electrical works specifications

A Guide toSewer Selectionand Installation

ISSUE: 01JANUARY 2007

Electrical WorksSpecifications

PED/SDQS/EWS/SPEC/0507/003

Electrical Works Specifications

Electrical Works Specifications iIssue 01 / Revision 01February 2007

Electrical Works Specification

Section 1 Low Voltage Switchboard and Components SpecificationSection 2 Standby Generator SpecificationSection 3 Small Power and LightingSection 4 High Tension Components SpecificationsSection 5 Motor SpecificationSection 6 Low Voltage Cable Specification & InstallationSection 7 Earthing, Lightning and Surge Protection


Electrical Works Specifications iiIssue 01 / Revision 01February 2007

Page

Section 1 - Low Voltage Switchboard and Components Specification

1.0 Design and Construction 1-12.0 Dimension 1-13.0 Capacitor Bank 1-24.0 Contactor For Capacitor Switching 1-35.0 Busbars and Small Wiring 1-36.0 Air Circuit Breakers 1-47.0 Moulded Case Circuit Breaker (MCCB) 1-48.0 Miniature Circuit Breaker (MCB) 1-59.0 Residual Current Circuit Breaker (RCCB) 1-510.0 Fuses In General 1-511.0 Current Transformers 1-612.0 Indicating Instruments 1-613.0 Electronic Overload Relay 1-614.0 Motor Starters 1-1115.0 Indicating Lamps and Fittings 1-1716.0 Push Buttons 1-1817.0 Anti-Condensation Heaters 1-1818.0 Labels 1-1819.0 Padlocks 1-1920.0 Cable Entries 1-1921.0 Junction Box 1-19

Appendix A - Metal Treatment and Painting Procedures (Electro-Galvanised Metal Sheet) A-1

Appendix B - Floor Mounted Switchboard Compartment Dimensions B-1Appendix C - Typical Switchboard Drawings (Floor Mounted, Wall

Mounted and Outdoor Type) C-1Appendix D - Digital Protective Relay Standards D-1Appendix E - Digital Protective Relay Operating Conditions E-1Appendix F - Digital Protective Relay Metering Functions F-1


Electrical Works Specifications iiiIssue 01 / Revision 01February 2007

Appendix G - Digital Protective Relay Network, Machine andSwitchgear Diagnosis G-1

Appendix H - Meaning of Colours from IEC 60073 and IEC 60204-1 H-1

Section 2 - Standby Generator Specification

1.0 General 2-12.0 Engine 2-13.0 Lubrication System 2-14.0 Exhaust Fan 2-15.0 Radiator Air Discharge 2-26.0 Fuel System 2-27.0 Engine Governing 2-28.0 Engine Instrumentation 2-29.0 Alternator And Exciter 2-310.0 Voltage Regulation 2-311.0 Voltage Waveform 2-312.0 Starting System 2-313.0 Fuel Supply System 2-414.0 Protective Devices 2-515.0 Control Panel 2-616.0 Automatic Mains Failure (AMF) Switchboard 2-617.0 Changeover Contactor 2-818.0 Earthing System 2-9

Section 3 - Small Power and Lighting

1.0 Material Panel 3-12.0 Distribution Board 3-13.0 PVC Electrical Conduit and Fittings 3-24.0 Spacer Bar Saddles 3-25.0 Distance Saddle 3-26.0 Ceiling Fan 3-27.0 Light Fittings and Ancillary Equipment to Lamps 3-38.0 Street and Perimeter Lighting 3-49.0 Materials and Equipment 3-7



Section 4 – High Tension Components Specifications

1.0 11 kV / 22kV Vacuum Circuit Breaker Specification 4-12.0 Specification for 11 kV Oil Immersed Natural Cooled Transformers 4-63.0 Cast Resin Transformer 4-114.0 11 kV Cable Specification 4-17

Section 5 – Motor Specification

1.0 Submersible Motor 5-12.0 Surface Mounted Motors 5-2

Section 6 – Low Voltage Cable Specification & Installation

1.0 Type of Cable and Application 6-12.0 Cable Installation 6-23.0 Requirements 6-44.0 Cable Trench 6-45.0 Cable Ducts 6-66.0 Cable Termination and Jointing 6-67.0 Cable Accessories 6-6

Section 7 – Earthing, Lightning and Surge Protection

1.0 Common Earth Termination Network 7-12.0 Surge Protection 7-33.0 Lightning Protection 7-5


Electrical Works SpecificationsIssue 01 / Revision 01February 2007

Section 1Low Voltage Switchboard and

Components Specification

Section 1 – Low Voltage Switchboard and Components Specification


Page

Section 1 Low Voltage Switchboard and Components Specification

1.0 Design and Construction 1-12.0 Dimension 1-1

2.1 Appearance 1-12.2 Wall Mounted 1-22.3 Floor Mounted 1-22.4 Outdoor Type 1-2

3.0 Capacitor Bank 1-24.0 Contactor For Capacitor Switching 1-3

4.1 Up To 60 kVAr – 400 V 1-34.2 Greater Than 60 kVAr – 400 V 1-3

5.0 Busbars and Small Wiring 1-36.0 Air Circuit Breakers 1-47.0 Moulded Case Circuit Breaker (MCCB) 1-4 8.0 Miniature Circuit Breaker (MCB) 1-5 9.0 Residual Current Circuit Breaker (RCCB) 1-510.0 Fuses In General 1-511.0 Current Transformers 1-612.0 Indicating Instruments 1-613.0 Electronic Overload Relay 1-6

13.1 Protection Relays 1-613.2 Digital Protective Relay 1-7

13.2.1 General Design Requirements 1-713.2.2 General and Practical Operating Requirements 1-813.2.3 Installation and Requirements 1-813.2.4 Protection 1-913.2.5 Control and Monitoring 1-913.2.6 Metering 1-1013.2.7 Network, Machine and Switch Gear Diagnosis 1-1013.2.8 Relay Diagnosis 1-1013.2.9 Programming and Configuration Software 1-1013.2.10 User Machine Interface 1-1013.2.11 Communication 1-11

Section 1 – Low Voltage Switchboard and Components Specification


14.0 Motor Starters 1-1114.1 Direct-On-Line (DOL) 1-1214.2 Star Delta 1-1214.3 Auto Transformer 1-12 14.4 Soft Starter 1-12

14.4.1 Performance Functions 1-1314.4.2 Power Connection 1-1314.4.3 Protection Functions 1-1314.4.4 Sundry Features 1-1314.4.5 Function Facilitating the Integration of Control System 1-1414.4.6 Options 1-14

14.5 Variable Speed Drive 1-1414.6 Contactor for Motor Starters 1-17

15.0 Indicating Lamps and Fittings 1-1716.0 Push Buttons 1-1817.0 Anti-Condensation Heaters 1-1818.0 Labels 1-1819.0 Padlocks 1-1920.0 Cable Entries 1-1921.0 Junction Box 1-19

Appendix A - Metal Treatment and Painting Procedures (Electro-Galvanised Metal Sheet) A-1

Appendix B - Floor Mounted Switchboard Compartment Dimensions B-1Appendix C - Typical Switchboard Drawings (Floor Mounted, Wall

Mounted and Outdoor Type) C-1Appendix D - Digital Protective Relay Standards D-1Appendix E - Digital Protective Relay Operating Conditions E-1Appendix F - Digital Protective Relay Metering Functions F-1Appendix G - Digital Protective Relay Network, Machine and Switchgear

Diagnosis G-1Appendix H - Meaning of Colours from IEC 60073 and IEC 60204-1 H-1


Electrical Works Specifications Sec 1 - 1Issue 01 / Revision 01February 2007

SECTION 1 - LOW VOLTAGE SWITCHBOARD &COMPONENTS SPECIFICATION

1.0 DESIGN AND CONSTRUCTION

Switchboards, sub-switchboards, control panels, distribution board and all other equipment shallcomply with the relevant current British Standard and IEC specification.

Each item shall be enclosed in a vermin proof steel cubicle of rigid construction and made of sheetsteel of such thickness that it is free from distortion and with no entries for insect whatsoever. Wheretwo or more cubicles are fitted together they shall form a continuous flush front. All units shall befloor mounted unless otherwise specified.

The door of the switchboard shall be hinged such that they can be operated through an arc of 180degrees. A minimum of 3 hinges shall be chrome-plated and of a good quality.

All switchboards, together with switch gears, control gears, etc. shall be capable of withstanding faultconditions of not less than 31 MVA at 415 V for 3 seconds as defined in IEC 60439-1 and off Form3B.

The cubicle framework shall be fabricated from rolled steel angle sections and shall be self-supporting when assembled, uniform in height and depth from front to back. The rigid constructionshall be designed to withstand without any sag, deformation or warping, the loads likely to beexperienced during normal operating, maintenance or maximum fault conditions. Sheet steel usedshall not be less than 2.3 mm anti-rust zinc. Cross-structs shall not be used.

The manufacturer's name shall be incorporated on the switchboards.

The interior and exterior of each cubicle shall be finished with light gray paint (ICI Ref. No: ICI 104or OXYPLAST paint: FF160/8250/CS9. The cubicle shall be off electro-plated mild steel sheets. Itshall be treated to prevent corrosion. Refer to Appendix A – Metal Treatment and Painting Procedure(Electro-Galvanised Metal Sheet). All cubicles shall be dust, insect and vermin proof. The interior ofeach piece of equipment shall be clearly marked to show phases and to this end coloured plasticsleeving shall be employed. Plastic tape will not be permitted.

Steelwork necessary for supporting the switchboards shall also be included.

2.0 DIMENSION

2.1 Appearance

Panel thickness - 2.3 mm and 90 µm of paint thicknessFrame Thickness - 2.3 mm and 90 µm of paint thickness



2.2 Wall Mounted

Wall mounted switchboard shall not be more than 1.6 m height and located 0.2 m from floor. Wherenecessary, a step or a working platform that is insulated must be provided.

For a range of up to 100 Amps switchboard: -

• Incoming compartment : 450 mm• Subsequent compartment : 450 mm• Cable compartment : 125 mm• Cables to be glanded at bottom entry of the switchboard

2.3 Floor Mounted

Floor mounted switchboard shall not be more than 2.1 m height and located 0.2 m from floor. Wherenecessary, a step or a working platform that is insulated must be provided.

Refer to Appendix B - Floor Mounted Switchboard Dimensions (up to 100 A, more than 100 A up to400 A, 400 A and above)

2.4 Outdoor Type

The outdoor main switchboard shall be off self-contained, free standing or wall mountedweatherproof cabinets to be constructed of electro-galvanised metal plates. Control indication andalarm facilities shall be mounted on internal doors enclosing compartments housing electrical plantand equipment. Wall mounted outdoor weather proof control panel shall come with awning extendedby at least 2 m from wall and floor mounted outdoor weather proof control panel shall come with roofawning extended 2 m from the panel. External doors with security locking facilities and double roofson cabinets to reduce solar effects shall be provided.

Refer to Appendix C – Typical Switchboard Drawings (floor mounted, wall mounted and outdoorswitchboard).

3.0 CAPACITOR BANKThe power factor (p.f.) of the assembly shall be design for 0.95 or better. Should it be less than 0.95,provision shall be made in the panel to incorporate additional power factor correction to improve thepower factor to the minimum value required. Power factor regulation shall be of multiple steps,individual capacitors are allowed only if the load is lower than 5 kVAr. In any case the total powerfactor for the assembly shall not fall below 0.95. Where multiple steps are provided, in case of failure,the smallest step shall be duplicated to act as a back-up. Capacitors shall be protected with itsindividual capacitor switching contactors and MCCB.



4.0 CONTACTOR FOR CAPACITOR SWITCHING

4.1 Up to 60 kVAr – 400 V

The contactors shall be specifically designed for capacitor switching. Particularly shall be included aset of contact and current limiting resistors which shall be switched off after initial switching peakcurrent. The contactors shall comply with IEC 70 and IEC 831. All contactors will have the referencenumber on the front of the contactor. All contactors shall be climate proof as standard. The ratedimpulse voltage shall be 8 kV. The contactor shall work up to 55oC ambient temperature withoutderating. The coil operating range shall be between 0.85 and 1.1 times of the rated voltage (AC).

All contactors shall be finger safe as standard or with adaptable covers and available in a variablecomposition for auxiliary contact. The safety clearance on the front of the contactor shall be less than15 mm. The coil wire insulation shall be Class F. The contactors shall be cadmium free and built withrecyclable materials. The contactor shall include a system to prevent resistor burning in case ofabnormal pole operation.

The switching contactors shall be of AC3 load switching.

4.2 Greater than 60 kVAr – 400 V

The switching contactors shall be of AC4 load switching. All contactors shall incorporate air break orvacuum contactor rated for frequent duty in accordance with IEC 60947.

5.0 BUSBARS AND SMALL WIRINGBusbars marking and arrangement, connection and grade of copper shall all comply as appropriatewith BS EN 13601.

The switchboards shall be so arranged that the busbars run horizontally through each sectionalisedlength and shall comprise three or four bars as appropriate fabricated from hard drawn highconductivity copper rigidly mounted on non-hygroscopic insulators with connection from the busbarsto the circuit breakers and switches effected by copper bars or cables securely clamped to the bars andidentified by means of coloured plastic sleeving or painting to indicate the phase colours. All cablesupports shall be non-hygroscopic.

All small wiring shall be of adequate size to suit their current ratings but in any case not less than 1.5square mm. in section for cables, insulated with PVC and shall be fixed securely without strain bycleats of the compression type. For the purpose of identification different insulant colours shall beprovided to distinguish the various circuits and each connection shall terminate at an approved type ofterminal block placed in an easily accessible position for testing at site with coded ferrules of anapproved type at both ends of each connector. No connectors or soldered joints will be permitted inthe wiring. The wiring shall be formed in a neat and systematic manner, with cables supported clearof panels and without cross-overs. Bushers shall be provided wherever necessary to prevent chafingof cables.



6.0 AIR CIRCUIT BREAKERSAll air circuit breakers used for the incoming shall be of four pole. All other air circuit breakersdownstream shall be of triple pole. Association of Short-Circuit Testing Authority (ASTA) orKeuring Van Electrotechnische Materialen (KEMA) certified for a minimum rupturing capacity of 26MVA at 415 V with a short time rating of 3 seconds.

Air circuit breakers shall be used for all current ratings of 600 A and above.

Units shall be hand charged spring closed with ratings and instrumentation as specified and of thehorizontal draw-out isolation type so arranged that they may be completely isolated from theswitchboard except that secondary circuits shall not be broken with the circuit breaker in the “test”position in order to permit test tripping or closing.

Closing mechanism shall be of trip free type and incorporate mechanical "ON/OFF" and "SPRINGCHARGED/SPRING FREE" indicators mechanically and positively coupled to the operatingmechanism and mechanically interlocked to prevent:- (i) Withdrawal or plugging of the circuit breaker in the closed position (ii) Closure unless either fully plugged or fully isolated(iii) Opening of cubicle door until breaker is isolated(iv) Prevent insertion of the racking handle when the cubicle door is open

Contacts shall be of adequate rating to ensure that they can carry continuously full rated currentwithout overheating, damage or deterioration and shall be individually spring loaded, hard silverplated of the magnetically "blown on" type so arranged that electro-magnetic forces arising undershort circuit conditions do not tend to reduce contact pressure. The arc chutes shall be removable onsite. No safety clearance shall be required around drawout circuit breakers. For fixed circuit breakers,150 mm of free space shall be provided above the arc chutes to allow removal of the latter. Screeningshutters actuated automatically with the circuit breaker isolated and withdrawn and capable ofpadlocking in the screened position. The arc chutes shall be equipped with metal filters to reduceeffects perceptible from the outside during current interruption. The breaker shall have the option toinstall shunt trip coil energised through relay contacts, “Close” and “Trip” push buttons.

7.0 MOULDED CASE CIRCUIT BREAKER (MCCB)Moulded case circuit breakers shall comply fully with BS 4752: Part 1 and the case shall be ofmoulded insulating materials of good mechanical strength and non-tracking properties. The trippingmechanism shall be calibrated in compliance with British Standards at the factory and the breakershall be sealed to prevent tampering.

MCCBs shall be used for all current ratings less than 600 A.

MCCBs shall be rated at not less than 25 kA 0.3 sec. of below 100 A and 50 kA 0.3 sec. of above 100A.

MCCBs shall be of manual or automatic operation as required. The automatic type shall eachincorporate a trip unit to provide overload and short circuit protection. The trip unit for each poleshall provide inverse time delay under overload conditions and instantaneous magnetic tripping forshort circuit protection, with five adjustable trip setting. The trip units in all the circuit breakers shallbe interchangeable.



The MCCB shall be so designed that when on tripped condition, the circuit breaker cannot beswitched on again unless it has been reset by switching to OFF position first. The operatingconditions (i.e. ON, OFF or TRIP) of the circuit breaker shall be clearly indicated.

MCCBs shall be Single Pole and Neutral (SPN), Double Pole (DP) or Triple Pole and Neutral (TPN)type as required. However, MCCBs at the incoming shall be of Four Pole. The construction andoperation of the circuit breakers shall be such that as a fault occurs, all the poles of the circuitbreakers shall operate simultaneously to isolate and clear the fault efficiently and safely without anypossible risk to the operator or to the installation. Each circuit breaker shall incorporate "trip-free"mechanism to ensure that the breaker cannot be held closed in fault conditions.

The operating mechanism of the circuit breakers shall be hermetically sealed at the factory and allmetallic parts associated with the operating mechanism shall be treated against rust and corrosion.The short-circuit breaking capacity of the MCCB shall not be less than the maximum prospectivefault levels at the point where the MCCB is installed.

8.0 MINIATURE CIRCUIT BREAKER (MCB)MCBs shall have a breaking capacity of not less than 5 kA (rms). They shall comply with BS EN60947-2, BS EN 60898 or IEC 157-1, fully tropicalised and suitable for use on a 240/415 V, 50 HzAC system and up to an ambient temperature of 400 °C.

MCBs shall be quick-make, quick-break and trip-free type complete with de-ion arc interrupters. Thetripping elements shall be thermal magnetic type with inverse time delay over-current andinstantaneous short circuit characteristics. They shall be able to respond to overload and the responseshall be independent of variations in ambient temperature.

MCBs shall be manually operated by means of toggle type handles having visual indication ofwhether the breaker is opened, closed or tripped. Multi-pole breakers shall be provided withcommon-trip mechanisms for simultaneous operation of all the poles.

9.0 RESIDUAL CURRENT CIRCUIT BREAKER (RCCB)RCCBs shall be current operated type complying with IEC 61008-1. RCCBs shall be used forincoming rating of up to and including 60 A. They shall be either double pole or four pole type. Thesensitivity, unless otherwise specified, shall not exceed 100 mA for double pole type and 300 mA forfour pole type. Test push button and visual indication for ‘ON’ and ‘OFF’ shall be provided. Theyshall be equipped with screw clamping type cable terminals.

10.0 FUSES IN GENERALFuses shall comply with BS 88. Unless otherwise specified all fuses shall be of the HRC type and ofan approved make. Fuse bases and carriers shall be of the unbreakable type and shall be arranged forsafe and easy replacement of fuses. All live connections including fuse base contacts shall beefficiently shrouded. The fuses fitted on a circuit shall be of such rating as to give maximumprotection to the apparatus it supplies.



11.0 CURRENT TRANSFORMERSCurrent transformer shall comply with BS 3938 and shall have short time ratings not less than that ofthe switch panels in which they are incorporated.

Identification labels shall be fitted giving type, ratio, rating, output and serial numbers and duplicaterating labels are to be fitted on the exterior of the mounting chambers suitably allocated to enablereading without the removal of any cover or metal sheeting forming part of the structure of theswitchboards.

All current transformers shall be of Class 3, 5 VA for all metering circuits shall, unless otherwisestated. For all protection circuits, the current transformer shall be of 10P10 and a burden of 15 VA.For power factor regulation the current transformer shall be of Class and a burden of 15 VA.

12.0 INDICATING INSTRUMENTSIndicating instruments on switchboards shall be flush mounted and shall generally be of the samepattern and appearance throughout. They shall be of a type giving no parallax error and their normalmaximum reading shall be at about 60% full-scale deflection. Ammeters in motor starter circuitsshall be capable of withstanding the starting current. All voltmeter shall have selector switchesenabling any phase to phase to neutral voltage to be read.

Indicating instruments shall be fitted with zeroing devices and shall be positioned with dial centresnot more than 1.85 m and not less than 0.75 m above floor level. Indicating instruments shall complywith BS 89 and shall be of industrial grade accuracy.

Panels with incoming 400 A and above, a digital power meter shall be provided.

13.0 PROTECTION RELAYS

13.1 Electronic Overload Relay

These relays shall have definite time characteristics: current threshold and time based function.

The relay shall be functional in the case of long starting time or frequent starting. The relay shallprovide protection at minimum for over-current, rotor locked and phase failure. The relay shall beincorporate individual adjustable trip time and delay time setting for staring, over-current and rotorlocked.

The over-current trip preset value for the relay shall be at minimum 110% of the operating currentand with adjustable range. The relay shall incorporate LED indication light to assist fast diagnostic ofstatus, operation and type of failure. The allowable error of the relay shall be 5% for current and time.The relay shall confirm to IEC 60255-6 and IEC 60947 standard. The degree of protection shall beIP20 and confirming to IEC 60529 standard.

The relay shall be operation in temperature up to 60oC in normal operation without derating andconfirming to IEC 60947-4-1 standard. The relay shall withstand surge up to 6 kV and confirming to



IEC 61000-4-5 standard. The sensing and control of the relay shall be through built-in currenttransformer and micro CPU.

13.2 Digital Protective Relay

The Digital Protective Relay shall comply with the most relevant national, international standards andrecommendations for industrial electrical distribution (IEC, EN, UL, and CSA). The Digital ProtectiveRelay shall be CE marked, conforming to European Low Voltage (73/23 EEC and 93/68 EEC) andEMC (89/336/EEC).

Refer to Appendix D – Digital Protective Relay Standards.

13.2.1 General Design Requirements

• Technology and functionality:

The Digital Protective Relay design shall be based on a microprocessor technology and shallaccommodate a hardware and software architecture consisting of a multifunction protection andcontrol platform with logic/analogue inputs and outputs, including Protections, Metering, Control &Monitoring, User Machine Interface with alphanumeric display, Communication Interface, Network,Machine, Switch gear and relay diagnosis functionality.

• Programming and configuration

The Digital Protective Relay shall be programmable and configurable with an appropriate user-friendly setting software using a MS Windows program running on a standard PC. The programmingand configuration shall be carried out locally (front access) through a RS 232 port or remotelythrough a communication network, mainly an Engineering LAN (E-LAN) with adequate passwords toprevent any unwanted intrusion.

Programming and configuration shall also be able to be prepared on a PC file directly (unconnectedmode) and down-loaded locally or remotely into the relay.

• Hardware and software architecture

The hardware and software architecture shall be modular and disconnectable to adapt the protectionand control unit to the required level of complexity of the applications.

The architecture shall allow future extensions by simple and easy hardware and firmware upgradingof the protection and control unit and shall be designed to enable upward compatibility betweenDigital Protective Relay of different generations of the manufacturer.

The Protective Digital relay shall accommodate digital and isolated inputs/outputs. The inputs shallbe used to monitor the status of the complete panel as well as receive external signal while the outputsshall be used for circuit breaker, inter-tripping between panels and remote alarms.



13.2.2 General and Practical Operating Requirements

The Digital Protective Relay shall operate according to the following conditions: -

• The circuit breaker control output relay contact shall be capable of withstanding a 30A DCcurrent for 0.2 seconds and 2,000 operating cycles according to ANSI C37.90-Clause 6.7.

• Other logic output relay contacts shall be capable of withstanding a 8A DC/AC steady statecurrent

• Logic input pilot voltage shall be rated as per the auxiliary power supply of external drivendigital signals from the control system (RTU or PLC) and shall comply with IEC 60011-32.

• Current carrying terminal from current sensors shall be automatically short circuited whenwithdrawing current sensor modules.

• Provisions shall be made in the switchgear cubicle for testing and calibrating the relay bycurrent injection using an external source, without disconnecting the permanent wiring.

• CT/VT and Trip coil supervision facilities shall be provided to check the wiring circuitcontinuity with relevant alarms and messages.

• The Digital Protective Relay shall be continuously rated and shall maintain the setting accuracywithout setting drift over time and full range of auxiliary voltage variations as per therequisition.

• The Digital Protective Relay shall be capable of withstanding the output current of theassociated current transformers corresponding to a primary current equal to the specified shortcircuit withstand current and time of the assembly ( 4 In permanent, 100 In 1 second).

Refer to Appendix E – Digital Protective Operating Conditions.

13.2.3 Installation and requirements

The Digital Protective Relay shall be able to be flush mounted or mounted inside the Low Voltagecompartment and shall have an IP52 mechanical protection degree according to IEC 60529.

To operate properly and to achieve satisfactory operating quality, the Digital Protective Relay shall beinstalled so that it shall be protected against EMC, and the following points shall be required: -

• A single equipotential earth system used as the site potential reference• A power distribution with TN-S earthing system• Separation of different kinds of cables (power, power supply, auxiliary, data, measures)• Use of screened cables for data and measure• A power supply protection (filtering, over voltage protection)• Equipment and installation protection against the indirect effects of lightning



13.2.4 Protection

The Digital Protective Relay shall integrate all the necessary ANSI code protections according to thedifferent levels of applications and shall provide wide setting ranges mainly for current protectionsand a large choice of tripping curves through two setting groups (normal/back-up mode network)operated by logic input: -

- Definite Time (DT) curve- IDMT curves set by T time delay or TMS factor, including:-- IEC curves (SIT, VIT/LTI, EIT)- IEEE curves (MI, VI, EI)- Usual curves (UIT, RI, IAC)- Customised tripping curve possibilities shall be available for specific Phase, Earth fault over

current.

ANSI code Tripping curve Threshold Tripping time delay

50/51(Low, Mid-endsolutions/applications)

DTIDMT Is set point 0,1 to 24 In

0,1 to 2,4In

Inst: 0,05 sec to 300sec0,1 sec to 12,5 sec at10 Is

50N/51N(Low, Mid-endsolutions /applications)

DTIDMT Is0 set point 0,1 to 15 In0

0,1 to 1 In0

Inst: 0,05 sec to300sec0,1sec to 10 Is0

• Overload protection shall be based on RMS current value (Minimum 13th Harmonic) and shalltake the ambient temperature into account.

• Phase over current and earth fault protection shall have an adjustable timer hold to allow re-striking fault detection

• Earth fault protection shall integrate a H2 Harmonic restraint for transformer start-up inrushcurrent to be activated or inhibited

• Alternative over current setting groups shall be selectable by logical conditions through logicinputs, to adapt a fast protection plan change as well as setting facilities for thresholds and timedelay adjustment.

• The Digital and protective Relay shall allow the use of upstream and logic discrimination in acascading scheme or closed loop applications.

13.2.5 Control and monitoring

The Digital Protective Relay shall basically carry out all the ANSI code Control and Monitoringfunctions necessary to control the Circuit Breaker or Contactor for electrical operations. Theseoperations shall be performed from pre-defined functions using logic inputs/outputs and shall beprocessed from internal and external data.



13.2.6 Metering

The Digital Protective Relay shall include accurate measurement processing functions and shalldisplay the metering data on the User Machine Interface to operate the different applications andcarry out commissioning and maintenance as per Appendix F – Digital Protective Relay MeteringFunctions.

13.2.7 Network, machine and switch gear diagnosis

The Digital Protective Relay shall provide diagnosis facilities for process management andmaintenance purpose as per Appendix G – Digital Protective Relay Network, Machine andSwitchgear Diagnosis.

13.2.8 Relay diagnosis

The Digital Protective Relay shall contain self-test diagnosis facilities to: -

• Detect internal relay failures that may cause nuisance tripping or failed fault tripping• Set the relay in fail-safe position leading to a fall-back position to avoid any unwanted tripping

if a major internal failure is detected. A Watchdog relay with change over contact (NO+NC)shall provide an alarm or information to activate a back-up protection. Any minor failure shallnot interrupt the protection function operations and the relay shall operate in downgraded mode

• Inform for maintenance operation• Detect unplugged connectors resulting in a major internal failure• Check the hardware configuration:-

- The absence or failure of a remote module shall be considered as a minor failure.- The absence or failure of a Logic input/output module shall be considered as a major failure

13.2.9 Programming and configuration software

The Digital Protection Relay shall use a user-friendly setting and operating multi-lingual software inWindows environment

13.2.10 User Machine Interface

• The Digital Protective Relay shall incorporate a User Machine Interface (or UMI) with analphanumeric graphical LCD and back-light display screen indicating:-

- Measurement values- Operating messages in major international languages- System maintenance messages



13.2.11 Communication

• The Digital Protective Relay shall be communicating through one or two communication portsand integratable in communication architecture with information remote access. It shall be ableto be interfaced to two types of communication networks providing access to data on eachcommunication port, via:-

- A multi-protocol based Supervisory Local Area Network (S-LAN) to supervise functionsregarding the installation and the electrical network from a supervision system (SCADA orRTU).

- Modbus based Engineering Local Area Network (E-LAN) to configure, set up the relay, collectoperating and diagnosis information, monitor the status of the electrical network and rundiagnostics on electrical network incidents from the programming and configuration software.

14.0 MOTOR STARTERS The starters shall be of the following types: (a) Up to 3.7 kW Direct-On-Line starters (b) Above 3.7 and up to 7.5 kW Star/Delta starters (c) Above 7.5 and up to 22 kW Auto-transformer starters (d) More than 22 kW Soft starter (e) 75 kW and above Variable Speed Drive

Motor starters shall be in accordance with IEC 60947-1 and IEC 60947-4-1 and equipped withoverload and no volt protection. Where MCC are supplied as a stand alone unit, it shall comply withthe switchboard specification. Single phase and earth leakage protection shall be deemed to beincluded. Starters shall be of the contactor type with coils wound for 230Volts 50 cycles operation.

All starters shall be capable of at least 15 starts per hour at 100% full load torque. The motor startershall be of rating to carry the full load current of its rated duty at its most severe load conditions

All motor starters shall be of automatic and manual control type with “Start/Stop/Reset" facility,MCCB mechanically inter-lockable with access door, independent control circuit with fuses/MCBand provision for remote control as required.

Individual starters shall be provided for each equipment and housed in a separate compartment, whichare mounted in switchboard cubicles. The starter cubicles shall be easily accessible for maintenancepurpose constructed of ingress protection IP42. Unless otherwise approved, the metal surface of thecubicle wall adjacent to the contactors shall be protected by fireproof insulating material. Allsecondary wiring shall be so arranged and protected as to prevent it being damaged by arcing. Wheredraw-out patterns motor starter is specified, the starter shall be easily withdrawable and can bereplaced with another spare starter of similar rating.



14.1 Direct-On-Line (DOL)

For DOL starters, an air-break tripole electromagnetic contactor starter with a normal open retainingauxiliary contact, shall be provided. The auxiliary contact shall be complete with one closing/holdingcoil 230 V, 50 Hz (no-volt coil inherent) and EOCR with resetting devices and auxiliary signal lampcontact. The reset push button shall be accessible from outside.

14.2 Star Delta

For Star Delta starters, an air-break triple pole electromagnetic ‘LINE’ contactor fitted with necessaryauxiliary contacts, closing / holding coil, EOCR, etc. shall be provided. The EOCR shall be connectedin the Delta position and thus give automatic single phase protection. The starter shall contain an airbreak triple pole and neutral ‘STAR’ contactor fitted with the necessary auxiliary contacts and an airbreak triple pole and neutral ‘DELTA’ contactor fitted with the necessary auxiliary contacts. The StarDelta contactors shall be electrically and mechanically interlocked. The starter shall be complete withnecessary time delay contacts to effect the correct sequence of operation.

14.3 Auto Transformer

Auto Transformer shall be fitted with multipole contactors which increase the supply voltage to thestarter by changing out sections of the starting transformer tabs. The three phase, air cooled autotransformer shall be accommodated in a separate section mounted at the top within the switchboardcubicle of the starter. Tapping shall be provided at 40%, 60% and 75% of the voltage. The star pointcontactors and run contactors shall be mechanically interlocked. The starter shall be complete withtiming relays. Where indicated, EOCR, earth fault and single phasing relays shall be provided.

Auto transformer starter shall consist of three contactors with current rating similar to the peakcurrent. All auto transformer shall be incorporated with thermal switch connected with control circuit.

14.4 Soft Starter

Soft Starter shall be a controller with 6 thyristors, which is used for the torque-control of soft startingand soft stopping of three-phase squirrel cage induction motor.

The Soft Starter shall be housed in the respective MCC or Starter Panel Board. Adequate natural orforced ventilation shall be ensured for continuous operations at the maximum specified 50 oC (122 oF)ambient temperature. Harmful deposition of dust shall be excluded by suitable filters.

All Soft Starters shall be sized to drive the duty motors in a particular group to which it is designated.The Power (kW) rating of the Soft Starters shall exceed the total driven load and shall make fullallowance for the following: -



14.4.1 Performance Functions

• Constant Current Mode and Current Ramp Mode.• Constant control of the torque supplied to the motor during acceleration and deceleration

period.• Kickstart – shall provide “Extra Torque” at the beginning of a start (High Breakaway Torque)

but then accelerate freely with lower torque.• Bypass contactor - shall retain Motor Protection & Current Monitoring Features Function.• Wide frequency tolerance for generator set power supplies.• The starter shall be able to connect to the motor delta terminals in series with each winding.• Soft Stop – Shall be able to automatically monitors & extends motor deceleration time and will

provide optimum control of most application.• DC Braking – Greater Braking Torque shall be available for very high inertia loads by use of

“Soft Braking” technique.

14.4.2 Power Connection

• 3 wires Configuration• 6 wires Configuration – Shall allow to control motors 50% larger than possible 3 wires

connection• Three phase voltage 230 V to 415 V50/60 Hz

14.4.3 Protection functions

• Built – in motor thermal protection• Processing of information from PTC thermal probes• Monitoring of the starting time• Motor preheating function• Protection against under loads and over current during continuous operation• Phase Imbalance – Sets the sensitivity of the “Phase Imbalance Protection”• Phase Sequence• Electronic Shearpin• Auxiliary Trip Input• Excess Start Time – Protect the Soft Starter from being operated outside its rated start capacity• Supply Frequency• Shorted SCR• Motor Connection• Serial Interface Failure

14.4.4 Sundry Features

• IP42 or IP54 - 253 Amps and below• IP00 - 302 Amps and above• Current Read – out• Motor Temperatures Read – out• Trip Log (eight (8) position )• Multiple Function Sets



• Restart Delay – sets the minimum time between the end of a stop and the beginning of the nextstart

• Pre-Start Tests – shall have self diagnostic test• Low current flag• High current flag• Motor Temperature Flag• Auto-Stop• Start Counter• Function Lock / Password Protection• Store / Restore Function Settings• Thermal Mode Override

14.4.5 Function Facilitating the Integration of Control System

• Minimum shall consists of 4 logic inputs, 2 logic outputs, 3 relay outputs and 1 analogueoutput.

• Plug-in I/O connectors.• Function for configuration a second motor and easy to adapt settings• Display of electrical values, the state of the loads and the operating time.• RS 485 serial link for connection to Modbus.

14.4.6 Options

• A remote terminal can be able to mount on the door of a wall – fixing or floor – standingenclosure.

• Advanced dialogue solutions such as power suite pocket PC with PPC type terminal and powersuite software workshop.

• A range of wiring accessories for connection the starter to PLCs via a Modbus connection.• Bus communication and Ethernet, DeviceNet and Profibus DP network communication options.

14.5 Variable Speed Drive

Variable Speed Drives (AC Drives) shall utilise a standard AC Squirrel Cage Induction Motoroperating from a Variable Frequency Static Converter Speed Controllers. AC Drives shall operate inproportion to a measured Analogue Signal (0-10 V & 4-20 mA).

The AC Drives shall be suitable for operation on a 380 – 500 Vac 3 Phase 50 Hz Power Supply withminimum Supply Tolerance -15% to +10% and shall provide a 415 Volt 3 Phase Variable FrequencyOutput suitable for driving a standard AC Squirrel Cage Induction Motors at high 50 oC (122 oF)ambient temperatures.

The AC Drives shall be suitable for automatic control in response to 4-20mA Input Analogue Signaland its frequency output of 0-50 Hz via 4-20 mA Analogue Signal shall be in proportion to this signalrange.

The AC Drives shall operate on Pulse Width Modulation (PWM) principle either with the ControlMethod of Frequency Control (V/F) or Open Loop Vector Control (provide unequalled Motor Speedand Torque Control at low speed).



The current of the motor shall have a low content of harmonics to ensure high motor efficiency. Slipcompensation shall be provided so that the speed holding accuracy shall be better than +/- 0.5.

Each AC Drives shall be sized to drive all duty motors in a particular group to which it is designated.The Power (kVA) rating of the AC Drives shall exceed the total driven load. Operating frequencyrange 10 to 50 Hz.

For each process control, the application listed below shall be made available:-

• Basic - Suitable for most purposes or applications.• Standard - Basic, with more programming possibilities.• Local / Remote Control - Two (2) external control plates.• Multi-Step Speed Control - Intended for switching between 16 preset fixed speeds.• PID Process Controller - Matching Pump/Fan speed to process requirements.• Multi-Purpose Control - Most flexible of all.• Pump and Fan Control - Control of up to five (5) pumps with Auto-Change. Can be used for

controlling one (1) AC drives and a total of four (4) auxiliary AC Drives. Can detect “BurstPipe” or “Loss Of Prime”. Full Motor Protection. Reduce Load Disturbance.

Shall have a built in Integrated AC Line Chokes (Reactors) to maximum protection and minimise anymain disturbances (harmonics) and Integrated EMC/Noise Filter compliant with immunity to fulfillall EMC Immunity requirements. Emissions to EMC Class H complying with IEC61800-3 and shallhave built in Input Line Fuses – Fast Acting Semiconductor Fuses (for motor sizes 100 kW andabove) and Integrated Braking Chopper.

Shall allow for starting motors in cascade and assume starting current is not less than eight (8) timesthe motor full load current (FLC) and suitable for Multi-Motor drive system.

Take account of Motor Power Factor and Efficiency with built in PFC with Autochange Function forCentrifugal Pumps and Fans.

The Acceleration & Deceleration Time: 0 to 3,000 sec. The Relative Humidity: 0 to 95% RH: Non-Condensing, Non-Corrosive, No Dripping Water. Shall allow for Constant Torque (Overload Factor:1.5 x IH @ 50 oC) characteristics. High Starting Torque: > 200% (depending on motor and AC Drivesizing) with Low Ripple in the Torque. High Starting Current: 2.0 x IH. Full Torque Control at allspeed all speed, including zero (0) speed or 0.0 Hz. The Torque Accuracy shall be less than 3%.

Where the AC Drives controls more than one (1) motor, a standby AC Drives shall be provided.

• Drive and Motor Input and Output Circuit Protection:-

− Overvoltage and undervoltage− Earth or ground fault,− Main Supervision (Single Phasing) - Trips if any input phase is missing− Motor Phase Supervision – Trip if any output cables/phase is missing− Drive Overtemperature− Overcurrent− Motor Phase Supervision− Motor Overload− Motor Stall− Short-Circuit of +24 V and +10 V Reference Voltages.



− Motor Underload - “Loss Of Prime” or “Belt Damage”, when the AC Drives has brought themotor up to speed, an adjustable Underload Setting will detect the loss of load due to “Loss OfPrime – Pump Application” or “Belt Damage – Fan Application”.

• Common Spare Parts:-

− Same Human Machine Interface (HMI) for all models.− Same Control Unit for all models.

• Adjustable Switching Frequency – 1 to 16 kHz (Silent Motor Operation)• Removable / Detachable Keypad & Alphanumeric Display Unit (RS232C c/w 3 m cables)

mounted on the front side of panel door at approximately 1.5 m height from the floor.• Intelligent and easily configurable Multilingual Control Keypad and Display.• Inputs / Outputs (I/O) connections with simple quick connection terminal and Expandable

Inputs / Outputs (I/O) configuration.

• All AC Drives are Constant Torque suitable for Pumps & Fans Application with PFC (PumpFan Control) Autochange Function.

• Fixed Speed / Off / Variable Speed Switch for selection of control mode.• Panel mounted facility for local setting of frequency manually in the event of a failure of the

control signal.• Digital indication of output voltage.• Indication of output voltage.• Drives “Running / Failed” indicator.• Main Supply Isolating Switch.

The AC Drives unit shall include but not limited to the following protections: -

• Phase to Phase and Phase to Ground (Earth) Short Circuit Protection.• Line Transient Protection.• Three (3) Phase Short Circuit Protection at output terminals.• Insensitive to incoming Power Phase Sequence.• Built-in Thermal Relay for excessive temperature and shall be reset manually.• Current Limiting feature.

Failure of the control signal shall stop the drive. Facilities shall be provided for indication of: -

• Control signal failure alarm.• Variable frequency supply output failure alarm.• Variable frequency control unit failure alarm.

A summary Alarm Volt-Free Contact and five (5) Inputs / Outputs Card Slots shall be provided toinitiate an alarm to the SCADA System when any one or more of these alarms are on.

Diagnostic fault indicators and messages in Alphanumeric (plain English) shall also be provided.

The AC Drives shall be housed in the respective MCC or Starter Panel Board. Adequate natural orforced ventilation shall be ensured for continuous operations at the maximum specified 50 oC (122 oF)ambient temperature. Harmful deposition of dust shall be excluded by suitable filters.



The driven motor frame size shall be selected to ensure that the motor will operate correctly withoutoverheating when fed from the Variable Frequency Drives (AC Drives) and operating over the speedrange of 10 to 50 Hz.

The AC Drives shall operate with an Input Power Factor not less than 0.95 throughout the speedrange.

Under any conditions of operation, the AC Drives shall not emit signals that may interface with RadioTransmission or Operation. The AC Drives shall meet the requirements of EMC Class: H – IEC61800-3 or higher regarding the emission of Radio Frequency Interference (RFI). Radio frequenciesemitted by other equipment according to EMC Class: H – IEC 61800-3 shall not hamper the correctoperation of the AC Drives.

The AC Drives shall not product Harmonics and Voltage Distortion that may affect the operation ofother equipment connected to the MCC or Starter Panel Board. Voltage and Current Distortionsproduced by the AC Drives at the input side shall be limited to the values specified relevantStandards, which are applicable for industrial distribution system.

14.6 Contactor for Motor Starters

All contactor starters shall incorporate air break or vacuum contactor rated for frequent duty inaccordance with IEC 60947-1 and IEC 60947-4-1. Contactor shall be rated to make and breakaccording to Category AC3 of IEC 60947-4-1. All contactors shall have the reference number on thefront of the contactor. All contactors shall be climate proof as standard. The rated impulse voltageshall be at least 6 kV. The contactor AC3 current shall work up to 55oC ambient temperature withoutderating. All contactors shall be finger safe as standard or with adaptable covers. The safety clearanceon the front of the contactor shall be less than 15 mm. The coil wire insulation shall be Class F. Thecontactors shall be cadmium free and built with recyclable materials.

The Starters shall be incorporated to detect failure of any phase (single phasing or reverse polarity orvoltage and current unbalance) to interrupt the circuit when the contactor is de-energised. All startersshall incorporate triple pole MCB. Overcurrent, Phase Sequence and earth leakage protection relaysshall be incorporated as later specified together with all necessary auxiliary relays, contactors, timers,MCB, wiring and terminals. Controls system and indication facilities shall be provided on eachstarter and incorporate with single pole MCB as specified.

All medium voltage starters shall incorporate a triple pole fully interlocked load breaking isolatingswitch capable of breaking the stalled motor current and suitable for use on a 230/415 Volt, 50Hz, ACsystem.

15.0 INDICATING LAMPS AND FITTINGSThe indicating lamp shall enclosed type and complies with IP40. The indication light size shall be 25mm in diameter.

Lamps shall be easily removed and replaced from the front of the panel by manual means notrequiring the use of extractors. The lamps shall be cluster LED type and fitted into an acceptedstandard form of lamp holder. The rated lamp voltage shall be 24 V DC/1A (resistive).



The bezels of metal or other approved material holding the lens shall be of an approved finish andeasily removed from the body of the fittings so as to permit access to the lamp and lens. The lens shallbe in standard colours, red, green, blue, white and amber. The colour shall be in the lens and not anapplied coating and the different coloured lens shall be fully interchangeable. The lens holder shallincorporates a reflector ideally designed to eliminate light loss and marking plate serves as a filter todiffuse the light effectively, ensuring a clear illumination face.

The service life at nominal voltage and at an ambient temperature of 25oC shall be 100,000 hours.

Indicating lamps fitted to the facias of switch and instrument cubicles or panels shall be adequatelyventilated.

Refer to Appendix H - Meaning of Colours from IEC 60073 and IEC 60204-1.

16.0 PUSH BUTTONSAll stop push buttons whether forming part of a switchboard or supplied as a separate control station,shall be of the stay-put pattern arranged to permanently open a circuit until deliberate reset action hasbeen carried out.

All emergency push buttons shall have red mushroom headed pushes of the stay-put pattern, shall beconnected in control circuits such that they are effective under all conditions and shall be positionedin the immediate vicinity of the associated pump motor.

The start push buttons shall be effective only in selected circuits, primarily hand control circuits only.Emergency push buttons located next to equipment (outdoor) shall be of weather proof type.

17.0 ANTI-CONDENSATION HEATERSA thermostatically controlled anti-condensation heater shall be provided at the back of the floormounted switchboards and starter boards together with an over-riding rotary isolating switch. As ageneral rule the heaters shall be placed in a separate compartment at the bottom in such a way that theviscosity of oil in any dashpot is not affected and the thermostats shall be adjustable over the range ofat least 21 °C to 50 °C.

The heaters shall operate at 230 volts and the supply is therefore to be taken from one phase andneutral of 415 Volt system.

18.0 LABELSInternally fitted labels shall be finished white engraved letters and numbers filled with blacklaminated material such as Traffolyte may be used on rear engraved and filled plastic.

Externally fitted labels shall be of perspex or other approved transparent plastic with letters andnumbers rear engraved and filled with black. The back surface of each label shall be finished with afirst coat of aluminium paint and a second coat of paint of the same colour as the panel externalfinish.



19.0 PADLOCKSPadlocks and keys shall be minimum of the Yale type in an incorrodible metal.

20.0 CABLE ENTRIESAll switchboards, starter panels and TNB meter panel shall unless otherwise specified, shall havecables glanded at bottom entry of the switchboard. Removable glands plates shall be mounted at least300 mm above the base of the panels. If gland plates are provided inside the switchboards/starterpanel cubicle entries in the base of the cubicle shall be made dust-proof in an approved manner.

Refer to Appendix I – Switchboard Plinth and Cable Trench Design Drawing.

21.0 JUNCTION BOXThe junction box or enclosures shall be IP66, dust/damp proof according to IEC 529. It shall be withhigh mechanical impact up to 55 N/mm2. It shall good resistance to UV radiation. Able to withstandtemperature range up to 75°C.

It shall resistance to chemical, detergent solvent, grease and oil. It shall also non-hygroscopic (doesnot absorb moisture) type. Can be made of high quality thermoplastic (industrial grade), ABSthermoplastic or polyurethane. All the cable entries are must from bottom and enclosed withwatertight coupler. The gasket piece used must from polyurethane for a continuous seal to maximisethe IP rating. The junction boxes shall be watertight surface mounting type. The screws used shall betype self-tight screws and made of the same material as the box.

Appendix A - Metal Treatment and Painting Procedures (Electro-Galvarnised Metal Sheets)


Appendix AMetal Treatment and Painting

Procedures (Electro-GalvarnisedMetal Sheets)

Section 1: Appendix A – Metal Treatment and Painting Procedures (Electro-Galvarnised Metal Sheets)

Electrical Works Specifications App: A - 1Issue 01 / Revision 01February 2007

APPENDIX A

A-2 ELECTRO-GALVANISED METAL SHEETS

PROCESS 1

Metal parts are soaked in alkaline degreaser

TANK 1 (ALKALINE DEGREASER)

Chemical : SPU 8 - 30 Alkaline Liquid DegreaserDilution : 1: 5 parts of waterChemical Required : 140 litresMethods : ImmersionTime : 15 - 30 minutesTank Material : Stainless Steel 316

PROCESS 2

Water spray gun - To clean the alkaline residue

PROCESS 3

The metal treated should be left for air dry prior for powder coating

PAINTING PROCESS

- Selection of color of epoxy powder paint and filled up in the spray tank.- Parts are hung up in the spray booth- The parts are electrostatically sprayed with the epoxy powder paint.- Sprayed parts are removed from the booth and placed in an infrared oven.- Parts are then baked in the oven at 180 degree Celsius for a minimum of 30 minutes- Cured parts are then removed from oven.

Quality Checks: -

- Painted parts are checked for the quality of paint.- Dry film thickness are checked with an elcometer- Dry film thickness should be a minimum of 45 micron as standard. Dry film thickness of 60 - 80 microns are non standard and available on request.- Rejected parts are to be reworked.

Appendix B - Floor Mounted Switchboard Compartment Dimensions


Appendix BFloor Mounted Switchboard

Compartment Dimensions

Section 1: Appendix B - Floor Mounted Switchboard Compartment Dimensions

Electrical Works Specifications App: B - 1Issue 01 / Revision 01February 2007

APPENDIX B

Up to 100 Amps (MCCB) More Than 100 Amps and UpTo 400 Amps (MCCB) 400 Amps and Above

Incoming : 450 mm Incoming : 550 mm 2 panels : 1. MSB 2. MCC

Subsequent Compartment :450 mm

Subsequent Compartment : 500mm(Until last compartment)

MSB MCC

Cable Compartment : Behind Cable compartment : Behind Incoming :600 mmSubsequentcompartment :450 mm

Subsequentcompartment :450 or 500 mm

Cables shall be glanded atbottom entry of theswitchboard

Cables shall be glanded atbottom entry of the switchboard

Cables shall be glanded atbottom entry of the switchboard

Floor Mounted Switchboard Compartment Dimensions

Appendix C - Typical Switchboard Drawings (Floor Mounted, Wall Mounted and Outdoor Type)


Appendix CTypical Switchboard Drawings

(Floor Mounted, Wall Mounted andOutdoor Type)


App: C - 1


App: C - 2


App: C - 3


App: C - 4


App: C - 5


App: C - 6

RYB4 R BY

S/T COIL6A 1P MCB

(HANDLE LOCK)

ASA

VVS

0-100A

0-500V

TO CONTROL

CL.1 15VA CT1-100/5A

B

2xEXHAUST FAN

ELR

ZCT100/5A

100A 4PMCCB 50KA

3x6A 1P

HEATERN

PH

N

SWITCH

UUU T/H

PANEL

60W

CL.3 5VA CT3X100/5A

ON/OFF

MCB

10 KVARCAP. BANK

RR

CAP. BANK

YMCCB 25KA60A TPN

RYB3

3X6A MCB

20A TP20A TP

RYB2

PFR

R

&PF

SINGLE LINE DIAGRAM

4 STEP CAPACITOR BANK PANEL

MCCBMCCB

5 KVAR

30A TPN 32A

MCB2POLE

DOL DOLDOLA/TA/TA/TA/TA/T DOLA/T

MCCB 10KA(HANDLE

3x6A 1P MCB

6A 1P MCB

6A 1P MCB

ON/OFFSWITCH

N

MCCB 25KA60A TPN

SWITCHING SWITCHING20A TP

CONTACTOR CONTACTOR

20A TPSWITCHINGSWITCHING

20A TP

CONTACTOR

SHALL BE USED

FOR 200A AND ABOVE IDMT, OC / EF

LOCK)(HANDLEMCCB 10KA16A TPN16A TPN

MCCB 10KA(HANDLELOCK)LOCK)

(HANDLEMCCB 10KA16A TPN16A TPN






(HANDLEMCCB 10KA30A TPN

LOCK)

CU. BUSBAR (RYBN)4-6MM x 25MM TINNED

RYB12R13RYB11RYB10RYB9RYB7 RYB8RYB6RYB5RYB4RYB3RYB2RYB1

PH. SEQ. RELAYPSR

PF

SURGE PROTECTOR3x60A FUSE+NCONTACTOR

10 KVARCAP. BANK

20A TP

RYB1

15A TP

R

MCCB

10 KVAR

MCCB20A TP

CAP. BANK

R


App: C - 7


App: C - 8


App: C - 9


App: C - 10


App: C - 11

(HANDLE LOCK)

CAP. BANK

10A TP

3 KVAR3 KVAR

MCB


SINGLE LINE DIAGRAM

10A TP

CAP. BANK

R

MCB

R

10A TP

SWITCHING

CAP. BANK2 KVAR

CONTACTOR

MCB10A TP

CAP. BANK3 KVARR R

MCB

CU. BUSBAR (RYBN)5MM X 25MM TINNED

RYB1 RYB2 RYB3

RYB1

3X6A MCB

RYB4

30A TPNMCCB 10KA

RYB2

R

RYB6(HANDLE LOCK)

A/T

30A TPNMCCB 10KA

A/T

30A TPN

CL.1 15VA CTPF

60A 4P

AS

(HANDLE LOCK)

EXHAUST FAN 3X60/5ACL.3 5VA CT

RCCB 4P RCCB

MCCB 25KA

63/0.3A

0-60AA

VS

PH. SEQ. RELAY

(HANDLE LOCK)

PANEL HEATER

&PFPFR

Y

RYB3

B

NPH

N

RYB4

60W UUU

(HANDLE LOCK)

A/T

30A TPN

DOL

15A TPN

ON/OFFSWITCH

T/H

RYB5

1-60/5A

3x6A 1P

R7

MCB

(HANDLE LOCK)

DOL

15A TPNMCCB 10KA30A 2P

TO CONTROL

0-500V

R

V

Y B

PSR

MCB3x6A 1P

MCB6A 1P

MCCB 10KA MCCB 10KA MCCB 10KA MCCB 10KA(HANDLE LOCK)

20A TPSWITCHINGCONTACTOR

20A TP

CONTACTORSWITCHING20A TP

SWITCHINGCONTACTOR

20A TP


App: C - 12


App: C - 13


App: C - 14

LOCK)(HANDLEMCCB 35KA200A TPN200A TPN








(HANDLEMCCB 10KA20A TPN

LOCK)

CU. BUSBAR (RYBN)4-6MM x 50MM TINNED

RYB12R13RYB11RYB10RYB9RYB7 RYB8RYB6RYB5RYB4RYB3RYB2RYB1

PH. SEQ. RELAYPSR

PF

SURGE PROTECTOR3x60A FUSE+N

CAP. BANK

RYB1

R

MCCB

CAP. BANK

R

RYB4-6R BY

S/T COIL6A 1P MCB

(HANDLE LOCK)

DPM

TO CONTROL

CL.1 15VA CT1-100/5A

B

2 x EXHAUST FAN

IDMT

CL.10P104-400/5A

400A 4PMCCB 50KA

3x6A 1P

HEATERN

PH

N

SWITCH

UUU T/H

PANEL

60W

CL.3 5VA CT3X400/5A

ON/OFF

MCB

CAP. BANK

RR

CAP. BANK

YMCCB 35KA200A TPN

RYB3

3X6A MCB

RYB2

PFR

R

&PF

SINGLE LINE DIAGRAM


20A TPN

VSD VSDS/SA/TA/TS/DS/DS/D S/SS/D

MCCB 10KA(HANDLE

3x6A 1P MCB

6A 1P MCB

6A 1P MCB

ON/OFFSWITCH

N

MCCB 25KA100A TPN

TO SUITDESIGN STEP

TO SUITDESIGN STEP DESIGN STEP

TO SUIT

DESIGN STEPTO SUITMCCB MCCB

TO SUITDESIGN STEP

TO SUITDESIGN STEP DESIGN STEP

TO SUIT

DESIGN STEPTO SUITMCCB

15VA CTS

EF/OC

30A 2PMCCB 10KA(HANDLELOCK)

6A MCB

(SWITCHINGCONTACTOR) CONTACTOR)

(SWITCHINGCONTACTOR)(SWITCHING (SWITCHING

CONTACTOR)


App: C - 15

Appendix D - Digital Protective Relay Standards


Appendix DDigital Protective Relay Standards

Section 1: Appendix D - Digital Protective Relay Standards

Electrical Works Specifications App: D - 1Issue 01 / Revision 01February 2007

APPENDIX D – DIGITAL PROTECTIVE RELAY STANDARDSRequirements Standards Level

Protection relays IEC 60255Electro MagneticCompatibility (EMC)

Emission testsDisturbing field emission

Conducted field emission

Immunity testsRadiated disturbances– radiated fields

– electrostatic discharge– to power magnetic fields at networkfrequency

Conducted disturbances– RF disturbances– fast transient bursts

– damped oscillating waves– surges– voltage interruptions

IEC 60255-25EN 55022IEC 60255-25/EN 55022

IEC 60255-22-3IEC 61000-4-3ANSI C37.90.2IEC 60255-22-2, ANSIC37.90.3IEC 61000-4-8

IEC 60255-22-6IEC 60255-22-4IEC 61000-4-4ANSI C37.90.1IEC 60255-22-1, ANSIC37.90.1IEC 61000-4-5IEC 60255-11

A

III

4

IIIA and BIV

III

EnvironmentalMechanicalconstraints

In operation– vibrations– shocks– earthquakesDe-energised– vibrations– shocks– jolts

IEC 60255-21-1IEC 61000-2-6IEC 60255-21-2IEC 60255-21-3

IEC 60255-21-2IEC 60255-21-2IEC 60255-21-2

2Fc22

222

Safety Enclosure tests– Mechanical protection degree– Fire withstandElectrical tests– earth continuity– 1.2/50µs impulse wave– dielectric at network frequency

IEC 60529NEMAIEC 60695-2-11

IEC 61131-2IEC 60255-5IEC60255-5, ANSIC37.90

IP52Type 12

Climatic conditions In operation– to cold– to dry heat– to damp heat– salt mist– corrosion influence/Gas test

IEC 61068-2-1IEC 61068-2-2IEC 61068-2-78IEC 61068-2-52IEC 61068-2-60

AdBdCabKb/2

Section 1: Appendix D - Digital Protective Relay Standards

Electrical Works Specifications App: D - 2Issue 01 / Revision 01February 2007

In storage– temperature variation– to cold– to dry heat– to damp heat

IEC 61068-2-14IEC 61068-2-1IEC 61068-2-2IEC 61068-2-78IEC 61068-2-30

NbAbBbCabDb

Requirements Standards LevelCertification (*) CE

ULCSAGOST

EN 50263 HarmonisedStandard EuropeanDirectiveUL508CSA C22.2

Low Voltageelectrical installations

IEC 60364

Functional Safety ofelectronic safetyrelated systems

IEC61508

Communication Data transmission industrial protocol:Modbus RTUBetween protective relay and controlsystem inside a power stationFor power substation automationinside the substation

IEC 61158 Field BusFoundation

EC 870-5 series andIEC 870-5-103 – DNP3

IEC 61850

Appendix E - Digital Protective Relay Operating Conditions


Appendix EDigital Protective Relay Operating

Conditions

Section 1: Appendix E - Digital Protective Relay Operating Conditions

Electrical Works Specifications App: E - 1Issue 01 / Revision 01February 2007

APPENDIX E – DIGITAL PROTECTIVE RELAY OPERATINGCONDITIONS

Temperature: - 25°C to +70°C

External auxiliary power supply:- For Low and Mid-end solutions/applications- For High-endsolutions/applications:

From AC/AC UPS system or dual battery charger24V-250V DC and 110V-240V AC (50Hz/60Hz)24V-250V DC

Current sensors: In/1A or In/5A current transformers, Core Balance CT’s orinterposing ring CT

Voltage sensors: 100V, 110V, 100V/ √3, 110V/√3 and voltages as per IEC 60255-6

Appendix F - Digital Protective Relay Metering Functions


Appendix FDigital Protective Relay Metering

Functions

Section 1: Appendix F - Digital Protective Relay Metering Functions

Electrical Works Specifications App: F - 1Issue 01 / Revision 01February 2007

APPENDIX F – DIGITAL PROTECTIVE RELAY METERINGFUNCTIONS

Low-end solutions /Applications

DesignationCurrent or Voltage

Mid-endsolutions/

Applications

Phase current I1, I2, I3 RMSCalculated residual current I0ΣDemand current I1, I2, I3Peak demand current IM1, IM2, IM3

Measured residual current I0, I’0

Voltage U21, U32, U13, V1, V2, V3Residual voltage V0Positive sequence voltage Vd/rotation directionNegative sequence voltage ViFrequency

Active power P, P1, P2, P3Reactive power Q, Q1, Q2, Q3Apparent power S, S1, S2, S3Peak demand power PM, QMPower factor

(P) (Q) (S)

Calculated active and reactiveenergy(±Wh,±VAR)

Active and reactive energy by pulse counting(±Wh,±VAR)

Temperature

Appendix G - Digital Protective Relay Network, Machine and Switchgear Diagnosis


Appendix GDigital Protective Relay Network,

Machine and SwitchgearDiagnosis

Section 1: Appendix G - Digital Protective Relay Network, Machine and Switchgear Diagnosis

Electrical Works Specifications App: G - 1Issue 01 / Revision 01February 2007

APPENDIX G – DIGITAL PROTECTIVE RELAY NETWORK,MACHINE AND SWITCHGEAR DIAGNOSIS

Designation Low-end solutions /Applications

Mid-end solutions/Applications

Switchgear Diagnosis

CT/VT supervision – ANSI 60/60FL

Trip circuit supervision – ANSI 74

Auxiliary power supply monitoring

Cumulative breaking current

Number of operations, operating time, chargingtime, number of racking out operations

Network and Machine Diagnosis

Tripping contextTripping current Trip I1, I2, I3, I0

Phase fault and earth fault trip counters

Unbalance ratio / negative sequence current Ii

Phase displacement φ0, φ’0, φ0 ΣPhase displacement φ1, φ2, φ3

Disturbance recording

Thermal capacity used

Remaining operating time before overloadtrippingWaiting time after overload tripping

Running hours counter / operating time

Starting current and time

Section 1: Appendix G - Digital Protective Relay Network, Machine and Switchgear Diagnosis

Electrical Works Specifications App: G - 2Issue 01 / Revision 01February 2007

Designation Low-end solutions /Applications

Mid-end solutions/Applications

Start inhibit timeNumber of starts before inhibition

Unbalance ratio / negative sequence I’i

Appendix H - Meaning of Colours from IEC 60073 and IEC 60204-1


Appendix HMeaning of Colours from IEC 60073

and IEC 60204-1

Section 1: Appendix H - Meaning of Colours from IEC 60073 and IEC 60204-1

Electrical Works Specifications App: H - 1Issue 01 / Revision 01February 2007

APPENDIX H

COLOURS MEANING EXPLANATION ACTION BY OPERATOR

Red Emergency Hazardous conditionImmediate action to deal withhazardous condition (e.g. byoperating emergency stop)

Yellow Abnormal Abnormal condition impendingcritical condition

Monitoring and/or intervention(e.g. by re-establishing theintended function)

Green Normal Normal condition Optional

Blue Mandatory Indication of a condition thatrequires action by the operator Mandatory action

White Neutral

Other conditions; may be usedwhenever doubt exists aboutapplication of Red, Yellow,Green & Blue

Monitoring

Appendix I – Switchboard Plinth and Cable Trench Design Drawing


Appendix ISwitchboard Plinth and Cable

Trench Design Drawing

SWITCHBOARD

CABLE GLAND

PLINTH

GLAND PLATEWALL WALL

CABLE

CABLE TRENCH

200m

m

2100

mm

1000mm 1000mm

-

-SPECIFICATION AND DESIGN OF SWITCHBOARD PLINTH AND CABLE TRENCH


App: I - 1



Section 2Standby Generator Specification

Section 2 – Standby Generator Specification


PageSection 2 - Standby Generator Specification

1.0 General 2-12.0 Engine 2-13.0 Lubrication System 2-14.0 Exhaust Fan 2-15.0 Radiator Air Discharge 2-26.0 Fuel System 2-27.0 Engine Governing 2-28.0 Engine Instrumentation 2-29.0 Alternator And Exciter 2-310.0 Voltage Regulation 2-311.0 Voltage Waveform 2-312.0 Starting System 2-313.0 Fuel Supply System 2-4

13.1 Fuel Tank 2-413.2 Fuel Transfer System 2-413.3 Fuel Supply Piping 2-5

14.0 Protective Devices 2-515.0 Control Panel 2-616.0 Automatic Mains Failure (AMF) Switchboard 2-617.0 Changeover Contactor 2-818.0 Earthing System 2-9



SECTION 2 - STANDBY GENERATOR SPECIFICATION

1.0 GENERALThis section describes the specification of diesel generator set. The set shall comprise a diesel enginedirectly coupled to a 3 phase alternator with auxiliary equipment as further described below and shallbe capable of maintaining a continuous output of not less than the kVA specified at 0.8 lagging powerfactor, 415 volts, 3 phase, 4 wire, 50 Hz supply. Under the operating conditions specified hereafterand within a guaranteed range of frequency and voltage fluctuations after making full allowance forall internal losses and power consumed by ancillaries.

The operating conditions shall be:-

• Total baromatic pressure : 750 mm Hg.• Air temperature : 40 °C• Relative humidity : 95%

2.0 ENGINEThe engine shall be multi cylinder, vee/in line configuration, 2/4 stroke, naturally aspirated/turbocharged, air-cooled or water cooled with fan and radiator, instant starting and in general compliancewith BS 5514 as minimum requirements. Engine speed shall be 1500 rpm. and capable of producingcontinuously the service power not less than that required by the alternator for the generation of therequired output under the specified operating conditions. The engine shall be able to withstand anoverload of 10% for 1 hour in any period of 12 hours consecutive running.

Engine base mounting shall be fabricated steel channel base frame complete with spring typevibration damper.

3.0 LUBRICATION SYSTEMThe engine shall be complete with enclosed force-feed lubricating system by gear type oil pump withfull flow replaceable paper element type oil filter. Oil pan shall be of the sump type.

4.0 EXHAUST FANThe engine shall be provided with a suitable exhaust system capable of carrying exhaust gases fromthe engine and dissipate them to the atmosphere as quickly and silently as possible. The piping andfitting shall have minimum thickness of 3 mm and shall be suitably protected from corrosion byapplication of heat resistant paint.

A suitable flexible connection shall be made between the section of piping fixed to the engine and thepiping fixed to the building structure.



The exhaust system shall incorporate an efficient residential type silencer of the absorption-typecapable of reducing the exhaust noises of the engine to an acceptable level. Exhaust piping inside theGenerator Room shall be fully lagged with minimum 20 mm thick asbestos rope that in turn sheathedwith tinfoil. Silencer shall be lagged with minimum 35 mm thick fibre glass section. A metal thimbleguard shall be installed where the exhaust pipe passes through the wall.

5.0 RADIATOR AIR DISCHARGEUnless otherwise dictated by room design, engine radiator discharge air shall be directed outdoorsthrough an approved discharged duct that connects the engine radiator to an opening in an externalwall. The duct shall be as short as possible. A length of flexible duct shall be provided between theradiator and the fixed air discharge duct.

Shall provide an aluminium automatic self-opening and self-closing shutter complete with aluminiumframe to be mounted on the wall opening. The automatic shutter shall be self-closing when the engineis not in operation. When the engine starts the shutter shall be opened outwards by air dischargedfrom the radiator. The automatic shutter system shall be so designed as to keep the noise level to aminimum. In the case of an air cooled engine, air discharge ducting system complete with aluminiumautomatic shutter as above shall be provided.

6.0 FUEL SYSTEMThe engine shall be capable of operating on 'Class A' fuel to BS 2869. The fuel pump shall be of thegear type complete with governor and throttle and capable of fuel delivery to injectors under allpower conditions of the engine. The pump shall be self- adjusting for wear and fuel viscosity. Fuelfilter shall be of heavy duty, replaceable and paper element type.

7.0 ENGINE GOVERNINGThe governing accuracy of the engine shall be in accordance with BS 5514 part 4, 'Class A1'. Thespeed droop shall be less than 5%.

8.0 ENGINE INSTRUMENTATIONThe instruments and gauges shall be flush mounted on the metal clad panel and shall include but notlimited to the following: -

• Elapsed hours running meter• Lubricating oil pressure gauge• Cooling water temperature gauge• Tachometer



9.0 ALTERNATOR AND EXCITERThe alternators shall be of screen protected, drip-proof, revolving fields, brushless, salient pole type,directly coupled to the engine and fitted with an exciter to comply in all respects to BS 4999 and BS5000. Insulation shall conform to BS 2757 Class 'F'. The rotor or armature shall be of one piece, fourpole type with lamination pressed and keyed to the shaft. The stator shall be of the multiplicity typefor high or low voltages in 'Star' or 'Delta' connections. Damper windings shall be provided in thepole faces. The alternator of brushless type shall be continuously rated not less than themanufacturer's rated kVA specified at 0.8 power factor lagging when wound for 415 volts, 3 phase, 4wire, 50 Hz supply.

10.0 VOLTAGE REGULATIONThe voltage regulation shall be of solid state transistor amplified type capable of providing voltageregulation Grade VR 2.21 of BS 4999 part 40. The alternator, when driven its rated speed andoperating with its normal excitation control system, shall be capable of maintaining the voltage understeady state conditions within + 2.5% of rated voltage for all loads between no-load and rated load atrated power factors. Following transient changes the voltage shall restored to within these limits inless than 10 seconds. When alternator, driven at rated speed and giving its rated voltage on no loadunder its normal excitation control system is switched on to a symmetrical load which would absorb60% of rated current at rated voltage at a power factor between 0.4 and zero lagging, the initialvoltage drop shall be limited to 15% of rated voltage and the voltage shall recover to at least 97% ofrated voltage in less than 1.5 seconds. The transient rise in voltage after a sudden rated load rejectionat rated power factor and constant speed shall not exceed 20%. Normal voltage shall be variable bymeans of voltage trimmer within +5% of rated voltage.

11.0 VOLTAGE WAVEFORMThe voltage waveform shall approximate closely to a sine wave both at no load and full load with alagging power factor of 0.8 and shall not exceed the limits as stated in BS 4999 part 40.

12.0 STARTING SYSTEMEach engine shall be fitted with electric starting system with a 24 volt heavy duty nickel cadmiumbattery of sufficient capacity to provide a minimum of six (6) successive abortive starts of the enginewithout recharging. The minimum cranking period for each abortive starts shall be 15 seconds. Thebattery shall be connected to the starter motor starting and stopping circuit complete with indicatingor signal devices. Capacity of the nickel cadmium battery shall be as recommended by the batterymanufacturer for particular make and model of the generator set that required to operate the dcindicating, tripping and control circuits.

Battery shall be housed in a rack or crate located beside the generator set and covered on top by aremovable wooden cover with sufficient ventilation. The battery charger shall be of automaticconstant potential type with two rates of charging complete with ammeters, voltmeters, mainisolators, indicating lights for `Mains On', `Trickle Charge', `Boost Charge', `AC Failure' and etc.



It shall employ fixed resistance charging and transistor switched relay to switch in the boost chargeresistor when the battery voltage falls below a predetermined level recommended by the batterymanufacturer. After the boost period, the relay shall be de-energised automatically and the circuitreverts to trickle charge condition. A milliammeter and an ammeter of suitable range shall beprovided to indicate trickle and boost charge currents respectively. The battery charger shall beincorporated in the generator switchboard.

The starter motor for the engine shall be automatic type to be controlled by the automatic starting andstopping system. In the event of more than one generator sets are installed then each engine shall beprovided with its own nickel cadmium battery and battery charger as above.

13.0 FUEL SUPPLY SYSTEM

13.1 Fuel Tank

A fuel tank having a capacity for a minimum of 8 hours continuous operation at full load or 1,000litres capacity whichever is larger supported by suitable angle irons to permit gravity feed to theengine pumps. The fuel tank shall be fabricated from 2.5 mm thick mild steel sheet construction, notgalvanised but painted inside and outside with oil resistant prime and externally finished withundercoat and topcoat. A dial type level indicator calibrated in litres shall be provided.

A breather is to be provided. The breather opening must be adequate to vent gases and air from thefuel tank without back pressure.

The fuel pump suction line shall pick fuel about 30 mm from the bottom of the fuel tank completewith fuel strainer. The fuel return line shall be so located so as to allow separation of the fuel andvapour or gases in the expansion space above the normal fuel level and shall be pointed away fromthe breather and suction area.

A drain valve complete with padlock shall be provided at a low point in the fuel tank in an accessiblelocation to allow periodic removal of water condensation and sediment.

If more than one generator sets are installed in the Generator Room, a common fuel tank may be usedunless otherwise specified. However, the common fuel tank shall be off sufficient capacity, orotherwise specified elsewhere, to run the generator sets simultaneously for a minimum of 8 hourscontinuous operation at full load. Shall supply a full tank of fuel at the time of handing over. Fuelrequired to carry out all tests including work test and site tests shall be supplied and shall beadditional to the full tank of fuel mentioned above.

13.2 Fuel Transfer System

Fuel transfer system for transferring fuel from drums into the fuel tank shall be supplied and installed.The fuel transfer system shall consist of hand operated pump installed in parallel with an electricmotor-driven pump.



A filler pipe shall be installed from the inlet point of the fuel tank to the outlet point of the fueltransfer pumps. A suitable length of flexible transparent oil resistant hose shall be connected from theinlet of the fuel pumps for off-loading from drums.

The fuel transfer pumps shall be installed as close to the fuel tank as possible. The electric motordriven pump shall be of the self-priming type and shall have sufficient suction lift to deliver a transferrate of 50 litres per minute. The electric motor driven pump shall be suitable for operation from singlephase, 230 V, 50 Hz supply.

To carry out wiring in galvanised steel conduit from the electric starter point on nearby wall to theelectric motor-driven pump.

13.3 Fuel Supply Piping

Fuel piping and plumbing shall be of black iron pipe or 'steam' pipe. The diameter of the pipe shall beas recommended by the generator set supplier. Seamless synthetic rubber flexible hose shall be usedfor connection to the engine fuel inlet and return outlet. Must keep the number of bends to aminimum. Feeding fuel pipe from the fuel tank shall be with a shut-off valve near the fuel tanks formaintenance purposes. Facilities shall be provided to padlock the shut-off valves in open position.Overflowing fuel from the engine shall be fed back to the fuel tank by means of fuel pipe completewith check valve near the fuel tank. Keys alike shall be provided for the padlocks used for shut-offvalves of the fuel feeding pipe and the padlocks used for drain valves of the fuel tank. Fuel pipeswhere required to be distinguished from pipelines of other services shall be brown as a basicidentification colour in compliance with BS 1710.

14.0 PROTECTIVE DEVICESThe generator set shall be provided with protective devices to provide warning and automaticshutdown under the following conditions: -

• Low oil pressure - warning and trip• High jacket water temperature - warning and trip• Fail to start - warning and trip• Over speed - trip• Low fuel level (1st.stage) - warning• Low fuel level (2nd.stage) - trip

The low oil pressure warning and shut-down and the high jacket water temperature warning and shut-down protective devices shall be set at the manufacturer's recommended pressures and temperaturerespectively. The overspeed shutdown protective devices shall also be set at the speed recommendedby the manufacturer. The `failure to start' warning and shut-down protective devices shall operate ifthe engine should fail to start within a adjustable pre-set time and stop the automatic starting cycle toavoid successive depletion of the battery charge. The time shall be set to allow for 6 attempts instarting each with a rest interval of half the time setting of the attempt to start. Under any of the aboveconditions, a common alarm bell of 250 mm diameter installed at the control panel shall sound.

In addition, indication lamps showing operation of each engine protective devices shall also beprovided. Shall arrange for simulation tests of the above on completion of the generator set erection.



15.0 CONTROL PANELA generator set control panel housing control switches and buttons, relays, timers, indicating lights,indicating instruments, selector switches, alarms and etc. shall be supplied and installed.

The control panel shall be cubicle construction suitable for floor standing. All control wiring shall beproperly labelled with number sleeves.

The following facilities shall be incorporated as minimum requirements: -

• Indication lamps showing operation of each engine protective devices• A lamp test button• Alarm bell indicating operation of each engine protective devices with Àlarm Silence' button• Selector switch giving Àuto', `Test', Òff', and `Manual', operation modes. The function of

each mode is as follows:-

- ‘Auto’ mode - This places the generator set in its normal standby mode- ‘Test’ mode - To test the auto-start by simulating TNB power failure

without actually changing over the load from the TNB supply to thegenerator set. However if TNB supply fails during `Test' mode, loadconnection to the generator set must operate.

- ‘Off’ mode - To cut out the starting circuit so that the engine cannotbe started.

- ‘Manual’ mode - To permit manual operation of the generator set.

• A timer (t1) adjustable up to 15 seconds for starting the generator set; a timer (t2) adjustable upto 60 seconds for load connection to the generator set after starting up the generator set; a timer(t3) adjustable up to 5 minutes before the automatic changeover contactor changes to TNBsupply after a mains failure; a timer (t4) adjustable up to 10 minutes for shutting down thegenerator set after load connection to TNB supply on restoration of TNB supply. All timersshall have calibrated scales in seconds or minutes as appropriate complete with an adjustableknob and pointer.

• `Start' and `Stop' push buttons• Self-latching mushroom head type 'Emergency Stop' button (One to be provided at the control

panel and another one in the vicinity of the generator set to be decided on site)

16.0 AUTOMATIC MAINS FAILURE (AMF) SWITCHBOARDThe generator switchboards shall be of the self-contained cubicle type, free standing floor mounted,metalclad, flush fronted suitable for front and rear access housing switchgear and controlgear,protective relays, meters, indicating lamps, cable terminating boxes, and all other necessary items ofequipment. Whether specified hereinafter or on the drawings or not it shall be suitable for operationon a 415/230 V, 3 phase, 4 wire, 50 Hz system with solidly earthed.

Unless otherwise specified elsewhere, the generator switchboards shall be in general compliance withBS 5486 Part 1 and capable of withstanding without damage fault condition of not less than 31 MVAat 415 volts for 1 second.



The framework of the switchboard shall be fabricated from rolled steel sections and shall be self-supporting when assembled, uniform in height and depth from front to back. The rigid constructionshall be designed to withstand without any sag, deformation or warping, the loads likely to beexperienced during normal operating, maintenance or maximum fault conditions. The front shall beprovided with covers/doors of box formation. The rear shall be provided with hinged removable doorsof box formation. The rear doors shall be of double-leaf type with rebated edges and each leaf shouldpreferably not be wider than 450 mm. Each leaf of door shall have 2 pairs of approved hinges. Thedoor shall be fitted with approved type of surface- mounted espagnolette or cremate bolts completewith approved locking device operated by a satin chrome lever handle at the centre fixing. The topand sides shall be of removable panels. All panels, covers and doors shall be fabricated from electro-galvanised metal plates of thickness not less than 2.3 mm with paint thickness of 90 µm. The interiorand exterior of each cubicle shall be finished with light gray paint (ICI Ref. No: ICI 104 orOXYPLAST paint: FF160/8250/CS9 and so constructed as to provide a clear, flush and pleasingappearance. The panels, covers and front doors shall be secured to the enclosure by means of chrometype of screws with cylindrical knurled head complete with retaining clips. Welded cross struts shallnot be used. Refer to Appendix A – Metal Treatment and Painting Procedure (Electro-GalvanisedMetal Sheet).

The generator switchboard shall be dust and vermin proof. All covers and doors shall be providedwith grommets and seals to exclude dust and dirt. Louvres shall be provided at the sides and back foradequate ventilation. The whole cubicle shall undergo de-rusting treatment, followed by anti-rusttreatment and with the exterior be finished semi-gloss enamel grey and interior finished matt white.

Busbars shall be tinned hard drawn high conductivity copper of adequate rectangular cross section tocarry continuously the rated normal current at a rated frequency of 50 Hz with a temperature rise inaccordance with the requirements of BS EN 13601. The busbar rating shall be based on the currentdensity of not more than 1.5 A/sq. mm. Busbars shall be arranged and rigidly mounted on non-hygroscopic insulators so as to withstand any mechanical forces to which they may be subjectedunder the maximum fault conditions. Where multiple parallel bars are used, they shall be separated bytinned copper spacers at spacing equal to the bar thickness. The main busbars shall be run for the fulllength of the generator switchboard without reduction in size and shall be arranged in the horizontalplane and in the order Red phase, Yellow phase, Blue phase and Neutral from back to front. In eachpanel, connections shall be Red phase, Yellow phase, Blue phase and Neutral from left to right,viewed from the front of the panel. The neutral busbar shall be of full size and full length as that ofthe phases. Tinned copper earthing bar of 6 mm x 25 mm cross section shall run to the full length atthe base of the generator switchboard. Busbars shall be identified with standard colour code Red,Yellow, Blue, Black and Green at appropriate points to distinguish the phases, neutral and earthrespectively. Connections from busbars to the switchgears shall be effected by means of copper barsor copper insulated conductors and shall be identified by means of coloured plastic sleeving orpainting in accordance with the standard colour code. All connections shall be made up with bronzeor other copper alloy bolts and nuts utilizing tension washers on both outer faces. Precautions shall betaken to prevent overheating through hysteresis and Eddy current losses.

All secondary wiring shall be of not less than 1.5 sq. mm. section insulated with PVC and shall befixed securely without strain by cleats of the compression type. All secondary wiring shall beproperly labelled with number sleeves.

Flexible protective conductor of not less than 2.5 sq. mm section insulated with PVC shall be fixedsecurely between the lids, doors, cover plates and etc. with electrical equipment attached to them andthe main cubicle to ensure continuity of the protective circuits.



All switchgear, controlgear, indicating and measuring instruments, measuring transformers, protectiverelays and etc. provided shall comply with the relevant specifications. Automatic changeovercontactors shall be as specified hereinafter.

Refer to 13.2 – Electronic Protection Relay (Section B – Low Voltage Switchboard and ComponentsSpecification).

One number anti-condensation heater shall be installed for every two (2) panels at the generatorswitchboards. Each heater shall be complete with automatic thermostat, control switch and indicatinglamp. A tool compartment of sufficient size shall be provided at the base of the generator switchboardfor storage of tool kit used for the generator set. The door for tools compartment shall be hinged typecomplete with lockable handle with keys. Engraved labels with white lettering on a black backgroundmade of laminated materials shall be provided and fastened on the front panels of each switchgearand items of equipment. Wording shall be clear and coincide. Rubber mat of width 1,000 mm andthickness 12 mm shall be provided in front of the generator switchboard. It shall extend to the fulllength of the generator switchboard.

17.0 CHANGEOVER CONTACTORThe automatic changeover contactor, unless otherwise specified, shall be bar mounted type with fixedbar and moving shaft made of steel and bearing supports made of aluminium/bronze alloy. They shallbe mechanically held, mechanically and electrically interlocked, double air-break, quick-make andquick-break type complying fully with IEC 60947. They shall be dust-proof, rust protected, fullytropicalised and suitable for use on 230/415 V, 50 Hz AC system.

The operating coil shall be 230 V/415 V, 50 Hz AC type and shall operate satisfactorily when thevoltage at the coil terminals is between 85% and 110% of the nominal voltage. The electromagnetshall be of laminated type. The automatic changeover contactors shall be four pole types. Each poleshall comprise three main parts: -

• The main contacts shall be of 'butt-contact' pattern without sliding or rolling and shall operatewith absolute minimum contact bounce.

• The blow out coil shall be rated to carry the total current flowing through the main pole andaccording to the thermal rating of the contactor.

• The arc chute shall be De-ion type or the type having 'arc splitter' for rapid extinction of electricarc. Each arc chute shall have a steatite disc on its internal faces for preventing rapid erosion ofthe chute by the effect of arcs. The arc chutes shall be easily removable to allow inspection ofthe main contacts and where necessary their replacement.

• The main contacts shall be able to carry continuously the rated current without damage in anenclosure having an ambient temperature up to 40 degrees Celsius. They shall be of categoryAC 4 as defined in IEC 60947.

• Unless otherwise specified, a minimum of four normally close and four normally open auxiliarycontacts shall provided.

• A transparent protection screen of full compartment size shall be provided in front of theautomatic changeover contactor.



18.0 EARTHING SYSTEMIndependent earthing system shall be provided for each generator set. Earthing to earth Resistance notexceeding one (1) Ohm (Ω) shall be effected by 3 mm x 25 mm copper tape and 16 mm diametercopper jacketed steel core rods. The copper jacket shall be of minimum thickness 0.25 mm and shallbe permanently bonded to the steel core to ensure that the copper jacket and steel core are notseparable. Earth chambers and covers used for earthing rods shall be reinforced concrete type. Eachgenerator set earthing point shall be identified by permanent label legibly marked with the words'GEN-SET EARTH' permanently fixed to the point of connection of every earthing conductor and theearth electrode.



Section 3Small Power and Lighting

Section 3 – Small Power and Lighting


PageSection 3 – Small Power and Lighting

1.0 Material Panel 3-12.0 Distribution Board 3-13.0 PVC Electrical Conduit and Fittings 3-24.0 Spacer Bar Saddles 3-25.0 Distance Saddle 3-26.0 Ceiling Fan 3-27.0 Light Fittings and Ancillary Equipment to Lamps 3-3

7.1 Light Fittings for Use with Tubular Fluorescent Lamps 3-37.2 Flexible Cords 3-37.3 Installation of Fluorescent Light Fittings 3-37.4 Self-Contained Emergency Lights 3-37.5 Light Fittings to be Supplied and Installed 3-47.6 LUX Levels 3-4

8.0 Street and Perimeter Lighting 3-48.1 Scope of Works 3-48.2 Light Distribution 3-48.3 Street Lighting Lanterns 3-58.4 High Pressure Sodium Vapour (HPSV) Lamp 3-58.5 Columns and Bracket Arms 3-6

9.0 Materials and Equipment 3-79.1 General 3-79.2 Ballast 3-79.3 Ignitors 3-79.4 Service Fuse / Cut-Outs. 3-7



SECTION 3 – SMALL POWER AND LIGHTING

1.0 MATERIAL PANELProvision shall be made in the panels for the installation of the meters by TNB. Sufficient length ofcable shall be provided for termination of cables at the meters.

2.0 DISTRIBUTION BOARDThe boards shall be provided with Miniature Circuit Breakers (MCB) and arranged in such a mannerthat the incoming cables to the MCB is connected direct to the other MCB terminal. It shall be sodesigned that the MCB can be replaced without disturbing or removing the adjacent units and busbarconnectors. All boards shall incorporate a main isolator of appropriate rating, which shall be positionedat the lower part of the panel along the centerline. The interior of the panel shall be provided with aremovable internal shroud, giving access to the MCB dollies, but covering the reminder of the interiorfor neat appearance after wiring. The internal shroud shall be off the same finish as the exterior of theboard. Labels for phase and circuit identification and current ratings shall be fixed on this internalshroud either above or below the dollies.

On the outside face of each board cover, a black Perspex label with the number of the distribution boardand engraved in the white on chrome-yellow lettering shall be provided and fixed thereon. For TPNtype distribution boards, bearing the letters: “DANGER 415V; 3-PHASE SUPPLY” engraved in redcolor thereon shall be installed.

Isolators used shall be of the heavy duty “ON LOAD” type and of a approved make.

All distribution boards shall be fitted with suitable means for terminating incoming and outgoing cablesand final subcircuit wiring.

The distribution board shall be of totally enclose type construction and be suitable for installation onwalls or be recessed in walls of buildings. All boards shall be rated for the intended voltage and be inaccordance with relevant British Standard.

Busbars for the main shall be of copper and sized in accordance with the relevant British Standard.Unless otherwise noted full size neutral busbars shall be provided. Busbars shall be braced throughoutto conform to standard practice governing short circuit stresses in distribution boards.

Spare ways shall be installed with MCBs and be fully wired and labeled.

For those not exposed to the sewage emitted vapors and gases, the distribution board panel thicknessshall be of 2 mm and 60 µm of paint thickness. However for distribution boards in contact with thesewage emitted vapors and gases shall be of 2.3 mm in thickness and 90 µm of paint thickness.



3.0 PVC ELECTRICAL CONDUIT AND FITTINGSThe PVC Electrical Conduit and Fittings shall be of proven durable and effective for years maintenancefree performance in exposed and encased applications in accordance with NEMA TC-2 Specification.All conduit and its fitting materials shall comply to the following:

• Rigid Non-metallic Conduit: Schedule 40, high impact PVC with 5,000 psi tensile strength at73.4 degrees F and approved for 90 degrees C rated by UL Standard 651.

• Corrosion Proof : Resistant to most chemicals• Properties make shall be of PVC fire resistant.• Non-Magnetic and Non-Galvanic: Properties shall be of good insulation and No power loss or

conductor heating.

4.0 SPACER BAR SADDLESSpacer bar saddles and bases shall be of Rigid Non-metallic, Schedule 40 high impact PVC with 5,000psi tensile strength at 73.4 degrees F and approved for 90 degrees C rated by UL standard 651. Saddlebases shall be 3 mm deep and may be solid or pressed from PVC of not less than 1 mm thick.

Saddle tops shall be fluted. The screw holes shall be of either slotted or keyhole pattern to permit theassembly and removal of the saddle top without removal of the retaining screws.

Retaining screws shall be 2 BA in size and be of brass or steel and zinc plated to comply with BS 3382:Part 2. Retaining screws shall engage not less than 1.5 full thread in bases pressed from steel.

5.0 DISTANCE SADDLEDistance saddle shall be of Rigid Non-metallic, Schedule 40 high impact PVC with 5,000 psi tensilestrength at 73.4 degrees F and approved for 90 degrees C rated by UL Standard 651. Saddle bases solidor pressed from PVC of not less than 1 mm thick.

Saddle bases shall be of such depth that the nominal clearance of 6 mm between the conduit and thewall of surface to which the saddle are fixed is provided.

Retaining screws for saddle tops shall be of brass complying with BS 3382.

6.0 CEILING FANCeiling fans shall be 1,524 mm sweep model fitted with capacitor type motor suitable for operation on240V 50Hz AC single-phase and supplied complete with down rods to suit mounting heights and speedregulators.



7.0 LIGHT FITTINGS AND ANCILLARY EQUIPMENT TOLAMPS

7.1 Light Fittings for Use with Tubular Fluorescent Lamps

All fluorescent tubes shall comply with MS 619 or relevant British Standard and be of 26 mm diameter.They shall be “switch-start”, “white light” with a correlated color temperature of 3,000°K and haveaverage life span of 15,000 hours. The lamp lumens shall be 3,200.

Lamp holders shall be bi-pin, spring loaded, designed to retain positively the lamp caps independentlyof the contact springs and of robust construction complying with BS 5101.

Power factor correction capacitors shall be of the metal foil type enclosed in a metal case with twoinsulated connections, safety discharge resistor and impregnated with “Arcolor” or other approvedmedium. Power factor shall be corrected to capacitors shall comply with the relevant British Standardor MS 279.

Ballast for fluorescent lamps shall be polyester vacuum impregnated, built-in, switch-start type, havinga hot loss of 8 W (for 36 W lamp) and comply with BS 2818.

Diffusers depend on type of fittings.

7.2 Flexible Cords

Flexible cards for use with light fittings employing tubular fluorescent lamps, or apparatus operating atnormal room temperature shall comply with BS 6500 and shall have conductor of plain copper.

7.3 Installation of Fluorescent Light Fittings

All fluorescent light fittings shall be supplied complete with tubes, lampholders and control gear. Theyshall be completely wired and fully tested to ensure reliable performance and quality. All internalwiring shall be neatly arranged and taped with intermediate terminals provided with externalconnection. All wiring shall be of heat resistant type and be PVC insulated.

Brass earthing screws with spider washers shall be provided for earthing the fittings.

The cutting of down rods or the provision of extended down rods to suite mounting height shall beundertaken. Where fluorescent light fittings are to be installed on the underside of the ceilings, suitablespacers which shall be inserted between the top of the fittings and underside of the ceiling in such amanner as to allow a minimum clearance of 12 mm shall be provided.

7.4 Self-Contained Emergency Lights

The unit shall be designed such that the cover can be readily removed for ease of installation. The unitshall be suitable for mounting on walls or on ceiling as required. The diffuser shall be of clear acrylic.



The unit shall be equipped with nickel cadmium sealed cells and an automatic charger main failurerelay and shall be maintenance free. The emergency duration shall not be less than 3 hours for a fullycharged battery.

Illumination shall be provided by one 300 mm 10 W fluorescent lamp. The unit shall be equipped withLED to indicate mains ‘on’ and a test switch to simulate main failure.

7.5 Light Fittings to be Supplied and Installed

• 2 x 36 W fluorescent fitting c/w acrylic prismatic diffuser corrosion resistent recessed mounted.• 2 x 36 W fluorescent fitting c/w acrylic prismatic diffuser corrosion resistent surface mounted.• 150 W sodium vapour explosion proof floodlight lamps.• 150 W sodium vapour weatherproof floodlight lamps.• 1 x 70 W high-pressure sodium street lighting fitting c/w single arm and 3 m pole and

accessories.

7.6 LUX Levels

The lighting for the various location listed below shall be as follows: -

(a) Pump room, blower room, switchboard room, workshop, equipment rooms and other enclosedwork areas – 500 Lux

(b) Office, Administration Area – 350 Lux(c) Toilets, pantry, corridors, walkways, staircase and etc. – 250 Lux

8.0 STREET AND PERIMETER LIGHTING

8.1 Scope of Works

The works shall be consist of the supply and delivery to site of lanterns, fittings, switch-gears, bracketarm, columns, bases, cable, feeder pillars and all necessary ancillary equipment for the assembly,erection, connection, testing and commissioning of the complete street lighting system.

The work shall also include the supply and delivery of one hydraulic working platform.

8.2 Light Distribution

The light distribution for all the street lanterns shall be of cut-off. It could be either semi-cut-off or fullycut-off.

The specification of the lighting scheme shall conform to the following: -The road shall be assumed with an average road luminance factor of 0.08, a specular factor of 0.37 andmaintenance factor of 0.7.



The light distribution shall consist of: -

(a) Minimum average road surface luminance of 30 Lux(b) Minimum average perimeter luminance of 150 Lux(c) Uniformity of luminance i.e. L min/L av. of 0.4.

8.3 Street Lighting Lanterns

All lanterns shall be new, totally enclosed, dustproof, insect proof and watertight and shall be tested inaccordance with BS 4533 part 2. All exposed parts shall be of non-corrosive stainless steel materials.The lanterns shall provide the required light distribution with the size and type of lamp specified. Thelight distribution shall be semi cut-off or cut-off. Each lantern shall be supplied complete with all thenecessary integral control gear fully wired and ready for erection.

The lantern wiring shall be of the size and insulated with materials that will more than effectivelywithstand the current, voltage and temperatures expected within the lantern during both the starting andoperating model in the ambient temperature of the site.

The lamp compartment of the lantern shall be accessible via a hinged, glazed acrylic bowl which shall,in the closed position, bed firmly upon a soft resilient neoprene gasket shall be positively secured in thelantern housing and shall be of weather resistant type. The bowl and its frame or housing shall besecured firmly to the lantern body, by means of stainless steel clips and hinge pins. In the loweredposition of the bowl it shall be restrained from becoming detached or being blown against the otherportion of the lantern or the column arm.

The polar curves of the lanterns in both horizontal and vertical planes shall be smooth and free from anyabrupt variations so that the luminous intensity diminished smoothly and progressively from themaximum. The lantern shall incorporate high intensity aluminium mirrors, chemically anodized to yieldoptimum reflection of light distribution.

8.4 High Pressure Sodium Vapour (HPSV) Lamp

All lamp supplied shall be of a High Pressure Sodium Vapour (HPSV) type and shall have a colourtemperature of approximately 2100°K and 5000°K respectively. The majority of the light output shallfall within the 560-610 nanometre waveband i.e. Yellow/Orange range for the HPSV.

The lamp shall have an initial luminous efficiency of approximately 83 lumens per watt.



8.5 Columns and Bracket Arms

All Columns and bracket arms shall be manufactured to comply with BS 1840: 1972. The columns andbracket arms shall be manufactured from steel conforming to BS 4360: 1976 – Grade 43C or Grade50C. The columns shall be of continuously tapered octagonal sections, connected together by forced fitslip joints. Each column shall have a base compartment and a weatherproof door, measuring 600 mm x130 mm, with a tamperproof column and be flush with the column, providing a watertight fittingagainst a non-perishable resilient gasket. Door keys shall be supplied at the completion.

The columns shall be supported connected by flange plates on concrete footings. Flange plates shall beof at least 18 mm thickness. Concrete footings shall be cast with appropriately sized holding down boltsas recommended by the column manufacturer and have lead-in / lead-out ducts and shall be responsiblefor the size of the concrete footings depending on soil conditions.

A 16 mm thick Tufnol baseboard, measuring 600 mm x 130 mm, shall be included in the basecompartment. The baseboard shall be securely fixed in position inside the column by countersunk screwto hidden treaded bushes. No part of this fixing shall protrude through the column.

All metal parts of each column shall be earthed and the column and bracket arms shall be electricallycontinuous.

A corrosion resistant electrical earthing terminal in the form of a stud of not less than 6 mm in thediameter and 20 mm long shall be attached close to the door opening within each column. Two suitablesized washers and two nuts shall be fitted.

All columns shall be erected in to a perpendicular position with the door on the opposite side to the on-coming traffic except at the parapets of bridges and retaining walls. In each run of columns of five ormore, every fifth column shall be checked for vertically with a theodolite. If less than five columns areerected in line than one column shall be so checked. Shim washers may be use to achieve verticallywhere necessary.

The bracket arms shall be of the safe shape and finish as the column. The smaller end of the curve armfinish with a spigot, suitable for the safe mounting of the lantern to be installed.

Individual sections of each column, bracket arm and flange plate shall be protected against corrosion byhot-dip galvanising internally and externally in accordance with BS 729: 1971.

All welding work shall be done prior to galvanising. The joining of two parts by welding aftergalvanising shall not be permitted. The treatment prior to galvanising shall include degreasing, rinsing,pickling, then rinsing and fluxing. Post treatment such as chromating or phosphating shall then beapplied. The minimum average zinc coating weight shall conform to the recommendations of BS 729.



9.0 MATERIALS AND EQUIPMENT

9.1 General

Items of equipment and material shall have maker’s specification agreeing with those of BritishStandard. The equipment offered shall be suitable for continuous trouble free operation under adverseconditions.

9.2 Ballast

Only ballast manufactured for high-pressure sodium vapour lamp applicants shall be used. Thecombination of MBF control gear and retrofit sodium vapour lamp shall not be acceptable.

The ballast shall be an open style polyester resin filled type. It shall be enclosed in the suitable steelcanister, encapsulated and finished in white enamel. The windings shall be dual polyester amide / amidecopper wire, and both windings and core insulation materials shall be Class H. The ballast shall bedesigned to operate over a range of main voltage from 200 to 250 volts by means of suitable tapings.

9.3 Ignitors

Ignitors for the HPSV lamps shall be rated with the appropriate voltage. The unit shall be capable ofoperating from a range of voltage from 200 to 250 volts. The ignitor shall be highly efficient, housed ina cylindrical aluminium canister and provided with ‘wither pin’ terminations of ‘flying leads’.

The ignitor shall be of the Pulse Transformer type incorporating electronic circuitry and suitable for thetype of ballast’s and lamp to be installed. The output pulse shall be substantially independent of bothsupply voltage and ballast parameter. A cut-out circuit shall be incorporated so that pulsing will ceaseafter approximately two minutes, in the event of no ignition.

9.4 Service Fuse / Cut-Outs.

The service fuse / cut-outs shall be of an approved equivalent.

Service fuse unit for each lantern shall be of the correct rating and of HRC type. The unit housing hashigh mechanical and dielectric strength, and shall be suitable for use in the tropics.

Section 4 - High Tension Components Specifications


Section 4High Tension Components

Specifications



PageSection 4 - High Tension Components Specifications

1.0 11 kV / 22 kV Vacuum Circuit Breaker Specification 4-11.1 General 4-11.2 Design Features and Construction 4-1

1.2.1 Cubicles 4-11.3 Main Components 4-2

1.3.1 Incoming circuit breaker 4-21.3.2 Outgoing feeder circuit breaker 4-21.3.3 Bush bar Chamber 4-2

1.4 Description 4-21.4.1 Circuit breaker compartment 4-21.4.2 Metering compartment 4-31.4.3 Bus bar compartment 4-31.4.4 Potential Transformer 4-31.4.5 Metal Treatment 4-41.4.6 Tests 4-4

1.5 Required Technical Parameters 4-41.6 Specification for Panels 4-4

1.6.1 Incomer Panels 4-41.6.2 Outgoing Panels 4-5

2.0 Specification for 11 kV Oil Immersed Natural Cooled Transformers 4-62.1 General 4-62.2 Standards and Approval 4-62.3 Transformers 4-62.4 Type of Transformer 4-62.5 Voltage Ratios 4-62.6 Winding Connections and Vector Group 4-72.7 Impulse Withstand Voltage 4-72.8 Impedance Voltage 4-72.9 Flux Density 4-72.10 Tapping Range and Method 4-72.11 Limits of Temperature Rise 4-82.12 Class of Winding Insulation 4-8



2.13 Cooling System 4-82.14 Fittings 4-82.15 Terminal Marking and Rating Plates 4-92.16 Oil 4-92.17 Earthing 4-92.18 Transformer Room 4-10

3.0 Cast Resin Transformer 4-113.1 Scope 4-113.2 Standards 4-113.3 Description 4-11

3.3.1 Magnetic Core 4-113.3.2 LV Windings 4-123.3.3 HV Windings 4-123.3.4 MV Winding Support Spacers 4-123.3.5 HV Connections 4-133.3.6 LV Connections 4-133.3.7 HV Tapping 4-13

3.4 Accessories and Standard Equipment 4-143.5 Thermal Protection 4-143.6 Metal Enclosure 4-143.7 Electrical Protection 4-15

3.7.1 Protection relay 4-153.7.2 MV surge arresters 4-153.7.3 RC filters (repetitive switching operations) 4-15

3.8 Climatic and Environmental Classifications 4-163.9 Fire Behaviour Classification 4-16

4.0 11 kV CABLE SPECIFICATION 4-174.1 Types Of Cables 4-174.2 Cable Trench 4-174.3 Cable Ducts 4-174.4 Cable Marker 4-18

Section 4 - High Tension Components Specification


SECTION 4 - HIGH TENSION COMPONENTSSPECIFICATIONS

1.0 11 kV / 22kV Vacuum Circuit Breaker Specification

1.1 General

This specification covers the technical details of operating requirement, constructional details andprovides some guidelines for testing of 11 kV Vacuum circuit breaker and panel. The panel shall bemade out of 2 mm. CRCA steel sheet, dust & vermin proof, duly painted with red oxide & powdercoated with steel grey paint after pretreatment of acid/alkali wash with a provision for incoming sidecable entry & outgoing bottom cable entry. This specification shall be applicable for indoor installedswitchboard connected to control incoming supply and to primary side of power transformers.

All circuit breakers shall be arranged for Solenoid closes and shunt tripping, both operating from 110V.D.C. source. The close/trip control switch shall be of pistol grip type. The closing and trippingcircuits shall be self-opening on completion of their respective functions irrespective of the positionof the control switch. A readily identifiable mechanical trip device shall be provided with eachbreaker.

The mechanism shall be trip-free at any position of the closing stroke. A visual ON/OFF indicatorshall be provided positively coupled to the operating mechanism. Manual charging facility of thespring and manual tripping arrangement shall also be provided. Anti-pumping facility shall beprovided.

1.2 Design Features and Construction

1.2.1 Cubicles

Each unit shall be housed in a 2 mm thick MS steel sheet cubicle having the bus-bars, C.T.'s, mainand control cable c/w terminals, nations, all at the rear and accessible by removing detachable panels.A lockable hinged lift off type front door shall enclose the truck and shall carry the control switches,indicating instruments and lamps. Fuses shall be mounted on the fixed part of the cubicle, preferablyat the rear. The ammeter shall have red mark at full load rating.

Protection relays shall be mounted on a separate swing panel above the cubicle frame work. Thepanel should conf. to IP54 degree of protection.



1.3 Main Components

1.3.1 Incoming circuit breaker

This shall be provided with protective and instrument panel. This shall be drawn out type withvertical isolation and bus bar chamber for inter-trunking with other breakers. Incoming cable boxshall be provided with provision for spare cable entry.

1.3.2 Outgoing feeder circuit breaker

This shall be provided with protective and instrumental panel. This shall be draw out type withvertical isolation and bus bar chamber for inter trucking with other breakers. Outgoing cable boxshall be provided.

1.3.3 Bus bar Chamber

• Adequately rated potential transformer/current transformer• Complete with protection fuses• Indicating and measuring devices• Protective relays• Trip free operating mechanism• Safety interlocks• Wiring for control circuit, measuring, indicating and protective devices• Frame earthing• Operation counters• "ON" and "TRIP" push button• Pressure release vent• Test terminal blocks

1.4 Description

1.4.1 Circuit breaker compartment

This compartment shall consist of a truck carriage on rollers on which the circuit breaker shall bemounted. The raising and lowering mechanism shall be designed so as to enable the breaker to beplugged in or out with minimum physical strain. The mechanism employed shall enable the breakersto be self-supporting at all positions. Positive interlocks shall be provided to ensure that the circuitbreaker is taken out from or put into service position only when it is in “OFF" position. Further more,circuit breaker shall be operable only when it is in "FULL SERVICE" position or in "TEST" position.

The circuit breaker shall be provided with a manually charged spring assisted stored energy closingmechanism with electrical tripping and switching device. The following mechanical and electricalinterlocks shall be provided in the spring charging mechanism.



When the breaker is in "ON" position it will not be possible to charge the main spring. It will not bepossible to close the circuit breaker if the spring is not fully charged. Rapid opening of the breakerwill be ensured.

1.4.2 Metering compartment

Each unit should have its own metering chamber with hinged door, centralized wiring and fuses. Themeters provided should be flush type and mounted on floor.

1.4.3 Bus bar compartment

All bus bars shall be air-insulated, PVC encapsulated, amply rated and shall be fitted in the top rearposition. The bus bars and their main current carrying connections shall have the same sectional areathrough out their length.

Where bus bars are taken through the partitions of adjacent cubicle, sealing shall be provided toprevent spread of fire from one unit to the next.

The bus bar shall be of hard drawn copper and these shall be supported on suitable insulatingmaterials at sufficiently close intervals to prevent bus bar sag and to effectively withstand electro-magnetic stresses in the event of short circuit.

Provision for the interconnection of the circuit breakers by trucking arrangement and through terminalbox shall be provided. Each group of bus bar feeder spouts shall be fitted with automatically operatedsafety shutters.

All incomer panels, sectionaliser and other feeders shall be provided with: -

• One set of 3 single phase bar primary current transformer for instrumentation of panel(Accuracy Class 0.5)

• One set of 3 single phase bar primary current transformer for protective devices (AccuracyClass 5 P 10)

The switchgear shall be provided with cable sealing hoses to in terminate the incoming and outgoingcables.

1.4.4 Potential Transformer

All incomer panels and sectionliser shall be provided with adequately rated 3 phase, 11 kV/110 Volts,200 VA potential transformers with current limiting resistors and H.T. & L.T. fuses for protection.These shall be used for all measuring instruments proposed in the Technical Parameters and toprovide control circuit actuation of all the panels of the switchboard.

The potential transformers shall be core type air insulated and housed in sheet steel cubicles. Indoorplugs shall be provided for simulation disconnections of both primary and secondary winding of thetransformer. Causing of the potential transformers shall be efficiently earthed.



1.4.5 Metal Treatment

Enclosure shall undergo rigorous rust proofing process comprising of alkaline degreasing, pickling,phosphate coating of primer and finally standard approved colour to provide an elegant and enduringfinish.

1.4.6 Tests

Shall ensure that the tests mentioned in BS 2037, BS 116 or relevant have been performed.

1.5 Required Technical Parameters

Service : IndoorNominal System Voltage : 11 kV / 22 kVHighest System Voltage : 12 kV / 24 kVNo. Of phases : 3 (three)Frequency : 50 HZSystem Earthing : Non effectively Earthed systemType : Vacuum Circuit BreakerSymmetrical breaking capacity : 26.2 kA corresponding to 500 MVAShort Time breaking capacity : 26.2 kARated insulation Levels : One minute power frequencyWithstand voltage : 28 kV RMSImpulse withstand test voltage : With standard full wave(1.2/50 microsecond wave) : 75 kV PeakClass of Insulation : BBus bar capacity : 800 AMPSBus bar material : Electrolytic copperMaximum ambient temperature : 50 degree C

1.6 Specification for Panels

1.6.1 Incomer Panels

No. Of units required : One No.Nominal rated current : 630 AMPSPurpose : To control the incoming power supplyC.T Ratio : 100-50/5+5 having 15 VA burden per core &

accuracy Cl.:0.5 for meter & 5 P 10 for protectionsIncoming Cable Size : 1 No.11 kV x 3 x 120 sq.mm XLPE Copper conductor

cablePotential Transformer : 1 No. 11 kV/110 V, 200 VA per phase & Cl.: 1

accuracy for metering & protective Relays



Protections : - Numerical Type, Microprocessor based, one 3 Ph. - IDMT and high set instantaneous relay consisting of three overload units (Range 50% to 200%) one earth fault unit (range 5% to 80%) & three high set instantaneous units - 1 Single pole instantaneous relay for heavy earth fault

with setting 5-80% - Over voltage Relay

Measuring Instruments : - Ammeter with selector switch (Duel Range) - Voltmeter with selector switch (Range 0 - 15 kV)

Indicating Lamps : - GREEN for breaker 'OFF' - RED for breaker 'ON' - AMBER for breaker 'AUTO TRIP' on fault - WHITE for ‘TRIP CIRCUIT HEALTHY’

1.6.2 Outgoing Panels

No. Of units required : 3 Nos. (Three)Nominal rated current : 630 AmpsLabel Reading : Transformer Feeder.Purpose : Control of supply to transformerC.T. Ratio : 30/5+5 Amps having 15 VA burden per core &

accuracy Cl.:0.5 for meter & 5 P 10 for protectionsOutgoing cable size : 1 No. 11 kV x 3 C x 120 sq.mm XLPE Copper

Conductor Cable for each panel.Measuring Instruments : Ammeter with selector switch (Range 0-30 A)Protections : - Numerical Type, Microprocessor based, combined

IDMT and high set instantaneous relay consisting of three overload units (Range 50% to 200%) one earth fault unit (range 5% to 80%) & three high set instantaneous units.

- Over Voltage RelayIndicating Lamps : - GREEN for breaker 'OFF'

- RED for breaker 'ON' - AMBER for breaker 'AUTO TRIP’ on fault. - WHITE for ‘TRIP CIRCUIT HEALTHY



2.0 Specification for 11 kV Oil Immersed Natural CooledTransformers

2.1 General

This section of the Specification describes and specifies requirements for 11 kV / 415 V distributiontransformer.

2.2 Standards and Approval

The transformers shall comply with the latest relevant British Standard Specifications, MalaysiaStandard or IEC.

2.3 Transformers

The transformers shall be suitable for continuous operation on 3 phase, 50 Hz electrical powerdistribution system with neutral earthing conditions and maximum phase fault levels as follows :-

• 11 kV• 350 MVA6.6kV• 150 MVA3.3 kV• 75 MVA415V• 31 MVA

They shall be fully tropicalised and suitable for continuous operation at an ambient temperature up to40 degree Celsius, relative humidity up to 100%, isoceraunic level up to 200 days per-annum andaltitude up to 1,000 meters above sea level.

2.4 Type of Transformer

The transformers shall be oil-immersed natural cooled and hermetically sealed type complying withBS 171 or IEC 76 and suitable for indoor duties. Unless otherwise specified, they shall be low loss,step-down type of distribution transformers fitted with skid type bases.

2.5 Voltage Ratios

The standard voltage ratios at no-load shall be as:

(a) 11000/433-250 V, so as to deliver load at the declared voltage of 415/240 Volts, 3 phase, 4 wiresystem with the neutral solidly earthed.

(b) 11000/3300 V(c) 6600/433-250 V



2.6 Winding Connections and Vector Group

Unless otherwise specified, the winding of all 3 phase step-down transformers shall be connected asfollows:-

Higher Voltage – Delta Lower Voltage - Star Vector Group - Dyn11

2.7 Impulse Withstand Voltage

Completed transformers arranged for service but with arcing horns removed shall be capable ofwithstanding the following negative polarity 1.2/50 microseconds impulse voltage on the highervoltage windings:-

Nominal System Voltage Impulse Withstand Voltage (Volt rms) (kV peak)

3300 456600 6011000 75

All impulse shall be carried out in accordance with the provisions of BS 923 BS 171 or IEC 76.Typetest certificates may be accepted in lieu of separate impulse tests at the discretion of the IWK/JPP

2.8 Impedance Voltage

For the purpose of protection against short circuit stresses, the minimum value of impedance voltageat 75 degrees Celsius rated current shall be as follows: -4.75% for transformer up to 1,000 kVA.

5.5% for transformer between 1,000 – 1,500 kVA 6.0% for transformer between 1,500 - 2,000 kVA.

2.9 Flux Density

The maximum flux density at any point in the magnetic circuit when the transformer is connectedon the principal tapping and operating at normal voltage and frequency shall normally be in theregion of 1.55 to 1.65 Tesla, but at the time of tendering alternative designs employing higher fluxdensities may be may be submitted. However with such higher flux densities for consideration themagnetic circuit shall not unduly saturate during system over voltage conditions.

2.10 Tapping Range and Method

Tapping shall be provided on the higher voltage winding for a variation of the no-load voltage of +5.0%, + 2.5%, 0%, - 2.5% and-5.0%. All tap changing shall be carried out with the transformers offcircuit by means of an externally operated tapping switch with tap position indications. The operationhandle shall be mounted on the tank side and provision shall be made for padlocking in any tapposition. Padlocks of any approved type shall be supplied.



2.11 Limits of Temperature Rise

The transformers shall be designed for continuous operation at their rated power without exceedingthe temperature rise limits as follows:-

• In Top Oil : 50 degrees Celsius• In Inding : 55 degrees Celsius

2.12 Class of Winding Insulation

The Class of winding insulation shall be Class A to BS 2757.

2.13 Cooling System

Cooling tubes or fins shall be fitted on the sides of the transformer. The arrangement of the tubes orfins shall be such that all painted surfaces can be readily cleaned and painted in position. The tubes orfins shall be designed to allow free circulation of oil and to prevent any accumulation of moisture.

2.14 Fittings

Unless otherwise stated in the in the specification transformers covered by this specification shall beprovided with the following standard fittings: -

• Terminal Marking and Rating Plates• Lifting Lugs• Jacking Lugs• Earthing Terminal (two numbers on opposite side)• Oil Level Indicator• Oil Temperature Indicator• Thermometer Pocket• Winding Temperature Indicator• Drain Valve• Filter Valve• Pressure/Vacuum Bleeding Device• Pressure/Vacuum Relief Device• Pressure/Vacuum Gauge



2.15 Terminal Marking and Rating Plates

The terminal marking plate shall show a plan view of the terminals with the characters of terminalmarkings as per Appendix D of BS 171 or IEC 76 engraved thereon. It shall also show the tappings ina tabulated form. The rating plate shall indicate the following:-

• Manufacturer's name and address• Transformer Specification Reference• Manufacturer's Serial Number• Year Of Manufacture• Rating in kVA• Volts at no-load on normal tapping :-− High Voltage− Low Voltage

• Current at rated load on normal tapping :-− High Voltage− Low Voltage

• Number of phases• Frequency• Vector Group Symbol• % Impedance Voltage at Normal Tapping at 75 degrees Celsius

The terminal marking and rating plates shall be of a durable and corrosion resisting material and themarkings thereon shall be permanently legible. The two plates may be combined into a single plate.

2.16 Oil

Transformers shall be supplied filled with oil and hermetically sealed. The oil shall meet therequirements of BS 148 and shall be completely free from PCB.

2.17 Earthing

The neutral point of the low voltage system of the transformer shall be solidly earned to achieve anearth resistance not exceeding one ohm. The frameworks and all non-current carrying metal parts ofthe transformer shall be earthed similarly to achieve an earth resistance not exceeding one ohm. Anearth bar of flat hard drawn copper with dimension not less than 25 mm x 6 mm shall be installedaround the four walls of the transformer room at a height of 300 mm from the finished floor level.The earth bar shall be bolted to the frame earth of the transformer. All joints of the earth bar shall betinned and bolted. The earth bars shall be painted with approved green enamel.

Unless otherwise specified, the neutral earth and the frame earth of the transformer shall be separatelyconnected to its own group of earth electrodes. The neutral earth and the frame earth shall beconnected to its electrodes by means of two numbers green PVC insulated copper cable of crosssectional area not less than 70 sq.mm.



The two groups of earth electrodes after having been hang verifies by the IWK/JPP. Each of earthresistance not exceeding one ohm, shall be linked together by means of PVC cables as mentionedabove unless otherwise specified. At least two points of the frame earth system of the transformershall be connected to the earth electrodes.

Earth electrodes shall be of copper jacketed steel core rods with 16 mm diameter and supplied in 2.4m length and shall have provision for screw coupling with another standard length. The copper jacketshall be of minimum thickness 0.25 mm and shall bi-metallically bonded to the steel core to ensurethat the copper jacket and steel core are not separable. Where the desired earth resistance value cannotbe driven, sufficient number of sets of earth electrodes shall be installed outside the resistance areaand linked together by PVC copper cables as mentioned above until the required value is reached.Each set of earth electrode shall be provided with brass connecting clamp and approved type of pre-cast heavy duty concrete inspection chamber with removable cover.

The earthing points shall be identified by permanent label legibly marked with the words`Transformer Frame Earth' or `Transformer Neutral Earth' permanently fixed at the point ofconnection of every earthing conductor to an earth electrode.

2.18 Transformer Room

Approved type of rubber mat shall be provided around the transformers. The rubber mat shall extendto the full length and width of the transformer and shall be of thickness not less than 12 mm andwidth 1,000 mm.

`BAHAYA' sign, `DILARANG MASUK' sign, sign indicating `Substation No:' and shock treatmentchart shall be installed to the requirement of the Suruhanjaya Tenaga. ` DILARANG MEROKOK 'sign shall also be installed.

All trenches in the transformer rooms shall be filled up with clean sand to a level above cable ducts.As fitted layout plans, schematic wiring diagrams, and plans showing cable routes and positions ofearthing point with reference to easily recognizable buildings and structures shall be suitably framedup in the transformer room. These plans and diagrams shall be in addition to the four sets of printsrequired to be submitted to the IWK/JPP. All main High voltage switch room, Transformer roomshall be fitted with automatic triggered release CO2 system, controlled by heat and smoke sensor..



3.0 Cast Resin Transformer

3.1 Scope

Three-phase transformers of cast resin type, Class F insulation system with natural (AN) cooling forindoor installation, destined for use in three-phase HV/LV distribution systems.

If required forced cooling (AF) to increase the rated power up to 40%.

3.2 Standards

These transformers will be in compliance with the following standards:

• IEC 60076-1 to 60076-5: power transformers• IEC 60076-11 : Dry type transformers• CENELEC Harmonisation Documents• HD 464 S1 : 1988 + / A2 : 1991 + / A3 : 1992 for dry-type power transformers• HD 538-1 S1 : 1992 for three-phase dry-type distribution transformers 50 Hz, from 100• To 2500 kVA with highest voltage for equipment not exceeding 24 kV.• IEC 905: 1987 - Load guide for dry-type power transformers.

These transformers will be manufactured in accordance with:

• A quality system in conformity with ISO 9001• An environmental management system in conformity with ISO 14001, both certified by an

official independent organisation.

3.3 Description

3.3.1 Magnetic Core

This will be made from laminations of grain oriented silicon steel, insulated with mineral oxide andwill be protected against corrosion with a coat of varnish.

In order to reduce the power consumption due to transformer no-load losses, the magnetic core isstacked using overlapping-interlocking technology, with at least 6 overlaps.

In order to reduce the noise produced by the magnetic core, it is equipped with noise-dampingdevices.



3.3.2 LV Windings

The LV winding is produced using aluminium or copper foils (according to the manufacturer’spreference) in order to cancel out axial stress during short circuit ; this foil will be insulated betweeneach layer using a heat-reactivated Class F pre-impregnated epoxy resin film

The ends of the winding are protected and insulated using a Class F insulating material, covered withheat reactivated epoxy resin

The whole winding assembly will be polymerised throughout by being autoclaved for 2 hours at130°C, which will ensure:

• High level of resistance to industrial environments• Excellent dielectric withstand• Very good resistance to radial stress in the instance of a bolted short circuit.

3.3.3 HV Windings

They will be separated from the LV windings to give an air gap between the MV and LV circuits inorder to avoid depositing of dust on the spacers placed in the radical electrical field and to makemaintenance easier.

These will be independent of the LV windings and will be made of aluminium or copper wire or foil(according to the manufacturer's preference) with Class F insulation.

The HV windings will be vacuum cast in a Class F fireproof epoxy resin casting system composed of:

• An epoxy resin• An anhydride hardener with a flexibilising additive• A flame-retardant filler.

The flame-retardant filler will be thoroughly mixed with the resin and hardener. It will be composedof trihydrated alumina powder (or aluminium hydroxide) or other flame-retardant products to bespecified, either mixed with silica or not.

The casting system will be of Class F. The interior and exterior of the windings will be reinforcedwith a combination of glass fibre to provide thermal shock withstand

3.3.4 MV Winding Support Spacers

These will provide sufficient support in transport, operation and during bolted short circuit conditionsas well as in the case of an earthquake.

These spacers will be circular in shape for easy cleaning. They will give an extended tracking line togive better dielectric withstand under humid or high dust conditions.



These spacers will include an elastomer cushion that will allow it to absorb expansion according toload conditions. This elastomer cushion will be incorporated in the spacer to prevent it beingdeteriorated by air or UV.

3.3.5 HV Connections

The HV connections will be made from above on the top of the connection bars. Each bar will bedrilled with a 13 mm hole ready for connection of cable lugs on terminal plates.

The HV connection bars will be in rigid copper bars protected by heat shrinkable tubing.

HV connections in cables are not allowed, in order to avoid all risk of contact, due to cables flapping.

The HV connections will be in copper.

3.3.6 LV Connections

The LV connections will be made from above onto bars located at the top of the coils on the oppositeside to the HV connections.

Connection of the LV neutral will be directly made to the LV terminals between the LV phase bars.

The LV connection bars will be in copper or in tinned aluminium (according to preference of themanufacturer).

The output from each LV winding will comprise a tin-plated aluminium or copper connectionterminal, enabling all connections to be made without using a contact interface (grease, by-metallicstrip).

These will be assembled according to current practices, notably using spring washers under thefixings and nuts.

Devices in the 630 to 2,500 kVA range will be easy to connect using factory-built electrical ductingthrough an optional interface. Stress withstand in the instance of a bolted short circuit on theconnector will be guaranteed by the manufacturer.

3.3.7 HV Tapping

The tapping which act on the highest voltage adapting the transformer to the real supply voltagevalue, will be off-circuit bolted links.

Tapping with connection cables are not allowed.

These bolted links will be attached to the HV coils.



3.4 Accessories and Standard Equipment

These transformers will be equipped with:

• 4 flat bi-directional rollers• lifting lugs• haulage holes on the underbase• 2 earthling terminals• 1 rating plate• 1 "Danger Electricity" warning label (T 10 warning)• 1 routine tests certificate• 1 instruction manual for installation, commissioning and maintenance in English.

3.5 Thermal Protection

These transformers will be equipped with a thermal protection device which will comprise:

2 sets of 3 PTC sensors, one sensor for "Alarm 1", one for "Alarm 2" per phase, installed in the coilsof the transformer. They will be placed in a tube to enable them to be replaced if ever necessary.

An electronic converter with two independent monitoring circuits equipped with a changeover switch,one for "Alarm 1" the other for "Alarm 2". The position of the relays will be indicated by differentcoloured indicator lights. A third indicator light will indicate the presence of voltage.

These three indicator lights will be on the front of the converter. The electronic converter will beinstalled away from the transformer.

A plug-in terminal block for connection of the PTC sensors to the electronic converter.

The PTC sensors will be supplied assembled and wired to the terminal block fixed on the upper partof the transformer. The converter will be supplied loose with the transformer, packaged completewith its wiring diagram.

3.6 Metal Enclosure

On request, these transformers will be equipped with a metal enclosure for indoor installationcomprising an integral IP31 (except the base which may be IP21) metal enclosure, that can bedismantle on request, with:

• an anti-corrosion protection in the manufacturer's standard colour• lifting lugs enabling the transformer and enclosure assembly to be handled• a bolted access panel on the enclosure front to allow access to the HV connections and to the

tapping. This will be fitted with handles, it will have one "Danger Electricity" warning label (T10 warning), a rating plate and a visible braid for earthling

• blanked off holes for fitting Ronis ELP 1 or alternatively Proflux P1 type key locks on thebolted access panel to enable it to be locked



• 2 undrilled gland plates on the roof: one on the HV side, one on the LV side (drilling and cablegland not supplied)

• 1 plate at the right HV side on the bottom of the enclosure for the HV cables for connectionsfrom the bottom

• as an option, a HV cables clamping system shall be provided when the cables are coming fromthe bottom

3.7 Electrical Protection

3.7.1 Protection relay

The installation must have a protection relay to protect the transformer from:

• overload,• short circuits (internal or external),• earth faults,• overflow.

3.7.2 MV surge arresters

It is advisable to check that the installation will not be subjected to over voltage of any kind(atmospheric or switching over voltage).

If there is a risk, the transformer should be protected by phase-earth surge arresters installed directlyon the MV connection terminals (top or bottom).

Phase-earth surge arresters are absolutely essential in the following cases:

• If the lightning impact level Nk is greater than 25. The risk of direct or induced atmosphericover voltage is directly proportional to Nk.

• During the occasional switching (less than 10 operations a year) of a transformer with a weakload, or during a magnetisation period.

They are highly recommended in the following case:

• If the substation is supplied by a network including overhead parts, then a cable which is longerthan 20 m (for example, an overhead-underground network).

3.7.3 RC filters (repetitive switching operations)

If the installation is likely to be subjected to repetitive switching operations (e.g. connected with aprocess), it should be protected from the resulting surges, which are particularly harmful to thetransformer.

The ideal solution for protecting the installation completely from these surges (with high frequencyoscillations), consists in fitting an RC damping filter between the phases and the earth.



This RC filter should be placed as close as possible to the transformer’s primary terminals.

This gets rid of the high frequency phenomenon, and limits voltages at the transformer terminals.

The filter should consist of 3 units, 50 Ohm resistors (of the RWST type), and 3 units, 0.25 µFcapacitors, insulation level 24 kV.

It may be placed either in a separate metal enclosure or, preferably, inside the metal enclosure of thetransformer.

3.8 Climatic and Environmental Classifications

These transformers will be of climatic Class C2 and of environmental Class E2 as defined inAppendix B of HD 464 S1: 1988 / A2 : 1991. C2 and E2 Classes will be indicated on the rating plate.

The manufacturer must produce a test report from an official laboratory for a transformer of the samedesign as those produced.

The tests must have been performed in accordance with Appendix ZA and ZB of CENELEC HD 464S1: 1988 / A3: 1992.

3.9 Fire Behaviour Classification

These transformers will be of Class F1 as defined in article B3 of CENELEC HD 464 S1: 1988 / A2:1991. F1 Class will be indicated on the rating plate.

The manufacturer must produce a test report from an official laboratory on a transformer of the samedesign as those produced and on the same transformer which have initially passed the here aboveClimatic and Environmental tests. This test must have been performed in accordance with AppendixZC of CENELEC HD 464 S1: 1988 / A3: 1992.



4.0 11 kV CABLE SPECIFICATION

4.1 Types of Cables

The cable to be supplied under this specification shall be manufactured and tested in accordance withBS 6480: Part 1: 1969 and shall be of XLPE type to a voltage rating suitable for continuous operationon a 11 kV, 3-phase, 50 Hz distribution system.

4.2 Cable Trench

Cable trenches shall be 750 mm deep. The trenches shall be of sufficient width to enable provision ofadequate spacing between cables but in any case shall not be less than 450 mm wide. Trenches shallbe kept as straight as possible and shall have vertical sides which shall be timbered where necessaryso as to avoid subsidence and damage. The bottom of the trenches shall be firm and of smoothcontour and any other objects likely to damage the cable sheathing shall be removed. The materialexcavated from the trenches shall be placed or removed so as to prevent nuisance or damage toadjacent areas or buildings. The trench excavation and filling in shall be so executed that all roads,walls, sewers, drains, pipes, cables, structures etc. shall be reasonably secured against risk ofsubsidence damage. Provision shall be made, during excavation and until interim restoration has beencompleted, for reasonable access of persons and vehicles to the areas of buildings adjacent to thetrenches. The Electrical Contractor shall provide pumps and other appliances for the necessarypumping required for the disposal of water so as to prevent any risk of the cables and other materialsto be laid in the trenches being detrimentally affected. Where necessary, bailing shall be provided.Where trenches pass from a footway to a roadway or at other position where a change of level isnecessary, the bottom of the trench shall rise or fall gradually.

4.3 Cable Ducts

At road crossings, sewerage pipe crossing, water pipe crossings, paved areas, concrete areas andwhere specified cables shall be protected by galvanized steel pipes buried to a depth of 900 mmbelow finished ground level. The pipes shall be of heavy duty type, complying with BS 1387 andcomplete with screwed and socket joints. Unless otherwise specified the pipes shall be 150 mm indiameter. Where it is necessary to cross drains, culverts or similar obstruction which is too deep forthe cables to be buried below, galvanized steel pipes as specified above shall be provided. The pipesshall be supported at each end in a concrete block and shall project through the blocks into the groundat a depth of at least 750 mm. All ducts shall be extended at least 600 mm beyond paved areas,concrete areas, drains, road crossing, pipe crossings etc. Cable entering a building shall be protectedby pitch fiber ducts of 150 mm diameter, complying with BS 4108, completed with bend pieces,buried to a depth of 900 mm and encased with 75 mm of concrete all round. The ducts shall beinstalled with a gradient so as to drain away any water in the ducts. All ducts passing through wallsshall be effectively sealed and made water-tight. The number of cables installed in each duct shall besuch that the space factor shall not be less than 60%. A draw wire shall be provided for each duct.Unless specified to be provided by others, the above galvanized steel pipes and/or pitch fiber ductsshall be provided.



4.4 Cable Marker

Cable markers shall be of heavy duty reinforced concrete construction. The cable marker shall be oftrapezoidal block with 100 mm square top face, 150 mm square bottom face and 400 mm in height.The top face shall be indented with bold lettering `H.V.' and directional sign indicating thedirection/directions of the cable route.

Section 5 - Motor Specification


Section 5Motor Specification

Section 5 – Motor Specification


PageSection 5 – Motor Specification

1.0 Submersible Motor 5-1 2.0 Surface Mounted Motors 5-2

2.1 General 5-22.2 Indoor Type Motor 5-32.3 Outdoor Type Motor 5-3



SECTION 5 – MOTOR SPECIFICATION

1.0 SUBMERSIBLE MOTORThe electric motor shall be a 3 phase, squirrel-cage induction type running at not more than 1,500 rpmsuitable for 50 cycles, 415 V and complying with BS 5000 or BS 4999. The motor shall be built forsubmersible operation, Class IP68 according to IEC. The motor shall be able to withstand a minimumdepth of 20 m submergence.

The motor stator shall be shrunk fit into an air-filled watertight stator casing. Externally mountedscrews that may cause leakage into the motor shall not be used. The motor casing and sealingarrangements shall be designed waterproof to Class IP68.

Motor bearing and shaft shall all the loads induced by the short-coupled i.e. pump impeller and mixerpropeller.

The motor shall be capable of operating continuously with full load without overloading throughoutthe operation. It shall be able to tolerate voltage variations of up to ±10% of the rated voltage of 415V without overheating. The motor shall operate at voltage imbalance of up to 2% between phases andcurrent imbalance of up to 4% between phases.

The motor shall start by direct on-line, star-delta, auto transformer, soft starter and variable speeddrive in accordance with the size of the motors.

The motor shall run continuously or intermittently with a maximum of 15 evenly spaced starts perhour. The motor shall be tested in accordance to IEC 34-1.

The stator shall be moisture-resistant and triple-varnished and shall be insulated to Class F (IECpublication) capable of withstanding temperatures up to 155oC (to confirm the spec.), however themaximum temperature rise shall not exceed 80oC.

The motor shall have a terminal box capable of sealing off the junction box completely from thestator casing to prevent leakage through the junction box into the stator housing. The cable entrywater-seal design shall be such that the cables are sealed off by a compressible rubber bush and fittedwith cable strain relief clamps. The design shall preclude specific torque requirements to ensure awater tight and submersible seal. Epoxies, silicon resin or other secondary sealing systems shall beused.

The stator shall incorporate three thermal switches connected in series for monitoring purposes.Thermal sensors shall protect the stator from overheating in the case of asymmetric phase loading orvoltage, continuous dry run or excessive temperatures in the medium itself. For motor rating of 37kW and below, a minimum motor protection shall incorporate a leakage sensor at the seal chamberand a PT 100 or better in the stator winding. For motor rating of 37 kW and above, a full monitormotor protection shall be incorporated. The leakage sensor shall be located at the upper terminal area,lower motor area and seal chamber. The thermal sensor shall be located at the upper and lowerbearing housing and stator winding.

Power to the motor is supplied by one or several flexible cable(s) that connect to the motor through asealed inlet to a connection box. The cable is supplied to specified length by the manufacturer.



The cables contain a sufficient number of leads for motor start and operation as well as for controlimpulse transmission.

The motor is dimensioned for cooling submergence in the pumped liquid. For dry installation, coolingis provided by liquid circulating in a cooling jacket or by other means of heat transfer into thepumped liquid.

2.0 SURFACE MOUNTED MOTORS

2.1 General

Electric motors shall be manufactured and shop tested to BS 4999 and BS 5000. Motors shall betropicalised 3 phase squirrel cage induction type. Both indoor and outdoor surface mounted motorsshall comply with IEC 34-1 Electrical and IEC 72-1 Mechanical Specification. The motor shall betested in accordance to IEC 34-1. 3-phase cage rotors shall be robust in design and construction andcapable of running continuously for prolonged periods with minimum attention.

Motor bearing and shaft shall carry all the loads induced by the short-coupled i.e. pump impeller andmixer propeller.

The motor shall be manufactured in a one-piece stator frame casing. The feet shall be integrally castinto the stator frame. For most frames the terminal box shall be mounted on the top as standard. Theterminal box can be rotated so that cables can be connected from the right and left.

All shaft diameters shall be machined to IEC 60072 for ease of fitting, removing or securing fitments,a tapped hole in the drive end shaft.

Tolerances on main performances parameter shall comply with IEC 60034-1 specifies allowabletolerances for efficiency, power factor, speed, locked rotor torque, pullout torque, starting current andmoment of inertia.

Ball bearings shall be used for motors having aluminium frames. Motors with cast iron or fabricatedsteel frames shall have ball or roller bearings. Ball bearings shall be grease lubricated. Workingthrust loads shall not be placed on the motor bearing.

The motor fan shall be made of light aluminum alloy.

The motor shall start by direct on-line, star-delta, auto transformer, soft starter and variable speeddrive in accordance with the size of the motors. Motors shall be equipped with their own starters andshall run at not more than 1,500 rpm, unless specified otherwise. Motor starters shall be fitted with ano-volt release and thermal overload in each phase. Motors and their associated starters shall besuitable for operation on a 415 V, 3-phase and 50 Hz supply.

Motors shall be capable of continuously running and shall be able to tolerate voltage variations of upto ± 10% without overheating in accordance with BS 5000 S1 designation. The motor shall operate atvoltage imbalance of up to 2% between phases and current imbalance of up to 4% between phases.



PT 100 or better shall be built into the motor windings for motors above 3.75 kW. It shall act either togive an alarm or to stop the motor.

The stator shall be moisture-resistant and triple-varnished and shall be insulated to Class F (IECpublication) capable of withstanding temperatures up to 155oC, however the maximum temperaturerise shall not exceed 80oC, Class B.

2.2 Indoor Type Motor

The types of motor enclosures and degree of protection for electric motors to be used in differentareas shall be as follows: -

Totally Enclosed Fan Cooled Type (TEFC) to be used in damp and dusty indoor areas and shall havea service factor of not less than 1.15 or greater.

2.3 Outdoor Type Motor

The types of motor enclosures and degree of protection for electric motors to be used in differentareas shall be as follows: -

Motors shall be with Class F insulation and IP55 enclosure. Motors shall be single speed TotallyEnclosed Fan Cooled (TEFC) and rated for continuous use. It shall have a service factor of not lessthan 1.15 or greater.

Section 6 - Low Voltage Cable Specification & Installation


Section 6Low Voltage Cable Specification &

Installation



PageSection 6 – Low Voltage Cable Specification & Installation

1.0 Type of Cable and Application 6-11.1 Type of Cables 6-21.2 Application of Cables 6-2

2.0 Cable Installation 6-22.1 Cable Laid Direct In Ground 6-22.2 Submerged Cable 6-3

3.0 Requirements 6-4 3.1 Colours 6-4 3.2 Conductors 6-4

4.0 Cable Trench 6-44.1 Cables in Pre-Cast Concrete Trenches 6-54.2 Cables on Walls and Under Floor Slabs 6-54.3 Surface Cabling 6-5

5.0 Cable Ducts 6-66.0 Cable Termination and Jointing 6-67.0 Cable Accessories 6-6

7.1 Metallic And Non-Metallic Conduits 6-77.2 Cable Trays 6-7 7.3 Clipped Direct 6-77.4 Cable Fixings 6-87.5 Cable Glands 6-87.6 Cable Marker 6-8



SECTION 6 – LOW VOLTAGE CABLE SPECIFICATION &INSTALLATION

1.0 TYPES OF CABLE AND APPLICATION

1.1 Type of Cables

(i) PVC/SWA/PVC CABLE

Cable shall be manufactured and tested in accordance with MS 274 or BS 6346 and shall have highconductivity plain copper stranded conductors insulated with PVC suitable for a voltage of 600/1000V laid together and bedded with PVC, armoured with galvanised steel wires and sheathed with PVC.

(ii) XLPE/SWA/PVC CABLE

Cable shall be manufactured and tested in accordance to BS 5467 or IEC 60502 and shall have highconductivity plain copper stranded conductors, insulated with cross-linked polyethylene (XLPE),suitable for a voltage of 600/1000 V laid together and bedded with extruded PVC, armoured withgalvanised steel wires and sheathed with PVC.

(iii) XLPE/AWA/PVC CABLE

Cable shall be manufactured and tested in accordance to BS 5467 or IEC 60502 and shall have highconductivity plain copper stranded conductors, insulated with cross-linked polyethylene (XLPE),suitable for a voltage of 600/1000 V laid together and bedded with extruded PVC, armoured withaluminium wires and sheathed with PVC.

(iv) XLPE/PVC CABLE

Cable shall be manufactured and tested in accordance to BS 5467 or IEC 60502 and shall have highconductivity plain copper stranded conductors, insulated with cross-linked polyethylene (XLPE),suitable for a voltage of 600/1000 V laid together and bedded with extruded PVC and sheathed withPVC.

(v) PILCDSTAS CABLE

Cable shall be manufactured and tested in accordance with BS 6480 Part 1 and shall have highconductivity plain copper stranded conductors, insulated with strong long fibre paper, uniform intexture, free from metallic particles, mass impregnated with non-draining insulating oil compoundsuitable for a voltage of 600/1000 V, lead alloy sheathed, double steel type armoured and served.

Refer to Appendix 01 – Abbreviation.



1.2 Application of Cables Cables shall be segregated into the following categories: -

(i) Power (less than 1,000 V phase to phase)

• PVC/PVC multicore cable to BS 6346 installed in floor ducts or conduits.• PVC single core non-sheathed (600/1 000 V) to BS 6231 installed as internal wiring within

switchgear and control assemblies.• PILCDSTAS Cable shall be manufactured and tested in accordance with BS 6480 Part 1 and

shall have high conductivity plain copper stranded conductors, insulated with strong longfibre paper, uniform in texture, free from metallic particles, mass impregnated with non-draining insulating oil compound suitable for a voltage of 600/1000 V, lead alloy sheathed,double steel type armoured and served.

(ii) Instrumentation/telemetry

• PE/PSCR/OSCR/PE/SWA/PVC. Plain annealed multistranded copper conductors, solidpolyethylene insulation with aluminium-mylar pair screening including drain wire, withcollective aluminium mylar screen including drain wire, solid polyethylene bedded steel wirearmour with an outer sheath of flame retardant PVC. PVC sheath to be blue colour forintrinsically safe circuits, black for AC and DC non-intrinsically safe circuits, 300/500 Vgrade to BS 5308: Part 1, Type 2.

(iii) Control Digital

• PE/OSCR/PE/SWA/PVC. Plain annealed multi stranded copper conductors, solidpolyethylene insulation collective aluminium mylar screen including drain wire, solidpolyethylene bedded steel wire armour with an outer sheath of flame retardant PVC. PVCsheath to be blue colour for intrinsically safe circuits, black for AC and DC non-intrinsicallysafe circuits, 300/500 V grade to BS 5308: Part 1, Type 2.

2.0 CABLE INSTALLATIONAll cables shall be handled, laid and installed according to BS 7671, cable manufacturer'srecommendations and ERA Reports by using proper installation equipment and tools. Cables shall belaid in a manner such that any electrical interference between cables shall not have a detrimentaleffect on the life and operation of equipment installed within the installation.

As a general rule the following minimum clearances shall be adhered to wherever practical. Thereshall be a minimum separation of 300 mm between all cables.

Unless otherwise permitted by the JPP/IWK Representative no cable shall be laid and covered up inthe absence of the JPP/IWK Representative. Cables shall be installed in such a way that the minimumbending radius is not reduced when installed or during installation. Cables shall not be installed inambient temperatures below that recommended by the cable manufacturer.



The minimum internal bending radius of the cable shall not be less than 12 times the overall diameterof the cable. Wherever cables are cut, the ends shall be immediately sealed in an approved mannerunless; it is intended to proceed with cable jointing for termination straight away.

For groups of more than one cables laid in the same trench, they shall be spaced by the horizontalclearance between adjacent cables of at least twice the overall diameter of the adjacent largest sizecables. Cables grouped together shall have insulation capable of withstanding the highest voltagepresent in the group.

Where practical a separate cable support system shall be provided for power and non-power cables.Where this is not practical a separation of 150 mm shall be maintained between power and non-powercables when run on the same support system.

In order to make economic use of the cable support system, cables shall be arranged in groups of 50mm maximum overall diameter. These groups shall be securely tied to the cable support system atintervals not exceeding 900 mm for horizontal runs and 300 mm intervals on vertical runs.

Refer to Appendix 01 – Abbreviation.

2.2 Submerged Cable

Cable shall be manufactured and tested in accordance with DIN VDE 0282-4. They fulfill therequirements specified for cables used in contaminated water. The cables shall have a highconductivity copper finely stranded, Class 5 to DIN VDE 0295 and IEC 60228 insulated with specialrubber compound, EPR (Ethylene Propylene Rubber) base suitable for a voltage of 450/750 Vsheathed with: - (i) Single-sheath

This is provided with all single-core cables and for all multicore cables with conductor cross-sections up to and including 10 mm2. Special synthetic rubber compound, minimumspecifications as for compound types EM2 and 5GM3 to DIN VDE 0207-21. Thickness toDIN VDE 0282-4.

(ii) Two-sheath

This is to provide for multicore cables with conductor cross-sections of 16 mm2 and more.Inner sheath shall be of a special rubber compound, EPR base, and minimum specificationsas for EM1 and GM1b to DIN VDE 0207-21. Sheath thickness to DIN VDE 0282-4. Outersheath shall be of a special sythentic rubber compound, minimum specifications as forcompound types EM2 and 5GM3 to DIN VDE 0207-21. Sheath thickness to DIN VDE 0282-4.



3.0 REQUIREMENTS

3.1 Colours

The colour coding shall be in accordance to IEEE latest edition. The following shall serve as aguide: -

i. 3-phase Red, Yellow and Blue ii. Single phase or DC Red and Black iii. Earth Green/Yellow iv. Control Blue (DC), Red (AC)

3.2 Conductors

Copper conductors shall comply with BS EN 60228. The size of conductors shall be made referenceto Section 1 – Low Voltage Switchboard and Components Specification and Section 3 – Small Powerand Lighting.

4.0 CABLE TRENCHUnless otherwise specified, cable trenches shall be 750 mm deep. The trenches shall be of sufficientwidth to enable provision of adequate spacing between cables but in any case shall not be less than450 mm wide.

Trenches shall be kept as straight as possible and shall have vertical sides which shall be protectedwhere necessary so as to avoid subsidence and damage. The bottom of the trenches shall be firm andof smooth contour and any other objects likely to damage the cable sheathing shall be removed.

The material excavated from the trenches shall be placed or removed so as to prevent nuisance ordamage to adjacent areas or buildings.

The trench excavation and filling in shall be so executed that all roads, walls, sewers, drains, pipes,cables, structures etc. shall be reasonably secured against risk of subsidence damage. Provision shallbe made, during excavation and until interim restoration has been completed, for reasonable access ofpersons and vehicles to the areas of buildings adjacent to the trenches.

The trench excavation shall provide pumps and other appliances for the necessary pumping requiredfor the disposal of water so as to prevent any risk of the cables and other materials to be laid in thetrenches being detrimentally affected. Where necessary, bailing shall be provided. Where trenchespass from a footway to a roadway or at other position where a change of level is necessary, thebottom of the trench shall rise or fall gradually.

Refer to Appendix B – Laying of Underground Cable Drawing



uPVC cable protective covers shall be of polyvinylchloride without plasticiser type with specificdensity between 1.37 g/cm3 to 1.42 g/cm3. The uPVC cover shall be resistant to aggressive soils andof dimension 150 mm wide and 1,000 mm long.

The covers shall be single coloured orange and top side shall be embossed with standard danger signand bold letters “BAHAYA! KABEL ELEKTRIK DI BAWAH”.

The covers shall be provided with male and female interlocking device. An orange coloured, multi-strand nylon rope of minimum 6 mm diameter shall be laid at along the trench to identify the cableroute.

Refer to Appendix B – Laying of Underground Cable Drawing

4.1 Cables in Pre-Cast Concrete Trenches

Cable tray specification shall be made reference to 7.2 – Cable Trays.In the case of single core cable, non-ferrous saddle shall be used.

The cable tray shall be supported by mild steel brackets. The bracket shall be hot dipped galvanised.All brackets shall be securely fastened with steel raw bolts and nuts.

All cable tray joints shall be bridged by means of tinned copper tape of dimension not less than 25mm x 3 mm. All saddles for cables on cable trays shall be installed by bolts, washers and nuts. Allcable tray tees, intersection units, adaptor units etc. shall be factory manufactured.

4.2 Cables on Walls and Under Floor Slabs

Cable tray specification shall be made reference to 7.2 – Cable Trays. Cable run on walls and underfloor slabs shall be mounted on cable trays. Method of installation of the cables shall be in accordancewith Method 11 and 12 of BS 7671 Table 4A. The construction and finished of the cable trays and theway of installation of the cables on the cable trays shall be made reference to 4.1 – Cable in Pre-CastConcrete Trenches.

The cable trays shall be suspended from floor slabs by hangers or mounted on wall by brackets at 600mm interval. The material and finishes of the hangers, brackets and other suspending and supportingstructures shall be made reference to 4.1 - Cable in Pre-Cast Concrete Trenches.

Where cable trays pass through floors or fire resistant walls, the surrounding hole shall be sealed tofull thickness of the floor or wall with non-hygroscopic fire-resisting material of minimum 2 hour firerating approved by Jabatan Bomba Dan Penyelamat Malaysia.

4.3 Surface Cabling

Surface cabling shall be carried out with PVC insulated PVC sheathed cables of 300/500 V grade toMS 136 and 600/1000 V grade to MS 274. The conductors shall be of stranded plain annealed copper



to MS 69 and MS 280. The insulation shall be suitable for continuous operation at a maximum cabletemperature of 70 0C and comply with MS 138.

The cables shall be run on the surface of the walls, floor slabs and in the ceiling spaces. The cablesshall be secured by lead alloy saddles.

Cables crossing metal surface shall be enclosed in PVC conduit. Saddles shall be fixed by brass nailsand spaced at not more than 150 mm apart.

5.0 CABLE DUCTSAt road crossings, sewerage pipe crossing, water pipe crossings, paved areas, concrete areas, concreteareas and where specified, the cables shall be protected by galvanised steel pipes. The pipes shall beof heavy duty type, complying with BS 1387. Unless otherwise specified the pipes shall be 150 mm indiameter.

Spare cable ducts of 150 mm diameter galvanized steel pipes shall be provided at all road crossings.Spare ducts to be provided with draw wires and temporarily sealed to prevent ingress of water.

Cable entering a building shall be protected by heavy duty galvanised steel pipes complying with BS1387 of 150 mm diameter completed with bend pieces.

6.0 CABLE TERMINATION AND JOINTINGCable termination and jointing is not encouraged, however if required, all such termination and jointsshall be provided for installations of more than 1,000 m of cable. All joints and termination shall haveprior approval before commencements of works.

A plastic laminated plate engraved with details such as size of cable, number of core, date ofcommissioning, date of jointing, length of cable, distance of cable joint and etc. shall be securelyfixed near the termination.

The heat shrinkable termination materials used shall be supplied in a complete kit to suit various sizesof cable and to provide stress control, non-tracking and environmentally sealed termination. It shallconsist of high permittivity, high resistivity, heat shrinkable, stress control, UV stable, non-trackingpolymeric materials and heat activated sealant to prevent ingress of moisture and contamination.

The type of cable boxes, compound and jointing materials used shall be factory manufactured. Unlessotherwise specified cast iron joint boxes shall be used, and all jointing kits shall be approved by theJPP/IWK Representative before joints being carried out.



7.0 CABLE ACCESSORIES

7.1 Metallic and Non-Metallic Conduits

Steel conduits shall be of galvanized, heavy gauge, Class B, screwed type complying with MS 275-1,IEC 60614-1, IEC 60614-2-1 and IEC 60423. All steel conduit fittings shall comply with MS 275-2,IEC 61035-1 and IEC 61035-2-1.

The steel conduits shall be fitted with brass bushes at the free ends and expansion devices. The endsof each length of steel conduit shall be properly reamed. The termination to the distribution boards,consumer units, switchgears and outlet boxes shall be effected by brass type smooth-bore bushes.

For cable size 25 mm and below junction box specification shall be made reference to Section 1 –Low Voltage Switchboard and Components Specification. For cable 35 mm and above, junction boxshall be 2.3 mm thickness electro-plated mild steel sheet with 90 µm paint thickness. It shall betreated to prevent corrosion. The junction box shall be able to accommodate the cable size and thebending radius shall be taken into consideration.

For non-metallic conduits and fittings, they shall be of rigid high impact PVC and approved byJabatan Bomba Dan Penyelamat Malaysia for use in electrical installation.

The colour of the conduit for concealed wiring shall be of orange. Unless otherwise for purposes ofidentification or distinguishing from another services, white coloured conduit shall be used forsurface wiring. Rigid high impact PVC conduits shall comply with IEC 60614-1, IEC 60614-2-2 andIEC 60423 and fittings shall comply with MS 67, IEC 61035-1 and IEC 61035-2-2.

All fittings for the rigid high impact PVC conduits shall be made and supplied by the samemanufacturer for the rigid high impact PVC conduit. The ends of each length of rigid high impactPVC conduit shall be properly reamed. The termination to the distribution boards, consumer units,switchgears and outlet boxes shall be effected by adaptors and lock-rings. Flexible metallic and non-metallic conduits shall comply with IEC 60614-1 and IEC 60614-2-5 and its fittings complying withIEC 61035-1 and IEC 61035-2-3.

Steel saddles shall be used for steel conduits. Unless otherwise specified, steel conduits and steelfittings shall be used.

7.2 Cable Trays

Cable trays shall be fabricated from perforated hot dip galvanised sheet steel complete with allnecessary bends, tee pieces, adaptors and other accessories. Minimum thickness for the sheet steel ofthe perforated hot dipped galvanised cable trays shall be 2.0 mm.

All supports, hangers and structures shall be of hot dipped galvanised type, robust in construction andadequately installed to cater for the weights of the cables and trays supported on them so that cabletrays and cables will not sag. The cable tray spacing shall be 300 to 600 mm depend on the size andnumbers of the cables.



Fixing clips and cleats for cables on trays shall be installed by means of bolts, washers and nuts. Alltees, intersection units, adaptor units etc. shall be the type manufactured by the cable traymanufacturer unless otherwise approved.

7.3 Clipped Direct

All cable hangers, clips, cleats and saddles shall be of an approved type and appropriate to the typeand size of cable installed.

7.4 Cable Fixings

Ties and strapping shall be made of hot dip galvanized steel bends installed at intervals of every 600mm. All bolts and nuts used shall be of hot dip galvanized steel.

7.5 Cable Glands

Glands shall generally be of the mechanical double compression hexagon type. Earth continuity ofbrass glands shall be assured. This may be achieved by the rigid clamping of the armour within thegland and the intimate contact between the threaded components of the gland and the equipment.

Glands for single core cables shall be constructed from non-magnetic materials.

Each gland shall be installed complete with a proprietary non-ferrous lock nut to secure the glandbody to the equipment where the entry hole is plain, i.e. not tapped.

7.6 Cable Marker

Cable markers shall be of heavy duty reinforced concrete construction. The cable marker shall be oftrapezoidal block with 100 mm square top face, 150 mm square bottom face and 400 mm in height.The top face shall be indented with bold lettering `L.V.' and directional sign indicating thedirection/directions of the cable route.

Appendix A – Abbreviation


Appendix AAbbreviation

Section 6: Appendix A – Abbreviation

Electrical Works Specifications App: A - 1Issue 01 / Revision 01February 2007

APPENDIX A

ABBREVIATION

PVC Polyvinyl ChlorideSWA Steel Wired ArmouredXLPE Cross Linked PolyethyleneAWA Aluminium Wired ArmouredPILCDSTAS Paper Insulated Lead Covered Double Steel Tape Armoured and ServedOSCR Overall ScreenedPSCR Pair ScreenedPE Polyethylene

Appendix B – Laying of Underground Cable


Appendix BLaying of Underground Cable

TYPICAL DRAWING FOR LAYING OF UNDERGROUNDCABLE DIRECT TO GROUND

Note:Actual width of cable trench will dependOn number of cables laid.

GROUND SURFACE

EARTH

CABLE

SAND

150mm

uPVC CABLE PROTECTIVE COVER

76m

m76

mm

750m

m

450mm/min

a) SINGLE CABLE b) DUAL CABLE (RUNNING PARALLEL)

GROUND SURFACE

750m

m

450mm/min

CABLESAND

76m

m76

mm

EARTH

150mm 150mm

TYPICAL DRAWING FOR LAYING OF UNDERGROUNDCABLE USING G.I PIPE

Note:Number of GI pipes laid

450mm/min

GROUND SURFACE

CABLE

152m

m15

2mm

GI PIPE

SAND

750m

m

914m

m

150mm150mm

EARTH



Section 7Earthing, Lightning and Surge

Protection



PageSection 7 – Earthing, Lightning and Surge Protection

1.0 Common Earth Termination Network 7-11.1 Requirements 7-11.2 Specifications 7-2

1.2.1 Copper Tape Conductor 7-21.2.2 Ground Electrodes 7-21.2.3 Exothermic Welding 7-21.2.4 Inspection Chamber 7-31.2.5 Main Ground Bar 7-3

2.0 Surge Protection2.1 Requirements 7-32.2 Specifications 7-4

2.2.1 Surge Protection Device 7-42.2.2 Sub Circuit – Circuit Connected To Sensitive Equipment

E.G. Compact Plc, Plc. 7-53.0 Lightning Protection 7-5

3.1 Requirement 7-53.2 Installation 7-6

Section 7 - Earthing, Lightning and Surge Protection


SECTION 7 – EARTHING, LIGHTNING AND SURGEPROTECTION

1.0 COMMON EARTH TERMINATION NETWORK

1.1 Requirements

The purpose of the Common Earth Termination Network (CETN) is to eliminate potential differencebetween two or more earthing system within a facility, providing equipotential earthing system for allservices, thus providing:

• Adequate path for earth fault return• To ensure personnel safety from electrical shock hazard• To prevent hazardous discharge of static electricity and fire risk• To provide low impedance and resistance path for high frequency current discharge

It is important for the CETN to able to last for a minimum of 25 years, hence, it is important that allcomponents required/necessary for the completion of CETN be of high quality.

All services earth and metallic part of structure must be properly bonded to the CETN.

CETN, when completed, shall form the common earth termination network system for:

• Direct Strike Lightning Protection System (LPS)• Electrical Distribution• Genset (Frame & Neutral)• Supply intake (TNB)• Electronics• Telecommunications

The interconnection of all ground points shall be by means of flat bare copper tape conductor withdimension of not less than 25 mm (width) × 3 mm (thickness). Flat bare copper tape conductorproduces much less inductance compared to that of copper stranded cable.

The copper tape conductor shall be bonded to ground points by means of Exothermic Welding only.Any other type of mechanical clamps, brazing is not acceptable as these method are subjected tocorrosion, loosening, mechanical failure, electrical failure and disconnection.

Main ground bars (MGB) shall be provided at suitable locations for termination of allmetallic/conductive surface e.g. metallic enclosures, earthing of equipment(s) or surge protectors.MGB shall be wall mounted at a pre-specified height for termination convenience. Good, strong andpermanent connections by means of Exothermic Welding must be provided for the electricallycontinuous connection of MGB and external/underground CETN. Each MGB shall have a minimumof two tinned copper conductor interconnection between MGB and external CETN.



Dimension & sizes of MGB, conductor shall be as per table below: -

Prospective earth fault currents(I) for 1s duration

Main Ground Bar MGB & CETN interconnectingconductor

40 kA < I ≤ 50 kA 50 mm x 6 mm 2 mm x 25 mm x 3 mm

The following standards & regulations shall be adhered to for the works: -

• BS 6651 Lightning & Common earth termination network• BS 7430 Earthing• IEEE Std 81.2 Measurement of Resistance/Impedance of Earth System• IEEE Std 837 Qualifying Permanent Connection• UL/ANSI Electrical Safety Standard

The earth resistance for the Common Earth Termination Network (CETN) shall be 1 Ohm (Ω) or less.

1.2 Specifications

1.2.1 Copper Tape conductor

Flat bare copper tape conductor shall be in compliance to BS 1432 for soft drawn conductor. Coppertape conductor shall have dimension not less than 25 mm (width) × 3 mm (thickness). Copper tapeconductor shall be buried at a minimum of 600 mm depth.

1.2.2 Ground Electrodes

Auxiliary ground electrode shall be of the molecularly copper bonded steel ground electrodes.Copper clad and jacketed type earth electrodes are not acceptable. Copper coating thickness onground electrode shall be minimum 0.254 mm in accordance to UL & ANSI specifications.

The ground electrode shall not be less than 14.2 mm (5/8”) in diameter and 1,800 mm (6’) in length.The ground electrode shall be extended to required electrode length using high strength electrodecoupling.

The ground electrodes shall have a minimum driven depths of not less than 3,600 mm and equallyspaced (using the < 2 × L formula as per BS 7430) to maximize each points’ potential.

1.2.3 Exothermic Welding

Exothermic welding materials shall be in compliance to UL for approvals of grounding and bondingproducts. Exothermic welding connections must also be tested to guidelines in accordance to IEEEStd. 837.



1.2.4 Inspection Chamber

Each ground electrodes point shall be provided with a heavy duty type inspection chamber withremovable cover. The inspection chamber shall have a minimum dimension of 345 mm (width) ×345 mm (length) × 210 mm (depth). Lifting hook shall be provided for removable cover.

1.2.5 Main Ground Bar

The Main Ground Bar (MGB) shall be of high conductivity copper bar. MGB shall have a minimumof 6 × M8 hole for termination of earth conductors. All termination to MGB shall be using stainlesssteel bolts & nuts and proper/suitable compression lug.

The MGB shall not be less than 450 mm (length) × 50 mm (width) × 6 mm (thickness).

The MGB shall be properly isolated from structure wall using high resistance insulators.

A transparent protective cover of sufficient thickness and dimensions with label engraved and markedin red legibly with words “Main Earthing Terminals Safety Electrical Connections – Do NotRemove” shall be installed to cover full length of the MGB.

Two earthing conductors of tinned copper tae of dimension as indicated in table above shall beprovided to connect the MGB to external CETN. The earthing conductors shall be protected, wherenecessary, by means of galvanized steel conduit and buried in the ground at a depth of not less than450 mm below finished ground level.

Interconnecting conductors between MSB/SSB and MGB shall be by similar earthing conductors tothose between MGB & CETN. These conductors shall be mechanically protected using PVCrectangular channel flushed with the floor slab.

2.0 SURGE PROTECTION

2.1 Requirements

The lightning surge protection devices (SPD) shall be installed at specific locations for specificequipments and panels as per design, drawing and engineer’s specifications.

The SPD shall be installed with care to minimize the amount of let through voltage into equipments.

The SPD shall conform to various international standards for its surge handling capability, let-throughvoltage and short circuit current handling capability.

All materials, equipment and components for a safe & durable lightning SPD must be UL certified.

Standards & Regulations

IEC 62305-4 Protection Against Lightning Part 4 – Electrical & Electronic Systems within Structure



ANSI/IEEE C62.41 High Energy Lightning & Switching Standard

IEC 61643 Surge Protection Devices connected to low-voltage distribution systems

UL1449 Electrical Safety Standard

2.2 Specifications

2.2.1 Surge Protection Device

The surge protection device (SPD) shall be compatible with the system it is protected and shallprovide phase-to-neutral, phase-to-earth and neutral-to-earth protection for either single phase orthree phase power supply system. The normal operating voltage of the SPD for phase-to-neutralconnection shall be 240 V and the maximum operating voltage is 275 V. SPD for phase-to-earth andneutral-to-earth connections shall be rated at 415 V and the maximum operating voltage of 475 V.The leakage current shall not exceed 3.5 mA. Unless otherwise specified, the type of SPD to beinstalled with respect to the location of switchboard shall be as in Table 1 below: -

Location of switchboard

Main switchboard orSub switchboard

receiving energy fromlicensee or other

building

Switchboard and/ordistribution board

receiving energy frommain switchboard and

or Sub switchboardlocated in the same

building

Location Category C B

Exposure Level High High

Peak DischargeCurrent (8/20 µs test

waveform)40 kA 20 kA

Peak Transient Let ≤ 800 V (20 kV, 1.2/50 ≤ 600 V (6 kV, 1.2/50

Through Voltage forall modes

µs and 10 kA, 8/20 µstest waveforms)

µs and 3 kA, 8/20 µstest waveforms)

Table 1 - Types of Surge Protection Device

The peak transient let-through voltage or voltage protection level for all modes (phase-to-neutral,phase-to-earth and neutral-to-earth) shall be as in Table 1 above. Unless otherwise specified, the SPDshall be of the type complying with BS 6651 and/or IEC 61024-1 and IEC 61643-1, IEC 61312-1 andIEC 61312-3.



The surge protection device shall incorporate continuous indication of its protection status, via fullprotection present, reduced protection - replacement required and no protection - failure of protection.The connecting leads shall be as short as possible and not more than 1,000 mm in length, and shall betightly bound together over throughout the whole length. Unless otherwise specified, four-polemoulded case circuit breaker or fuses of rating as recommended by the SPD manufacturer shall beprovided to enable full isolation of SPD from the system for maintenance.

2.2.2 Sub Circuit – circuit connected to sensitive equipment e.g. CompactPLC, PLC.

SPD shall be installed as secondary protection for sensitive electronics equipments to minimize therisk & danger of lightning surge current (let through voltage of MSB SPD). The power SPD shallhave a minimum 16 kA 8/20µs surge handling capability.

The SPD shall be equipped with series LC filter to ensure low let-through voltage of not more than600 V when tested using 3 kA 8/30µs wave shape as per IEC 61643-1 Class II.

Status indication of SPD shall be of either mechanical flag or LED.

Surge protection shall be provided at the main incoming supply of the panels/switchboards wherethere is electronic devices are connected or those with incoming breaker ratings of 100 A and above.Protection shall be provided between live and earth as well as neutral and earth.

Surge protection units shall be designed for multiple applications (as lightning consists of a numberof pulses) and components shall be able to withstand the vibration caused by the pulses. Surgeprotection devices shall be designed so that alarm outputs can be retrofitted whenever required. Thetotal surge rating in a 8/20 microsecond waveform shall not be less than 100 kA.

The let-through voltage shall not exceed 900 V. The surge protection device shall comply with thefollowing standards: -

• IEC - 801 - 5• IEC - C -62.41 - 1991• BS EN 60099-1:1994• IEC 587 Category E• IEC 1024 - 1 (Zone O)

3.0 LIGHTNING PROTECTION

3.1 Requirement

The lightning protection system (LPS) network shall comprise of the following (but not limited to):-

• Aluminium air terminal• Aluminium tape roof & down conductor• Aluminium tape saddle• Bi-Metallic connector



• Copper tape down conductor• Copper Plate type test clamp• Earthing network termination system

The LPS network shall comply with the latest applicable provisions and recommendations of: -

• BS 6651 Code of practice for Protection of Structures Against Lightning• BS 7430 Code of practice for Earthing• IEC 62305 Code of practice for lightning protection system

3.2 Installation

Air terminations shall be firmly secured by suitable mounting mast, fixing bolts, screws and clampsto establish good electrical continuity from air terminal to downconductor and to ensure they aresecurely held in position under the influence of mechanical stresses during the passage of lightningcurrents.

All roof air terminations shall be of aluminium type material.

The number of downconductor shall be in accordance with BS 6651. Downconductors shall bebrought down from roof air termination using the least number of loops as possible.

The aluminium downconductor shall be terminated at approximately 1,800 mm from finish floor levelas indicated in the design drawing. Thereafter, Bi-Metallic connector shall be used to connect thealuminium downconductor to copper earth termination conductor.

The copper earth termination conductor shall be embedded within the wall. The copper earthtermination conductor shall be routed directly to ground point and terminated.

Termination of the copper earth conductor to ground points (copper ground rods) shall be by meansof Exothermic Welding connection for a permanent & long lasting termination as well as to preventloosening & disconnection.

The earth termination network shall consist of copper ground rods conductor with minimum drivendepths of not less than 3,600 mm and equally spaced (using the < 2 × L formula as per BS 7430) tomaximize each points’ potential. Each ground points (ground rods) shall be interconnected using barecopper tape conductor buried underground with buried depth of not less than 600 mm.

A complete lightning protection network shall be provided in accordance with MS 939:1984.

All exposed non-conducting metal parts in the plant shall be bonded to earth. The lightning protectionsystem shall comply with BS 6651 and shall take the form of a closed network and down conductorsusing aluminium strip.

Conductors shall be fixed to the roof of any buildings in an approved manner. Waterproof barriersshall not be penetrated. Where fixings are required to pass through waterproof membranes, theapproval of the Technical Committee of the Sewerage Services Department shall be obtained prior tothe commencement of work.



Final connection to the earth electrode shall be made using aluminium strip installed in high impactheavy gauge PVC Class D conduit for below ground level installation.

Wherever possible natural contact between dissimilar metals shall be avoided. Joints between copperand aluminium conductor shall be made as follows:

• Contact area of copper shall be tinned• Contact area of aluminium shall be cleaned and coated with an oxide resisting paste• Make off joint using copper rivets or purpose made clamps• Joint to be liberally coated with bitumen paint and totally encased in a heat shrink sleeve

electrical works specifications

Documents

appendix h

low voltage switchboard

kv cable specification

motor specificationsection

components specification1

earthing system

fuel system

protective devices