance between Busbar supports mm *

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