VOLUME 2 FOR DURAVIT

VOLUME 2

SECTION J : TECHNICAL SPECIFICATION OF WORKMANSHIP ANDPRIVATE MATERIALS

ELECTRICAL SPECIFICATIONS

General

The Tenderers shall furnish catalogues, engineering data, technical information, design documents, drawings etc., fully in conformity with the technical specification.

It is recognized that The Contractor may have standardized on the use of certain components, materials, processes or procedures different from those specified herein. Alternate proposals offering similar equipment based on the Manufacturers standard practice will also be considered provided such proposals meet the specified designs, standard and performance requirements. Unless brought out clearly, the Tenderer shall be deemed to conform to this specification scrupulously. All deviations from the specification shall be clearly brought out in the respective schedule of deviations. Any discrepancy between the specification and the catalogues or the bid, if not clearly brought out in the specific requisite schedule, will not be considered as valid deviation.

Wherever a material or article is specified or defined by the name of a particular brand, Manufacturer or Supplier, the specific name mentioned shall be understood as establishing type, function and quality and not as limiting competition.

Equipment furnished shall be complete in every respect with all mountings, fittings, fixtures and standard accessories normally provided with such equipment and/or needed for erection, completion and safe operation of the equipment as required by applicable codes though they may not have been specifically detailed in the Technical Specifications unless included in the list of exclusions. Materials and components not specifically stated in the specification but which are necessary for commissioning and satisfactory operation of the switchyard/substation/lines unless specifically excluded shall be deemed to be included in the scope of the specification and shall be supplied without any extra cost. All similar standard components/parts of similar standard equipment provided, shall be interchangeable with one another.

All 0.433 KV cable requirements to be incorporated for earthed system.

All Miscellaneous items & sundries e.g. glands, ferrules, tape etc will be in the scope of Erection The Contractor.

The following type, acceptance and routine tests and tests during Manufacture shall be carried-out on the material. For the purpose of this clause:

Type Tests shall mean those tests which are to be carried out to prove the process of Manufacture and general conformity of the material to this Specification. These tests shall be carried out on samples prior to commencement of commercial production against the order. The Tenderer shall indicate his schedule for carrying out these tests.

Acceptance Tests shall mean those tests which are to be carried out on samples taken from each lot offered for pre-dispatch inspection, for the purposes of acceptance of that lot.

Routine Tests shall mean those tests, which are to be carried out on the material to check requirements, which are likely to vary during production.

Tests during Manufacture shall mean those tests, which are to be carried out during the process of Manufacture and end inspection by The Contractor to ensure the desired quality of the end product to be supplied by him.

The norms and procedure of sampling for these tests will be as per the Quality Assurance Programme to be mutually agreed to by The Contractor and the Owner.

The standards and norms to which these tests will be carried out are listed against them. Where a particular test is a specific requirement of this Specification, the norms and procedure of the tests shall be as per this specification or as mutually agreed to between The Contractor and the Owner in the Quality Assurance Programme.

For all type and acceptance tests, the acceptance values shall be the values specified in this specification, Approved Quality Plan or guaranteed by the Tenderer, as applicable.

The Owner will have the right of having at his own expenses any other test(s) of reasonable nature carried out at The Contractors premises or at site or in any other place in addition of aforesaid type and routine tests, to satisfy that the material comply with the specification.

The Owner reserves the right for getting any field tests not specified in respective sections of the technical specification conducted on the completely assembled equipment at site. The testing equipments for these tests shall be provided by the Owner.

The price of conducting type tests and additional type tests shall be included in Bid price.

The Owner, his duly authorized representative and/or outside inspection agency acting on behalf of the Owner shall have at all reasonable times free access to The Contractors/Suppliers premises or Works and shall have the power at all reasonable times to inspect and examine the materials and workmanship of the Works during its Manufacture or erection if part of the Works is being Manufactured or assembled at other premises or works, The Contractor shall obtain for the Engineer and for his duly authorized representative permission to inspect as if the works were Manufactured or assembled on The Contractors own premises or works. Inspection may be made at any stage of Manufacture, dispatch or at site at the option of the Owner and the equipment if found unsatisfactory due to bad workmanship or quality, material is liable to be rejected.

It is the intention of the specification and drawings to call for finished work, tested and ready for operation. Whenever the words, "Supply" or "Provide" are used, it shall mean provide and complete, and ready for use. Any apparatus, material or work not shown on drawings but mentioned in the specification,vice versa, or anyincidental accessoriesnecessarytomakethe work complete completeandperfectinallrespects and ready for operation, even if not particularly specified, shall be furnished, delivered and installed by the Contractor without additional expense to the Owner. Minor details not usually shown or specified, but necessary for the proper installation and operation, shall be included in the work and in The Contractor's price, as if herein specified or shown.

The electrical drawings shall be readin conjunction with the existing Architectural / Structural drawings and verified with site dimensions.

Any damage/loss caused by The Contractor/Sub-The Contractor due to defective or ill-timed work shall be borne by The Contractor;

Take precautionary measures to protect the underground and other services lines viz. cables, water and sewer lines, etc. and if damaged shall rectify the same at its own cost.

All electrical installations shall be of high quality,safe, complete and fully operational including all necessary items and accessorieswhether or not specifiedindetail. All electrical work shall be completed in accordance with the regulations and standards to the satisfaction of the Consultant. The general provisions, special provisionsand generalrequirements apply to all sections of this specifications.

The work shall be carried out simultaneously with building work andshall becontinuedtill itis completed satisfactorily along with the completion of essential portions of the building works.

During the progress of work, completed portion of the building may be occupied and be put to use by the Owner but the The Contractor will remain fully responsible for the maintenance of electrical installations till the entire workcovered by this contract is satisfactorily completed by him and handed over to the owner.

The Contractor shall submit all test certificates for all the electrical equipment / material / system. Theseshall be issued by a government recognized inspection office certifying that all equipment, materials, construction and functions are in agreement with the requirements of these specifications and accepted standards.

The The Contractor shall bring all the necessary tools / tackles like Zari Cutter for wall conduit, drill, ladder, crimping tool, hardware and other sundry materials necessary to complete the job.

Prior to execution of any work the The Contractor shall prepare for the Consultant's approval, sample and sketch / Shop drawing of each and every item he intends to use in the said Electrical work. The approved sample of the work shall be kept on site all the time as per the instruction of the Consultant. Nothing extra will be paid for these.

Appropriate arrangements for the electrician / labour / workmen for the different types of the work shall be made by The Contractor, along with coordinating with RSEBs power supply Division.

The The Contractor shall prepare and produce instruction, operation and maintenance manuals in English for the use, operation and the maintenance of the supplied equipment and installations, and submit to the Consultant/Engineer at the time of handing over.The number of copies shall be in accordance with the general conditions of contract.PRE-COMMISSIONING AND COMMISSIONING TESTS

Pre-commissioning tests

On completion of erection of the equipment and before charging, each item of the equipment shall be thoroughly cleaned and then inspected jointly by the Owner and The Contractor for correctness and completeness of installation and acceptability for charging, leading to initial pre-commissioning tests at Site. The lists of pre-commissioning tests to be performed are given in respective chapters and shall be included in The Contractors quality assurance programme.

Commissioning Tests

The available instrumentation and control equipment will be used during such tests and the Owner will calibrate, all such measuring equipment and devices as far as practicable.

Any special equipment, tools and tackles required for the successful completion of the Commissioning Tests shall be provided by The Contractor, free of cost.

The Contractor shall be responsible for obtaining statutory clearances from the concerned authorities for commissioning the equipment. However necessary fee only official shall be reimbursed by METSO MINERALS ( INDIA) PVT. LTD. on production of requisite documents.

Packaging & protection

All the equipments shall be suitably protected, coated, covered or boxed and crated to prevent damage or deterioration during transit, handling and storage at Site till the time of erection. On request of the Owner, the Contractor shall also submit packing details/associated drawing for any equipment/material under his scope of supply, to facilitate the Owner to repack any equipment/material at a later date, in case the need arises. While packing all the materials, the limitation from the point of view of availability of Railway wagon sizes in India should be taken into account. The Contractor shall be responsible for any loss or damage during transportation, handling and storage due to improper packing. Any demurrage, wharfage and other such charges claimed by the transporters, railways etc. shall be to the account of the Contractor. Owner takes no responsibility of the availability of the wagons.

All coated surfaces shall be protected against abrasion, impact, discoloration and any other damages. All exposed threaded portions shall be suitably protected with either a metallic or a non-metallic protecting device. All ends of all valves and piping and conduit equipment connections shall be properly sealed with suitable devices to protect them from damage.

Finishing of metal surfaces

All metal surfaces shall be subjected to treatment for anti-corrosion protection. All ferrous surfaces for external use unless otherwise stated elsewhere in the specification or specifically agreed, shall be hot-dip galvanized after fabrication. High tensile steel nuts & bolts and spring washers shall be electro galvanized to service condition 4. All steel conductors including those used for earthing/grounding (above ground level) shall also be galvanized according to IS: 2629. Fasteners exposed to atmosphere will be of stainless steel.

Painting

All sheet steel work shall be degreased, pickled, phosphated in accordance with the IS- 6005 Code of practice for phosphating iron and sheet. All surfaces, which will not be easily accessible after shop assembly, shall beforehand be treated and protected for the life of the equipment. The surfaces, which are to be finished painted after installation or require corrosion protection until installation, shall be shop painted with at least two coats of primer. Oil, grease, dirt and swag shall be thoroughly removed by emulsion cleaning. Rust and scale shall be removed by pickling with dilute acid followed by washing with running water, rinsing with slightly alkaline hot water and drying.

After phosphating, thorough rinsing shall be carried out with clean water followed by final rinsing with dilute dichromate solution and oven drying. The phosphate coating shall be sealed with application of two coats of ready mixed, stoving type zinc chromate primer. The first coat may be flash dried while the second coat shall be stoved.

After application of the primer, two coats of finishing synthetic enamel paint shall be applied, each coat followed by stoving. The second finishing coat shall be applied after inspection of first coat of painting.

The exterior colour of the paint shall be as per shade no: 697 of IS-5 and inside shall be glossy white for all equipment, marshalling boxes, junction boxes, control cabinets, panels etc. unless specifically mentioned under respective sections of the equipments. Each coat of primer and finishing paint shall be of slightly different shade to enable inspection of the painting. A small quantity of finishing paint shall be supplied for minor touching up required at site after installation of the equipments. In case the Tenderer proposes to follow his own standard surface finish and protection procedures or any other established painting procedures, like electrostatic painting etc., the procedure shall be submitted along with the Bids for Owners review & approval.

Handling, storing and installation

In accordance with the specific installation instructions as shown on Manufacturers drawings or as directed by the Owner or his representative, the Contractor shall unload, store, erect, install, wire, test and place into commercial use all the equipment included in the contract. Equipment shall be installed in a neat, workmanlike manner so that it is level, plumb, square and properly aligned and oriented. Commercial use means completion of all site tests specified and energisation at rated voltage.

The Contractor shall unload, transport, store, erect, test and commission the equipment as per instructions of the Manufacturers supervisory Engineer(s) and shall extend full cooperation to them.

In case of any doubt/misunderstanding as to the correct interpretation of Manufacturers drawings or instructions, necessary clarifications shall be obtained from the Owner. The Contractor shall be held responsible for any damage to the equipment consequent to not following Manufacturers drawings/instructions correctly.

Where assemblies are supplied in more than one section, The Contractor shall make all necessary mechanical and electrical connections between sections including the connection between buses. The Contractor shall also do necessary adjustments/alignments necessary for proper operation of circuit breakers, isolators and their operating mechanisms. All components shall be protected against damage during unloading, transportation, storage, installation, testing and commissioning. Any equipment damaged due to negligence or carelessness or otherwise shall be replaced by The Contractor at his own expense.

The Contractor shall be responsible for examining all the shipment and notify the Owner immediately of any damage, shortage, discrepancy etc. for the purpose of Owners information only. The Contractor shall submit to the Owner every week a report detailing all the receipts during the weeks. However, The Contractor shall be solely responsible for any shortages or damages in transit, handling and/or in storage and erection of the equipment at Site. Any demurrage, wharf age and other such charges claimed by the transporters, railways etc. shall be to the account of The Contractor.

The Contractor shall be fully responsible for the equipment/material until the same is handed over to the Owner in an operating condition after commissioning. The Contractor shall be responsible for the maintenance of the equipment/material while in storage as well as after erection until taken over by Owner, as well as protection of the same against theft, element of nature, corrosion, damages etc.

Where material / equipment is unloaded by Owner before the Contractor arrives at site or even when he is at site, Owner by right can hand over the same to The Contractor and there upon it will be the responsibility of The Contractor to store the material in an orderly and proper manner.

The Contractor shall be responsible for making suitable indoor storage facilities, to store all equipment which requires indoor storage.

The words erection and installation used in the specification are synonymous.

Exposed live parts shall be placed high enough above ground to meet the requirements of electrical and other statutory safety codes.

The design and workmanship shall be in accordance with the best engineering practices to ensure satisfactory performance throughout the service life. If at any stage during the execution of the Contract, it is observed that the erected equipment(s) do not meet the above minimum clearances as given in IS The Contractor shall immediately proceed to correct the discrepancy at his risks and cost.

Tools and tackles

The Contractor shall supply with the equipment one complete set of all special tools and tackles for the erection, assembly, de-assembly and maintenance of the equipment. However, these tools and tackles shall be separately, packed and brought on to Site.

Support structure

The Support structures for all equipments shall be designed and supplied by The Contractor. All brackets, angels, stool or other members necessary for attaching the operating mechanism to the supporting structure shall be engineered and supplied by The Contractor.

The support structures should be hot dip galvanised with minimum 610 gram / sq.m net of zinc.

In case of any deviation in this regard the bid is liable to be considered technically non responsive and shall be liable to be rejected.

2.POWER CONTROL CENTRE & POWER DBS

.01 Scope

This scope shall cover design, Manufacture, check test, and supply, installation, testing and commissioning of various medium voltage Panel Board as described in Bill of quantities and drawings.

Medium voltage Panel Board will be installed indoor and is connected through the bus duct / cables.

.02 Service conditions at site

Ambient Temperature :Max. / Min. = 50 C. / 6 C.

Design temperature

: 50 Degree C.

Relative humidity

: 95% max.

Altitude

:20 M above MSL

Location

: E-CITI, Ahmedabad

Voltage

: 415+/- 10%, TPN

Frequency

:50 Hz. + 3% to -6%

Neutral

: Solidly / earthed neutral.

Fault level

: 24 MVA, Symmetrical at 415V solidly earthed.

.03Documentations

.03.1The Contractor shall furnish drawings, data and manuals in six sets along with equipment supplied.

General arrangement drawing indicating accessories and dimensions

Foundation plan and loading

Termination arrangement with dimensions

Three phase wiring diagrams

SLDs and control schemes

Terminal plans

Bill of quantity for each panel

.03.2 Documents to be submitted after placement of order.

As per 3.1 above for comments and approval for Manufacture.

Schematic and sectional drawing.

.03.3 Final documents

As built drawings with RTP ( Reproducible Tracing Paper).

Instruction and maintenance manual - Six copies.

Test certificates - Six copies.

.04General Specifications

.04.1All the Panels shall be metal clad, totally enclosed, rigid, floor / wall mounting, air insulated, cubicle type suitable for operation on three phase / single phase, 415 V / 230 V / 240 V, 50 Hz., neutral effectively / non-effectively grounded at transformer and short circuit level as mentioned in the drawings.

All the panels shall be IP54 protection class construction.

The painting of all the metal part shall be as per the painting specification as defined in the datasheet.

.04.2 The Panels shall be designed to withstand the heaviest condition at site, with maximum expected ambient temperature of 50 c., 95% humidity.

.05 Standards and Codes

The Panels shall comply with the latest edition of relevant Indian Standards and Indian Electricity Rules and Regulations. The following Indian Standards shall be complied with:

IS : 4237General requirements for switchgear and control gear for

voltages not exceeding 1000 V a.c. or 1200 V d.c.

IS : 5578Guide for marking of insulated conductors.

IS : 11353Guide for uniform system of marking and identification of

conductors and apparatus Terminals.

IS : 13947Low voltage switchgear and control gear.

IS : 8197Terminal marking for electrical measuring instrument and their

accessories.

IS : 2551Danger notice plates

IS : 10118Code of Practice for selection, installation and maintenance of

switchgear and control gear.

IS : 8623 Specification for factory built assemblies of switchgear and

control gear for voltage up to and including 1000 V A.C. and 1200 V.D.C.

IS : 8828Miniature circuit breakers.

IS : 9224HRC fuse links

IS : 2705Current transformer

IS : 3156Voltage transformer

IS : 3231Electrical relay for protection

IS : 1248Indicating instrument

IS : 722Integrating instrument

IS : 6875Control switches and push buttons

IS : 1822A.C. motor starters of voltage not exceeding 1000 V

Indian Electricity Act and Rules (as amended up to date) and approval of FIA of India.

The Panels also require approval of the Owner/Consultant at various stage of their Manufacture such as design, selection, construction, testing, shipping etc..

.06 Construction

.06.1Cubical Type Panels

.06.1.1 Structure

The Panels shall be of compartmentalized design so that circuit arc / flash products do not create secondary faults and be fabricated out of high quality CRCA sheet, suitable for indoor installation having dead front operated and floor / wall mounting type.

All CRCA sheet steel used in the construction of Panels shall be 2 mm. thick and shall be folded and braced as necessary to provide a rigid support for all components. Joints of any kind in sheet steel shall be seam welded, all welding slag grounded off and welding pits wiped smooth with plumber metal.

The Panels shall be totally enclosed, completely dust and vermin proof and degree of protection being not less than IP: 54 to IS: 2147. Gaskets between all adjacent units and beneath all covers shall be provided to render the joints dust proof. All doors and covers shall be fully gasketed with foam rubber and /or rubber strips and shall be lockable.

All panels and covers shall be properly fitted and screwed with the frame and holds in the panel correctly positioned. Fixing screws shall enter into holes, taped into an adequate thickness of metal or provided with bolts and nuts. Self-threading screws shall not be used in the construction of Panels.

A base channel of 75 mm. x 40 mm. x 6 mm. thick shall be provided at the bottom. A clearance of 300 mm. between the floor of the Panels and the bottom of the lower most unit shall be provided.

Panels shall be preferably arranged in multi-tier formation. The Panels shall be of adequate size with a provision of 20% spare space to accommodate possible future additional switchgear. The size of the Panels shall be designed in such a way that the internal space is sufficient for hot air movement and the electrical component does not attain temperature more than 50(c.. If necessary, openings shall be provided for natural ventilation, but the said openings shall be screened with fine weld mesh. All the electrical component shall be derated for 50(c.

Knock out holes of appropriate size and number shall be provided in the Panels in conformity with the number, and the size of incoming and outgoing conduits / cables.

Alternately, the Panels shall be provided with removable sheet steel plates at top and bottom to drill holes for cable / conduit entry at site.

The Panels shall be designed to facilitate easy inspection, maintenance and repair.

The Panels shall be sufficiently rigid to support the equipment without distortion under normal and under short circuit condition. They shall be suitably braced for short circuit duty.

.06.1.2Protection Class

All the indoor Panels shall have protection class of IP : 54 .

.06.1.3Painting

The painting shall be seven-tank process with epoxy paint.

.06.1.4Circuit Compartments

Each circuit breaker and switch fuse unit shall be housed in separate compartments and shall be enclosed on all sides. Sheet steel hinged lockable door shall be duly interlocked with the breaker / switch fuse unit in `ON and `OFF position. Safety interlocks shall be provided for air circuit breaker to prevent the breaker from being drawn out when the breaker is in `ON position.

The door shall not form an integral part of draw out position of the circuit breaker. All instruments and indicating lamp shall be mounted on the compartment door. Sheet steel barriers shall be provided between the tiers in a vertical section.

.06.1.5 Instrument Compartments

Separate adequate compartment shall be provided for accommodating instruments, indicating lamps, control contactors / relays and control fuses etc. These components shall be accessible for testing and maintenance without any danger of accidental contact with live parts of the circuit breaker / switch fuse unit, bus bar and connections.

.06.1.6Busbars

The bus bar shall be air insulated and made of high quality, high conductivity, high strength Aluminium.

The bus bar shall be of 3 phases and neutral system with separate neutral and earth bar. The size of neutral bus bar in all main panels or lighting panels and feeders for LDB shall be equal to phase bus bar. The bus bar and interconnection between bus bars and various components shall be of high conductivity Aluminium. The bus bar shall be of rectangular cross-section designed to withstand full load current for phase bus bars and half rated current for neutral bus bars in case of MCC panels only and shall be extensible on either side. The bus bar size shall be as per drawing. The bus bar shall have uniform cross-section throughout the length.

The bus bars and interconnections shall be insulated with epoxy coated bus sleeves. The bus bar shall be supported on bus insulators of FRP type at sufficiently close intervals to prevent bus bars sag and shall effectively withstand electromagnetic stresses in the event of short circuit capacity of 35 KA RMS symmetrical for 1 sec.

The bus bar shall be housed in a separate compartment. The bus bar shall be isolated with 3 mm. thick bakelite sheet to avoid any accidental contact. The bus bar shall be arranged such that minimum clearance between the bus bar are maintained as below:

Between phases

:25 mm. minimum

Between phases and neutral

:25 mm.

Between phases and earth

:25 mm.

Between neutral and earth

:20 mm. minimum

All bus bar connections shall be done by drilling holes in bus bars and connecting by chromium plated or tinned plated brass bolts and nuts. Additional cross-section of bus bar shall be provided in all Panels to cover up the holes drilled in the bus bar. Spring and flat washers shall be used for tightening the bolts.

All connections between bus bars and circuit breakers / switches and cable terminals shall be through aluminium strips of proper size to carry full rated current. These strips shall be insulated with insulating tapes.

Panel to panel entry of bus bar shall be effectively sealed by electrical and thermal insulation barriers so that products of flashover do not travel from one panel to another panel creating multiple faults.

Bus bar shall be calculated on 50 deg. C. ambient temp. and 85 deg. C. for continuous and short time rating . Busbar surrounding air temperature shall be considered 70 deg. C. for bus bar calculation

All joint shall have non-flammable insulation shrouds for secondary insulation purpose

.06.1.7Electrical Power and Control Wiring Connection

Terminal for both incoming and outgoing cable connections shall be suitable for 1100 V grade, aluminium / copper conductor XLPE insulated and PVC sheathed, armoured cable and shall be suitable for connections of solderless sockets for the cable size as indicated on the appended drawings for the Panels.

Power connections for incoming feeders of the main Panels shall be suitable for 1100 V grade aluminium conductor (XLPE) cables.

Both control and power wiring shall be brought out in cable alley for ease of external connections, operation and maintenance.

Both control and power terminals shall be properly shrouded.

10% spare terminals shall be provided on each terminal block. Sufficient terminals shall be provided on each terminal block, so that not more than one outgoing wire is connected per terminal.

Terminal strips for power and control shall preferably be separated from each other by suitable barriers of enclosures.

Wiring inside the modules for power, control, protection and instruments etc. shall be done with use of 660 / 1100 V grade, FRLS insulated copper conductor wires conforming to IS : 694 & 8130 Power wiring inside the starter module shall be rated for full current raring of respective contactor, but not less than 4.0 sq. mm. cross-section area. For current transformer circuits, 2.5 sq. mm. copper conductor wire shall be used. Other control wiring shall be done with 1.5 sq. mm. copper conductor wires. Wires for connections to the door shall be flexible. All conductors shall be crimped with solderless sockets at the ends before connections are made to the terminals.

Control power supply to modules through the control transformer only. Control power wiring shall have MCB for circuit protection. All indicating lamps shall be protected by MCB.

Particular care shall be taken to ensure that the layout of wiring is neat and orderly. Identification ferrules shall be fitted to all the wire termination for ease of identification and to facilitate checking and testing.

Spring type washers shall be used for all copper and aluminium connections.

Final wiring diagram of the Panels power and control circuit with ferrules numbers shall be submitted along with the Panels as one of the documents against the contract.

.06.1.8Terminals

The outgoing terminals and neutral link shall be brought out to a cable alley suitably located and accessible from the panel front. The current transformers for instruments metering shall be mounted on the disconnecting type terminal blocks. No direct connection of incoming or outgoing cables to internal components of the distribution board is permitted, only one conductor may be connected in one terminal.

.06.1.9Wire ways

A horizontal / vertical metal / Al. wire way with screwed covers shall be provided at the top to take interconnecting control wiring between different vertical sections.

.06.1.10 Cable Compartments

Cable Compartments of minimum 300 mm size shall be provided in the Panels for easy termination of all incoming and outgoing cables entering from bottom or top. Adequate supports shall be provided in the cable compartments to support cables. All outgoing and incoming feeder terminals shall be brought out to terminal blocks in the cable compartment.

.06.1.11 Earthing

AL earth bars of 50 mm x 10 mm shall be provided in the Panels for the entire length of the panel. The frame work of the Panels shall be connected to this earth bar. Provisions shall be made for connection from this earth bar to the main earthing bar coming from the earth pit on both sides of the Panels.

The earth continuity conductor of each incoming and outgoing feeder shall be connected to this earth bar. The armour shall be properly connected with earthing clamp, and the clamp shall be made for connection from this earth pit on both sides of the Panels.

The earth continuity conductor of each incoming and outgoing feeder shall be connected to this earth bar. The armour shall be properly connected with earthing clamp, and the clamp shall be ultimately bonded with the earth bar.

.06.1.12 Labels

Engraved PVC labels shall be provided on all incoming and outgoing feeders. Single line circuit diagram showing the arrangements of circuit inside the distribution board shall be pasted on inside of the panel door and covered with transparent laminated plastic sheet.

.06.1.13 Name Plate

A name plate with the Panel's designation in bold letters shall be fixed at top of the central panel. A separate name plate giving feeder details shall be provided for each feeder module door.

Inside the feeder compartments, the electrical components, equipments, accessories like switchgear, control gear, lamps, relays etc. shall suitably be identified by providing stickers.

Engraved name plates shall preferably be of 3 ply, (Red-White-Red or Black-White-Black) lamicold sheet. However, black engraved perpex sheet name plates shall also be acceptable. Engraving shall be done with square groove cutters.

Name plate shall be fastened by counter sunk screws and not by adhesives.

.06.1.14 Danger Notice Plates

The danger notice plate shall be affixed in a permanent manner on operating side of the Panels.

The danger notice plate shall indicate danger notice both in Hindi and English and with a sign of skull and bones.

The danger notice plate, in general, meets the requirements of local inspecting authorities.

Overall dimensions of the danger notice plate shall be 200 mm. wide x 150 mm. high.

The danger notice plate shall be made from minimum 1.6 mm. thick mild steel sheet and after due pre-treatment to the plate, the same shall be painted white with vitreous enamel paint on both front and rear surface of the plate.

The letters, the figures, the conventional skull and bones etc. shall be positioned on plate as per recommendation of IS: 2551-1982.

The said letters, the figures and the sign of skull and bones shall be painted in signal red colour as per IS: 5-1978.

The danger plate shall have rounded corners. Location of fixing holes for the plate shall be decided to suit design of the Panels.

The danger notice plate, if possible, be of ISI certification mark.

.06.1.15 Internal Components

The Panels shall be equipped complete with all types of required number of Air circuit breakers, MCCBs, soft starters, switch fuse units, contactors, relays, fuses, meters, instruments, indicating lamps, push buttons, equipment, fittings, bus bars, cable boxes, cable glands etc. and all the necessary internal connections / wiring as required and as indicated on relevant drawings. Components necessary for the proper and complete functioning of the Panels but not indicated on the drawings shall be supplied and installed on the Panels.

All parts of the Panels carrying current including the components, connections, joints and instruments shall be capable of carrying their specified rated current continuously, without temperature rise exceeding the acceptable values of the relevant specifications at the part of the Panels.

All units of the same rating and specifications shall be fully interchangeable.

.07 Components

.07.1 General

The type, size and rating of the components shall be as indicated on the relevant drawings.

While selection of the capacity of the components resulting from the prevailing conditions like ambient temperature shall be allowed for the thermal and magnetic trip rating shall be compensated for the ambient temperature.

The rating indicated on the drawing are ratings anticipated at prevailing site conditions.

.07.2Fuse Switch Units

The fuse switch units shall be 3 poles, double break type heavy duty suitable for load break duty (AC 23), quick make and break action. Separate neutral link shall be provided in the switch. All fuse switch units shall be provided with hinged doors, duly interlocked with operating mechanism so as to prevent opening of the door when the switch is in `ON position and also prevent closing of the switch when the door is not properly secured. All contacts shall be silver-plated and all live parts shall be shrouded. The incoming and outgoing terminals of the switch shall be adequately sized to receive proper size of the cables. High rupturing capacity (HRC) fuse links shall be provided with switch fuse units and shall be in accordance with IS : 9224-1979 and having rupturing capacity of not less than 35 MVA at 415 V. HRC fuse links shall be provided with visible indicators to show that they have operated. The switch fuse unit shall be Manufactured in accordance with IS : 13947.

.07.3 Air Circuit Breaker

.07.3.1 Construction

The ACBs shall have following features:

Motorised with 110 V D.C. motor.

110 V D.C closing and shunt trip coil

Draw out type with "service", "test", "isolated" and "maintenance" position.

Safety shutter of Fibre glass / polycarbonate sheet of 2mm thickness shall be provided

Mechanically trip free plus anti pumping feature is to be provided.

Electrical trip free plus anti pumping shall be provided with relay ONLY and not by contactors.

Electrical/Mechanical operation counter shall be provided.

Door interlock with defeat features to be provided.

ACB shall be lockable in isolation position.

.07.3.2 Release

Microprocessor based release shall be direct acting type tripping ACB mechanically.

Short circuit, overload and earth fault protection shall be provided.

The Contractor to suggest release type for feeders of supply range characteristic and accuracy.

.07.4 ACB Performance

ACB performance inside panels at ambient 50 Degree.

Ith Symmetrical breaking, 35KA

Making capacity peak 87.5 KA

Short time rating , 1sec. 35KA

.07.5Fuse

Fuses shall be of high rupturing capacity (HRC) fuse links and shall be in accordance with IS: 2000-1962 and having high rupturing capacity of not less than 35 MVA at 415 V. The back-up fuse rating for each motor / equipment shall be so chosen that the fuse does not operate on starting of motors / equipment. HRC fuses shall be of the make as specified in Make of Material.

.07.6Moulded Case Circuit Breaker

The moulded case circuit breaker (MCCB) shall be air break type and having quick make - quick break with trip free operating mechanism.

Housing of the MCCB shall be of heat resistant and flame retardant insulating material.

Operating handle of the MCCB shall be in front and clearly indicate ON/OFF/TRIP positions.

The electrical contacts of the circuit breaker shall be of high conducting non- deteriorating silver alloy contacts.

The MCCB shall be provided with thermal / magnetic type bi-metal overload release and electro magnetic short circuit protection device with adjustable time delay. All the releases shall operate on common trip busbar so that in case of operation of any one of the releases in any of the three phases, it will cut off all the three phases and thereby single phasing of the system is avoided.

The MCCB wherever called for in the appended drawings shall provide an earth fault relay.

The MCCB shall provide two sets of extra auxiliary contacts with connections for additional controls at future date.

The electrical parameters of the MCCB shall be as per the description given in the appended drawings.

Draw out type MCCB shall be provided for the feeder indicated in the single line diagram. The MCCB shall be provided with 110 V D.C motor for closing and tripping / switching off for the feeders indicated in single line diagram.

.07.7Miniature Circuit Breakers

Miniature Circuit breakers shall be current limiting type conformed with British standard BS: 3871 (Part I) 1965 and IS: 8828. The housing of MCBs shall be heat resistant and having high impact strength. The fault current of MCBs shall not be less than 9000 A at 240 V. The MCBs shall be flush mounted and shall be provided with trip free manual operating mechanism with mechanical `ON and `OFF indications.

The circuit breaker dollies shall be of the trip free pattern to prevent closing the breaker on a faulty circuit.

The MCB contacts shall be silver nickel and silver graphite alloy and tip coated with silver. Proper arc chutes shall be provided to quench the arc immediately. MCBs shall be provided with magnetic fluid plunger release for over current and short circuit protection. The overload or short circuit device shall have a common trip bar in the case of DP and TPN miniature circuit breakers. All the MCBs shall be tested and certified as per Indian Standards, prior to installation.

.07.8Contactors

The contactors shall meet with the requirements of IS : 13947 and BS : 775.

The contactors shall have minimum making and breaking capacity in accordance with utilization category AC3 and shall be suitable for minimum Class II intermittent duty.

If the contactor forms part of a distribution board then a separate enclosure is not required, but the installation of the contactor shall be such that it is not possible to make an accidental contact with live parts.

.07.9Load Manager

The load manager shall be of Digital type of about 190 x 145 mm size having real time clock and RS 485 port communication port. Suitable software ( 1 set ) shall also be supplied. Suitable RS-485 to RS- 232 converter shall also be part of supply.

.07.10Voltmeter

Voltmeter shall be digital. The dial of the meter shall be square in shape of 96 x 96 mm.

The voltmeter selector switch shall be arranged to provide line to line voltage reading and line neutral voltage.

.07.11Ammeter

Ammeter shall be digital. The dial of the ammeter shall be square in 96 x 96 mm. Separate current transformer shall be provided for all ammeters.

.07.12Current Transformer

Where ammeters are called for C.T.s shall be provided for current measuring. Each phase shall be provided with separate current transformer of accuracy Class I and suitable VA burden for operation of associated metering and controls. Current transformer shall be in accordance with IS: 2705 - 1992 as amended upto date.

.07.13Push Buttons

The push button unit shall comprise of the contact element, a fixing holder, and a push button actuator. The push button shall be momentary contact type. The contacts shall be of silver alloy and rated at 10 Amps. continuous current rating. The actuator shall of standard type and colour as per its usage for ON, OFF and TRIP. Wiring for Remote ON, OFF push button is to be required.

.07.14Indicating Lamps

Indicating lamps assembly shall be screw type with built in resistor having non fading color lens. LED type lamps are required. Wiring for Remote ON, OFF, TRIP indicating lamp is required.

Colour shade for the indicating lamps shall be as below :

ON indicating lamp

:Red

OFF indicating lamp

:Green

TRIP indicating lamp

:Amber

PHASE indicating lamp

:Red, Yellow, Blue

TRIP circuit healthy lamp

:Milky

Closing circuit DC control supply:Milky

Tripping circuit DC control supply:Milky

DC Fail

:Yellow

.08Shop Drawings

Prior to fabrication of the Panels the Supplier / Contractor shall submit for the Consultants approval the shop drawing consisting of G.A. drawing, sectional elevation, single line diagram, bill of material etc. and design calculations indicating type, size, short circuiting rating of all the electrical components used, busbar size, internal wiring size, Panels dimension, colour, mounting details etc. in 6 sets. The Contractor shall also submit Manufacturers catalogues of the electrical components installed in the Panels along with the drawing.

.09Inspection

At all reasonable times during production and prior to transport of the Panels to site, the Supplier / The Contractor shall arrange and provide all the facilities at their plant for inspection.

.10Test Certificates

Testing of Panels shall be carried out at factory and at site as specified in Indian Standards in the presence of the Consultant. The test results shall be recorded on a prescribed form. The Test Certificate for the test carried out at factory and at the site shall be submitted in duplicate to the Owner/ Consultant for approval.

3.BUS DUCT

General Specification:

Supply, Design, Assembling, Testing of metal enclosed three phase neutral Bus Duct,

The bus duct shall be of box frame construction of sheet steel enclosure suitably braced to withstand the maximum mechanical and electrodynamics forces.

The bus duct enclosure shall be fabricated from 14 SWG (2 mm) sheet steel. Eddy current heating, if applicable, shall be taken in to account.

The degree of protection shall be IP 54.

The bus duct enclosure shall be suitable for Indoor / Out door installation as specified. The out door portion of bus duct shall be suitable for out door installation with out any additional protection from the Owner end. However, rain hood shall be provided as an additional protection for out door installation. Canopy & proper fixing arrangement shall be provided for the same.

The bus duct shall be provided with removable top covers fitted with gaskets secured by sufficient No. of nuts, bolts to ensure that these covers are dust proof. All joints and covers shall be provided with non - deteriorating type gasket of neoprene between joints. These covers shall be of suitable length for ease of removal and shall be arranged to give complete accessibility to the Bus Bars, Joints, Bends and supports etc. the entire bus duct shall be dust and vermin proof . Louvers shall not be provided. Suitable drain hole shall be provided for natural draining of any water collections within the enclosure due to moisture condensation.

Unless otherwise specified in specific requirement, the section of the bus duct shall be rectangle.

The design of bus duct enclosure shall be such that it will withstand the conditions arising out of the following:

1) Normal Operating Conditions.

2) Momentary Short Circuit Current(peak)

3) Rigours of adverse weather conditions.

4) Combination of 2 & 3

The bus duct shall be provided with flanged ends to connect the bus duct to transformer at one end and Main Switch Gear at panel end. These flanges shall match with corresponding flanges in the equipment to which these are connected. Bus bar disposition for termination at transformer, PCC or alternator will be as per ISI.

Termination arrangement for 415 Volt Alternator / Switch Gear and Transformer shall be provided by the Contractor. Proper Alignment and co ordination between the bus duct and Transformer / 415 V Switchgear or Alternator terminations shall be the responsibility of the bus duct Supplier. The Owner will provide the drawing of transformer cable end box or Alternator.

The bus duct shall be supplied complete with all the hard wares necessary for making the terminations inclusive of copper flexible.

All hard wares shall be hot dip GI / Cadmium plated. The bolts shall be full threaded and high tensile quality. Belleville washer for all current carrying conducting parts of the bus bar and Plain washer shall be provided for every bolt.

If specified filter type drain holes shall be provide for draining out condensed moisture. The filter element shall be such that it will allow escape of moisture but prevent ingress of dust. This shall be removable type for cleaning purpose.

The transformer and the Alternator / Switchgear flanges are generally Top Connections.

Bolted inspection cover shall be provided wherever necessary. At the wall crossing of the bus duct, these should not be removable type inspection cover.

Proper wall sealing arrangement shall be provided at the wall where bus duct enters the substations building. Bus duct with wall mounting flanges will be acceptable for sealing arrangement.

Top cover of the bus duct shall be so located that they will not fall within the wall crossing section. Bus duct shall be supported from overhead hangers inside the sub station.

The enclosure shall be provided with suitable mounting lugs at suitable intervals. The mounting lugs shall be suitable for hanger type supports. The Contractor shall design and indicate the supporting arrangement for bus duct.

Bus duct shall be segregated or non segregated type as mentioned in the specific requirement. For segregated phase bus duct suitable phase segregation barriers shall be provided between phases.

Supporting arrangement

Bus duct supplier shall also quote separately for bus duct and supports with details of the supporting members and quantity being offered.

The supports shall be as below.

1 Supporting structure shall be fabricated from standard steel sections and shall be hot dip Galvanization after fabrication.

2 Support structure shall be designed to withstand the dead weight of the bus duct and short circuit forces under maximum fault conditions.

3 Support structure shall include support members like brackets, hangers, vertical / longitudinal channels , nuts, bolts, washers and other hardware require for erection and support of entire bus duct.

4 Indoor portion of the bus duct may be supported from wall or ceiling as per layout furnished. Out door portion of the bus duct shall be supported from ground below on suitable foundations in ground.

.01Busbars

The bus bar shall be of Electric Grade Al. of adequate size to carry maximum current. The final temperature of bus bar and connectors at joints between connectors and bus bar should not be exceeding 80 Deg. C when carrying rated current.

Bimetallic strips covering full joints surface shall be provided wherever copper to aluminum connections are envisaged. Bus bar clamps shall be provided to maintain the bus bar in position. These clamps shall be made out of fully heat-treated magnesium silicate aluminum alloy.

For fixing the bus bars the bus bar support cadmium plated bolts, nuts and washers shall be used.

Wherever required for long run of bus duct, expansion joints with Flexible Strip shall be provided to allow for expansion and contractions due to temp. Variation arising out of normal continuous current flow and short circuit current flow for specified duration. Minimum one expansion for each 3000 mm long straight length of bus duct.

.02Busbars Supports

Non- hygroscopic, non- carbursing solid core resin cast epoxy insulators shall support the bus bar. The spacing of the support shall be decided on the basis of the fault withstand capacity.

.03Termination at ends of Busduct

The bus duct shall be provided with flexible at both ends for connecting it with Transformer at one end and 415 V Switchgears at other end.

The flexible shall be made of thin copper strips, Copper Plates shall clamp the ends of the flexible. The ends of flexible shall be tin-plated.

.04Earth Bus

The earth bus of 2 x 40x 6 mm. Thk. Al. run on the external side of the bus duct through the length of bus duct and connected to body of the bus duct. The ends of the earth bus to be connected to earthing pit.

All bus duct part like enclosures, adaptor box, Hood, Covers, Supports, Bus bars, fish Plates shall be identified distinctly by clear numbers.

.05Painting

All metal surfaces shall be totally cleaned and provide proper treatment of seven tank process or Sand Blasting with proper primer (Zinc Chromate).

After proper treatment the surface shall be coated with two coats of epoxy paint of simense grey shade. Painting : Powder Coated with Sand Blasting Or with

Seven tank treatment process.

Painting Shed: Siemens Grey

Busbar : Electrolytic Grade Aluminium.

4. LIGHTING DISTRIBUTION BOARDS

.01 Scope

This section relates to specifications for supply, assembly, installation, connection, testing and commissioning of lighting distribution board (LDB) using TPN/FP/DP/SP MCB isolator & ELMCB, Earthing terminal, connector strip for phase neutral and earth for each circuit, CRCA sheet steel housing and complete the item installation. Common banking of neutral and earth conductor is not allowed. Cu. Conductor should be considered for bus bar.

.02System

The lighting distribution boards shall be suitable for operation on 415/240 volt, 50 cycles per second, A.C supply system. The lighting distribution boards MCB shall be capable of withstanding short circuit current of 10 KA.

.03 Construction

The DBs shall be factory made and of those and as per the G.A. layout enclosed. General arrangement lay out of the DBs shall be approved by the Consultants before starting the Manufacture.

The DB shall metal clad duly fabricated from 2mm. thick high quality CRCA sheet metal.

The DB shall be wall mounted and dead front operated.

The DB shall totally be enclosed and made dust, vermin and weather proof such that it meets to IP54 protection classification for installation.

A detachable cover plate of 2 mm thick CRCA sheet to be provided on front of the board such that all live parts of the electrical accessories mounted on the board can be accessible only on removal of the said cover plate.

The cover plate shall be fixed to the board with adequate size zinc passivated machine screws.

Above the detachable cover plate, one additional hinged door of 2 mm thick CRCA sheet shall be provided with a suitable locking arrangement.

The hinged door shall be provided with a suitable gasket capable of withstanding corrosive & humid atmosphere and to maintain degree of enclosure protection to IP 54 as per IS: 13947 for installation.

The DB shall have top / Bottom entry arrangement for incoming and out going cables/conduits.

All hardware to be used in Manufacture of the DB shall be S.S 304 to prevent corrosion due to humid atmosphere prevailing at the project site.

All internal electrical connections shall be carried out using 660/1100 volt grade, FRLS insulated, Copper conductor of ISI approved make, having rated current carrying capacity to carry continuous full current of respective switch Fuse rating at operating conditions prevailing at the project site.

The DB internals shall be earthed with use of Copper wires/strips running through out the length. Size of the earthing strip/wire shall be as shown in the respective drawing.

All non current carrying metal surface of the DBs shall adequately be treated and painted.

The surface imperfection shall then be rectified with applications of putty.

The DBs shall be provided with electric components and accessories as per the details shown in the drawing for the respective electric distribution board. The circuit connection from all the circuit MCB shall be brought to connector provided on top or bottom of the DB with suitable lugs. The connector shall be suitable to receive phase, neutral and earth wire/cable coming from each individual circuit. The connectors shall have circuit identification tag.

Use of paper / fabric base laminates is not acceptable.

.04.Painting

The painting shall be as per "PAINTING" specification only.

.05Inspection

The DBs shall be inspected and checked as per inspection manual of the DB Manufacturer.

Various electrical components and accessories of the DBs shall be checked as per the drawing for the respective DBs.

The DBs shall be checked for rigid mounting, earthing connection, proper rating & size of components, internal wiring, etc.

All mechanical fasteners and electrical connections shall be checked and tightened before installation.

.06Installation

The DBs shall be assembled and aligned together and be installed at site as per installation manual / instruction of the DB Manufacturer.

The DB shall be installed in surface manner at the various locations.

All minor electrical and mechanical work required to be attended to on the DB shall be completed in an approved manner after installation but before energizing the DBs.

The M.S. angle/channel iron frame used for installation of D.B. shall be hot dip galvanized (816 g / m).

The DB shall be mounted on angle / channel frame with Anchor fastening only. Civil grouting is not acceptable.

.07Test

Prior to commissioning of the DBs following tests shall be carried out.

Mechanical endurance test shall be carried out by closing and opening of all the MCBs, switches etc.

Insulation resistance test shall be carried out between phases and between phase to earth bus, keeping the isolating switch in open position. Similar test shall be carried out keeping the isolating switch in closed position.

All the interlocks, controls and tripping mechanism of the switch gears shall be tested for their proper functioning.

5.CAPACITOR & APFCR PANEL

.01Scope

This specification covers design, Manufacture, supply, installation, testing and commissioning of automatic power factor correction panel with capacitor banks suitable for continuous duty.

.02.Codes and Standards

The design, Manufacture and performance of the power factor correction panel with capacitor banks shall comply with all currently applicable statutes, regulations and safety codes in the locality where the equipment will be installed. The equipment will also conform to the latest applicable Indian / British / IEC standards. In particular the equipment shall conform to the latest revisions of the following:

IS : 2834

Shunt capacitors for power system.

IS : 9224

Low voltage fuses.

When the above standards are in conflict with the stipulation of this specification, this specification supersedes them.

.03Construction

.03.1Capacitor Bank

Capacitor banks shall comprise of identical delta connected three phase units. The individual capacitor unit shall be manufactured out of double layer APP design comprising of double hazy and thick polypropylene film between two electrodes of thick aluminium foil. Each individual element of the capacitor tissue unit shall be provided with silver fuse wire. The capacitor unit shall consist of many such elements in series / parallel combinations for getting the desired KVAR output. The capacitor shall be vacuum impregnated with liquid dielectric having high thermal stability. The dielectric losses of the capacitor shall be restricted to 1.5 watts per KVAR. The phase terminal connections of the capacitor unit shall be brought out at the top through metal insulators which should be soldered to the fabricated top cover. The capacitor shall be provided with suitably rated discharge resistors. The capacitor shall be designed to withstand the electro dynamic and thermal stresses caused by transient over current during switching.

.03.2 Busbars Chamber

Capacitor bank shall be provided with a bus bar chamber. The chamber shall be dust and vermin proof in construction, fabricated from 2 mm thick sheet steel. Continuous neoprene rubber gaskets shall be provided on all mating surfaces. TP Bus-bars shall be of AL supported on FRP insulators of adequate rating and strips.

The bus bar sizes and clearances shall be suitable for connection of cables through crimping type cable lugs. Bus bar chamber shall be extended suitably on one side to enable termination of cable. There shall be a provision of cable end box at the end of bus bar chamber undrilled removable gland plate and access covers to be provided for cable entry as required.

.04Earthing

The enclosure of individual capacitor unit shall be provided with 2 nos. 10 mm earth terminals each complete with two plain and one spring washer, nuts etc. These terminals shall be effectively bonded to the common sheet steel frame work. Each bank will have two external earth terminals in the bus bar chambers complete with hardware.

.05Painting

The painting shall be as per "PAINTING" specification only.

.06Drawings

The following drawings shall be submitted along with the bid :

General arrangement drawing showing overall dimensions, weight, internal arrangement and mounting details.

Terminal chamber, showing bus-bar arrangement with all dimensions.

.07Test & Test Certificates

The Contractor shall carry out all routine tests as specified in IS: 2834 and shall furnish the test certificates.

The Contractor shall also carry out the thermal stability test on the units in the presence of Owners representatives.

The capacitor units shall be tested from electric supply authorities like state / local electricity board and the test certificates in duplicate shall be furnished to Owner and also the copy shall be submitted to the electric supply authority while getting the power supply released from them.

.08Capacitor Panel

Capacitor control panel shall be automatic as specified in the data sheet and bill of quantity.

The panel for capacitor shall be fabricated from 2.0 mm thick sheet steel and shall be finished as per clause no. 5.0. Earthing terminals shall be provided as per clause no. 4.0. The panel shall be provided with suitably rated TPN AL bus bar supported on FRP insulator and with heat shrinkable type sleeves. Each capacitor unit shall be connected to main bus bar through contactors of suitable rating (double the rating of capacitor current) with safety margin. Each unit shall be of suitable KVAR rating as specified. Protective HRC switch fuses of suitable rating shall be provided with base / holders as mentioned in the drawing.

Connections shall be made with FRLS insulated flexible copper cables having crimped Cu. lugs. Continuous earthing conductor / strip shall run through and all capacitor units shall be earthed. Sufficient ventilation shall be provided in the capacitor compartment to limit the temperature rise to 85 C. Cooling fans shall be provided with ON-OFF switches as per requirements. Drawing pocket shall be provided for each panel at the door. Also, a 15 A switched socket and a lamp holder shall be provided for panel illumination at suitable location.

The main bus bar shall be terminated on suitably rated SFU with fuse links or MCCB as per Drawing. Vertical compartment with detachable gland plate shall be kept for incoming cable connections from bottom or top as specified. The gland plate shall be provided with required size and nos. of knockouts.

Capacitor units shall be mounted on angle frame of strong construction.

The panel shall be mounted on M.S. channel section at bottom for easy installation.

The panel shall be provided with lifting hooks / Eye bolts for handling.

Automatic power factor correction sensing relays ( APFCR ) shall be provided with all related circuits and contactors for controlling the power factor to max. 0.98 by energizing the contactor and related capacitor bank ON or OFF as per load conditions.

The controller shall be set for time lag of 40-60 seconds so that on sensing the low or high power factor it energize or de energize the contactor after 40-60 seconds.

The Dust and Vermin proof-switching compartment shall be isolated from capacitor mounting compartment.

The panel shall be provided as per the respective drawing.

The following drawings shall be submitted before procurement for approval from the Owner / Consultant.

General arrangement and Fabrication details.

Power wiring diagram of capacitor panel.

Control wiring diagram of capacitor panel.

C.T. connection.

Manual for Automatic Power Factor Correction Relay.

6L. V. XLPE CABLE

.01 Design Conditions

All equipment and materials will be selected and rated for use at the following site conditions.

Ambient air temperature

50 C.

Ground temperature

30 C.

Solar gain

1100 w / m2

Earth resistivity

200 deg. C. cm / w

Relative Humidity

95% Max.

Atmospheric condition Non corrosive, Humid and Dusty

.02Scope

This section shall cover supply, laying, testing and commissioning of medium voltage XLPE cables.

This specification gives the general requirement of cables. However, it is the responsibility of the Contractor to take the joint measurement and obtain Owners approval before the placement of orders to the main Supplier / Manufacturer.

.03Standards

The following standards and rules shall be applicable:

IS : 7098 Part IXLPE insulated electric cables (heavy duty).

IS : 3961

Recommended current ratings for cables.

IS : 8130

Aluminium conductors for insulated cables

Indian Electricity Act and Rules

.04Measurements

The cables will be measured in meters. The unit rate shall include cutting the cable into required lengths, packing, loading, unloading, insurance, transportation, delivery to stores/site as per work order, stocking in stores, testing of cables at stores etc. of medium voltage cable. Total quantity in meters shall be measured lug to lug basis.

.05General

The medium voltage cables shall be supplied, laid, connected, tested and commissioned in accordance with the drawings, specifications, relevant Indian Standards specifications, Manufacturers instructions. The cables shall be delivered at site in original drums with Manufacturers name, size, and type, clearly written on the drums.

.06Material

Medium voltage cable shall be XLPE insulated. PVC sheathed, aluminium or copper conductor, armoured conforming to IS: 7098 Part I.

.06.1 Type

The cables shall be circular, multi core, annealed copper or aluminium conductor, XLPE insulated and PVC sheathed, armoured or unarmoured.

.06.2 Conductor

Uncoated, annealed copper / aluminium, of high conductivity up to 4 mm. size, the conductor shall be solid and above 4 mm., conductors shall be concentrically stranded as per IEC: 228.

.06.3 Insulation

XLPE rated 70 c. extruded insulation

.06.4 Core Identification

Two core

:Red and Black

Three core

:Red, Yellow and Blue

Four core

:Red, Yellow, Blue and Black

Single core

:Green, Yellow for earthing

Black shall always be used for neutral.

.06.5 Assembly

Two, three or four insulated conductors shall be laid up, filled with non-hygroscopic material and covered with an additional layer of thermoplastic material.

.06.6 Armour

Galvanised steel flat strip / round wires applied helicaly in single layers complete with covering the assembly of cores.

For cable size upto 25 Sq. mm.: Armour of 1.4 mm dia G.I. round wire

For cable size above 25 Sq. mm.: Armour of 4 mm wide 0.8 mm thick G.I. strip

.06.7 Sheath

XLPE 70 deg. c. rated extruded.

Inner sheath shall be extruded type and shall be compatible with the insulation provided for the cables.

Outer sheath shall be of an extruded type layer of suitable PVC material compatible with the specified ambient temp. 50 deg. C and operating temperature of cables. The sheath shall be resistant to water, ultraviolet radiation, fungus, termite and rodent attacks. The colour of outer sheath shall be black.

Sequential length marking required at every 1.0 meter interval on outer sheath.

The Contractor has to furnish resistance / reactance / capacitances of the cable.

.06.8 Rating

Upto and including 1100 Volts.

.07General

All cables shall be adequately protected against any risk of mechanical damage to which they may be liable in normal conditions of handling during transportation, loading, unloading etc.

The cable shall be supplied in single length i.e. without any intermediate joint or cut unless specifically approved by the Owner.

The cable ends shall be suitably sealed against entry of moisture, dust, water etc. with cable compound as per standard practice.

.08Testing

.08.1 Finished Cable Tests at Manufacturers Works

The finished cables shall be tested at Manufacturers works. Following routine tests for each and every length of cable and copy of test results shall be furnished for each length of cable along with supply. If specified, the cables shall be tested in presence of Owners representative.

.08.1.1Voltage Test

Each core of cable shall be tested at room temperature at 3 KV A.C. R.M.S. for duration of 5 minutes.

.08.1.2Conductor Resistance Test

The D.C. Resistance of each conductor shall be measured at room temperature and the results shall be corrected to 20 c. to check the compliance with the values specified in IS 8130 - 1976.

.08.2 Cable test before and after laying of cables at site

Insulation Resistance test between phases and phase to Neutral and phase to earth

Continuity test of all the phases, neutral and earth continuity conductor

Sheathing continuity test

Earth resistance test of all the phases and neutral

All tests shall be carried out in accordance with relevant Indian Standard Code of practice and Indian Electricity Rules. The Contractor shall provide necessary instruments, equipments and labour for conducting the above test and shall bear all expenses in connection with such tests. All tests shall be carried our in the presence of the Owner or Owners representative and results shall be recorded in the prescribed forms.

.09Cable Marking

Embossing on Outer Sheath

The outer sheath shall be legibly embossed with following legend:

ELECTRIC CABLE: 1100 V, SIZE: 3.5 C x ----- mm

Manufacturers Name & year of manufacturing

.10Sealing, Drumming & Packing

After tests at the Manufacturers works, both ends of the cable shall be sealed to prevent the ingress of moisture during transportation and storage.

Cable shall be supplied in length of 500 10% meters, packed non-returnable drums of sufficiently sturdy construction.

Cables of length more than 250 meters shall also be supplied on non-returnable drums.

The spindle hole shall be 110 mm minimum diameter.

Each drum shall bear on the outside flange, legibly and indelibly in the English literature, a distinguishing number, the Manufacturers name and particulars of the cable i.e. voltage grade, length, conductor size, cable type, insulation type and gross weight shall also be clearly visible. The direction for rolling shall be indicated by an arrow. The drum flange shall also be marked with Manufacturers name and year of manufacturing etc.

.11Transportation & Delivery

The cable shall be supplied in the actual length as per detailed purchase order.

The cable shall be despatched at Owners stores or at site as per detailed instructions given by Owner at later stage.

The cable shall be loaded from the Suppliers store and properly stacked as per instruction of Owners local representative. All such labour and transportation charges shall be clearly mentioned in

7.CABLE TRAY

Cable trays shall be delivered in suitable lengths adequate for transport and storage or fabricated at factory site with proper care.

The cable trays used for the power distribution in the mechanical and service areas.

They shall be supplied complete with galvanized brackets for fixing to the walls on ceiling, the galvanized bolts, the galvanized accessories for connection of different elements, the angle elements and the derivations elements.

Cable trays shall be stored indoor in a dry area.

Cable trays shall be fabricated ladder type mild steel.

If the cable trays are to be used in extreme weather like plant room condition than a coating of sinter coat E shall be applied on the mild steel.

Cable trays shall be so designed as to take the full load which they will be carrying, without any distortion or bending.

Cable trays shall be supplied complete with straight runs and necessary fittings like elbows, risers, crosses, tees, reducers, splice plates and associated hardware and all necessary accessories to enable the complete installation possible.

Supports are to be installed within 300mm of any splice, joint and at frequency determined by mechanical strength of tray.

Cables shall be secured on cable trays with universal clip.

Cable shall not be overlapped on each other while laying Minimum distance of one diameter shall be left between two cables.

Cable trays shall be secured fast to wall brackets or suspensions from ceilings.

The support and fixing details shall be approved by the Engineer prior to erection.

The maximum permissible spacing between the supports shall be 1.5m.

Where trays pass through walls, partitions or ceilings, the surrounding hole shall be made good for precaution against spread of fire as per I.E.E.

Where trays are installed in damp situation or exposed to weather it shall be installed as per I.E.E.

Construction of tray, laying of cables and all metal work of wiring system (other than current carrying parts) shall be as per I.E.E.

The trays shall be welded to the mounting / carrier structure.

The scope of cable tray installation shall include the supply, installation fixing of the associated accessories like coupler plates, elbows, dropouts, tees, bends, as required.

The cable trays shall be earthed at distance not exceeding 10 m by means of minimum size 25 x 3 mm GI /CU. Flat.

Following items of cable trays shall be painted :

Mounting arrangements of cable trays. Any cable trays junction bends which are non standard shall be fabricated as racks to suit installation drawings.

Vertical cable race ways and steel accessories (angles and plates) required to seal the floor openings in the case of indoor raceways.

Cable carrier structure (racks) for cable trenches and tunnels.

Supporting steel for junction / marshaling boxes, push buttons, vertical structures for clamping cable boxes if mounted below switchgear etc. as required.

The mounting structures / racks shall be fabricated from standard structural steel members (channels, plates, angles and flats) The supply of steel if required shall be supplied by the Contractor and the rate for the same shall be stated separately.

The scope of installation shall include fabrication, installation, painting, earthing to system grid of all vertical raceways and cable carriers structures in tunnel / trenches by minimum size 25 x 5 mm M. S. Flat as indicated in enclosed drawings / notes, supply of all incidental accessories like anchor fasteners, bolts, nuts, washers, welding works as required for fabrication and installation. However if floor plates are required in certain locations for convenience of cable routing, the same shall be fixed by anchor fasteners.

8.INTERNAL WIRING

.01 Scope

This section covers, definition of point wiring, system of wiring and supply, installation, connection, testing and commissioning of point wiring for light points, ceiling fan points, exhaust fan points, convenience socket points, power socket outlet points, bell outlet points, etc. including fixing of light fixtures, ceiling fan, exhaust fan, wall fan, bell etc.

.02 Standards

The following standards and rules shall be applicable:

IS: 732 Code of practice for electrical wiring installation (System voltage not exceeding 650 V)

IS: 1646 Code of practice for fire safety of buildings (General) Electrical installation.

IS: 1653 Rigid steel conduits for electrical wiring

IS: 2667 Fittings for rigid steel conduits for electrical wiring

IS: 3480 Flexible steel conduits for Electrical wiring

IS: 3837 Accessories for rigid steel conduit for electrical wiring

IS: 694 PVC insulated cables

IS: 2509 Rigid non-metallic conduits for electrical wiring

IS: 6946 Flexible (Pliable) non-metallic conduits for electrical installation

IS: 1293 3 Pin plugs and sockets

IS: 8130 Specifications of conduits for electrical installation

IS: 3854 Switches for domestic purpose

IS: 3415 Fittings for rigid non-metallic conduits

IS: 4648 Guide for electrical lay out in residential building Indian electricity act and rules

Regulations for the electrical equipment in buildings issued by the Bombay Regional Council of Insurance association of India All standards and codes mean the latest.

.03 Point Wiring

A point shall consist of the branch wiring from the distribution board together with a switch as required, include, in addition, the earth continuity conductor / wire from the distribution board to the earth pin / stud of the outlet / switch box and to the outlet points.

The point wiring shall be carried out in the under mentioned manner:

.03.1 Supply, installation, fixing of conduits with necessary accessories, junction / pull / inspection / switch boxes and outlet boxes.

.03.2Supplying and drawing of wires of required size including earth continuity wire.

.03.3Supply, installation and connection of flush type switches, sockets, cover plates, switch plates, and fixing fan etc.

.03.4 The point shall be complete with the branch wiring from the distribution board to the outlet point, through board, conduit with accessories, junction, pull, inspection boxes, control switch, socket, outlet boxes, ceiling roses, button/swan holder, connector etc.

.04 Point Rate

The rate per point shall include supply, installation, connection, testing and commissioning of point as described under "point wiring". The measurement of the points will be enumerated.

.05 System of wiring

Unless otherwise mentioned on the drawings , the system of point wiring shall be as follows :

The system of wiring shall consist of single core, PVC Insulated, 650/1100 Volt grade, stranded copper conductor wires/cables laid through concealed or exposed PVC conduits as directed. Conduits shall be concealed / embedded in slab / walls / floor in all the area except where specified as surface mounted in mechanical and plant room area. Rigid non-metallic, PVC conduit shall be used for concealed / embedded installation while steel conduits shall be used for surface installation and shall have stove enameled finished surface except installation in damp / wet area, the steel conduit shall be GI conduits.

.06 General

Prior to laying of conduits, the Contractor shall submit for approval, the shop drawing for conduit layout indicating the route of the conduits, number and size of the conduits, location of junction / inspection / pull / outlet boxes, size and location of switch boxes, number and size of wires pulled through each conduit and all other necessary relevant details. Only after the drawings are approved, The Contractor shall proceed the work of laying of conduits.

.07 Materials

.07.1 PVC Conduits

All non-metallic PVC conduits shall conform to IS: 9537. The conduit shall be plain end type as specified in IS: 9537 and shall be used with the corresponding accessories (Refer IS: 3419 specification for fittings for rigid non PVC metallicconduits). PVC conduits shall be rigid unplasticised, heavy gauge having 1.5 mm wall thickness up to 19 mm conduit and 1.8 mm wall thickness for all sizes above 19 mm diameter.

.07.2 Boxes

All the boxes for switches, sockets, and other receptacles, junction boxes, pull boxes and outlet boxes shall be fabricated from 2.0 mm thick mild sheet steels duly painted with two coats of red-oxide and then two coats of enamel paints as called for. Color of the paints shall be as approved by the Owner. The boxes shall have smooth external and internal finished surface. Boxes in contact with earth or exposed to the weather shall be of 2 mm thick mild steel and hot dip galvanized after fabrication. Separate screwed earth terminal shall be provided in the box for earthing purpose. All boxes shall have adequate no. of knock out holes of required diameter for conduit entry. Switch boxes to receive switches, socket outlets, power outlets, telephone outlets, fan regulators, etc. shall be fabricated to the approved shape and size to accommodate all the devices without overcrowding. Outlet boxes to receive ceiling shall be fitted with adequately sized rod / hook to fix ceiling fan. The boxes shall be of a minimum depth of 65 mm.

Boxes installed for concealed wiring shall be provided with suitable extension rings or plaster covers as required. Boxes for use in masonry block or tiled walls shall be square cornered tile type, or standard boxes having square cornered tile type covers. These boxes shall be installed in the center of the masonry block or tiles.

Cast metal boxes installed in wet locations and boxes installed flush with the outside of exterior surface shall be gasketed.

.07.3 Cover Plate

The cover of the switch boxes to receive outlet points shall be of best anodized sheet cut to shape and size as approved by the Owner. For factory building and all other mechanical Area. Standard Piano type switches hylam or formica cover plate of minimum 3 to 5mm thk, all junction boxes, pulls boxes, boxes shall be provided with 3 mm thick anodized sheet cover in factory building and hylam / formica cover plate for office building.

.07.4 Wire and Cables

The cables shall confirm to IS: 694. For all internal wiring PVC HR FRLS insulated cables of 650/1100 volts grade, single core shall be used. Theconductors shall be plain annealed copperconductors complying with IS: 1554. The conductors shall be circular stranded copper conductor. The minimum number and diameter of wires for circular stranded conductor shall meet the requirements set out in the relevant Indian Standards.

The insulation shall be PVC HR FRLS compound complying with the requirements of IS: 694. It shall be applied by an extrusion process and shall form a compact homogeneous body. The thickness of PVC insulation shall be as set out in the relevant standards.

The cores of all cables shall be identified by colors in accordance with the following sequence.

Single phase - Red.

Three phase - Red, Yellow, Blue

Neutral - Black.

Earth - Green or Green/Yellow.

Means of identifying the Manufacturer shall be provided throughout the length of cable.

The earth continuity conductor shall be similar to circuit cables and shall be drawn through conduit along with other circuit cables.

Separate circuit shall run for each water heater, kitchen equipment, window air conditioner, and similar outlets at location as shown on drawings.

.07.5Switches

.07.5.1For Factory, Utility Area

Switches shall confirm to IS : 3854, IS : 1293 and IS : 4615. The switches shall be single pole, single or two way and shown on the drawings or as specified. They shall be of the INDUSTRIAL TOGGLE type rated for 250 Volt, and of full 5/15 Amp. capacity. They shall be provided with insulated dollies and covers.

The switches shall be rocker operated with a quite operating mechanism with bounce free snap action mechanism enclosed in an arc resistant chamber. The switches shall have pure silver and silver cadmium contacts. The switches shall be INDUSTRIAL TOGGEL TYPE . The make of the switches shall be as indicated in the drawings or BOQ or as suggested and approved by the Owner. The switches installed in outdoor area shall be industrial, metal clad type, and shall be provided in weather proof enclosures, complete with weather proof gasketed covers.

.07.5.2For Office Area

Switches shall confirm to IS : 3854, IS : 1293 and IS : 4615. The switches shall be single pole, single or two way and shown on the drawings or as specified. They shall be of the MODULAR TYPE type rated for 250 Volt, and of full 10/ 20 Amp. capacity. They shall be provided with insulated dollies and covers.

The switches shall be rocker operated with a quite operating mechanism with bounce free snap action mechanism enclosed in an arc resistant chamber. The switches shall have pure silver and silver cadmium contacts. The switches shall be MODULAR type. The make of the switches shall be as indicated in the drawings or BOQ or as suggested and approved by the Owner. The switches installed in outdoor area shall be industrial, metal clad type, and shall be provided in weather proof enclosures, complete with weather proof gasketed covers.

.07.6Sockets

The sockets shall conform to IS: 1293. Each sockets shall be provided with control switch of appropriate rating. The sockets shall be moulded type, rated for 250 volts, and either of full 5 Amp or 15 Amp. capacity, as mentioned on the drawings.

For Factory :

The INDUSTRIAL TYPE sockets shall conform to IS: 1293. Each sockets shall be provided with control switch of appropriate rating. The INDUSTRIAL sockets shall be METAL CLAD type, rated for 250 volts, and either of full 10 Amp or 20 Amp. capacity, as mentioned on the drawings.

Sockets shall be of three pin type, the third pin being connected to earth continuity conductor. The socket shall be flush modular type. The sockets installed in machine room, plant room or wet / damp area shall be metal clad weather proof type. The finishing and make of all the sockets shall be same as light switch. The socket shall have fully sprung socket contacts and solid brass shrouded terminals to ensure positive electrical connections.

The sockets shall be provided with automatic shutters, which opens only when earth pin of the plug inserts in the socket.

07.7 Lighting Fixtures, Fans, Exhaust Fans

The light fixtures and fittings shall be assembled and installed in position complete and ready for service, in accordance with details, drawings, Manufacturer's instructions and to the satisfaction of the Owner.

Pendant fixtures specified with overall seam lengths are subject to change and shall be checked with conditions on the job and installed as directed. All suspended fixtures shall be mounted rigid and fixed in position in accordance with drawings, instructions and to the approval of the Owner. Fixtures shall be suspended true to alignment, plumb, in level and capable of resisting all lateral and vertical forces and shall be fixed as required.

All suspended light fixture, fans etc. shall be provided with concealed suspension arrangement in the concrete slab roof members. It is the duty of the Contractor to make these provisions at the appropriate stage of construction Exhaust fans shall be fixed at a location as shown on the drawings or as directed at later stage. They shall be plugged to a socket outlet installed at a convenient location near the fan. All switch and ou